Ameristar M952V Installation Manual

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18-CD37D1-2-EN

INSTALLER'S GUIDE

Upﬂow / Horizontal and Downﬂow / Horizontal, Gas-Fired, Direct Vent, 2-Stage Condensing Furnaces with Variable Speed Inducer

M952V060BU36AA M952V080BU36AA M952V100CU48AA M952V120DU60AA

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.

OPTIONAL ACCESSORIES

Model Number Description

BAYBASE205 Downﬂow subbase for downﬂow models only

BAYFLTR200 External side ﬁlter rack

BAYFLTR203 Filter kit horizontal for 17.5" cabinet

BAYFLTR204 Filter kit horizontal for 21" cabinet

BAYFLTR205 Filter kit horizontal for 24.5" cabinet

BAYFLTR317 Cleanable ﬁlter for 17.5" cabinet upﬂow only

BAYFLTR321 Cleanable ﬁlter for 21" cabinet upﬂow only

BAYFLTR324 Cleanable ﬁlter for 24.5" cabinet upﬂow only

BAYLPKT210B Propane conversion kit

BAYLPSS210B LP kit with stainless steel burners

BAYMFGH100A Manufactured / mobile home kit

BAYRACK960A Internal ﬁlter rack kit for upﬂow models

BAYAIR30AVENTA Concentric vent kit for 2,2.5,3" vent system

BAYVENT200B Sidewall vent termination kit for direct vent furnaces

BAYVENT500A Side vent kit for downﬂow models only

BAYSWT10AHALTA High altitude switch kit - UF/DF 060

BAYSWT08AHALTA High altitude switch kit - UF/DF 080-120

KIT09224 Filter clip kit

BAYBRCKFLT10 Downﬂow bracket kit

M952V060BD36AA M952V080BD36AA M952V100CD48AA M952V120DD60AA

M952 Furnace

M952 Upﬂow models can also be used in the Horizontal Left conﬁguration.

M952 Downﬂow models can also be used in the Horizontal Right conﬁguration.

Figure 1

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Installer’s Guide

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WARNING

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.

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WARNING

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WARNING

HAZARD OF EXPLOSION! NEVER USE AN OPEN FLAME TO DETECT GAS LEAKS. EXPLOSIVE CONDITIONS MAY OCCUR. USE A LEAK TEST SOLUTION OR OTHER APPROVED METHODS FOR LEAK TESTING. FAILURE TO FOLLOW RECOMMENDED SAFE LEAK TEST PROCEDURES COULD RESULT IN DEATH OR SERIOUS INJURY OR EQUIPMENT OR PROPERTY-ONLY-DAMAGE.

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WARNING

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CAUTION

Careful consideration must be taken in the installation process to avoid personal injury, property damage or equipment damage. These instructions do not cover all variations in systems or provide for every possible contingency. Should further information 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.

Safety signal words are used to designate a degree or level of seriousness associated with a particular hazard. The signal words for safety markings are WARNING, and CAUTION.

a. WARNING indicates a potentially hazardous situation

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

b. CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices and hazards involving only property damage.

WARNING

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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

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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 when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

SAFETY SECTION

FIRE OR EXPLOSION HAZARD FAILURE TO FOLLOW THE SAFETY WARNINGS EXACTLY COULD RESULT IN SERIOUS INJURY, DEATH OR PROPERTY DAMAGE. IMPROPER SERVICING COULD RESULT IN DANGEROUS OPERATION, SERIOUS INJURY, DEATH, OR PROPERTY DAMAGE.

SAFETY HAZARD THIS INFORMATION IS INTENDED FOR USE BY INDIVIDUALS POSSESSING ADEQUATE BACKGROUNDS OF ELECTRICAL AND MECHANICAL EXPERIENCE. ANY ATTEMPT TO REPAIR A CENTRAL AIR CONDITIONING PRODUCT MAY RESULT IN PERSONAL INJURY AND OR PROPERTY DAMAGE. THE MANUFACTURER OR SELLER CANNOT BE RESPONSIBLE FOR THE INTERPRETATION OF THIS INFORMATION, NOR CAN IT ASSUME ANY LIABILITY IN CONNECTION WITH ITS USE.

Sharp Edge Hazard. Be careful of sharp edges on equipment or any cuts made on sheet metal while installing or servicing. Personal injury may result.

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Installer’s Guide

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CAUTION

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WARNING

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WARNING

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.

WARNING

To prevent shortening its service life, the Furnace should not be used as a “Construction Heater” during the ﬁnishing phases of construction until the requirements listed in item 9, a-g of the safety section of this publication have been met. Condensate in the presence of chlorides and ﬂuorides from paint, varnish, stains, adhesives, cleaning compounds, and cement create a corrosive condition which may cause rapid deterioration of the heat exchanger.

FIRE & EXPLOSIVE HAZARD. DO NOT USE SEMI-RIGID METALLIC GAS CONNECTORS (FLEXIBLE GAS LINES) WITHIN THE FURNACE CABINET. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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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 WARNING DEVICE. IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO CONTACT A GAS SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does not test any detectors and makes no representations regarding any brand or type of detector

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Installer’s Guide

The following safety practices and precautions must be followed during the installation, servicing, and operation of this Furnace.

1. Use only with the type of gas approved for this Furnace. Refer to the Furnace rating plate.

2. Install this Furnace only in a location and position as speciﬁed in “Location and Clearances” (page 5) of these instructions.

3. Provide adequate combustion and ventilation air to the Furnace space as speciﬁed in “Air for Combustion 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 15), of these instructions.

5. Never test for gas leaks with an open ﬂame. Use a commercially available soap solution made speciﬁcally for the detection of leaks to check all connections, as speciﬁed in the “Gas Piping” section of these instructions on page 31.

6. Always install the Furnace to operate within the Furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as speciﬁed on the unit rating plate. Airﬂow with temperature rise for cfm versus static is shown in the Service Facts accompanying this Furnace.

7. When a Furnace is installed so that supply ducts carry air circulated by the Furnace to areas outside the space containing the Furnace, the return air shall also be handled by a duct(s) sealed to the Furnace casing and terminating outside the space containing the Furnace.

8. A gas-ﬁred Furnace for installation in a residential garage must be installed as speciﬁed in “Location and Clearances” section (page 5) , of these instructions.

9. The Furnace may be used for temporary heating of buildings or structures under construction only when the following conditions have been met:

a. The Furnace venting system must be complete and

installed per manufacturers instructions.

b. The Furnace is controlled only by a room Comfort

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 marking.

e. 100% of the Furnace combustion air requirement

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 operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer's instructions.

