TRANE Furnace/Heater, Gas Manual L0903222

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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*UD-IN-2F

18-CD19D7-13

Upflow /Horizontal _ Downflow /Horizontal,

Gas=Fired Furnaces, "Fan Assisted

Combustion System"

*UD040C-K *UD100C=K *DD040C=F *DD100C-F

*UD060C-K *UD120C-K *DD060C-F *DD120C-F

*UD080C-K *UD140C-K *DD080C-F *DD140C-F

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

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

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

Please return to service information pack upon completion of work.

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-CH23D1-2

Upflow /Horizontal* Downflow /Horizontal*

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

A341789P01

|nsta||er's Guide

SAFETY SECTION

The following safety practices and precautions nmst 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 eombustion and ventilation air to the

furnace space as specified in "Air for Combustion and

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

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 17), 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

allowable 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 is not to be used for temporary heating of

buildings or structures under construction.

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

seriousness associated with a particular hazard. The signal

words for safety markings are DANGER, WARNING, and

CAUTION.

a. DANGER indicates an imminently hazardous situation

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

injury. This signal word is limited to the most extreme

situations.

b. WARNING indicates a potentially hazardous situation

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

injury.

c. CAUTION indicates a potentially hazardous situation

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

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.

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.

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.

|nsta||er's Guide

GENERAL

The manufacturer assumes no responsibility for equipment

installed in violation of any code or regulation.

It is recommended that Manual J of the Air Conditioning

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

estimating heating requirements. When estimating heating

requirements for installation at Altitudes above 2000 ft.,

remember the gas input must be reduced (See GAS INPUT

ADJUSTMENT).

Material in this shipment has been inspected at the

factory and released to the transportation agency

without known damage. Inspect exterior of carton for

evidence of rough handling in shipment. Unpack

carefully after moving equipment to approximate

location. If damage to contents is found, report the

damage immediately to the delivering agency.

Codes and local utility requirements governing the installa-

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

connections must be adhered to. In the absence of local

codes, the installation must conform with the National Fuel

Gas Code ANSI Z223.1 "latest edition" or CAN/CGA B149

Installation Codes. The latest code may be obtained from the

American Gas Association Laboratories, 8501 E. Pleasant

Valley Rd., Cleveland, Ohio 44131.

These furnaces have been classified as Fan Assisted Combus-

tion 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).

These furnaces may be twinned. They shall have

common returns with equal pressure drops or ducts

with equivalent lengths and sizes. See Field Wiring

Diagrams for Twinning on page 16 for proper hookup.

To prevent shortening its service life, the furnace should

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

phases of construction. The low return air temperatures

can lead to the formation of condensate even though this is

anon-condensing model. Condensate in the presence of

chlorides and fluorides from paint, varnish stains, adhe-

sives, cleaning compounds, and cement create acorrosive

condition which may cause rapid deterioration of the heat

exchanger.

These furnaces are not approved or intended for installa-

tion in manufactured (mobile) housing, trailers, or recre-

ational vehicles. Failure to follow this warning could result

in property damage, personal injury, or death.

Do not install the furnace in acorrosive or contaminated

atmosphere.

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?

Contents

Installation instructions

General

Location And Clearances

Outline Drawings

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

Twinning Connection Diagrams

Gas Piping

Sequence Of Operation

Start-up And Adjustment

Preliminary Inspections

Combustion And Input Check

High Altitude Derate

Lighting Instructions

Controls And Safety Switch Adjustment

Abnormal Conditions

IFC Error Flash Codes

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)

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.

A furnace shall be installed so electrical components are

protected from water.

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-CD19D7-13 3

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MODEL DIM "A" DIM "B" DIM "C" DIM °D°

*UD040C924,*

*UD040C930_ i,1 i/2' 9 5/8'

_Ui)060C92,1_*

*UD0606936,

_UD080C924_÷

_UDOUOC936**

*UD080C948_*

_UDiOOC936_ 16"

_UDiOOC945_

_UDiOOC945÷*

_U}080C960_

*UDiOOC948**

÷UDiOOC960*÷ i9Ji2 _

*UDi20C954_*

_gD[OOC9i2_*

*UDi20C960*_

*UDi40C960.* 23"

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24i/2' i55'16"

13 i/4 I 13 I

16 i/4"

193/4"

