TRANE Furnace/Heater, Gas Manual L0902549

User Manual: TRANE TRANE Furnace/Heater, Gas Manual TRANE Furnace/Heater, Gas Owner's Manual, TRANE Furnace/Heater, Gas installation guides

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IIIIII IIIIIIIIIIIIII IIIIII II

1 8- CD1 9D8- 1 5

Upflow /Horizontal & Downflow /Horizontal,

Gas-Fired, Direct Vent, 2-Stage Condensing

Furnaces with Variable Speed Inducer

*UX2B060A9362A *UX2B080A9422A *UX2C100A9482A

*UX2D120A9602A *DX2B060A9362A *DX2B080A9422A

*DX2C100A9482A *DX2D120A9602A

*__First letter may be"A" or "T"

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT -- This Document is customer property and is to remain with this unit.

Please return to service information pack upon completion of work.

*UX2 *DX2

A/R

FLOW

UPFLOW

DOWNFLOW

A!R

FLOW

AIR

FLOW

UPFLOW/HORIZONTAL LEFT

DOWNFLOW/HORIZONTAL RIGHT

/_FLOW

i°

A341624P03

Installer's Guide

SAFETY SECTION

The following safety practices and precautions must be

followed during the installation, servicing, and operation of

this furnace.

1. Use only with the type of gas approved for this furnace.

Refer to the furnace rating plate.

2. Install this furnace only in a location and position as

specified in "Location and Clearances" (page 3), of these

instructions.

3. Provide adequate combustion and ventilation air to the

furnace space as specified in "Air for Combustion and

Ventilation" (pages 7-8), of these instructions.

4. Combustion products must be discharged outdoors.

Connect this furnace to an approved vent system only, as

specified in the "Venting" section (pages 13-23), of these

instructions.

5. Never test for gas leaks with an open flame. Use a

commercially available soap solution made specifically

for the detection of leaks to check all connections, as

specified in "Gas Piping" (page 31), of these instructions.

6. Always install the furnace to operate within the furnace's

intended temperature-rise range with a duct system

which has an external static pressure within the allow-

able range, as specified on the unit rating plate. Airflow

with temperature rise for cfm versus static is shown in

the Service Facts accompanying this furnace.

7. When a furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space

containing the furnace, the return air shall also be

handled by a duct(s) sealed to the furnace casing and

terminating outside the space containing the furnace.

8. A gas-fired furnace for installation in a residential

garage must be installed as specified in "Location and

Clearances" section (page 3), of these instructions.

9. The furnace may be used for temporary heating of

buildings or structures under construction only when the

following conditions have been met:

a. The furnace venting system must be complete and

installed per manufacturer's instructions.

b. The furnace is controlled only by a room thermostat

(no field jumpers).

c. The furnace return air duct must be complete and

sealed to the furnace and clean air filters are in place.

d. The furnace input rate and temperature rise must be

verified to be within nameplate marking.

e. 100% of the furnace combustion air requirement must

come from outside the structure.

f. The furnace return air temperature range is between

55 and 80 degrees Fahrenheit.

g. Clean the furnace, duct work, and components upon

substantial completion of the construction process,

and verify furnace operating conditions including

ignition, input rate, temperature rise and venting,

according to the manufacturer's instructions.

10. This product must be gas piped by a Licensed Plumber or

Gas Fitter in the Commonwealth of Massachusetts.

To prevent shortening its service life, the furnace should

not be used as a "Construction Heater" during the finishing

phases of construction until the requirements listed in item

9, a-g of the safety section of this publication have been

met. Condensate in the presence of chlorides and fluo-

rides from paint, varnish, stains, adhesives, cleaning

compounds, and cement create a corrosive condition which

may cause rapid deterioration of the heat exchanger.

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 shall 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. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and

horizontal pitch, as required in the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 or the CAN/CGA B149

Installation Codes and these instructions. Determine

that there is no blockage or restriction, leakage,

corrosion and other deficiencies which could cause an

unsafe condition.

3. As far as practical, close all building doors and

windows and all doors between the space in which the

appliance(s) connected to the venting system are

located and other deficiencies which could cause an

unsafe condition.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any exhaust

fans, such as range hoods and bathroom exhausts, so

they are operating at maximum speed. Do not operate

a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the thermostat

so appliance is operating continuously.

7. If improper venting is observed during any of the above

tests, the venting system must be corrected in

accordance with the National Fuel Gas Code,

ANSI Z221.1/NFPA 54 and/or CAN/CGA B149

Installation Codes.

8. After it has been determined that each appliance

connected to the venting system properly vents where

tested as outlined above, return doors, windows,

exhaust fans, fireplace dampers and any other gas-fired

burning appliance to their previous conditions of use.

Safety signal words are used to designate a degree or level

of seriousness associated with a particular hazard. The

signal words for safety markings are DANGER, WARNING,

and CAUTION.

a. DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

This signal word is limited to the most extreme situations.

b. WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

c. CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in

serious injury, death or property damage.

Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

GENERAL

The manufacturer assumes no responsibility for equipment

installed in violation of any code or regulation.

It is recommended that Manual J of the Air Conditioning

Contractors Association (ACCA) or A.R.I. 230 be followed in

estimating heating requirements. When estimating heating

requirements for installation at Altitudes above 2000 ft.,

remember the gas input must be reduced (See GAS INPUT

ADJUSTMENT).

Material in this shipment has been inspected at the

factory and released to the transportation agency

without known damage. Inspect exterior of carton for

evidence of rough handling in shipment. Unpack

carefully after moving equipment to approximate

location. If damage to contents is found, report the

damage immediately to the delivering agency.

Codes and local utility requirements governing the installa-

tion of gas fired equipment, wiring, plumbing, and flue

connections must be adhered to. In the absence of local codes,

the installation must conform with latest edition of the

National Fuel Gas Code ANSI Z223.1 • National Installation

Code, CAN/CGA B149.1. The latest code may be obtained

from the American Gas Association Laboratories, 400 N.

Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or

www.aga.org

These furnaces have been classified as CATEGORY IV

furnaces in accordance with latest edition of ANSI Z21.47

standards ° CAN/CGA 2.3. Category IV furnaces operate

with positive vent static pressure and with a flue loss less

than 17 percent. These conditions require special venting

systems, which must be gas tight and water tight. These

Category IV Direct Vent furnaces are approved for installa-

tion in Manufactured/Mobile housing when used with

BAYMFGH001A.

LOCATION AND CLEARANCES

The location of the furnace is normally selected by the

architect, the builder, or the installer. However, before the

furnace is moved into place, be sure to consider the following

requirements:

1. Is the location selected as near the chimney or vent and

as centralized for heat distribution as practical?

2. Do all clearances between the furnace and enclosure

equal or exceed the minimums stated in Clearance Table

on the Outline Drawings.

3. Is there sufficient space for servicing the furnace and

other equipment? A minimum of 24 inches front accessi-

bility to the furnace must be provided. Any access door

or panel must permit removal of the largest component.

4. Are there at least 3 inches of clearance between the

furnace combustion air openings in the front panel and

any closed panel or door provided?

5. Are the ventilation and combustion air openings large

enough and will they remain unobstructed? If outside

air is used, are the openings set above the highest snow

accumulation level? (See the Air for Combustion and

Ventilation section.)

6. Allow sufficient height in supply plenum above the

furnace to provide for cooling coil installation, if the

cooling coil is not installed at the time of this furnace

installation.

7. A furnace shall be installed so electrical components are

protected from water.

8. If the furnace is installed in a residential garage, it

must be installed so that the burners, and the ignition

Installer's Guide

Contents

Installation Instructions

General

Location and Clearances

Outline Drawings

Upflow Installation

Downflow Installations

Air For Combustion and Ventilation

Duct Connections

Return Air Filters

General Venting

Venting Materials

Vent Tables

Horizontal Venting Through Wall

Venting Through the Roof

Venting Routed Through a Masonry Chimney

Downward Venting

Condensate Drain Instructions

Field Wiring Diagrams

Electrical Connections

Gas Piping

Combustion and Input Check

High Altitude Derate

Start-up and Adjustment

Preliminary Inspections

Lighting Instructions

Sequence of Operation

Control and Safety Switch Adjustments

Abnormal Conditions

IFC Error Flash Codes

Fault Code Recovery

source are located not less than 18 inches above the floor

and the furnace must be located or protected to avoid

physical damage from vehicles.

IMPORTANT:

The furnace must be installed level The only allowable variation

would be slightly to the left and/or forward in upflow installations

or slightly toward the front in horizontal installations. This is

necessary for proper condensate drainage.

Do not install the furnace in a corrosive or contaminated

atmosphere. Failure to follow this warning could result in

early equipment failure.

Do not install the furnace directly on carpeting, tile or other

combustible material other than wood flooring. For vertical

downflow application, subbase (BAYBASE205) must be

used between the furnace and combustible flooring. When

the downflow furnace is installed vertically with a cased

coil, a subbase is not required.

18-CD19D8-15 3

DIM "C"

5/8" J

-,-- 5/8" 4- I/ilJ

OUTLET t°_

AIR /._

OUTSIDEAIR

7/8" HOLE_

ELECTRICALLY.... _ ,

SUPPLY ,_._ .... _1

1/78" x 7/8"_

SLOT KNOCKOUT

CONDENSATE DRAIN

(HORIZONTAL)

I-I/8" KNOCKOUT-

CONDENSATE DRAIN

I-5/16"--=-

,l-m..

01_0

23-3/4"

-i

DIM "D"

3/4,,_-

3/4" --_

--,_ 28- I /2" -_,.

INLET I • I

AIR "

I_ 24- I/32" _-J L 3-7/32"

DIM "B"

_---r_2"FLUE CONNECT

SEE NOTES I & 2

"E"

"'--4-1/16"

*UX2 UPFLOW /HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

',1-3-15/16"

"--2-1/16"

-¢1-1/2" GAS

SUPPLY

"-2-1/8"

__T

I -7/8 22-

--__20-1/4"

18-

2 ii

[

;0-5/8"

/4" I

IZONTAL APPLICATION

IS SIDE ONLY)

I/2"_

40"

DIM "A" ---,'-

-,- I/2"

Model DIM "A" DIM "B" DIM "C" DIM "D" DIM "E" DIM "F"

(See Note 1 & 2)

*UX2B060A9362A 17-1/2" 2-1/4" 16-1/4" 16" 7-1/2" 2"

*UX2B080A9422A

*UX2C100A9482A 21" 2-1/2" 19-3/4" 19-1/2" 9" 3"

*UX2D120A9602A 24-1/2" 2-15/16" 23-1/4" 23" 10" 3"

* Prefix May Be "A" or "T" Notes:

1. *UX2D120A9602A Requires 3" Diameter Vent Pipe.

*UX2C100A9482A Requires 2-1/2" or 3" Diameter Vent Pipe.

2. Diameter of Vent Pipe may be limited to 2-1/2" or 3" on some

models at different altitudes. Refer to the Vent Length Table for

proper application.

7/8" KNOCKOUT

ELECTRICAL

SUPPLY

(ALTERNATE)

-_1-1/2" KNOCKOUT

GAS SUPPLY

(ALTERNATE)

I/8" KNOCKOUT

DRAIN

(ALTERNATE)

MINIMUMCLEARANCETO

COMBUSTIBLE MATERIALS

SIDES O IN.

REAR 0 IN.

FRONT 3 IN,

TOP I IN.

FLUE 0 IN.

HORIZONTAL(FLUE

BSCHARGE ON THE LEFTI

ALCOVE

SIDES

RIGHT O IN

LEFT O IN

REAR 6 IN

FRONT 18 IN

TOP I IN,

FLUE 0 IN,

CLOSET

SIDES

RIGHT I IN

LEFT I IN

REAR 3 IN

FRONT 3 IN

TOP I IN

FLUE 0 IN,

From Dwg. 21C341884 Rev. 1

ltl

Ill

t_n

....... 19 5'8 .......

......._2" F u

, CON'\ECT

SEE IOTE J

DIM "D"

3/4

o_ a,,6,_.... j i 7 _,,4"

*DX2 DOWNFLOW /HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

From Dwg. 21C341885 Rev. 1

,; llOlR z.N '. t,,_l C,\I ON

',, IS _i i . I

2-i ,'8 ........."-

' 0 "

DIM "A" ,.-.- 23/i6"

Model DIM "A" DIM "B" DIM "C" DIM "D"

(See Note 1)

*DX2BO60A9362A 17-1/2" 2-1/4" 16-1/4" 16"

*DX2BO80A9422A

*DX2C100A9482A 21" 2-1/2" 19-3/4" 19-1/2"

*DX2D120A9602A 24-1/2" 2-15/16" 23-1/4" 23"

Prefix May Be "A" or "T" Notes:

1. Diameter of Vent Pipe may be limited

to 2-1/2" or 3" on some models at

different altitudes. Refer to the Vent

Length Table for proper application.