10. This product must be gas piped by a Licensed Plumber or Gas Fitter in the Commonwealth of Massachusetts.

Contents

Safety Section ................................................................2

Installation Instructions ........................ 5

General ........................................................................... 5

Location and Clearances ................................................ 5

Outline Drawings .......................................................... 6

Upﬂow Installation .......................................................... 8

Downﬂow Installation ......................................................8

Horizontal Installation ..................................................... 8

Air For Combustion and Ventilation ................................ 9

Duct Connections ......................................................... 10

Return Air Filters .......................................................... 11

General Venting ............................................................ 15

Vent Tables ................................................................... 19

Horizontal Venting ....................................................... 20

Horizontal Venting Through a Wall................................ 21

Venting Through The Roof ............................................ 24

Venting Routed Through a Masonry Chimney ..............24

Downward Venting ........................................................ 26

Condensate Drain Instructions ..................................... 27

Gas Piping .................................................................... 32

Combustion and Input Check ....................................... 32

High Altitude Derate ..................................................... 35

Electrical Connections .................................................. 36

Field Wiring Diagrams .................................................. 36

Start-up and Adjustment .................... 41

Preliminary Inspections ................................................ 41

Lighting Instructions ..................................................... 41

Sequence of Operation ................................................ 41

Control and Safety Switch Adjustments .......................42

Conditions Affecting System Operation ........................... 43

IFC Error Flash Codes ......................... 44

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Installer’s Guide

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WARNING

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CAUTION

GENERAL INSTALLATION INSTRUCTIONS

The manufacturer assumes no responsibility for equipment installed in violation of any code or regulation.

It is recommended that Manual J of the Air Conditioning Contractors Association (ACCA) or A.R.I. 230 be followed in estimating heating requirements. When estimating heating requirements for installation at Altitudes above 2000 ft., remember the gas input must be reduced (See combustion and input check page 31).

Material in this shipment has been inspected at the factory and released to the transportation agency without known damage. Inspect exterior of carton for evidence of rough handling in shipment. Unpack carefully after moving equipment to approximate location. If damage to contents is found, report the damage immediately to the delivering agency.

Codes and local utility requirements governing the installation of gas ﬁred equipment, wiring, plumbing, and ﬂue connections must be adhered to. In the absence of local codes, the installation must conform with latest edition of the National Fuel

Gas Code ANSI Z223.1 • National Installation Code, CAN/CGA

B149.1. The latest code may be obtained from the American Gas Association Laboratories, 400 N. Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or www.aga.org.

These Furnaces have been classiﬁed as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21.47 stan-

dards • CSA 2.3. Category IV furnaces operate with positive

vent static pressure and with a ﬂue loss less than 17 percent. These conditions require special venting systems, which must be gas tight and water tight. These Category IV Direct Vent Furnaces are approved for installation in Manufactured/ Mobile housing when used with BAYMFGH100A.

LOCATION AND CLEARANCES

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 12" above the highest snow accumulation level?

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.

IMPORTANT: The Furnace must be installed level. The only allowable variation would be slightly to the left and/ or forward in upﬂow installations or slightly toward the front in horizontal installations. This is necessary for proper condensate drainage.

7. A Furnace shall be installed so electrical components are protected from water.

8. If the Furnace is installed in a garage, it must be installed so that the burners, and the ignition source are located not less than 18 inches above the ﬂoor and the Furnace must be located or protected to avoid physical damage from vehicles.

FIRE HAZARD. 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 contaminated atmosphere. Failure to follow this caution 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 enclosure equal or exceed the minimums stated in Clearance Table on the Outline Drawings?

3. Is there sufﬁcient space for servicing the Furnace and other equipment? A minimum of 24 inches front accessibility to the Furnace must be provided. Any access door or panel must permit removal of the largest component.

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Installer’s Guide

Figure 2. Upﬂow Outline Drawing

MODEL (SEE NOTE 1&2) DIM "A" DIM "B" DIM "C" DIM "D" DIM "E" DIM "F"

17-1/2" 2-1/4" 16-1/4" 16" 7-1/2" 2"

M952V060BU36A*

M952V080BU36A*

REQUIRES 2-1/2" OR 3" DIAMETER VENT PIPE.

SOME MODELS ARE DIFFERENT ALTITUDES. REFER TO THE VENT

LENGTH TABLE FOR PROPER APPLICATION.

1. M952V120DU60AA REQUIRES 3" DIAMETER PIPE. M952V100CU48AA

2. DIAMETER OF SOME VENT PIPE MAY BE LIMITED TO 2-1/2" OR 3" ON

* SUFFIX LETTER MAY BE A-Z

NOTES:

M952V100CU48A* 21" 2-1/2" 19-3/4"" 19-1/2" 9" 3"

M952V120DU60A* 24-1/2" 2-15/16" 23-1/4" 23" 10" 3"

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Installer’s Guide

Figure 3. Downﬂow Outline Drawing

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

MODEL (SEE NOTE 1&2) DIM "A" DIM "B" DIM "C" DIM "D"

M952V060BD36A*

M952V080BD36A*

M952V100CD48A* 21" 2-1/2" 19-3/4"" 19-1/2"

M952V120DD60A* 24-1/2" 2-15/16" 23-1/4" 23"

* SUFFIX LETTER MAY BE A-Z

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Installer’s Guide

UPFLOW

FURNACE

CASED

COIL

SCREWS

(BOTH SIDES)

STANDOFFS

(BOTH SIDES)

STANDOFFS (4)

DRILL SCREWS (4)

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WARNING

INSTALLATION INSTRUCTIONS

FIRE HAZARD. DO NOT INSTALL THE FURNACE DIRECTLY ON CARPETING, TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING. FOR VERTICAL DOWNFLOW APPLICATION, SUBBASE (BAYBASE205) MUST BE USED BETWEEN THE FURNACE AND COMBUSTIBLE FLOORING. WHEN THE DOWNFLOW FURNACE IS INSTALLED VERTICALLY WITH A CASED COIL, A SUBBASE IS NOT REQUIRED.

The bottom panel of the upﬂow furnace must be removed for bottom return air. Remove the ﬁlter and lay the furnace on its back. Remove the two 5/16" hex screws securing the bottom front channel to the cabinet. Lower the front edge of the bottom front channel and pull forward to remove the channel. The bottom return air panel will now easily slide out of the cabinet. Reinstall the bottom front channel and ﬁlter for upﬂow bottom return installations.

