TRANE Furnace/Heater, Gas Manual L0905285

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

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1 8- CD2 1 D1 - 4

High Efficiency Single Stage Upflow/Horizontal

and Downflow/Horizontal Gas-Fired Furnaces,

"Fan Assisted Combustion System"

*UDIA040A9H21 B

*UDIB060A9H31 B

*UDIB080A9H31 B

*UDIC080A9H41 B

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

*UD1 B100A9H31 B

*UDIC100A9H51 B

*UD1 D120A9H51 B

*UD1D140A9H51B

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

*DD1 B060A9H31B

*DD1 B080A9H31B

*DD1 C100A9H51B

*DD1 D120A9H51B

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

Please return to service information pack upon completion of work.

For VENT SIZING INFORMATION see:

USA --

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

CANADA --

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

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

USA/CANADA ALTERNATE --

Category I Venting Guide .................................. Pub. No. 18-CH23D1-2

C _

Upflow/Horizontal* Downflow/Horizontal*

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

A341789P07

Installer's Guide

SAFETY SECTION

The following safety practices and precautions must be

followed during the installation, servicing, and opera-

tion 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 (pages 13-

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" (page 618), 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 accom-

panying 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 manufacturer's instructions.

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

stat (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 requirement

must come from outside the structure.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each

appliance connected to the venting system being

placed into operation could result in carbon monoxide

poisoning or death.

The following steps shall be followed for each appliance

connected to the venting system being placed into

operation, while all other appliances connected to the

venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal

pitch, as required in the National Fuel Gas Code,

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.

Close fireplace dampers.

Turn on clothes dryers and any appliance not connected

to the venting system. Turn on any exhaust fans, such

as range hoods and bathroom exhausts, so they are

operating at maximum speed. Do not operate a summer

exhaust fan.

Follow the lighting instructions. Place the appliance be-

ing inspected into operation. Adjust the thermostat so

appliance is operating continuously.

If improper venting is observed during any of the above

tests, the venting system must be corrected in

accordance with the National Fuel Gas Code,

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

Installation Codes.

8. After it has been determined that each appliance

connected to the venting system properly vents where

tested as outlined above, return doors, windows, exhaust

fans, fireplace dampers and any other gas-fired burning

appliance to their previous conditions of use.

10.

£The furnace return air temperature range is be-

tween 55 and 80 degrees Fahrenheit.

g. Clean the furnace, duct work, and components

upon substantial completion of the construction

process, and verify furnace operating conditions

including ignition, input rate, temperature rise

and venting, according to the manufacturer's in-

structions.

This product must be gas piped by a Licensed

Massachusetts.Plumberor Gas Fitter in the Commonwealth of

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.

Installer's Guide

Contents

Installation Instructions

General Installation Instructions

Location and Clearances

Outline Drawing

Upflow Installation

Downflow Installation

Air For Combustion and Ventilation

Duct Connections

Return Air Filters

Typical Upflow ReturnAir Filter Installations

Alternate Upflow FilterClip /Bracket Installation

Typical Downflow Furnace ReturnAir Filter Installations

General Venting Instructions

Venting Into a Masonry Chimney

Electrical Connections

Field Wiring Diagrams

Gas Piping

Sequence of Operation

Start Up and Adjustment

Preliminary Inspections

Combustion and Input Check

High Altitude Derate

Lighting Instructions

Control and Safety Switch Adjustment

IFC Error Flash Codes

Abnormal Conditions

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.

These furnaces are not approved or intended for instal-

lation in manufactured (mobile) housing, trailers, or

recreational vehicles.

Failure to follow this warning could result in property

damage, personal injury, or death.

Do NOT install the furnace in a corrosive or contami-

nated atmosphere.

18-CD21 D1-4 3

Installer's Guide

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 must be

reduced (See GAS INPUT ADJUSTMENT).

Material in this shipment has been inspected at

the factory and released to the transportation

agency without known damage. Inspect exterior

of carton for evidence of rough handling in 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 Fan Assisted

Combustion system CATEGORY I furnaces as required

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

Therefore they do not require any special provisions for

venting other than what is indicated in these instruc-

tions. (Category I defined on page 14).

These furnaces may be twinned. They shall have

common returns with equal pressure drops or

ducts with equivalent lengths and sizes. See Field

Wiring Diagrams for Twinning on page 17 for

proper hookup.

LOCATION AND CLEARANCES

The location of the furnace is normally selected by the

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

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

following requirements:

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

and as centralized for heat distribution as practical?

2. Do all clearances between the furnace and enclo-

sure equal or exceed the minimums stated in Clear-

ance Table on the Outline Drawings.

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 combustion air openings in the front panel

and any dosed panel or door provided?

5. Are the ventilation and combustion air openings

large enough and will they remain unobstructed? If

outside air is used, are the openings set above the

highest snow accumulation level? (See the Air for

Combustion and Ventilation section.)

6. Allow sufficient height in supply plenum above the

furnace to provide for cooling coil installation, if the

cooling coil is not installed at the time of this furnace

installation.

7. A furnace shall be installed so electrical components

are protected from water.

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

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

nition source are located not less than 18 inches

above the floor and the furnace must be located or

protected to avoid physical damage from vehicles.

4 18-CD21 D1-4

Installer's Guide

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UPFLOW INSTALLATION

Standoffs and screws (See Figure 1 on page 6) are in-

cluded with the cased coils for attachment to the fur-

nace. There are clearance alignment holes near the bot-

tom of the coil wrapper and drill screws are used to en-

gage the furnace top flange. The standoff is inserted

into the cabinet alignment hole. The drill screws are in-

serted through the standoffs then screwed into the fur-

nace flange. The coil is always placed downstream of

the furnace airflow. These instructions apply only if the

coil is on top of an upflow furnace.

(_ STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

INSTALLATIONS:

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATION

Do NOT install the furnace directly on carpeting, tile or

other combustible material other than wood flooring.

