TRANE Furnace/Heater, Gas Manual L0903066

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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IIIIIIIIIIIIIIIIIIIIIIIIIIII

18- CD20 D1 - 18

AVAILABLE IN FRENCH CANADIAN (FC)

Variable Speed, 2-Stage

Upflow /Horizontal and Downflow /Horizontal,

Gas-Fired Furnaces, "Fan Assisted

Combustion System"

*UD060R9V3K *UD100R9V5K

*UD080R9V3K *UD120R9V5K

*UD080R9V4K *UD140R9V5K

*UD100R9V3K *DD060R9V3F

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

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

*DD080R9V3F

*DD100R9V5F

*DD120R9V5F

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

Please return to service information pack upon completion of work.

For VENT SIZING INFORMATION see:

USA --

National Fuel Gas Code ......... ANSI Z223.1/NFPA 54 (latest version)

CANADA --

Natural Gas Installation Code ...... CAN/CGA-B149.1 (latest version)

Propane Installation Code ............. CAN/CGA-B149.2 (latest version)

USA/CANADA ALTERNATE --

Category I Venting Guide ......... Pub. No. 18-CH23D1 (latest version)

Downflow /Horizontal* Upflow /Horizontal*

*Horizontal Conversion for these furnaces may be left or right side rotation.

A341789P03

Installer's Guide

SAFETY SECTION

The following safety practices and precautions must be

followed during the installation, servicing, and operation of

this furnace.

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

Refer to the furnace rating plate.

Install this furnace only in a location and position as

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

instructions.

3. Provide adequate combustion and ventilation air to the

furnace space as specified in "Air for Combustion and

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

4. Combustion products must be discharged outdoors.

Connect this furnace to an approved vent system only, as

specified in the "Venting" section (pages 13-14), 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 18) of these instructions.

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

intended temperature-rise range with a duct system

which has an external static pressure within the allow-

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

with temperature rise for cfm versus static is shown in

the Service Facts accompanying this furnace.

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

circulated by the furnace to areas outside the space

containing the furnace, the return air shall also be

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

terminating outside the space containing the furnace.

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

garage must be installed as specified in "Location and

Clearances" section (page 3) of these instructions.

9. The furnace may be used for temporary heating of

buildings or structures under construction only when the

following conditions have been met:

a. The furnace venting system must be complete and

installed per manufacturer's instructions.

b. The furnace is controlled only by a room thermostat

(no field jumpers).

c. The furnace return air duct must be complete and

sealed to the furnace and clean air filters are in

place.

d. The furnace input rate and temperature rise must be

verified to be within nameplate marking.

e. 100% of the furnace combustion air requirement must

come from outside the structure.

f. The furnace return air temperature range is between

55 and 80 degrees Fahrenheit.

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

substantial completion of the construction process,

and verify furnace operating conditions including

ignition, input rate, temperature rise and venting,

according to the manufacturer's instructions.

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

Gas Fitter in the Commonwealth of Massachusetts. I

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.

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.

Close fireplace dampers.

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.

Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the thermostat

so appliance is operating continuously.

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.

After it has been determined that each appliance

connected to the venting system properly vents where

tested as outlined above, return doors, windows,

exhaust fans, fireplace dampers and any other gas-fired

burning appliance to their previous conditions of use.

Safety signal words are used to designate a degree or level of

seriousness associated with a particular hazard. The signal

words for safety markings are 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.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in

serious injury, death or property damage.

Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

GENERAL 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 Fan Assisted

Combustion system CATEGORY I furnaces as required by

ANSI Z21.47 "latest edition" and CAN/CGA 2.3. Therefore

they do not require any special provisions for venting other

than what is indicated in these instructions. (Category I

defined on page 13).

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.

Do not install the furnace in a corrosive or contaminated

atmosphere.

These furnaces are not approved or intended for installation

in manufactured (mobile) housing, trailers, or recreational

vehicles. Failure to follow this warning could result in

property damage, personal injury, or death.

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.

Installer's Guide

Contents

Installation Instructions

General Installation Instructions

Location and Clearances

Outline Drawing

Upflow Installation

Downflow Installation

Horizontal Installation

Air for Combustion and Ventilation

Duct Connections

Return Air Filters

General Venting Instructions

Venting into a Masonry Chimney

Electrical Connections

Field Wiring Diagrams

Gas Piping

Combustion and Input Check

High Altitude Derate

Start Up and Adjustment

Preliminary Inspections

Lighting Instructions

Sequence Of Operation

Control and Safety Switch Adjustment

Abnormal Conditions

IFC Error Flash Codes

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.

18-CD20D1-18 3

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RETURN

AIR

23-1/2_ L3-13/16

*UDIR9VIK OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

I/2

--_7/8 KNOCK OUT

ELECTRICAL CONNECTION

(ALTERNATE)

\ _1-1/2 KNOCKOUT_

\GAS CONNECTION_

\ (ALTERNATE)/

_,__ .... ,

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MODEL DIM "A" DIM °B°DIM "C" DIM "D°

*UDOBORgVS*_

*UDOBOR9V3** 17-I/2 II 9-5/8" 16-IX4 II 16 II

*UDIOORgV3**

*UDOBOR9V4**

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*UDIBORgV5** 24-I/2 II l§-B/IB II 2_11/4 II 23"

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PREFIX LETTER MAY BE IIAIIOR IITII

H SUFFIX LETTERS MAY BE IIKII(0 THROUGH 9)

MINIMUMCLEARANCETO COMBUSTIBLEMATERIALS

UPFLOWCLOSET

LEFT SIBE O IN FRONT 3 IN (SEE NOTE I)

RIGHT SIDE +O IN BACK O IN.

FLUE #6 IN TOP I IN

HORIZONTAL CLOSET (SEE NOTE 2)

TOP +2 IN BACK 3 IN

FLUE #6 IN SIDES I IN

FRONT 18 IN (SEE NOTE I)

HORIZONTAL ALCOVE (SEE NOTE 2)

TOP +1 IN BACK 0 IN

FLUE #6 IN SIDES O IN

FRONT 18 IN

# - MAv BE III WHEN TYPE B-I VENT IS USED

+- FORI_-I/B II CABINETS SII WHENSINGLE

WALL VENT PIPE IS USED,

WHEN 14-1/211 CABINETS (ALL *UDO4OC-,

÷UDO4OR-, *UDO60C-, AND _UDOGOR936) ARE

INSTALLED IN A HORIZONTAL POSITION AND A

SINGLE WALL VENT PIPE IS USED, A 6 INCH

CLEARANCE MUST BE SUPPLIED BETWEEN

THE VENT PIPE AND COMBUSTIBLE FLOORING

NOTES:

I) MINIMUM CLEARANCE TO FRONT ON

_UBI_OR960 AND _UDI40C960 IS 6 INCHES.