UPFLOW INSTALLATION

Standoffs and screws (See Figure 4) are included with the cased coils for attachment to the Furnace. There are clearance alignment holes near the bottom of the coil wrapper. Drill screws are used to engage the Furnace top ﬂanges. The standoff is inserted into the cabinet alignment hole. The drill screws are inserted through the standoffs then screwed into the Furnace ﬂange. The coil is always placed downstream of the Furnace airﬂow. The above instructions apply only if the coil is on top of an upﬂow Furnace

FOR VERTICAL

Figure 4

DOWNFLOW INSTALLATION

Figure 5

Table 1 Required ﬂoor opening: (DOWNFLOW)

CABINET

WIDTH

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"

RETURN

DUCT WIDTH

FLOOR OPENING PLENUM OPENING

"A" "B"

"C" "D"

A (width)

FURNACE

FRONT

B (depth)

Figure 6

HORIZONTAL INSTALLATION

The coil and Furnace must be fully supported when used in the horizontal position. It is always recommended that an auxiliary drain pan be installed under a horizontally installed evaporator coil or 90% Gas Furnace. Connect the auxiliary drain line to a separate drain line (no trap is needed in this line). Three brackets (with screws) are included with downﬂow furnaces for installation to stabilize and secure the 2/4TXC cased coil in the horizontal position. See Figure 8.

The cased coil is secured to the Furnace. The brackets mount using the rear screws on the coil case. Use the screws provided to secure the bracket to the Furnace. The remaining bracket is placed as close to horizontal center as possible between the coil and the Furnace, converted to horizontal, aligns and attaches to the TXC coil.

The Furnace and the cased coil must be properly supported.

The Furnace may be installed in an attic or crawl space in the horizontal position by placing the Furnace on the left side (as viewed from the front in the vertical position). The horizontal Furnace installation in an attic should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of the Furnace (See Figure 6 & 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. The Furnace may be placed horizontally in a crawl space on a pad or other noncombustible material which will raise the unit for sufﬁcient protection from moisture.

The Furnace must be supported at both ends and the middle when installed horizontally. The Furnace must also be elevated approximately 4-6 inches to allow clearance for the condensate drain to exit the cabinet in the horizontal position.

Table 2 - MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR UPFLOW/HORIZONTAL

AND DOWNFLOW/ HORIZONTAL FURNACES

UNIT LOCATION

FURNACE SUR-

FAC E

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

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VERTICAL CLOSET HORIZONTAL CLOSET

HORIZONTAL ALCOVE /

ATTIC

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.

Page 9

The horizontal Furnace may also be suspended from the joists

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.

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WARNING

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 supported at all four corners and in the middle at the front of the Furnace.

UPFLOW/ HORIZONTAL SHOWN WITH DIRECT VENT

Figure 7

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW FUR-

NACE IN HORIZONTAL

DOWNFLOW ONLY

Figure 8

AIR FOR COMBUSTION AND VENTILATION

Installer’s Guide

Table 3

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE MAXI-

MUM BTUH INPUT

RATING

60,000

80,000 100,000 120,000 140,000

MINIMUM AREA IN SQUARE FEET OF UN-

Unconﬁned space is deﬁned in Table 3 and Figure 9. These spaces may have adequate air by inﬁltration to provide air for combustion, ventilation, and dilution of ﬂue gases. Buildings with tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), may need additional air provided as described for conﬁned space.

1. All air from inside the building as in Figure 11: The conﬁned space shall be provided with two permanent openings communicating directly with an additional room(s) of sufﬁcient volume so that the combined volume of all spaces meets the criteria for an unconﬁned space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Refer to Table 4, for minimum open areas required.

2. All air from outdoors as in Figure 12: The conﬁned space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure.

The openings shall communicate directly, or by ducts,

with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 4, for minimum open areas required.

WITH 8 FT. CEILING

CONFINED SPACE

375 500 625 750 875

Adequate ﬂow of combustion and ventilating air must not be obstructed from reaching the Furnace. Air openings provided in the Furnace casing must be kept free of obstructions which restrict the ﬂow of air. Airﬂow restrictions affect the efﬁciency and safe operation of the Furnace. Keep this in mind should you choose to remodel or change the area which contains your Furnace. Furnaces must have a free ﬂow of air for proper performance.

Provisions for combustion and ventilation air shall be made in accordance with “latest edition” of Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CSA B149.1 Installation Codes, and applicable provisions of the local building codes. Special conditions created by mechanical exhausting of air and ﬁreplaces must be considered to avoid unsatisfactory Furnace operation.

UNCONFINED

50 CU. FT. OR MORE PER 1000 BTU/ HR. INPUT ALL EQUIP. INSTALLED

Furnace locations may be in a conﬁned space (see Figure

10) or an unconﬁned space (See Figure 9).

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Figure 9

CONFINED

LESS THAN 50 CU. FT. PER 1000 BTU/HR. INPUT ALL EQUIP INSTALLED

Figure 10

Table 4

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace Max

BTUH/INPUT Rtg

60,000

80,000 100,000 120,000 140,000

Air From

Inside

100 100 100 120 140

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 10. Air for combustion and ventilation requirements can be supplied from inside the building as in Figure 11 or from the outdoors, as in Figure 12.

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.

Air From Outside

Vertical Duct Horizontal Duct

15 20 25 30 35

30 40 50 60 70

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Installer’s Guide

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CAUTION

SAFETY HAZARD Sharp Edge Hazard. Be careful of sharp edges on equipment or any cuts made on sheet metal while installing or servicing. Personal injury may result.

Exposure to the following substances in the combustion

air supply will also require OUTDOOR AIR for combus-

tion: * Permanent wave solutions * Chlorinated waxes and cleaners * Chlorine based swimming pool chemicals * Water softening chemicals * Deicing salts or chemicals * Carbon Tetrachloride * Halogen type refrigerants * Cleaning solvents (such as 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 corrosive atmospheres, including but limited to, dry cleaners, beauty shops, and printing facilities.

DUCT CONNECTIONS

Figure 11

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.

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 dampers or other means used to control ﬂow of air shall be adequate to prevent chilled air from entering the Furnace, and if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in full heat or cool position.

Flexible connections of nonﬂammable material may be used for return air and discharge connections to reduce the 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, 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 designed 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 installation of air return remote from the living area (i.e. central hall).

When the Furnace is installed so that the supply ducts carry air circulated by the Furnace to areas outside the space containing the Furnace, the return air shall also be handled by a duct(s) sealed to the Furnace and terminating outside the space containing the Furnace.