23_/4'

PRFIX t1[ R MAY B ,s" OR ]'

_ SIi_F IX iEi iERS _,I/,Y ii(i "'I'_ (0 iHROU6_ 9)

MINIMUMCLEARANCETO COMBUSTIBLEMATERIALS

UPFLOW CLOS_[

LEFI SiDE 0 IN rRONI 3iN (SEE NO]£ I)

@i@l!i SIDE _O IN B_CK =3 iN

FLUE ii6 IN iCP i iN

ZOP _2 IN BACK 3 iN

FLU_ ii6 IN S}DES i iN

FRONi i8 IN {S_F NOiE i)

HORIiOHIA( ALCOii (SEE !iOIE 2}

iOP +i IN B/,C_ O iN

FiU_ _6 IN SIDtS O iN

_RONI i8 IN

iOR 4 I/8 C,SUINiJiS 3 WHEN SiNgti

W,_il. vENT PIPE IS USED

WNEN i4 Ji2" O\Bi_iETS (Ati _UDO40_ ,

_tJDC,4OR ,_UDO60C , /_D _UDC,eOR936) /,RE

iNSTAi[ED iN /_ IIORiZO_'iTAI POSiTIO_ AND A

SiNglE W;i[ VENT PiPE JS USED, A 6 INCH

¢i E/,R&NCE _UST BE 5UPPi lED BETWEE_

TiiE ,'[NT _iPE _r'aD COMBUSTi81 r FIOORIN6

N()TFS:

i) MiNiM@M CLLARAHCE [0 FRONI ON

_UDi46ii960 AND _UDI40C960 i8 6 iNCiiUS

2) _A¥ BE iNS]ALLED O_ ¢OMUUS_i@LL

I[OOR Wil[_ _YP( B i VEH; iS USeD

From Dwg. 21C341699 Rev. 4

mill

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..................... ELNE

o OPENING

INET

A ..........;2:0-

_11/2 HOLE

GAS CONNECTION

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_28 1/2

2 1/16

*DD-C-F OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

k ......................................................................•.....

....... DIM "A" ......

SIDE PANEL ¢U]OU1

HORIZONTAL VENTING

]NROUGN CABINEI

_24-1/2

P I/8

29 /2 r

20 !/4

I( ;

¢/2 KNOCK OUT _

GAS CONNZC ON

(ALI RNAT )

.1_11 .........

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MINIMUMCLEARANCE TO COMBUSTIBLEMATERIALS

DOWNFLOW CLOSET

SIDES 5_ IN W/SINGlE WAlL VENI 0 IN W/TYPE B I VENT

PLUF 6 IN W/SINGlE WAlL VENT - I IN W/TYPE B-I VENT

FRONT 6 IN BACK I IN

RIONT SIDE ONlY FOR 145" CABINETS,

0 IN TO LEFI SIDE 0 IN FOR REMAINING

CAB!NE7 SIZES (17 5", 210 <', 24 5")

HORIZONTAL CLOSET tFLU5 DIICHAROE LEFTi

TOP 3_ IN WISING{[ WAIL VENT 2 IN W/TYPE B I VENT

FLUE 6 IN W/SINGlE WAlL VENT - I IN W/[YPE 8-1 VENT

FBONI 6 IN BACK 3 IN SLOES I IN

TOP ON!Y FOR 145 '_ CABINETS

2 IN FOR RENAINING CABINET

SIZES (175", 210 <', 245")

HORIXONTA_QSET |FLUE D!$CHARGERIGHTI

TOP 8 IN WlSINGL[ WALL VENT

FLUE 6 IN WlSINGL[ WALL VENT I IN W/TYPE B I VENT

FBONI 6 IN BACK 3 IN SLOES I IN

FOl:/ !NSTALLATION ON COMBUS!IBLE FLOORING ONLY

WILES 8-1 VENT CONNECTOR IS USED

HOR!gON

lOP 5_ IN W/SINGLE WALL VEN/ - I IN W/TYPE B-I VENT

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

FRONT 18 IN BACK 0 IN SIDES O IN

TOP ONLY FOR 145 <' CABINETS

l IN _OR REMA!NING CABINE]

SIZES (175", 210", 245")

HQ_ONTAL AL_OV_ (FLU5 PI@¢HARQE _GHT)

TOP IIN WISING{[ WAkL VENT

FLUE 6 !N W/SINGlE WAlL VENI I IN W/TYPE B I VENT

ERONI 18 !N BACK 0 IN S!OES 0 IN

_1/8 KNOCK OUI

[{EC[R ICAL

CONNECTION

(ALTERNATE)

DIM "D"

3/4 _

3/4 ......

