TRANE Furnace/Heater, Gas Manual L0902557

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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1 8 - CD2 0 D3 - 21

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Upflow /Horizontal and Downflow /Horizontal,

Gas-Fired, Direct Vent, 2-Stage Condensing

Furnaces with Variable Speed Inducer

*UY060R9V3W *UY100R9V4W *DY060R9V3W *DY100R9V4W

*UY080R9V3W *UY120R9V5W *DY080R9V3W *DY120R9V5W

*__First letter may be "A" or 'q-"

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.

*UY-R9V-V *DY-R9V-V

(

AIR

FLOW

UPFLOW

DOWNFLOW

A_t

FLOW

AN UPFLOW/HORIZONTAL

FLOW

DOWNFLOW/HORIZONTAL F_O_W_

/_ \

A341624P04

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" (page 7), 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 13-24), 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.

I10. TGhisslpirltdru_t thUStcboeja:pip:dbhYc_ Lh_aCsenascedPlet_!)erot1

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 WARNING and

CAUTION.

a. WARNING indicates a potentially hazardous situation

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

b. CAUTION indicates a potentially hazardous situation

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

injury. It is also used to alert against unsafe practices

and hazards involving only property damage.

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.

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.

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 fluorides from

paint, varnish, stains, adhesives, cleaning compounds, and

cement create a corrosive condition which may cause rapid

deterioration of the heat exchanger.

GENERAL INSTALLATION INSTRUCTIONS

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

BAYMFGH100A.

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

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.

18-CD20D3-21

Installer's Guide

Contents

Installation Instructions

General Installation Instructions

Location and Clearances

Outline Drawing

Upflow Installation

Downflow Installations

Horizontal Installation

Air for Combustion and Ventilation

Duct Connections

Return Air Filters

General Venting Information

Venting Materials

High Altitude Derate

Horizontal Venting

Downward Venting

Venting Through the Roof

Venting Routed Through a Masonry Chimney

Electrical Connections

Field Wiring Diagrams

Condensate Drain Instructions

Gas Piping

Combustion and Input Check

Start-up and Adjustment

Preliminary Inspections

Lighting Instructions

Sequence of Operation

Control and Safety Switch Adjustments

Airflow Adjustment

Abnormal Conditions

IFC Error Flash Codes

Fault Code Recovery

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 installa-

tions. 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.

(3O

1",3

14 7/8"

SIDE

, RETURN

AIR

DIM "B"

INLET Io

AIR °

?4 1'{57"

40"

a' @

DIM "A"

_C'}7,8" KtOCI{,OUT

ELECTFi IC_L

5UPPL','

_2 I 16" // (_LTEUi,LTE}

SIDE

RETURN

AIR

MODEL

(SEE NOTE 1 &2)

÷LJYOGORgVS÷÷÷

÷L.YOOORgVS÷÷÷

_57

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

I/ I/2" 2 I/4" IG I/4" 16" 7 1i2" P"

÷UYIOORgV4÷÷÷ 21" ? I/2" 19 3/4" 19 I/2" 9" 3"

÷UYIPOE!gVS÷÷÷ 24 I/2" 2 15/16" 23 I/4" 73" I0" 5"

÷ REFI: N# BE "A" O_ "T"

÷_ SUFFIX LETTER lqAf IIDII THRO 9

}_ II _@_ SUFFIX LETTER PlAY E IlWlI THRU a

NOTES

I ÷UXI20C960 REQUIRES 3" DIAMETER VENT PiPE

{UX100C948 & {UXIOOC960 REQUIRES 2 I/2" OR 3"

DIAMETER VENT PIPE

2 DIAMETER Of VENT PIPE MAY BE LIMITED TO 2 I/2" OR 3"

ON SOME MODELS AT DIFFERENT ALTITUDES REFER TO THE

VENT LENGTH TABLE FOR PROPER APPLICATIOB

_.,I I 2" FI, OCKOUT

(}AS SUP>L '

(ALTERNATE)

MINIMUM CLEARANCE TO

COMBUSTIBLE MATERIALS

UPFLOW

SIDES 0 IN

NEAR 0 IN

FRONT 5 IN

TOP I IN

FLuE 0 IN

HORIZONTAL(FLUE

DISCHARGEON THE LEF_

ALCOVE

SIDES

RIGHT 0 IN

LEFT 0 IN

REAR 6 IN

FRONT 18 IN

TOD I IN

FLOE O IN

CLOSET

SIDES

RIGHT I IN

LEFT I IN

REAR 3 IN

FRONT 3 IN

TOP I IN

FLOE 0 IN

From Dwg. 21C341884 Rev. 1

1tl

I-I,

Iit

(3O

I-O

*DY-R9V-W DOWNFLOW /HORIZONTAL OUTLINE DRAWING

5/8" _

DIM "C"

_/8 II

4 1/2" _

INLET

19 5/8" _

41/16" _

?" FLUE

CONNECT

SEE NOTE I

¢3" OPENING

AIR INTAKE

NOR, ONTALCONDE fT

I 7/8" x 7/8"

SLOT KNOCKOUT

7/8"_

ELECTRICAL

SUPPLY

!_1/2"

_3 15/16"

DIM "D"

OUTLET

AIR

", I a_ _/I 6" _,"- 7 3/4"

(ALL DIMENSIONS ARE IN INCHES)

HORIZONTALAPPLICATION

(THIS SIDE ONLY)

\\\ I/2"

\\\\\\

CONNECTION

AIR INTAKE

40 "

7/8" ELECTRICAL

CONNECTION(ALTERNATE)

DIM "A"

MODEL DIM "A°

(SEE NOTE 1)

÷DY060RgVS÷÷÷

÷DY080Rgvs÷÷÷ I1 I/2"

÷DVl00Rgv4÷÷÷ 21"

÷DYI2OR9VS÷÷÷ 24 I/2"

DIM "e" DIM °C" DIM "D"

2 I/4" 16 I/4" 16"

2 I/2" 19 3/4" 19 I/2"

2 15/16 23 I/4" 23"

KNOCKOUT

_1 I/2" GAS

CONNECTION

25"

20 I/4"

CONDENSATE DRAIN

KNOCKOUT

PREFIX MAY BE "A" OR "T"

** SUFFIX LETTER MAY BE "D" O THRN 9

*** SUFFIX LETTER MAY BE IlWll 0 THRU 9

NOTES:

I DIAMETER OF VENT PIPE MAY BE LIMITED

TO 2 I/2" OR 3" ON SOME MODELS AT DIFFERENT

ALTITUDES REFER TO THE VENT LENGTH TABLE

FOR PROPER APPLICATION

MINIMUM CLEARANCE TO

COMBUSTIBLE MATERIALS

DOWNFLOW

SLOES 0 IN

REAR oIN.