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Figure 12

Page 11

Installer’s Guide

Where there is no complete return duct system, the return connection must be run full size from the Furnace to a location outside the utility room, basement, attic, or crawl space.

Do Not install return air through the back of the Furnace

cabinet.

Do Not install return air through the side of the furnace cabinet on horizontal applications.

Carbon monoxide, ﬁre or smoke can cause serious bodily injury, death, and/or property damage.

A variety of potential sources of carbon monoxide can be found in a building or dwelling such as gas-ﬁred clothes dryers, gas cooking stoves, water heaters, furnaces and ﬁreplaces. The U.S. Consumer Product Safety Commission recommends that users of gas-burning appliances install carbon monoxide detectors as well as ﬁre and smoke detectors per the manufactures installation instructions to help alert dwelling occupants of the presence of ﬁre, smoke or unsafe levels of carbon monoxide. These devices should be listed by Underwriters Laboratories, Inc. Standards for Single and Multiple Station Carbon

Monoxide Alarms, UL 2034 or CSA International Standard, Residential Carbon Monoxide Alarming Devices, CSA 6.19.

NOTE: The manufacturer of your Furnace DOES NOT test any detectors and makes no representations regarding any brand or type of detector.

All return air duct systems should provide for installation of return air ﬁlters.

PREPARATION FOR UPFLOW BOTTOM AND SIDE RETURN AIR FILTER INSTALLATION

All return air duct systems should provide for installation of return air ﬁlters.

1. Determine the appropriate position to set the furnace in order to existing supply and return ductwork.

2. The return air ﬁlter is shipped in either the bottom or side location. Remove the ﬁlter by ﬁrst turning the two latches on the blower door and tilting the door forward to remove. Remove the ﬁlter by sliding it out.

3. For upﬂow side return installations, remove the insulation around the opening in the blower compartment.

4. The side panels of the upﬂow furnace include locating notches that are used as guides for cutting an opening for return air, refer to Figure 13 and the outline drawing on page 6 for duct connection dimensions for various furnaces.

5. If a 3/4" ﬂange is to be used for attaching the air inlet duct, add to cut where indicated by dotted lines in Figure 13. Cut corners diagonally and bend outward to form ﬂange.

6. If ﬂanges are not required, and a ﬁlter frame is installed, cut between locating notches (See Figure 13).

7. The bottom panel of the upﬂow furnace must be removed for bottom return air. After removing the ﬁlter, lay the furnace on its back. Remove the two 5/16" hex screws securing the front of the bottom channel to the cabinet. Rotate the channel downward (or remove by lowering the front edge of the channel and pulling forward).

Slide the bottom return air panel out of the cabinet. Rotate

the front channel to its original position and reinstall the two 5/16” screws.

8. The horizontal installation of the upﬂow furnace

requires an external ﬁlter section. Do NOT use the bottom return ﬁlter within the furnace. Filter kits are available for horizontal applications.

9. Connect duct work to furnace. See Outline Drawing for supply and return duct size and location. Flexible duct con nectors 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.

Return Air Filters

TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS

Filters are factory supplied for these furnaces. These furnaces require high velocity type air ﬁlters. The ﬁlters may be installed within the furnace blower compartment for UPFLOW furnaces in either a BOTTOM or SIDE (left side or right side) return air inlet. Some ﬁlters may need to be trimmed for side or bottom ﬁlter use.

Table 5

MODELS

NUMBERS

M952V060BU36A M952V080BU36A M952V100CU48A M952V120DU60A

*Last letter may be "A" or "T" **NOTE: For upﬂow 5 ton airﬂow models where the airﬂow requirement exceeds 1800 CFM - Models will require return air openings and ﬁlters on: (1) both sides, or (2) one side and the bottom, or (3) just on the bottom

NOTE: For upﬂow 5 ton airﬂow models where the airﬂow requirement exceeds 1800 CFM - Models will require return air openings and ﬁlters on: (1) both sides, or (2) one side and the bottom, or (3) just the bottom.

UPFLOW FURNACE ONLY

LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT

*SEE OUTLINE DRAWING

CABINET

WIDTH

FILTER

QTY & SIZE

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"

FRONT of Furnace

Figure 13

18-CD37D1-2-EN 11

Page 12

Installer’s Guide

Filter

The furnace and the bottom ﬁlter rack, BAYRACK960, installation can be seen in Figure 14.

Blower Deck Engagement

Hole

Airflow

Blower Door Hinge and Bottom Filter Rack Installation

Filter Rack Assembly

ALTERNATE FILTER RACK INSTALLATION FOR BOTTOM RETURN - BAYRACK960

The following checklist should be used when installing as a bottom return ﬁlter on an upﬂow furnace:

a. Remove the ﬁlter.

b. Remove the bottom panel.

c. Pre-drill two engagement holes with 3/16" drill at dimple

locations. See Figure 16.

d. With the ﬁlter removed, the ﬁlter rack is compressed

and then inserted into the bottom of the furnace. The retaining screw/pin on each side inserts into engagement holes at the bottom of the furnace cabinet side. See Figure 17.

e. Reinstall the furnace ﬁlter in the bottom position by

inserting the chamfer end ﬁrst into the ﬁlter rack.

Figure 14

Figure 15

PRE-DRILL

Two clearance holes with a 3/16” drill at dimple locations (one per side)

VIEW

Figure 16

Furnace

Rack

Cabinet

Side

Filter Rack Retaining

Engagement Hole For

Filter Rack Installation With Bottom Return (Pre-drill 3/16” diameter clearance holes)

Figure 17

ALTERNATE FILTER RACK INSTALLATION FOR SIDE RETURN AIR ON UPFLOW FURNACES (Left or Right) BAYRACK960

The following checklist should be used when installing a right or left side return ﬁlter on an upﬂow furnace:

a. Remove the ﬁlter.

b. Leave the bottom panel in place.

c. Make side cutout by following the directions in the

“Return Air Duct Connections” section on page 11.

d. Compress the ﬁlter rack and reinstall in the side

position on the furnace. Conﬁrm that the upper retaining pin/screw locks into the engagement hole in the blower deck and the lower pin/screw rests against the side of the bottom panel. See Figures 16, 18-21.

e. Reinstall the furnace ﬁlter in the side position by

inserting the chamfer end ﬁrst into the ﬁlter rack.