OUTLET

19 9/16 ............7 3/4_ ..............

MODEL A B C D

*DDO40C924F

*DDO60C924F 14-1/4" 9-5/8" 13-1/4" 13"

*DDO60C936F

*DDO80C936F

*DDO80C945F 17-1/2" 9-5/8" 16-1/4" 16"

*DD100C945F

*DD100C948F

*DD100C954F 21" 13-1/16" 19-3/4" 19-1/2"

*DD120C954F

*DD120C960F 24-1/2" 15-5/16" 23-1/4" 23"

*DD140C960F

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|nstaIIer's Guide

UPFLOW INSTALLATION

Standoffs and screws (See Figure i on page 6) are included CABINET

with the cased coils for attachment to the furnace. There are WIDTH

clearance alignment holes near the bottom of the coil wrap- 14-I/2"

per and drill screws are used to engage the furnace top

flange. The standoff is inserted into the cabinet alignment 17-I/2"

hole. The drill screws are inserted through the standoffs then 21"

screwed into the furnace flange. The coil is always placed 24-I/2"

downstream of the furnace airflow. These instructions apply

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

(_ STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

iNSTALLATiONS:

SCREWS

(BOTH SIDES)

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATION

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 --_

SUS-BASE_,111

FLANGE q_

(BENT UP) y

SUB-_

SUB-BASE

FLANGE

(BENT UP)

Required floor opening: (DOWNFLOW)

See Figure 2 and Table 1 m

_(width) I

(depth) 4.

D 1

TABLE 1

RETURN FLOOR OPENING PLENUM OPENING

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

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

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.

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.

The coil is placed downstream of the furnace, with the apex of

the coil pointing in the direction of the airflow for horizontal

installation. The cased coil is secured to the furnace and

both the furnace and the cased coil must be properly sup-

ported. 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.

©CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

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).

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 6). Line contact is only permissible

between lines formed by the intersection of the top and two

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

framing.

// _//

TYPICAL ATTIC PLATFORM INSTALLATION

(UPFLOW/HORIZONTAL FURNACE SHOWN)

6 18-CD19D7-13

|nstaI|er's Guide

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 INSTALLATION

(UPFLOW/HORIZONTAL FURNACE SHOWN)

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 aft_ct 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 7.

These spaces may have adequate air by infiltration to

provide 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

confined space.

UNCONFINED

50 CU. FT. OR MORE

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

DOORS

WATER CLOTHES

FURNACE HEATER DR'fEn

CONFINED

LESS THAN 50 CU. FT.

PER 1000 BTU/HR. INPUT

ALL EQUIP INSTALLED

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

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

Air for combustion and ventilation requirements can be

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

outdoors, as in Figure 10.

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

confined space shall be provided with two permanent

openings communicating directly with an additional

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

of all spaces meets the criteria for an unconfined space.

The total input of all gas utilization equipment installed

in the combined space shall be considered in making this

determination. Refer to Table 3, for minimum open

areas required.

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 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 combustion

air supply will also reqmre 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 lINPUT RATING

40,000

60,000

80,000

100,000

120,000

140,000

WITH 8FOOT CEILING

MINIMUM AREA IN SQUARE FEET

OF UNCONFINED SPACE

25O

375

500

625

750

875

18-CD19D7-13 7

iiiiiiiiiiii

|nsta||er's Guide

TABLE 3

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING

Furnace

Maximum

BTUH/INPUT

Rating

40,000

60,000

80,000

100,000

120,000

140,000

Air From

Inside

lOO

12o

14o

FURNACE ONLY)

Air From Outside

Vertical

Duct

Horizontal

Duct

®CONFINED SPACE _-_

AIR FROM iNSIDE BUILDING

SPACE

PERMANENT

OPENINGS

(_ CONFINED SPACE

AiR FROM OUTDOORS

SPACE OUTLET 1

CONFINED SPACE

AiR FROM VENTILATED ATTIC/CRAWL SPACE

_ TTIC LOUVERS

TO OUTDOORS

_-.OUTLET

CONFINED AIR

SPACE

ALTERNATE INLET

INLET AIR _" A_R DUCT

CONFINED SPACE

AIR FROM

TO OUTDOORS

CONFINED -

SPACE

OUTLET

tNLET

AIR DUCT

DUCT CONNECTIONS

Air duct systems should be installed in accordance with

standards for air conditioning systems, National Fire Protec-

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

accordance with ACCA Manual D or whichever is applicable.