For vertical downflow application, subbase

(BAYBASE205) must be used between the furnace and

combustible flooring. When the downflow furnace is

installed vertically with a cased coil, a subbase is not

@CABINET SIDE .][.K./ CABINET SIDE

(BENT UP) (BENT UP)

Installer's Guide

required.

REQUIRED FLOOR OPENING:

SEE FIGURE 3 AND TABLE 1

TABLE1

CABINET RETURN FLOOR OPENING PLENUM OPENING

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

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

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

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

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

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used

in the horizontal position.

Three brackets (with screws) are included with downflow

furnaces for installation to stabilize and secure the fur-

nace and TXC cased coil in the horizontal position.

See Figure 4.

IMPORTANT:

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

furnace. In horizontal installations, the apex of the coil

may point either toward or away from the furnace. See

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

©CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

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

nace 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 cen-

ter 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.

This furnace may be installed in an attic or crawl space

in the horizontal position by placing the furnace on the

left or right side (as viewed from the front in the up-

right position). The horizontal furnace installation in an

attic should be on a service platform large enough to al-

low for proper clearances on all sides and service access

to the front of the furnace (See Clearance Table on Out-

line Drawings and Figure 5).

18-CD21 D1-4 7

Installer's Guide

If the furnace is suspended using perforated steel strap

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

ners and in the middle at the front of the furnace.

The forward most screw on the side of the furnace

may be used to connect the strapping (See Figure 6).

Line contact is only permissible between lines formed

by the intersection of the top and two sides of the fur-

nace casing and the building joists, studs, or framing.

TYPICAL ATTIC PLATFORM INSTALLATION

(UPFLOW/HORIZONTAL FURNACE SHOWN)

A cutout is provided on both sides of the downflow fur-

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

the cabinet and the vent piping to connect there. In

horizontal, the downflow furnace may be vented

through the top of the cabinet if needed. In vertical con-

figuration, the downflow furnace may be vented using

the side cabinet cutouts. This venting configuration

could be used if an electronic air cleaner is installed.

When the downflow furnace is vented through

the left side of the furnace cabinet in horizontal

or vertical configuration, Type B vent pipe must

be used within the cabinet.

Typical Suspended Installation

(Upflow/Horizontal Furnace Shown)

UNCONFINED

50 CU. FT. OR MORE

PER 1000 BTU/HR.

INPUT ALL EQUIP-

MENT INSTALLED

0,o(-I

wA,

AIR FOR COMBUSTION AND VENTILATION

Adequate flow of combustion and ventilating air must

not be obstructed from reaching the furnace. Air open-

ings provided in the furnace casing must be kept free of

obstructions which restrict the flow of air. Airflow re-

strictions affect the efficiency and safe operation of the

furnace. Keep this in mind should you choose to re-

model or change the area which contains your furnace.

Furnaces must have a free flow of air for proper perfor-

mance.

Provisions for combustion and ventilation air shall be

made in accordance with "latest edition" of Section 5.3,

Air for Combustion and Ventilation, of the National

Fuel Gas Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4

of CAN/ CGA B149 Installation Codes, and applicable

provisions of the local building codes. Special conditions

created by mechanical exhausting of air and fireplaces

must be considered to avoid unsatisfactory furnace op-

eration.

Furnace locations may be in "confined space" or "uncon-

fined space". Unconfined space is defined in Table 2 and

Figure 7. These spaces may have adequate air by infiltra-

tion to provide air for combustion, ventilation, and dilu-

tion of flue gases. Buildings with tight construction (for

example, weather stripping, heavily insulated, caulked,

vapor barrier, etc.), may need additional air provided as

described for confined space.

(_ CONFINED

LESSTHAN 50 CU. FT.

PER 1000 BTU/HR.

INPUTALL EQUIP-

MENT INSTALLED

IFURNACE

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 9 or from the outdoors, as in Figure 10.

8 18-CD21 D1-4

1. All air from inside the building as in Figure 9: 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 3, for minimum open areas required.

2. All air from outdoors as in Figure 10: 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 3, for minimum open

areas required.

3. 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 commercial laundry rooms

* Furnaces installed in hobby or craft rooms

* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combus-

tion air supply will also require OUTDOOR AIR for

combustion:

* Permanent wave solutions

* Chlorinated waxes and cleaners

* Chlorine based swimming pool chemicals

* Water softening chemicals

* Deicing salts or chemicals

* Carbon Tetrachloride

* Halogen type refrigerants

* Cleaning solvents (such as perchloroethylene)

* Printing inks, paint removers, varnish, etc.

* Hydrochloric acid

* Cements and glues

* Antistatic fabric softeners for clothes dryers

* Masonry acid washing materials

TABLE2

MINIMUM AREA IN SQUARE FEET FOR

UNCONFINED SPACE INSTALLATIONS

FURNACEMAXIMUM

BTUH/INPUT RATING

40,000

60,000

80,000

100,000

120,000

140,000

WITH 8 FOOT CEILING

MINIMUM AREA IN SQUARE FEET

OF UNCONFINED SPACE

250

375

500

625

750

875

Installer's Guide

TABLE 3

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING FURNACE ONLY)

Furnace Air From Outside

Maximum Air From

BTUH/INPUT Inside Vertical Horizontal

Rating

40,000

60,000

80,000

100,000

120,000

140,000

lOO

12o

14o

Duct

CONFINED SPACE

AIR FROM OUTDOORS

SPACE

CONFINED SPACE

AIR FROM VENTILATED ATTIC!CRAWL SPACE

1"-_ OUTLETAIR I

INLET

AIR DUCT

18-CD21 D1-4 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. Check on controls to make certain

they are correct for the electrical supply.

Central furnaces, when used in connection with cooling

units, shall be installed in parallel or on the upstream

side of the cooling units to avoid condensation in the

heating element, unless the furnace has been specifi-

cally approved for downstream installation. With a par-

allel flow arrangement, the dampers or other means

used to control flow of air shall be adequate to prevent

chilled air from entering the furnace, and if manually

operated, must be equipped with means to prevent op-

eration of either unit unless the damper is in full heat

or cool position.