Conversion kits for horizontal ﬁlters are BAYFLTR203 for 17 1/2" width cabinets, BAYFLTR204 for 21" width cabinets, and BAYFLTR205 for 24" width cabinets. These include ﬁlters and brackets necessary for horizontal ﬁlters. See Figure 25.

Screw/Pin

12 18-CD37D1-2-EN

Page 13

Installer’s Guide

Filter Rack Assembly

Furnace Blower Deck

Filter Rack Retaining Screw/Pin

Engagement Hole For

Return

Filter Rack Installation With Side

Furnace

Cabinet

Side

CHAMFER

END OF

FILTER GOES

INTO FILTER RACK FIRST

Filter Rack

RETAINING

(Both Sides)

SPRINGS

SIDE

CUTOUT

FILTER

RACK

RAILS

BOTTOM

PANEL

INSTALLED

Airflow

RETAINING

(Both Sides)

SPRINGS

SIDE

CUTOUT

FILTER

RACK

RAILS

BOTTOM

PANEL

INSTALLED

Airflow

Furnace

Cabinet

Side

BOTTOM ENGAGEMENT

BLOWER DECK

Retaining Screw/Pin

Figure 18

Filter Rack

Bottom Panel

Figure 21

Typical Upﬂow Right Side Return Filter Rack Installation

Airflow

Figure 19

Figure 22

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 furnace 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 23.

Typical Upﬂow Left Side Return Filter Rack Installation

18-CD37D1-2-EN 13

Figure 20

Accessory ﬁlter kit BAY-

Figure 23

FLTR203, 204, or 205 used for Upﬂow Horizontal furnaces.

Typical Horizontal Filter Installation

Airﬂow

Page 14

Installer’s Guide

UPFLOW FILTER CLIP / BRACKET INSTALLATION

1. Determine the location to be used. The furnace cabinet has dimples for location of the furnace clips (Side return only). Predrill clearance holes with a 3/16" drill. Bottom return holes are pre-drilled.

2. Install the clips in front and rear of the desired location using the screws provided. The ﬁlter clip with the leaf spring mounts in the rear of the cabinet. See Figure 24.

Figure 24

SIDE

CUT-OUT

ALTERNATE SIDE

FILTER CLIPS

LOCATIONS

ALTERNATE BOTTOM

FILTER CLIPS LOCATIONS

Important: When using the supplied high velocity ﬁlters, the ﬁlter support base must be installed into the furnace duct ﬂange prior to ductwork installation.

Remove the brackets from the blower compartment. They are wrapped in foam and taped to the side of the downﬂow unit.

Remove the four screws securing the top panel. Save screws.

Slide the top panel forward approximately 1”.

With support tabs facing up, install the ﬁlter base by inserting one end tab into the duct ﬂange at the rear of the furnace.

Slide the top panel back to its original position, engaging the other end tab in the slot. Replace screws.

INSTALLING THE FILTER

The ﬁlter may need to be cut to ﬁt the unit depending on the location of the return air ﬁlter.

A score line and the words “CUT HERE” are located on the end of the ﬁlter. If your application requires cutting the ﬁlter, do so as indicted by the score mark.

Table 6

RETURN AIR

UNIT SIZE

BOTTOM SIDE

17-1/2" DO NOT CUT DO NOT CUT

21" DO NOT CUT CUT ON LINE

24-1/2" DO NOT CUT CUT ON LINE

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS

Two ﬁlters are factory supplied for each downﬂow furnace. These furnaces require high velocity type air ﬁlters. Downﬂow furnace ﬁlters must be located outside the furnace cabinet. Typical installations are shown in Figure 25. Table 8 provides information for installation of the ﬁlter retaining brackets shipped with downﬂow furnaces.

Table 7

MODELS

NUMBERS

M952V060BD36A M952V080BD36A

M952V100CD48A 21" 2 - 16" X 20" X 1" M952V120DD60A 24-1/2" 2 - 16" X 20 X 1"

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

DOWNFLOW

CABINET

WIDTH

FILTER

QTY & SIZE

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

Remove brackets

Airﬂow

Screw locations

Flanges upward

Figure 25

DOWNFLOW/ HORIZONTAL

Airﬂow

14 18-CD37D1-2-EN

Page 15

▲

WARNING

Table 8

▲

WARNING

LOCATING FILTER RETAINER BRACKETS IN DUCTWORK

CABINET

WIDTH

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

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

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

* LOCATION DIMENSION IS FROM END OF DUCT AGAINST THE FURNACE TO THE SCREW HOLES FOR THE BRACKET.

RETURN

DUCT

WIDTH

DIMENSION

"A"

DIMENSION

"B"

FILTER

BRACKET

LOCATION*

GENERAL VENTING

WARNING

▲

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 when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

Installer’s Guide

CARBON MONOXIDE POISONING HAZARD FAILURE TO FOLLOW THE DURAVENT INSTALLATION INSTRUCTIONS IF THE POLYPROPELENE VENTING SYSTEM IS BEING PLACED INTO OPERATION COULD RESULT IN CARBON MONOXIDE POISONING OR DEATH.

CARBON MONOXIDE POISONING HAZARD FURNACE MUST BE VENTED PROPERLY. FAILURE TO FOLLOW THE INSTALLATION INSTRUCTIONS FOR THE VENTING SYSTEM COULD RESULT IN CARBON MONOXIDE POISONING, FIRE OR SMOKE THAT CAN CAUSE SERIOUS BODILY INJURY, DEATH OR PROPERTY DAMAGE.

FURNACE EXHAUST MUST BE VENTED TO THE OUTDOORS. THESE FURNACES ARE INDUCED DRAFT VENTED AND MUST NOT BE CONNECTED TO ANY VENT SERVING ANOTHER APPLIANCE. PLEASE NOTE THAT THESE FURNACES USE POSITIVE-PRESSURE VENT SYSTEMS.

Proper venting is essential to obtain maximum efﬁciency from a condensing Furnace. Proper installation of the vent system is necessary to assure drainage of the condensate and prevent deterioration of the vent system.

American Gas Association has certiﬁed the design of condensing Furnaces for a minimum of 0" clearance from combustible materials with a single wall plastic vent pipe.

The recommended system is assembled from 2", 2-1/2", or 3" plastic pipe and ﬁttings (See Table 9, page 18). Where the system is routed to the outdoors through an existing masonry chimney containing ﬂue products from another gas appliance, or where required by local codes, then 3" venting of Type 29-4C stainless steel must be used in place of PVC material.

