TRANE Furnace/Heater, Gas Manual L0906046

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 4 D1 - 2

Available in French Canadian (FC)

Variable Speed, 2-Stage, 80% Upflow/Horizontal

Gas-Fired Furnaces, "Fan Assisted Combustion

System" with Whole House Air Cleaner

*UD2B060AFV32A

*UD2B080AFV32A

*UD2C080AFV42A

*UD2B100AFV32A

*UD2D120AFV52A

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

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

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

Please return to service information pack upon completion of work.

For VENT SIZING INFORMATION see:

USA --

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

CANADA--

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

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

USA/CANADA ALTERNATE --

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

This unit is equipped with an integrated high efficiency

Whole House Air Cleaner. Careful consideration must

be taken in the installation process to avoid personal in-

jury, property damage or equipment damage. These in-

structions do not cover all variations in systems or pro-

vide for every possible contingency. Should further in-

formation be desired or particular problems arise which

are not covered sufficiently by this manual, contact

your local distributor or the manufacturer as listed on

the Furnace nameplate.

In addition, these Furnaces are suitable for installation

in an attic, garage or crawl space with ducted supply

and return air.

Upflo_ Horizontal*

*Units are BOTTOM RETURN only

Horizontal Conversion for these furnaces

may be left or right side rotation.

Safety signal words are used to designate a degree or level of seriousness associated with a particular hazard. The

signal words for safety markings are WARNING and CAUTION.

a. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious in-

jury.

b. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate in-

jury. It is also used to alert against unsafe practices and hazards involving only property damage. A341789P08

Installer's Guide

SAFETY SECTION

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 CSA

B149.1 Natural Gas and Propane Installation Code

and these instructions. Determine that there is no

blockage or restriction, leakage, corrosion and other

deficiencies which could cause an unsafe condition.

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

windows and all doors between the space in which

the appliance(s) connected to the venting system

are located and other deficiencies which could

cause an unsafe condition.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any

exhaust fans, such as range hoods and bathroom

exhausts, so they are operating at maximum speed.

Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the

thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances

at the draft hood relief opening after 5 minutes of

main burner operation. Use the flame of a match or

candle.

8. 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 CSA B149.1 Natural

Gas and Propane Installation Code.

9. After it has been determined that each appliance

connected to the venting system properly vents

where tested as outlined above, return doors,

windows, exhaust fans, fireplace dampers and any

other gas-fired burning appliance to their previous

conditions of use.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could re-

sult in serious injury, death or property damage.

Improper servicing could result in dangerous opera-

tion, serious injury, death, or property damage.

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.

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" (page 9), of these instructions.

4. Combustion products must be discharged outdoors.

Connect this Furnace to an approved vent system

only, as specified in the "Venting" section (page 12),

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 the "Gas Piping" section of

these instructions on page 19.

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.

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-i 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.

Chemicals used to during construction may cause

damage to the COLLECTION CELL.

DO NOT USE SEMI-RIGID METALLIC GAS CONNEC-

TORS (FLEXIBLE GAS LINES) WITHIN THE FURNACE

CABINET.

FAILURE TO FOLLOW THIS WARNING COULD RESULT

IN PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH.

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 Com-

fort Control (no field jumpers).

c. The Furnace return air duct must be complete

and sealed to the Furnace.

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.

f. The Furnace return air temperature range is

between 550 and 800 Fahrenheit.

g. Clean the Furnace, duct work, and components

upon substantial completion of the construction

process, and verify Furnace and whole house

air cleaner operating conditions including igni-

tion, input rate, temperature rise and venting,

according to the manufacturer's instructions.

h. Remove the Whole House Air Cleaner and

store in a clean, dry location during the

construction process. To be reinstalled when

construction is complete. See page 27 for proper

air cleaner removal.

i. An external field supplied air filter must be

used during construction.

Installer's Guide

Contents

Safety Section

Installation Instructions

General

Location and Clearances

Outline Drawings

Upflow Installation

Horizontal Installation

Air For Combustion and Ventilation

Duct Connections

General Venting

Venting RoutedThrough a Masonry Chimney

Field Wiring Diagrams

Electrical Connections

Gas Piping

Combustion and Input Check

High Altitude Derate

Start-up and Adjustment

Preliminary Inspections

Lighting Instructions

Sequence of Operation

Control and Safety Switch Adjustments

Conditions Affecting System Operation

Whole House Air Cleaner Maintenance

IFC Error Flash Codes

Checkout Procedure

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

Plumber or Gas Fitter in the Commonwealth of I

Massachusetts.

18-CD24D 1-2 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 combustion and input check page 21).

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 pages 12 and 13).

LOCATION AND CLEARANCES

Do NOT install the Furnace directly on carpeting, tile or

other combustible material other than wood flooring.

Do NOT install the Furnace in a corrosive or contami-

nated atmosphere.

Failure to follow this warning could result in early

equipment failure.

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 closed panel or door provided?

5. Are the ventilation and combustion air openings

large enough and will they remain unobstructed? If

outside air is used, are the openings set above the

highest snow accumulation level? (See the Air for

Combustion and Ventilation section, page 9)

6. A heavy gauge steel plate is attached to the

bottom of the unit for protection during ship-

ping and handling prior to the unit installa-

tion. Leave this plate in place until the unit is

ready to be connected to the ductwork.

7. A Pre-filter is not required to be installed with

the furnace containing a Whole House Air

Cleaner. If the use of a Pre-Filter is desired, it

must be installed at least 6" away from the Whole

House Air Cleaner. The additional pressure drop

of the Pre-Filter must be considered during duct

design or evaluation to ensure proper airflow.

8. 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.

9. A Furnace shall be installed so electrical compo-

nents are protected from water.

10. DO NOT use silicon based sealant in the airstream.

This causes a coating on the FIELD CHARGER pins

that will decrease the efficiency of the air cleaner.

11. Allow a minimum of 24 inches clearance in front of

the air cleaner to permit removal of COLLECTION

CELL and FIELD CHARGER.

12. DO NOT install furnace where the air cleaner can

be exposed to UV light.

4 18-CD24D 1-2

NOTE: Do NOT install an atomizing style humidifier in

the return plenum of this unit.

13. Flow-through Bypass Humidifiers

Excessive bypass air may cause water blow-off,

which will adversely affect system operation and air

cleaner performance. To verify bypass airflow, fol-

low the Bypass Humidifier Pre-Installation Check-

out and Set-Up Procedures available through your

local distributor. Ask for publication number 18-

CH37Dl-1.

Steam and Flow-through Fan Power Duct-

mounted Humidifiers

Follow the humidifier installation instructions.

These should only be installed on the supply air

side of the system.

Other Duct Mounted Humidifiers are not rec-

ommended for installation with the air

cleaner.

14. 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.

15. The whole house air cleaner is designed to run at a

maximum indoor relative humidity of 65%.

Installer's Guide

Figure 1. COMPONENTS OF THE INTEGRATED WHOLE HOUSE AIR CLEANER

Components of the integrated Whole House Air Cleaner:

1) FIELD CHARGER - Charges the contaminants

2) COLLECTION CELL - removes and collects very small

impurities from the air.

3) Power Supply - the solid state power supply converts

the 24 Volt AC to the high-voltage, direct current

required to power the FIELD CHARGER and COLLEC-

TION CELL.

Check carefully for any shipping damage. This

must be reported to and claims made against the

transportation company immediately. Check to be

sure all major components are in the unit. Any

missing parts should be reported to your supplier

at once, and replaced with authorized parts only.

18-CD24D 1-2 5

Installer's Guide

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6 18-CD24D 1-2

INSTALLATION INSTRUCTIONS

Bottom panel for furnace to remain in place until unit

reaches final installation location. If bottom panel is re-

moved before installation the collection cell and field

charger must also be removed to protect installation

personnel.

Remove the COLLECTION CELL and remove and dis-

card the cardboard over the cell.