On any job, flexible connections of nonflammable ma-

terial may be used for return air and discharge con-

nections 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, am-

plify the slightest vibration to the annoyance level.

When the furnace is located in a utility room adjacent

to the living area, the system should be carefully de-

signed with returns which minimize noise transmission

through the return air grille. Although these winter air

conditioners are designed with large blowers operating

at moderate speeds, any blower moving a high volume

of air will produce audible noise which could be objec-

tionable 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 per-

mits the installation of air return remote from the liv-

ing 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.

Minimum return air "entering temperature" for

the furnace is 55 ° F.

Where there is no complete return duct system, the re-

turn connection must be run full size from the furnace

to a location outside the utility room, basement, attic,

or crawl space.

DO NOT install return air through the back of the

furnace cabinet.

RETURN AIR DUCT CONNECTION

NOTE:

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

quirement exceeds 1800 CFM, these models will re-

quire return air openings and filters on both sides; OR

1 side and the bottom; OR just the bottom.

All return air duct systems should provide for installa-

tion of return air filters.

1. Set the furnace in place.

2. For side return installations on upflow models, re-

move the insulation around the opening in the

blower compartment.

3. The side panels on upflow furnaces include locating

notches which may be used as guides for cutting an

opening for return air. Refer to Figure 12 and the

outline drawing on page 4 for duct connection di-

mensions for various furnaces.

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

let duet, add to cut where indicated by solid lines

in Figure 12. Cut corners diagonally and bend out-

ward to form flange.

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

stalled, cut along knockout guidelines.

6. Upflow Furnaces: a filter rack is factory supplied

for bottom or side return. Use the filter rack on ei-

ther side or on the bottom if the filter is to be used

within the furnace cabinet.

IDo NOT install the filter in the return duct directly

above the furnace in horizontal applications. Install

the filter remotely. Installing the filter directly above

the furnace in horizontal applications may cause

property damage, serious injury or death.

TO PREVENT INJURY OR DEATH DUE TO CONTACT

WITH MOVING PARTS, TURN THE POWER TO THE

FURNACE OFF BEFORE SERVICING FILTERS.

When the upflow furnace is installed in the horizon-

tal right or left application and a return duct is at-

tached to the top side as shown in Figure 11, re-

move the filter from the furnace and install in a re-

mote location.

Do not install the filter in the return duct directly

above the furnace in horizontal applications.

When the upflow furnace is installed in the horizon-

tal right or left application and a close coupled (less

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

of the furnace as shown in Figure 11, securely at-

tach a 1/2" mesh metal hardware cloth protective

screen to the inside bottom of the filter grill to pre-

vent personal injury from contacting moving

parts when reaching into the return opening

to replace the filter.

10 18-CD21 D1-4

REMOVE FILTER FROM UPFLOW

FURNACE WHEN RETURN DUCT IS

ATTACHED TO FURNACE TOP SIDE

(HORIZONTAL LEFT OR RIGHT

APPLICATIONS) AS SHOWN.

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Close coupled (less than 36")

return (filter directly beneath bottom

side return) not recommended due to

noise considerations. If used, securely

attach 1/2" mesh metal hardware cloth

protective screen to the inside bottom of

filter grill.

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

beneath bottom side return) is not recommended

due to noise considerations.

Downflow Furnaces: Brackets are factory sup-

plied to mount filters in the return air duct work.

7. Connect the duct work to the furnace. See Outline

Drawing for supply and return duct size and loca-

tion. Flexible duct connectors are recommended to

connect both supply and return air ducts to the fur-

nace.

If only the front of the furnace is accessible, it is

recommended that both supply and return air ple-

nums are removable.

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

cleaned out. Thin cloths should be placed over the

registers and the furnace fan should be run for

10 minutes. Don't forget to remove the cloths be-

fore you start the furnace.

RETURN AIR FILTERS

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.

Some filters may need to be trimmed for side or bottom

filter use.

Installer's Guide

NOTE:

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

quirement exceeds 1800 CFM, these models will require

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

the bottom.

LOCATING

NOTCHES

PROVIDED

FORSIDE

RETURN

CUTOUT _ I

*SEE OUTLINE DRAWING _""

CUT OUT

/FOR

SIDE

FILTER

._o ,FRuOrNTce

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. The fur-

nace filter in the bottom or side configc_ration can be re-

moved by simply turning the two latches on the blower

door and tilting the door forward.

BlowerDoor Hingeand Bottom FilterRack Installation

18-CD21 D1-4 11

Installer's Guide

TABLE 4

UPFLOWFURNACERETURN AIR FILTERS

CABINET CABINET

QTY*

WIDTH BOTTOM FILTER

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

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

21" 1 20" X 25" X 1"

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

CABINET

SIDE FILTER

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

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

requirement exceeds 1800 CFM, these models will

require return air openings and filters on both sides;

O__RR1 side andthe bottom; O__RRjust the bottom.

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 14.

Typical Filters of Upflow in Horizontal

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 15. The bottom of the blower door will catch in the

bottom of the furnace front channel for door replace-

ment.

ALTERNATE UPFLOW FILTER CLIP/BRACKET INSTAL-

LATION

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.

ALTERNATE FILTER

CLIPS LOCATION

Door Hinge Removed

12 18-CD21 D1-4

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER

INSTALLATIONS

These furnaces require high velocity type air filters.

Downflow furnace filters must be located outside the

furnace cabinet. Typical installations are shown in Fig-

ure 17. Tables 5 and 6 provide information for installa-

tion of the filter retaining brackets shipped with

downflow furnaces.

TABLE 5

CABINET FILTER FILTER BRACKET

WIDTH SIZE LOCATION *

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

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

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

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

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

TABLE 6

CABINET RETURN FILTER ACCESS FILTER ACCESS

DUCT OPENING - OPENING -

WIDTH WIDTH DIMENSION"A" DIMENSION"B"

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

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

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

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

Installer's Guide

GENERAL VENTING INSTRUCTIONS

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each

appliance connected to the venting system being

placed into operation could result in carbon

monoxide poisoning or death.