2) MAY BE INSTALLED ON COMBUSTIBLE

FLOOR WHEN TYPE B-I VENT IS USED

14-7/8

I-9/16

I-5/16

From Dwg. 21C341699 Rev. 4

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HORIZONTAL VENTING

THROUGH CABINET

7/8

ELECTRICAL

CONNECTION

¢11/2 HOLE

GAS CONNECTION

I/2

I/2 1

_51/2

_2 I/8

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*DD-R9V-F OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

DIM "A" _d

SIDE PANEL CUTOUT

HORIZONTAL VENTING

THROUGH CABINET

T f N

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20 I/4

¢11/2 KNOCK OUT"

GAS CONNECTION

(ALTERNATE)

MINIMUMCLEARANCE TO COMBUSTIBLEMATERIALS

DOWNFL0W CLOSET

SIDES 3+ IN W/SINGLE WALL VENT 0 IN W/TYPE B I VENT

FLuE 6 IN W/SINGLE WALL VENT I IN W/TYPE B I VENT

FRONT 6IN BACK I IN

÷ RIGHT SIDE ONLY FOR 145" CABINETS,

0 IN TO LEFT SIDE 0 IN FOR BEMAINING

CABINET SIZES {175", 210 II , 245 II }

HI_RIZONTAL CLOSET )FLUE DISCHARGE LEFT}

TOP 5÷ IN W/SINGLE WALL VENT 2 IN W/TYPE B I VENT

FLuE 6 IN W/SINGLE WALL VENT I IN W/TYPE B I VENT

FRONT 6 IN BACK 3 IN SIDES I IN

÷ TOP ONLY FOR 145" CABINETS

2 IN FOR REMAINING CABINET

SIZES {175", 210", 245")

HORIZONTAL CLOSET )FLUE DISCHAROE RIGHT)

TOP 2 IN W/SINGLE WALL VENT

FLUE 6 IN W/SINGLE WALL VENT I IN W/TYPE B I VENT

FRONT 6 IN BACK 3 IN SIDES I IN

FOR INSTALLATION ON COMBUSTIBLE FLOORING ONLY

WHEN B I VENT CONNECTOR IS USED

HORIZONTAL ALCOVE }FLUE DISCHARGE LEFT)

TOP S÷ IN W/SINGLE WALL VENT

FLUE 6 IN W/SINGLE WALL VENT

FRONT 18 IN BACK 0 IN

÷ TOP ONLY FOR 145" CABINETS

I IN FOR REMAINING CABINET

SIZES {175", 210", 245")

IN W/TYPE B I VENT

IN WTVPE B I VENT

SIDES 0 IN

HORIZONTAL ALCOVE }FLUE DISCHARGE RIGHT}

TO _ I IN W/SINGLE WALL VENT

FLuE 6 IN W/SINGLE WALL VENT

FRONT IB IN BACK O IN

IN, W/TYPE B I VENT

SIDES 0 IN

7/8 KNOCK OUT _

ELECTRICAL

CONNECTION

(ALTERNATE)

MODEL A B C D

*DDO6OR9V3F 17-1/2" 9-5/8" 16-1/4" 16"

*DDO8OR9V3F

*DDIOOR9V5F 21" 13-1/16" 19-3/4" 19-1/2"

*DD120R9V5F 24-1/2" 15-5/16" 23-1/4" 23"

* - The First Letter May Be "A" or "T"

From Dwg. 21C341700 Sh. 1 Rev. 0

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Installer's Guide

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.

UPFLOW INSTALLATION

Standoffs and screws (See Figure 1, page 6) are included with

the cased coils for attachment to the furnace. There are

clearance alignment holes near the bottom of the coil wrap-

per. 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 down-

stream of the furnace airflow. The above instructions apply

only if the coil is on top of an upflow furnace.

(_ STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

INSTALLATIONS:

SCREWS

STANDOFFS

TABLE 1

CABINET RETURN FLOOR OPENING PLENUM OPENING

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

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

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

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

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used in

the horizontal.

Three brackets (with screws) are included with downflow fur-

naces 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 re-

maining bracket is placed as close to center as possible (hori-

zontally) between the coil case front and the furnace bottom

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

screws provided to secure the bracket.

©CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOWINSTALLATION

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.

@CABINET SIDE

Bg_24_E

(BENT UP)

SUB-_

;_./ CABINET SIDE

-- _ FLANGE

(BENT UP)

REQUIRED FLOOR OPENING: (DOWNFLOW)

See Figure 3 and Table 1

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

horizontal position by placing the furnace on the left or right

side (as viewed from the front in the upright 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

Clearance Table on Outline Drawings and Figure 5).

Typical Upflow/Horizontal Attic Installation

If the furnace is suspended using perforated steel strap

(plumber's strap), it must be supported at all four corners

and in the middle at the front of the furnace. The forward

most screw on the side of the furnace may be used to connect

the strapping (See Figure 5). Line contact is only permis-

sible between lines formed by the intersection of the top

and two sides of the furnace casing and the building joists,

studs, or framing.

6 18-CD20D 1-18

A cutout is provided on both sides of the downflow furnace

cabinet to allow a 90 ° elbow to be attached inside the cabinet

and the vent piping to connect there. In horizontal, the

downflow furnace may be vented through the top of the

cabinet if needed. In vertical configuration, the downflow

furnace may be vented using the side cabinet cutouts. This

venting configuration could be used if an electronic air

cleaner is installed.

When the downflow furnace is vented through the left

side of the furnace cabinet in horizontal or vertical

configuration, Type B vent pipe must be used within

the cabinet.

Typical Suspended Upflow/Horizontal Furnace

AIR FOR COMBUSTION AND VENTILATION

Adequate flow of combustion and ventilating air must not be

obstructed from reaching the furnace. Air openings provided

in the furnace casing must be kept free of obstructions which

restrict the flow of air. Airflow restrictions affect the effi-

ciency 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, or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149

Installation Codes, and applicable provisions of the local

building codes. Special conditions created by mechanical

exhausting of air and fireplaces must be considered to avoid

unsatisfactory furnace operation.

Furnace locations may be in "confined space" or "unconfined

space". Unconfined space is defined in Table 2 and Figure 6.

These spaces may have adequate air by infiltration to pro-

vide air for combustion, ventilation, and dilution of flue

gases. Buildings with tight construction (for example,

weather stripping, heavily insulated, caulked, vapor barrier,

etc.), may need additional air provided as described for con-

fined 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.

1. All air from inside the building as in Figure 8: 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.

Installer's Guide

UNCONFINED

50 CU. FT. OR MORE

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

CONFINED I

LESS THAN 50 CU. FT.

PER 1000 BTU/HR. INPUT

ALL EQUIP INSTALLED

FURNACE

The total input of all gas utilization equipment installed

in the combined space shall be considered in malting this

determination. Refer to Table 3, for minimum open

areas required.

All air from outdoors as in Figure 9: 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 3, for

minimum open areas required.

