TRANE Furnace/Heater, Gas Manual L0903224

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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18- CD1 9 D6- 3 1

Available in French Canadian (FC)

Upflow/Horizontal and Downflow/Horizontal

Gas-Fired, DirectVent Condensing Furnaces

*UX1 B040A9241A

*UX1 B060A9241A

*UX1 B060A9361A

*UX1 B080A9241A

*UX1 B080A9421A

*UXIC080A9601A

*UX1 C100A9361A

*UX1 C100A9481A

*UXID100A9601A

*UXID120A9601A

*DX1 B040A9241A

*DX1 B060A9361A

*DX1 B080A9421A

*DXIC100A9481A

*DX1 D120A9601A

*__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.

*UX-1 *DX-1

AIR

FLOW

UPFLOW

DOWNFLOW

A!R

FLOW

A_ UPFLOW/HORIZONTAL

FLOW

DOWNFLOW/HORIZONTAL 20%

elIID

A341624P06

Installer's Guide

SAFETY SECTION

The following safety practices and precautions must be

followed during the installation, servicing, and operation

of this furnace.

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

nace. Refer to the furnace rating plate.

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

specified in "Location and Clearances" (page 4), of

these instructions.

3. Provide adequate combustion and ventilation air to

the furnace space as specified in "Air for Combus-

tion and Ventilation" (pages 8-9), of these instruc-

tions.

4. Combustion products must be discharged outdoors.

Connect this furnace to an approved vent system

only, as specified in the "Venting" section (starting

on page 15), of these instructions.

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

commercially available soap solution made specifi-

cally for the detection of leaks to check all connec-

tions, as specified in "Gas Piping" (pages 31-33), 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 accompa-

nying 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 fur-

nace casing and terminating outside the space con-

taining the furnace.

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

garage must be installed as specified in "Location

and Clearances" section (page 4), of these instruc-

tions.

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 manufacturers instructions.

b. The furnace is controlled only by a room ther-

mostat (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 mark-

ing.

e. 100% of the furnace combustion air require-

ment must come from outside the structure.

The furnace return air temperature range is

between 55 and 80 degrees Fahrenheit.

Clean the furnace, duct work, and components

upon substantial completion of the construction

process, and verify furnace operating conditions

including ignition, input rate, temperature rise

and venting, according to the manufacturer's

instructions.

10. This product must be gas piped by a Licensed

Plumber or Gas Fitter in the Commonwealth of

Massachusetts.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each ap-

pliance connected to the venting system being placed

into operation could result in carbon monoxide poi-

soning or death.

The following steps shall be followed for each appli-

ance 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, ANSIZ223.1/NFPA 54 or the CAN/CGA

B149 Installation Codes and these instructions.

Determine that there is no blockage or restriction,

leakage, corrosion and other deficiencies which

could cause an unsafe condition.

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

windows and all doors between the space in which

the appliance(s) connected to the venting system

are located and other deficiencies which could

cause an unsafe condition.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not con-

nected 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 appli-

ance 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 B149.1 In-

stallation Codes.

8. After it has been determined that each appliance

connected to the venting system properly vents

where tested as outlined above, return doors, win-

dows, 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 situa-

tion 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 mod-

erate injury. It is also used to alert against unsafe

practices and hazards involving only property dam-

age.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could re-

sult in serious injury, death or property damage.

Improper servicing could result in dangerous opera-

tion, serious injury, death, or property damage.

GENERAL INSTALLATION INSTRUCTIONS

The manufacturer assumes no responsibility for equip-

ment installed in violation of any code or regulation.

It is recommended that Manual J of the Air Condition-

ing Contractors Association (ACCA) or A.R.I. 230 be fol-

lowed in estimating heating requirements. When esti-

mating heating requirements for installation at alti-

tudes above 2000 ft., remember the gas input may need

to be reduced (See High Altitude Installation).

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 ship-

ment. Unpack carefully after moving equipment

to approximate location. If damage to contents is

found, report the damage immediately to the de-

livering agency.

Codes and local utility requirements governing the

installation of gas fired equipment, wiring, plumbing,

and flue connections must be adhered to. In the ab-

sence of local codes, the installation must conform with

latest edition of the National Fuel Gas Code ANSI

Z223.1 • National Installation Code, CAN/CGA B149.1.

The latest code may be obtained from the American Gas

Association Laboratories, 400 N. Capitol St. NW,

Washington D.C. 20001.

1-800-699-9277 or www.aga.org

These furnaces have been classified as CATEGORY IV

furnaces in accordance with latest edition of ANSI

Z21.47 • CAN/CGA 2.3 standards.

Installer's Guide

Contents

INSTALLATION INSTRUCTIONS

General Installation Instructions

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 Material

VentingTables

Horizontal Venting

VentingThrough The Wall

VentingThrough The Roof

Downward Venting

Venting Through a Masonry Chimney

Condensate Drain Instructions

Electrical Connections

Field Wiring Diagrams

Gas Piping

Combustion Input Checks

Start Up and Adjustment

Preliminary Inspections

Lighting Instructions

Sequence Of Operation

Control And Safety Switch Adjustments

Airflow Adjustment

Abnormal Conditions

IFC Error Flash Code

Category IV furnaces operate with positive vent static

pressure and with a flue loss less than 17 percent.

These conditions require special venting systems, which

must be gas tight and water tight. These Category IV

Direct Vent furnaces are approved for installation in

Manufactured/ Mobile housing when used with

BAYMFGH100A.

18-CD19D6-31 3

Installer's Guide

To prevent shortening its service life, the furnace

should not be used as a "Construction Heater" during

the finishing phases of construction until the require-

ments listed in item 9, a-g of the safety section of this

publication have been met. Condensate in the pres-

ence of chlorides and fluorides from paint, varnish,

stains, adhesives, cleaning compounds, and cement

create a corrosive condition which may cause rapid de-

terioration of the heat exchanger.

Do NOT install the furnace in a corrosive or contami-

nated atmosphere.

EXPLOSION HAZARD!

PROPANE GAS IS HEAVIER THAN AIR AND MAY

COLLECT IN ANY LOW AREAS OR CONFINED

SPACES. IN ADDITION, ODORANT FADE MAY MAKE

THE GAS UNDETECTABLE EXCEPT WITH A WARN-

ING DEVICE. IF THE GAS FURNACE IS INSTALLED

IN A BASEMENT, AN EXCAVATED AREA OR A

CONFINED SPACE, IT IS STRONGLY RECOM-

MENDED TO CONTACT A GAS SUPPLIER TO IN-

STALL A GAS DETECTING WARNING DEVICE IN

CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOTtest

any detectors and makes no representations regarding

any brand or type of detector.

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 vent and as cen-

tralized for heat distribution as practical?

2. Do all clearances between the furnace and enclo-

sure equal or exceed the minimums shown in the

Table 1.

3. Is there sufficient space for servicing the furnace

and other equipment? A minimum of 24 inches

front accessibility 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 front panel and any closed panel or door

provided?

5. Are the vent pipe and combustion air inlet pipe

within vent table lengths? Will the pipes remain un-

obstructed?

6. Allow sufficient height in supply plenum above or

below the furnace to provide for cooling coil installa-

tion if the cooling coil is not installed at the time of

this furnace installation.

7. A furnace shall be installed so electrical components

are protected from water.

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

it must be installed so that the burners and the ig-

nition source are located not less than 18 inches (46

cm) above the floor and the furnace must be located

or protected to avoid physical damage from ve-

hicles.

IMPORTANT:

The furnace must be installed level The only allowable

variation would be slightly to the left and/or forward in

upflow installations or slightly toward the front in horizontal

installations. This is necessary for proper condensate drain-

age.

4 18-CD19D6-31

Installer's Guide

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Installer's Guide

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Installer's Guide

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UPFLOW INSTALLATION

Standoffs and screws (See Figure 1) are included with

the eased coils for attachment to the furnace. There are

clearance alignment holes near the bottom of the coil

wrapper. Drill screws are used to engage the furnace

top flanges. The standoff is inserted into the cabinet

alignment hole. The drill screws are inserted through

the standoffs then screwed into the furnace flange.

The coil is always placed downstream of the furnace air-

flow.

STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

INSTALLATIONS:

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

Do NOT install the furnace directly on carpeting, tile or

other combustible material other than wood flooring.

For vertical downflow application, subbase (BAYBASE-

205) must be used between the furnace and combus-

tible flooring. When the downflow furnace is installed

vertically with a cased coil, a subbase is not required.

Required floor opening:

CABINET_SIDE _CABINET SIDE

SUB-BASE SUB-BASE

FLANGE _FLANGE

(BENT UP) (BENT UP)

SUB-BASE _

IN PLENUMSULATIONDUCT ZLOOCOMBL'STFBI,N_SUB*BASE

SUBBASE CROSS SECTION

CABINET

WIDTH

17-1/2"

21"

24-1/2"

TABLE 1

RETURN FLOOR OPENING PLENUM OPENING

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

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

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

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

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used

in the horizontal position. It is always recommended

that an auxiliary drain pan be installed under a horizon-

tally installed evaporator coil or 90% gas furnace. Con-

nect the auxiliary drain line to a separate drain line (no

trap is needed in this line).

Three brackets (with screws) are included with down-

flow furnaces for installation to stabilize and secure the

furnace and TXC cased coil in the horizontal posi-

tion. See Figure 4.

IMPORTANT:

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

furnace. In horizontal installations, the apex of the coil

may point either toward or away from the furnace. See

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

The cased coil is secured to the furnace and both the

furnace and the cased coil must be properly supported.

The brackets mount using the rear screws on the coil

case and use the screws provided to secure the bracket

to the furnace. The remaining bracket is placed as close

to center as possible (horizontally) between the coil case

front and the furnace bottom channel (for downflow/

horizontal furnace). Use four of the screws provided to

secure the bracket. The upflow furnace, converted to

horizontal, aligns and attaches the TXC coil as in Fig-

ure 1. However, the coil requires additional support.