NOTE: No sheetmetal screws may be used from 0-4"

from the bottom of the unit. Screws will interfere with

the Air Cleaner. See Figure 4.

REMOVING THE BOTTOM PLATE

a. Once the furnace is in place, remove the two screws

located at the front bottom corners of the Furnace.

b. Lean the furnace back slightly and remove the bot-

tom panel.

c. Replace the two screws removed in step a.

REMOVING THE COLLECTION CELL AND FIELD

CHARGER

When COLLECTION CELLS and FIELD CHARGER

must be removed, follow the steps below.

a. Remove the lower furnace door.

b. Remove the four screws holding the inner blower

panel and remove panel. Set aside in a safe place

until the unit is set in place and ready to start up.

e. Remove the COLLECTION CELL by sliding for-

ward. Remove the cardboard from the COLLEC-

TION CELL and discard. Set aside in a safe place

until the unit is set in place and ready to start up.

d. Disconnect the Green return wire and the Red high

voltage wire. Twist and pull the connector on the

Red wire to release.

e. Remove the two hold down screws on the bottom of

the FIELD CHARGER and retain.

f. Remove the Field Charger. Set aside in a safe

place until the unit is set in place and ready to start

up.

g. Set furnace in place. Repeat step a-g in reverse or-

der. Do Not put cardboard back in Furnace. Inner

blower door MUST be put back into place.

Installer's Guide

UPFLOW INSTALLATION

Standoffs and screws (See Figure 2) 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 Fur-

nace top flanges. The standoff is inserted into the cabi-

net alignment hole. The drill screws are inserted

through the standoffs then screwed into the Furnace

flange. The coil is always placed downstream of the Fur-

nace airflow. The above instructions apply only if the

coil is on top of an upflow Furnace.

FORVERTICAL

STANDOFFS (4) DRILL SCREWS (4)

STANDOFFS Figure 2

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used

in the horizontal position.

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 eased coil is secured to the Furnace and both the

Furnace and the eased coil must be properly supported.

The brackets mount using the rear screws on the coil

ease 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 ease front and the upflow Furnace, converted to

horizontal, aligns and attaches to the TXC coil. How-

ever, the coil requires additional support.

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 3 & Clearance Table

1). 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-CD24D 1-2 7

Installer's Guide

Typical Upflow/Horizontal Attic Installation

// ////

Figure 3

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 in-

stalled horizontally. The Furnace must also be elevated

approximately 4-6 inches to allow clearance for the con-

densate drain to exit the cabinet in the horizontal posi-

tion.

The horizontal Furnace may also be suspended from the

joists using all-thread rods with a substantial metal support

frame that supports the entire length of the furnace. The rods

need to be of sufficient length to allow for proper clearances

from combustible materials. The frame needs to be at least

32" in length to allow for access to service panels.

If the Furnace is suspended using steel strap, it must be sup-

ported at all four corners and in the middle at the front of the

Furnace.

NOTE: No sheetmetal

screws may be used

from 0-4" from the

bottom of the unit.

Screws will interfere

with the air cleaner.

Figure 4

NOTE: Do NOT install screws to the bottom of the

unit except with Duct Flanges and Screws provided.

Materials

• Duct Flanges

Two 23.5" Flanges

Two Additional Flanges

15.92" (for 17.5" cabinet)

19.42" (for 21" cabinet)

21.92" (for 24.5" cabinet)

• Screws

Eight 5/16" Blunt Tip Screws with 5/16" Hex

Head

Steps

1. See Figures 5, 6, and 7 for flange orientation.

2. Attach flanges 1, 2, and 3 (Fig 7) to the unit using

the factory provided screws and the pre-drilled

holes in the wrapper. Flanges 1 and 2 are the

23.5" flanges that are generic to all units. Flange

3 will be one of two short flanges and the length

of which is dependent on the cabinet size.

3. Attach flange 4 (Fig 7) to the duct work (Flanges

should be inside duct work). Flange 4 is the

remaining short flange.

4. Place duct work with single flange over the 3

flanges that are currently attached to the unit

5. Attach duct work to remaining 3 flanges.

6. Attach the front flange from step 3 to the unit by

drilling 1/8" holes into the bottom channel. Use

the factory provided 5/16" blunt tip screws to

attach.

7. Use field supplied material to make an adequate

seal. DO NOT use silicon based sealant in

the airstream.

Figure 5: Horizontal Left

i 3

GUIDE FOR THE INSTALLATION OF DUCT FLANGES

Failure to use pre-drilled holes and the factory

provided screws can potentially damage air cleaner

components.

8 18-CD24D 1-2

Installer's Guide

Use pre-

Use pre-drilled /_ drilled

holes holes

.................i)_ Use pre-

drilled

holes

Figure 7: Bottom View -

Flange Attachment

Table 1

Minimum Clearance to Combustible Materials

Upflow Closet

Left Side 0 inches Front 3 inches (note 1)

Right Side 0 inches Back 0 inches

Flue 6 inches * Top 1 inch

Horizontal Closet

(see note 2)

Top 2 inches Back 3 inches

Flue 6 inches * Sides 1 inch

Front 18 inches (note 1)

Horizontal Alcove

(see note 2)

Top 1 inch Back 0 inches

Flue 6 inches Sides 0 inches

Front 18 inches

• May be 1" when type B-1 vent is used

NOTES:

1) Minumum clearance to front on *UD2D120 is 6 inches

2) May be installed on combustible floor when type B-1 vent is used.

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 CSA B149.1 Installation Codes, and applicable provi-

sions of the local building codes. Special conditions cre-

ated 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 8. These spaces may have adequate air by infil-

tration to provide air for combustion, ventilation, and

dilution of flue gases. Buildings with tight construction

(for example, weather stripping, heavily insulated,

caulked, vapor barrier, etc.), may need additional air

provided as described for confined space.

UNCONFINED

50 CU. FT. OR MORE

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

DOORS

WATER CLOTHES

Figure 8

TABLE 2

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE WITH 8 FT.CEILING

MAXIMUM BTUH MINIMUM AREA IN SQUARE

INPUT RATING FEET OF UNCONFINED SPACE

60,000 375

80,000 500

100,000 625

120,000 750

140,000 875

1. All air from inside the buildina as in Figure 10: 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.

18-CD24D 1-2 9

Installer's Guide

2. All air from outdoors as in Figure 11: 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 communicate directly, or by

ducts, with the outdoors or spaces (crawl or attic)

that freely communicate with the outdoors. Refer

to Table 3, for minimum open areas required.

CONFINED

LESS THAN 50 CU. FT.

PER 1000 BTU/HR. INPUT

ALL EQUIP INSTALLED

Figure 9

IFURNACE

TABLE 3

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000

80,000

100,000

120,000

140,000

Air

From

Inside

lOO

1oo

lOO

120

140

Air From Outside

Vertical

Duct

Horizontal

Duct

Confined spaces are installations with less than 50 cu.

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

installed. Confined space is defined in Figure 9. Air for

combustion and ventilation requirements can be sup-

plied from inside the building as in Figure 10 or from

the outdoors, as in Figure 11.

3. The following types of installations will require use

of OUTDOOR AIR for combustion, due to chemical

exposures:

* Commercial buildings

* Buildings with indoor pools

* Furnaces installed in commercial laundry rooms

* Furnaces installed in hobby or craft rooms

* Furnaces installed near chemical storage areas.

Exposure to the following substances in the com-

bustion 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

NOTE: Extended warranties are NOT available in some

instances. Extended warranty does NOT cover repairs

to equipment installed in establishments with corro-

sive atmospheres, including but limited to, dry clean-

ers, beauty shops, and printing facilities.

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 ad-

equate to prevent chilled air from entering the Furnace,

and if manually operated, must be equipped with means

to prevent operation of either unit unless the damper is

in full heat or cool position.