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 commercial laundry rooms

* Furnaces installed in hobby or craft rooms

* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combus-

tion 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

TABLE 2

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE

MAXIMUM BTUH

INPUT RATING

60,000

80,000

100,000

120,000

140,000

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE

FEET OF UNCONFINED SPACE

375

500

625

750

875

18-CD20D1-18 7

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Installer's Guide

TABLE 3

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING

Furnace

Maximum

BTUH/INPUT

Rating

60,000

80,000

100,000

120,000

140,000

Air

From

Inside

FURNACE ONLY)

Air From Outside

Vertical Horizontal

Duct Duct

100 15 30

100 20 40

100 25 50

120 30 60

140 35 70

®CONFINED SPACE k

AI_UlLDING _

PERMANENT

OPENINGS

(_ CONFINED SPACE

AIR FROM OUTDOORS

CONFINED-

SPACE

CONFINED SPACE k

AIR FROM VENTILATED ATTIC/CRAWL SPACE

AIR

INLET

AtR DUCT

DUCT CONNECTIONS

Air duct systems should be installed in accordance with

standards for air conditioning systems, National Fire Protec-

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

accordance with ACCA Manual D or whichever is applicable.

Check on controls to make certain they are correct for the

electrical supply.

Central furnaces, when used in connection with cooling units,

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

cooling units to avoid condensation in the heating element,

unless the furnace has been specifically approved for down-

stream installation. With a parallel flow arrangement, the

dampers or other means used to control flow of air shall be

adequate to prevent chilled air from entering the furnace,

and if manually operated, must be equipped with means to

prevent operation of either unit unless the damper is in full

heat or cool position.

On any job, flexible connections of nonflammable material

may be used for return air and discharge connections to

prevent transmission of vibration. Though these units have

been specifically designed for quiet, vibration free opera-

tion, air ducts can act as sounding boards and could, if

poorly installed, amplify the slightest vibration to the

annoyance level.

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

living area, the system should be carefully designed with

returns which minimize noise transmission through the

return air grille. Although these winter air conditioners 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.

Minimum return air/"air entering" temperature for

the furnace is 55 ° F.

Where there is no complete return duct system, the return

connection must be run full size from the furnace to a

location outside the utility room, basement, attic, or crawl

space.

DO NOT install return air through the back of the

furnace cabinet.

RETURN AIR DUCT CONNECTION

NOTE:

On upflow 5 or 6 ton airflow models, if the airflow require-

ment 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.

All return air duct systems should provide for installation of

return air filters.

1. Set the furnace in place.

2. For side return installations on upflow models, remove

the insulation around the opening in the blower

compartment.

8 18-CD20D 1-18

3. The side panels on upflow furnaces include locating

notches which may be used as guides for cutting an

opening for return air. Refer to Figure 12 and the

outline drawing on page 4 for duct connection dimen-

sions for various furnaces.

4. If a 3/4" flange is to be used for attaching the air inlet

duct, add to cut where indicated by solid lines in

Figure 12. Cut corners diagonally and bend outward to

form flange.

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

cut along knockout guidelines.

6. Upflow Furnaces: a filter rack is factory supplied for

bottom or side return. Use the filter rack on either side

or on the bottom if the filter is to be used within the

furnace cabinet.

When the upflow furnace is installed in the horizontal

right or left application and a return duct is attached to

the top side as shown in Figure 11, remove the filter

from the furnace and install in a remote location.

Do not install the filter in the return duct directly above the

furnace in horizontal applications. Install the filter remotely.

Installing the filter directly above the furnace in horizontal

applications may cause property damage, serious injury or

death.

TO PREVENT INJURY OR DEATH DUE TO CONTACT

WITH MOVING PARTS, TURN THE POWER TO THE

FURNACE OFF BEFORE SERVICING FILTERS.

Do not install the filter in the return duct directly above

the furnace in horizontal applications.

When the upflow furnace is installed in the horizontal

right or left application and a close coupled (less than

36") return duct is attached to the bottom side of the

furnace as shown in Figure 11, securely attach a 1/2"

mesh metal hardware cloth protective screen to the

inside bottom of the filter grill to prevent personal

injury from contacting moving parts when reach-

ing into the return opening to replace the filter.

REMOVE FILTER FROM UPFLOW

FURNACE WHEN RETURN DUCT IS

ATTACHED TO FURNACE TOP SIDE

(HORIZONTAL LEFT OR RIGHT

APPLICATIONS) AS SHOWN.

DDDBBHIIIDDHHB_

IIDIDIt!IB1111

IBBBBDIIIBDDDD

BDDBIIIII11111

IIIIIIIIIIII II

IIIIIIIIIIII I I +

Close coupled (less than 36")

return (filter directly beneath bottom

side return) not recommended due to

noise considerations. If used, securely

attach 1/2" mesh metal hardware cloth

protective screen to the inside bottom of

filter grill.

Installer's Guide

Close coupled (less than 36") return (filter directly

beneath bottom side return) is not recommended due to

noise considerations.

Downflow Furnaces: Brackets are factory supplied to

mount filters in the return air duct work.

Connect the duct work to the 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 recom-

mended that both supply and return air plenums are

removable.

8. When replacing a furnace, old duct work should be

cleaned out. Thin cloths should be placed over the

registers and the furnace fan should be run for 10 min-

utes. Don't forget to remove the cloths before you start

the furnace.

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.

NOTE:

On upflow 5 or 6 ton airflow models, if the airflow require-

ment 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.

LOCATING F" I/

NOTCHES *

PROVIDED I

FOR SIDE /

RETURN ,,,L,,,/ I

CUTOUT ,4_ _i:_/

•SEE OUTLINE DRAWING

CUT OUT

FOR

SIDE

FILTER

_RuOr N:e

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. 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.

!iiii!ii!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!!_iii

18-CD20D1-18 9

iiiiiiiiiiii

Installer's Guide

TABLE 4

UPFLOW FURNACE RETURN AIR FILTERS

CABINET CABINET

QTY*

WIDTH BOTTOM FILTER

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

21" 1 20" X 25" X 1"

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

CABINET

SIDE FILTER

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

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

requirement exceeds 1800 CFM, these models will

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

OR just the bottom.

(_ FILTER

RACK "-_

RETAINING

(Both Sides)

Filter Rack Assembly

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 Hin(

and Bottom Filter Rack Installation

.,-.% ,"

Blower Deck

Engagement

Hole

%,,=,

ENGAGEMENT

HOLE DETAIL

(Typicalboth sides

and blower deck)

®Furnace

Cabinet

Side

Engagement Hole

For Filter Rack

Installation With

Bottom Return

Filter

Rack

Filter Rack

Retaining

Screw/Pin

18-CD20D 1-18

Cabinet Width Left Side Bottom Right Side

17,5 X X X

21 X X X

24,5 X X X

1, UD060C/R936K0 has 10x7 blower which requires use of alternate

filter clips for left side filter, "K1" and later use the filter rack,

2, Remove bottom front channel to install or reposition filter rack,

X - All Models

FILTER RACK INSTALLATION FOR SIDE RETURN AIR

ON UPFLOW FURNACES (LEFT OR RIGHT)

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

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

side. The following instructions should be used:

a. Open or remove the blower door.

b. Remove the filter.

c. Compress the filter rack to disengage the retaining

pins/screws from the furnace sides and slide the filter

rack out.

d. Leave the bottom panel in place.

e. After the side cutout is made following the directions

in the "Return Air Duct Connections" section on

pages 8 and 9; compress the filter rack and reinstall

in the side of the furnace. Confirm that the upper

retaining pin/screw locks into the engagement hole in

the blower deck and the lower pin/screw rests against

the side of the bottom panel. See Figures 14 - 19.

f. Reinstall the furnace filter on the side.