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

The furnace may be installed in an attic or crawl space

in the horizontal position by placing the furnace on the

left side (as viewed from the front in the vertical posi-

tion). The horizontal furnace installation in an attic

should be on a service platform large enough to allow

for proper clearances on all sides and service access to

the front of the furnace (See Figure 4 & Clearance

Table). Line contact is only permissible between lines

formed by intersections of the top and two sides of the

furnace casing and building joists, studs, or framing.

18-CD19D6-31 7

Installer's Guide

UPFLOW/

HORIZONTAL

SHOWN

The furnace may be placed horizontally in a crawl space

on a pad or other noncombustible material which will

raise the unit for sufficient protection from moisture.

The furnace must be supported at both ends and

the middle when installed horizontally.

The furnace must also be elevated a minimum of 6

inches to allow clearance for the condensate drain

to exit the cabinet in the horizontal position.

The horizontal furnace may also be suspended from the

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

underneath the furnace to form a hanging rack at both

ends and the midpoint. The rods need to be of sufficient

length to allow for proper clearances from combustible

materials. The angle iron needs to be at least 32" in

length to allow for access to service panels.

50 CU. FT. OR MORE

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

WATER ICLOTHES

FiACE HE;R _DRYER

UNCONFINED

AIR FOR COMBUSTION AND VENTILATION

If these furnaces are installed in a nondirect vent capac-

ity then the adequate flow of combustion and ventilat-

ing air must not be obstructed from reaching the fur-

nace. Air openings provided for combustion air must be

kept free of obstructions which restrict the flow of air.

Airflow restrictions affect the efficiency and safe opera-

tion of the furnace. Keep this in mind should you

choose to remodel or change the area which contains

your furnace. Furnaces must have a free flow of air for

proper performance.

Provisions for combustion and ventilation air shall be

made in accordance with latest edition of Section 5.3,

Air for Combustion and Ventilation, of the National

Fuel Gas Code, ANSI Z223.1 --CAN/CGA B149.1 or ap-

plicable provisions of the local building codes. Special

conditions created by mechanical exhausting of air and

fireplaces must be considered to avoid unsatisfactory

furnace operation.

OUTSIDE AIR IS RECOMMENDED

The use of indoor air for most applications is acceptable,

unless there is the presence of corrosive chemicals

or contamination. Certain types of installation will

require the use of outside air for combustion.

The following types of installations will require use of

OUTDOOR AIR for combustion, due to chemical expo-

sures:

*Commercial buildings

* Buildings with indoor pools

* Furnaces installed in "confined" laundry rooms

* Furnaces installed in "confined" hobby or craft rooms

* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion

air supply will also require OUTDOOR AIR for combus-

tion:

* 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 perehloroethylene)

* Printing inks, paint removers, varnish, etc.

* Hydrochloric acid

* Cements and glues

* Antistatic fabric softeners for clothes dryers

* Masonry acid washing materials

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

"unconfined space".

Unconfined space is defined in Figure 5. These spaces

may have adequate air by infiltration to provide air for

combustion and ventilation. Buildings with tight

construction (for example, weather stripping, heavily

insulated, caulked, vapor barrier, etc.), may need addi-

tional air to be provided as described for confined space.

Confined spaces are installations with less than 50 cu.

ft. of space per 1000 BTU/hr input from all equipment

installed. Air for combustion and ventilation require-

ments can be supplied from inside the building as in

Figure 8 or from the outdoors, as in Figure 9.

8 18-CD1 9D6-31

_F MINIMUM AREA IN SQUARE FEET

OR UNCONFINED SPACE INSTALLATIONS

FURNACE WITH 8 FT. CEILING

MAXIMUM BTUH MINIMUM AREA IN SQUARE FEET

INPUT RATING OF UNCONFINED SPACE

60,000 375

80,000 500

100,000 625

120,000 875

-I,,

CONFINED

SPACE LESS THAN 50 CU. FT.

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

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

confined space shall be provided with two perma-

nent openings communicating directly with an addi-

tional room(s) of sufficient volume so that the com-

bined volume of all spaces meets the criteria for an

unconfined space. The total input of all gas utiliza-

tion equipment installed in the combined space

shall be considered in making this determination.

Refer to Table 2 for minimum open areas require-

ments.

2. All air from outdoors as in Figure 9: The confined

space shall be provided with two permanent open-

ings, one commencing within 12 inches of the top

and one commencing within 12 inches of the bot-

tom of the enclosure. The openings shall communi-

cate directly, or by ducts, with the outdoors or

spaces (crawl or attic) that freely communicate with

the outdoors. Refer to Table 2, for minimum open

areas requirements.

TABLE2

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING FURNACEONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000

80,000

100,000

120,000

Air

From

Inside

1oo

120

Air From Outside

Vertical

Duct

Horizontal

Duct

Installer's Guide

CONFINED SPACE

AIR FROM INSIDE BUILDING

ISPACE

PERMANENT

OPENINGS

CONFINED SPACE

AIR FROM OUTDOORS

CONFINED

SPACE

_///////////////////////L

OUTLET l

OUTDOOR

AIR DUCTS

INLET 1

_/z'/////////////J///////z

CONFINED SPACE

AIR FROM VENTILATED ATTIC/CRAWL SPACE

TO OUTDOORS

CONFINED-

SPACE

ALTERNATE

INLET AIR

CONFINED SPACE

AIR FROM VENTILATED ATTIC

•"_ OUTLET

SPACECONFINED lAIR INLET

AIR DUCT

18-CD19D6-31 9

Installer's Guide

DUCT CONNECTIONS

Air duct systems should be installed in accordance with

standards for air conditioning systems, National Fire

Protection Association Pamphlet No. 90. They should

be sized in accordance with ACCA Manual D or which-

ever is applicable.

Central furnaces, when used in connection with cooling

units, shall be installed in parallel or on the upstream

side of the cooling coil to avoid condensation in the heat

exchanger. With a parallel flow arrangement, the damp-

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

adequate to prevent chilled air from entering the fur-

nace, 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 mate-

rial 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 de-

signed with returns to minimize noise transmission

through the return air grille. Although these furnaces

are designed with large blowers operating at moderate

speeds, any blower moving a high volume of air will

produce audible noise which could be objectionable

when the unit is located very close to a living area. It is

often advisable to route the return air ducts under the

floor or through the attic. Such design permits the in-

stallation 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 termi-

nating outside the space containing the furnace.

RETURN AIR DUCT SYSTEMS

Where there is no complete return duct system,

the return connection must be run full size from

the furnace to a location outside the utility room,

basement, attic, or crawl space.

DoNor install return air through the back of the fur-

nace cabinet

Do Not install return air through the side of the fur-

nace cabinet on horizontal applications.

NOTE:

Minimum return air temperature is 55 °F.

All return air duct systems should provide for installa-

tion of return air filters.

1. Set the furnace in place.

2. For upflow side return installations, remove the

insulation around the opening in the blower compart-

ment.

3. The side panels of the upflow furnace include locat-

ing notches that are used as guides for cutting an

opening for return air, refer to Figure 10 and the

outline drawing on page 4 for duct connection di-

mensions for various furnaces.

NOTE:

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

ment exceeds 1800 CFM, these models will require re-

turn air openings and filters on both sides; OR 1 side

and the bottom; OR just the bottom.

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

let duct, add to cut where indicated by dotted lines

in Figure 10. Cut corners diagonally and bend out-

ward to form flange.

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

stalled, cut between locating notches (See Figure

10).

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

moved for bottom return air. Lay the furnace on its

back. Remove the two 1/4" hex screws securing the

bottom front channel to the cabinet. Lower the

front edge of the bottom front channel and pull for-

ward to remove the channel. The bottom return air

panel will now easily slide out of the cabinet. Rein-

stall the bottom front channel for upflow bottom re-

turn installations.

7. Use the filter retainer on side or bottom if filter is to

be used within the furnace cabinet on upflow only

installations.

8. The horizontal installation of the upflow fur-

nace requires an external filter section. Filter

kits are available for horizontal applications.

9. Connect duct work to furnace. See Outline Drawing

for supply and return duet size and location. Flex-

ible duet connectors are recommended to connect

both supply and return air duets to the furnace. If

only the front of the furnace is accessible, it is rec-

ommended that both supply and return air plenums

are removable.

10 18-CD1 9D6-31

RETURN AIR FILTERS

(Filters not supplied with unit)

TYPICAL UPFLOW RETURN

AIR FILTER INSTALLATIONS

These furnaces require high velocity type air filters.

The filters may be located within the furnace blower

compartment for UPFLOW furnaces in either a BOT-

TOM or SIDE (left side or right side) return air inlet.

TABLE3

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*UXl B040A9241A

*UXl B060A9241A

*UX1B060A9361A 17-1/2" 1 - 17"X 25"X 1"

*UXl B080A9241A

*UXl B080A9421A

*UXlC080A9601A

*UXlC100A9361A 21" 1 - 20" X 25" X 1"

*UXlC100A9481A

*UXl D100A9601A

*UX1D120A9601A 24-1/2" 1 -24"X 25"X 1"

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

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

exceeds 1800 CFM, these models will require filters on both sides;

OR 1 side and the bottom; OR just the bottom.

NOTE:

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

ment exceeds 1800 CFM, these models will require re-

turn air openings and filters on both sides; OR 1 side

and the bottom; OR just the bottom.