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 operation,

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 "entering temperature" for the

furnace is 50 °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

_rnace cabinet.

RETURN AIR DUCT CONNECTION

NOTE:

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

ment exceeds 1800 CFM, these models will require filters

on both sides; OR Iside 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 com-

partment.

8 18-CD19D7-13

|nsta||er's Guide

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 3 for duct connection dimen-

sions for various furnaces.

4. Ifa 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 flame is installed,

cut along knockout guidelines.

6. Upflow furnaces: a filter rack is fhctory 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 2J

ATTACHED TO FURNACE TOP SIDE

(HORIZONTAL LEFT OR RIGHT

APPLICATIONS) AS SHOWN.

UDDBBHHH_BDHBB_

IHBDDDDB_DBDBDB

IDDDBDB_BBDDDDB

/DDDDDDBBIDBDDD o

IDD_DIDIDDDDDDD

IDHHD_DI_UHDHD_ 4II

Close coupled (less than 36") I _

return (filter directly beneath bottom _xx****_**L_ _=

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.

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.

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 fhctory 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 filters

on both sides; OR I side and the bottom; OR just the

bottom.

LOCATING _" -.,.

NOTCHES

PROVIDED I

FOR SIDE

RETURN /

CUTOUT _.

*SEE OUTLINE DRAWING

I CUT OUT

FOR

I_ /SIDE

FILTER

I "

FRONT

of Furnace

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.

18-CD19D7-13 9

iiiiiiiiiiii

|nsta||er's Guide

TABLE 4

UPFLOW FURNACE RETURN AIR FILTERS

CABINET CABINET

QTY*

WIDTH BOTTOM FILTER

14-1/2" 1 14" X 25" X 1"

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 5ton airflow models, if the airflow

requirement exceeds 1800 CFM, these models will

require filters on both sides; OR 1 side andthe bottom;

OR just the bottom.

NOTE:

The narrow 14.5" width furnace cabinet prevents use of the

filter rack for right side return. The 14.5" width furnace

models will ship with both an adjustable filter rack for

bottom or left and filter clips for right side return air appli-

cations. The filter clips are the same as previously used on

all upfiow furnaces and will be shipped in aplastic bag

attached to the control platform. The furnace cabinet has

dimples for location of the alternate furnace clips. Pre-drlll

clearance holes and then attach filter clips with the screws

provided. The filter clip with the leaf spring mounts in the

rear of the cabinet

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.

NOTE:

Remove the bottom front channel to install the filter rack in

the 14=1/2" width cabinet furnaces.

Blower Door Hinge and Bottom Filter Rack Installation

(_ FILTER

RACK -'_

RAILS

_- SPRINGS

AUTOMATIC

ADJUSTMENT RETAINING

(Both Sides)

Filter Rack Assembly

ENGAGEMENT

HOLE DETAIL

(Typicalbothsides

andblowerdeck)

Furnace /

Cabinet

Side

Engagement Hole

For Filter Rack

Installation With

Bottom Return

Filter

Rack

Filter Rack

Retaining

Screw/Pin

10 18-CD19D7-13

|nsta||er's Guide

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. "KI" and later usethe 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.

Leave the bottom panel in place.