FRONT 3 IN.

TOP I IN

FLUE 0 IN.

HORIZONTALFLUE

BSCHARGE ON 11-1ELB='E_

ALCOVE

SIDES

RIGHT 0 IN,

LEFT 0 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 I N.

FLUE 0 IN,

From Dwg. 21C341885 Rev. 1

(I}

iiiiiiiiiiii

Installer's Guide

UPFLOW INSTALLATION

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

cased coils for attachment to the furnace. There are clearance

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)

STANDOFFS

(BOTH SIDES)

FOR VERTICAL

INSTALLATIONS:

SCREWS

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

@CABINET BIDE _CABINET SIDE

SUB-BASE SUB-BASE

FLANGE _FLANGE

(BENT UP) I_-- (BENT UP)

SUB-BASE _ i SUB-BASE

PLENUM

_--J-_DUCT

CO_mCSTmI,E

FLOOtl

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 1

CABINET

WIDTH

17-1/2"

21"

24-1/2"

TABLE 1

RETURN FLOOR OPENING PLENUM OPENING

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

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

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

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 Figure 4.

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

CASED COIL CONNECTION _ I

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

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 platform

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 permissible

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. The furnace must be

supported at both ends and the middle when installed

horizontally. The furnace must also be elevated approxi-

mately 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 underneath

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

)anels.

6 18-CD20D3-21

50 CU. FT. OR MORE

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

w,t..IoLo,,.s

UNCONFINED

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 open-

ings provided for combustion air must be kept free of obstruc-

tions which restrict the flow of air. Airflow restrictions 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 B149.1 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".

Installer's Guide

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 8 or from the

outdoors, as in Figure 9.

_F MINIMUM AREA IN SQUARE FEET

OR 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--I-

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 malting 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

1oo

120

Air From Outside

Vertical

Duct

Horizontal

Duct

18-CD20D3-21 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

Protection 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 spe-

cifically designed for quiet, vibration free operation, air ducts

can act as sounding boards and could, if poorly installed, am-

plify 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 fur-

nace to a location outside the utility room, basement,

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 [hrnace 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 insulation

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.

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 (See Figure 11).

6. The bottom panel of the upflow furnace must be removed

for bottom return air.

8 18-CD20D3-21

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

TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS

Filters are factory supplied for these furnaces. These fur-

naces 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

*UYO6OR9V3

*UYO8OR9V3 17-1/2" 1 -17"X 25"X 1"

*UYIOOR9V4 21" 1 -20" X 25" X 1"

*UY120R9V5 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 1800 CFM, these models will require return air openings

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

bottom.

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 I side and the

bottom; OR just the bottom.

®UPFLOW FURNACE ONLY

LOCATING *'_

NOTCHES PRO-"T.,.

VIDED FOR SIDETI

RETURN CUTOUT

-. Ij

CUT OUT FOR

J SIDE FILTER

ONT

/of Furnace

*SEE OUTLINE DRAWING

Installer's Guide

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 _?

4__SPRINGS

ADJUSTMEN TAINING

-_// PI;ides)

(Both

Filter Rack Assembly

18-CD20D3-21 9

iiiiiiiiiiii

Installer's Guide

-. : ""'"';

Engagement II _

iiiII

tlV

%.,,

ENGAGEMENT

HOLE DETAIL

(Typical both sides

and blower deck)

FILTER RACK INSTALLATION FOR SIDE RETURN AIR

ON UPFLOW FURNACES (Left or Right)

NOTE:

The filter rack installation is not allowed for right side return

on the following models: *UYO6ORDV3 & *UYO8ORDV3.

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

(_ Filter

Furnace

Cabinet

Side Rack

Filter Rack

7_ _1_......_ Retaining

Screw/Pi n

Engagement Hole

For Filter Rack

Installation With

Bottom Return

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

BOTTOM ENGAGEMENT

Filter Rack

., Retaining

Screw/Pin

Engagement Hole

For Filter Rack

Installation With _)_

Bottom Return

Filter

Rack

)

Bottom Panel

BLOWER

DECK

Furnace

Cabi net

Side

Engagement Hole Furnace

For Filter Rack Blower

Installation With

Side Return Deck

_./

_N Filter

Retaining Rack

Screw/Pin Assembly

(_ SIDE

CUTOUT

RETAINING \

BOTTOM

PANEL

INSTALLED

Typical Upflow Left Side Return Filter Rack Installation

10 18-CD20D3-21

Installer's Guide

BLOWER DOOR/HINGE REMOVAL

Ifclearance or other problems create a problem in using the

tiltingdoor, the blower door hinge may be removed without

creating any problems with the sealof the furnace. To remove

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

To remove the tiltfeature,simply remove the lower hinge as

shown in Figure 20. The bottom of the blower door willcatch

in the bottom ofthe furnace front channel fordoor replace-

ment.

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 20.

TYPICAL RETURN AIR FILTER INSTALLATION IN

UPFLOW MODEL IN HORIZONTAL POSITION

Door Hinge Removed

ALTERNATE UPFLOW FILTER

CLIP /BRACKET INSTALLATION

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

has dimples for location of the alternate furnace clips

(Side return only). Pre-_'ill 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

18-CD20D3-21 11

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"

BOTTOM

DO NOT CUT

RETURN AIR

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 23.

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

*DY060R9V3

*DY080R9V3 17-1/2" 2 - 14" X 20" X 1"

*DY100R9V4 21" 2 - 16" X 20" X 1"

*DY120R9V5 24-1/2" 2 - 16" X 20" X 1"

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

TABLE 5

LOCATING FILTER RETAINER BRACKETS IN DUCTWORK

RETURN FILTER

CABINET DIMENSION DIMENSION

WIDTH DUCT "A .... B" BRACKET

WIDTH 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

OOptional

BAYFL TR206

Door Kit

DOWNFLOW

Airflow

Optional

BAYFL TR206 _

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-CD20D3-21

Installer's Guide

GENERAL VENTING INFORMATION

THIS FURNACE MUST BE VENTED TO THE OUTDOORS.

THESE FURNACES ARE INDUCED DRAFT VENTED

AND MUST NOT BE CONNECTED TO ANY VENT

SERVING 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 condens-

ing furnaces for a minimum of 0" clearance from combustible

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 appli-

ances.