®BOTTOM ENGAGEMENT

Filter Rack

Retaining

Furnace . m Screw/Pin Filter

Cabinet ...,,]_1

/Rack

Side !_ t

Engagement HoleFor Filter Rack

Installation With

Bottom Return

Bottom Panel

BLOWER

DECK

Furnace

Cabinet

Side

Engagement Hole Furnace

For Filter Rack Blower

Installation With

Side Return Deck

Retaining Rack

Screw/Pin Assembly

Installer's Guide

BOTTOM

PANEL

INSTALLED

Typical Upflow Left Side Return Filter Rack Installation

Typical Upflow Right Side Return Filter Rack Installation

Typical Filters of Upflow in Horizontal

18-CD20D1-18 11

Installer's Guide

RETURN AIR FILTERS FOR UPFLOW FURNACE

IN HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in the horizontal

configuration, the return air filters must be installed exterior

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

owner convenience or the filters may be installed in the duct

work upstream of the furnace. See Figure 21.

BLOWER DOOR/HINGE REMOVAL

If clearance or other problems create a problem in using the

tilting door, the blower door hinge may be removed without

creating any problems with the seal of the furnace. To

remove the blower door, tilt the door forward 2 to 3 inches

and pull up. To remove the tilt feature, simply remove the

lower hinge as shown in Figure 22. The bottom of the blower

door will catch in the bottom of the furnace front channel for

door replacement.

INSTALLING THE FILTER

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

location of the return air filter.

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

end of the filter. If your application requires cutting the

filter, do so as indicted by the score mark.

UNIT

SIZE

17-1/2"

21"

24-1/2"

RETURN AIR

BOTTOM SIDE

DO NOT CUT DO NOT CUT

DO NOT CUT CUT ON LINE

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-drill clearance holes with a

3/16" drill. Bottom return holes are pre-drilled.

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

using the screws provided. The filter clip with the leaf

spring mounts in the rear of the cabinet.

ALTERNATE FILTER

CLIPS LOCATION

TYPICAL DOWNFLOW FURNACE

RETURN AIR FILTER INSTALLATIONS

Two filters are factory supplied for each downflow furnace.

These furnaces require high velocity type air filters. Down-

flow furnace filters must be located outside the furnace

cabinet. Typical installations are shown in Figure 24. Tables

5 and 6 provide information for installation of the filter

retaining brackets shipped with downflow furnaces.

12 18-CD20D 1-18

Installer's Guide

TABLE 5

CABINET FILTER FILTER BRACKET

WIDTH SIZE LOCATION *

17-1/2" 2 -16X20X1 14-3/8"

21" 2- 16X20X1 13-1/8"

24-1/2" 2 - 16X20X1 11-5/8"

• Location dimension is from end of duct to the screw holes for the bracket.

TABLE 6

RETURN FILTER ACCESS FILTER ACCESS

CABINET DUCT OPENING - OPENING -

WIDTH WIDTH DIMENSION"A" DIMENSION"B"

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

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

24-1/2" 23-1/4" 22" 14"

GENERAL VENTING INSTRUCTIONS

VENT PIPING

These furnaces have been classified as Fan-Assisted Combus-

tion System, Category I furnaces under the "latest edition"

provisions of ANSI Z21.47 and CAN/CGA 2.3 standards.

Category I furnaces operate with a non-positive vent static

pressure and with a flue loss of not less than 17 percent.

NOTE:

If desired, a side waft termination can be accomplished

through the use of an "add-on" draft inducer. The inducer

must be installed according to the inducer manufacturer's

instructions. Set the barometric pressure relief to achieve

-0.02 inch water column.

NOTE: When the downflow furnace is vented through the

left side of the furnace cabinet using the provided cutout,

Type B vent piping must be used.

The furnace shaft be connected to a factory built chimney

or vent complying with a recognized standard, or a ma-

sonry or concrete chimney lined with a lining material

acceptable to the authority having jurisdiction.

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 spaces of the building.

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.

Furnace venting into an unlined masonry chimney or

concrete chimney is prohibited. Failure to follow this

warning could result in property damage, personal injury,

or death.

VENTING INTO A MASONRY CHIMNEY

If the chimney is oversized, the liner is inadequate, or flue-

gas condensation is a problem in your area, consider using

the chimney as a pathway or chase for type "B" vent or flex-

ible vent liner. If flexible liner material is used, size the vent

using the "B" vent tables, then reduce the maximum capacity

by 20% (multiply 0.80 times the maximum capacity).

Masonry Chimney Kit BAYVENT800B may be used with

these furnaces (Upflow model furnaces only) to allow

venting into a masonry chimney. Refer to the BAYVENT800B

Installer's Guide for application requirements.

Internal Masonry Chimneys

Venting of fan assisted appliances into a lined, internal

masonry chimney is allowed only if it is common vented with

at least one natural draft appliance; OR, if the chimney is

lined with type "B", double wall vent or suitable flexible liner

material (See Table 7).

The chimney liner must be thoroughly inspected to insure

no cracks or other potential areas for flue gas leaks are

present in the liner. Liner leaks will result in early deteriora-

tion of the chimney.

Failure to follow this warning could result in carbon monox-

ide poisoning or death.

18-CD20D1-18 13

Installer's Guide

NOTE:

The following section does not apply if BA YVENTSOOB

(Masonry Chimney Vent Kit) is used. All instructions with

the kit must be followed.

TABLE 7

MASONRY CHIMNEY VENTING

Type Furnace

Single Fan

Assist

Fan Assist

Natural

Tile Lined Chimney

Internal External

No No

Yes No

Chimney Lining

Flexible

"B" Vent Metal Liner

Yes Yes*

Yes*

Yes

Flexible chimney liner size is determined by using the type "B" vent size for

the available BTUH input, then reducing the maximum capacity by 20%

(multiply maximum capacity times 0.80). The minimum capacity is the same

as shown in the "B" vent tables.

EXTERNAL MASONRY CHIMNEY

Venting of fan assisted appliances into external chimneys

(one or more walls exposed to outdoor temperatures), re-

quires the chimney be lined with type "B', double wall vent

or suitable flexible chimney liner material. This applies in

all combinations of common venting as well as for fan

assisted appliances vented alone.

The following installation practices are recommended to

minimize corrosion caused by condensation of flue products

in the furnace and flue gas system.

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.

1. Avoid an excessive number of bends.

2. Horizontal runs should pitch upward at least 1/4" per foot.

3. Horizontal runs should be as short as possible.

4. All vent pipe or connectors should be securely supported

and must be inserted into, but not beyond the inside wall

at the chimney vent.

5. When vent connections must pass through walls or

partitions of combustible material, a thimble must be

used and installed according to local codes.

6. Vent pipe through the roof should be extended to a

height determined by National Fuel Gas Code or local

codes. It should be capped properly to prevent rain

water from entering the vent. Roof exit should be

waterproofed.