On any job, flexible connections of nonflammable material

may be used for return air and discharge connections to

prevent transmission of vibration. Though these units

have been specifically designed for quiet, vibration free op-

eration, air ducts can act as sounding boards and cotfld, if

poorly installed, result in 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.

Where there is no complete return duct system,

the return connection must be run full size from

the Furnace to a location outside the utility

room, basement, attic, or crawl space.

Do NOT install return air through the back of the Fur-

nace cabinet.

10 18-CD24D1-2

Bottom Return Only

NOTE: Minimum return air temperature is 55 °F.

NOTE: No sheetmetal screws may be used from 0-4"

from the bottom of the unit. Screws will interfere with

the air cleaner. See Figure 4.

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

Hazardous Gases!

Exposure to fuel substances or by-products of

incomplete fuel combustion is believed by the state of

California to cause cancer, birth defects, or other

reproductive harm.

Carbon monoxide, fire or smoke can cause serious

bodily injury, death, and/or property damage.

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 Com-

mission recommends that users of gas-burning appli-

ances install carbon monoxide detectors as well as fire

and smoke detectors per the manufacturers installation

instructions 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 Labo-

ratories, 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 detectors and makes no representations regarding

any brand or type of detector.

Connect duct work to Furnace. See Outline Drawing for

supply and return duct size and location. Flexible duct

connectors are recommended to connect both supply

and return air ducts to the Furnace. If only the front of

the Furnace is accessible, it is recommended that both

supply and return air plenums are removable.

Installer's Guide

Figure 11

CONFINED SPACE

AIR FROM OUTDOORS

CONFINED

SPACE

_'///////////////"////////,

OUTLET

OUTDOOR

AIR DUCTS

INLET

_///////7///._ ¢//7///._

CONFINED SPACE k

AIR FROM VENTILATED ATTIC/CRAWL SPACE

TO OUTDOORS

CONFINED-

SPACE

ALTERNATE

INLET AtR

CONFINED SPACE

AIR FROM VENTILATED ATTIC

•"_ OUTLET

SPACECONFINED lAIR INLET

AIR DUCT

Figure 10

CONFINED SPACE

AIR FROM INSIDE BUILDING

SPACE

PERMANENT

OPENINGS

18-CD24D 1-2 11

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 CSA

B149.1 Natural Gas and Propane Installation Code

and these instructions. Determine that there is no

blockage or restriction, leakage, corrosion and other

deficiencies which could cause an unsafe condition.

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

windows and all doors between the space in which

the appliance(s) connected to the venting system

are located and other deficiencies which could

cause an unsafe condition.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any

exhaust fans, such as range hoods and bathroom

exhausts, so they are operating at maximum speed.

Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the

thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances

at the draft hood relief opening after 5 minutes of

main burner operation. Use the flame of a match or

candle.

8. 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 CSA B149.1 Natural

Gas and Propane Installation Code.

9. 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.

VENT PIPING

These Furnaces have been classified as Fan-Assisted

Combustion System, Category I Furnaces under the

"latest edition" provisions of ANSI Z21.47 and CAN/

CGA 2.3 standards. Category I Furnaces operate with a

non-positive vent static pressure and with a flue loss of

not less than 17 percent.

NOTE: If desired, a side wall termination can be accom-

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

The inducer must be installed according to the inducer

manufacturer's instructions. Set the barometric pres-

sure relief to achieve -0.02 inch water column.

NOTE: The Furnace shall be connected to a chimney or

vent complying with a recognized standard, or a ma-

sonry or concrete chimney lined with a lining material

acceptable to the authority having jurisdiction.

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

BAYVENT800B may be used with these Furnaces

(Upflow model furnaces only) to allow venting into a

masonry chimney. Refer to the BAYVENT800B

Installer's Guide for application requirements.

Internal Masonry Chimneys

Venting of fan assisted appliances into a lined, internal

masonry chimney is allowed only if it is common vented

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

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

able flexible liner material (See Table 4).

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.

12 18-CD24D 1-2

Installer's Guide

TABLE 4

MASONRY CHIMNEY VENTING

Type Furnace

Single Fan

Assist

Fan Assist

Natural

Tile Lined Chimney

Internal External

No No

Yes No

Chimney Lining

Flexible

"B" Vent Metal Liner

Yes Yes*

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

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

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

as shown in the "B" vent tables.

External Masonry Chimney

Venting of fan assisted appliances into external 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.

The following installation practices are recommended to

minimize corrosion caused by condensation of flue prod-

ucts in the Furnace and flue gas system.

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 =_(0*y X7

Lined Chimney Flow Area 4

*Drafthood outlet diameter, flue collar' diameter, or listed appliance categorized vent di-

ameter.

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.

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.

1. Avoid an excessive number of bends.

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

foot.

3. Horizontal runs should be as short as possible.

4. All vent pipe or connecters 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 lo-

cal codes. See Figure 12 and Table 5. It should be

capped properly to prevent rain water from enter-

ing the vent. Roof exit should be waterproofed.

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

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

8. Where long periods of airflow are desired for 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.

The Integrated Furnace Control is polarity sensitive.

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

the BLACK field lead.

To prevent injury or death due to electrical shock or

contact with moving parts, lock unit disconnect switch

in the open position before servicing the unit.

Failure to follow this warning could result in electrical

shock, personal injury, or death.

TABLE5

GAS VENT TERMINATION

ROOF PITCH

FLAT TO 7/12

OVER 7/12 TO 8/12

OVER 8/12 TO 9/12

OVER 9/12 TO 10/12

OVER 10/12 TO 11/12

OVER 11/12 TO 12/12

OVER 12/12 TO 14/12

OVER 14/12 TO 16/12

OVER 16/12 TO 18/12

OVER 18/12 TO 20/12

OVER 20/12 TO 22/12

MINIMUM HEIGHT

1.0 FEET *

1.5 FEET

2.0 FEET

2.5 FEET

3.25 FEET

4.0 FEET

5.0 FEET

6.0 FEET

7.0 FEET

7.5 FEET

8.0 FEET

* THIS REQUIREMENT COVERS MOST INSTALLATIONS

18-CD24D 1-2 13

Installer's Guide

FIGURE 12 VERTICAL WALL

8'MIN

LISTED LOWESTDISCHARGE

CAP OPENING

THE VENT TERMINATION SHOULD NOT BE

LESS THAN 8 FT FROM A VERTICAL WALL

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

VARIABLE SPEED

2-STAGE FURNACE 1. Be sure power agrees with equipment nameplates.

2. Low voltage (24 volt 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.

0"-., 5. These leads provide 115V. power for connection of humidifier

w14 MAX. load 1.0 amp.

(7/_ 6. When a single stage heating thermostat without fan switch

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

7. W1 and W2 must be jumpered together for proper operation.

Second stage heat will begin 10 minutes after first stage.

W14 JUMPER 8. Set dip switches with power off per installation instructions

SEE NOTE 11 to set airflow and indoor fan off delays.

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

10. This wire is only for thermostats requiring connection to

transformer common terminal.

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

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

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

SEE

_NOTE 9 variable speed single-zone and multi-zone system controllers. On single speed cooling

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

and the humidistat. For two compressor or two speed systems, jumper YLo to O.

FIELD ADDED JUMPER GROUND

Wl TOW2. _ 'SCREW

2NDSTAGEWILLFIRE i_rL_---._l,_ F U R N ACE

10 MINUTES AFTER 1ST iII I_BK kl ¢" T

-"'l I _ _K [JU .... I0N

J ', BOX

FL. I

TO115V1PH., / ..... I_WHA

60 HZ., POWER I II

SUPPLY PER _} I I_

LOCAL CODES |LN _ _-.Ig_U_.-q

Lrl-U

Wl-I I

G HUM SEE r=J

NOTE 1_."K

From Dwg. B342027 Rev. 0

14 18-CD24D 1-2

Installer's Guide

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTAT

NO COOLING

T'STAT VARIABLE SPEED

2-STAGE FURNACE

E_--

[_--

SEE

.NOTE6.