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. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a

match or candle, or smoke from a cigarette, cigar, or pipe.

6. 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.

HORIZONTAL INSTALLATION

(UPFLOW /HORIZONTAL OR DOWNFLOW /HORIZONTAL)

NOTE:

In horizontal venting when the factory supplied "off-set" (2X3

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

following models: *UC120 & *DC120, *UX120 & *UY120

*UXIO0 & *UYIO0, *UX808C960, and all *DX & *DY models.

WHEN THE FACTORY SUPPLIED "OFF-SET" (2X3

REDUCING COUPLING) IS USED FOR 3" VENT PIPE

INSTALLATION, MAKE SURETHE MARKING "TOP" IS

LOCATED ON THETOP SIDE OFTHE PIPE.

LABEL

SAYS

"TOP"

STRAIGHT SIDE MUST BE

ON BOTTOM FOR PROPER

CONDENSATE DRAINAGE.

2" ,_' COUPLING

FACTORY SUPPLIED ONLY WITF

T_E FOLLOWING MODELS:

UC120 & DC120

120 & UY120

| UXl00 & UY100

UX080C960

MODLES

VENT

VENTET V

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.

18-CD20D3-21 13

Installer's Guide

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 detectors 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 detectors and makes no representations regarding any brand

or type of detector.

IMPORTANT:

These furnaces may be installed as Direct Vent (sealed

combustion) or as Nondirect vent (single pipe). The furnaces

are shipped DIRECT VENT with sealed combustion.

For DIRECT VENT APPLICATION: The fumaces 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 2

below).

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.

NOTE:

BAYVENT2OOB 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.

Air

Inlet

Vent

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.

Vent

Inlet",,4 II I

(seeNot_ [_[L] Furnace

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 _L I 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 VENTILA-

TION. Attic

_ Vent

L _

Air jr

Inlet

(See Note)

Furnace[_

NOTE:

If 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.

14 18-CD20D3-21

Installer's Guide

TABLE 7

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

1-5/8"

J_____

WALL MOUNT FLANGE

BAY69X 148

2-3_16"

I'_---- 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)]

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 Fittings -ASTM D1785, D2466, D2661, & D2665

PVC Primer and Solvent Cement -ASTM D2564.

Procedure for Cementing Joints Ref-ASTM D2855

Cut pipe square, remove ragged edges and burrs. Cham-

fer end of pipe, then clean fitting socket and pipe joint

area of all dirt, grease, moisture or chips.

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.

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.

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 cement.

IMPORTANT'.

All joints must be water tight. Flue condensate is somewhat

acidic, and leaks can cause equipment damage.

18-CD20D3-21 15

Installer's Guide

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.

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.

@VENT AND INLET AIR CONNECTIONS

Seal VENT PIPE

with RTV sealant

Seal INLET AIR PIPE

with RTV sealant

Front of Furnace

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 INCH PIPE

UY/DYO6OR9V3 200 200 200

UY/DYO8OR9V3 50 120 200

UY/DYIOOR9V4 Not Allowed 60 200

UY/DY120R9V5 Not Allowed Not Allowed 200

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

UY/DYO6OR9V3 1O0 1O0 1O0

UY/DYO8OR9V3 25 60 1O0

UY/DYIOOR9V4 Not Allowed 30 100

UY/DY120R9V5 Not Allowed Not Allowed 1O0

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

UY/DYO6OR9V3 50 50 50

UY/DYO8OR9V3 Not Allowed 30 50

UY/DYIOOR9V4 Not Allowed Not Allowed 50

UY/DY120R9V5 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 BAYAIR3OAVENTA termination kit is

used, the equivalent length of pipe is 5 feet. BAYVENT2OOB equivalent length is 0 feet.

6. Pipe adapters are field supplied. Downflow models, UYIO0 and UY120 include a 2" X 3" adapter.

HIGH ALTITUDE 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 ob-

tained from the local utility supplier for the gas being deliv-

ered 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).

16 18-CD20D3-21

TABLE8

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL DRILL

SIZE SIZE

PART

NUMBER

ORF00501

ORF00644

ORF00909

ORF00910

ORF01099

ORF00503

ORF00493

PART

NUMBER

ORF00555

ORF00693

ORF00907

ORF00908

ORF01338

ORF01339

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:

Reinstafl the propane orifices to the same depth as the orifices

supplied with the equipment.

See Table 9 for help in selecting orifices if orifice change is

required. Furnace input rate and temperature rise should be

checked again after changing orifices to confirm the proper

rate for the altitude.

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.

Installer's Guide

The Vent Length Table on page 16 shows the required vent

lengths for installations at various altitudes. An optional

high altitude kit is available for installations above 5000 feet

(Installations above 12,000 feet are not allowed).

TABLE 9

Orifice

Twist Drill

Size If

Installed

At Sea

Level

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

2000 3000 4000 5000 6000 7000 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

49 49 49 50 50 50 51 51 52

50 50 50 51 51 51 52 52 52

51 51 51 51 52 52 52 53 53

51 52 52 52 52 53 53 53 54

52 53 53 53 53 53 54 54 54

54 54 54 54 54 54 55 55 55

54 55 55 55 55 55 56 56 56

55 55 55 56 56 56 56 56 57

56 56 57 57 57 58 59 59 60

58 59 59 60 60 61 62 63 63

59 60 60 61 62 62 63 63 64

From National FuelGas Code- Table F-4

HORIZONTAL VENTING

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.

ELBOW AND TEE MUST

BE AS CLOSE TO-

GETHER

AS POSSIBLE

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

18-CD20D3-21 17

Installer's Guide

IMP OR TANT: r!_ :e_lj_o] _I

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 11-,4venting systems (up to

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

changed with other vent systems or unlisted pipe or fit-

tings. Plastic components, specified primers, and glues

must be from a single system manufacturer and not inter-

mixed with other system manufacturer's vent system

parts. In addition, the first three feet of the vent pipe must

be visible for inspection.

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 112inch (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.

(_ DOWNWARD VENTING

Furnacemaybe in verticalor horizontalconfiguration.

All horizontal pipes must be

supported at a maximum of

3foot intervals

Slope 1/4" per ft.

÷ ,

1I|

DOWNWARDVENT LENGTHIS I

LIMITEDTO A MAXIMUMOF I15 EQUIVALENTFEET.

SEE

NOTES

40 Inch

__ Upflow or__

Downflow

Furnace

-F

6" Min.

__t_

NOTES:

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 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.