M_er 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

Side !_I Rack

Engagement HoleFor Filter Rack

Installation With

Bottom Return m

Bottom Panel

BLOWER

DECK

Furnace

Cabinet

Side

Engagement Hole Fu mace

For Filter Rack B_ower

Installation With

Side Return Deck

_o/

NFilter

Retaining Rack

Screw/Pin Assembly

(_ SIDE

CUTOUT

RETAINING

PIN _

(Both S_I

fj RACK

RAILS

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-CD19D7-13 11

|nstaIIer's Guide

RETURN AIR FILTERS FOR UPFLOW FURNACE

IN HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in a horizontal con-

figuration, the filter must never be installed inside or outside

the cabinet directly above the blower assembly. See Figure

11. Remote filter grilles may be used for homeowner conve-

nience or the filters may be installed in the duct work

upstream of the furnace. See Figure 11 and 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

14-1/2"

17-1/2"

21"

24-1/2"

RETURN AIR

BOTTOM SIDE

CUT ON LINE DO NOT CUT

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-CD19D7-13

|nsta||er's Guide

TABLE 5

CABINET FILTER FILTER BRACKET

WIDTH SIZE LOCATION *

14-1/2" 2 - 14X20X1 12-7/8"

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

CABINET RETURN FILTER ACCESS FILTER ACCESS

DUCT OPENING - OPENING -

WIDTH WIDTH DIMENSION "A" DIMENSION "B"

14-1/2" 13-1/4" 12" 14"

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:

ff desired, a side wall 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 shall be connected to afactory built chimney

or vent complying with a recognized standard, or ama-

sonry or concrete chimney lined with alining 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 deterio=

ration of the chimney.

Failure to follow this warning could result in carbon monox=

ide poisoning or death.

NOTE:

The following section does not apply if BAYVENT8OOB

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

the kit must be followed.

18-CD19D7-13 13

|nsta||er's Guide

TABLE7

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*

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.

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.

The following installation practices are recommended to

minimize corrosion caused by condensation of flue products

in the furnace and flue gas system.

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.).

TABLE 8

GAS VENT TERMINATION

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 WALL 41

LOWE ST DISC HARGE

OPENING

.if"

(

ROOF PITCH S X/z12

THE VENT TERMINATION SHOULO NOT BE_

LESS THAN 8 FT FROM A VERTICAL WALL

Where long periods of airflow are desired for comfort, use

long fan cycles instead of continuous airflow.

Apply other good venting practices as stated in the

venting section of the National Fuel Gas Code

ANSI Z223.1 "latest edition".

12.

13.

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.

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.

A furnace shall not be connected to a chimney or flue

serving a separate appliance designed to burn solid fuel.

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 = _(_)2 X 7

Lined Chimney Flow Area 4

"Drafthood outlet diameter, flue collar diameter, or listed appliance categorized vent

diameter.

ELECTRICAL CONNECTIONS

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 warn-

ing 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-CD19D7-13

|nsta||er's Guide

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 accor-

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

the National Electrical Code, ANSIfNFPA 70 "latest edition"

or Canadian 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.

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

T"SIAl" FURNACE

-- SEE --

NOTE 7

D rq

[]

[] []

SEE

[] NOTE6 []

N [ { NqP0['4[:N ",/, RIN(

24 v. -N 7_E D

iii NE " _;>WI _, {

24 V. L FAC O_Y

--L NE ,/ )r,,/,71:_ I O

NO!ES:

I, 8E SURE POWER AGREES WITH EQUIPMENT NAMP[ATE(S)

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

3 GROUNDING Of EQUIPMENT MUSt COMPLY WlqH LOCAL CODES

4. SFP THERMOS/A1 NEAT AN]ICIPA[OR PER UN![ WIRING DIAGRAM,

5 _HESE LEADS PROVIDE 115 V POWER J:OR CONNECTION 0!: E/FC1RON}C AIR

CLEANER AND HUMIDIFIER MAX LOAD I 0 AMPS EACH

6, THIS CONNECTION IS ONLY USED EOR THERMOSTATS REQUIRING

CONNECTION TO THE 24 V POWER SUPPLY. (COMMON)

7SEE ]WINNING CONNKC]ION DIAGRAMS FOR PROPER CONNEC]IONS

WHEN USING tHIS FEATURE

,ll

TO 115V1PH f =i_

60 HZ., POWEI_

SUPPLY PER

LOCAL CODES = L N

HUM SEENOTE 5

WH J

EACESEE _Ut< =

From Dwg. 21 B341437 Rev. 1

OUTDOORUNIT

(NOrnANSFORMER)

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

[]

T"SPAT FURNACE

-- SEE --

NOTE 7

L--.F;q

[]

SEE

NOTE 8 []

[]

SEE

NOTE 6 [] i

INTER CObPONE_,T ",,,_,71Ri_,G

24 v', -'L PiE D

L ] N E " "x f"/V' ::i / N (

2q N,', A 9_,Y

-- 1bE ',/. f ",iV :{11 (;

NOTS:

BE SURE POWER AGREES W}]H EOUIPMEN1NAMPLA[E(S)

lOW VOLYAGE (24v. WIRING) TO lIE NO. 18 A.W.G. MIN.