These Furnaces have been classiﬁed as CATEGORY IV Furnaces in accordance with ANSI Z21.47 “latest edition” standards. Category IV Furnaces operate with positive vent pressure and with a vent gas temperature less than 140°F above the dewpoint. These conditions require special venting systems, which must be gas tight and water tight.

NOTE: When an existing Furnace is removed from a venting system serving other gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances.

IMPORTANT: These Furnaces may be installed as Direct Vent

(sealed combustion) or as Nondirect Vent (single pipe). The Furnaces are shipped DIRECT VENT with sealed combustion.

Important: Products installed in Canada must use vent systems that are certiﬁed to the Standard for Type BH Gas Venting Systems (ULC S636) for Class II-A venting systems (up to 65°C). Components of the vent system must not be interchanged with other vent systems or unlisted pipe or ﬁttings. Plastic components, speciﬁed primers, and glues must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts. In addition, the ﬁrst three feet of the vent pipe must be visible for inspection.

DO NOT Install return air through the side of furnace cabinet on horizontal applications.

NOTE: Minimum return air temperature is 55° F.

18-CD37D1-2-EN 15

Page 16

Installer’s Guide

Furnace

Vent

Air

Inlet

(See Note)

Furnace

Air Inlet

ent

Furnace

Air

Inlet

Vent

Attic Vent

(See Note)

VENT TERMINATIONS

For DIRECT VENT APPLICATION: The Furnaces must be vented to the exterior of the house and combustion air MUST come through the inlet air pipe FROM OUTSIDE AIR.

NOTE: BAYVENT200* accessories can be used for inlet and outlet terminals when the pipes do not exit the structure together. For Canadian applications, venting systems must meet ULC-S636 requirements.

For NONDIRECT VENT APPLICATION: The Furnace shall be vented to the exterior of the house, but combustion air may enter from the surrounding area as long as combustion air requirements are met. (See AIR FOR COMBUSTION AND VENTILATION)

FURNACE VENT / INLET PIPE INSTALLATION IN TWO PRESSURE ZONE CONFIGURATIONS

There are many different variations of the vent / inlet air pipe combination. The vent / inlet air combination used for installation of these Furnaces depends on the needs of the location. However, these guidelines must be followed:

1. The Furnace must vent outside the structure.

2. Furnace combustion air requirements must be met for non-direct, single pipe applications.

3. For direct vent application of these Furnaces, the vent pipe and air inlet pipe do not have to exit in the same air space or even on the same surface of the structure.

However, the longest individual pipe will decide the value for the longest allowable equivalent vent/ inlet air length as shown in the vent length table on page 19.

NOTE: For single pressure zone applications, see Figure

30.

Example 2

EX. 3 —

Example 3 shows the vent exiting one side of the house while the inlet air is on the opposite side of the structure. Here the vent pipe length must be within the allowable length for the size of Furnace and size of the vent pipe. This example demonstrates that the pipes do not have to exit on the same side of the structure.

The following are EXAMPLES ONLY:

EX. 1 —

Example 1 shows that the vent may go vertical while the inlet air may be on any side of the structure. The vent pipe would decide the maximum equivalent length for the pipe depending on the furnace and pipe size.

ent

Example 1

Air Inlet

EX. 2 —

Example 2 shows the vent pipe exhausting through the roof and the inlet air coming from the interior of the house. The inlet air coming from the interior of the house must meet combustion requirements for area, etc., as shown in the section AIR FOR COMBUSTION AND VENTILATION in this Installer’s Guide.

Furnace

Example 3

EX. 4 —

The inlet air does not have to come from outside the structure. Example 4 shows the inlet air, may come from the attic if the requirements for combustion air are met as shown in the section AIR FOR COMBUSTION AND VENTILATION.

NOTE: If only the ﬂue gas pipe is to the outside of the structure, a straight section of pipe (long enough to exit the Furnace cabinet) must be attached to the inlet air side with an elbow (which is 5 to 10 equiv. ft.) installed on the end to prevent dust and debris from falling directly into the Furnace.

16 18-CD37D1-2-EN

Example 4

Page 17

Installer’s Guide

▲

WARNING

▲

WARNING

Seal VENT PIPE with RTV sealant

Seal INLET AIR PIPE

with RTV sealant

Front of Furnace

▲

WARNING

VENT FITTING MATERIAL – PLASTIC

Gas and liquid tight single wall vent ﬁttings, designed for resistance to corrosive ﬂue condensate, MUST be used throughout.

Listed in Table 9, page 18, are designations for different types of 2" and 3" size pipe and ﬁttings that meet these requirements. The materials listed are various grades of PVC, CPVC, ABS, and DuraVent PolyPro®.

ATTACHING VENT PIPING

PIPE JOINTS: All joints must be fastened and sealed per manufacturer instructions and local and national codes to prevent escape of combustion products into the building.

MANUFACTURED MODULAR VENTING SYSTEMS

CARBON MONOXIDE POISONING HAZARD See Table 9 for manufactured modular venting systems that are approved for use with this product. Follow the manufacturer's installation instructions when installing the venting system. Failure to follow this warning may result in property damage, severe personal injury, or death.

CARBON MONOXIDE POISONING HAZARD Do not use cement on polypropelene venting systems. Follow the manufacturer's installation instructions when installing the venting system. Failure to follow this warning may result in property damage, severe personal injury, or death.

Procedure for Cementing Joints – Ref ASTM D2855

1. Cut pipe square, remove ragged edges and burrs. Chamfer end of pipe, then clean ﬁtting socket and pipe joint area of all dirt, grease, moisture or chips.

2. After checking pipe and socket for proper ﬁt, wipe socket and pipe with cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe.

DO NOT ALLOW PRIMER TO DRY BEFORE APPLYING

CEMENT.

3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy coat of cement to the pipe end and insert pipe into ﬁtting with a slight twisting movement until it bottoms out.

4. Hold the pipe in the ﬁtting for 30 seconds to prevent tapered socket from pushing the pipe out of the ﬁtting.

5. Wipe all excess cement from the joint with a rag. Allow 15 minutes before handling. Cure time varies according to ﬁt, temperature and humidity.

NOTE: Follow venting instructions carefully when using PVC cement.

IMPORTANT: All joints must be water tight. Flue condensate is somewhat acidic, and leaks can cause equipment damage.

Connection of the pipe and collar of the combustion air inlet should just be a friction ﬁt. It is recommended that the inlet air joint be sealed with RTV type sealant to allow the joint to be separated for possible future service. The inlet and vent pipes must be properly supported throughout the entire length. See Figure 26.