,__{-_

r-q

D: I

, -- {_'J

'--{_

-- [BT_

0_\ \

W14 I

W14 dUMPER

SEE NOTE 9

SEE

NOTE 7

INTER-C(}MPONENT WIRIN(]}

24 V. L. FIELD

----LINE Y..f WIRING

24 V. _._ FACTORY

--LINE V.j_WIRING

1, Be sure power agrees with equipment nameplates,

2, Low voltage (24 volt 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,

5, These leads provide 115V. power for connection of humidifier

MAX, load 1,0 amp,

6, This wire is only for thermostats requiring connection to

transformer common terminal,

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

8, Set dip switches with power off per installation instructions

to set airflow and indoor fan off delays,

9, Optional humidistat is to be connected between R and BK, Factory

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

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

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

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

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

For two compressor or two speed systems, jumper YLo to O,

GROUND

I_S--C--R-_.,..--- FURNACE

',1 I r JUNCTION

I_ ', BOX

r-,. .KI1_

TOl15Vl PH., / ..... _ WH/_I

60 HZ., POWER !I, _ I

SUPPLYPER _I [-- I

LOCALCODES/-L_---- ---_4-1-n I

L [ T21

H I I

HUMSEE F wH "_ Ii _II

NOTE I

From Dwg. B342025 Rev. 0

18-CD24D 1-2 15

Installer's Guide

OUTDOOR UNIT

(NO TRANSFORMER)

.......

?°

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

1 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

---[_ --

IT]---

[_]---

VARIABLE SPEED

?-STAGE FURNACE

......... E_

SEE

"NO-TEL- -F'_

......... E_

.........[_]_

SEE

.NO_T_E_6_.__@

INTER COMPONENT WIRING

;>4 ,/. _% FIELD

---- LINE i.y Y,_'N_IIX_

24 _/. !, FACTORY

-- LINE _Yv]I<IN@

0-,

w14\1 5

C_/_. 6

w14 JUMPER

SEE NOTE 9

NOT E S

I BE SURE POWER AGREES ,#ITH EOUlPbIEqT R_4EPLATE{S}

2 LO'a VOLTAGE(24 V ¢_1_<1_,3) TO BE NO 18 £ _ G t41N

3GROJNDING OF EO IPk,IEtT MUST EO_,PLY '£ITH LOEAL CODES

SET THERqOST_T HEJiT _NTICIPAT,OR PER UNIT '#IRING DIASRA4

THESE LEADS PROVI[E 115 O'2'ER FOR {ON E(TION OF

THE HUbIIDIFIE_ tqAX LOA} I 0 AMPS EACH

THIS C/IRE IS ONLY FOR THERMOSTATS REOLIRIN(

CONNECT I O:x TO TRANSFORMER (OHm'ON TER_ I NAL

THE "'" TERwI:xAL FROH THE THERbIOSTAT M ST _E /_I_ED

TO THE "Y" TERblNAL OF THE F _NA(E (0 TRDL FOR N_()PER SLOWER

OPERFTIO DUEING COOLING

SET DI S,_'ITCHES '¢_ITH F'OV,_ER OFF :_E_ INSTALLATION INST_U(TIONS

TO SET AI ?FL()_t A%D IN)(}()_ FAN OFF I)ELAYS

9 O_TIONAL HLJ_ql)ISTAT IS TO BE EON ECTED BET'dEEN R AND BK F_(TORY

INSTALLE) JLqPE_ R TO BK ()t THE CII(UIT BO_i![) _4LST _E COT IF OITIONAL

Hdkl)ISTAT IS USED THE J MPER 1,4[JST ALSO BE (UT ,'_HE:x AP>LYING _N AIRFLOW

COS4,_:\) SISN/_L TO THE K INPt}T S[JCH A q_ WITH THE VARIABLE SPEED SItGLE /O E

sND b'bLTI ZONE S'STEM CONTROLLE_<S OH SIFGLE SPEED COOLI:xG CNL'/NON HEAT PlqP

S_STEMS }J_PER _ TO 0 FOR ROPER 0 ERATIO OF THE DELAY PROFILES AN) THE

HUMIDISTAT FCR T'/'_O COMPRESSOR O r; TWO S_EED SfSTE_4S, s MER 1LO TO 0

GROUND

FIELD ADDED JUMPER _£CREW

W1 TOW2 _._-- B,,_-,_,j-_ FUR NACE

2NDSTAGEWILL'FIRE '11 I__,KrJUNCTION

/10 MINUTES AFTER 1ST II _ II BOX

LH BK /I

TO115V1PH,, r ..... _,_ wN

SUPPLY PER I I

LOCAL CODES LN _ I

L ,, F U Td

• .UMSEE --,

NO,E L. K

From drawing B342022 Rv 0

16 18-CD24D 1-2

Installer's Guide

OUTDOOR UNIT

(NO TRANSFORMER)

I, B

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING, 1 STAGE COOLING

USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

VARIABLE SPEED

T'STAT 2-STAGE FURNACE

SEE

NOTE 9

L--q-U I

SEE

.NOTE_7_.__E_

......... [_

......... []

......... r-_

SEE

.N_O_T_E_e_.__@

...............................

E_---

[_--

E_---

C_\

o-'\

W14 JUMPER

SEE NOTE 9

INTER COMPONENT WIRING

24 V. _._ FIELD

----LINE V°jF WIRZNG

24 V, _ FACTORY

_LINE V°jF WIRZNG

NOTE:

I.) BE SURE POWER AGREES WITH EQUIPMENT NAMEPLATE(S).

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

3.) GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL BUILDING CODES.

4.) SET THERMOSTAT BEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

5.) THESE LEADS PROVIDE II5V. POWER FOR CONNECTION OF

THE HUMIDIFIER. MAX. LOAD 1.0 AMPS EACH.

6.) THIS WIRE IS ONLY FOR THERMOSTATS REQUIRING CONNECTION TO

TRANSFORMER COMMON TERMINAL.

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

"Y" TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWER

OPERATION DURING COOLING.

8.) SET DiP SWITCHES WITH POWER OFF PER INSTALLATION INSTRUCTIONS

TO SET AIRFLOW AND INDOOR FAN OFF DELAYS.

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

FACTORY INSTALLED JUMPER "R" TO "BH" ON THE CIRCUIT BOARD MUST

BE CUT IF OPTIONAL HUMIDISTAT IS USED. THE JUMPER MUST ALSO BE

CUT WHEN APPLYING AN AIRFLOW COMMAND SIGNAL TO THE "BK" INPUT

SUCH AS WITH THE VARIABLE SPEED SINGLE-ZONE AND MULTI-ZONE

SYSTEM CONTROLERS. ON SINGLE SPEED COOLING ONLY INON-HEAT PUMP

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

PROFILES AND THE HUMIDISTAT. FOR TWO COMPRESSOR OR TWO SPEED

SYSTEMS, JUMPER "YLO" TO "0",

1_: --_ f--- FURNACE

'll ! _ ? r JUNCTION

i_, BOX

r-L. BKII_

TO 115V I PH., I ..... _ WH/II

60 HZ.,POWER J I _ II

SUPPLY PER _ I I-- l

LOCALCODES ILN __ WH_I__I.FI I

L I F U

rWH I I I I

HUMSEEJ""' --J ii [i ,,

.OTE_b_ ,__

From Dwg. B342020 Rev. 0

18-CD24D 1-2 17

Installer's Guide

OUTDOOR UNIT NO1

(NOTRANSFORMER)

SEENOTE3

.......