/_,S,'8' L C R CAL

/(ONNIC ON AI Ei!'NA I

/ / ,_'S'/6' i( IRICA

/CONN ?liON ,*,L ERNAIE)

/NOC Oi

k c,,,INE_T k.

i?5"

0/z"

"--- ¢ ......s

,,,Jr ,E DA

--w u T

If ,,,,J v ,

MINIMUM CLEARANCE TO

COMBUSTIBLE MATERIALS

DOWNFLOW

SIDES 0

REAR 0

I ROi' I 3 ',

O[ N

i I b E 0 N

HORIZONTAL (FLUE

DISCHARGE ON THE LEFT)

ALCOVE

SIDES

RI iT 0 \

REAR 6 _N

iRON[ 18 N

-OR N

FlU 0 \

CLOSET

SIDES

[EFT ;N

REAR _N

FRONT _N

lOP iN

FI U_ i N

Itl

Iit

Installer's Guide

UPFLOW INSTALLATION

Standoffs and screws (See Figure 1) are included with the

cased coils for attachment to the furnace. There are clear-

ance alignment holes near the bottom of the coil wrapper.

Drill screws are used to engage the furnace top flanges. The

standoff is inserted into the cabinet alignment hole. The drill

screws are inserted through the standoffs then screwed into

the furnace flange. The coil is always placed downstream of

the furnace airflow.

STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

- SCREWS

(BOTH BIDES)

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

(_ CABINET SIDE CABINET SIDE

SUB-BASE SUB-BASE

FLANGE FLANGE

(BENT UP) (BENT UP)

DUCT

Do not install the furnace directly on carpeting, tile or other

combustible material other than wood flooring. For

vertical downflow application, subbase (BAYBASE205)

must be used between the furnace and combustible

flooring. When the downflow furnace is installed vertically

with a cased coil, a subbase is not required.

Required floor opening: (DOWNFLOW)

See Figure 3 and Table I

TABLE 1

CABINET RETURN FLOOROPENING PLENUM OPENING

WIDTH DUCT WIDTH "A.... B.... C.... D"

14-1/2" 13-1/4" 13-5/8" 20-1/8" 12-5/8" 19-3/8"

17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"

21" 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8"

24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8"

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used in

the horizontal position. It is always recommended that an

auxiliary drain pan be installed under a horizontally in-

stalled evaporator coil or 90% gas furnace. Connect the

auxiliary drain line to a separate drain line (no trap is

needed in this line).

Three brackets (with screws) are included with downflow

furnaces for installation to stabilize and secure the furnace

and TXC cased coil in the horizontal position. See Fig-

ure 4.

©CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

IMPORTANT:

The 2/4TXC cased coil must be placed downstream of the

furnace. In horizontal installations, the apex of the coil

may point either toward or away from the furnace. See

the 2/4TXC coil Installer's Guide for more details.

The cased coil is secured to the furnace and both the furnace

and the cased coil must be properly supported. The brackets

mount using the rear screws on the coil case and use the

screws provided to secure the bracket to the furnace. The

remaining bracket is placed as close to center as possible

(horizontally) between the coil case front and the furnace

bottom channel (for downflow/horizontal furnace). Use four of

the screws provided to secure the bracket. The upflow furnace,

converted to horizontal, aligns and attaches the TXC coil as in

Figure 1. However, the coil requires additional support.

The furnace may be installed in an attic or crawl space in the

horizontal position by placing the furnace on the left side (as

viewed from the front in the vertical position). The horizontal

furnace installation in an attic should be on a service plat-

form large enough to allow for proper clearances on all sides

and service access to the front of the furnace (See Figure 5 &

Clearance Tables, pages 4-5). Line contact is only permis-

sible between lines formed by intersections of the top and two

sides of the furnace casing and building joists, studs, or

framing.

The furnace may be placed horizontally in a crawl space on a

pad or other noncombustible material which will raise the

unit for sufficient protection from moisture.

UPFLOW/ I

HORIZONTAL I

SHOWN WITH

DIRECT VENT

18-CD19D8-15

Installer's Guide

50 CU. FT. OR MORE

UNCONFINED

[--

.....\ /

The furnace must be supported at both ends and the

middle when installed horizontally. The furnace must

also be elevated approximately 4-6 inches to allow

clearance for the condensate drain to exit the cabinet in

the horizontal position.

The horizontal furnace may also be suspended from the joists

using 3/8" all-thread rods with pieces of angle iron under-

neath the furnace to form a hanging rack at both ends and

the midpoint. The rods need to be of sufficient length to

allow for proper clearances from combustible materials. The

angle iron needs to be at least 32" in length to allow for

access to service panels.

AIR FOR COMBUSTION AND VENTILATION

If these furnaces are installed in a nondirect vent capacity

then the adequate flow of combustion and ventilating air

must not be obstructed from reaching the furnace. Air

openings provided for combustion air must be kept free of

obstructions which restrict the flow of air. Airflow restric-

tions affect the efficiency and safe operation of the furnace.

Keep this in mind should you choose to remodel or change

the area which contains your furnace. Furnaces must have a

free flow of air for proper performance.

Provisions for combustion and ventilation air shall be made

in accordance with latest edition of Section 5.3, Air for

Combustion and Ventilation, of the National Fuel Gas Code,

ANSI Z223.1 -- CAN/CGA B 149.1 or applicable provisions of

the local building codes. Special conditions created by

mechanical exhausting of air and fireplaces must be con-

sidered to avoid unsatisfactory furnace operation.

OUTSIDE AIR IS RECOMMENDED

The use of indoor air for most applications is acceptable,

unless there is the presence of corrosive chemicals or

contamination. Certain types of installation will require

the use of outside air for combustion.

The following types of installations will require use of

OUTDOOR AIR for combustion, due to chemical exposures:

* Commercial buildings

* Buildings with indoor pools

* Furnaces installed in "confined" laundry rooms

* Furnaces installed in "confined" hobby or craft rooms

* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion air

supply will also require OUTDOOR AIR for combustion:

* Permanent wave solutions

* Chlorinated waxes and cleaners

* Chlorine based swimming pool chemicals

* Water softening chemicals

* Deicing salts or chemicals

* Carbon Tetrachloride

* Halogen type refrigerants

* Cleaning solvents (such as perchloroethylene)

* Printing inks, paint removers, varnish, etc.

* Hydrochloric acid

* Cements and glues

* Antistatic fabric softeners for clothes dryers

* Masonry acid washing materials

Furnace locations may be in a "confined space" or an

"unconfined space".

Unconfined space is defined in Figure 6. These spaces may

have adequate air by infiltration to provide air for combustion

and ventilation. Buildings with tight construction (for

example, weather stripping, heavily insulated, caulked, vapor

barrier, etc.), may need additional air to be provided as

described for confined space.

Confined spaces are installations with less than 50 cu. ft. of

space per 1000 BTU/hr input from all equipment installed.

Air for combustion and ventilation requirements can be

supplied from inside the building as in Figure 9 or from the

outdoors, as in Figure 10.

QMINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE WITH 8 FT. CEILING

MAXIMUM BTUH MINIMUM AREA IN SQUARE FEET

INPUT RATING OF UNCONFINED SPACE

60,000 375

80,000 500

100,000 625

120,000 875

® -I

mFURNAOF

CONFINED

SPACE LESS THAN 50 CU. FT.

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

All air from inside the building as in Figure 9: The

confined space shall be provided with two permanent

openings communicating directly with an additional

room(s) of sufficient volume so that the combined volume

of all spaces meets the criteria for an unconfined space.

The total input of all gas utilization equipment installed

in the combined space shall be considered in making this

determination. Refer to Table 2 for minimum open areas

requirements.

All air from outdoors as in Figure 10: The confined space

shall be provided with two permanent openings, one

commencing within 12 inches of the top and one com-

mencing within 12 inches of the bottom of the enclosure.

The openings shall communicate directly, or by ducts,

with the outdoors or spaces (crawl or attic) that freely

communicate with the outdoors. Refer to Table 2, for

minimum open areas requirements.

TABLE 2

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000

80,000

100,000

120,000

Air

From

Inside

lOO

12o

Air From Outside

Vertical

Duct

Horizontal

Duct

18-CD19D8-15 7

iiiiiiiiiiii

Installer's Guide

CONFINED SPACE

AIR FROM INSIDE BUILDING

CONFINED

SPACE

PERMANENT

OPENINGS

CONFINED SPACE

AIR FROM OUTDOORS

CONFINED-

SPACE

CONFINED SPACE k

AIR FROM VENTILATED ATTIC/CRAWL SPACE

_ATTIC LOUVERS

DOORS

,UTLET

CONFINED -AIR

SPACE

ALTERNATE INLET

INLET A_R _AIR DUCT

CONFINED SPACE

AIR FROM VENTILATED ATTIC

:LOUVERS

TO OUTDOORS

CONFINED-

SPACE

INLET

AIR DUCT

DUCT CONNECTIONS

Air duct systems should be installed in accordance with

standards for air conditioning systems, National Fire Protec-

tion Association Pamphlet No. 90. They should be sized in

accordance with ACCA Manual D or whichever is applicable.

Central furnaces, when used in connection with cooling units,

shall be installed in parallel or on the upstream side of the

cooling coil to avoid condensation in the heat exchanger. With

a parallel flow arrangement, the dampers or other means used

to control flow of air shall be adequate to prevent chilled air

from entering the furnace, and if manually operated, must be

equipped with means to prevent operation of either unit

unless the damper is in full heat or cool position.

On any job, flexible connections of nonflammable material may

be used for return air and discharge connections to prevent

transmission of vibration. Though these units have been

specifically designed for quiet, vibration free operation, air ducts

can act as sounding boards and could, if poorly instMled,

amplify the slightest vibration to the annoyance level.

When the furnace is located in a utility room adjacent to the

living area, the system should be carefully designed with

returns to minimize noise transmission through the return

air grille. Although these furnaces are designed with large

blowers operating at moderate speeds, any blower moving a

high volume of air will produce audible noise which could be

objectionable when the unit is located very close to a living

area. It is often advisable to route the return air ducts under

the floor or through the attic. Such design permits the

installation of air return remote from the living area (i.e.

central hall).

When the furnace is installed so that the supply ducts carry

air circulated by the furnace to areas outside the space

containing the furnace, the return air shall also be handled

by a duct(s) sealed to the furnace and terminating outside

the space containing the furnace.

RETURN AIR DUCT SYSTEMS

Where there is no complete return duct system, the

return connection must be run full size from the

furnace to a location outside the utility room, base-

ment, attic, or crawl space.

Do Not install return air through the back of the furnace

cabinet.

Do Not install return air through the side of the furnace

cabinet on horizontal applications.

NOTE:

Minimum return air temperature is 55 °F.

All return air duct systems should provide for installation of

return air filters.

1. Set the furnace in place.

2. For upflow side return installations, remove the insula-

tion around the opening in the blower compartment.

3. The side panels of the upflow furnace include locating

notches that are used as guides for cutting an opening

for return air, refer to Figure 11 and the outline

drawing on page 4 for duct connection dimensions for

various furnaces.

NOTE:

On upflow 5 ton airflow models, if the airflow requirement

exceeds 1800 CFM, these models will require return air

openings and filters on both sides; OR 1 side and the

bottom; OR just the bottom.

8 18-CD19D8-15

4. Ifa 3/4" flange is to be used for attaching the air inlet duct,

add to cut where indicated by dotted lines in Figure 11.

Cut corners diagonally and bend outward to form flange.

5. If flanges are not required, and a filter frame is installed,

cut between locating notches (Figure 11).

6. The bottom panel of the upflow furnace must be re-

moved for bottom return air. Remove the filter and lay

the furnace on its back. Remove the two 1/4" hex screws

securing the bottom front channel to the cabinet. Lower

the front edge of the bottom front channel and pull

forward to remove the channel. The bottom return air

panel will now easily slide out of the cabinet. Reinstall

the bottom front channel and filter for upflow bottom

return installations.

7. The filter retainer is factory supplied for upflow bottom

return. Use the filter retainer on side or bottom if filter

is to be used within the furnace cabinet on upflow only

installations.

8. The horizontal installation of the upflow furnace

requires an external filter section. Do NOT use the

bottom return filter within the furnace. Filter kits

are available for horizontal applications.

9. Connect duct work to furnace. See Outline Drawing for

supply and return duct size and location. Flexible duct

connectors are recommended to connect both supply and

return air ducts to the furnace. If only the front of the

furnace is accessible, it is recommended that both supply

and return air plenums are removable.

RETURN AIR FILTERS (NOT SUPPLIED)

TYPICAL UPFLOW RETURN AIR FILTER

INSTALLATIONS

Filters are not factory supplied for these furnaces. These

furnaces require high velocity type air filters. The filters may

be located within the furnace blower compartment for

UPFLOW furnaces in either a BOTTOM or SIDE (left side or

right side) return air inlet. Some filters may need to be

trimmed for side or bottom filter use.

TABLE 3

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*UX2B060A9362A 17-1/2" 1- 17"X25"X 1"

*UX2B080A9422A

*UX2C100A9482A 21" 1 - 20" X 25" X 1"

*UX2D120A9602A 24-1/2" 1 - 24" X 25" X 1"

* First letter may be "A" or "T"

** NOTE - On 5 ton airflow models, if the airflow requirement exceeds

1800CFM, these models will require return air openings and filters

on both sides; OR 1 side and the bottom; OR just the bottom.

LOCATING *_

NOTCHES PRO-

VIDED FOR SIDE

RETURN CUTOUT

4..

-,. I/-

*- I

UPFLOW FURNACE ONLY I

j CUT OUT FOR

SIDE FILTER

"_ ,_ RONT

*SEE OUTLINE DRAWING _ of Furnace

Installer's Guide

NOTE:

On upflow 5 ton airflow models, if the airflow requirement

exceeds 1800 CFM, these models will require return air

openings and filters on both sides; OR 1 side and the

bottom; OR just the bottom.