GROUND}NG OF EQUIPMENT MUST COMPLY WITH lOCAL CODES

SET TNERMQSTAT HEAT ANTICIPATOR PER UN}T W}RING DIAGRAM

THESE LEADS PROVIDE 1!5 V POWER FOR CONNFCFION OF ELECTRONIC AIR

CLEANER AND NUM}DIFIER MAX lOAD I0 AMPS EACH

tHIS CONNEC]ION IS ONlY USED FOR qHERMOSqA[S REQUIRING

CONNECT}ON TO TIlE 24 V POWER SUPPLY (COMMON)

SEE TW}NNING CONNFCTION DIAGRAMS FOR PROPER CONNECTIONS

WHEN USING THIS FEATURE

FHE "Y" /ERMIN}NA/ FROM IHE ]HERMOSFA/ MUST BE WIRED

TO THE "Y" TERM}NA[ OF THE FURNACE CONTRO! FOR PROPER BLOWER

OPERATION DURING COOL!NG

,tt

TO 115V 1PH.,

60 HZ.,POWER

SUPPLYPER

LOCALCODES L N

HUMSEE

NOTE5

EACSEEI_=--=

NOTE5 From Dwg, 21B341436 Rev, 1

18-CD19D7-13 15

iiiiiiiiiiii

|nsta||er's Guide

TWiNNiNG

These furnaces may be twinned. Twinning requires that two

furnaces with the same configuration, capacity, and airflow

must be used. They shall have common returns with equal

pressure drops or ducts with equivalent lengths and sizes.

See Field Wiring Diagrams below for proper hookup.

STAGE HEAT

ONLY

THERMOSTAT

(WITH FAN SWITCH)

%SEE NOTE 3

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEATING ONLY THERMOSTAT

FURNACE NO. 1

Rll

iSOLATiONRELAY

(FIELD SUPPLIED)

SEE NOTE4

FURNACE NO. 2

BLOWER OPERATION OF

UNiT NO 2 IS SYNCRONIZED

WITH UNiT NO l ViA SIGNALS

FROM TWIN CONNECTION

SEE NOTE 4

F-_-I

Rll i

/,0_ 5

i !7('+ _Us4_'4_ 5 !,!{',$7 sj POliRs) i£S!_/

rile 5At'{ i75{ ,¸ iL6 0/: CiTr, Ui PAt,j_

MS'RE 2_7 _UR_MCE TRAt¢SFO,%IERS ARE

R' PHAS_ PRIOR 70 COMPLE7i_,G COIRTUTiOI, S,

CHECK VOLTAGL B_7#E£N 'R' _LRM/#AL5 Of

_ACH FURNAC_¸ if ¸VOiTA6E 15 GReATeR 7f!AN

iOY , REYiTPS_ T_E _L _N R_ ,S_{O#_/,12Y i_AB$

ON ORE OF THL FUR_fACE TRA_SFOR£ERS

3FO;st'iECT Oh t4/Y 8E _E@t' aED FOp

_L_C ITONIC i lL_@'OSMi

f (Usifl '7i 7XCEEOS DT s_yOSTAi d_/ sl #7

?HOW#¸ (DO _OT CORRECT WTO W)

iSOL47iON R_LAY NO7 "TL_b_D /f 7HL 7HLRMOSTA7¸

C0#74C75 ARE RATIO AI¸ i OA O_ A_OV_

ISOLATION RELAY

SEE NOTE 4

N i EF:7 COvIF _ONEN f 'A"]I:R NO

AL i*_,_V!!i_ fl'lR t,tG COt,F/_t'fb',7 iOt_,

Si t_O; 4

2 4 ',,/ : I[ )

----I NE _" VV C_iNO

24 '<,", t i'C TO_{Y

--I NK ,/. ["Vv' R NG

From Dwg. 21B341422 Rev. 2

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEAT /1 STAGE COOL THERMOSTAT

1 STAGE

OUTDOOR UNIT HEATING /COOLING

WITH TRANSFORMER THERMOSTAT FURNACE NO. 1

'23'

ooi

',_ .......i ...........................