The upflow furnace blower door has a hinge at the bot-

tom which allows the door to tilt forward for filter re-

placement without the door being removed (See Figure

®UPFLOW FURNACE ONLY

LOCATING *"_

NOTCHES

PROVIDED FOR

SIDE RETURN

CUTOUT

_. I CUT OUT

///FOR SIDE

_ FILTER

of Furnace

*SEE OUTLINEDRAWING

11). The optional 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 adjust-

ment to allow standard size, locally obtainable replace-

ment filters. The filter rack itself slides to adjust to the

required width needed for bottom or side return (See

Figure 12).

Installer's Guide

Blower Door Hinge and Bottom Filter Rack Installation

FILTER

RACK -'_

RAILS

AUTOMATIC

ADJUSTMENT b

RETAINING

(Both Sides)

Optional Filter Rack Accessory Kit

BA YRACK960A

OPTIONAL 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 engage-

ment holes at the bottom of the furnace cabinet side.

OPTIONAL FILTER RACK INSTALLATION FOR SIDE

RETURN AIR ON UPFLOW FURNACES (Left or Right)

NOTE:

The optional filter rack installation is not allowed for

right side return on the following model: *UXICO80-

A9601.

18-CD19D6-31 11

Installer's Guide

%...,

ENGAGEMENT

HOLE DETAIL

(Typical both sides

and blower deck)

If side air return is desired, the following instructions

should be used:

a. Open or remove the blower door.

b. Leave the bottom panel in place.

c. After the side cutout is made following the direc-

tions in the "Return Air Duct Connections" sec-

tion on pages 8 and 9, compress the optional ill-

ter 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 - 18.

d. Install the optional furnace filter on the side in-

setting the chamfer end first.

RETURN AIR FILTERS FOR UPFLOW FURNACE IN

HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in the horizontal

configuration, the return air filters must be installed

exterior to the cabinet. Remote filter grilles may be

used for homeowner convenience or the filters may be

installed in the duct work upstream of the furnace. See

Figure 20.

(_ Filter

Furnace

Cabinet

Side

Engagement Hole

For Filter Rack

installation With

Bottom Return

Rack

Filter Rack

Retaining

Screw/Pin

®BOTTOM ENGAGEMENT

Filter Rack

Retaining

Screw/Pin/

Furnace

Cabinet

Side

Filter

Rack

Engagement Hole

For 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

_./

_W___r _k _Filter

Retaining Rack

Screw/Pin Assembly

SIDE

CUTOUT

RETAINING

(B° PIN "_

1II f/ FILTER

IU _/ RACK

RAILS

BOTTOM

PANEL

INSTALLED

Typical Upflow Left Side Return Filter Rack Installation

12 18-CD1 9D6-31

Typical Upflow Right Side Return Filter Rack Installation

CHAMFER

END OF

FILTER GOES

INTO FILTER

RACK FIRST

BLOWER DOOR/HINGE REMOVAL

If clearance or other problems create a problem in us-

ing the tilting door, the blower door hinge may be re-

moved 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 fea-

ture, simply remove the lower hinge as shown in Fig-

ure 21. The bottom of the blower door will catch in the

bottom of the furnace front channel for door replace-

ment.

Installer's Guide

TYPICAL RETURN AIR FILTER INSTALLATION IN

UPFLOW MODEL IN HORIZONTAL POSITION

ALTERNATE UPFLOW FILTER CLIP/

BRACKET INSTALLATION

1. Determine the location to be used. The furnace

cabinet has dimples for location of the alternate fur-

nace 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 loca-

tion using the screws provided. The filter clip with

the leaf spring mounts in the rear of the cabinet.

Door Hinge Removed

INSTALLING THE FILTER

The optional filter may need to be cut to fit the unit de-

pending 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.

18-CD19D6-31 13

iiiiiiiiiiii

Installer's Guide

UNIT

SIZE

17-1/2"

21"

24-1/2"

DOWNFLOW

ALTERNATE FILTER

CLIPS LOCATION

RETURN AIR

BOTTOM

DO NOT CUT

SIDE

DO NOT CUT

CUT ON LINE

TYPICAL DOWNFLOW FURNACE RETURN

AIR FILTER INSTALLATIONS

Two high velocity type air filters are required for each

downflow furnace. Downflow furnace filters must be lo-

cated outside the furnace cabinet. Typical installations

are shown in Figure 23. Tables 5 and 6 provide informa-

tion for installation of the filter retaining brackets

shipped with downflow furnaces.

TABLE 4

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*DX1 B040A9241A

*DX1B060A9361A 17-1/2" 2 - 14"X 20"X 1"

*DX1 B080A9421A

*DX1C100A9481A 21" 2 - 16"X 20"X 1"

*DX1D120A9601A 24-1/2" 2 - 16"X 20"X 1"

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

TABLE 5

LOCATING FILTER RETAINER BRACKETS IN DUCTWORK

FILTER

CABINET RETURNDUCT DIMENSION DIMENSION BRACKET

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

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

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

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

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

SCREW HOLES FOR THE BRACKET.

Airflow

Joow.F,OW,

HORIZONTAL

TABLE 6

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/HORIZONTAL FURNACES

UNIT LOCATION

VERTICAL HORIZONTAL HORIZONTAL

FURNACE SURFACE CLOSET CLOSET ALCOVE /ATTIC

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

14 18-CD19D6-31

GENERAL VENTING

THIS FURNACE MUST BE VENTED TO THE OUT-

DOORS.

THESE FURNACES ARE INDUCED DRAFT VENTED

AND MUST NOT BE CONNECTED TO ANY VENT

SERVING ANOTHER APPLIANCE. PLEASE NOTE

THAT THESE FURNACES USE POSITIVE-PRES-

SURE VENT SYSTEMS.

Proper venting is essential to obtain maximum effi-

ciency from a condensing furnace. Proper installation of

the vent system is necessary to assure drainage of the

condensate and prevent deterioration of the vent

system.

American Gas Association has certified the design of

condensing furnaces for a minimum of 0" clearance

from combustible materials with a single wall plastic

vent pipe.

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

or 3" plastic pipe and fittings (See Table 7, page 14).

Where the system is routed to the outdoors through an

existing masonry chimney containing flue products

from another gas appliance, or where required by local

codes, then 3" venting of Type 29-4C stainless steel

must be used in place of PVC material.

These furnaces have been classified as CATEGORY IV

furnaces in accordance with the latest edition of

ANSI Z21.47 • CAN/ CGA-2.3 Standards. Category IV

furnaces operate with positive vent pressure and with a

vent gas temperature less than 140°F above the

dewpoint. These conditions require special venting sys-

terns, which must be gas tight and water tight.

NOTE:

When an existing furnace is removed from a venting

system serving other gas appliances, the venting sys-

tem is likely to be too large to properly vent the re-

maining attached appliances.

IMPORTANT:

These furnaces may be installed as Direct Vent (sealed

combustion) or as Nondirect vent (single pipe). The fur-

naces are shipped DIRECT VENT with sealed combus-

tion.

For DIRECT VENT APPLICATION: The furnaces must be

vented to the exterior of the house and combustion air

MUST come through the inlet air pipe FROM OUTSIDE

AIR.

For NONDIRECT VENT APPLICATION: The furnace shall

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

may enter from the surrounding area as long as combus-

tion air requirements are met. (See AIR FOR COMBUS-

TION AND VENTILATION)

Installer's Guide

The following steps shall be followed with each appli-

ance remaining connected to the common venting sys-

tern placed in operation, while the other appliances re-

maining connected to the common venting system are

not in operation.

1. Seal any unused openings in the common venting

system.

2. Visually inspect the venting system for proper size

and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion or other

deficiencies which could cause an unsafe condition.

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

windows and all doors between the space in which

the appliances remaining connected to the common

venting system are located and other spaces of the .........................................................................

building. Turn on clothes dryers and any appliances

not connected to the common venting system. Turn

on any exhaust fans, such as range hoods and bath-

room exhausts, so they will operate at maximum

speed. Do not operate a summer exhaust fan, close

fireplace dampers.

4. Follow the lighting instructions. Place the appliance

being inspected in operation. Adjust thermostat so

appliance will operate continuously.

5. Test for spillage at the draft hood relief opening af-

ter 5 minutes of main burner operation. Use the

flame of a match or candle, or smoke from a ciga-

rette, cigar, or pipe.

6. After it has been determined that each appliance re-

maining connected to the common venting system

properly vents when tested as outlined above, re-

turn door, windows, exhaust fans, fireplace dampers

and any other gas-burning appliance to their previ-

ous conditions of use.

If improper venting is observed during any of the above

tests, the remaining common venting system must be

corrected. Correction of the remaining common vent

system should be done by referring to the latest edition

of the National Fuel Gas Code (ANSI Z223.1)° CAN/

CGAB149.1 Installation Codes or "Exhibit J" of

ANSI Z21.47 ° CAN/CGA-2.3 Standards. The following

are general steps to be used to correct or resize a re-

maining vent system when a furnace which may not be

common vented is removed from the system:

a. Determine the Btu per hour input of all remain-

ing appliances attached to the venting system.

b. Determine the diameter, rise, and lateral of the

existing venting system, as well as quantity and

type of bends.

c. Use the appropriate tables in the latest edition of

the National Fuel Gas Code (ANSI Z223.1 °

CAN/CGA B149.1 Installation Codes or "Exhibit

J" of ANSI Z21.47 ° CAN/ CGA-2.3 Standards.

"Exhibit J" includes examples and drawings of

typical venting systems.

_iiiliiiiXi_iii!!i!!i!!i!!i!!i!!i!!i!!i!!i!!i!!!!iii_

18-CD19D6-31 15

Installer's Guide

PVC VENT FITTING MATERIAL

These fittings are available from your Gas Furnace

Distributors.

Straight Pipe Sections, Couplings, 45° Elbows, 60 ° El-

bows, 90° Elbows, Vent or Sanitary Tee, or other neces-

sary fittings may be 2", 2½", 3", or 4" diameter. The al-

lowable materials are shown in Table 7.