The following steps shall be followed for each appliance

connected to the venting system being placed into

operation, while all other appliances connected to the

venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and

horizontal pitch, as required in the National Fuel

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

B149 Installation Codes and these instructions.

Determine that there is no blockage or restriction,

leakage, corrosion and other deficiencies which

could cause an unsafe condition.

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

windows and all doors between the space in which

the appliance(s) connected to the venting system

are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any

exhaust fans, such as range hoods and bathroom

exhausts, so they are operating at maximum speed.

Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the

thermostat so appliance is operating continuously.

7. If improper venting is observed during any of the

above tests, the venting system must be corrected

in accordance with the National Fuel Gas Code,

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

Installation Codes.

8, After it has been determined that each appliance

connected to the venting system properly vents

where tested as outlined above, return doors,

windows, exhaust fans, fireplace dampers and any

other gas-fired burning appliance to their previous

conditions of use.

18-CD21 D1-4 13

Installer's Guide

VENT PIPING

These furnaces have been classified as Fan-Assisted

Combustion System, Category I furnaces under the "lat-

est edition" provisions of ANSI Z21.47 and CAN/CGA

2.3 standards. Category I furnaces operate with a non-

positive vent static pressure and with a flue loss of not

less than 17 percent.

NOTE:

If desired, a side wall termination can be accomplished

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

ducer must be installed according to the inducer

manufacturer's instructions. Set the barometric pres-

sure relief to achieve -0.02 inch water column.

NOTE: When the downflow furnace is vented through

the left side of the furnace cabinet using the provided

cutout, Type B vent piping must be used.

The furnace shaft be connected to a factory built chim-

ney or vent complying with a recognized standard, or a

masonry or concrete chimney lined with a lining mate-

rial acceptable to the authority having jurisdiction.

Furnace venting into an unlined masonry chimney or

concrete chimney is prohibited.

Failure to follow this warning could result in property

damage, personal injury, or death.

VENTING INTO A MASONRY CHIMNEY

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

flue-gas condensation is a problem in your area, con-

sider using the chimney as a pathway or chase for type

"B" vent or flexible vent liner. If flexible liner material

is used, size the vent using the "B" vent tables, then re-

duce the maximum capacity by 20% (multiply 0.80

times the maximum capacity). Masonry Chimney Kit

BAYVENTS00B may be used with these furnaces

(Upflow model furnaces only) to allow venting into a

masonry chimney. Refer to the BAYVENTS00B

Installer's Guide for application requirements.

INTERNAL MASONRY CHIMNEYS

Venting of fan assisted appliances into a lined, internal

masonry chimney is allowed only if it is common vented

with at least one natural draft appliance; OR, if the

chimney is lined with type "B", double wall vent or suit-

able flexible liner material (See Table 7).

The chimney liner must be thoroughly inspected to in-

sure no cracks or other potential areas for flue gas

leaks are present in the liner. Liner leaks will result in

early deterioration of the chimney.

Failure to follow this warning could result in carbon

monoxide poisoning or death.

NOTE:

The following section does not apply if BAYVENT8OOB

(Masonry Chimney Vent Kit) is used. All instructions

with the kit must be followed.

TABLE 7

MASONRY CHIMNEY VENTING

Type Furnace

Single Fan

Assist

Fan Assist

Natural

Tile Lined Chimney

Internal External

No No

Yes No

Chimney Lining

Flexible

"B" Vent Metal Liner

Yes *Yes

*Yes

Yes

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

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

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

as shown in the "B" vent tables.

External Masonry Chimney

Venting of fan assisted appliances into external chim-

neys (one or more walls exposed to outdoor tempera-

tures), requires the chimney be lined with type "B",

double wall vent or suitable flexible chimney liner ma-

terial. This applies in all combinations of common vent-

ing as well as for fan assisted appliances vented alone.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the installation instructions for the

venting system being placed into operation could re-

sult in carbon monoxide poisoning or death.

The following installation practices are recommended to

minimize corrosion caused by condensation of flue prod-

ucts in the furnace and flue gas system.

1. Avoid an excessive number of bends.

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

foot.

3. Horizontal runs should be as short as possible.

4. All vent pipe or connectors should be securely sup-

ported and must be inserted into, but not beyond

the inside wall at the chimney vent.

5. When vent connections must pass through walls or

partitions of combustible material, a thimble must

be used and installed according to local codes.

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

height determined by National Fuel Gas Code or

local codes. It should be capped properly to prevent

rain water from entering the vent. Roof exit should

be waterproofed.

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

routed through cool spaces (below 60° F.).

14 18-CD21 D1-4

TABLE 8

GAS VENT TERMINATION

ROOF PITCH

FLAT TO 7/12

OVER 7/12 TO 8/12

OVER 8/12 TO 9/12

OVER 9/12 TO 10/12

OVER 10/12 TO 11/12

OVER 11/12 TO 12/12

OVER 12/12 TO 14/12

OVER 14/12 TO 16/12

OVER 16/12 TO 18/12

OVER 18/12 TO 20/12

OVER 20/12 TO 22/12

MINIMUM HEIGHT

1.0 FEET *

1.5 FEET

2.o FEET

2.5 FEET

3.25 FEET

4.o FEET

5.0 FEET

6.0 FEET

7.0 FEET

7.5 FEET

8.0 FEET

* THIS REQUIREMENT COVERS MOST INSTALLATIONS

(_ VERTICAL WALL

ff MIN.

LISTED LOWEST DISC HARGE

CAP N OPENING

THE VENT TERMINATION SHOULO NOT BE

LESS THAN 8 FT FROM AVERTICAL WALL

8. Where long periods of airflow are desired for com-

fort, use long fan cycles instead of continuous air-

flow.

9. Apply other good venting practices as stated in the

venting section of the National Fuel Gas Code

ANSI Z223.1 "latest edition".

10. Vent connectors serving appliance vented by

natural draft or non-positive pressure shall

not be connected into any portion of a mecha-

nized draft system operating under positive

pressure.