.... -'#!--Bl

OUTDOORUNITNO 2 I

(NOTRANSFORMER)

/Y l

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING, 2 STAGE COOLING

(OUTDOOR SECTION WITHOUT TRANSFORMER)

,--_--

---[_]- - -

[_]---

[_---

[_]---

E_'--

VARIABLE SPEED

2-STAGE FURNACE

......... D

......... F_

SEE

NOTE 7 "--D

......... []

......... E_

SEE

;

INTER-COMPONENT WIRING

0"-\

INSTALLED

JUMPER

NOTES :

I, BE SURE POWER AGREES WITH EQUIPMENT NAMEPLATE(SI

2, LOW VOLTAGE(24 V, WIRINGI 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 OIAGRAM,

5, THESE LEADS PROVIDE IIS V, POWER FOR CONNECTION OF THE

HUMIDIFIER MAX, LOAD 1,0 AMPS EACH,

6, THIS WIRE IS ONLY FOR THERMOSTATS REQUIRING

CONNECTION TO TRANSFORMER COMMON TERMINAL,

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

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

OPERAT ION DUR [NG COOL [NG.

8. SET DIP SWITCHES WITH POWER OFF PER INSTALLATION INSTRUCTIONS

TO SET AIRFLOW AND INDOOR FAN OFF DELAYS.

9. OPTIONAL HUM[DISTAT IS TO BE CONNECTED BETWEEN RAND BK. FACTORY

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

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

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

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

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

AND THE HUM]D]STAT. FOR TWO COMPRESSOR OR TWO SPEED SYSTEMS. JUMPER YLOTO O.

,ll

TO 1t5V 1PH, F 'LH

LOCAL CODES "1_"_ _ m

HUMSEEl- --I

NOTE 5 [_. BK

WI4

GROUND

_s-C-R._..]ji- F U R NAC E

[ _ ?[JUNCTION

I _ I BOX

E-T

24 V, q FIELD

LINE V.J WIRING

24 V, "7 FACTORY

LINE v.J WIRINGf

From Dwg. B342018 Rev. 0

HUMIDISTAT HOOKUP

If an optional Humidistat is to be connected between

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

and "BK" on the circuit board must be cut. If an op-

tional Humidistat is used, the jumper must also be cut

when applying an airflow command signal to the "BK"

input such as with the variable speed single-zone and

multi-zone system controller. On single speed cooling

only/ non-heat pump systems, jumper '_" to "O" for

proper operation of the delay profiles and the Humidis-

tat. For two compressor or two speed systems, jumper

%_1o"to "0".

FIGURE 13

The factory installed jumper between

"R" and "BK" on the circuit board

must be cut if an optional Humidistat

is installed.

_N_ W1 R G B YYLO 0

18 18-CD24D 1-2

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 pro-

teetion device" 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 inte-

grated Furnace control is polarity sensitive. The

hot leg of the 120V power supply must be connected to

the black power lead as indicated on the wiring dia-

gram. Provision for hooking up a humidifier is provided

on the integrated control.

Refer to the SERVICE FACTS literature and unit wiring

diagram attached to furnace.

GAS PIPING

DO NOT USE SEMI-RIGID METALLIC GAS CONNEC-

TORS (FLEXIBLE GAS LINES) WITHIN THE FURNACE

CABINET. 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.

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.

Installer's Guide

EXPLOSION HAZARD!

ODORANT FADE MAY MAKE THE GAS UNDETECT-

ABLE EXCEPT WITH A WARNING DEVICE. IF THE

GAS FURNACE IS INSTALLED IN A BASEMENT, AN

EXCAVATED AREA OR A CONFINED SPACE, IT IS

STRONGLY RECOMMENDED TO CONTACT A GAS

SUPPLIER TO INSTALL A GAS DETECTING WARN-

ING DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOT

test any detectors and makes no representations re-

garding any brand or type of detector.

TABLE6

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

INPUT

RATING

BTUH

60,000

80,000

100,000

120,000

TABLE7

ORIFICE SIZES

NUMBER

BURNERS

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 56

EXPLOSION HAZARD!

PROPANE GAS IS HEAVIER THAN AIR AND MAY

COLLECT IN ANY LOW AREAS OR CONFINED

SPACES. IF THE GAS FURNACE IS INSTALLED IN A

BASEMENT, AN EXCAVATED AREA OR A CONFINED

SPACE, IT IS STRONGLY RECOMMENDED TO CON-

TACT A GAS SUPPLIER TO INSTALL A GAS DETECT-

ING WARNING DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does not

test any detectors and makes no representations re-

garding any brand or type of detector.

Use a backup wrench on the Gas Valve when installing

gas piping to prevent damage to the Gas Valve and

Manifold Assembly.

The installation of piping shall be in accordance with

piping codes and the regulations of the local gas com-

pany. Pipe joint compound must be resistant to the

chemical reaction with liquefied petroleum gases.

Refer to piping Table 6, for delivery sizes. Connect gas

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

manual shut-off Valve as shown in Figures 14 and 15.

National codes require a condensation drip leg to be in-

stalled ahead of the controls as shown in Figures 14 and

15.

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).

18-CD24D 1-2 19

Installer's Guide

The Furnace must be isolated from the gas supply pip-

ing by closing its individual manual shut-off Valve dur-

ing 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. Maxi-

mum 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!

Figure 14 LEFT SIDE PIPING (STANDARD)

MANUAL MAIN

SHUTOFF

GROUND

UNION JOINT

DRIP LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

RIGHT SIDE PIPING (OPTIONAL)

SHUTOFF VALVE

(

UNION JOINT

DRIP LEG

WITH MANUAL SHUTOFF

TOP VIEW OF RIGHT SIDE PIPING

I IIII_ )

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

GROUND UNION DRIP LEG

AIR FLOW

MAIN MANUAL

SHUTOFFVALVE

DRIPLEG

GROUND UNION

JOINT

Figure 15 HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

(Typical UPFLOW Furnace in horizontal configuration shown)

20 18-CD24D1-2

COMBUSTION AND INPUT CHECK

(See also High Altitude Derate)

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, property damage, or death.

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

nace.

2. Clock the gas meter with the Furnace operating

(determine the dial rating of the meter) for one

revolution.

3. Match the "See" column in the gas flow (in efh)

Table 8 with the time clocked.

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

onds clocked.

5. Use the following factors if necessary:

For 1 Cu. Ft. Dial Gas Flow CFH = Chart Flow

Reading +2

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

Reading +4

For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading +4

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

gas obtained from the utility company and compare

to the nameplate rating. This must not exceed the

nameplate rating.

7. Changes can be made by adjusting the Manifold

Pressure (See Table 9), or changing orifices (orifice

change may not always be required). To adjust the

Manifold Pressure:

a. Turn off all electrical power to the system.

Installer's Guide

b. Attach a Manifold Pressure gauge to the outlet

pressure tap marked "OUT PRESS TAP" on

White-Rodgers gas valve model 36G. (see Figure

17 for White-Rodgers gas valve model 36G). At-

tach flexible tubing and a Manometer to the

barbed fitting. For the Gas Valve model 36G, do

not remove the pressure tap test screw. Loosen

the pressure tap test screw one turn and install

flexible tubing and a Manometer directly onto

the outlet pressure boss.

c. The other side of the Manifold Pressure Gauge

must be referenced to the Burner Box as shown

in Figure 16.

d. Turn on system power and energize Valve.

e. For the White-Rodgers Gas Valve model 36G:

1. Adjust low fire by removing the low adjust-

ment regulator cover screw (See Figure 17).

2. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet

pressure, turn the regulator adjust screw

counterclockwise. Adjust regulator until pres-

sure shown on Manometer matches the pres-

sure specified in Table 9.

3. Replace and tighten the regulator cover screw

securely.

4. Cycle the Valve several times to verify regula-

tor setting.

5. Adjust high fire by removing the high adjust-

ment regulator cover screw (See Figure 17).