VENT FITTING MATERIAL - PLASTIC

Gas and liquid tight single wall vent fittings, designed

for resistance to corrosive flue condensate, MUST be

used throughout.

Listed in Table 8 & 9 are 2", 2½", 3", and 4" size fittings

that meet these requirements. The materials listed are

various grades of PVC and ABS plastic.

PIPE JOINTS: All joints must be fastened and sealed to

prevent escape of combustion products into the build-

ing.

NOTE:

It is recommended that the first joints from the furnace

be connected and sealed with high temperature RTV.

This will enable the pipes to be removed later without

cutting.

Be sure to properly support these joints.

BONDING OF PVC

Commercially available solvent cement must be used to

join the pipe and fittings. Follow instructions on the

container carefully.

Procedure for Cementing Joints:

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

Chamfer end of pipe, then clean fitting socket and

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

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

socket and pipe with cleaner-primer. Apply a liberal

coat of primer to inside surface of socket and out-

side of pipe.

DO NOT ALLOW PRIMER TO DRY BEFORE AP-

PLYING CEMENT.

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

Quickly apply a heavy coat of cement to the pipe

end and insert pipe into fitting with a slight twisting

movement until it bottoms out.

4. Hold the pipe in the fitting for 30 seconds to pre-

vent tapered socket from pushing the pipe out of

the fitting.

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

Allow 15 minutes before handling. Cure time varies

according to fit, temperature and humidity.

IMPORTANT:

Products installed in Canada must use vent systems

that are certified to the Standard for Type BH Gas Vent-

ing Systems (ULC $636) for Class II-A venting systems

(up to 65°C). Components of the vent system must not

be interchanged with other vent systems or unlisted

pipe or fittings. Plastic components, specified prim-

ers, and glues must be from a single system manufac-

turer and not intermixed with other system

manufacturer's vent system parts. In addition, the first

three feet of the vent pipe must be visible for inspec-

tion.

TABLE 7

PLASTIC PIPE DESIGNATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

F891 CELLULAR CORE "158 ASTM F891

D2665 DWV PIPE *'158 ASTM D2665

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

D2241 SDR SERIES *'158 ASTM D2241

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41 *'212 ASTM D2846

F441 SCH 40, 80 *'212 ASTM F441

F442 SDR SERIES *'212 ASTM F442

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV **'180 ASTM D2661

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

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

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

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

16 18-CD19D6-31

Installer's Guide

@VENT AND INLET AIR CONNECTIONS

Seal VENT PIPE

with RTV sealant

Front of Furnace

Seal INLET AIR PIPE

with RTV sealant

NOTE:

Follow venting instructions carefully when using PVC

cement.

IMPORTANT:

All joints must be water tight. Flue condensate is some-

what acidic, and leaks can cause equipment damage.

Connection of the pipe and collar of the combustion

air inlet should just be a friction fit. It is recommended

that the inlet air joint be sealed with RTV type sealant

to allow the joint to be separated for possible future ser-

vice. The inlet and vent pipes must be properly sup-

ported throughout the entire length.

Connection of the vent pipe to the vent collar should

also be accomplished using RTV type sealant. This type

sealant provides a connection which remains flexible

and can be separated in the future if service needs re-

quire the removal of the vent pipe for service or dear-

ance.

NOTE:

To ensure proper operation at the vent lengths indi-

cated, the combustion air inlet and vent terminals

should be in the same pressure zone. Terminating the

vent and inlet in different pressure zones will change

the maximum vent lengths and may cause nuisance

tripping of the pressure switch(es). The amount of

change can not be predicted. The selection of the inlet

and outlet terminal locations are the responsibility of

the designer/installer, ff the installer chooses separate

pressure zones for the terminals, the combustion air

inlet termination must be in the higher (more positive)

pressure zone.

UPFLOW/HORIZONTAL VENTING TABLE

TABLE 8

MAXIMUM VENT LENGTH:

DIRECT VENT (2 PIPE SYSTEM) - NONDIRECT VENT (1 PiPE SYSTEM) -MAXIMUM TOTAL

MAXIMUM TOTAL EQUIVALENT FEET FOR EQUIVALENT FEET FOR

VENT AND INLET AIR PIPES (See Notes) VENT PIPE ONLY (See Notes)

2" PIPE 2-1/2" PIPE 3" PIPE 4" PIPE 2" PIPE 2-1/2" PIPE 3" PIPE 4" PIPE

MODEL & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS

*UXIB040A9241A 60 80 100 130 50 80 80 130

*UXIB060A9241A 60 80 100 130 50 80 80 130

*UXIB060A9361A 60 80 100 130 50 80 80 130

*UXIB080A9241A 50 80 100 130 40 80 80 130

*UXIB080A9421A 50 80 100 130 40 80 80 130

*UX1C080A9601A NOT ALLOWED 60 100 130 NOT ALLOWED 60 80 130

*UX1C100A9361A NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130

*UX1C100A9481A NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130

*UXID100A9601A NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130

*UXID120A9601A NOT ALLOWED 15 60 130 NOT ALLOWED 25 70 130

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

1. The INLET AIR of one pipe systems require the installation of a 90 ° elbow (to prevent dust and debris from falling straight into thefurnace) and a 2 foot

horizontal or vertical straight pipe section connected before or after the elbow.

2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace).

If different inlet and vent pipe sizes are used, the vent pipe must adhere te the maximum length limit shown in the table above (See Note 7 below for exception).

The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

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

(Vent or Inlet air pipes in two pipe systems).

4. One standard radius 90 ° elbow is equivalent to 12' of 4" pipe; one SHORT radius 90 ° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is

equivalent to 6' of 3" pipe. One SHORT/LONG radius 90 ° elbow is equivalent to 71/2' of 21/2 pipe, & 5' of 2" pipe. Two 45 ° elbows equal one 90°elbow.

5. The termination tee or bend must be included in the total number of elbows. If the BAYVENT100 termination kit is used, the equivalent length of pipe is 5 feet.

There is zero equivalent length for the BAYVENT200.

6. Pipe adapters are field supplied.

7.4" pipe may be reduced to 3" for termination with BAYAIR30AVENTA or BAYVENT200 without additional length restriction.

18-CD19D6-31 17

Installer's Guide

DOWNFLOW/HORIZONTAL VENTING TABLE

TABLE 9

MAXIMUM VENT LENGTH:

DIRECT VENT (2 PIPE SYSTEM)- NONDIRECT VENT (1 PIPE SYSTEM)-

MAXIMUM TOTAL EQUIVALENT FEET FOR MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT AND INLET AIR PIPES (See Notes) VENT PIPE ONLY (See Notes)

2" PIPE 2-1/2" PIPE 3" PIPE 4" PIPE 2" PIPE 2-1/2" PIPE 3" PIPE 4" PIPE

MODEL & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS & FITTINGS

*DX1 B040A9241A 60 80 100 130 50 80 80 130

*DXl B060A9361A 50 80 100 130 50 80 80 130

*DXl B080A9421A 45 80 100 130 40 80 80 130

*DXlC100A9481A NOT ALLOWED 80 100 130 NOT ALLOWED 80 80 130

*DX1D120A9601A NOT ALLOWED 15 60 130 NOT ALLOWED 25 70 130

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

1. The INLET AIR of one pipe systems require the installation of a 90 ° elbow (to prevent dust and debris from falling straight into the furnace) and a 2 foot

horizontal or vertical straight pipe section connected before or after the elbow.

2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace).

If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See Note 7 below for exception).

The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

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

(Vent or Inlet air pipes in two pipe systems).

4. One standard radius 90 ° elbow is equivalent to 12' of 4" pipe; one SHORT radius 90 ° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is

equivalent to 6' of 3" pipe. One SHORT/LONG radius 90 ° elbow is equivalent to 7Y2' of 2Y2" pipe, & 5' of 2" pipe. Two 45 ° elbows equal one 90°elbow.

5. The termination tee or bend must be included in the total number of elbows. If the BAYVENTIO0 termination kit is used, the equivalent length of pipe is 5 feet.

There is zero equivalent length for the BAYVENT200.

6. Pipe adapters are field supplied.

7.4" pipe may be reduced to 3" for termination with BAYAIR3OAVENTA or BAYVENT200 without additional length restriction.

SINGLE PIPE VENTING

UPFLOW FURNACE

I--B--I t- A (0-2') or greater

___ B (0-2')or greater

A+B = 2' minimum

Air lnle/t __ _entu_snldY.

DOWN FLOW

Air Inlet

%, FURNACE

....=

A = 2' minimum

(_ F_ VENTTERMINAL (_) AIR SUPPLY INLET [] AREAWHERETERMINALISNOTPERMITTED

_K_

18 18-CD19D6-31

Installer's Guide

Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch, deck, or 12 inches (30 cm) 12 inches (30 cm)

A= balcony

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9

inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/< inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/<

B= Clearance to window or door that may be opened 100,000 Btuh (30 kw), 36 inches (91 cm) for appliances > 50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000

100,000 Btuh (30 kw) Btuh (15 kw)

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the

D= terminal within a horizontal distance of 2 feet (61 cm)

from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G- Clearance to inside corner

Clearance to each side of center line extended above 3 feet (91 cm) with a height 15 feet (4,5 m) above the

H= meter/regulator assembly meter/regulator assembly

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

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9

j= Clearance to nenmechanical air supply inlet to building inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/< inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/<

or the combustion air inlet to any other appliance 100,000 Btuh (30 kw), 35 inches (91 cm) for appliances > 50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000

100,000 Btuh (30 kw) Btuh (15 kw)

K= Clearance to a mechanical air supply inlet 6 feet (1,83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally

L= Clearance above a paved sidewalk or paved driveway

located on public property 7 feet (2,13 m) t

M- Clearance under veranda, porch, deck, or balcony "12 inches (30 cm) _:

Notes:

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

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

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

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

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

Non-Direct Vent Terminal Clearances

A= Clearance above grade, veranda, porch, deck, or

balcony

B= Clearance to window or door that may be opened

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the

D= terminal within a horizontal distance of 2 feet (61 cm)

from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line extended above

H= meter/regulator assembly

I= Clearance to service regulator vent outlet

J= Clearance to nonmechanical air supply inlet to building

or the combustion air inlet to any other appliance

K= Clearance to a mechanical air supply inlet

L= Clearance above a paved sidewalk or paved driveway

located on public property

M= Clearance under veranda, porch, deck, or balcony

Canadian Installations

12 inches (30 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/<

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

100,000 Btuh (30 kw)

3 feet (91 cm) with a height 15 feet (4,5 m) above the

meter/regulator assembly

3 feet (91 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/<

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

100,000 Btuh (30 kw)

6 feet (1,83m)

7 feet (2.13 m) 1

"12 inches (30 cm) _:

US Installations

12 inches (30 cm)

4 feet (1,2m) below or to the side of opening; 1 foot (0,3m)

above opening.