11. Horizontal pipe runs must be supported by hangers,

straps or other suitable material in intervals at a

minimum of every 3 feet of pipe.

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

flue serving a separate appliance designed to burn

solid fuel.

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

or chimney shall not exceed 7 times the smallest

listed appliance categorized vent area, flue collar

area, or draft hood outlet area unless designed in

accordance with approved engineering methods.

Maximum Vent or Tile = _(D*)2 X 7

Lined Chimney Flow Area 4

*Drafthood outlet diameter, flue collar diameter, or listed appliance cat-

egorized vent diameter.

Installer's Guide

ELECTRICAL CONNECTIONS

The cabinet must have an uninterrupted or unbroken

ground according to National Electrical Code, ANSI/

NFPA70 - "latest edition" and Canadian Electrical

Code, CSA C22.1 or local codes to minimize personal

injury if an electrical fault should occur.

Failure to follow this warning could result in an electri-

cal shock, fire, injury, or death.

The integrated furnace control is polarity sensitive. The

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

BLACK field lead.

To prevent injury or death due to electrical shock or

contact with moving parts, lock unit disconnect switch

in the open position before servicing the unit.

Failure to follow this warning could result in electri-

cal shock, personal injury, or death.

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 it be provided with a separate "circuit protection

device" electric circuit. The furnace must be electrically

grounded in accordance with local codes or in the ab-

sence of local codes with the National Electrical Code,

ANSI/NFPA 70 "latest edition" or Canadian Electrical

Code, CSA C22.1, if an external electrical source is uti-

lized.

All field supplied wiring must conform with the tem-

perature limitation for Type T wire [63° F. (35 ° C)],

when installed in accordance with these instructions

and wiring diagrams supplied with the furnace. A dis-

connecting means must be located within sight from,

and readily accessible to, the furnace.

Refer to the SERVICE FACTS literature for unit wiring

diagrams in addition to the diagram inside the blower

door.

18-CD21 D1-4 15

Installer's Guide

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING

T'STAT

SEE

NOTE 7

FURNACE

--F-q

__t-_- I

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

NOTES"

I. BE SURE POWERAGREESWITH EOUIPMENT NAMPLATE(S).

2, LOWVOLTAGE (24V, WIRING) TO BE NO. 18 A.W.G. MIN..

3. GROUNDINGOF EOUIPMENT MUST COMPLYWITH LOCAL CODES.

4. SET THERMOSTATHEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

5. THESE LEADS PROVIDE 115 V. POWERFOR CONNECTIONOF ELECTRONIC AIR

CLEANER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.

6. THIS CONNECTION IS ONLY USED FOR THERMOSTATSREOUIRING

CONNECTIONTO THE ?4 V. POWERSUPPLY. (COMMON)

7. SEE TWINNING CONNECTIONDIAGRAMS FOR PROPERCONNECTIONS

WHENUSING THIS FEATURE.

_---

E_""

E_--

SEE

,NOTEG_

--D

--E_

__Fc-1

INTER-COMPONENT WIRING

24. V, }FIELD

----LINE V. WIRING

24 V. _FACTORY

--LINE V..j'-WIRING

T_ GROUND

_r_tCR_--_ j ,_ FURNACE

'11 !_ T rJUNCTION

, BOX

r- LH BK I_ w./,'ll

LOCALOOOES/ I

L ! 'I"_ _"_I

rw.l I ,_,

HUM SEE J"** ,_I I: I_ :

NOTE 5 /BK ,_ ....

.-w. /

EACSEE

NOTE 5 L BK ' From Dwg. B341437 Rev. 1

OUTDOOR UNIT

(NO TRANSFORMER /

y._l_,_..........

_--

[_]---

E_--

L.............................. II

INTER-COMPONENT WIRING

24 V, }FIELD----LINE V. WIRING

24 V. _FACTORY

--LINE V.jrWIRING

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 FURNACE

SEE NOTES:

NOTE7 _ I. BE SURE POWERAGREESWITH EQUIPMENT NAMPLATE(S).

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

3. GROUNDINGOF EQUIPMENT MUST COMPLYWITH LOCAL CODES.

4. SET THERMOSTATHEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

......... E_ S. THESE LEADS PROVIDE 115 V. POWERFOR CONNECTION OF ELECTRONIC AIR

CLEANER AND HUMIDIFIER MAX, LOAD 1.0 AMPS EACH.

SEE 6. THIS CONNECTION IS ONLY USED FOR THERMOSTATSREQUIRING

NOTE8 _ CONNECTION TO THE 24 V. POWERSUPPLY. (COMMON)

........ 11 I 7. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS

WHEN USING THIS FEATURE.

8. THE "Y" TERMININAL FROM THE THERMOSTATMUST BE WIRED

........ E_ TO THE "Y" TERMINAL OF THE FURNACECONTROL FOR PROPER BLOWER

OPERATION DURING COOLING.

........ _'_ ,r GROUND

SEE ----_I_R--_--I,_ --- FURNAC E

.NOTEG_ __fB"_'1: i _ TrJUNCTION

'," ,- _, _----J/, BOX

TOIISVIPH, I 'M'I "

', soNZPOWERJ IJI

I SUPPLY PER "I I I'-- I

LOCAL CODES |I_N --.--_II_-I--I_ I

L F_'_ ''u "El

,.-_/ /,._1 ,

HUMSEE J"r''_l II1_ :

NOTE 5 I. BK ,_

L---- --t --N3._,2

_. I ,I,

EAC SEE I--- -- --I I I'_ I

NOTES L' _. _ _._1 FrO,TDw'_.E?4143GR,_/.!

16 18-CD21 D1-4

Installer's Guide

TWINNING

These furnaces may be twinned. Twinning requires that

two furnaces with the same configuration, capacity, and

airflow must be used. They shall have common returns

with equal pressure drops or ducts with equivalent

lengths and sizes. See Field Wiring Diagrams below for

proper hookup.

S'fAGE HEA'[

ONLY

THERMOSTA_

(WITH FAN SWITCH

F_ .....