The upflow furnace blower door has a hinge at the bottom

which allows the door to tilt forward for filter replacement

without the door being removed (See Figure 12). The furnace

filter in the bottom or side configuration can be removed by

simply turning the two latches on the blower door and tilting

the door forward.

The filter rails are spring loaded for automatic adjustment to

allow standard size, locally obtainable replacement filters.

The filter rack itself slides to adjust to the required width

needed for bottom or side return (See Figure 13).

BOTTOM FILTER RACK INSTALLATION

With the filter removed, the filter rack is compressed and

then inserted into the bottom of the furnace. The retaining

screw/pin on each side inserts into engagement holes at the

bottom of the furnace cabinet side.

Blower Door Hinge and Bottom Filter Rack Installation

®FILTER

RACK

RAILS

'_ SPRINGS

AUTOMATIC

ADJUSTMENT RETAINING

(Both Sides)

Optional Filter Rack Accessory Kit - BAYRACK960A

18-CD19D8-15 9

iiiiiiiiiiii

Installer's Guide

_ _ BOTTOM ENGAGEMENT

",.: ..... ..

BlowerDeck _II Furnace "

Engagement II •"II Cabinet

iiii II _ II Side

Engagement Hole

For Filter Rack

!'" '_" I1..... 11 _lnstallation With_)_Bottom Return

ENGAGEMENT

HOLE DETAIL

(Typical both sides

and blower deck) BLOWER EngagementHole

For Filter Rack

Installation With

Side Return

OPTIONAL FILTER RACK INSTALLATION FOR SIDE RE-

TURN AIR ON UPFLOW FURNACES (Left or Right)

If side air return is desired, it is necessary to move the filter

rack from the bottom of the furnace and reinstall it on the

side. The following instructions should be used:

a. Open or remove the blower door.

b. Remove the filter.

c. Compress the filter rack to disengage the retaining

pins/screws from the furnace sides and slide the filter

rack out.

d. Leave the bottom panel in place.

e. After the side cutout is made following the directions

in the "Return Air Duct Connections" section on

pages 8 and 9, compress the filter rack and reinstall

in the side of the furnace. Confirm that the upper

retaining pin/screw locks into the engagement hole in

the blower deck and the lower pin/screw rests against

the side of the bottom panel. See Figures 15-19.

f. Reinstall the furnace filter on the side inserting the

chamfer end first.

Furnace

Cabinet

Side

Filter

Rack

EngagementHole

ForFilter Rack

InstallationWith

BottomReturn

Filter Rack

Retaining

Screw/Pin

Furnace

Cabi net .,.,,)_

Side

Filter Rack

Retaining

Screw/Pin Filter

Rack

Bottom Panel

Furnace

Blower

Deck

Retaining Rack

Screw/Pin Assembly

SIDE

CUTOUT

RETAINING \

PIN -_

(Bo_[__,

III J/ FILTER BOTTOM

I I.] JJ RACK PANEL

[[I // RAILS INSTALLED

I[ V/zJ Typical Upflow Left Side Return Filter

L_z/Rack Installation

Optional Filter Rack Accessory Kit - BAYRACK960A

10 18-CD19D8-15

Typical Upflow Right Side Return Filter Rack Installation

CHAMFER

END OF

FILTER GOES

INTO FILTER

RACK FIRST

RETURN AIR FILTERS FOR UPFLOW FURNACE IN

HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in the horizontal

configuration, the return air filters must be installed exterior

to the cabinet. Remote filter grilles may be used for home-

owner convenience or the filters may be installed in the duct

work upstream of the furnace. See Figure 21.

TYPICAL RETURN AIR FILTER INSTALLATION IN

UPFLOW MODEL IN HORIZONTAL POSITION

Installer's Guide

BLOWER DOOR/HINGE REMOVAL

If clearance or other problems create a problem in using the

tilting door, the blower door hinge may be removed without

creating any problems with the seal of the furnace. To remove

the blower door, tilt the door forward 2 to 3 inches and pull up.

To remove the tilt feature, simply remove the lower hinge as

shown in Figure 22. The bottom of the blower door will catch

in the bottom of the furnace front channel for door replacement.

Door Hinge Removed

ALTERNATE UPFLOW FILTER CLIP /BRACKET

INSTALLATION (KIT09224)

1. Determine the location to be used. The furnace cabinet

has dimples for location of the alternate furnace clips

(Side return only). Pre-drill clearance holes with a 3/16"

drill. Bottom return holes are pre-drilled.

2. Install the clips in front and rear of the desired location

using the screws provided. The filter clip with the leaf

spring mounts in the rear of the cabinet.

ALTERNATE FILTER

CLIPS LOCATION

FILTER CLIP - KIT09224

18-CD19D8-15 11

iiiiiiiiiiii

Installer's Guide

INSTALLING THE FILTER

The filter may need to be cut to fit the unit depending on the

location of the return air filter.

A score line and the words "CUT HERE" are located on the

end of the filter. If your application requires cutting the

filter, do so as indicted by the score mark.

UNIT

SIZE

17-1/2"

21"

24-1/2"

RETURN AIR

BOTTOM

DO NOT CUT

SIDE

DO NOT CUT

CUT ON LINE

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER

INSTALLATIONS

Two filters are factory supplied for each downflow furnace.

These furnaces require high velocity type air filters. Down-

flow furnace filters must be located outside the furnace

cabinet. Typical installations are shown in Figure 24.

Tables 5 and 6 provide information for installation of the

filter retaining brackets shipped with downflow furnaces.

TABLE 4

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*DX060R936 17-1/2" 2- 14" X 20" X 1"

*DX080R942

*DX100R948 21" 2 - 16" X 20" X 1"

*DX120R960 24-1/2" 2 - 16" X 20" X 1"

*First letter may be "A" or "T"

TABLE 5

LOCATING FILTER RETAINER BRACKETS IN

DUCTWORK

FILTER

CABINET RETURNDUCT DIMENSION DIMENSION BRACKET

WIDTH WIDTH "A .... B" LOCATION*

17-1/2" 16-1/4" 15" 14" 14-3/8"

21" 19-3/4" 19-1/2" 14" 13-1/8"

24-1/2" 23-1/4" 22" 14" 13-5/8"

* LOCATION DIMENSION IS FROM END OF DUCT AGAINST THE FURNACE TO THE

SCREW HOLES FOR THE BRACKET.

@Optional

BAYFLTR206

Door Kit

DOWNFLOW

Airflow

BOptiyFLnTRI06

/ ow% ow;

TABLE 6

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/HORIZONTAL FURNACES

UNIT LOCATION

VERTICAL HORIZONTAL HORIZONTAL

FURNACE SURFACE CLOSET CLOSET ALCOVE /ATTIC

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

12 18-CD19D8-15

I The following warning complies with State of California law, Proposition 65.

Hazardous Gases!

Exposure to fuel substances or by-products of incomplete

fuel combustion is believed by the state of California to

cause cancer, birth defects, or other reproductive harm.

Carbon monoxide, fire or smoke can cause serious bodily

injury, death, and!or property damage.

A variety of potential sources of carbon monoxide can be

found in a building or dwelling such as gas-fired clothes

dryers, gas cooking stoves, water heaters, furnaces and

fireplaces. The U.S. Consumer Product Safety Commission

recommends that users of gas-burning appliances install

carbon monoxide detectors as well as fire and smoke detec-

tors per the manufacturer's installation instructions to help

alert dwelling occupants of the presence of fire, smoke or

unsafe levels of carbon monoxide. These devices should be

listed by Underwriters Laboratories, Inc. Standards fbr

Single and Multiple Station Carbon Monoxide Alarms,

UL 2034 or CSA International Standard, Residential

Carbon Monoxide Alarming Devices, CSA 6.19

NOTE:

The manufacturer of your furnace does not test any detec-

tors and makes no representations regarding any brand or

type of detector.

GENERAL VENTING

THIS FURNACE MUST BE VENTED TO THE OUTDOORS.

THESE FURNACES ARE INDUCED DRAFT VENTED

AND MUST NOT BE CONNECTED TO ANY VENT SERV-

ING ANOTHER APPLIANCE. PLEASE NOTE THAT

THESE FURNACES USE POSITIVE-PRESSURE VENT

SYSTEMS.

Proper venting is essential to obtain maximum efficiency

from a condensing furnace. Proper installation of the vent

system is necessary to assure drainage of the condensate

and prevent deterioration of the vent system.

American Gas Association has certified the design of con-

densing furnaces for a minimum of 0" clearance from com-

bustible materials with a single wall plastic vent pipe.

The recommended system is assembled from 2", 2-1/2", or 3"

plastic pipe and fittings (See Table 7, page 15). Where the

system is routed to the outdoors through an existing masonry

chimney containing flue products from another gas appliance,

or where required by local codes, then 3" venting of Type 29-4C

stainless steel must be used in place of PVC material.

These furnaces have been classified as CATEGORY IV

furnaces in accordance with ANSI Z21.47 "latest edition"

standards. Category IV furnaces operate with positive vent

pressure and with a vent gas temperature less than 140 ° F.

above the dewpoint. These conditions require special venting

systems, which must be gas tight and water tight.

NOTE:

When an existing furnace is removed from a venting

system serving other gas appliances, the venting system is

likely to be too large to properly vent the remaining

attached appliances.

Installer's Guide

The following steps shall be followed with each appliance

remaining connected to the common venting system placed

in operation, while the other appliances remaining connected

to the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion or other deficiencies which

could cause an unsafe condition.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which the

appliances remaining connected to the common venting

system are located and other spaces of the building. Turn

on clothes dryers and any appliances not connected to

the common venting system. Turn on any exhaust fans,

such as range hoods and bathroom exhausts, so they will

operate at maximum speed. Do not operate a summer

exhaust fan, close fireplace dampers.

4. Follow the lighting instructions. Place the appliance

being inspected in operation. Adjust thermostat so

appliance will operate continuously.

5. After it has been determined that each appliance remain-

ing connected to the common venting system properly

vents when tested as outlined above, return door, win-

dows, exhaust fans, fireplace dampers and any other gas-

burning appliance to their previous conditions of use.

If improper venting is observed during any of the above tests,

the remaining common venting system must be corrected.

Correction could require rerouting or resizing the remaining

vent system.

IMPORTANT:

These furnaces may be installed as Direct Vent (sealed com-

bustion) or as Nondirect vent (single pipe). The furnaces are

shipped DIRECT VENT with sealed combustion.

For DIRECT VENT APPLICATION: The furnaces must be

vented to the exterior of the house and combustion air MUST

come through the inlet air pipe FROM OUTSIDE AIR. The pipes

DO NOT have to exit the exterior of the house together or on the

same side of the house.

For NONDIRECT VENT APPLICATION: The furnace shall be

vented to the exterior of the house, but combustion air may

enter from the surrounding area as long as combustion air

requirements are met. (See AIR FOR COMBUSTION AND

VENTILATION)

FURNACE VENT/INLET PIPE INSTALLATION

There are many different variations of the vent/inlet air pipe

combination. The vent/inlet air combination used for instal-

lation of these furnaces depends on the needs of the location.

However, these guidelines must be followed:

1. The furnace must vent outside the structure.

2. Furnace combustion air requirements must be met for

nondirect, single pipe applications (See example on

next page).

3. For direct vent application of these furnaces, the vent

pipe and air inlet pipe do not have to exit in the same air

space or even on the same surface of the structure.

However, the longest individual pipe will decide the value

fbr the longest allowable equivalent vent/inlet air length

as shown in the vent length table.

18-CD19D8-15 13

Installer's Guide

NOTE:

BAYVENT200* accessories can be used for inlet and outlet

terminals when the pipes do not exit the structure together.

The following are EXAMPLES ONLY:

EX. 1 --

Example 1 shows that the vent may go vertical while the inlet

air may be on any side of the structure. The vent pipe would

decide the maximum equivalent length for the pipe depending

on the furnace and pipe size.

Vent

Air

Inlet =_ Furnace

EX. 2 --

Example 2 shows the vent pipe exhausting through the roof

and the inlet air coming from the interior of the house (See

Note). The inlet air coming from the interior of the house

must meet combustion requirements for area, etc., as shown

in the section AIR FOR COMBUSTION AND VENTILA-

TION in this Installer's Guide.

Air_ _ Vent

Inlet_

(See Note)

EX. 3 --

Example 3 shows the vent exiting one side of the house while

the inlet air is on the opposite side of the structure. Here the

vent pipe length must be within the allowable length for the

size of furnace and size of the vent pipe. This example

demonstrates that the pipes do not have to exit on the same

side of the structure.

Air

Inlet

=_ Furnace

Vent

EX. 4--

The inlet air does not have to come from outside the structure.

Example 4 shows the inlet air (See Note), may come from the

attic if the requirements for combustion air are met as shown

in the section AIR FOR COMBUSTION AND VENTILATION.

Attic

_(Soe Note)

FurnaceL

Vent

NOTE:

ff only the flue gas pipe is to the outside of the structure, a

straight section of pipe (long enough to exit the furnace

cabinet) must be attached to the inlet air side with an elbow

(which is 5 to 10 equiv, ft.) installed on the end to prevent

dust and debris from falling directly into the furnace.

VENT FITTING MATERIAL - PLASTIC

Gas and liquid tight single wall vent fittings, designed for

resistance to corrosive flue condensate, MUST be used

throughout.