4 feet (1,2 m) below or to side of opening; 1 foot (300 m) above

opening

3 feet (91 cm) above if within 10 feet (3m) horizontally

7 feet (2,13 m)

Notes:

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

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

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

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

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

18-CD19D6-31 19

Installer's Guide

6" i

MAX 4

ELBOW AND TEE MUST "_

BE AS CLOSE TO-

GETHER i.=

AS POSSIBLE

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

HORIZONTAL VENTING

NOTE:

Vent termination kit BAYAIR3OAVENTA or

BAYVENT2OOB may be used instead of the horizontal

and vertical termination options shown in the follow-

ing figures.

When the vent pipe is exposed to temperatures below

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

etc., the pipe must be insulated with 112 inch (22.7 mm)

thick Armaflex-type insulation or equal. If the space is

heated sufficiently to prevent freezing, then the insula-

tion would not be required. If domestic water pipes are

not protected from freezing then it is assumed the

space meets the condition of a heated space.

HORIZONTAL VENTING THROUGH WALL

These furnaces may be installed as direct vent (as

shipped) or as nondirect vent. Installation must

conform to national, state, and local codes.

VENT

CAP

MAINTAIN 12" (18' FOR CANADA) P,

CLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

BAYVENT2OOB "" "" _

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

minimum above normally expected snow accumulation

level.

Avoid areas where staining or condensate drippage may

be a problem.

Location of the vent/wind terminal should be chosen to

meet the requirements of Figure 26 for either direct or

non-direct vent applications.

20 18-CD19D6-31

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

per foot pitched upward to insure that condensate

drains back to the furnace.

FLUE GAS DEGRADATION - The moisture content

of the flue gas may have a detrimental effect on some

building materials. This can be avoided by using the

roof or chimney venting option. When wall venting is

used on any surface that can be affected by this mois-

ture, it is recommended that a corrosion resistant

shield (24 inches square) be used behind the vent termi-

BAYAIR30AVENTA

(Sidewall)

nal. This shield can be wood, plastic, sheet metal, etc.

Also, silicone caulk all cracks, seams and joints within 3

feet of the vent terminal.

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials

must be maintained when using single wall stainless

steel venting. See Figure 30 above.

Shield material to be a minimum of 24 gauge stainless

or aluminized sheet metal. Minimum dimensions are

12"x12". Shield must be fastened to both inside and out-

side of wall. Use screws or anchor type fasteners suited

to the outside or inside wall surfaces.

NONCOMBUSTIBLE MATERIAL WALL

The hole through the wall must be large enough to

maintain pitch of vent and properly seal.

Use cement mortar seal on inside and outside of wall.

See Figure 31.

Installer's Guide

COUPLING

( PLASTIC

VENTING

IN. MII

(0JOIP

1" CLEARANCE

(AIR SPACE )

II /[OPTIONAL)

12" MIN. ABOVE

HII NORMALLYEXPECTED

_.__ _ snowACCUMULATION

VENTINGTHROUGH COMBUSTIBLE WALLS

Pitch-- 1/4InchPerFt.

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

( PLASTIC

VENTING )

14 6 IN. MIN.

INSIDE &I,_

OUTSIDE

PVC WALL

MOUNT FLANGE

(OPTIONAL)

/APPROVED

TERMINATION

12" MIN. ABOVE

NORMALLY EXPECTED

SNOW ACCUMULATION

VENTING THROUGH NON-COMBUSTIBLEWALLS

Pitch-114InchPerFt.

SUPPORT HORIZONTAL PIPE EVERY 3'

0" WITH THE FIRST SUPPORT AS

CLOSE TO THE FURNACE AS POSSIBLE,

INDUCED DRAFT BLOWER, HOUSING,

AND FURNACE MUST NOT SUPPORT

THE WEIGHT OF THE FLUE PIPE,

:IRST

lACE

;To_"

JE PIPE,

coupu_a

pL_srlc w_r5

40" UPFLOVV OR DOtNNFLOW " FURNACE

HORIZONIAL ANDVERIICAL

.,'F.>---, o,a,r .... n....

18-CD19D6-31 21

Installer's Guide

COMBUSTION

AIR INLET

40" UPFLOW OR

DOWNFLOW MODELS

SEE VENTING TABLE NOTE: VENT AND INLET MUST BE SUPPORTED

AT A MAXIMUM OF 3' INTERVALS

STRAPS OR OTHER SUITABLE SUPPORTS

AT MAXIMUM OF 3'-0" INTERVALS USE ONLY

APPROVED

TERMINATIO_

_X UPWARD PITCH -- 1/4" PER FOOTFIRST SUPPORT SHOULD BE AS

CLOSE TO FURNACE CONNECTION

AS POSSIBLE. OUTSIDE

WALL

NOTE: ANY FITTINGS PASSING

THROUGH AN UNHEATED SPACE

MUST BE INSULATED.

45°ELBOW

TEE

OUTSIDE

WALL

STUB CUT AT

45 _ANGLE

COMBUSTION

STRAP AIR

(FIELD SUPPLIED) x RAIN CAP

VENT _/

COMBUSTION AIR (FIELD 1_

BAYAIR3OAVENTA BAYVENT2OOB WALL CAVITIES

22 18-CD19D6-31

DOWNWARD VENTING @

Furnacemay be invertical or horizontalconfiguration.

DOWNWARD VENT

LENGTH IS LIMITED

TO A MAXIMUM OF 15

EQUIVALENT FEET.

Slope 1/4" per ft. t_

40 Inch

__ Upflow or

Downflow

Furnace

6" Min,

All horizontal pipes must be supported

at a maximum of 3 foot intervals

NOTES:

A) Condensate trap for vent pipe must be a minimum

of 6 inches in height.

B) Condensate trap for vent and inlet pipe must be

connected into a condensate drain pump; an open

or vented drain; or it can be connected to the outlet

hose of the furnace's condensate trap. Outdoor

draining of the furnace and coil condensate is per-

missible if allowed by local codes. Caution should

be taken to prevent drains from freezing or causing

slippery conditions that could lead to personal in-

jury. Excessive draining of condensate may cause

saturated ground conditions that may result in

damage to plants.

C) The condensate trap should be primed at initial

start up prior to heating season operation.

VENTING THROUGH THE ROOF

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

electrical conduit flashing may be used for a weather

tight seal. Lubricate flexible seal on flashing before PVC

pipe is pushed through the seal. (Field Supplied)

NOTE:

No vent cap as shown in Figure 35 is the preferred

method for vertical vent termination in extremely cold

climates.

In extreme climate conditions, insulate the exposed

pipe above the roof line with Armaflex type insulation.

VENTING ROUTED THROUGH A MASONRY CHIMNEY

VENT FITTING MATERIAL - STAINLESS STEEL

Gas and liquid tight single wall metal vent fitting, de-

signed for resistance to corrosive flue condensate such

as Type 29-4C MUST be used throughout.

These fittings and fitting accessories are to be supplied

locally.

Installer's Guide

DIRECTION OF STAINLESS STEEL FITTING

All stainless steel fitting must be installed with male

end towards the furnace.

All horizontal stainless steel sections must be posi-

tioned with the seam on top.

All long horizontal sections must be supported to pre-

vent sagging.

24" MAX.

VENT_N_ _ 9"r_,..

__N _12 -INCH CL_a'4ANCE MuST BE

12' ± l' MAINIAIRED ABOVE HIGHEST

ANnCIPATED SNOW LEVEL

24 INCHES ABOVE I_OOF,

DISTANCE FROM TOP

OF VENT TO BO]TOM

OF AIR INLET MUST

BE 12" ± l" ,J

COMBUSTION

®VENT

MAINTAIN 12 IN.

18 IN. FOR CANADA)

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN, ABOVE ROOF.

BAYAIR30AVENTA

®REMOVE RIBS

FROM CAP

COMBUSTION

AIR

ROOFBOOT ))

VENT

MAINTAIN 12 IN,

(18 IN. FOR CANADA)

MINIMUM CLEARANCE

IABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF

(FIELD SUPPLIED)

ELBOW

(FIELD SUPPLIED)

COMBUSTION

18-CD19D6-31 23

Installer's Guide

®SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL,

WITH HI TEMP RTV SILICONE SEALANT

SUPPORT

FLANGE _='-_,,.,=

FLOOR _

CLEARANCE

,_RESTOP)

| ...........

FLUE PIPE

(0" ACCEPTABLE FOR PVC VENT PIPE )

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

VENTING THROUGH FLOOR

(_ TYPE 29-4C STAINLESS STEEL VENTING -

USED THROUGH CHIMNEY THAT VENTS

ANOTHER GAS APPLIANCE

STAINLESSSTEEL

VENTCAP

(OPTIONAL)

SEE CAUTION 6 IN. MIN.