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

18 18-CD20D3-21

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

BAYVENT2OOB "'.

STRAP

(FIELD SUPPLIED L

VENT

COMBUSTION AIR (FIELD

SUPPLIED)

BAYAIR30AVENTA

(Sidewall)

COMBUSTION

AIR

HORIZONTAL VENT CLEARANCES

(See clearance tables on page 20)

INSIDE

CORNER DETAIL

i+G

["_ VENTTERMINAL (_) AIR SUPPLY INLET E_ AREAWHERETERMINAL IS NOT PERMITTED

HORIZONTAL VENTING THROUGH WALL

These furnaces may be installed as direct vent (as

shipped) or as nondirect vent. Installation must con-

form to national, state, and local codes.

The vent & inlet terminals must he 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 29 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.

FLI_ GAS DEGRADATION - The moisture content of the

flue gas may have a detrimental effect on some building

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.

18-CD20D3-21 19

Installer's Guide

Table 11 Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch, deck,

A= or 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

D= above the terminal within a horizontal distance

of 2 feet (61 cm) from the center line ef 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

H= above meter/regulator assembly the meter/regulator assembly

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

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

12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 4 feet (1.2 m) below or to side of opening;

J= building or the combustion air inlet to any other 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

L= Clearance above a paved sidewalk or paved

driveway located on public property 7 feet (2.13 m) 1- 7 feet (2.13 m)

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

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.

Table 12 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

H= extended above meter/regulator 3 feet (91 cm) with a height 15 feet (4.5 m) above the

assembly meter/regulator assembly

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

Clearance to nenmechanical 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 and =/< 100,000 Btuh (30 kw), and =/< 50,000 Btuh (15 kw), 12 inches (30 cm) for

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

Clearance to a mechanical

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

Clearance above a paved sidewalk

L= or paved driveway located on 7 feet (2.13 m) 1-

public property

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

porch, deck, 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.

20 18-CD20D3-21

COMBUSTION

AIR INLET

T/ J

40" UPFLOW OR

DOWN FLOW/,_ODE LS

OUTSIDE

WALL

STUB CUT AT

45 °ANGLE

Installer's Guide

SEE VENT ING TABLE ,_-

USE ONLY

STRAPS OR OTHER SUITABLE SUPPORTS AT A APPROVED

MAXIMUM OF 3' 0" INTERVALS P"'I TERMINATION

RRST SUPPORT SHOULD BE T

CLOSETO RIRNACE CONNECTION

AS POS:_IBLE OUTSIDE

WALL

NOTE: ANY FI1-BN,GS PASSING

THROUGH AN UNHEATED SPACE

MUST BE INSULATED

NOTE: VENT AND INLET MUST BE SUPPORTED

AT A MAXIMUM OF 3' INTERVALS

BAYAIR3OAVENTA [_ COMBUSTION

STRAP I_/

(FIELD SUPPLIED) _RAIN CAP

VENT /

.- ILF HI, ,.._.,,2..

CONBUST,ONA,R"_

SUPPLIED)

45° ELBOW

t/" .-I_I_L# ICOUPLING _i_'_;:_

L.J[ -- H FIELD SUPPLIED ;;_:":'_!_

TEE I,__,I I I IF NEEDED !i[......(:itS!":':_

.-, (( (

I_ 2% 2-1/2" _ ....................................................I_--. i.....................................................................

hIIII _ I _ Jor 3" PIPING "_; ",_'_=_? .......

3" PIPING 1[_ ::"._;_,_:

SEAL ALL /_1_ _ J

WALL CAVITIES

®COUPLING

( PLASTIC

VENTING

IN. MIP

(:)JOIN

1" CLEARANCE

( AIR SPACE )

DVC WALL

MOUNT FLANGE

[OPTIONAL)

APPROVED

TERMINATION

12" MIN. ABOVE

NORMALLY EXPECTED

_,NOW ACCUMULATION

VENTINGTHROUGH COMBUSTIBLEWALLS

Pitch-- 1/4Inch PerFt.

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

COMBUSTIBLE MATERIAL WALL

A minimum clearance of i" 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.

COUPLIN G

(PLASTIC

VENTING )

14 6IN,MIN.

III(ToJolNT

]

M OCRET_ENTAL_-_

INSIDE &

OUTSIDE

PVC WALL

MOUNT FLANGE

[OPTIONAL)

APPROVED

TERMINATION

12" MIN. ABOVE

NORMALLY EXPECTED

SNOW ACCUMULATION

VENTING THROUGH NON-COMBUSTIBLE WALLS

I_fPh - 1/.4 Inrh ID_r Ff

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 above.

18-CD20D3-21 21

iiiiiiiiiiii

Installer's Guide

VENTING THROUGH THE ROOF

SUPPORT HORIZONTAL PIPE EVERY 3'

0" WITH THE FIRST SUPPORT AS CLOSE

TO THE FURNACE AS POSSIBLE.

INDUCED DRAFT BLOWER, HOUSING,

FurnaCE OTSU O TD

THE WEIGHTOF THE FLUE PIPE.

°' //

40" UPFLOW OR DOWNFLOW FURNACE

HORIZONTAL AND VERTICAL VERTICAL

!UTLET

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 33 is the

preferred method for vertical vent termi-

nation 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.

9" MIN.

VENT_'_ .L-_.I_'_/- "'""" 12-INCH CLEAr4ANCE MUST BE

]2' ± ],_1_ MAINTAINED ABOVE HIGHEST

AN'nC1PA]ED SNOW LEVEL

MAXIMUM NOT TO EXCEED

24 INCHES ABOVE ROOF,

D,STANCE FROM TOP _

OF VENT TO BOSOM

OF AIR INLET MUST

BE 12' ± 1' )

COMBUSTION

AIR INLET

MAINTAIN 12 IN.

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF.

VENT

REMOVE RIBS

FROM CAP

COMBUSTION

AIR

ROOF BOOT

MAINTAIN 12 IN.

VENT (18 IN. FOR CANADA)

_i" MINIMUM CLEARANCE

IBOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF

suP

(FIELD SUPPLIED)

ELBOW

(FIELD SUPPLIED)

VENT-_

COMBUSTION

AIR

BAYAIR30AVENTA (VERTICAL)

_SEAL BETWEEN FLANGE,PIPE,

COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT

COUPLING

SUPPORT

FLANGE

CEILING

GALVANIZED FIRESTOP SHOULD

BE FABRICATED WITH 3-7/8" DIA.