NOTE: For U.S. applications ONLY, vent termination kit BAYAIR30AVENTA or BAYVENT200B may be used in addition to the horizontal and vertical termination options.

For Canadian applications, venting systems must meet ULC-S636 requirements.

VENT AND INLET AIR CONNECTIONS

For manufactured modular venting systems that are approved with this product see Table 9. Do not drill into polypropelene venting pipes

BONDING OF PVC

NOTE: It is recommended that the ﬁrst joints from the Furnace be connected and sealed with high temperature RTV. This will enable the pipes to be removed later without cutting.

Be sure to properly support these joints.

Commercially available solvent cement for PVC must be used to join PVC pipe ﬁttings. Follow instructions on container carefully.

Pipe and Fitting – ASTM D1785, D2466, D2661, & D2665

PVC Primer and Solvent Cement – ASTM D2564

18-CD37D1-2-EN 17

Figure 26

CARBON MONOXIDE POISONING HAZARD FAILURE TO FOLLOW THE INSTALLATION INSTRUCTIONS FOR THE VENTING SYSTEM BEING PLACED INTO OPERATION COULD RESULT IN CARBON MONOXIDE POISONING OR DEATH.

Page 18

Installer’s Guide

APPROVED VENT PIPE MATERIALS

Table 9

PVC VENT FITTING MATERIAL These ﬁttings are available from your Gas Furnace Distributors.

PLASTIC VENT PIPE DESIGNATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE °F MARKING

F891 CELLULAR CORE

D2665 DWV PIPE

D1785 SCH 40, 80, 120

D2241 SDR SERIES

1 158

2 158

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41

F441 SCH 40, 80

F442 SDR SERIES

2 212

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV

F628 SCH 40 DWV CELLULAR CORE

3 180

DuraVent PolyPro® 45

ASTM STANDARD PIPE TYPE

NA NA 230 ULC-S636

1 Allowable temperatures based on classiﬁcations covered in ASTM D4396 [Deﬂection Temps Under Load (264 PSI)] 2 Allowable temperatures based on classiﬁcations covered in ASTM D1784 [Deﬂection Temps Under Load (264 PSI)] 3 Allowable temperatures based on classiﬁcations covered in ASTM D3965 [Deﬂection Temps Under Load (264 PSI)] 4 This furnace family is approved for venting with DuraVent PolyPro® venting systems. 5 Canadian venting systems must be composed of materials that meet ULC-S636.

ALLOWABLE TEMPERATURE MARKING

ASTM F891

ASTM D2665

ASTM D1785

ASTM D2241

ASTM D2846

ASTM F441

ASTM F442

ASTM D2661

ASTM F628

18 18-CD37D1-2-EN

Page 19

Installer’s Guide

▲

WARNING

MAXIMUM VENT LENGHT TABLE

CARBON MONOXIDE POISONING HAZARD FAILURE TO FOLLOW THE INSTALLATION INSTRUCTIONS FOR THE VENTING SYSTEM BEING PLACED INTO OPERATION COULD RESULT IN CARBON MONOXIDE POISONING OR DEATH.

Table 10

VENT LENGTH TABLE

ALTITUDE

0-7,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

M952V060BU36A M952V060BD36A M952V080BU36A

M952V080BD36A M952V100CU48A M952V100CD48A M952V120DU60A M952V120DD60A

7,000-9,500 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

M952V060BU36A M952V060BD36A M952V080BU36A M952V080BD36A M952V100CU48A M952V100CD48A M952V120DU60A M952V120DD60A

9,500-12,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

M952V060BU36A M952V060BD36A M952V080BU36A M952V080BD36A M952V100CU48A M952V100CD48A M952V120DU60A M952V120DD60A

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

1. FOR DURAVENT MANUFACTURED MODULAR VENTING SYSTEMS THAT ARE APPROVED IN TABLE 9, EQUIVALENT VENT

LENGTHS MAY BE DIFFERENT FROM WHAT IS SHOWN ABOVE. REFER TO THE VENTING SYSTEM MANUFACTURER'S INSTALLATION INSTRUCTIONS FOR APPROPRIATE VENTING DIAMETERS AND EQUIVALENT LENGTHS.

2. Minimum vent length for all models: 3' horizontal or 3' vertical.

3. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace). If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See note 6 below for exception). The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

4. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH OF EACH (Vent or Inlet air pipes).

5. One SHORT radius 90° elbow is equivalent to 10' of 4" pipe, 10' of 3" pipe, or 8’ of 2” pipe. One LONG radius elbow is equivalent to 6' of 4" pipe, 7’ of 3” pipe, 6’ of 2.5” pipe, or 5' of 2" pipe. Two 45° elbows equal one 90° LONG elbow.

6. The termination tee or bend must be included in the total number of elbows. If the BAYAIR30AVENTA termination kit is used, the equivalent length of pipe is 5 feet. BAYVENT200B equivalent length is 0 feet.

7. Pipe adapters are ﬁeld supplied (except for the M952V120DU60A/M952V120DD60A models).

8. For Canadian applications, venting systems must meet ULC-S636 requirements.

200 200 200

50 120 200

Not Allowed 60 200

Not Allowed Not Allowed 200

100 100 100

25 60 100

Not Allowed 30 100

Not Allowed Not Allowed 100

50 50 50

Not Allowed 30 50

Not Allowed Not Allowed 50

MAXIMUM TOTAL EQUIVALENT LENGTH IN FEET

for Vent and Inlet Air (SEE NOTES)

18-CD37D1-2-EN 19

Page 20

Installer’s Guide

▲

CAUTION

6” Min. 24” Max

HORIZONTAL VENTING

(Upﬂow/ Horizontal)

When the vent pipe is exposed to temperatures below freezing, e.g., when it passes through unheated spaces, etc., the pipe must be insulated with 1/2 inch (22.7 mm) thick Armaﬂex-type insulation or equal. If the space is heated sufﬁciently to prevent freezing, then the insulation will not be required. If domestic water pipes are not protected from freezing then the space meets the condition of a heated space.

Figure 27

NOTE: If your furnace comes with a factory supplied 2" X 3" offset reducing coupling is used for 3" vent pipe installation, make sure the marking “TOP” is located on the top side of the pipe. The straight side of the coupling must be on bottom for proper drainage of condensate. See Figure 27.

Horizontal Venting

NOTE: Vent termination kit BAYAIR30AVENTA or BAYVENT200B may be used in addition to the horizontal and vertical termination options shown in the following ﬁgures.