SUPPORT THE SINGLE WAL

STAINLESS STEEL GAS

VENTING AND CENTER IT IP

THE CHIMNEY OPENING WI'

ANGLES AS SHOWN OR

ANOTHER EQUIVALENT

MANNER.

NOTE:

HORIZONTAL VENTING

TO VERTICAL VENTING

Do NOT run vent through chimney for wood burn-

ing or oil furnaces or incinerators.

If remaining free area between single wall flue pipe

and masonry chimney is to be used for another gas

appliance venting area must be sufficient to vent

that appliance and that appliance must be con-

nected to chimney with separate entry openings.

IMPORTANT -

The single wall flue pipe joints must be sealed.

The 90 ° elbow connection to vertical pipe must be

sealed to prevent condensate leakage to base of ma-

sonry chimney.

SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT [J

FLANGE • "

SUPPORT __

v/I n CEILING

GALVANIZED FIRESTOP SHOULD /_, )

BE FABRICATED WITH 3-718" DIA. /

HOLE FOR SUPPORTFLANGE .... /

(12 x12 PANEL OR12" DIA MIN.) /

CLEARANCE (0" ACCEPTABLE FOR PVC VENT PIPE)

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

VENTING THROUGH CEILING

PVC PLASTIC VENTING - ONLY

THROUGH UNUSED CHIMNEY

STAINLESS STEEL

VENTCAP

(OPTIONAL)_

SEE CAUTION 6 IN. MIN.

FLUE PIPE

3UPLING TO SUPPORT

PE FROM ANGLES

ROTHER SUITABLE

JPPORT METHOD

SUPPORT THE SINGLE

WALL FLUE PIPE AND

CENTER IT IN THE

CHIMNEY OPENING WI

ANGLES AS SHOWN O

ANOTHER EQUlVALEN

MANNER.

COUPLING

AS REQUIRED

FLUE PIPE

NOTE:

HORIZONTAL VENTING

TO VERTICAL VENTING

Do NOT run vent through chimney for wood burning or

oil furnaces or incinerators or any other gas appliance.

IMPORTANT-

The single wall flue pipe joints must be sealed.

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

prevent condensate leakage to base of masonry chimney.

24 18-CD19D6-31

Installer's Guide

IMPORTANT:

The Commonwealth of Massachusetts requires compliance

with regulation 248 CMR 4.00 and 5.00 for installation of

through - the - wall vented gas appliances as follows:

For all side wall horizontally vented gas fueled equipment

installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those

owned or operated by the Commonwealth and where the

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

feet above finished grade in the area of the venting,

including but not limited to decks and porches, the

following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE

DETECTORS. At the time of installation of the side wall

horizontal vented gas fueled equipment, the installing

plumber or gasfitter shall observe that a hard wired

carbon monoxide detector with an alarm and battery back-

up is installed on the floor level where the gas equipment

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

gasfitter shall observe that a battery operated or hard

wired carbon monoxide detector with an alarm is installed

on each additional level of the dwelling, building or

structure served by the side wall horizontal vented gas

fueled equipment. It shall be the responsibility of the

property owner to secure the services of qualified licensed

professionals for the installation of hard wired carbon

monoxide detectors

a. In the event that the side wall horizontally vented

gas fueled equipment is installed in a crawl space or an

attic, the hard wired carbon monoxide detector with alarm

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

floor level.

b. In the event that the requirements of this

subdivision can not be met at the time of completion of

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

days to comply with the above requirements; provided,

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

operated carbon monoxide detector with an alarm shall be

installed.

2. APPROVED CARBON MONOXIDE

DETECTORS. Each carbon monoxide detector as required

in accordance with the above provisions shall comply with

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

3. SIGNAGE. A metal or plastic identification plate

shall be permanently mounted to the exterior of the

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

directly in line with the exhaust vent terminal for the

horizontally vented gas fueled heating appliance or

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

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

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of

the side wall horizontally vented gas fueled equipment

shall not approve the installation unless, upon inspection,

the inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of 248

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

This appliance requires a special venting system. If

BAYAIR30AVENTA or BAYVENT200B are used, a copy of

the installation instructions for the kit shall remain with

the appliance or equipment at the completion of

installation. The venting system installation instructions

can be obtained from the manufacturer by writing to the

following address:

American Standard, Inc.

6200 Troup Highway

Tyler, TX 75707

Attention: Manager of Field Operations Excellence

18-CD19D6-31 25

Installer's Guide

HORIZONTAL INSTALLATION

(Upflow/Horizontal or Downflow/Horizontal)

NOTE:

In horizontal venting when the factory supplied "off-

set" (2X3 reducing coupling) is used for 3" vent pipe

installation, make sure the marking "Top" is located on

the top side of the pipe. The straight side must be on

bottom for proper condensate drainage. This coupling

is factory supplied only with the following models:

*UC120 & *DC120, *UX120 &*UY120 *UXIO0 &*UYIO0,

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

....

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

REDUCING COUPLING) IS USED FOR 3" VENT PIPE

INSTALLATION, MAKE SURE THE MARKING "TOP" IS

LOCATED ON THE TOP SIDE OF THE PIPE.

LABEL

SAYS

"TOP"

STRAIGHT SIDE MUST BE

ON BOTTOM FOR PROPER

CONDENSATE DRAINAGE.

CONDENSATE DRAIN INSTRUCTIONS

IT IS RECOMMENDEDTHAT A DRAIN PAN BE INSTALLED

UNDERTHE FURNACETO PREVENT PROPERTY DAMAGE,

PERSONAL INJURY OR DEATH FROM LEAKING CONDEN-

SATE.

UPFLOW (VERTICAL)

Right side

2"TO 3" COUPLING

FACTORY SUPPLIED ONLY WITH

THE FOLLOWING MODELS:

UC120 & DC120

UX120 & UY120

UXl00 & UY100

UX080C960

ALL DX & DY MODLES

VENT

OUTLET

All pipe joints must be fastened and sealed to prevent

escape of combustion products into the building.

NOTE:

Both venting methods shown in Figure 39 & 41 must

also have the combustion air inlet installed -meeting

dimension requirements of Figure 35.

Use Inducer Drain

hose without

extension

UPFLOW HORIZONTAL 17" UNITS

(Left side only)

VERTICAL APPLICATIONS

Upflow furnace -The connection tubing for left and

right side drainage is shipped in the blower compart-

ment. Install the connection tubing from the trap to the

side of the unit and trim all excess tubing to avoid

kinks.

26 18-CD19D6-31

Downflow furnace -The furnace is shipped with the

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

remove the drain lines from the trap, rotate the trap

180 ° so it exits to the right, reconnect the lines, and run

a 1/2" CPVC pipe from the trap out through the right

side knock-out. Use RTV silicone sealant to connect the

CPVC pipe to the trap for ease of removing to clean the

trap.

Left side

UPFLOW (VERTICAL)

extension

hose here

UPFLOW HORIZONTAL 21" & 24" UNITS

(Left side only)

HORIZONTAL APPLICATIONS

Upflow and Downflow furnaces -All horizontal ap-

plications are left side only. It is always recommended

that the auxiliary drain pan be installed under a hori-

zontally installed evaporator and/or 90% gas furnace.

Connect the auxiliary drain pan to a separate drain line

(no trap is needed in this line).

The trap must be repositioned to the exterior of the

cabinet. Remove the trap from its present location and

reposition the trap outside of the unit, through the long

circular hole, next to the secondary recuperated cell.

Remove the larger drain line (from the secondary cell)

and trim to fit between the secondary cell and the new

trap location. On upflow units, plug the hole in the

blower deck where the tube went through.

Remove the hose from the induced blower and reposi-

tion into the other drain tap of the inducer, which is lo-

Installer's Guide

Left

side

DOWNFLOW (VERTICAL)

side

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

DOWNFLOW (VERTICAL)

Cut off curved end of

Inducer drain hose

DOWNFLOW (HORIZONTAL)

cated 90° clockwise around the inducer. Move the cap

from that drain tap to the unused drain tap. On upflow

units, plug the hole in the blower deck where the tube

went through. This tube on downflow units will need to

be cut to fit between the inducer and the trap. On

upflow units, this tube may need to be extended, using

the tubing shipped with the furnace.

18-CD19D6-31 27

Installer's Guide

Connections must be made to an OPEN/ VENTED

DRAIN. Outdoor draining of the furnace and coil con-

densate is permissible if allowed by local codes. Caution

should be taken to prevent drains from freezing or caus-

ing slippery conditions that could lead to personal in-

jury. Excessive draining of condensate may cause satu-

rated ground conditions that may result in damage to

plants.

NOTE:

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

quired for drain connections (fittings, pipe and solvent

cement not provided).

NOTE:

A corrosion resistant condensate pump must be used

if a pump is required for a specific drain system.

IMPORTANT:

The condensate drain should be installed with provisions to

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

zen condensate will block drains, resulting in furnace shut-

down. If the drain line cannot be installed in a conditioned

space, then UL listed heat tape should be applied as re-

quired to prevent freezing (per manufacturer's instructions).

The heat tape should be rated at 5 or 6 watts per foot at

120volts. Self-regulating (preferred) or thermostatically

controlled heat tape is required.

Evaporator and furnace condensate drain piping may

be manifolded together as shown in Figure 45. A pri-

mary drain vent stack must be installed and termi-

nated below the outlet of the secondary heat exchanger

drain connection to prevent water from damaging fur-

nace controls if the primary drain outlet plugs up.

Where the furnace is installed above a finished ceiling,

the primary drain vent stack must be installed such

that overflow from the vent stack opening will flow into

an axillary drain pan in order to prevent water damage

to the finished ceiling below.

if upflow furnace is installed

over a finished ceiling, overflow [

from the primary drain vent

stack must flow into an auxiliary

drain pan to prevent damage to ::

the finished ceiling below.