7. Use type "B" double wall vent when vent pipe is routed

through cool spaces (below 60 ° F.).

8. Where long periods of airflow are desired for comfort,

use long fan cycles instead of continuous airflow.

9. Apply other good venting practices as stated in the

venting section of the National Fuel Gas Code

ANSI Z223.1 "latest edition".

10. Vent connectors serving appliance vented by

natural draft or non-positive pressure shall not be

connected into any portion of a mechanized draft

system operating under positive pressure.

TABLE 8

GAS VENTTERMINATION

ROOF PITCH

FLAT TO 7/12

OVER 7/12 TO 8/12

OVER 8/12 TO 9/12

OVER 9/12 TO 10/12

OVER 10/12 TO 11/12

OVER 11/12 TO 12/12

OVER 12/12 TO 14/12

OVER 14/12 TO 16/12

OVER 16/12 TO 18/12

OVER 18/12 TO 20/12

OVER 20/12 TO 22/12

MINIMUM HEIGHT

1.0 FEET *

1.5 FEET

2.0 FEET

2.5 FEET

3,25 FEET

4.0 FEET

5.0 FEET

6.0 FEET

7.0 FEET

7.5 FEET

8.0 FEET

THIS REQUIREMENT COVERS MOST INSTALLATIONS

LISTED

CAP

VERTICAL W.,_l

OPENING II

THE VENT TERMINATION SHOULD NOT BE

LESS THAN 8 FT FROM AVERTICAL WALL

11. Horizontal pipe runs must be supported by hangers,

straps or other suitable material in intervals at a

minimum of every 3 feet of pipe.

12. A furnace shall not be connected to a chimney or flue

serving a separate appliance designed to burn solid fuel.

13. The flow area of the largest section of vertical vent or

chimney shall not exceed 7 times the smallest listed

appliance categorized vent area, flue collar area, or draft

hood outlet area unless designed in accordance with

approved engineering methods.

Maximum Vent or Tile =_:(D*)---_2X 7

Lined Chimney Flow Area 4

*Draf'_hood outlet diameter, flue collar' diameter, or' listed appliance categorized vent

diameter.

The cabinet must have an uninterrupted or unbroken ground

according to National Electrical Code, ANSI/NFPA 70 -

"latest edition" and Canadian Electrical Code, CSA C22.1 or

local codes to minimize personal injury if an electrical fault

should occur. A failure to follow this warning could result in

an electrical shock, fire, injury, or death.

The integrated furnace control is polarity sensitive. The hot

leg of the 115 VAC power must be connected to the BLACK

field lead.

To prevent injury or death due to electrical shock or contact

with moving parts, lock unit disconnect switch in the open

position before servicing the unit. Failure to follow this

warning could result in electrical shock, personal injury, or

death.

14 18-CD20D1-18

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 shall be connected into a permanently live

electric circuit. It is recommended that it 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 "latest edition" or Cana-

dian Electrical Code, CSA C22.1, if an external electrical

source is utilized.

All field supplied wiring must conform with the temperature

limitation for Type T wire [63 ° F (35 ° C)], when installed in

accordance with these instructions and wiring diagrams

supplied with the furnace. A disconnecting means must be

located within sight from, and readily accessible to, the

furnace.

Refer to the SERVICE FACTS literature for unit wiring

diagrams in addition to the diagram inside the blower door.

T'STAT

[]

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

1 STAGE HEATING

SEE

] NOTE6

USING

VARIABLE SPEED

2-STAGE FURNACE

[]

] W14JUMPER

SEE NOTE11

[]

r_-., SEE

I_NOTE 9

tT1/

A 1 STAGE HEATING THERMOSTAT

NO COOLING

1. Be sure power aglees with equipment nameplates.

2. Low voltage (24 volt wiling) to be No. 18 A.W.G. min.

3. Grounding of equipment must comply with local codes.

4. Set thermostat heat anticipatol per unit wiling diaglam.

5. These leads provide 115V. 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 lot proper operation.

Second stage heat wiR begin 10 minutes aftel fhst stage.

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 whe is only lot theimostats lequMng 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 multi-zone system contiolleis. On single speed cooling

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

and the humidistat. For two compressol st two speed systems, jumper YLo to O.

FIELD ADDED JUMPER G ou rl S

Wl TOW2. _ SCREW

[_ J_ 2ND STAGEWILL FIRE ]_ FU 1:2N A C E

L_ L_U,, _J ................. ,I _ _K JJNCTIO

I_ I_ I _ox

LH BK

[] ........... +,1

SEE 60 HZ., POWER _ I

NOTE 10 SUPPLY PER I I

[] [] ..........t+

I I r /I_H / I

]NTER )VP NET W[R]NG ...... jWH , I I / I

NOTES I_K --_--_=Ln .... I

24 '/. mk_ F]ELIU

IIL]NE 'i'J i'N'JR[q"; EACSEE [_ WH __ [ I _ I

24 g. "k FAtZTE) RY ..... ]_BK _ _

-- L ] N E v'. _" W I Y¢[ N ,_] From Dwg. B342027 Rev. 0

T'STAT

[]

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTAT

NO COOLING

VARIABLE SPEED

B-STAGE FURNACE I.

-- 2.

[] t

[] 6,

] WI4JUMPER

SEE NOTE 9

[]

F_.,

i_ SEE

]J NOTE 7

[]

SEE

NOTE 6 []

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 115M 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,

7, Continuous fan airflow can be increased by adding this jumper,

8, Set dip switches with power off per installation instructions

to set airflow and indoor fan off delays,

9, 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 multbzone 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, jumper YLo to O

I I

INTER CUdPSNENT ",t71R[N _

P4 V "_L FIELD

II [_ iNE" ,/. ]k ',B,'[_i IN G

24 ,/. m(> FA T'F_Y

-- L ]NE ,/.J 'TR[R IN G From Dwg. B342025 Rev. 0

18-CD20D1-18 15

Installer's Guide

OUTDOOR UNIT

(NO TRANSF©RMER)

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)

T"STAT

[]

VARIABLE SPEED

?-STAGE FURNACE

[] o-,

[]

SEE

D NOTE7[]

W14JUMPER

SEENOTE9

NOTES "

I BE SURE POWER AGREES WITH EQUIPMENT NAMEPLATE[S)

2 LOW VOLTAGE(24 v WIRING) TO BE O 18 A w G MIN

5 GRO NDING OF EQUISMENT MUST COMPLY WITH LOCAL CODES

4 SET THERMOSTAT HEAT ANTICIPATOR PER NIT WIRING DIAGRAM

5 THESE LEADS PROVIDE 115 V POWER FOR CONNECTIO OF ELECTRONIC AIR

CLEANER AND HUMIDIFIER MAX LOAD I O AMPS EACH

6 THIS WIRE IS ONLY FOR THERMOSTATS REO IRING

CO ECTION TO TRANSFORMER COMMO TERMINAL

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

TO THE "Y" TERMINAL OF THE FUR ACE CONTROL FOR PROPER BLOWER

OPERATION DURING COOLING

8 SET DIP SWITCHES WITH POWER OFF PER INSTALLATION INSTRUCTIONS

TO SET AIRFLOW AND INDOOR FAN OFF DELAYS

9 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 BH 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 BELAY PROFILES AND THE

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

] [] VGROUND

FIELD ADDED JUMPER SC REW

_-_ FURNACE

Wl TO W2. BK

_ 2ND STAGE WILL FIRE II I J U N C T ] 0 N

L_J, 10 MINUTES AFTER lS1_ I / I ClcqV

L,._ ,I-- ,

I'_'_'-I J TO 115V ' P"., [--LH B--_I<"'1--1-[_ .... I

"l.Ld BB.Z.,POWERJ I _ ,

SUPPLY PER II I

SEE LOCALCODES 1 LN WH S J

.w./ / ,_,

; HUM SEE J "" .--I JI S I

• NOTE5 L} BK __Jr ___ _ ,I

INTER COM_OkEIxT W]_]NG I I h'B!