SEE NOTE 3

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEATING ONLY THERMOSTAT

FURNACE NO 1

_ .....

..... _--4_

..... F_

ISOLATIONRELAY

(FEELDSUPPUED)

__22E N_O_TE_4___

____.

..... I

FURNACE NO, 2

BLOWEROPErATiONOF

UNit NO2 ISSYNCROfqZED

WiTHUNITNO 1WASIGNALS

FROMTWiNCONNECTION

...... F_ 2

SEE NOTE 4

Rll 1

SEE NOTE 4

NOTES

I BOTH FURNACES MUST Bf ROWfSED fROM

THE SAME IISV LED OF CIRCUIT PANEL

INSURE S4V FURNACE TRANSFORMERS ARE

IN PHASE PRIOR TO COMPLETING CONNECTIONS,

CHECK VOITAUE SET#EEN "R' TERMINALS OF

EACH FURNACE If VOLTAGE IS GREATER THAN

IOV, REVERSE THE SL AN RD SECONDARY IEADS

ON ONE OF THE FURNACE TRANSFORMERS

CONNECTION MAY BE REOUIRED FOR

EIECTRONIC THERMOSTAT

I# CURRENT EXCEEDS THERMOSTAT CURRENT

RATING, USE iSOLATION RELAYS [_RI') AS

SHOWN (DO NOT CONNECT W TO W)

ISOLATION RELAY NOT NEEDED If THE THERMOSTAT

CONTACTS ARE RATED AT IOA OR ABOVE

INTER-COMPONENT WIRING

AITERNAT# #IRIN6 CONFIGURATION

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

24 V. "_FIELD

----LINE V..! WIRING

24 V. __FACTORY

ILINE V.._ WIRING

From Dwg. 21B341422 Rev. 3

OUTDOOR UNIT

WITH TRANSFORMER

1S_GE

HE_ING/COOLING

THERMOSTAT

i 301

io;

ISOLATIONRELAy

_FIELDSUPPUED)

SEENOTE3

OUTDOOR UNIT

(NO TRANSFORMER)

SEE NOTE 5

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEAT /1 STAGE COOL THERMOSTAT

}

R1; _> ;

ISOLATIO N RELAY

(FIELD SUPPLIED)

SEE NOTE 4

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO 2 _S SYNCRON]ZED ?

SEE NOTE 4

1 1

Rli_ i

TH_ S#_W _L S 0 C [2C_¢T p4t,I_[

)S}R 24V F M'NAC_TRAASFORMRSAR_

i_¸ _#_S£ _R_O_ TO COt#PLET_5 _O,_',%CT_Ot_S

C_EC_ VOLT4S__EZ_'_E_ _ T_?_t,,4L5¸Of

_OUTDOOr,_ 7 H45 4 24v TRANSFO_WE#

tSOL/TrO/ ,?_L_YI,_U3T_ _fl_TALLE_

,R(_, SUCH _ R__0"];'5 _ $_ 4_T CO_NCT;O_,'¸

f CURRE&T#XEEDS THER#OSTATCUI_E_T

RAT_!_6 IJ_E IROtATtOt_ RE_AY$ if _l 4S

S_O_ ' _'_0 _OT COt_t_ECTWTO _

T_ER_OST_TS

I N • E R C O M P 0 Ix E N • il/'_'] ] N O

4TiRI_,_TFil'iR td O_ ISUi_AT@/

SEE 'dOTE

24 v. 'k_ FIELD

----LINE /._ '¢,i]RING

24 '/. _ FACTORY

--LINE M.) /WIRING

From Dwg 21 B341423 Rev 2

18-CD21 D1-4 17

Installer's Guide

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could re-

sult in serious injury, death or property damage. Never

test for gas leaks with an open flame. Use a commer-

cially available soap solution made specifically for the

detection of leaks to check all connections. A fire or ex-

plosion may result causing property damage, personal

injury, or loss of life.

@LEFT SIDE PIPING (STANDARD)

MANUAL MAIN

SHUTOFF

UNION JOINT

DRIP LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

RIGHT SIDE PIPING (OPTIONAL)

iSHUTOFF VALVE

UNION JOINT

AUTOMATIC GAS VALVE

WiTH MANUAL _UTOFF

TOP VIEW OF RIGHT SIDE PIPING

TOP VIEW

GAS PIPING

This unit is shipped standard for left side installation of

gas piping. A piping knockout is also provided in the

right side for an alternate piping arrangement. The in-

stallation of piping shall be in accordance with piping

codes and the regulations of the local gas company. Pipe

joint compound must be resistant to the chemical reac-

tion with liquefied petroleum gases.

Refer to piping Table 9 for delivery sizes. Connect gas

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

manual shut-off valve as shown in Figure 19. National

codes require a condensation drip leg to be installed

ahead of the controls as shown in Figure 19.

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

connected from the gas supply piping system during any

pressure testing of that system at test pressures in ex-

cess of 1/2 psig.

The furnace must be isolated from the gas supply piping

by closing its individual manual shut-off valve during

any pressure testing of the gas supply piping system at

test pressures equal to or less than 1/2 psig.

Use a backup wrench on the gas valve when installing

gas piping to prevent damage to the gas valve and

manifold assembly.

NOTF"

Maximum pressure to the gas valve for natural gas is

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

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

Minimum pressure is 11.0" W.C.

All gas fittings must be checked for leaks using a soapy

solution before lighting the furnace.

DO NOT CHECK WITH AN OPEN FLAME!

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

Hazardous Gases!

Exposure to fuel substances or by-products of

incomplete fuel combustion is believed by the state of

California to cause cancer, birth defects, or other

reproductive harm.

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.

TO PREVENT AN EXPLOSION OR POSSIBLE INJURY,

DEATH AND EQUIPMENT DAMAGE, DO NOT STORE

COMBUSTIBLE MATERIALS, GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS NEAR THE UNIT.

18 18-CD21 D1-4

As the induced draft blower comes up to speed, the

pressure switch contacts will close and the ignitor warm

up period will begin. The ignitor will heat for approx. 20

seconds, then the gas valve is energized to permit gas

flow to the burners. The flame sensor confirms that ig-

nition has been achieved within the 6 second ignition

trial period.