P?_o:tdr=oir._........ ,_

mM_LI I II II IdL_

secondary heat exchanger i

condensate drain outlet, i

T"STAT

-- SEE

NOTE 7

[]

SEE

] NOTE 6

INTER (MP NENT WIR]N

P M. ]_ FIEL }

----[l E v'. WI_I 0

24 W. "_,. FA( TORY

--LI E ',,._)/ "/VI_RIN S

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

FURNACE [_()TE:_::

[]

I BE SURE POWERAGREES WITH EOUIPMENT NAMPLATE(S}

2 LOW VOLTAGE (24V WIRING) TO BE NO 18 AW6 MIN

3 GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES

4 SET THERMOSTATHEAT ANTICIPATOR PER UNIT WIRING DIAGRAM

S THESE LEADS PROVIDE 115 V POWERFOR CONNECTIONOF ELECTRONIC AIR

{LEANER AND HUMIDIFIER MAX LOAD I0 AMPS EACH

6 THIS CONNECTION IS ONLY USED FOR THERMOSTATSREOUIRING

CONNECTION TO THE 24 V POWER SUPPLY (COMMON)

iSEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS

WHEN USIN(_ THIS FEATURE

From drawing B341437 Rv 1

28 18-CD19D6-31

Installer's Guide

OUTDOORUNIT

(NO TRANSFORMER)

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'STAT

SEE

NOTE 6

SEE

NOTE 8

FURNACE

t-q

{N•ER 7 7MPONEN• ",,/'i]R]NG

m i

2 d ',.J". ,.. F I E L D

----LINE Yv'IRIN@

2d '/. 'k F£CTORY

--LINE ....vg"IR IN O

NOTES:

h BE SURE POWER AGREES WITH EQUIPMENT NAMEPLATE{S}

2. LOW VOLTAGE{24 V. WIRING} TO BE NO. 18 A.W.G. MIN.

3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.

4. SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

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

CLEANER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.

6. THE "Y" TERMINAL FROM THE THERMOSTAT MUST BE WIRED TO THE

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

DURING COOL]NO.

7. IGNITION CONTROL 1S POLARITY SENSITIVE. HOT LEG OF 120 VOLT POWER

SUPPLY MUST BE CONNECTED TO THE BLACK LINE POWER LEAD AS INDICATED

ON THE WIRING DIAGRAM OR IGNITION LOCKOUT WILL OCCUR.

8. THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING

CONNECTION TO THE 24 V POWER SUPPLY (COMMON)

,ill

TO 115V 1 PH., F LH

60 HZ., POWER l

SUPPLY PER

LOCAL CODES L N

GROUND

2 SCREW

JUNCTION

BOX

HUM SEE

NOTE5

_j WH

EAC SEE

NOTE 5 BK

From drawing B340388 Rv 2

ELECTRICAL CONNECTIONS

Make wiring connections to the unit as indicated on en-

closed wiring diagram. As with all gas appliances using

electrical power, this furnace shall be connected into a

permanently live electric circuit. It is recommended

that furnace be provided with a separate "circuit protec-

tion device" in the electric circuit. The furnace must be

electrically grounded in accordance with local codes or

in the absence of local codes with the National Electri-

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

if an external electrical source is utilized.

The integrated furnace control is polarity sensi-

tive. The hot leg of the 120V power supply must be con-

nected to the black power lead as indicated on the wir-

ing diagram. Provision for hooking up an electronic air

cleaner and or humidifier is provided on the integrated

control.

Refer to the SERVICE FACTS literature and unit wiring

diagram attached to furnace diagram attached to fur-

nace.

18-CD19D6-31 29

iiiiiiiiiiii

1 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

qr< ISOLATIONRELAY

(FIELDSUPPLED)

SEENOTE4

____.

FURNACE NO, 2

BLOWER OPERATION OF

UNIT NO 2 IS SYNCRON]ZED

WITHUNITNO 1VIA SIGNALS

FROMTWINCONNECTION

SEE NOTE 4

Rll- i

/IOT_$

BOTH FU#)MC_S MOST BE POF/b9[ 'fRO),

THE SA74£ 5V LEG OK /ROUT PA#EL

IHSUR# 2#Y #Ui!#ACL TRANSFORMERS ARE

IN PHASk P_IOR TO COMPLklI#C COHNECTiO#$,

CHEC_ FOLTAGF _FFW_N R¸T_£_/#Ai$ OF

EACH FuRnACE iF VOLTAS_ /$ GR_AT_£ IH4#

/OY, REVERSE _H_¸ Bi A# RD $_CO£DARY itADS

0£ O#E OF THL FU£NACE 7RA£SFO£HER$

3C<_'H CTiOtl _,!A}' _ R gUHE_) FO!

tCTiOt_C T# Rt/,OSTAT

iF C_)_RFHT [XCE_DS _H_R#OSTA7 CURR£NT

RMiNd, US_ ISOLATIOH RELAYS ('R{') AS

SHOW#¸ (DO NOT CONNECT W _0 #)

ISOLAT/O_ RELAY _0/ #EED_D fF THE THFRMOST_

CO#TACT$ 4RE R_T£_ AT iOA OR ABOYE

iSOLATiON RELAY

SEE NOTE 4

INTE i CO['d:)ONENT Y',/]F_INO

CLTER_'ATE /IiRM'_ CONF f_URAT O_'

24 '/. "k FIELD

----kI\E 7.jSYv'IRING

24 v". i F#CTO:_Y

-- LI_E /.S ?-',/',iI _ING

From Dwg. 21B341422 Rev. 3

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

, 3g'

I_o_o i

s_ NOT_

OUTDOORTRANSFORMER}UNIT I_

(NO

% ........%

FURNACE NO. 2

BLOWER OPERATION O_

UNIT NO 2 IS SYNORONIZED

SEE NOTE 4

nf,--i

_SOLATION RELAy

it_SURE 24i' £URA4CE T_/)_SFOR!_ERS_RE

E4C_¸ FURt_4CE _F VOLT4_E_S GRE_TE_ THe,',,¸

_OY , i_V[R$_ THEfiL A_ RO S[20_b_i_ _4_$

OUTDOO£U#tT H_S ,4 24' T,Afl FO!t_ _i

A_,,¸_OL_T_Ot_ ,_L4_ MUST_ i_,_ST_LL_D

INTER COMPONENT WIRING

24 ',/. _ FIEL "

11 L ]NE / /"

24 V. t, FACTOi<Y

--LINE /_-Yv']RING

.j,

From Dwg21B341423 Rev, 2

TWINNING FURNACES

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 duets with equivalent

lengths and sizes. See Eield Wiring Diagrams for proper

hookup.

Installer's Guide

GAS PIPING

The upflow/horizontal furnace is shipped standard for

left side installation of gas piping. A knock-out is pro-

vided on the right side for an alternate gas piping ar-

rangement. See Figure 46.

The installation of piping shall be in accordance with

piping codes and the regcdations of the local gas com-

pany. Pipe joint compound must be resistant to the

chemical reaction with liquefied petroleum gases.

Refer to piping Table 10, for delivery sizes. Connect gas

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

manual shut-off valve as shown in Figures 46-48.

National codes require a condensation drip leg to be in-

stalled ahead of the controls as shown in Figc_res 46-48.

The furnace and its individual shut-off valve must be

disconnected from the gas supply piping system during

any pressure testing of that system at test pressures in

excess of 1/2 psig (3.5 kPa).

The furnace must be isolated from the gas supply piping

by dosing its individual manual shut-off valve during

any pressure testing of the gas supply piping system at

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

NOTE:

Maximum pressure to the gas valve for natural gas is

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

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

Minimum pressure is 11.0" W.C.

All gas fittings must be checked for leaks using a

soapy solution before lighting the furnace. DO NOT

CHECK WITH AN OPEN FLAME!

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF AUTOMATICGASVALVE

WITHMANUALSHUTOFF MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

UPFLOW- LEFT HAND GAS PIPING UPFLOW- RIGHT HAND GAS PIPING

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

18-CD19D6-31 31

Installer's Guide

@AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

MAINMANUAL

SHUTOFFVALVE /GROUND UNION JOINT

DRIP

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE (UPFLOW SHOWN)

Use a backup wrench on the gas valve when installing

gas piping to prevent damage to the gas valve and

manifold assembly.

TABLE 10

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE LENGTH OF PIPE

SIZE 10 20 30 40 50 60 70

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

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

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

TABLE 11

ORIFICE SIZES

MAIN BURNERORIFICE

DRILLSIZE

INPUT

RATING

BTUH

40,000

60,000

80,000

100,000

120,000

NUMBER

BURNERS

NAT. GAS

LP GAS

COMBUSTION AND INPUT CHECK

1. Make sure all gas appliances are off except the fur-

nace.

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

termine the dial rating of the meter) for one revolu-

tion.

3. Match the "Sec" column in the gas flow (in cfh)

Table 13 with the time clocked.

4. Read the "Flow" column opposite the number of sec-

onds clocked.

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

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.

Changes can be made by adjusting the manifold

pressure 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 51 for White-Rodgers gas

valve model 36F and Figure 52 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

pressure 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 ma-

nometer directly onto the outlet pressure boss.

c. Turn on system power and energize valve.

&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 counterclockwise to de-

crease the gas flow rate using a 3/32" hex wench.

32 18-CD19D6-31

f. The final manifold pressure setting shall be as

specified in Table 12 with an input of no more

than nameplate rating and no less than 93% of

the nameplate rating, unless the unit is derated

for high altitude.

g. Replace the regulator adjustment screw cap and

tighten securely.

h. Turn off all electrical power to the system.

i. Remove the manometer and flexible tubing. Re-

move the barbed fitting and replace the plug or

tighten the pressure test screw.

j. Turn on electrical power to the system and ener-

gize valve.

k. Using a leak detection solution or soap suds,

check for leaks at plug or pressure boss screw.