Listed in Table 7 are 2", 2-1/2", and 3" size fittings that meet

these requirements. The materials listed are various grades

of PVC and ABS plastic.

PIPE JOINTS: All joints must be fastened and sealed to

prevent escape of combustion products into the building.

NOTE:

It is recommended that the first joints from the furnace be

connected and sealed with high temperature RTV. This will

enable the pipes to be removed later without cutting.

Be sure to properly support these joints.

BONDING OF PVC

Commercially available solvent cement for PVC must be

used to join PVC pipe fittings. Follow instructions on con-

tainer carefully.

Pipe and Fitting -ASTM D1785, D2466, D2661, & D2665

PVC Primer and Solvent Cement - ASTM D2564

Procedure for Cementing Joints - RefASTM D2855

1. Cut pipe square, remove ragged edges and burrs.

Chamfer end of pipe, then clean fitting socket and pipe

joint area of all dirt, grease, moisture or chips.

2. After checking pipe and socket for proper fit, wipe socket

and pipe with cleaner-primer. Apply a liberal coat of

primer to inside surface of socket and outside of pipe.

DO NOT ALLOW PRIMER TO DRY BEFORE APPLY-

ING CEMENT.

3. Apply a thin coat of cement evenly in the socket. Quickly

apply a heavy coat of cement to the pipe end and insert

pipe into fitting with a slight twisting movement until it

bottoms out.

14 18-CD19D8-15

Installer's Guide

4. Hold the pipe in the fitting for 30 seconds to prevent

tapered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow

15 minutes before handling. Cure time varies according

to fit, temperature and humidity.

NOTE:

Follow venting instructions carefully when using PVC

cemenL

IMPORTANT:

All joints must be water tight. Flue condensate is somewhat

acidic, and leaks can cause equipment damage.

TABLE 7

PVC VENT FITTING MATERIAL These fittings are available from your Gas Furnace Distributors.

1-518"

[

i_ 4-1/2"

WALL MOUNT FLANGE

BAY69X 148

2-3/16"

_----- 5-5/8"

WALL MOUNT FLANGE

BAY69X 147

PLASTIC PIPE DESIGNATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

F891 CELLULAR CORE "158 ASTM F891

D2665 DWV PIPE *'158 ASTM D2665

D1785 SCH 40, 80, 120 *'158 ASTM D1785

D2241 SDR SERIES *'158 ASTM D2241

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41 *'212 ASTM D2846

F441 SCH 40, 80 *'212 ASTM F441

F442 SDR SERIES *'212 ASTM F442

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV **'180 ASTM D2661

F628 SCH 40 DWV CELLULAR CORE **'180 ASTM F628

* - Allowable temperatures based on classifications covered in ASTM D4396 [Deflection Temps Under Load (264 PSI)]

** - Allowable temperatures based on classifications covered in ASTM D1784 [Deflection Temps Under Load (264 PSI)]

*** - Allowable temperatures based on classifications covered in ASTM D3965 [Deflection Temps Under Load (264 PSI)]

Connection of the pipe and collar of the combustion air inlet

should just be a friction fit. It is recommended that the inlet

air joint be sealed with RTV type sealant to allow the joint to

be separated for possible future service. The inlet and vent

pipes must be properly supported throughout the entire

length.

Connection of the vent pipe to the vent collar should also be

accomplished using RTV type sealant. This type sealant

provides a connection which remains flexible and can be

separated in the future if service needs require the removal of

the vent pipe for service or clearance.

NOTE:

Vent termination kit BA YAIR3OAVENTA or BA YVENT2OOB

may be used in addition to the horizontal and vertical

termination options shown in the following figures.

(_ VENT AND INLET AIR CONNECTIONS

Seal VENT PIPE

withRTV sealant

Seal INLET AIR PIPE

with RTV sealant

Front of Furnace

18-CD19D8-15 15

iiiiiiiiiiii

Installer's Guide

VENT LENGTH TABLE

ALTITUDE MAXIMUM TOTAL EQUIVALENT LENGTH IN FEET

FOR VENT AND INLET AIR (SEE NOTES)

0-7,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

UX2/DX2B060A9362A 200 200 200

UX2/DX2B080A9422A 50 120 200

UX2/DX2C100A9482A Not Allowed 60 200

UX2/DX2D120A9602A Not Allowed Not Allowed 200

7,000-9,500 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

UX2/DX2B060A9362A 100 100 100

UX2/DX2B080A9422A 25 60 100

UX2/DX2C100A9482A Not Allowed 30 100

UX2/DX2D120A9602A Not Allowed Not Allowed 100

9,500-12,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

UX2/DX2B060A9362A 50 50 50

UX2/DX2B080A9422A Not Allowed 30 50

UX2/DX2C100A9482A Not Allowed Not Allowed 50

UX2/DX2D120A9602A Not Allowed Not Allowed 50

NOTES: * - First letter may be "A" or "T"

1. Minimum vent length for all models: 3' horizontal or 3' vertical.

2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except

adapters at the top of the furnace). If different inlet and vent pipe sizes are used, the vent pipe must adhere to the

maximum length limit shown in the table above (See note 6 below for exception). The inlet pipe can be of a larger

diameter, but never smaller than the vent pipe.

3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS

THE MAXIMUM LENGTH OF EACH (Vent or Inlet air pipes).

4. One SHORT radius 90 ° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is equivalent to 6' of 3" pipe.

One 90 ° elbow is equivalent to 71/2' of 21/2'' pipe or 5' of 2" pipe. Two 45 ° elbows equal one 90°elbow.

5. The termination tee or bend must be included in the total number of elbows. If the BAYAIR30AVENTA termination kit is

used, the equivalent length of pipe is 5 feet. BAYVENT200B equivalent length is 0 feet.

6. Pipe adapters are field supplied (except 120).

HORIZONTAL INSTALLATION

(Upflow/Horizontal or Downflow/Horizontal)

NOTE:

In horizontal venting when the factory supplied "off-set" (2)(3

reducing coupling) is used for 3" vent pipe installation, make

sure the marking "Top" is located on the top side of the pipe.

The straight side must be on bottom for proper condensate

drainage. This coupling is factory supplied only with the

followinomodels: UC120 & DC120. UX120 & UY120

UXIO0 _UYIO0, UX808C960, and all DX & DY models.

LABEL

SAYS

"TOP" \\\\\

2" _' COUPLING

FACTORY SUPPLIED ONLY WITH

THE FOLLOWING MODELS:

UC120 & DC120

UX120 & UY120

UX100 & UY100

UX080C960

ALL DX & DY MODLES

VENT

OUTLET

16 18-CD19D8-15

Installer's Guide

ELBOW AND TEE MUST BE

AS CLOSE TOGETHER

AS POSSIBLE

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

iiiiliiiiii;iiiiiiliiliiliiliiliiliiliiliiliiliilli!ii¸

COMBUSTION

AIR INLET

40" UPFLOW OR

DOWNFLOW MODELS

OUTSIDE

WALL

45°ELBOW

STUB CUT AT

45 °ANGLE

SEE VENTING TABLE

STRAPS OR OTHER SUITABLE SUPPORTS

AT MAXIMUM OF 3'-0" INTERVALS

UPWARD PITCH -- 1/4" PER FOOT

FIRST SUPPORT SHOULD BE AS

CLOSE TO FURNACE CONNECTION

AS POSSIBLE.

NOTE:ANY FITTINGS PASSING

THROUGH AN UNHEATED SPACE

MUST BEINSULATED.

NOTE: VENT A ND INL ET MUS T BE SUPPOR TED

A T A MAXIMUM OF 3' INTER VALS

USE ONLY

APPROVED STRAP

TERMINATION (FIELDSUPPLIED)

--) /VENT X

OUTSIDE I1"_+1/2"

WALL

COMBUSTION AIR ELBOW

(FIELD

SUPPLIED)

COMBUSTION

AIR

RAIN CAI

BAYAIR3OAVENTA

18-CD19D8-15 17

Installer's Guide

12"MINIMUM

TO OVERHANG

VENT

CAP

MAINTAIN 12" (18" FOR CANADA) MINIMUM

CLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

BAYVENT200B

BAYAIR30AVENTA

(Sidewall)

When the vent pipe is exposed to temperatures below

freezing, i.e., when it passes through unheated spaces, etc.,

the pipe must be insulated with 112 inch (22.7 mm) thick

Armaflex-type insulation or equal.

If the space is heated sufficiently to prevent freezing, then

the insulation would not be required. If domestic water

pipes are not protected from freezing then it is assumed the

space meets the condition of a heated space.

HORIZONTAL VENTING THROUGH WALL

These furnaces may be installed as direct vent (as

shipped) or as nondirect vent. Installation must

conform to national, state, and local codes.

The vent & inlet terminals must be located at least 12"

minimum above normally expected snow accumulation level.

Avoid areas where staining or condensate drippage may be

a problem.

Location of the vent/wind terminal should be chosen to meet

the requirements of Figure 39 for either direct or nondirect

vent applications.

PITCH -- Venting through the wall must maintain 1/4" per

foot pitched upward to insure that condensate drains back to

the furnace.

FLUE GAS DEGRADATION -- The moisture content of

the flue gas may have a detrimental effect on some building

®COUPLING _'_ PVC WALL

(PLASTIC STU rI MOUNT FLANGE

•II /APPROVED

TERMINATION

NORMALLY EXPECTED

1" CLEARANCE SNOW ACCUMULATION

(AIR SPACE )

VENTINGTHROUGH COMBUSTIBLEWALLS

Pitch-- 1/4Inch PerFL

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

(1" ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE )

COUPLING

(PLASTIC

VENTING ) /

14 61N. MIN. I_--

j lj(TOJOINT)_

PVC WALL

MOUNT FLANGE

IOPTIONAL)

/APPROVED

TERMINATION

12" MIN. ABOVE

NORMALLY EXPECTED

SNOW ACCUMULATION

VENTING THROUGH NON-COMBUSTIBLE WALLS

Pitch- 1/4 Inch Per Ft.

materials. This can be avoided by using the roof or chimney

venting option. When wall venting is used on any surface that

can be affected by this moisture, it is recommended that a

corrosion resistant shield (24 inches square) be used behind

the vent terminal. This shield can be wood, plastic, sheet

metal, etc. Also, silicone caulk all cracks, seams and joints

within 3 feet of the vent terminal.

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials must be

maintained when using single wall stainless steel venting.

See Figure 31.

Shield material to be a minimum of 24 gauge stainless or

aluminized sheet metal. Minimum dimensions are 12"x12".

Shield must be fastened to both inside and outside of wall.

Use screws or anchor type fasteners suited to the outside or

inside wall surfaces.

NONCOMBUSTIBLE MATERIAL WALL

The hole through the wall must be large enough to maintain

pitch of vent and properly seal.

Use cement mortar seal on inside and outside of wall. See

Figure 32.

18 18-CD19D8-15

Installer's Guide

SUPPORT HORIZONTAL PIPE EVERY 3' 0"

WITH THE FIRST SUPPORTAS CLOSE TO

THE FURNACE AS POSSIBLE. INDUCED

DRAFT BLOWER, HOUSING, AND

FURNACE MUST NOT SUPPORT THE {_ {_ I_ I_

WEIGHT OF THE FLUE PIPE.

__ |_-I PITCH -t$4" PER FOOT

40" UPFLOVV OR.DO".rv_FLOW FURNACE

HORIZONTAL AND VERTICAL VERTICAL

®REMOVE RIBS

FROM VENT

VENT"_

12' :t I"_

DISTANCE FROM TOP

OF VENT TO BO1TOM

OF AIR INLET MUST I

9" MIN.

_ 12-INCH CLEAr4ANCE MUST BEMAINTAINED ABOVE HIGHEST

AN_C!PATED SNOW LEVEL

/ I I_ MAXIMUM NOT TO EXCEED

24 INCHES ABOVE ROOF,

COMBUSTION

AIR INLET

MAINTAIN 12 IN.

(18 IN. FOR CANADA)

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF.

VENT

REMOVE RIBS ,_

FROM CAP

COMBUSTION

AIR

ROOF BOOT

(FIELD SUPPLIED)

MAINTAIN 12 IN.

(18 IN. FOR CANADA)

MINIMUM CLEARANCE

_ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF

suP

(FIELD SUPPLIED)

ELBOW

(FIELD SUPPLIED)

COMBUSTION

AIR

BAYAIR30AVENTA (VERTICAL)

_ SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT

PIPE

COUPLING

SUPPORT

FLANGE

CEILING

GALVANIZED FIRESTOP SHOULD

BE FABRICATED WITH 3-7/8" DIA.

HOLE FOR SUPPORT FLANGE

(12" x 12" PANEL OR 12" DIA MIN.)

CLEARANCE (0" ACCEPTABLE FOR PVC VENT PIPE)

( 1 "ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE )

VENTING THROUGH CEILING

18-CD19D8-15 19

Installer's Guide

VENTING THROUGH THE ROOF

When penetrating roof with a 2" PVC vent pipe, a 2" electrical

conduit flashing may be used for a weather tight seal.

Lubricate flexible seal on flashing before PVC pipe is pushed

through the seal. (Field Supplied)

NOTE:

No vent cap as shown in Figure 34 is the preferred method

for vertical vent termination in extremely cold climates.

In extreme climate conditions, insulate the exposed pipe

above the roof line with Armaflex type insulation.

VENT FITTING MATERIAL - STAINLESS STEEL

Gas and liquid tight single wall metal vent fitting, designed

for resistance to corrosive flue condensate such as Type

29-4C MUST be used throughout.