After the flame sensor confirms that ignition has been

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

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

blower motor will be energized and will continue to run

during the heating cycle.

When the thermostat is satisfied, R and W thermostat

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

extinguish, and the induced draft blower will be de-en-

ergized. The indoor blower motor will continue to run

for the fan off period (fixed at 100 seconds), then will be

de-energized by the control module.

test for gas leaks with an open flame. Use a commer-

cially available soap solution made specifically for the

detection of leaks to check all connections. A fire or ex-

plosion may result causing property damage, personal

injury, or loss of life.

START-UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

With gas and electrical power "OFF"

1. Duct connections are properly sealed

2. Filters are in place

3. Venting is properly assembled

4. Blower door is in place

Turn knob on main gas valve within the unit to the

"OFF" position. Turn the external gas valve to "ON".

Purge the air from the gas lines. After purging, check

all gas connections for leaks with a soapy solution - DO

NOT CHECK WITH AN OPEN FLAME. Allow 5 min-

utes for any gas that might have escaped to dissipate.

LP Gas, being heavier than air, may require forced ven-

tilation. Turn the knob on the gas valve in the unit to

the "ON" position.

COMBUSTION AND INPUT CHECK

1. Make sure all gas appliances are off except the 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 12 with the time clocked.

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

onds clocked.

Installer's Guide

5. Use the following factors if necessary:

For 1 Cu. Ft. Dial Gas Flow CFH =

Chart Flow Reading + 2

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

Chart Flow Reading + 4

For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading + 4

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

gas obtained from the utility company and compare

to the nameplate rating. This must not exceed the

nameplate rating.

7.Changes can be made by adjusting the manifold

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 pres-

sure 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 Fig-

ure 21) for White-Rodgers gas valve model 36F and

Figure 20 for White-Rodgers gas valve model 36G).

For the gas valve model 36F, measurement re-

quires removal of the plug and installation of a

barbed fitting. Attach flexible tubing and a manom-

eter 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 in-

stall 5/16" flexible tubing and a manometer directly

onto the outlet pressure boss.

c. Turn on system power and energize valve.

d.Remove the regulator adjustment screw cap on the

gas valve for manifold pressure adjustment.

e.Turn the adjustment nut clockwise to increase the

gas flow rate, and counterclockwise to decrease the

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

f. The final manifold pressure setting shall be 3.5"

W.C. with an input of no more than nameplate rat-

ing 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 energize

valve.

k. Using a leak detection solution or soap suds, check

for leaks at plug or pressure boss screw.

18-CD21 D1-4 19

Installer's Guide

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.

For LP gases, the final manifold pressure setting shall

be 10.5" W.C. with an input of no more than the name-

plate rating and no less than 93% of the nameplate rat-

ing, unless the unit is derated for altitude.

Table 10 lists the main burner orifices shipped with the

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

input rate, refer to Table 11.

TABLE 9

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE LENGTH OF PIPE

SIZE 10 20 30 40 50 60 70

1_ 132 92 73 63 56 50 46

3_ 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

1-1_ 1050 730 590 520 440 400 370

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

TABLE 10

ORIFICE SIZES

INPUT

RATING

BTUH

40,000

60,000

80,000

100,000

120,000

140,000

NUMBER

BURNERS

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS

LP GAS

TABLE 11

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

PART

NUMBER

ORFO0501

0RF00644

ORFO0909

ORFO0910

0RF01099

ORFO0503

0RF00493

DRILL

SIZE

PART

NUMBER

0RF00555

0RF00693

ORFO0907

ORFO0908

0RF01338

0RF01339

HIGH ALTITUDE DEBATE

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 cannot 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 local codes, the Na-

tional Fuel Gas Code, ANSI Z223.1/ NFPA 54 or Na-

tional Standard of Canada, Natural Gas and Propane

Installation Code, CSA B149.1. Installation of this fur-

nace 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.

See Table 13 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.

EXPLOSION HAZARD!

PROPANE GAS IS HEAVIER THAN AIR AND MAY

COLLECT IN ANY LOW AREAS OR CONFINED

SPACES. IN ADDITION, ODORANT FADE MAY MAKE

THE GAS UNDETECTABLE EXCEPT WITH A WARN-

ING DEVICE. IF THE GAS FURNACE IS INSTALLED

IN A BASEMENT, AN EXCAVATED AREA OR A

CONFINED SPACE, IT IS STRONGLY RECOM-

MENDED TO CONTACT A GAS SUPPLIER TO IN-

STALL A GAS DETECTING WARNING DEVICE IN

CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOT test

any detectors and makes no representations regarding

any brand or type of detector.

20 18-CD21 D1-4

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!!!!!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!i_i!!_

TABLE 12

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

8 900 29 248 50 144 82 88

9 800 30 240 51 141 84 86

10 720 31 232 52 138 86 84

11 655 32 225 53 136 88 82

12 600 33 218 54 133 90 80

13 555 34 212 55 131 92 78

14 514 35 206 56 129 94 76

15 480 36 200 57 126 96 75

16 450 37 195 58 124 98 73

17 424 38 189 59 122 100 72

18 400 39 185 60 120 104 69

19 379 40 180 62 116 108 67

20 360 41 176 64 112 112 64

21 343 42 172 66 109 116 62

22 327 43 167 68 106 120 60

23 313 44 164 70 103 124 58

24 300 45 160 72 100 128 56

25 288 46 157 74 97 132 54

26 277 47 153 76 95 136 53

27 267 48 150 78 92 140 51

28 257 49 147 80 90 144 50

(_ Outlet Pressure Boss Regulator

Inlet Pressure

Boss (opt.) On/Off Switch

White-Rod_ers 3613 gas valve

On/Off Switch

White-Rodgers 36F gas valve

Installer's Guide

TABLE 13

Orifice

Twist Drill

Size If

Installed

At Sea

Level

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

2000 3000 4000 5000 6006 7000 8000 9000 10000

42 43 43 43 44 44 45 46 47

44 44 44 45 45 46 47 47 48

45 45 45 46 47 47 48 48 50

46 47 47 47 48 48 49 49 50

47 47 47 48 48 49 49 50 51

48 48 49 49 49 50 50 51 52

54 55 55 55 55 55 56 56 56

55 55 55 56 56 56 56 56 57

56 56 57 57 57 58 59 59 60

58 59 59 60 60 61 62 63 63

59 60 60 61 62 62 63 63 64

From National Fuel Gas Code - Table F-4

LIGHTING INSTRUCTIONS

DO NOT attempt to manually light the burner.