Installer's Guide

Replace manifold pressure tap threaded plug and leak

check after checking/adjusting manifold gas pressure.

Table 11 lists the main burner orifices used with the fur-

nace. If a change of orifices is required to correct the

furnace input rating refer to Table 14.

TABLE 12

FINAL MANIFOLD PRESSURE SETTINGS

FUEL PRESSURE

NATURAL GAS 3.5" W.C.

LP GAS 11.0" W.C.

CORRECT METHOD OF CHECKING DIRECT VENT MANIFOLD

PRESSURE WITH BURNER BOX REFERENCED

//_

Separate the tube

at the unit Tee and

reconnect with a

short piece of field

supplied tube and

another Tee with

the "U" Manometer

attached.

Be sure to reconnect

unit tubing to original

position after testing

the manifold pressu re!

Field supplied ba¢o fitting

wiSq manometer tube is

attached to the "OUTLET

PRESSURE TAP" on the

outlet side of the gas valve.

iiiiliiiiii;iiiiiiliiliiliiliiliiliiliiliiliiliilli!ii¸

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, ex-

plosion, or property damage.

NOTE:

The manifold pressure must be referenced to the

burner box. The burner box pressure tap equalizes the

gas valve pressure regulator. Manifold pressure is

checked by installing a tee (field supplied) in the tub-

ing, between the tee coming from the burner box tube

and the gas valve, in addition to the regular gas valve

pressure tap on the outlet side of the gas valve. See

Figure 49.

18-CD19D6-31 33

Installer's Guide

HIGH ALTITUDE DERATE

Input ratings (BTUH) of these furnaces are based on

sea level operation and should not be changed at eleva-

tions 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 sup-

plier for the gas being delivered at the installed altitude.

Input rate changes can be made by adjusting the mani-

fold 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 can not be achieved

with a change in manifold pressure, then the orifices

must be changed. LP installations will require an orifice

change.

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.

IMPORTANT:

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

orifices supplied with the equipment.

__ ROTATETHE FRONT

_COVERAS SHOWN

Ib It INSERTTHETOP

{-_// IJ FLANGEOF THE FRONT

[ J] COVER UNDERTHE LIP

_/Jj INSIDETHEBOX

MAKINGSURE THAT

ALLSIDE FLANGES

- ARE OUTSIDEOF THE

_BOX.

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

34 18-CD19D6-31

Installer's Guide

See Table 15 for help in selecting orifices if orifice

change is required. Furnace input rate and tempera-

ture rise should be checked again after changing ori-

rices 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 14

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

PART

NUMBER

ORFO0501

0RF00644

ORFO0909

ORFO0910

0RF01099

ORFO0503

0RF00493

DRILL

SIZE

PART

NUMBER

0RF00555

0RF00693

ORFO0907

ORFO0908

ORF01338

ORF01339

REINSTALLATION OF THE BURNER BOX COVER

Figure 50 shows the correct way to reinstall the burner

box cover if adjustment or replacement of the flame

sensor, hot surface igniter, or main burner orifices have

required removal of the cover.

TABLE 15

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

DO NOT CHECK WITH AN OPEN FLAME. Allow 5

minutes for any gas that might have escaped to dissi-

pate. LP Gas being heavier than air may require forced

ventilation. Flip the switch on the gas valve in the unit

to the "ON" position.

(_ Outlet Pressure Boss Regulator

Adjustment

Inlet Pressure

Boss (opt.) On/Off Switch

White-Rodgers 36G gas valve

@On/Off Switch

White-Rodgers 36F gas valve

LIGHTING INSTRUCTIONS

CARBON MONOXIDE POISONING HAZARD

Failure to follow the installation instructions for the

venting system being placed into operation could re-

sult in carbon monoxide poisoning or death.

START UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

With gas and electrical power "OFF"

I. Duct connections are properly sealed

2. Filters are in place

3. Venting is properly assembled

4. Blower door is in place

Flip the switch 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 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 instal-

lation 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 thermo-

stat above the indicated temperature. The ignitor will

automatically 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.

18-CD19D6-31 35

Installer's Guide

To shut off.

For complete shut-down: Flip the switch on the main

gas valve to the "OFF" position, (See Figure 51 & 52).

Disconnect the electrical supply to the unit.

If this is done during the cold weather months, provi-

sions 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 tem-

perature. This is very important during freezing

weather. If for any reason your furnace should

fail to operate damage could result, such as fro-

zen water pipes.

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 approxi-

mately 20 seconds, then the gas valve is energized to

permit gas flow to the burners. The flame sensor con-

firms that ignition has been achieved.

After the flame sensor confirms within a 4 second trial

period that ignition has been achieved, the delay to fan

ON period begins timing. After approximately 45 sec-

onds the indoor blower motor will be energized and con-

tinue 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-en-

ergized. The indoor blower motor will continue to run

for the fan off period (Field selectable at 60, 100, 140 or

180 seconds), then be de-energized by the control mod-

ule.

CONTROL AND SAFETY SWITCH ADJUSTMENTS

LIMIT SWITCH CHECK OUT

The limit switch is a safety device designed to close the

gas valve should the furnace become overheated. Since

proper operation of this switch is important to the

safety of the unit, it must be checked out on initial

start up by the installer.

To check for proper operation of the limit switches, set

the thermostat to a temperature higher than the indi-

cated temperature to bring on the gas valve. Restrict

the airflow by blocking the return air (disconnecting the

indoor blower may trip the inducer limit). When the

furnace reaches the maximum outlet temperature as

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

they do not shut off after a reasonable time and over-

heating 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 pa-

per or cardboard from the return air inlet. Refer to Ser-

vice Facts for additional instructions.

NOTE TO INSTALLER

Review the following warnings with the owner. Review

contents of USER'S INFORMATION MANUAL with the

owner.

AIRFLOW ADJUSTMENT

Check inlet and outlet air temperatures to make sure

they are within the ranges specified on the furnace rat-

ing nameplate. 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 shut-

down when the door is removed. Operation with the

door removed or ajar can permit the escape of danger-

ous fumes. All panels must be securely closed at all

times for safe operation of the furnace.

INDOOR BLOWER TIMING

Heating: The integrated furnace control module con-

trols the indoor blower. The blower start is fixed at 45

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

lectable by dip switches at 60, 100, 140, or 180 seconds.

The factory setting is 100 seconds (See wiring diagram).

Cooling: The fan delay off period is factory set at 0 sec-

onds. The option for 80 second delay off is field select-

able (See wiring diagram).

ROOM AIR THERMOSTAT

HEAT ANTICIPATOR ADJUSTMENT

Set the thermostat heat anticipator according to the

current flow measured, or the settings found in the

notes on the furnace wiring diagram (found in the SER-

VICE FACTS or inside the furnace easing).

INSTRUCTIONS TO THE OWNERS

In the event that electrical, fuel, or mechanical

failures occur, the owner should immediately

turn the gas supply off at the manual gas valve,

located in the burner compartment. Also turn off

electrical power to the furnace and contact the

service agency designated by your dealer.

36 18-CD19D6-31

Installer's Guide

BURNER BOX TEMPERATURE LIMIT DEVICE

All models are equipped with a manual reset tempera-

ture limit located on the burner box. In case of exces-

sive temperature, the limit will open and cause the cir-

cuit to open which shuts off all flow of gas.

ABNORMAL CONDITIONS

I. EXCESSIVE COMBUSTION PRESSURE (WIND IN

EXCESS OF 40 MP.H.) VENT OR FLUE BLOCK-

AGE

If pressure against induced draft blower outlet be-

comes 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 auto-

matically 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.

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. CONDENSATE DRAIN BLOCKAGE

If the condensate drain is blocked, either by debris,

improper draining, or by freezing condensate, the

pressure switch will sense the accumulation of con-

densate in the furnace drain pan. The pressure

switch contacts will open and remain open, not al-

lowing unit operation. The unit will not operate un-

til the condensate drain has been cleared, and the

condensate flows freely.

7. RESETAFTER LOCKOUT

When the integrated control module has shut the

system down and gone into lockout, the system

must be manually 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 ther-

mostat. The system will not reset unless the proce-

dure off-on-off-on is completed within 30 seconds.

8. RESET AFTER BURNER BOX LIMIT SHUT-

DOWN

If the furnace shuts down, one thing that can be

checked is the burner box temperature limit switch.

It is located on the bottom of the burner box. The

vent and combustion air inlet terminations should

be checked for blockage. If blockage exists, clear

the problem and then the reset button may be de-

pressed. If there is no blockage of the termina-

tions, the limit switch must be reset by a

qualified servicer.

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 Commis-

sion recommends that users of gas-burning appliances

install carbon monoxide detectors as well as fire and

smoke detectors per the manufacturers installation in-

structions to help alert dwelling occupants of the pres-

ence of fire, smoke or unsafe levels of carbon monoxide.

These devises should be listed by Underwriters Labora-

tories, Inc. Standards for Single and Multiple Station

Carbon Monoxide Alarms, UL 2034 or CSA Interna-

tional Standard, Residential Carbon Monoxide Alarming

Devices, CSA 6.19

NOTE:

The manufacturer of your furnace does not test any de-

tectors and makes no representations regarding any

brand or type of detector.

18-CD19D6-31 37

Installer's Guide

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

AWA RNING: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 !ong-

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 .... '..... :_" soapareas u_"uy w,u,

and warm water after handling.

38 18-CD19D6-31

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]

18-CD19D6-31 39

Trane

6200 Troup Highway

Tyler, TX 75707 03/08

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

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

TRANE Furnace/Heater, Gas Manual L0903224

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