Figure 16 CORRECT METHOD OF CHECKING DIRECT VENT MANIFOLD

PRESSURE WITH BURNER BOX REFERENCED

Separate the tube

at the unit Tee and

reconnect with a F-,, [I "_

short piece of field "J [I

supplied tube and _ _ 11

another Tee with //

the "U" Manometer /S!

attached, f//'__X

Be sure to reconnect {/ J:_:_ _-1)

unit tubing to original -- _ \'\ \

position after testing -- _L,__A\_

the manifold pressu re! \_! "_

Field su lied b

• pp arb fitting II

with manometer tube is _k

attached to the "OUTLET

PRESSURE TAP" on the

outlet side of the gas valve.

ACAUTION: Returnalltubing,caps,and/orplugsto originalpositionswhen pressurechecksare completed.

18-CD24D 1-2 21

Installer's Guide

6. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet

pressure, turn the regulator adjust screw

counterclockwise. The final Manifold Pressure

setting shall be as specified in Table 9 with an

input of no more than nameplate rating and

no less than 93% of the nameplate rating, un-

less the unit is derated for high altitude.

7. Replace high adjustment regulator cover screw

and tighten securely.

8. Cycle the Valve several times to verify regula-

tor setting.

f. Turn off all electrical power to the system.

g. Remove the Manometer and flexible tubing. Re-

move the barbed fitting and replace the plug or

tighten the pressure test screw.

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

gize valve.

i. Using a leak detection solution or soap suds,

check for leaks at plug or pressure boss screw.

NOTE: The Manifold Pressure must be referenced to

the Burner Box. The Burner Box pressure tap equal-

izes the Gas Valve pressure regulator. Manifold Pres-

sure is checked by installing a tee (field supplied) in

the tubing, between the tee coming from the Burner

Box tube and the Gas Valve, in addition to the regular

Gas Valve pressure tap on the outlet side of the Gas

Valve. See Figure 16.

Table 7 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 10.

TABLE 8

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

8 900 29 248 50 144 82 88

9 800 30 240 51 141 84 86

10 720 31 232 52 138 86 84

11 655 32 225 53 136 88 82

12 600 33 218 54 133 90 80

13 555 34 212 55 131 92 78

14 514 35 206 56 129 94 76

15 480 36 200 57 126 96 75

16 450 37 195 58 124 98 73

17 424 38 189 59 122 100 72

18 400 39 185 60 120 104 69

19 379 40 180 62 116 108 67

20 360 41 176 64 112 112 64

21 343 42 172 66 109 116 62

22 327 43 167 68 106 120 60

23 313 44 164 70 103 124 58

24 300 45 160 72 100 128 56

25 288 46 157 74 97 132 54

26 277 47 153 76 95 136 53

27 267 48 150 78 92 140 51

28 257 49 147 80 90 144 50

TABLE 9

FINAL MANIFOLD PRESSURE SETTINGS (inches w.c.)

FUEL 2nd Stage Max. 1st Stage Max.

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

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

REINSTALLATION OF THE BURNER BOX COVER

Figure 18 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.

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.

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

(610m) shall be in accordance of 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 149.1. 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.

The Furnace input rate shall be checked by clocking the

gas flow rate (CFH) and multiplying by the heating

value obtained from the local utility supplier for the gas

being delivered at the installed altitude. Input rate

changes can be made by adjusting the Manifold Pres-

sure (min 3.0 - max 3.7 in. W.C. - Natural Gas) or

changing orifices (orifice change may not always be re-

quired).

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.

IMPORTANT:

Reinstall the propane orifices to the same depth as the ori-

fices supplied with the equipment.

See Table 11 for help in selecting orifices if orifice change

is required. Furnace input rate and temperature rise

should be checked again after changing orifices to con-

firm the proper rate for the altitude.

An optional high altitude kit is available for installations

above 5000 feet. Installations above 12,000 feet are not

allowed.

22 18-CD24D 1-2

TABLE 10

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

PART

NUMBER

ORF00501

ORF00644

ORF00909

ORF00910

ORF01099

ORF00503

ORF00493

DRILL

SIZE

PART

NUMBER

ORF00555

ORF00693

ORF00907

ORF00908

OR F01338

OR F01339

Turn the main Gas Valve toggle switch (See Figures 17)

within the unit to the "OFF" position. Turn the external

gas valve to "ON". Purge the air from the gas lines. Af-

ter purging, check all gas connections for leaks with a

soapy solution -- DO NOT CHECK WITH AN OPEN

FLAME. Allow 5 minutes for any gas that might have

escaped to dissipate.

LP Gas being heavier than air may require forced ventila-

tion. Turn the toggle switch on the Gas Valve in the unit

to the "ON" position.

LIGHTING INSTRUCTIONS

DO NOT ATTEMPT TO MANUALLY LIGHT THE BURNER.

FAILURE TO FOLLOW THIS WARNING COULD RESULT

IN PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH.

Orifice

Twist Drill

Size If

Installed

At Sea

Level

TABLE 11

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

2000 300C 4000 5000 600C 7000 8000 900C 1000C

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

Figure 17 White-Rodgers 36G 2nd Stage (HI)

Manifold

Pressure

Adjustment

Gas Valve On /Off

Toggle Switch

1st Stage (LO)

Manifold

Pressure

Adjustment

Installer's Guide

START-UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

Disconnect power to the unit before removing the

blower door. Allow a minimum of 15 seconds for IFC

power supply to discharge to 0 volts.

Failure to follow this warning could result in property

damage, personal injury or death.

With gas and electrical power "OFF"

1. Duct connections are properly sealed.

2. Air cleaner and filters(if applicable) are in place.

3. Venting is properly assembled.

4. Blower door is in place.

Figure 18

ROTATE THE FRONT

COVER AS SHOWN

INSERT THE TOP FLANGE

OF THE FRONT COVER

UNDER THE LIP INSIDE

THE BOX

ALL SIDE FLANGES MUST

BE OUTSIDE OF THE BOX

ROTATE THE FRONT

COVER INWARD MAKING

SURE THAT ALL SIDE

FLANGES ARE OUTSIDE

OF THE BOX.

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.

Lighting instructions appear on each unit. Each installa-

tion 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 Comfort

Control 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 Comfort Control is satisfied.

To shut off.

18-CD24D 1-2 23

Installer's Guide

For complete shutdown: Turn the gas cock knob on the

main Gas Valve to the "OFF" position (See Figures 14 &

15).

Disconnect the electrical supply to the unit.

SEQUENCE OF OPERATION

NOTE: Whole House Air Cleaner is energized when

blower is operating and there is a call for heat or cool

This can result in brief periods of blower operation

with the whole house air cleaner off. This can occur

during the heat fan off period or if the enhanced

mode of operation is chosen for cooling.

Comfort Control call for heat (2-Stage Comfort Control)

Call for 1st Stage only:

Wl Comfort Control contacts close signaling the control

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

module has verified that the 1st Stage Pressure Switch

contacts are open and the Limit Switch(es) contacts are

closed, the draft blower will be energized.

As the induced draft blower comes up to speed, the

Pressure Switch contacts will close and the ignitor

warm up period will begin. The ignitor will heat for

approx. 20 seconds, then the Gas Valve is energized in

1st Stage to permit gas flow to the burners.

The flame sensor confirms that ignition has been

achieved within the 4 second ignition trial period.

As the flame sensor confirms that ignition has been

achieved, the delay to fan ON period begins timing and

after approx. 45 seconds the indoor blower motor will be

energized at low speed and will continue to run during

the heating cycle. The whole house air cleaner will en-

ergize.

Call for 2nd Stage after 1st Stage:

W2 Comfort Control contacts close signaling a call for

2nd Stage Heat. After a 30 second delay, the induced

draft blower will be energized on high speed and the

2nd Stage Pressure Switch contacts will close. The Gas

Valve is energized in 2nd Stage and the indoor blower

motor in high speed.