These fittings and fitting accessories are to be supplied

locally.

DIRECTION OF STAINLESS STEEL FITTING

Allstainlesssteelfittingmustbeinstalledwithmaleend

towards the furnace.

................................................................................All horizontal stainless steel sections must be positioned

with the seam on top.

All long horizontal sections must be supported to prevent

sagging.

All pipe joints must be fastened and sealed to prevent escape

of combustion products into the building.

®PVC PLASTIC VENTING - ONLY

THROUGH UNUSED CHIMNEY

STAINLESS STEEL

VENT CAP

FLUE PIPE

COUPLING TO SUPPORT

PIPE FROM ANGLES

OR OTHER SUITABLE

SUPPORT METHOD

6 IN. MIN.

SUPPORT THE SINGLE

WALL FLUE PIPE AND

CENTER IT IN THE

CHIMNEY OPENING WITH

ANGLES AS SHOWN OR

ANOTHER EQUIVALENT

MANNER.

COUPLING

AS REQUIRED

FLUE PIPE

®SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT

SUPPORT _

FLANGE

FLOOR

COUPLING

GALVANIZED

PANEL (FIRESTOP)

FLUE PIPE

CLEARANCE

(0"ACCEPTABLE FOR PVC VENT PIPE)

(1"ACCEPTABLE FOR TYPE29-4C STAINLESS STEELVENT PIPE)

TYPE 29-4C STAINLESS STEEL VENTING -

USED THROUGH CHIMNEY THAT VENTS

ANOTHER GAS APPLIANCE

STAINLESS STEEL

VENT CAP

(OPTIONAL)

SEE CAUTION 6 IN. MIN.

SUPPORT THE SINGLE WALL

STAINLESS STEEL GAS

VENTING AND CENTER IT IN

THE CHIMNEY OPENING WITH

ANGLES AS SHOWN OR

ANOTHER EQUIVALENT

MANNER.

NOTE:

HORIZONTALVENTING

TO VERTICAL VENTING

NOTE:

HORIZONTALVENTING

TO VERTICALVENTING

Do not run vent through chimney for wood burning or

oil furnaces or incinerators or any other gas appliance.

IMPORTANT-

The single wall flue pipe joints must be sealed.

The 90°elbow connection to vertical pipe must be sealed to

prevent condensate leakage to base of masonry chimney.

Do not run vent through chimney for wood burning or oil

furnaces or incinerators.

If remaining free area between single wall flue pipe and

masonry chimney is to be used for another gas appliance

venting area must be sufficient to vent that appliance and

that appliance must be connected to chimney with

separate entry openings.

IMPORTANT-

The single wall flue pipe joints must be sealed.

The 90 ° elbow connection to vertical pipe must be sealed to

prevent condensate leakage to base of masonry chimney.

VENTING ROUTED THROUGH A MASONRY CHIMNEY

20 18-CD19D8-15

Installer's Guide

HORIZONTAL VENT CLEARANCES

INSIDE

CORNER DETAIL

FV'] VENTTERMINAL (_) AIR SUPPLY INLET [] AREAWHERE TERMINAL IS NOT PERMITTED

Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch, deck, or

A= balcony 12 inches (30 cm) 12 inches (30 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

B= Clearance to window or door that may be opened 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 4 feet (1.2m) below or to the side of opening;

and =/< 100,000 Btuh (30 kw), 1 foot (0.3m) above opening.

36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit located above

D= the terminal within a horizontal distance of 2 feet

(61 cm) from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line extended 3 feet (91 cm) with a height 15 feet (4.5 m) above the

H= above meter/regulator assembly meter/regulator assembly

I= Clearance to service regulator vent outlet 3 feet (91 cm)

Clearance to nonmechanical air supply inlet to 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

J= building or the combustion air inlet to any other 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 4 feet (1.2 m) below or to side of opening;

and =/< 100,000 Btuh (30 kw), 1 foot (300 m) above opening

appliance 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within

10 feet (3m) horizontally

Clearance above a paved sidewalk or paved 7 feet (2.13 m) 1 7 feet (2.13 m)

L= driveway located on public property

M= Clearance under veranda, porch, deck, or balcony 12 inches (30 cm)

Notes:

1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

1. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings.

:l:. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

18-CD19D8-15 21

iiiiiiiiiiiii

iiiiiiiiiiii

Installer's Guide

Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch,

A= deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

B= Clearance to window or door that may be 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw)

opened and =/< 100,000 Btuh (30 kw), and =/< 50,000 Btuh (15 kw),

36 inches (91 cm) for appliances > 100,000 Btuh (30 kw) 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit

located above the terminal within a

D= horizontal distance of 2 feet (61 cm)

from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line 3 feet (91 cm) with a height 15 feet (4.5 m) above the

H= extended above meter/regulator assembly meter/regulator assembly

I= Clearance to service regulator vent outlet 3 feet (91 cm)

Clearance to nonmechanical air supply 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw)

J= inlet to building or the combustion air and =/< 100,000 Btuh (30 kw), and =/< 50,000 Btuh (15 kw),

inlet to any other appliance 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw) 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally

Clearance above a paved sidewalk or

L= paved driveway located on public property 7 feet (2.13 m) l-

M= Clearance under veranda, porch, deck, 12 inches (30 cm) :l:

or balcony

Notes:

1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

1-. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings.

:l:. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

@DOWNWARD VENTING

Furnace may be in vertical or horizontal configurat_

All horizontal pipes must be

supported at maximum of 3

foot intervals

Slope 1/4" per ft. \ II

Slope 1/4" per ft.

NOTES:

I I

DOWNWARD VENT LENGTH IS

LIMITED TO A MAXIMUM OF 15

SEQUIVALENT FEET.

40 Inch

SEE __ Upflow or

NOTES Downflow

Furnace

6" Min.

.._!._

A) Condensate trap for vent pipe must be a minimum of 6 inches in height.

B) Condensate trap for vent and inlet pipe must be connected into a condensate drain pump; an open or

vented drain; or it can be connected to the outlet hose of the furnace's condensate trap. Outdoor drain-

ing of the furnace and coil condensate is permissible if allowed by local codes. Caution should be taken

to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Exces-

sive draining of condensate may cause saturated ground conditions that may result in damage to plants.

c) The condensate trap should be primed at initial start up prior to heating season operation.

22 18-CD19D8-15

IMPORTANT:

The Commonwealth of Massachusetts requires compliance

with regulation 248 CMR 4.00 and 5.00 for installation of

through - the - wall vented gas appliances as follows:

For all side wall horizontally vented gas fueled equipment

installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those

owned or operated by the Commonwealth and where the

side wall exhaust vent termination is less than seven (7)

feet above finished grade in the area of the venting,

including but not limited to decks and porches, the

following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE

DETECTORS. At the time of installation of the side wall

horizontal vented gas fueled equipment, the installing

plumber or gasfitter shall observe that a hard wired

carbon monoxide detector with an alarm and battery back-

up is installed on the floor level where the gas equipment

is to be installed. In addition, the installing plumber or

gasfitter shall observe that a battery operated or hard

wired carbon monoxide detector with an alarm is installed

on each additional level of the dwelling, building or

structure served by the side wall horizontal vented gas

fueled equipment. It shall be the responsibility of the

property owner to secure the services of qualified licensed

professionals for the installation of hard wired carbon

monoxide detectors

a. In the event that the side wall horizontally vented

gas fueled equipment is installed in a crawl space or an

attic, the hard wired carbon monoxide detector with alarm

and battery back-up may be installed on the next adjacent

floor level.

b. In the event that the requirements of this

subdivision can not be met at the time of completion of

installation, the owner shall have a period of thirty (30)

days to comply with the above requirements; provided,

however, that during said thirty (30) day period, a battery

operated carbon monoxide detector with an alarm shall be

installed.

2. APPROVED CARBON MONOXIDE

DETECTORS. Each carbon monoxide detector as required

in accordance with the above provisions shall comply with

NFPA 720 and be ANSI!UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate

shall be permanently mounted to the exterior of the

building at a minimum height of eight (8) feet above grade

directly in line with the exhaust vent terminal for the

horizontally vented gas fueled heating appliance or

equipment. The sign shall read, in print size no less than

one-half (1/2) inch in size, "GAS VENT DIRECTLY

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

Installer's Guide

4. INSPECTION. The state or local gas inspector of

the side wall horizontally vented gas fueled equipment

shall not approve the installation unless, upon inspection,

the inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of 248

CMR 5.08(2)(a)1 through 4.

This appliance requires a special venting system. If

BAYAIR30AVENTA or BAYVENT200B are used, a copy of

the installation instructions for the kit shall remain with

the appliance or equipment at the completion of

installation. The venting system installation instructions

can be obtained from the manufacturer by writing to the

following address:

American Standard, Inc.

6200 Troup Highway

Tyler, TX 75707

Attention: Manager of Field Operations Excellence

IMPORTANT:

Products installed in Canada must use vent systems that

are certified to the Standard for Type BH Gas Venting Sys-

tems (ULC $636) for Class II-A venting systems (up to

65°C). Components of the vent system must not be inter-

changed with other vent systems or unlisted pipe or fittings.

Plastic components, specified primers, and glues must be

from a single system manufacturer and not intermixed with

other system manufacturer's vent system parts. In addi-

tion, the first three feet of the vent pipe must be visible for

inspection.

18-CD19D8-15 23

Installer's Guide

CONDENSATE DRAIN INSTRUCTIONS

IV!_ [q:la//[e] _I

It is recommended that a drain pan be installed under the

furnace to prevent property damage, personal injury or

death from leaking condensate.

UPFLOW (VERTICAL)

VERTICAL APPLICATIONS

Upflow furnace - The connection tubing for left and right

side drainage is shipped in the blower compartment. Install

the connection tubing from the trap to the side of the unit and

trim all excess tubing to avoid ldnks.

Downflow furnace -The furnace is shipped with the left

side drainage setup. To change the right side drain, remove

the drain lines from the trap, rotate the trap 180 ° so it exits

to the right, reconnect the lines, and run a 1/2" CPVC pipe

from the trap out through the right side knock-out. Use RTV

silicone sealant to connect the CPVC pipe to the trap for ease

of removing to clean the trap.

Right side

Left side

UPFLOW (VERTICAL)

Use Inducer Drain

hose without

extension

UPFLOW HORIZONTAL 17" UNITS

(Left side only)

Use

extension

hose here

UPFLOW HORIZONTAL 21" & 24" UNITS

(Left side only)

24 18-CD19D8-15

HORIZONTAL APPLICATIONS

Upflow and Downflow furnaces -All horizontal applica-

tions are left side only. It is always recommended that the

auxiliary drain pan be installed under a horizontally in-

stalled evaporator and/or 90% gas furnace. Connect the

auxiliary drain pan to a separate drain line (no trap is needed

in this line).

The trap must be repositioned to the exterior of the cabinet.

Remove the trap from its present location and reposition the

trap outside of the unit, through the long circular hole, next to

the secondary recuperative cell. Remove the larger &'ain line

(from the secondary cell) and trim to fit between the second-

ary cell and the new trap location. On upflow units, plug the

hole in the blower deck where the tube went through.

DOWNFLOW (VERTICAL)

Right

side

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

DOWN FLOW (VERTICAL)

Installer's Guide

Cut off curved end of

Inducer drain hose

DOWNFLOW (HORIZONTAL)

Remove the hose from the induced blower and reposition into

the other &'ain tap of the inducer, which is located 90 °

clockwise around the inducer. Move the cap from that &'ain

tap to the unused drain tap. On upflow units, plug the hole in

the blower deck where the tube went through. This tube on

downflow units will need to be cut to fit between the inducer

and the trap. On upflow units, this tube may need to be

extended, using the tubing shipped with the furnace.

Connections must be made to an OPEN/VENTED DRAIN.

Outdoor draining of the furnace and coil condensate is

permissible if allowed by local codes. Caution should be taken

to prevent drains from freezing or causing slippery conditions

that could lead to personal injury. Excessive draining of

condensate may cause saturated ground conditions that may

result in damage to plants.

NOTE:

Use 1/2" or larger PVC or CPVC pipe and fittings as required

for drain connections (fittings, pipe and solvent cement not

provided).

NOTE:

A corrosion resistant condensate pump must be used ifa

pump is required for a specific drain system.

IMPORTANT:

The condensate drain should be installed with provisions to

prevent winter freeze-up of the condensate drain line. Frozen

condensate will block drains, resulting in furnace shutdown, ff

the drain line cannot be installed in a conditioned space, then

UL listed heat tape should be applied as required to prevent

freezing (per manufacturer's instructions). The heat tape should

be rated at 5 or 6 watts per foot at 120 volts. Self-regulating

(preferred) or thermostatically controlled heat tape is required.

Evaporator and furnace condensate drain piping may be

manifolded together. A primary drain vent stack must be

installed and terminated below the outlet of the secondary

heat exchanger drain connection to prevent water from

damaging furnace controls if the primary drain outlet plugs

up. Where the furnace is installed above a finished ceiling,

the primary drain vent stack must be installed such that

overflow from the vent stack opening will flow into an axillary

drain pan in order to prevent water damage to the finished

ceiling below.