4 _ EAC SEE [- WH -- J I i,,__1 Ii

2 V. % FIELD NOTE5 _ Sl< l_q I

----LI E V._W]RING L" _--_

2 4 V. _ F A {" • 0 R Y From Dwg. B342022 Rev. 0

--LINE V.._ WIRING

OUTDOORUNIT

(NOTRANSFORMEf_)

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 TRANSFORMER)

VARIABLE SPEED

T'STAT ?-STAGE FURNACE

[] [] o.,

W141

SEE []

NOTE9

L .__/F_I W14JUMPER

SEE NGTE9

[]

SEE

[] []

SEE

L •

INTER COk,4POqENT ',,,,I,ilRING

-w

? 'v'. \ FIELD

-- -- . ',,/'/I IN',_

L ] I' E ,r

24 V. '_ FA,,'}•O _Y

--LINE ',,". _'v'v'IFINO

NOTE:

I BE SURE POWER AGREES WITH EQUIPMENT NAMEPLATE(S}

R LOW VOLTAGE (R4V WIRING) TO BE NO IBAWG MIN

3 GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL BUILDING CODES

4 SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM

5 THESE LEADS PROVIDE llSV POWER FOR CONNECTION OF ELECTRONIC

AIR CLEANER AND HUMIDIFIER MAX LOAD I0 AMPS EACH

6 THIS WIRE IS ONLY FOR THERMOSTATS REQUIRING CONNECTION TO

TRANSFORMER COMMON TERMINAL

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

"Y" TERMIRAL OF THE FURNACE CONTROL FOR PROPER BLOWER

OPERATION DURING COOLIRG

8 SET DIP SWITCHES WITH POWER OFF PER INSTALLATION INSTRUCTIONS

TO SET AIRFLOW AND INDOOR FAN OFF DELAYS

9) OPTIONAL HUMIDISTAT IS TO BE CONNECTED BETWEEN "R" AND "BK"

FACTORY IRSTALLED JUMPER "R" TO "BH" 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 "BN" INPUT

SUCH AS WITH THE VARIABLE SPEED SINGLE ZORE AND 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 TWO COMPRESSOR OR TWO SPEED

SYSTEMS, JUMPER "YLO" TO "0"

From Dwg B342020 Rev, 0

16 18-CD20D 1-18

Installer's Guide

OUTDOOR UNIT NO 1

(NO TRANSFORMER)

SEE NOTE 3

OUTDOOR UNIT NO 2 I

(NO TRANSFORMER} I

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING, 2 STAGE COOLING

(OURDOOR SECTION WITHOUT TRANSFORMER)

T'STAT

SEE

NOTE 7

SEE

NOTE6

[]

VARIABLE SPEED

2-STAGE FURNACE

D O_\

FACTORY

INSTALLED

JUMPER

NOTES :

I. BE SURE POWER AGREES W[TH EQUIPMENT NAMEPLATE(S}

2. LOW VOLTAGE 24 Y. WIRING) TO BE NO. 18 A.W.G. M[ .

2. GROUNDING OF EQUIPMENT MUST COMPLY W[TH LOCAL CODES.

4. SET THERMOSTAT HEAT ANTICI/SATOR >E_ UNIT WIRING D[AGRAM.

5. THESE LEA}S PROVIDE 115 V. PDWER FOR CONNECTION OF ELECTRONIC A[R

CLEANER AND HUM[D]FIER MAX. LOAD 1.0 AMPS EACH.

B. THIS WIRE IS ONLY FOR THERMOSTATS REQUIR[ O

CONNECT]ON TO TRANSFORMER COMMON TERMINAL.

7. THE *'Y2" TERM]NAL FROM THE THERMOSTAT MLGT BE WIRE[I)

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

OPERAT]ON DURING COOLING.

8. SET DIP SWITCHES WITH POWER OFF PER INSTALLAT]ON INSTRUCT]ONS

TG ET AIRFLOW AN[) INDOOR FAN OFF }ELAYS.

9. OPTIONAL HUM[D[STAT ]S TO BE CONNECTED BETWEEN R AND BK. FACTORY

IN TALLED J JMPER R TO BK ON THE CIRCUIT BOARD M/ T BE CLT ]F OPTIONAL

HUMIDISTAT [G SED. THE JUMPER MUST ALGO BE CUT WHEN APPLY] G AN AIRFLOW

COMMAND SIGNAL TO THE BK INPUT SUCH AS WITH THE VARIABLE SPEED S]NOLE ZONE

AND MULTI ZONE SYSTEM CONTROLLERS, ON SINGLE SPEED COOLING ONLY/NON HEAT

PUMPSYSTEMS, JUMPER Y TO 0 FOR PROPER OPERAT]ON OF THE DELAY PROFILES

AN[} THE H M1}1 TAT. FOR TWG COMPRESSOR OR TWO SPEED SYSTEMS, JUMPER YLO TO O.

INTER COMPONENT WIRING

24 V. _ FIELD

LINE V.• WIRING

24 V. _ FACTORY

LINE V.• WIRING

HUMIDISTAT HOOKUP

If an optional humidistat is to be connected between "R"

and "BK", the factory installed jumper between "R" and "BK"

on the circuit board must be cut. If an 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 controller. 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,

jumper "Ylo" to "0".

The factory installed jumper between

"R" and "BK" on the circuit board

must be cut if an optional Humidistat

is installed.

18-CD20D1-18 17

Installer's Guide

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in

serious injury, death or property damage.

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

mercially available soap solution made specifically for the

detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

injury, or loss of life.

(_ LEFT SIDE PIPING (STANDARD)

MANUAL MAIN

SHUTOFF

UNION JOINT

DRIP LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

RIGHT SIDE PIPING (OPTIONAL)

SHUTOFF VALVE

UNION JOINT

DRIP LEG

WITH MANUAL SHUTOFF

TOP VIEW OF RIGHT SIDE PIPING

TO PREVENT AN EXPLOSION OR POSSIBLE INJURY,

DEATH AND EQUIPMENT DAMAGE, DO NOT STORE

COMBUSTIBLE MATERIALS, GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS NEAR THE UNIT.