2nd Stage satisfied, 1st Stage still called:

W2 Comfort Control contacts open signaling that 2nd

Stage Heating requirements are satisfied.

The induced draft blower is reduced to low speed allow-

ing the 2nd Stage Pressure Switch contacts to open and

the Gas Valve is reduced to 1st Stage. The indoor

blower motor is reduced to low speed.

1st stage satisfied:

Wl Comfort Control contacts open signaling that 1st

Stage heating requirements are satisfied. The Gas

Valve will close and the induced draft blower and the

whole house air cleaner will be de-energized. The in-

door blower motor will continue to run for the fan off

period (Field selectable at 60, 100, 140 or 180 seconds),

then will be de-energized by the control module.

Comfort Control call for heat (1-Stage Comfort

Control)

Wl/ W2 (jumpered) Comfort Control contacts close sig-

naling a call for heat. 1st Stage sequence of operation

remains the same as above. 2nd Stage Heat will ener-

gize after the Stage delay timer (10 minutes) has ex-

pired.

Comfort Control satisfied:

Wl/ W2 (jumpered) contacts close signaling the control

module to close the Gas Valve. The induced draft blower

is switched to low speed and de-energized after the post

purge timer has expired. The indoor blower motor will

continue to operate after the flames are extinguished

and then is switched to low heat speed for the FAN-

OFF period. The whole house air cleaner will be de-en-

ergized.

NOTE TO INSTALLER

Review warnings and the contents of USER'S INFOR-

MATION MANUAL with the homeowner when installa-

tion is complete and equipment is ready to be turned

over to the homeowner for normal operation.

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 Comfort Control to a temperature higher than the

indicated temperature to bring on the Gas Valve. Re-

strict the airflow by blocking the return air or by dis-

connecting the blower. When the Furnace reaches the

maximum outlet temperature as shown on the rating

plate, the burners must shut off. If they do not shut off

after a reasonable time and overheating is evident, a

faulty Limit Switch is probable and the Limit Switch

must be replaced. After checking the operation of the

Limit Control, be sure to remove the paper or card-

board from the return air inlet, or reconnect the

blower. Refer to the Service Facts for additional in-

structions.

INDOOR BLOWER TIMING

DISCONNECT POWER TO THE UNIT BEFORE REMOV-

ING THE BLOWER DOOR.

FAILURE TO FOLLOW THIS WARNING COULD RESULT

IN PROPERTY DAMAGE, PERSONAL INJURY OR

DEATH.

24 18-CD24D 1-2

Heating: The Integrated Furnace Control (IFC) con-

trols the Variable Speed Indoor Blower. The blower

"on" time is fixed at 45 seconds after ignition. The

FAN-OFF period is field selectable by dip switches #1

and #2 located on the Integrated Furnace Control be-

tween the 5-pin and 9-pin wire connectors. The delay

may be set at 60, 100, 140, or 180 seconds. The factory

setting is 100 seconds (See unit wiring diagram).

Cooling: The fan delay-off period is set by dip switches

on the Integrated Furnace Control. The options for

cooling delay off is field selectable by dip switches #5

and #6.

The following table and graph explain the delay-off set-

tings: TABLE 12 FAN OFF- DELAY OPTIONS

NOMINAL

SWITCH SETTINGS SELECTION AIRFLOW

5 - OFF 6 - OFF NONE SAME

5 - ON 6 - OFF 1.5 MINUTES 100% *

5 - OFF 6 - ON 3 MINUTES 50%

Enhanced

5 - ON 6 - ON 50 - 100%

Mode**

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.

*- This setting is equivalent to BAY24X045 relay ben-

efit.

**- This selection provides ENHANCED MODE, which

is a ramping up and ramping down of the blower

speed to provide improved comfort, quietness, and

potential energy savings. See Wiring Diagram

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

plete wiring setup for ENHANCED MODE. The

graph which follows, shows the ramping process.

See Wiring Diagram on the unit or in the Service

Facts for complete wiring setup for Enhanced

Mode.

AIRFLOW ADJUSTMENT

Disconnect power to the unit before removing the

blower door. Allow a minimum of 15 seconds for IFC

power supply to discharge to 0 volts.

Failure to follow this warning could result in property

damage, personal injury or death.

Installer's Guide

Operation with the door removed or ajar can permit the

escape of dangerous fumes. All panels must be se-

curely closed at all times for safe operation of the Fur-

nace.

Failure to follow this warning could result in property

damage, personal injury or death.

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 Service Facts for information on

changing the speed of the blower motor.

100%

50% 50%

:ast Cooling Efficiency

Ill 7,5 I I 3I

minute minutes minutes

OFF

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.

ROOM AIR COMFORT CONTROL

HEAT ANTICIPATOR ADJUSTMENT

Set the Comfort Control 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 casing).

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.

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 a

qualified service technician.

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.

18-CD24D 1-2 25

Installer's Guide

CONDITIONS THAT AFFECT SYSTEM

OPERATION

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN

EXCESS OF 40 M,°.H.) VENT OR FLUE BLOCKAGE

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 Comfort

Control 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, than if ignition is not achieved,

the Integrated Control Module will shut off the Gas

Valve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE

If pressure is not sensed by the Pressure Switch,

the contacts will remain open and not allow the Gas

Valve to open, therefore the unit will not start. If

failure occurs during a running cycle, the Pressure

Switch contacts will open and the Gas Valve will

close to shut the unit down.

6. RESET AFTER LOCKOUT

When the Integrated Control Module has shut the

system down and gone into lockout, the system

must be 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 Com-

fort Control. The system will not reset unless the

procedure off-on-off-on is completed within 30 sec-

onds.

WHOLE HOUSE AIR CLEANER CHECKOUT

Before changing the position of the High Voltage se-

lector switch on the High Voltage power supply,

make sure the power has been removed from the fur-

nace and the High Voltage power supply.

Check out the Furnace Whole House Air Cleaner instal-

lation in accordance with this instructions page 30. Ad-

just ozone setting if needed. See Figure 22 on page 30.

NOTE: Whole House Air Cleaner is energized when

blower is operating and there is a call for heat or cool

This can result in brief periods of blower operation

with the whole house air cleaner off. This can occur

during the heat fan off period or if the enhanced

mode of operation is chosen for cooling.

WHOLE HOUSE AIR CLEANER

MAINTENANCE

1. For maximum efficiency the COLLECTION CELL

should be inspected and cleaned on a regular basis.

NOTE: A30to90 day cleaning interval is normal

for the COLLECTION CELL and should be ad-

justed based upon unit run time and the home

environment.

2. The FIELD CHARGER must be removed and

cleaned only by a qualified service professional.

3. The FIELD CHARGER must be cleaned at least once

a year.

4. The FIELD CHARGER may require more frequent

cleaning in homes with high indoor relative humid-

ity (greater than 65% RH).

5. Consult your service professional about cleaning

intervals.

TO PREVENT INJURY OR DEATH DUE TO CONTACT

WITH MOVING PARTS, TURN THE POWER TO THE

FURNACE OFF BEFORE CLEANING OR SERVICING

THE WHOLE HOUSE AIR CLEANER.

FAILURE TO FOLLOW THIS WARNING COULD RE-

SULT IN PROPERTY DAMAGE, PERSONAL INJURY

OR DEATH.

RISK OF ELECTRIC SHOCK:

THESE SERVICING INSTRUCTIONS ARE FOR USE BY

QUALIFIED PERSONNEL ONLY. TO REDUCE THE

RISK OF ELECTRIC SHOCK, DO NOT PERFORM ANY

SERVICING OTHER THAN THAT CONTAINED IN

THESE OPERATING INSTRUCTIONS UNLESS YOU

ARE QUALIFIED TO DO SO. FAILURE TO FOLLOW

THIS WARNING COULD RESULT IN PROPERTY DAM-

AGE, PERSONAL INJURY OR DEATH.