18-CD19D8-15 25

Installer's Guide

If upflow furnace is installed

over a finished ceiling, overflow

from the primary drain vent

stack must flow into an auxiliary

drain pan to prevent damage to

the finished ceiling below,

Primary drain vent stack

must terminate below

secondary heat exchanger

condensate drain outlet,

To drain opening

",,,

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

T"STAT

SEE

NOTE 7

[]

SEE

NOTE 8

[]

SEE

NOTE 6

[]

1 TER COMPO[ENT ,,MIRI G

24 V. "L FIELD

---- L ]NE v. _* M_'I_ [NG

24 V. _ FA;T{ _Y

-- L ]NE /.#>" 'A,'IR [MG

2 STAGE

FURNACE

[]

_]-_

[]

NOTES:

I BE SURE POWER AGREES WITH EOglPMENT NAMPLATE(S)

2LOW VOLTAGE (24V AIRING) TO BE NO 18 AW G MIN

3 GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES

SET THERMOSTAT HE_T ¢_TI_IPATOR PER UNIT AIRING DIAGR&M

: THESE LEADS PNOVIDE ,,yS ' ROWER FOR CO_'iMECTION OF ELECTRONIC AIR

CLEANER AND HUMIDIFIER MAX LOAD I0 AMPS EACH

6 THIS CONNECTION IS ONLY USED FOR THERMOSTATS REOUIRIMG

CONNECTION TO THE 24 V POWER SUPPLY (COMMAN)

7 SEE TWINNING CONNEDTION DIAGRAMS FOR PROPER CONNECTIONS

WHEX USING THIS FEATURE

8 WHEN A HEATING THERMOSTAT (WITHOUT FAN SWITCH) IS USED,

NO WIRING ON "G" TERMINAL OF IFD IS USED

9 AI _NI} A2 MilST BE JUM_ERED TOGETHER FOR _ROPER OPERATION

SECOND STAGE HEATING AILL BEGIN I0 MINUTES AFTER FIRST STAGE

_FIELD ADDED JUMPER • GROU N D

WlTOW2. \SCREW

T'STAT

SEE

NOTE 7

SEE

NOTE 6

2 STAGE

FURNACE

-D

INTER CII,!f:C ENT ',A"IF_]N("

24 V'. -L_ FIELD

----LINE ,/.j,/WIRI[ G

2 'M'. _, FACT Ow, Y

'_'11_I O

-- LINE ',,'. _,

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTAT

NO COOLING

NOTES'

BE SURE POWER AGREES WITH EQUIPMENT NAMPLATE(S).

LOW VOLTAGE (24V, WIRING) TO BE NO, 18 A.W,G. MIN.,

GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.

SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIR

CLEANER AND HUMIDIFIER MAX, LOAD 1.0 AMPS EACH.

THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING

CONNECTION TO THE 24 V. POWER SUPPLY (COMMON)

SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS

WHEN USING THIS FEATURE,

From Dwg. 21B342024 Rev. 0

{

26 18-CD19D8-15

Installer's Guide

OUTDOOR UNIT

(NO TRANSFORMER)

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

2 STAGE HEATING, 1 STAGE COOLING

USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

T'STAT

INTE:_ COM:_ONENT WIRING

24 V. \ FIELD

----LINE Y._ WIR ING

24 V. _ FACTORY

--LINE Y._ WIRIN(

2 STAGE

FURNACE

SEE

NOTE 7

t-q

SEE

NOTE 8 D

t--q

SEE

NOTE 6 @

NOTES:

I. BE SURE POWERAGREES WITH EQUIPMENT NAMPLATE(S)

2. LOW VOLTAGE (24V. WIRING) TO BE NO. 18 A.W.G. MIN..

3. GRO DIG OF EQ IPMENT MUST COMPLYWITH LOCAL CODES

4. SET THERMOSTATHEAT ANTICIPATOR PER U IT WIRING DIAGRAM

5. THESE LEADS PROVIDE 115 V. POWERFOR CON ECTION OF ELECTRONIC AIR

CLEA ER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.

6. THIS CONNECTION IS ONLY USED FOR THENMOSTATSREQUIRING

CONNECTION TO THE 24 V. POWERSUPPLY. (COMMO)

7. SEE TWINNING CO NECTION DIAGRAMS FOR PROPERCONNECTIONS

WHE USING THIS FEATURE

8. THE "Y" TERMINI AL FROM THE THERMOSTATM ST BE WIRED

TO THE "Y" TERMINAL OF THE FURNACECO TROL FOR PROPERBLOWER

OPERATION DUAl G COOLING.

TO 115Vl PH.,

60 HZ.,POWER

SUPPLY PER

LOCALCODES

HUM SEE

NOTE5

EAC SEE

NOTE5

From Dwg. B342021 Rev. 0

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

2 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

OUTDOOR UNIT

(NO TRANSFORMER) ......

T'STAT

E_---

SEE

NOTE 7

SEE

.N_O_T_E_S_

SEE

2 STAGE

FURNACE

-B

---D

--D

--[_.

- - [_1

INTER COMPONENT WIRING

...... 24 V. \ FIELD

----LINE V.TW]RING

24 V. "'_ FACTORY

--LINE V._y WIRING

NOTES:

I. BE SURE POWERAGREES WITH EQUIPMENT NAMPLATE(S).

2. LOW VOLTAGE (24V. WIRING) TO BE NO. 18 A.W.G. MIN..

3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.

4. SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

5. THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIR

CLEANER AND HUMIDIFIER MAX. LOAD I.O AMPS EACH.

6. THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING

CONNECTION TO THE 24 V. POWERSUPPLY. (COMMON)

7. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS

WHEN USING THIS FEATURE,

8. THE "Y" TERMININAL FROM THE THERMOSTAT MUST BE WIRED

TO THE "Y" TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWER

OPERATION DURING COOLING.

9. Wl AND W2 MUST BE JUMPERED TOGETHER FOR PROPER OPERATION.

SECOND STAGE HEATING WILL BEGIN I0 MINUTES AFTER FIRST STAGE.

'T GROUND

\ SCREW

FIELD ADDED _--_f,- ..................F U R N A C E

JUMPER (NOTE 9) ,I I ! _b iK! JUNCTION

['-LH B,<L_]_]_ I BOX

TO115V1 PH,, I .... "_'_' WH/II

60 HZ., POWER J I _ 11

SUPPLYPER 1I I'm I

LOCALCOOES| ,N ._______£_

rwH/I -- ,

HUM SEE J -- ,,_11 I

NOTE__ I

I ,,

EAC SEE

NOTE 5 , B_< From Dwg. B342019 Rev. 0

18-CD19D8-15 27

Installer's Guide

TWINNING CONNECTION DIAGRAM

FOR TWINNING UX/DX-R FURNACES

1 STAGE HEAT /1 STAGE COOLING THERMOSTAT

OUTDOOR UNIT NO. 1 1 STAGE

(WITH TRANSFORMER) HEATING /COOLING

SEE NOTE 3 THERMOSTAT FURNACE NO. 1

I :Ul

[ @@-(_ OI

(F_ELO SUPPUEO>

A_ERNaTE CONNECTION

OUTDOOR UNIT NO. 1

(NO TRANSFORMER)

ON BOTH UNITS.

2ND STAGE WILL FIRE

10 MINUTES AFTER 1 ST i

SEE NOTE 5

• i

r 1

ISOLATION RELAY

{HELD SUPPLIED}

SEE NOTE 4

FURNACE NO. 2

SLOWEn OPERATION OF

UNIT NO 2 IS SYNCRONIZED

WITH UNIT NO I VIA SIGNALS

FROM TWIN CONNECTION

SEE NOTE 4

,.J

TWINNING CONNECTION DIAGRAM

FOR TWINNING UX/DX-R FURNACES

2 STAGE HEAT/1 STAGE COOLING THERMOSTAT

OUTDOOR UNIT NO. 1 2 STAGE HEATING

(WITH TRANSFORMER) 1 STAGE COOLING

SEE NOTE 3 THERMOSTAT

OUTDOOR UNIT NO. 1

(NO TRANSFORMER)

Fq Fq

• "I

• i

ISaAT_ON RELAY

(F_ELD SUPPUEO)

SEE NOTE 4

r ,

R2; _1 :

--L-- ;

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO 2 iSSYNCRONIZED

WITH UMT NO 1 ViA SIGNA£5

FROM _IN CONNECTION

..... i

F-_-I

ISOLATION RELAy

SEE NOTE 4

NOTES

I_OTN FURNACESMUST 3_ ROWERE_FRON

THE SANE _lGV LEG OF D_RCNIT PANEL¸

2 _NSURE 24V FURNACE TRANSFORMERS ARE

IN PHASE PRIOR TO COMPLETING CONNECTIONS,

CHECK VOITAGE BET_EN "R" TERMINAIS OF

EACH FURNACE 1{ VOLTAGE fS GREATER THAN

/OV, REVERSE THE BL AN RD SECONDARY LEADS

ON ONE OF THE FURNACE TRANSFORNERS

IF OUTDOOR UNIT HAS A RAY TRANSFORNER,

AN iSOIATION R{!AY MUST B_ /NSTA!L[D

(FIELD SUPPLIED USE PILOT DUT_ RELAY

{'NC'), SUCH AS RLFORZ5) SEE ALT CONNECTION

IF CURRENT EXCEEDS THERMOSTAT CURRENT

RATING, US_ ISOLATION RELAYS _'Ri') AS

SRO_N _DO NOT CONNECT _TO #)

_SOLATION RELAY NOT NEEDED IF THE THERNOSTAT

CONTACTS AR_ RATED AT IOA OR A_OV_

CONNECTION MAY _R_OUIRED FOR ELECTRONIC

THERMOSTATS

I[ TER CO_,IPONENT "¢VIRING

AI TERNAT# NIR_ND EONF 16URATION

......... SE# #OT_ 4

24 V'. '_ FIELD

----LINE /uiv'v'IS<INO

h FACTO:{'{

24 V. /_> Y'i]R'ING

-- L INE .;,

From Dwg. 21B341336 Rev. 2

I_OTN EURNAC[S RUST B[ POWERED #RON

THE SAME HSV I£D O# CIRCUIT PANEl

RINSUR_ 24V FURNAC_ TRANSFORMERS AN_

IN PHASE PRIOR TO COMPLETING CONNECTIONS,

CHECK VOLTAGE BETNEEN "R" TERMINALS OF

EACH _URNACE /_ VOLTAGE IS GREATER THAN

JOY, REVERSE THE _L AN RD SECONDARY LEADS

ON ON# 0# THE #URNAC[ TRANSfORMeRS

S iF OUTDOOR UNIT HAS A RAY TRANSFORM[R,

AN ISOLATION RELAF MUST BE _NSTALLED

(FIELR SUPPLIEO USE PILOT DUTY REIAY

('RE'), SUCH AS RLYORYR ) SEE ALT CONNECTION

s?sj;? R

...... 'i

RI; L ;

I I

IF CURRENT EXCEEDS TNERNOGTAT CURRENT

RATING, USE ISOLATION RELAYS {'RI') AS

SNO_N (DO NOT CONNECT _TO _)

ISOIATION REIAY NOT NEEDED _F THE THERMOSTAT

CONTACTS ARE RATED AT IRA OR ABOVE

CONNECTION MAY DE REQUIRED FOR ELECTRONIC

THE RNOS TATS

INTER CO,,PC ENT ",/V]RINO

ATERRATE _INlflG CORF_G_RATION

......... SEE NOTE 4

24 ,/. h> F ]E kD

LINE ,/.J ',/'filING

24 '/. _ FACTO_{Y

-- LI[ E ._,/VIZ{IN("

From Dwg 21B341337 Rev, 2

,{]fffffffffffffff

28 18-CD19D8-15

Installer's Guide

OUTDOOR UNiT NO. 2

(NO TRANSFORMER}

SEE NOTE 3

OUTDOOR UNiT NO 1

(NO TRANSFORMER)

2STAGEHEATING

1STAGECOOLING

THERMOSTAT

TWINNING CONNECTION DIAGRAM

FOR TWINNING UX/DX-R FURNACES

2 STAGE HEAT /2 STAGE COOLING THERMOSTAT

SEE NOTE 5

FURNACE NO. 1

ISO_TIONRElY

(FIELDSUPPLIED)

RI; _ 'J

tO ::

a2l_; :

FURNACE NO.2

BLOWEROPEraTIONOr

°:ff_,22222°

wl_ UNIT.Olvl_sle._Ls

From Dwg. 21 B341338 Rev. 2

ISO_TI_ nE_¥

sY"°W

4¸;

m; ;

i_i I

R2;_; ;

i i i

I "

_OTE;

SOATO_ i #[iAr '¢0T _,_ F TU[ Trfl2_OSTRT

OUTDOORUNIT

HITH TRANSFORMER

SEE NOTE 3

, z0,

ISO_TION RElY

ACT_NAT_CO.NECTION

INTER CObIPONENT 'FT[R]NG

ALT!PNAT_ #HUt¢O (O_[ _PAT I_

24 /, I, FIE L D

IIL]NE /. _'¢V[RINQ

24 '/. ;% FA::T }RY--LINE " "A'[ _ IN G

CARBON MONOXIDE POISONING HAZARD

Failure to follow the installation instructions for the venting

system being placed into operation could result in carbon

monoxide poisoning or death.

ELECTRICAL CONNECTIONS

Make wiring connections to the unit as indicated on enclosed

wiring diagram. As with all gas appliances using electrical

power, this furnace shall be connected into a permanently

live electric circuit. It is recommended that furnace be

provided with a separate "circuit protection device" electric

circuit. The furnace must be electrically grounded in accor-

dance with local codes or in the absence of local codes with

the National Electrical Code, ANSI/NFPA 70 or CSA C22.1

Electrical Code, if an external electrical source is utilized.