ISOLATION RELAy

{FIELD SURPUED}

SEE NOTE 3

OUTDOOR UNIT __

(NO TRANSFORMER) _ _T -_

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO 2 IS SYNCRONIZ_O

WITH UNIT NO 1 VIA SIGNALS

FROM _IN CONNECTION

SEE NOTE 4

Rl i

L-i

iSOLATION RELAy

SEENOTE4

#oin iii*R_C_S #us _ POi'/ R,_ i_ou

TH S_UE MS/ : OF CIRO/ T R,_RFt

EAC FURRAC F _0_ TAGE tR GREATER ThAtV

,'or ,REVERSE 7F'E BL ,Itl,i R_ SECO_@ARY L£AD%

tS(} A)r OR R ){ RO R _Di9 i_ _R ifi_4OSlk_

CORTACT5 AR,_ RXTE_ 4T /OA OR A'_O_,E

COWNEEI)ON#AY _E R[OFIRED FOR £LFdTROR[{

_RERWOST47S

INTER -COMPONENT WIRING

AL ERFAH WK_F6 {ON_ ,R,,/,T ON

......... S_ R0_ 4

2 4 V. pF { )

----I 11\ ,/,j ',,"+'IR] O

24 V. _, PACTO_{Y

--I /NI ' f',x" RING

From Dwg, 21B341423 Rev, 2

16 18-CD19D7-13

|nsta||er'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.

GROUND_

UNION JOINT

DRIP LEG -'-'"--"'_ _

AUTOMATIC GAS VALVE

WiTH MANUAL SHUTOFF

LEFT SiDE PiPiNG (STANDARD)

RIGHT SiDE PiPiNG (OPTIONAL)

,_--t MANUAL MAIN

SHUTOFF VALVE

GROUND

UNION JOINT

_--_ DRIP LEG

AUTOMATIC GAS VALVE

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 9 for delivery sizes. Connect gas supply

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

valve as shown in Figure 26. National codes require a

condensation drip leg to be installed ahead of the controls as

shown in Figure 26.

The furnace and its individual shut-off valve 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.

The furnace must be isolated from the gas supply piping by

closing its individual manual shut-offvalve during any

pressure testing of the gas supply piping system at test

pressures equal to or less than 1/2 psig.

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 fi)r leaks using a soapy

solution befi)re lighting the [hrnace. DO NOT CHECK

WITH AN OPEN FLAME!

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.

SEQUENCE OF OPERATION

Thermostat call for heat

R and W thermostat contacts close signaling the control

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

has verified that the 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 to permit gas flow to the burners. The

flame sensor confirms that ignition has been achieved within

the 6 second ignition trial period.

After the flame sensor confirms that ignition has been

achieved, the delay fan ON period (fixed at 45 seconds)

begins timing. After the delay of 45 seconds, the indoor

blower motor will be energized and will continue to run

during the heating cycle.

When the thermostat is satisfied, R and W thermostat

contacts open, the gas valve will close, the flames will

extinguish, and the induced draft blower will be de-energized.

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

period (fixed at 100 seconds), then will be de-energized by the

control module.

18-CD19D7-13 17

|nstaIIer'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. Afire or

explosion may result causing property damage, personal

injury, or loss of life.

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 knob 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

' i [ 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.

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 "Sec" column in the gas flow (in cfh) Table 12

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.

7. Changes can be made by adjusting the manifold pres-

sure 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 36F or boss marked "OUT P" on

White-Rodgers gas valve model 36G. (See Figure 28

for White-Rodgers gas valve model 36F and Figure 27

for White-Rodgers gas valve model 36G.) For the gas

valve model 36F, measurement requires 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 pres-

sure tap test screw. Using a 3/32" hex wrench, loosen

the pressure tap test screw one turn and install 5/16"

flexible tubing and a manometer directly onto the

outlet pressure boss.

c. Turn on system power and energize valve.

d. Remove the regulator adjustment screw cap on the

gas valve for manifold pressure adjustment.

e. Turn the adjustment nut clockwise to increase the gas

flow rate, and counter-clockwise to decrease the gas

flow rate using a 3/32" hex wench.

f. The final manifold pressure setting shall be 3.5" W.C.