Failure to follow this warning could result in property

damage, personal injury or death.

Lighting instructions appear on each unit. Each

installation must be checked out at the time of

initial start up to insure proper operation of all

components. Check out should include putting

the unit through one complete cycle as outlined

below.

Turn on the main electrical supply and set the 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.

TO SHUT OFF

For complete shutdown: Move the control switch on the

main gas valve to the "OFF" position (See Figures 20

and 21). 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 in below freez-

ing weather. If for any reason your furnace

should fail to operate damage could result, such

as frozen water pipes.

18-CD21 D1-4 21

Installer's Guide

CONTROL AND SAFETY SWITCH

ADJUSTMENT

LIMIT SWITCH CHECK OUT

The limit switch is a safety device designed to close the

gas valve should the furnace become overheated. Since

proper operation of this switch is important to the

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

start up by the installer.

To check for proper operation of the limit switches, set

the thermostat to a temperature higher than the indi-

cated temperature to bring on the gas valve. Restrict

the airflow by blocking the return air or by disconnect-

ing the blower. When the furnace reaches the maxi-

mum outlet temperature as shown on the rating plate,

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

reasonable time and overheating is evident, a faulty

limit switch is probable and the limit switch must be re-

placed. After checking the operation of the limit control,

be sure to remove the paper or cardboard from the re-

turn air inlet, or reconnect the blower.

AIRFLOW ADJUSTMENT

Check inlet and outlet air temperatures to make sure

they are within the ranges specified on the furnace 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.

NOTE:

Direct drive motors have bearings which are perma-

nently lubricated and under normal use, lubrication is

not recommended.

INDOOR BLOWER TIMING

The control module controls the indoor blower. The

blower starts approximately 45 seconds after ignition.

The FAN-OFF period is approximately 100 seconds

from the interruption of gas flow.

ROOM AIR THERMOSTAT HEAT ANTICIPATOR

ADJUSTMENT

Set the thermostat heat anticipator according to the

current flow measured, or the settings found in the

notes on the furnace wiring diagram (found inside the

furnace casing).

INSTRUCTIONS TO THE OWNERS

In the event that electrical, fuel, or mechanical

failures occur, the owner should immediately

turn the gas supply off at the manual gas valve,

located in the burner compartment (See Figure

19). Also turn off electrical power to the furnace

and contact the service agency designated by

your dealer.

Should overheating occur, or the gas supply fail to

shut off, shut off the gas valve to the unit before shut-

ting off the electrical supply.

Failure to follow this warning could result in property

damage, personal injury or death.

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

This product contains fiberglass wool insulation!

Fiberglass dust and ceramic fibers are believed by the

State of California to cause cancer through inhalation.

Glasswool fibers may also cause respiratory, skin, or

eye irritation.

PRECAUTIONARY MEASURES

•Avoid breathing fiberglass dust.

•Use a NIOSH approved dust/mist respirator.

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

sleeved, loose-fitting clothing, gloves, and eye

protection.

• Wash clothes separately from other clothing: rinse ..............................................................................................

washer thoroughly.

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

spraying may generate fiber concentrations requiring

additional respiratory protection. Use the appropriate

NIOSH approved respirator in these situations.

FIRST AID MEASURES

Eye Contact - Flush eyes with water to remove dust. If

symptoms persist, seek medical attention.

Skin Contact - Wash affected areas gently with soap

and warm water after handling.

OPERATING INFORMATION

FLAME ROLL-OUT DEVICE

All models are equipped with a thermal control device

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

will cause the circuit to open which shuts off all flow of

gas.

22 18-CD21 D1-4

ABNORMAL CONDITIONS

1. EXCESSIVE COMBUSTION VENT PRESSURE OR

FLUE BLOCKAGE

If pressure against the induced draft blower outlet

becomes excessive, the pressure switch will shut off

the gas valve until acceptable combustion pressure

is again available.

2. LOSS OF FLAME OR GAS SUPPLY FAILURE

If loss of flame occurs during a heating cycle (when

flame is not present at the sensor), the control mod-

ule will retry the ignition sequence up to two times

after the sensor cools. If ignition is not achieved, it

will lockout the furnace.

3. POWER FAILURE

If there is a power failure during a heating cycle,

the system will restart the ignition sequence auto-

matieally when power is restored, if the thermostat

still calls for heat.

4. INDUCED DRAFT BLOWER FAILURE

If pressure is not sensed by the pressure switch, it

will not allow the gas valve to open, therefore the

unit will not start. If failure occurs during a running

cycle, the pressure switch will cause the gas valve

to close and shut the unit down.

Carbon monoxide, fire or smoke can cause serious

bodily injury, death, and/or property damage.

A variety of potential sources of carbon monoxide can be

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

dryers, gas cooking stoves, water heaters, furnaces and

fireplaces. The U.S. Consumer Product Safety 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-

Installer's Guide

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.

Failure to follow safety warnings exactly, could

result in a fire or explosion causing property

damage, personal injury or loss of life.

-- Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any

other appliance.

-- WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electrical switch;

do not use any phone in your building.

•Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

•If you cannot reach your gas supplier,

call the fire department.

-- Installation and service must be performed by

a qualified installer, service agency or the gas

supplier.

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-CD21 D1-4 23

Installer's Guide

Trane

6200 Troup Highway

Tyler, TX 75707

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

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

TRANE Furnace/Heater, Gas Manual L0905285

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