HOLE FOR SUPPORT FLANGE

(12" X12" PANEL OR 12" DIA MIN,) ,_

CLEARANCE {0" ACCEPTABLE FOR PVC VENT PIPE)

( 1" ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PII::_E )

VENTING THROUGH CEILING

22 18-CD20D3-21

®SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT

SUPPORT _

Installer's Guide

FLANGE _

FLOOR

COUPLING

GALVANIZED

PANEL (FIRESTOP)

FLUE PIPE

CLEARANCE

(0" ACCEPTABLE FOR PVC VENT PIPE)

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

DIRECTION OF STAINLESS STEEL FITTING

All stainless steel fitting must be installed with male end

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.

VENTING ROUTED THROUGH A MASONRY CHIMNEY

®PVC PLASTIC VENTING - ONLY

THROUGH UNUSED CHIMNEY

STAINLESSSTEEL

VENTCAP

(OPTIONAL) //

SEE CAUTION. _ _6 IN. MIN.

FLUE PIPE _ _j.

"_'_/I SUPPORT THE SINGLE

COUPLING TO SUPPORT ._ .#-._7_.........._ WALL FLUE PIPE AND

PIPE FROM ANGLES _L..._ "-b_.j//zp _iF) CENTER IT IN THE

OR OTHER SUITABLE "--_."'_._ "_/_, _CHIMNEY OPENING WITH

suPPORTMETHOD \_/ ANGLESASSHOWNOR

"">._1 ._ ANOTHER EQUIVALENT

-__ COUPLING

;_<"_/_S_ AS REQUIRED

FLUE PIPE

_NOTE:

•HORIZONTAL VENTING

TO VERTICAL VENTING

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.

TYPE 29-4C STAINLESS STEEL VENTING -

USED THROUGH CHIMNEY THAT VENTS

ANOTHER GAS APPLIANCE

STAINLESS STEEL

VENTCAP

(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:

HORIZONTAL VENTING

TO VERTICAL VENTING

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.

18-CD20D3-21 23

Installer's Guide

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".

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

24 18-CD20D3-21

Installer's Guide

ELECTRICAL CONNECTIONS

Make wiring connections to the unit as indicated on enclosed

wiring diagram. As with all gas appliances using electrical

power, this furnace shah 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 accordance 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 inte-

grated 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.

T'STAT

[]

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

VARIABLE SPEED

2-STAGE FURNACE

[]

W141

] W14JUMPER

SEE NOTE 11

[]

[_'_ SEE

_NOTE9

SEE I_

1. Be sure power agrees with equipment nameplates.

2. Low voltage (24 volt wiring) to be No. 18 A.W.G. rain.

3. Grounding of equipment must comply with local codes.

4. Set thermostat heat anticipator per unit wiring diagram.

5. These leads provide 115M power for connection of electronic

air cleaner and humidifier MAX. load 1.0 amps each.

6. When a single stage heating thermostat without fan switch

is used, no wiring on "G" terminal is used.

7. Wl and W2 must be jumpered together for proper operation.

Second stage heat will begin based on IFC swNch setting.

8. Set dip switches with power off per installation instructions

to set airflow and indoor fan off delays.

9. Continuous fan airflow can be increased by adding this jumper.

10. This wire is only for thermostats requiring connection to

transformer common terminal.

11. Optional humidistat is to be connected between R and BK. Factory installed jumper R

to BK on the circuit board must be cut if optional humidistat is used. The jumper must

also be cut when applying an airflow command signal to the BK input such as with the

variable speed single-zone and mugi-zone system controllers. On single speed cooling

only/non-heat pump systems, jumper Y to O for proper operation of the delay profiles

]. J and the humidistat. For two compressor or two speed systems, jumper YLo to O.] NOTE 6

FIELD ADDED JUMPER GROU N D

Wl TOW2. SCREW

_. J_ _SEE FURNACE WIRING DIAGRAM [_'_ FUR NACE

L_J L_J ,, _ FOR 2ND STAGE TIMING. ,if _ _iK JUNCTION

:_I BOX

NOTE 10 SUPPLY PER I I

[] [] ........... N __. I

Y _[--_4J BI,31

I I WH I I

INTE7 )MPONENT WIRI ', ...... j- _"/I II I _ I

..... LBK--q#--I _ ....I

24 g. \FIELD II _ I

----LINE ,,/., _/ilR[NE F WH fl i _-I i

J EAC SEE

V. _ FAT'. RY ..... L BK _ ,

--L[qE ,., ,',,IK[No FromDwg. B342027Rev. 1

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTAT

NO COOLING

VARIABLE SPEED

2-STAGE FURRACE 1.

-- 2.

[] s.

[]

T "STAT

[]

_,,

[] ED'

[] []

SEE

[] NOTE []

II'TE:7 COvq;ONENT '?#]_]NG

P4 '/. !, FIELD

---- L INE /"S vYlR ING

2q Y'. t. F_ TDRY

-- L INE /,j" 'A' I! IN G

W14JUMPER 8.

SEE NOTE9

_SEE

NOTE 7

Be sure power agrees with equipment nameplates.

Low voltage (24 volt wiring) to be No. 18 A.W.G. rain.

Grounding of equipment must comply with local codes.

Set thermostat heat anticipator per unit wiring diagram.

These leads provide 115V. power for connection of electronic

air cleaner and humidifier MAX. load 1.0 amps each.

This wire is only for thermostats requiring connection to

transformer common terminal.

Continuous fan airflow can be increased by adding this jumper.

Set dip switches with power off per installation instructions

to set airflow and indoor fan off delays.

Optional humidistat is to be connected between R and BK. Factory

installed jumper R to BK on the circuit board must be cut if optional

humidistat is used. The jumper must also be cut when applying an airflow

command signal to the BK input such as with the variable speed single-zone

and multi-zone system controllers. On single speed cooling only/non-heat pump

systems, jumper Y to O for proper operation of the delay profiles and the humidistat.

For two compressor or two speed systems, jumperYLo to O.