GAS PIPING

This unit is shipped standard for left side installation of gas

piping. A piping knockout is also provided in the right side

for an alternate piping arrangement. The installation of

piping shall be in accordance with piping codes and the

regulations of the local gas company. Pipe joint compound

must be resistant to the chemical reaction with liquefied

petroleum gases.

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

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

valve as shown in Figure 27. National codes require a

condensation drip leg to be installed ahead of the controls as

shown in Figure 27.

The furnace and its individual shut-off valve must be discon-

nected from the gas supply piping system during any pres-

sure testing of that system at test pressures in excess of

1/2 psig.

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.

Use a backup wrench on the gas valve when installing gas

piping to prevent damage to the gas valve and manifold

assembly.

NOTE:

Maximum pressure to the gas valve for natural gas is

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

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

Minimum pressure is 11.0" W.C.

All gas fittings must be checked for leaks using a soapy

solution before lighting the furnace. DO NOT CHECK WITH

AN OPEN FLAME!

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.

COMBUSTION AND INPUT CHECK

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

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

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

3. Match the "See" column in the gas flow (in cfh) Table 13

with the time clocked.

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

clocked.

5. Use the following factors if necessary:

For 1 Cu. Ft. Dial Gas Flow CFH =

Chart Flow Reading + 2

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

Chart Flow Reading + 4

For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading + 4

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.

18 18-CD20D 1-18

7. Changes can be made by adjusting the manifold pressure

(See Table 9), 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 28 for White-Rodgers gas valve model 36E and

Figure 29 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. Turn on system power and energize valve.

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

1. Adjust low fire by removing the low adjustment

seal screw (See Figure 28).

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 mano-

meter matches the pressure specified in Table 9.

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

regulator cover screw (See Figure 28).

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 9 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.

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

1. Adjust low fire by removing the low adjustment

regulator cover screw (See Figure 29).

2. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet pressure,

turn the regulator adjust screw counterclockwise.

Adjust regulator until pressure shown on manom-

eter matches the pressure specified in Table 9.

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 29).

6. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet pressure,

Installer's Guide

turn the regulator adjust screw counterclockwise.

The final manifold pressure setting shall be as

specified in Table 9 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.

f. Turn off all electrical power to the system.

g. Remove the manometer and flexible tubing. Remove

the barbed fitting and replace the plug or tighten the

pressure test screw.

h. Turn on electrical power to the system and energize

valve.

i. Using a leak detection solution or soap suds, check for

leaks at plug or pressure boss screw.

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.

For LP gases, the final manifold pressure setting shall be

10.5" W.C. with an input of no more than the nameplate

rating and no less than 93% of the nameplate rating, unless

the unit is derated for altitude.

@White-Rodgers 36E

2nd Stage (HI)

Pressure

Adjustment

Gas Valve On /Off

Toggle Switch

1st Stage (LO)

Manifold

Pressure

Adjustment

White-Rodgers 36G 2nd Stage (HI)

Manifold

Pressure

Adjustment

Gas Valve On /Off

Toggle Switch

Manifold

Pressure

Adjustment

18-CD20D1-18 19

Installer's Guide

Table 11 lists the main burner orifices shipped with the

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

rate, refer to Table 12.

TABLE 9

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.

TABLE 10

NATURALGAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUSPIPE 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

INPUT

RATING

BTUH

40,000

60,000

80,000

100,000

120,000

140,000

TABLE 11

ORIFICE SIZES

MAIN BURNER ORIFICE

DRILL SIZE

NUMBER

BURNERS

NAT. GAS

LP GAS

TABLE 12

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

PART

NUMBER

ORF00501

ORF00644

ORF00909

ORF00910

ORF01099

ORF00503

ORF00493

DRILL

SIZE

PART

NUMBER

ORF00555

ORF00693

ORF00907

ORF00908

ORF01338

ORF01339

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 clocking the

gas flow rate (CFH) and multiplying by the heating value

obtained from the local utility supplier for the gas being

delivered at the installed altitude. Input rate changes can be

made by adjusting the manifold pressure (min 3.0 - max

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

may not always be required). If the desired input rate cannot

be achieved with a change in manifold pressure, then the

orifices must be changed. LP installations will require an

orifice change.

Important:

Reinstall the propane orifices to the same depth as the orifices

supplied with the equipment.

See Table 14 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.

Installations above 4,000 feet may require a pressure switch

change. If required, use the BAYHALT*** Kit (High Altitude

Accessory Kit) listed in PRODUCT DATA.

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

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

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

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

Gas and Propane Installation Code, CSA 149.1. Installation of

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

in accordance with the listed high Altitude Conversion Kit

available with this furnace.

TABLE 13

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

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

54 54 55 55 55 55 55 56 56 56

55 55 55 55 56 56 56 56 56 57

56 56 56 57 57 57 58 59 59 60

57 58 59 59 60 60 61 62 63 63

58 59 60 60 61 62 62 63 63 64

From National Fuel Gas Code-Table F-4

18-CD20D1-1820

DO NOT attempt to manually light the burner. Failure to

follow this warning could result in property damage, per-

sonal injury or death.

START UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

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 knot) on main gas valve 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 knob on the gas

valve in the unit to the "ON" position.

LIGHTING INSTRUCTIONS

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: Move the control switch on the main

gas valve to the "OFF" position (See Figures 28 and 29).

Disconnect 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. Failure to follow this warning could

result in property damage.

Whenever your house is to be vacant, arrange to have

someone inspect your house for proper temperature. This

is very important in below freezing weather. If for any

reason your furnace should fail to operate damage could

result, such as frozen water pipes.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in

serious injury, death or property damage.

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

mercially available soap solution made specifically for the

detection of leaks to check all connections. A fire or

explosion may result causing property damage, personal

injury, or loss of life.

Installer's Guide

SEQUENCE OF OPERATION

Thermostat call for heat (2-stage thermostat)

Call for 1st stage only:

R and 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 2nd stage after 1st stage:

R and 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 allowing the gas valve to be energized

in 2nd stage and the indoor [)lower motor in high speed.

2nd stage satisfied, 1st stage still called:

n andW2thermostatcontactsopensignalingthat 2ndstage

heating requirements are satisfied. The induced draft [)lower

is reduced to low speed allowing the 2nd stage pressure

switch contacts to open and the gas valve is reduced to 1st

stage. After approx. 30 seconds the indoor blower motor is

reduced to low speed.

1st stage satisfied:

R and 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 - Factory setting is

100 seconds), then will be de-energized by the control module.

Thermostat call for heat (1-stage Thermostat)

R and W1/W2 (jumpered) thermostat contacts close signaling

a call for heat. 1st stage sequence of operation remains the

same as above. 2nd stage heat has a 10 minute delay from

the time of 1st stage ignition.

Thermostat satisfied:

R and W1/W2 (jumpered) contacts open signaling the control

module to close the gas valve and de-energize the induced

draft blower. The indoor blower motor will continue to

operate at high heat speed for approx. 30 seconds after the

flames are extinguished and then is switched to low heat

speed for the remaining FAN-OFF period.