The integrated furnace control is polarity sensitive.

The hot leg of the 120V power supply must be connected to

the black power lead as indicated on the wiring diagram.

Provision for hooldng up an electronic air cleaner and or

humidifier is provided on the integrated control.

Refer to the SERVICE FACTS literature and unit wiring

diagram attached to furnace.

18-CD19D8-15 29

Installer's Guide

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

MAIN MANUAL

SHUT-OFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

MAIN MANUAL m

SHUT-O FF VALVE

GROUND

UNION

JOINT ._

DRIP _

LEG

UPFLOW MAY BE LEFT OR

RIGHT HAND GAS PIPING

THE DOWNFLOW (VERTICAL) MAY BE INSTALLED

LEFT OR RIGHT SIDE GAS PIPING

iii!iiiiii'i_iiiiliiliiliiliiliiliiliiliiliiliiliiliiliiliil/

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

MAIN MANUAL

SHUT-OFF VALVE

GRO_

UNION JOINT !

MAIN MANUAL /GROUND UNION JOINT

SHUT-OFF _

VALVE DRIP

LEG

AIR

FLOW

AUTOMATIC GAS VALVE WITH

MANUAL SHUT-OFF

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

(Typical UPFLOW Furnace in horizontal configuration shown)

30 18-CD19D8-15

GAS PIPING

The upflow/horizontal furnace is shipped standard for left

side installation of gas piping. A knockout is provided on the

right side for an alternate gas piping arrangement. See Figure

45.

The installation of piping shall be in accordance with piping

codes and the regulations of the local gas company. Pipe joint

compound must be resistant to the chemical reaction with

liquefied petroleum gases.

Refer to piping Table 8, for delivery sizes. Connect gas supply

to the unit, using a ground joint union and a manual shut-off

valve as shown in Figures 44 & 45. National codes require a

condensation drip leg to be installed ahead of the controls as

shown in Figures 45 & 46.

Use a backup wrench on the gas valve when installing gas

piping to prevent damage to the gas valve and manifold

assembly.

The furnace and its individual shut-offvalve must be discon-

nected from the gas supply piping system during any pressure

testing of that system at test pressures in excess of 1/2 psig

(3.5 kPa).

The furnace must be isolated from the gas supply piping by

closing its individual manual shut-off valve during any

pressure testing of the gas supply piping system at test

pressures equal to or less than 1/2 psig (3.5 kPa).

NOTE:

Maximum pressure to the gas valve for natural gas is 13.8"

W.C. Minimum pressure is 5.0" W.C. Maximum pressure to

the gas valve for propane is 13.8" W.C. Minimum pressure

is 11.0" W.C.

All gas fittings must be checked for leaks using a soapy

solution before lighting the furnace. DO NOT CHECK

WITH AN OPEN FLAME!

Installer's Guide

TABLE 8 NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE LENGTH OF PIPE

SIZE 10 20 30 40 50 60 70

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

1-1/4 1050 730 590 520 440 400 370

This table is based on pressure drop of 0.3 inch W.C. and 0.6 SRGR. gas

TABLE 9 ORIFICE SIZES

INPUT

RATING

BTUH

60,000

80,000

100,000

120,000

NUMBER

BURNERS

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 56

COMBUSTION AND INPUT CHECK

(See also High Altitude Derate)

1. Make sure all gas appliances are off except the furnace.

2. Clock the gas meter with the furnace operating (deter-

mine the dial rating of the meter) for one revolution.

3. Match the "See" column in the gas flow (in cfh) Table 10

with the time clocked.

4. Read the "Flow" column opposite the number of seconds

clocked.

5. Use the following factors if necessary:

For 1 Cu. Ft. Dial Gas Flow CFH =

Chart Flow Reading + 2

For 1/2 Cu Ft. Dial Gas Flow CFH =

Chart Flow Reading + 4

For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading + 4

PRESSURE WITH BURNER BOX REFERENCED

Separate the tube I

at the unit Tee and _'

reconnectwith a ,.-. II "_t

shortpiece of field _ II I I

supplied tube and T 11 I I

anotherTeewith /7 _ I ]

the "U" Manometer /¢_/ /1

attached. /__ II

Besuretoreconneot I{ JJ

unit tubing to original -- _ \'\ _/

position after testing -- _k_

the manifold pressu re! ___.

Field supplied barb fitting |

with manom eter tube is _IL

attached to the"OUTLET _ j

PRESSURE TAP" on the

outlet side of the gas valve,

A CAUTION: Beturna,tubing,caps,an, orplugstooriginalpositionswhenpressurechecksare completed.

18-CD19D8-15 31

Installer's Guide

6. Multiply the final figure by the heating value of the gas

obtained from the utility company and compare to the

nameplate rating. This must not exceed the name-

plate rating.

7. Changes can be made by adjusting the manifold pressure

(See Table 11), or changing orifices (orifice change may

not always be required). To adjust the manifold pressure:

a. Turn off all electrical power to the system.

b. Attach a manifold pressure gauge to the outlet

pressure tap marked "OUT PRESS TAP" on

White-Rodgers gas valve model 36E or boss marked

"OUT P" on White-Rodgers gas valve model 36G. (See

Figure 48 for White-Rodgers gas valve model 36E and

Figure 49 for White-Rodgers gas valve model 36G).

For the gas valve model 36E, measurements require

removal of the plug and installation of a barbed

fitting. Attach flexible tubing and a manometer to the

barbed fitting. For the gas valve model 36G, do not

remove the pressure tap test screw. Loosen the

pressure tap test screw one turn and install flexible

tubing and a manometer directly onto the outlet

pressure boss.

c. The other side of the manifold pressure gauge must be

referenced to the burner box as shown in Figure 46.

d. Turn on system power and energize valve.

e. For the White-Rodgers gas valve model 36E:

1. Adjust low fire by removing the low adjustment

seal screw (See Figure 48).

TABLE 10

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

SEC. FLOW SEC.

8 900 29

9 800 30

10 720 31

11 655 32

12 600 33

13 555 34

14 514 35

15 480 36

16 450 37

17 424 38

18 400 39

19 379 40

20 360 41

21 343 42

22 327 43

23 313 44

24 300 45

25 288 46

26 277 47

27 267 48

28 257 49

FINAL MANIFOLD

FUEL

NATURAL GAS

LP GAS

FLOW SEC. FLOW SEC. FLOW

248 50 144 82 88

240 51 141 84 86

232 52 138 86 84

225 53 136 88 82

218 54 133 90 80

212 55 131 92 78

206 56 129 94 76

200 57 126 96 75

195 58 124 98 73

189 59 122 100 72

185 60 120 104 69

180 62 116 108 67

176 64 112 112 64

172 66 109 116 62

167 68 106 120 60

164 70 103 124 58

160 72 100 128 56

157 74 97 132 54

153 76 95 136 53

150 78 92 140 51

147 80 90 144 50

TABLE 11

PRESSURE SETTINGS (inches w.c.)

2nd Stage Max. 1st Stage Max.

3.5" W.C. 1.7" W.C.

10.5" W.C. 6.0" W.C.

2. To increase outlet pressure, turn the 3/32" socket

set screw clockwise. To decrease outlet pressure,

turn the set screw counterclockwise. Adjust regula-

tor until pressure shown on manometer matches

the pressure specified in Table 11.

3. Replace low adjustment seal screw and tighten

securely.

4. Cycle the valve several times to verify regulator

setting.

5. Adjust high fire by removing the high adjustment

seal screw (See Figure 48).

6. To increase outlet pressure, turn the 3/32" socket

set screw clockwise. To decrease outlet pressure,

turn the set screw counterclockwise. The final

manifold pressure setting shall be as specified in

Table 11 with an input of no more than nameplate

rating and no less than 93% of the nameplate

rating, unless the unit is derated for high altitude.

7. Replace high adjustment seal screw and tighten

securely.

8. Cycle the valve several times to verify regulator

setting.

f. For the White-Rodgers gas valve model 36G:

HIGHALTITUDE DERATE

Input ratings (BTUH) of these furnaces are based on sea

level operation and should not be changed at elevations up to

2,000 ft.

If the installation is 2,000 ft. or above, the furnace input rate

(BTUH) shall be reduced 4% for each 1,000 ft. above sea level.

The furnace input rate shall be checked by clocldng the gas

flow rate (CFH) and multiplying by the heating value

obtained from the local utility supplier for the gas being

delivered at the installed altitude. Input rate changes can be

made by adjusting the manifold pressure (min 3.0 - max

3.7 in. W.C. - Natural Gas) or changing orifices (orifice change

may not always be required).

If the desired input rate cannot be achieved with a change in

manifold pressure, then the orifices must be changed. LP

installations will require an orifice change.

IMPORTANT:

Reinstall the propane orifices to the same depth as the orifices

supplied with the equipment.

Installation of this furnace at altitudes above 2,000 ft.

(610m) shall be in accordance with the local codes, or in the

absence of local codes, the National Fuel Gas Code, ANSI

Z223.1 / NFPA 54 or National Standard of' Canada, Natural

Gas and Propane Installation Code, CSA 149.1. Installation of

this furnace at altitudes above 2,000 ft. (610m) shall be made

in accordance with the listed high Altitude Conversion Kit

available with this furnace.

TABLE 12

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

PART

NUMBER

ORF00501

ORF00644

ORF00909

ORF00910

ORF01099

ORF00503

ORF00493

DRILL

SIZE

PART

NUMBER

ORF00555

ORF00693

ORF00907

ORF00908

ORF01338

ORF01339

32 18-CD19D8-15

Installer's Guide

See Table 13 forhelp in selectingorificesiforificechange is

required. Fu_'nace input rate and temperature riseshould be

checked again afterchanging orificesto confirm the proper rate

forthe altitude.

The vent length table on page 16 shows the required vent

lengths for installationsat various altitudes. An optional

high altitudeidt isavailable for installationsabove 5000 feet

Installationsabove 12,000 feet are not allowed).

TABLE 13

Orifice

Twist Drill

Size If

Installed

At Sea

Level

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

2000 3000 400G 5000 6000 700G 8000 9000 10000

42 43 43 43 44 44 45 46 47

44 44 44 45 45 46 47 47 48

45 45 45 46 47 47 48 48 50

46 47 47 47 48 48 49 49 50

47 47 47 48 48 49 49 50 51

48 48 49 49 49 50 50 51 52

54 54 55 55 55 55 55 56 56 56

55 55 55 55 56 56 56 56 56 57

56 56 56 57 57 57 58 59 59 60

57 58 59 59 60 60 61 62 63 63

58 59 60 60 61 62 62 63 63 64

From N_ional Fuel Gas Code-Table F-4

White-Rodgers 36E

Gas Valve On /Off

Toggle Switch

2nd Stage (HI)

Manifold

Pressure

Adjustment

1st Stage (LO)

Manifold

Pressure

Adjustment

White-Rodgers36G 2nd Stage (HI) Manifold

Pressure Adjustment

Gas Valve On /Off

Toggle Switch

1st Stage (LO)

Manifold Pressure

Adjustment

1. Adjust low fire by removing the low adjustment

regulator cover screw (See Figure 49).

2. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet pressure,

turn the regulator adjust screw counterclockwise.

Adjust regulator until pressure shown on mano-

meter matches the pressure specified in Table 11.

3. Replace and tighten the regulator cover screw

securely.

ROTATE THE FRONT

COVER AS SHOWN

INSERT THE TOP FLANGE

OF THE FRONT COVER

UNDER THE LIP INSIDE

THE BOX

ALL SIDE FLANGES MUST

BE OUTSIDE OF THE BOX

ROTATE THE FRONT

COVER INWARD MAKING

SURE THAT ALL SIDE

FLANGES ARE OUTSIDE

OF THE BOX.

4. Cycle the valve several times to verify regulator

setting.

5. Adjust high fire by removing the high adjustment

regulator cover screw (See Figure 49).

6. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet pressure,

turn the regulator adjust screw counterclockwise.

The final manifold pressure setting shall be as

specified in Table 11 with an input of no more than

nameplate rating and no less than 93% of the

nameplate rating, unless the unit is derated for

high altitude.

7. Replace high adjustment regulator cover screw and

tighten securely.

8. Cycle the valve several times to verify regulator

setting.

g. Turn off all electrical power to the system.

h. Remove the manometer and flexible tubing. Remove

the barbed fitting and replace the plug or tighten the

pressure test screw.

i. Turn on electrical power to the system and energize

valve.

j.Using a leakdetectionsolutionor soap suds,check for

leaksatplugor pressurebossscrew.

NOTE:

The manifold pressure must be referenced to the burner

box. The burner box pressure tap equalizes the gas valve

pressure regulator. Manifold pressure is checked by

installing a tee (field supplied) in the tubing, between the

tee coming from the burner box tube and the gas valve,

in addition to the regular gas valve pressure tap on the

outlet side of the gas valve. See Figure 47.

18-CD19D8-15 33

Installer's Guide

EXPLOSION HAZARD!