From Dwg. B342025 Rev. 0

18-CD20D3-21 25

Installer's Guide

OUTDOOR UNiT

(NOTRANSFORMER}

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

1 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

VARIABLE SPEED NOTES:

T'STAT 2-STAGE FURNACE

I BE S RE POWER AGREES WITH EQUIPMENT NAMEPLATE(S)

2. LOW VOLTAGE(Z4 v WIRING) TO BE NO 18 A W G. MIN

D _ 3 GROUNDING OF EQUIPMENT M ST COMPLY WITH LOCAL CODES

l_2_J 0_\ 4 SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM

W14! S THESE LEADS PROVIDE 115 v POWER FOR CONNECTION OF ELECTRONIC AIR

/CLEANER AND HUMIDIFIER MAX LOAD I O AMPS EACH

r_ 6 THIS WIRE IS ONLY FOR THERMOSTATS REQUIRING

CO NECTION TO TRANSFORMER COMMON TERMINAL

7 THE "Y" TERMINAL FROM THE THERMOSTAT MUST BE WIRED

D W14JUMPER TO THE "Y" TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWER

OPERATION DINING COOLING

SEE NOTE 9

8 SET DIP SWITCHES WITH POWER OFF PER INSTALLATION INSTRUCTIONS

TO SET AIRFLOW AND INDOOR FAN OFF DELAYS

D 9 OPTIONAL HUMIDISTAT IS TO BE CONNECTED BETWEEN R AND BK. FACTORY

INSTALLED J£TPER R TO BK ON THE CIRCUIT BOARD MUST BE CUT IF OPTIONAL

SEE HUMIDISTAT IS USED THE JUMPER MUST ALSO BE CUT WHEN APPLYING AN AIRFLOW

COMMAND SIGNAL TO THE BH INP T S CH AS WITH THE VARIABLE SPEED,SINGLE ZONE

D NOTE7 _ AND MULTI ZONE SYSTEM CONTROLLERS, ON SINGLE SPEED COOLING ONLY/NON HEAT PUMP

I":_1 SYSTEMS JUMPER Y TO 0 FOR PROPER OPERATION OF THE DELAY PROFILES A O THE

HUMIDISTAT FOR TWO COMPRESSOR OR TWO SPEED SYSTEMS, JUMPER YLO TO 0

D D FIELD ADDED JUMPER _Cs_-_}_ .Z_ F U R N ACE

W1 TO W2. iBK ....

_ SEEFURNACEWIRINGDIAGRAM II I_ Be [" JUNCTION

L__[J ,1 FOR 2ND STAGE TIMING. Ii _ II BOX

jLH BK

TO 115V 1PH., [-- .... _ ..... I

BoHZ,POVVER! ,I_ ,

SUPPLY PER J I

SEE LOCALCODES 1 LN --I..._S I

B B LFr -=F 4J Tq

I WH / I I

I HUMSEE J_ wH "_ I II I'll II

•NOTE5 I BK--4 _I

INTER COMPONENT WIRING '- I - a_/21

WH I I

2 EAC SEE -- -- J

----LINE V._W[RING ° L I'_--_

24 v. _\ FACTORY FromDwg. B342022Rev. 1

--LINE V._'_ W[ _ IN G

OUTDOOR UNIT

(NOTRANSFOnMEn)

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING, 1 STAGE COOLING

USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORM ER)

T'STAT

[]

VARIABLE SPEED

2-STAGE FURNACE

] 0-\

W14/i

[]

SEE

NOTE 9

L--_F]

[]

SEE

NO E7[]

[] []

SEE

[] NOTE°

L J

W14 JUMPER

SEE NOTE 9

NOTE:

I BE SURE POWER AGREES WITH EQUIPMENT NAMEPLATE(S)

2 LOW VOLTAGE [24V WIRING) TO BE NO IBAWGMIN

S GROUNDINGOF EQUIPMENTMUST COMPLY WITH LOCAL BUILDING CODES

4 SET THERMOSTATHEAT ANTICIPATOR PER UNIT WIRING DIAGRAM

5 THESE LEADS PROVIDE 115V POWERFOR CONNECTIONOF ELECTRONIC

AIR CLEANER AND HUMIDIFIER MAX LOAD IO AMPS EACH

6 THIS WIRE IS ONLY FOR THERMOSTATSREQUIRING CONNECTIONTO

TRANSFORMERCOMMONTERMINAL

7 THE IIyIITERMINAL FROM THE THERMOSTAT MUST BE WIRED TO THE

IIyII TERMINAL OF THE FURNACECONTROLFOR PROPER BLOWER

OPERATION DURING COOLING

8 SET DIP SWITCHES WITH POWEROFF PER INSTALLATION INSTRUCTIONS

TO SET AIRFLOW AND INDOORFAN OFF DELAYS

9 OPTIONAL HUMIDISTAT IS TO BE CONNECTEDBETWEEN"R" AND "8H"

FACTORY INSTALLED JUMPER "R" TO "BK" ON THE CIRCUIT BOARDMUST

BE CUT IF OPTIONAL HUMIDISTAT IS USED THE JUMPERMUST ALSO BE

CUT WHENAPPLYING AN AIRFLOW COMMANDSIGNAL TO THE "BK" INPUT

SUCH AS WITH THE VARIABLE SPEED SINGLE ZONE AN[) MULTI ZONE

SYSTEM CONTROLERS ON SINGLE SPEED COOLING ONLY /NON HEAT PUMP

SYSTEMS, JUMPER "Y" TO "0" FOR PROPER OPERATION OF THE DELAY

PROFILES AND THE HUMIDISTAT FOR TWOCOMPRESSOR OR TWOSPEED

SYSTEMS, JUMPER IIyLOll TO IIOlI

INTER COMPONENT WIRING

24 V. FIELD

----LINE Y. WIRING

24 V. FACTORY

--LINE Y. WIRING

From Dwg B342020 Rev O

26 18-CD20D3-21

Installer's Guide

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING, 2 STAGE COOLING

(OUTDOOR SECTION WITHOUT TRANSFORMER)

VARIABLE SPEED NOTES :

T'STAT 2-STAGE FURNACE

OUTDOORUNITNO 1

(NO TRANSFORMER)

SEE NOTE3

?UT_OO;%T&Od'

t 0/

E2]

[]

SEE

NOTE 7

SEE

NOTE6

l-q

F-q

f-q

[]

INTER-COMPONENT WIRING

24 V. ] FIELD

LINE V.J wIRING

24 V. _ FACTORY

LINE V.J wIRINGf

0_\

FACTORY

INSTALLEO

JUMPER

I. BE SURE POWER AGREES WITH EQUIPMENT NAMEPLATE/SI

2. LOW VOLTABEI24 V. WIRING} TO BE NO. 18 A.W.G. M]N.

3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.

4. SET THERMOSTAT HEAT ANTICIPATOR PER LN]T WIRING DIAGRAM=

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

CLEANER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.

6. THIS WIRE iS ONLY FOR THERMOSTATS REQUIRING

CONNECTION TO TRANSFORMER COMMON TERMINAL.