High Voltage is present within the air cleaner for opera-

tion. Turn the power off and wait at least 15 seconds to

allow voltage to discharge.

NOTE: System Information

Before cleaning the coil or ducts in the furnace, re-

move the COLLECTION CELL and FIELD CHARGER

from the air cleaner. Chemicals used during the

cleaning of the Furnace, or ductwork can damage the

air cleaner components and degrade the perfor-

mance of the air cleaner.

26 18-CD24D 1-2

CLEANING THE COLLECTION CELL

1. Turn the air conditioning system off at the Comfort

Control and turn off service disconnect.

2. Remove top furnace door.

3. Slide COLLECTION CELL out of Furnace.

CLEANING

The COLLECTION CELL may be cleaned either by

vacuuming (recommended method) or by washing.

VACUUM CLEANING

Remove the COLLECTION CELL from the condi-

tioned space before vacuuming. Vacuum both sides of

the COLLECTION CELL to clean.

WASHING

Use low-pressure water spray, such as a sink sprayer

or garden hose to clean the COLLECTION CELL.

Some residue may require warm water to be re-

moved.

•Do NOT use soap or detergent in cleaning

the COLLECTION CELL.

•Do NOT immerse the COLLECTION CELL

completely in water.

•Do NOT place the COLLECTION CELL into

a dishwasher to clean.

•ALLOW THE COLLECTION CELL TO DRY

THOROUGHLY BEFORE REINSTALLING.

Slightly tap the COLLECTION CELL to remove water re-

tained in the filter. Allow the COLLECTION CELL to dry

thoroughly before reinstalling.

CLEANING THE FIELD CHARGER

FIELD CHARGER PINS ARE SHARP. DO NOT BEND

FIELD CHARGER PINS. WEAR APPROPRIATE GLOVES

WHEN HANDLING THE FIELD CHARGER.

1. Turn off the Comfort Control and the service dis-

connect.

2. Turn off power to the Furnace and remove the top

furnace door panel.

3. Remove COLLECTION CELL.

4. Remove the inner blower door panel by removing

four screws.

5. Disconnect green return wire and red high voltage 9.

wire. To remove high voltage wire, twist and pull

connecter apart. 10.

6. Remove the two 5/16" hold down screws at the front

center. 11.

7. Lift up the front of the FIELD CHARGER and slide

forward to remove from the case. Lay the FIELD 12.

CHARGER on a secured flat surface.

8. Wipe down the face Plate of the FIELD CHARGER 13.

with a dry shop towel or use a vacuum cleaner. Do

not disassemble the FIELD CHARGER.

Installer's Guide

Figure 19

Figure 20

NOTE: Do NOT use water, soap, detergent, or chemicals

to clean the FIELD CHARGER.

To clean pins, push a block of foam down over the

FIELD CHARGER Pin.

Rotate the foam block on the FIELD CHARGER

Pin.

Use the foam block to clean the faceplate opening

edges.

Repeat steps 9 and 10 for each FIELD CHARGER

Pin.

Reverse steps to reassemble the air cleaner. The

inner blower door MUST be reinstalled.

18-CD24D1-2 27

Installer's Guide

INDOOR MOTOR MAINTENANCE

NOTE: Direct drive motors have bearings which are

permanently lubricated and under normal use, lubri-

cation is not recommended.

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.

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.

INTEGRATED FURNACE CONTROL RED LED "ERROR" FLASH CODES

2 Flashes --- System Lockout (Retries or Recycles exceeded)

Draft Pressure Error- Possible problems:

a) Venting problem

b) Pressure switch problem

c) Inducer problem

3 Flashes ---

4 Flashes --- Open Temperature Limit Switch

5 Flashes --- Flame sensed when no flame should be present

115 volt AC power reversed, ignitor (Triac) fault, poor grounding or

6 Flashes--- system voltage too low

7 Flashes --- Gas valve circuit error

8 Flashes --- Low flame sense

9 Flashes --- Open Inducer Limit switch

10 Flashes --- Inducer communication error

Solid --- Internal GV error or Low TH voltage

Solid Red w/Solid Continuous Reset caused by a blown fuse or internal error.

Green "STATUS" LED

28 18-CD24D 1-2

FAULT CODE RECOVERY

On power up, last 4 Faults, if any, will be flashed on the

Red LED. The newest Fault detected will flash first and

the oldest last. There will be a 2 second delay between

Fault Code flashes. Solid Red LED error codes will not

be displayed.

The Green LED will be on solid during last Fault Re-

covery. At any other time the control is powered, the

Green LED indicator light will operate as shown in

Table 13 and the Red LED will flash LitePort data (one

flash) every 20 seconds.

TABLE 13

INTEGRATED FURNACE CONTROL

GREEN "STATUS" LED FLASH CODES

Flashing Slow --- Normal - No call for Heat

Flashing Fast --- Normal - Call for Heat

Fault Code Reset

The last 4 Fault Codes can be erased from memory by

powering up the control with "G" energized and then ap-

plying "R" to the "WI" terminal 3 times within 6 sec-

onds. The control will acknowledge the reset by turning

on the Red LED for 2 seconds.

Installer's Guide

Figure 21

*UX2/DX2 Integrated Furnace Control

Green Status

NOTE: In normal operation, the furnace makes a slight

sound as the air passes through and is cleaned. In

some applications, you may notice this sound coming

from the return air vent(s). If desired, this sound level

can be reduced with minimal impact on air cleaning ef-

ficiency by reducing the power setting of the FIELD

CHARGER. The unit is shipped with the power set at

9.6KV (high). If sound is heard, reduce power level to

8.0KV (low) at the switch on the power supply. See Fig-

ure 22.

High Voltage switch

9.6 to 8.0 KVDC

9.6 KVDC is top down I\

8.0 KVDC is bottom down I/

LED

Figure 22

Return from air cleaner

Green

High voltage power lead

Pink

24 VAC Hot

/Red

24 VAC Common

Blue

18-CD24D1-2 29

CHECKOUT PROCEDURES

After installation has been completed, it is recommended that the Furnace be checked against the following

checklist.

1. Make sure power is "OFF" at power disconnect

switch ................................................................. [ ]

2. Check all field wiring for tight connections. See

that grounding of unit is in accord with code... [ ]

3. Make sure unit suspension (if used) is secure and

that there are no tools or loose debris in, around or

on top of the unit ............................................... [ ]

4. Check all duct outlets; they must be open and unre-

stricted ............................................................... [

5. Check drain lines and be sure all joints are fight

...........................................................................

6. Make sure secondary drain pan is installed ..... [

7. Check power supply for correct requirements

unit nameplate .................................................. [

8. Energize the system and carefully observe its

eration; make any necessary adjustment ........ [

9. Adjust ozone setting, if needed ......................... [

10. Instruct owner on proper operating procedure

leave Use and Care Manual with owner .......... [

11. Check the Whole House Air Cleaner power output

by the Green LED illumination. If the LED is on,

this indicates High Voltage output to the air

cleaner ............................................................ [ ]

a) Turn the Comfort Control to fan only.

b) Remove blower door panel.

RISK OF ELECTRICAL SHOCK

]ELECTRICAL POWER IS PRESENT FOR THE

.. NEXT 2 STEPS. THESE STEPS SHOULD BE

] PERFORMED ONLY BY QUALIFIED PERSON-

NEL.

] FAILURE TO FOLLOW THIS WARNING COULD

per RESULT IN PERSONAL INJURY, ELECTRICAL

] SHOCK, OR DEATH.

op- c) Depress blower door switch.

] d) Verify with Fan running that green LED is il-

l luminated.

and e) Release Blower Door Switch and put Blower

] Door back on.

fl Turn Comfort Control to desired position.

Trane

6200 Troup Highway

Tyler, TX 75707

For more information contact

your local dealer (distributor)

03/08

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

right to change design and specifications without notice.

TRANE Furnace/Heater, Gas Manual L0906046

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