PROPANE GAS IS HEAVIER THAN AIR AND MAY COL-

LECT IN ANY LOW AREAS OR CONFINED SPACES. IN

ADDITION, ODORANT FADE MAY MAKE THE GAS

UNDETECTABLE EXCEPT WITH A WARNING DEVICE. IF

THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN

EXCAVATED AREA OR A CONFINED SPACE, IT IS

STRONGLY RECOMMENDED TO CONTACT A GAS

SUPPLIER TO INSTALL A GAS DETECTING WARNING

DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOT test any

detectors and makes no representations regarding any

brand or type of detector.

Lighting instructions appear on each unit. Each installation

must be checked out at the time of initial start up to insure

proper operation of all components. Check out should include

putting the unit through one complete cycle as outlined below.

Turn on the main electrical supply and set the thermostat

above the indicated temperature. The ignitor will automati-

cally heat, then the gas valve is energized to permit the flow

of gas to the burners. After ignition and flame is established,

the flame control module monitors the flame and supplies

power to the gas valve until the thermostat is satisfied.

To shut off

For complete shutdown: Turn the gas cock knob on the main

gas valve to the "OFF" position (See Figure 44). Disconnect

the electrical supply to the unit.

Replace and/or tighten all plugs removed or loosened

when adjusting gas pressure. Leak check the fittings

before placing the furnace into regular service. Failure

to follow this warning could result in fire, explosion, or

property damage.

Table 12 lists the main burner orifices used with the furnace.

If a change of orifices is required to correct the furnace input

rating refer to Table 13.

REINSTALLATION OF THE BURNER BOX COVER

Figure 49 shows the correct way to reinstall the burner box

cover if adjustment or replacement of the flame sensor, hot

surface igniter, or main burner orifices have required re-

moval of the cover.

START-UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

Disconnect power to the unit before removing the blower

door. Allow a minimum of 10 seconds for IFC power supply

to drain to 0 volts. Failure to follow this warning could

result in property damage, personal injury or death.

With gas and electrical power "OFF"

1. Duct connections are properly sealed

2. Filters are in place

3. Venting is properly assembled

4. Blower door is in place

Turn the main gas valve toggle switch (See Figures 48 & 49)

within the unit to the "OFF" position. Turn the external gas

valve to "ON". Purge the air from the gas lines. After purging,

check all gas connections for leaks with a soapy solution --

DO NOT CHECK W1TH AN OPEN FLAME. Allow 5 min-

utes for any gas that might have escaped to dissipate.

LP Gas being heavier than air may require forced ventilation.

Turn the toggle switch on the gas valve in the unit to the

"ON" position.

LIGHTING INSTRUCTIONS

DO NOT attempt to manually light the burner. Failure to

follow this warning could result in property damage,

personal injury or death.

Ifthis is done during the cold weather months, provisions

must be taken to prevent freeze-up of all water pipes and

water receptacles.

Whenever your house is to be vacant, arrange to have

someone inspect your house for proper temperature.

This is very important during freezing weather. If for

any reason your furnace should fail to operate dam-

age could result, such as frozen water pipes.

SEQUENCE OF OPERATION

Thermostat call for heat (2-stage thermostat)

Call for 1st stage only:

Wl thermostat contacts close signaling the control module to

run its self-check routine. After the control module has

verified that the 1st stage pressure switch contacts are open

and the limit switch(es) contacts are closed, the draft blower

will be energized.

As the induced draft blower comes up to speed, the pressure

switch contacts will close and the ignitor warm up period will

begin. The ignitor will heat for approx. 20 seconds, then the

gas valve is energized in 1st stage to permit gas flow to the

burners.

The flame sensor confirms that ignition has been achieved

within the 4 second ignition trial period.

As the flame sensor confirms that ignition has been achieved,

the delay to fan ON period begins timing and after approx.

45 seconds the indoor blower motor will be energized at low

speed and will continue to run during the heating cycle.

Call for 2nd stage after 1st stage:

W2 thermostat contacts close signaling a call for 2nd stage

heat. After a 30 second delay, the induced draft blower will

be energized on high speed and the 2nd stage pressure

switch contacts will close. The gas valve is energized in 2nd

stage and the indoor blower motor in high speed.

2nd stage satisfied, 1st stage still called:

W2 thermostat contacts open signaling that 2nd stage

heating requirements are satisfied.

The induced draft blower is reduced to low speed allowing

the 2nd stage pressure switch contacts to open and the gas

valve is reduced to 1st stage. The indoor blower motor is

reduced to low speed.

1st stage satisfied:

W1 thermostat contacts open signaling that 1st stage

heating requirements are satisfied. The gas valve will close

and the induced draft blower will be de-energized. The

indoor blower motor will continue to run for the fan off period

(Field selectable at 60, 100, 140 or 180 seconds), then will be

de-energized by the control module.

34 18-CD19D8-15

iiiiiiiii;iiiiiiiiiiiiIi iiiiiiliiiiiiiiHii

iiii!

Thermostat call for heat (1-stage Thermostat)

W1/W2 (jumpered) thermostat contacts close signaling a call

for heat. 1st stage sequence of operation remains the same

as above. 2nd stage heat will energize after the stage delay

timer (field selectable at .5, 5, 10 or 15 minutes) has expired.

Thermostat satisfied:

W1/W2 (jumpered) contacts open signaling the control

module to close the gas valve. The induced draft blower is

switched to low speed and de-energized after the post purge

timer has expired. The indoor blower motor will continue to

operate after the flames are extinguished and then is

switched to low heat speed for the FAN-OFF period.

CONTROL AND SAFETY SWITCH ADJUSTMENTS

LIMIT SWITCH CHECK OUT

The limit switch is a safety device designed to close the gas

valve should the furnace become overheated. Since proper

operation of this switch is important to the safety of the unit, it

must be checked out on initial start up by the installer.

To check for proper operation of the limit switches, set the

thermostat to a temperature higher than the indicated

temperature to bring on the gas valve. Restrict the airflow

by blocking the return air (disconnecting the indoor blower

may trip the inducer limit). When the furnace reaches the

maximum outlet temperature as shown on the rating plate,

the burners must shut off. If they do not shut off after a

reasonable time and overheating is evident, a faulty limit

switch is probable and the limit switch must be replaced.

After checking the operation of the limit control, be sure to

remove the paper or cardboard from the return air inlet. Refer

to Service Facts for additional instructions.

NOTE TO INSTALLER

Review the following warnings with the owner. Review con-

tents of USER'S INFORMATION MANUAL with the owner.

AIRFLOW ADJUSTMENT

Check inlet and outlet air temperatures to make sure they

are within the ranges specified on the furnace rating name-

plate. If the airflow needs to be increased or decreased, see

the wiring diagram for information on changing the speed of

the blower motor.

Installer's Guide

ROOM AIR THERMOSTAT

HEAT ANTICIPATOR ADJUSTMENT

Set the thermostat heat anticipator according to the current

flow measured, or the settings found in the notes on the

furnace wiring diagram (found in the SERVICE FACTS or

inside the furnace casing).

INSTRUCTIONS TO THE OWNERS

In the event that electrical, fuel, or mechanical failures

occur, the owner should immediately turn the gas

supply off at the manual gas valve, located in the

burner compartment. Also turn off electrical power to

the furnace and contact the service agency designated

by your dealer.

BURNER BOX TEMPERATURE LIMIT DEVICE

All models are equipped with a manual reset temperature

limit located on the burner box. In case of excessive tempera-

ture, the limit will open and cause the circuit to open which

shuts off all flow of gas.

Disconnect power to the unit before removing the blower

door. Allow a minimum of 10 seconds for IFC power supply

to drain to 0 volts. Failure to follow this warning could

result in property damage, personal injury or death.

This unit is equipped with a blower door switch which cuts

power to the blower and gas valve causing shutdown when

the door is removed. Operation with the door removed or ajar

can permit the escape of dangerous fumes. All panels must be

securely closed at all times for safe operation of the furnace.

INDOOR BLOWER TIMING

Heating: The integrated furnace control module controls the

indoor blower. The blower start is fixed at 45 seconds after

ignition. The FAN-OFF period is field selectable by dip

switches SW-2, #1 and #2 at 60, 100, 140, or 180 seconds.

The factory setting is 100 seconds.

Wl-W2 stage delay (jumpered together) is field selectable by

dip switch SW-1, #1 and #2 at .5, 5, 10 or 15 minutes. The

factory setting is 10 minutes. (See wiring diagram).

Cooling: The fan delay off period is factory set at 0 seconds.

The option for 80 second delay off is field selectable by dip

switch SW-2, #3 (See wiring diagram).

18-CD19D8-15 35

Installer's Guide

ABNORMAL CONDITIONS

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN

EXCESS OF 40 MP.H.) VENT OR FLUE BLOCKAGE

On a call for heat, the variable speed draft inducer must

first ramp up to speed and close the pressure switch

before the ignition sequence is allowed to begin. If the

pressure switch does not close, the motor will ramp up to

maximum speed and continue to operate there for about

i minute.

After one minute the integrated furnace control will turn

the motor off for about 30 seconds then back on in an

attempt to reestablish proper operation. This condition

is indicative of a highly restricted or blocked inlet or

outlet vent pipe or a failed pressure switch.

If pressure against induced draft blower outlet becomes

excessive, the pressure switch will open. If the pressure

switch is open for more than 3.5 seconds, the variable

speed draft inducer will speed up and attempt to close

the pressure switch. If the pressure switch is not closed

within 12 seconds or if the maximum speed of the motor

is reached, the draft inducer sends a fault signal to the

integrated furnace control. If the unit is operating in

second stage, an inducer fault will cause the furnace

control to transition the system to first stage and it will

operate there for 10 minutes before attempting to run

again in second stage. If the unit is operating in first

stage, an inducer fault will cause the furnace control to

shut the system down and wait 30 seconds before

attempting to reestablish operation in first stage.

2. LOSS OF FLAME

If loss of flame occurs during a heating cycle, or flame is

not present at the sensor, the flame control module will

close the gas valve. The flame control module will then

recycle the ignition sequence, then if ignition is not

achieved, it will shut offthe gas valve and lock out the

system.

3. POWER FAILURE

If there is a power failure during a heating cycle, the

system will restart the ignition sequence automatically

when power is restored, if the thermostat still calls for

heat.

4. GAS SUPPLY FAILURE

If loss of flame occurs during a heating cycle, the system

integrated control module will recycle the ignition sequence,

then if ignition is not achieved, the integrated control

module will shut offthe gas vNve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE

Please refer to the variable speed draft inducer

troubleshooting manual for diagnostic assistance.

6. CONDENSATE DRAIN BLOCKAGE

If the condensate drain is blocked, either by debris,

improper draining, or by freezing condensate, the

pressure switch will sense the accumulation ofconden-

sate in the furnace drain pan. The unit will not operate

properly until the condensate drain has been cleared, and

the condensate flows freely.

7. RESET AFTER LOCKOUT

When the integrated control module has shut the system

down and gone into lockout, the system must be manu-

ally reset before the unit will restart. The system can be

reset by turning the system power off for more than

1 second, or by removing 24VAC from the control for more

than 1 second, or by removing the thermostat call for

heat for more than 1 second but less than 20 seconds.

8. RESET AFTER BURNER BOX LIMIT SHUTDOWN

If the furnace shuts down, one thing that can be checked

is the burner box temperature limit switch. It is located

on the bottom of the burner box. The vent and combus-

tion air inlet terminations should be checked for block-

age. If blockage exists, clear the problem and then the

reset button may be depressed. If there is no block-

age of the terminations, the limit switch must be

reset by a qualified servicer.

36 18-CD19D8-15

Installer's Guide

FAULT CODE RECOVERY

On power up, last 4 faults, if any, will be flashed on the red

LED. The newest fault detected will flash first and the oldest

last. There will be a 2 second delay between fault code

flashes. Solid red LED error codes will not be displayed.

The Green LED will be on solid during last fault recovery.

At any other time the control is powered, the Green LED

indicator light will operate as shown in Table 14 and the red

LED will flash LitePort data (one flash) every 20 seconds.

Fault Code Reset

The last 4 fault codes can be erased from memory by power-

ing up the control with "G" energized and then applying "R"

to the "WI" terminal 3 times within 6 seconds. The control

will acknowledge the reset by turning on the red LED for

2 seconds.

TABLE 14

INTEGRATED FURNACE CONTROL

GREEN "STATUS" LED FLASH CODES

Flashing Slow --- Normal - No call for Heat

Flashing Fast --- Normal - Call for Heat

Green Status LED

*UX /DX Integrated Furnace Control

INTEGRATED FURNACE CONTROL RED LED "ERROR" FLASH CODES

2 Flashes --- System Lockout (Retries or Recycles exceeded)

Draft Pressure Error- Possible problems:

a) Venting problem

b) Pressure switch problem

c) Inducer problem

Open Temperature Limit Switch

Flame sensed when no flame should be present

115 volt AC power reversed, ignitor (Triac) fault, poor grounding or

system voltage too low

Gas valve circuit error

3 Flashes ---

4 Flashes ---

5 Flashes ---

6 Flashes---

7 Flashes ---

8 Flashes --- Low flame sense

9 Flashes --- Open Inducer Limit switch

10 Flashes --- Inducer communication error

Solid --- Internal GV error or Low TH voltage

Solid Red w/Solid Continuous Reset caused by a blown fuse or internal error.

Green "STATUS" LED

18-CD19D8-15 37

Trane

6200 Troup Highway

Tyler, TX 75707

03/08

For more information contact Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right to

your local dealer (distributor) change design and specifications without notice.

TRANE Furnace/Heater, Gas Manual L0902549

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