INDOOR BLOWER OPERATION WITH THERMOSTAT FAN

SWITCH "ON":

Fan is R-G.

R-W energized, fan continues to run without interruption.

Heat Low speed if it is a two stage furnace.

Heat speed if it is a single stage furnace.

18-CD20D1-18 21

Installer's Guide

EXPLOSION HAZARD!

PROPANE GAS IS HEAVIER THAN AIR AND MAY COL-

LECT IN ANY LOW AREAS OR CONFINED SPACES. IN

ADDITION, ODORANT FADE MAY MAKE THE GAS

UNDETECTABLE EXCEPT WITH A WARNING DEVICE. IF

THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN

EXCAVATED AREA OR A CONFINED SPACE, IT IS

STRONGLY RECOMMENDED TO CONTACT A GAS

SUPPLIER TO INSTALL A GAS DETECTING WARNING

DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOT test any

detectors and makes no representations regarding any

brand or type of detector.

CONTROL AND SAFETY SWITCH

ADJUSTMENT

LIMIT SWITCH CHECK OUT

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

valve should the furnace become overheated. Since proper

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

it must be checked out on initial start up by the

installer.

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

thermostat to a temperature higher than the indicated

temperature to bring on the gas valve. Restrict the airflow

by blocldng the return air or by disconnecting the blower.

When the furnace reaches the maximum outlet temperature

as shown on the rating plate, the burners must shut off. If

they do not shut off after a reasonable time and overheating

is evident, a faulty limit switch is probable and the limit

switch must be replaced. After checking the operation of the

................................................................................limit control, be sure to remove the paper or cardboard from

the return air inlet, or reconnect the blower.

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

complete wiring setup for ENHANCED MODE. The

graph which follows, shows the ramping process.

OFF

50%

80%

100% if necessary

50%

_ast Cooling Efficiency

I,I 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.

INDOOR BLOWER TIMING

Heating: The Integrated Furnace Control (IFC) controls the

variable speed indoor blower. The blower "on" time is fixed at

45 seconds after ignition. The FAN-OFF period is field

selectable by dip switches #1 and #2 located on the Inte-

grated Furnace Control between the 5-pin and 9-pin wire

connectors. The delay may be set at 60, 100, 140, or 180 sec-

onds. The factory setting is 100 seconds (See unit wiring

diagram).

Cooling: The fan delay-off period 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%

Disconnect power to the unit before removing the blower

door. Failure to follow this warning could result in property

damage, personal injury or death.

This unit is equipped with a blower door switch which cuts

power to the blower and gas valve causing shutdown when

the door is removed. Operation with the door removed or

ajar can permit the escape of dangerous fumes. All panels

must be securely closed at all times for safe operation of

the furnace.

NOTE:

Direct drive motors have bearings which are permanently

lubricated and under normal use, lubrication is not

recommended.

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 inside the furnace casing).

INSTRUCTIONS TO THE OWNERS

In the event that electrical, fuel, or mechanical fail-

ures occur, the owner should immediately turn the gas

supply off at the manual gas valve, located in the

burner compartment (See Figure 27).

Also turn off electrical power to the furnace and

contact the service agency designated by your dealer.

Should overheating occur, or the gas supply fail to shut off,

shut off the gas valve to the unit before shutting off the

electrical supply. Failure to follow this warning could result

in property damage, personal injury, or death.

22 18-CD20D1-18

ABNORMAL CONDITIONS

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN

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

If pressure against induced draft blower outlet becomes

excessive, the pressure switch will open and shut off the

gas valve until acceptable combustion pressure is again

available.

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 off the 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

If pressure is not sensed by the pressure switch, the

contacts will remain open and not allow the gas valve to

open, therefore the unit will not start. If failure occurs

during a running cycle, the pressure switch contacts will

open and the gas valve will close to shut the unit down.

6. 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. To reset, turn the

system power off, then on, then off and then on again

within 30 seconds. This may be done at the unit's power

source or at the thermostat. The system will not reset

unless the procedure of[:on-of[:on is completed within

30 seconds.

Carbon monoxide, fire or smoke can cause serious bodily

injury, death, and!or property damage.

A variety of potential sources of carbon monoxide can be

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

dryers, gas cooking stoves, water heaters, furnaces and

fireplaces. The U.S. Consumer Product Safety Commission

recommends that users of gas-burning appliances install

carbon monoxide detectors as well as fire and smoke detec-

tors per the manufacturers 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 ['or

Single and Multiple Station Carbon Monoxide Alarms,

UL 2034 or CSA International Standard, Residential

Carbon Monoxide Alarming Devices, CSA 6.19

NOTE:

The manufacturer of your furnace does not test any detec-

tors and makes no representations regarding any brand or

type of detector.

Installer's Guide

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

This product contains fiberglass wool insulation!

Fiberglass dust and ceramic fibers are believed by the

State of California to cause cancer through inhalation.

Glasswool fibers may also cause respiratory, skin, or

eye irritation.

PRECAUTIONARY MEASURES

•Avoid breathing fiberglass dust.

• Use a NIOSH approved dust/mist respirator.

• Avoid contact with the skin or eyes. Wear long-sleeved,

loose-fitting clothing, gloves, and eye protection.

• Wash clothes separately from other clothing: rinse

washer thoroughly.

• Operations such as sawing, blowing, tear-out, and

spraying may generate fiber concentrations requiring

additional respiratory protection. Use the appropriate

NIOSH approved respirator in these situations.

FIRST AID MEASURES

Eye Contact - Flush eyes with water to remove dust.

If symptoms persist, seek medical

attention.

Skin Contact - Wash affected areas gently with soap

and warm water after handling.

Failure to follow safety warnings exactly, could result

in a fire or explosion causing property damage,

personal injury or loss of life.

-- Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any

other appliance.

-- WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electrical switch;

do not use any phone in your building.

•Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

•If you cannot reach your gas supplier,

call the fire department.

Installation and service must be performed by

a qualified installer, service agency or the gas

supplier.

iiiliii_iiiiiiii!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!!iii

18-CD20D1-18 23

Installer's Guide

Flashing Slow---

Flashing Fast ---

Continuous ON ---

Continuous OFF ---

2 Flashes---

3 Flashes ---

4 Flashes ---

5 Flashes ---

6 Flashes ---

7 Flashes ---

8 Flashes ---

9 Flashes ---

INTEGRATED FURNACE CONTROL ERROR FLASH CODES

Normal - No call for Heat

Normal - Call for Heat

Replace IFC

Check Power

System Lockout (Retries or Recycles exceeded)

Draft Pressure Error - Possible problems:

a) Venting problem

b) Pressure switch problem

c) Inducer problem

Open Temperature Limit Circuit

Flame sensed when no flame should be present

115 volt AC power reversed, poor grounding or system voltage too low

Gas valve circuit error

Low flame sense signal

Check Ignitor Circuit and Line "N" to 24VAC "Common" voltage (_<2 volts)

[possible grounding problem]

Tl2Z_

6200 Troup Highway

Tyler, TX 75707

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

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

TRANE Furnace/Heater, Gas Manual L0903066

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