7. THE "Y2" TERMINAL PROM THE THERMOSTAT MUST BE WIRED

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

OPERATION DURING COOLING.

SET DIP SWITCHES WITH POWER OFF PER INSTALLATION INSTRUCTIONS

TO SET AIRFLOW AND INDOOR FAN OFF DELAYS.

OPTIONAL HUMID]STAT iS TO BE CONNECTED BETWEEN R AND BK= FACTORY

INSTALLED JUMPER R TO BK ON THE CIRCUIT BOARD MUST BE CUT IF OPTIONAL

HUM]D[STAT IS USED. THE JUMPER MUST ALSO BE CUT WHEN APPLYING AN AIRFLOW

COMMAND SIGNAL TO THE BK INPUT SUCH AS WITH THE VARIABLE SPEED SINGLE ZONE

AND MULTI ZONE SYSTEM CONTROLLERS: ON SINGLE SPEED COOLING ONLY!NON HEAT

PUMPSYSTEMS, JUMPER Y TO 0 FOR PROPER OPERATION OF THE DELAY PROFILES

AND THE HUMID]STAT. FOR TWO COMPRESSOR OR TWO SPEED SYSTEMS,JUMPERYLOTO O.

',1 I r JUNCTION

:_ : Box

so._v,pHI-L" BKL'_WH.,

60 HZ., POWER I II

SUPPLY PER II I

LOCALCODES _ LN RHI _ --_j ,

L .,--_=F_ Bwl

,-WH I /'_'

NU_SEEJ'"''J I I1_ ',

NOTE 5 | BK

L---- °vl

WH I I

EACSEEF----/ ,I_1 ,

NOTE 5 L" BK .____ From Dwg. B342018 aev. O

CONDENSATE DRAIN INSTRUCTIONS

r'!'_ [*,]'i_lj i [0] _I

It is recommended that a drain pan be installed under the

furnace to prevent property damage, personal injury or

death from leaking condensate.

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.

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

@i'

_ _ ---_ i°

°/_:--_-i !

18-CD20D3-21 27

Installer's Guide

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.

UPFLOW (VERTICAL)

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

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)

28 18-CD20D3-21

the secondary recuperated cell. Remove the larger drain 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.

Remove the hose from the induced blower and reposition into

the other drain tap of the inducer, which is located 90 °

clockwise around the inducer. Move the cap from that drain

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

DOWNFLOW (VERTICAL)

Right

side

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

DOWNFLOW (VERTICAL)

Installer's Guide

Cut off curved end of

Inducer drain hose

DOWNFLOW (HORIZONTAL)

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.

18-CD20D3-21 29

iiiiiiiiiiii

Installer's Guide

MAIN MANUAL m

SHUT-OFF VALVE

JOINT j_

DRIP_ .....

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

UPFLOW MAY BE LEFT OR RIGHT HAND GAS PIPING

MAIN MANUAL

SHUT-OFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

:_ o

THE DOWNFLOW (VERTICAL) MAY BE INSTALLED LEFT OR RIGHT SIDE GAS PIPING

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

SHUT-OFF VALVE

GRO DRI

UNION JOINT LEG !J

FLOW

MAIN MANUAL jGROUND UNION JOINT

SHUT-OFF _

VALVE _LEGDRIP

I I

AUTOMATIC GAS VALVE [_:_

WITH MANUAL SHUT-OFF !1

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

(Typical UPFLOW Furnace in horizontal configuration shown)

Use a backup wrench on the gas valve when installing gas piping to

prevent damage to the gas valve and manifold assembly.

30 18-CD20D3-21

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

42.

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 10, for delivery sizes. Connect gas

supply to the unit, using a ground joint union and a manual

shut-off valve as shown in Figures 43 & 44. National codes

require a condensation drip leg to be installed ahead of the

controls as shown in Figures 43 & 44.

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.

TABLE 10

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

All gas fittings must be checked for leaks using a soapy solution

be[bre lighting the furnace. DO NOT CHECK WITH AN

OPEN FLAME!

TABLE 11

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, page 16)

1. Make sure all gas appliances are offexcept 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 13

with the time clocked.

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

clocked.

Installer's Guide

5. Use the following factors if necessary:

For i 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

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 nameplate

rating.

7. Changes can be made by adjusting the manifold pressure

(See Table 12), 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 45 for White-Rodgers gas valve model 36E and

Figure 46 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 Fig-

ure 48.

Turn on system power and energize valve.

For the White-Rodgers gas valve model 36E:

1. Adjust low fire by removing the low adjustment

seal screw (See Figure 45).

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

set screw clockwise. To decrease outlet pressure,

turn the set screw counterclockwise. Adjust

regulator until pressure shown on manometer

matches the pressure specified in Table 12.

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 45).

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 12 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.

18-CD20D3-21 31

iiiiiiiiiiii

Installer's Guide

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

1. Adjust low fire by removing the low adjustment

regulator cover screw (See Figure 46).

2. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet pres-

sure, turn the regulator adjust screw counterclock-

wise. Adjust regulator until pressure shown on

manometer matches the pressure specified in

Table 12.

3. Replace and tighten the regulator cover screw

securely.

4. Cycle the valve several times to verify regulator

setting.

5. Adjust high fire by removing the high adjustment

regulator cover screw (See Figure 46).

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 12 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.

Turn off all electrical power to the system.

Remove the manometer and flexible tubing. Remove

the barbed fitting and replace the plug or tighten the

pressure test screw.

Turn on electrical power to the system and energize

valve.

Using a leak detection solution or soap suds, check for

leaks at plug or pressure boss screw.

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 48.

@White-Rodgers 36E

2nd Stage (HI)

Manifold

Adjustment

Gas Valve On /Off

Toggle Switch

1st Stage (LO)

Manifold

Pressure

Adjustment

@2nd Stage (HI) Manifold

Pressure Adjustment

Gas Valve On /Off

Toggle Switch

1st Stage (LO)

Manifold Pressure

Adjustment

White-Rodgers 36G gas valve

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.

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 11 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 14.

TABLE 12

FINAL MANIFOLD PRESSURE SETTINGS (inches w.c.)

FUEL 2nd Stage Max. 1st Stage Max.

NATURAL GAS 3.5" W.C. 1.7" W.C.

LP GAS 10.5" W.C. 6.0" W.C.