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.

g. Replace the regulator adjustment screw cap and

tighten securely.

h. Turn off all electrical power to the system.

Remove the manometer and flexible tubing. Remove

the barbed futting 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.

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.

Table 10 lists the main burner orifices shipped -with the

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

rate, refer to Table 11.

TABLE 9

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 SP.GR. gas

18 18-CD19D7-13

|nsta||er's Guide

INPUT

RATING

BTUH

40,000

60,000

80,000

100,000

120,000

140,000

TABLE 10

ORIFICE SIZES

NUMBER

BURNERS

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS

LP GAS

TABLE 11

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

PART

NUMBER

ORF00501

O RF00644

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:

Re=install the propane orifices to the same depth as the

orifices supplied with the equipment.

See Table 13 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.

TABLE 12

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

@Outlet Pressure Boss

\\\

ii i

Regulator

Adjust

On/Off Switch

White-Rodgers 36G gas valve

On/Off Switch

White-Rodgers 36F gas valve

18-CD19D7-13 19

|nsta||er's Guide

TABLE 13

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 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 NationalFuel Gas Code-Table F-4

LiGHTiNG iNSTRUCTiONS

DO NOT attempt to manually light the burner. Failure to

follow this warning could result in property damage,

personal 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: Move the control switch on the main

gas valve to the "OFF" position (See Figures 27 and 28).

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 fai! to operate

damage could result, such as frozen water pipes.

CONTROLS AND

SAFETY SWITCH ADJUSTMENT

LIMITSWITCH 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 stm_ up by the installer.

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

thermostat to a temperature higher than the indicated

temperature to bring on the gas valve. Restrict the airflow

by blocking the return air 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.

AIRFLOW ADJUSTMENT

Check inlet and outlet air temperatures to make sure they

are within the ranges specified on the furnace rating name-

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

the wiring diagram for information on changing the speed of

the blower motor.

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 recom-

mended.

INDOOR BLOWER TIMING

The control module controls the indoor blower. The blower

starts approximately 45 seconds after ignition. The FAN-

OFF period is approximately 100 seconds from the interrup-

tion of gas flow.

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 26). 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.

20 18-CD19D7-13

|nsta||er'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.

OPERATING iNFORMATiON

FLAME ROLL-OUT DEVICE

All models are equipped with a thermal control device on the

burner cover. In case of flame roll-out, the device will cause

the circuit to open which shuts off all flow of gas.

ABNORMAL CONDITIONS

1. EXCESSIVE COMBUSTION VENT PRESSURE OR

FLUE BLOCKAGE

If pressure against the induced draft blower outlet

becomes excessive, the pressure switch will shut offthe

gas valve until acceptable combustion pressure is again

available.

LOSS OF FLAME OR GAS SUPPLY FAILURE

If loss of flame occurs during a heating cycle (when flame

is not present at the sensor), the control module will

retry the ignition sequence up to two times after the

sensor cools. If ignition is not achieved, it will lockout

the furnace.

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.

INDUCED DRAFT BLOWER FAILURE

If pressure is not sensed by the pressure switch, it will

not allow the gas valve to open, therefore the unit will

not start. If failure occurs during a running cycle, the

pressure switch will cause the gas valve to close and

shut the unit down.

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, listed by a nationally recognized agency (e.g. Under-

writers Laboratories or International Approval Services), to

help alert dwelling occupants of the presence of fire, smoke or

unsafe levels of carbon monoxide.

NOTE:

The manufacturer of your furnace does not test any detec-

tors and makes no representations regarding any brand or

type of detector.

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]

18-CD19D7-13 21

|nsta||er's Guide

Notes

22 18-CD19D7-13

|nsta||er's Guide

Notes

18-CD19D7-13 23

American Standard Inc.

6200 Troup Highway

Tyler, TX 75707

Literature Order Number *UD-IN-2F P.I.

File Number SV-UN-FURN-*UD-IN-2F 11/02

Supersedes *UD-IN-2E

Stocking Location PI Louisville & Webb/Mason-Houston

For more information contact Since the manufacturer has a policy of contliTuous product and product data linprovement, it reserves the right

your loca! dealer(distributor) to change design and specifications without notice.

TRANE Furnace/Heater, Gas Manual L0903222

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