32 18-CD20D3-21

@CORRECT METHOD OF CHECKING DIRECT VENT MANIFOLD

PRESSURE WITH BURNER BOX REFERENCED

Installer's Guide

Separatethetube I I

at the unit Tee and _' !\

reconnect with a Fh I] "_t

short piece of field "J [] I

supplied tube and -- 11 I / I

another Teewith 2I /[[

the "U" Manometer .IS/ | [[

attached. //I

=esuretoreconnect I/ i 'bhJS jr

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

position after testing -- _--_k_ L._::::::=::==

the manifold pressure! k_>/(z-\ _.,

Field supplied barb fltling_J I

with manometer tube is _.

attached to the "OUTLET '_

PRESSURE TAP" on the

outlet side of the gas valve.

TABLE 13

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

Return all tubing, caps,

and/or plugs to original

positions when pressure

checks are completed.

SEC. FLOW SEC. FLOW SEC. FLOW SEC. FLOW

8 900 29 248 50 144 82 88

9 800 30 240 51 141 84 86

10 720 31 232 52 138 86 84

11 655 32 225 53 136 88 82

12 600 33 218 54 133 90 80

13 555 34 212 55 131 92 78

14 514 35 206 56 129 94 76

15 480 36 200 57 126 96 75

16 450 37 195 58 124 98 73

17 424 38 189 59 122 100 72

18 400 39 185 60 120 104 69

19 379 40 180 62 116 108 67

20 360 41 176 64 112 112 64

21 343 42 172 66 109 116 62

22 327 43 167 68 106 120 60

23 313 44 164 70 103 124 58

24 300 45 160 72 100 128 56

25 288 46 157 74 97 132 54

26 277 47 153 76 95 136 53

27 267 48 150 78 92 140 51

28 257 49 147 80 90 144 50

TABLE 14

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL DRILL

SIZE SIZE

PART

NUMBER

ORF00501

ORF00644

ORF00909

ORF00910

ORF01099

ORF00503

ORF00493

PART

NUMBER

ORF00555

ORF00693

ORF00907

ORF00908

ORF01338

ORF01339

REINSTALLATION OF THE BURNER BOX COVER

Figure 47 shows the correct way to reinsta]] the burner box

cover if adjustment or rep]acement of the flame sensor, hot

surface igniter, or main burner orifices have required removal

of the cover.

EXPLOSION HAZARD!

PROPANE GAS IS HEAVIER THAN AIR AND MAY

COLLECT IN ANY LOW AREAS OR CONFINED

SPACES. IN ADDITION, ODORANT FADE MAY MAKE

THE GAS UNDETECTABLE EXCEPT WITH A WARN-

ING DEVICE. IF THE GAS FURNACE IS INSTALLED

IN A BASEMENT, AN EXCAVATED AREA OR A

CONFINED SPACE, IT IS STRONGLY RECOM-

MENDED TO CONTACT A GAS SUPPLIER TO IN-

STALL 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.

18-CD20D3-21 33

Installer's Guide

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 44 & 45)

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 WITH AN OPEN FLAME. Allow

5 minutes for any gas that might have escaped to dissipate.

LP Gas being heavier than air may require forced ventilation.

Turn the knot) 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, per-

sonal injury or death.

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 Figures 41-43). Discon-

nect the electrical supply to the unit.

If this 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 damage

could result, such as frozen water pipes.

SEQUENCE OF OPERATION

Thermostat call for heat (2-stage thermostat)

Call for 1st stage only:

W1 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 2rid 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.

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.

34 18-CD20D3-21

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 op-

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

must be checked out on hlitial start up by the hlstaller.

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 maxi-

* - This setting is equivalent to BAY24X045 relay

benefit.

**- This selection provides ENHANCED MODE, which

is a ramping up and ramping down of the blower

speed to provide improved comfort, quietness, and

potential energy savings. See Wiring Diagram

notes on the unit or in the Service Facts for com-

plete wiring setup for ENHANCED MODE. The

graph which follows, shows the ramping process.

80%

100% if necessary

OFF

50% 50%

:ast Cooling Efficiency

I,I 75 I I 3I

minute minutes minutes

OFF

See Wiring Diagram on the unit or in the Service Facts

for complete wiring setup for Enhanced Mode.

mum outlet temperature as shown on the rating plate, the

burners must shut off. If they do not shut off after a reason-

able 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.

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 Airflow Label on the furnace or the unit's Service Facts for

information on changing the speed of the blower motor for

your specific model. Blower speed changes are made on the

Integrated Furnace Control (IFC).

There is a bank of 8 dip switches located near the thermostat

connections to the Integrated Furnace Control. The dip

switches work in pairs to match the airflow for the outdoor

unit size (tons), cooling airflow adjustment, cooling off-delay

options, and furnace heating airflow adjustment.

Installer's Guide

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.

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.

WI-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-offperiod is set by dip switches on the

Integrated Furnace Control. The options for cooling delay off

is field selectable by dip switches #5 and #6.

The following table and graph explain the delay-off settings:

COOLING OFF - DELAY OPTIONS

NOMINAL

SWITCH SETTINGS SELECTION AIRFLOW

5 - OFF 6 - OFF NONE SAME

5 - ON 6 - OFF 1.5 MINUTES 100% *

5 - OFF 6 - ON 3 MINUTES 50%

5-ON 6-ON ** 50- 100%

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.

NOTE TO INSTALLER

Review the following warnings with the owner. Review

contents of USER'S INFORMATION MANUAL with the

owner.

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 offall flow of gas.

18-CD20D3-21 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

1 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 off the gas valve and lock out the

system.

5. INDUCED DRAFT BLOWER FAILURE

Please refer to the variable speed &'aft inducer trouble-

shooting manual for diagnostic assistance.

6. CONDENSATE DRAIN BLOCKAGE

If the condensate drain is blocked, either by debris,

improper draining, or by freezing condensate, the pres-

sure switch will sense the accumulation of condensate 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 offfor more than

i 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 blockage

of the terminations, the limit switch must be reset

by a qualified servicer.

36 18-CD20D3-21

Installer's Guide

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

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.

TABLE 15

INTEGRATED FURNACE CONTROL

GREEN "STATUS" LED FLASH CODES

Flashing Slow --- Normal - No call for Heat

Flashing Fast --- Normal - Call for Heat

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 sec-

onds.

Green Status LED

18-CD20D3-21 37

Installer's Guide

Tl_e

6200 Troup Highway

Tyler, TX 75707

For more information contact

your local dealer (distributor)

Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right

to change design and specifications without notice.

18-CD20D3-21

TRANE Furnace/Heater, Gas Manual L0902557

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