For Canadian applications, venting systems must meet ULC-S636 requirements.

12” Min. 15” Max

6” Min. 24” Max

9” Minimum minimum from end of exhaust pipe to end of inlet pipe

6” Min. 24” Max

Figure 28

12” Min. 15” Max

9” Minimum minimum from end of exhaust pipe to end of inlet pipe

FURNACE VENT OUTLET

6” Min. 24” Max

2" TO 3" COUPLING

#CPL00938

FACTORY SUPPLIED ONLY WITH THE FOLLOWING MODELS: ALL 100,000 BTUH UPFLOW MODELS, ALL 120,000 BTUH UPFLOW MODELS, AND ALL DOWNFLOW MODELS

12” Min. 15” Max

9” Minimum minimum from end of exhaust pipe to end of inlet pipe

ELBOW AND TEE MUST BE AS CLOSE TOGETHER AS POSSIBLE

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS WHEN

Figure 30

20 18-CD37D1-2-EN

BOTH TERMINATIONS ARE LOCATED IN THE SAME PRESSURE ZONE

Page 21

ANCHORS

RAIN CAP

COMBUSTION AIR

STRAP

(FIELD SUPPLIED)

COMBUSTION AIR

VENT

ELBOW (FIELD SUPPLIED)

VENT

1" + 1/2"

▲

CAUTION

(4 req.)

7.2"

3.2"

COMBUSTION AIR

VENT

VENT CAP

VENT PLATE

VENT

MAINTAIN 12" MINIMUM CLEARANCE

ABOVE HIGHEST ANTICIPATED SNOW LEVEL

OR GRADE WHICHEVER IS GREATER

Figure 32. BAYVENT200B

For Canadian applications, horizontal vent termination kits must meet ULC-S636.

BAYAIR30AVENTA

(Sidewall)

12" MINIMUM TO OVERHANG

SCREWS (4 req.)

Installer’s Guide

HORIZONTAL VENTING THROUGH WALL

These Furnaces may be installed as direct vent (as shipped) or as nondirect vent. Installation must conform to national, state, and local codes.

The BAYVENT200B and BAYAIR30AVENTA vent & inlet terminals kits must be located at least 12" minimum above normally expected snow accumulation level.

Avoid areas where staining or condensate drippage may be a problem.

Location of the vent/wind terminal should be chosen to meet the requirements of Figure 30 for either direct or non-direct vent applications.

PITCH — Venting through the wall must maintain 1/4" per foot pitched upward to insure that condensate drains back to the Furnace.

FLUE GAS DEGRADATION — The moisture content of the ﬂue gas may have a detrimental effect on some building materials. This can be avoided by using the roof or chimney venting option. When wall venting is used on any surface that can be affected by this moisture, it is recommended that a corrosion resistant shield (24 inches square) be used behind the vent terminal. This shield can be wood, plastic, sheet metal, etc. Also, silicone caulk all cracks, seams and joints within 3 feet of the vent terminal.

For Canadian applications, horizontal vent termination

Figure 33

kits must meet ULC-S636.

12" MIN TO OVERHANG

1" + "

COMBUSTION AIR

VENT

MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SHOW LEVEL OR GRADE WHICH EVER IS GREATER

The vent for this appliance shall not terminate

(1) Over public walkways; or

(2) Near sofﬁt vents or crawl space vents or other areas

where condensate or vapor could create a nuisance or hazard or cause property damage; or

(3) Where condensate vapor could cause damage or could be

detrimental to the operation of regulators, relief valves. or other equipment.

Important: The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows:

For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁnished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁed:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasﬁtter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the ﬂoor level where the gas equipment is to be installed. In addition, the installing plumber or gasﬁtter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualiﬁed licensed professionals for the installation of hard wired carbon monoxide detectors

18-CD37D1-2-EN 21

Page 22

Installer’s Guide

COUPLING (PLASTIC VENTING)

PVC WALL MOUNT FLANGE (OPTIONAL)

APPROVED TERMINATION

CEMENT MORTAR SEAL INSIDE & OUTSIDE

VENTING THROUGH NON-COMBUSTIBLE WALLS Pitch - 1/4 Inch Per Foot

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

6 IN. MIN. (TO JOINT)

COUPLING (PLASTIC VENTING)

STUD

PVC WALL MOUNT FLANGE (OPTIONAL)

APPROVED TERMINATION

1” CLEARANCE (AIR SPACE)

VENTING THROUGH COMBUSTIBLE WALLS Pitch - 1/4 Inch Per Foot

CLEARANCE (0” ACCEPTABLE FOR PVC VENT PIPE) (1” ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE)

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

6 IN. MIN. (TO JOINT)

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂoor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁed.

3. SIGNAGE. A metal or plastic identiﬁcation plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2) (a)1 through 4.

This appliance requires a special venting system. If BAYAIR30AVENTA or BAYVENT200B are used, a copy of the installation instructions for the kit shall remain with the appliance or equipment at the completion of installation. The venting system installation instructions can be obtained from the manufacturer by writing to the following address:

Trane 6200 Troup Highway Tyler, TX 75707 Attention: Manager of Field Operations Excellence

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials must be maintained when using single wall stainless steel venting.

Shield material to be a minimum of 24 gauge stainless or aluminized sheet metal. Minimum dimensions are 12"x12". Shield must be fastened to both inside and outside of wall. Use screws or anchor type fasteners suited to the outside or inside wall surfaces.

NONCOMBUSTIBLE MATERIAL WALL

The hole through the wall must be large enough to maintain pitch of vent and properly seal.

Use cement mortar seal on inside and outside of wall. See Figure 35.

Figure 34

For Canadian installations, if you used a ULC-S636 approved manufactured modular venting system, a copy of the manufacturer's instructions should remain with the system. The installation instruction can be obtained from the vent termination manufacturer.

22 18-CD37D1-2-EN

Figure 35

Page 23

REMOVE RIBS FROM CAP

COMBUSTION AIR

ROOF FLASHING BOOT (FIELD SUPPLIED)

COMBUSTION AIR

VENT

ELBOW (FIELD SUPPLIED)

MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF

SUPPORT (FIELD SUPPLIED)

VENT

GALVANIZED FIRESTOP SHOULD BE FABRICATED WITH 3-7/8" DIA. HOLE FOR SUPPORT FLANGE (12" x 12" PANEL OR 12" DIA MIN.)

VENTING THROUGH CEILING

CEILING

SUPPORT

FLANGE

FLUE PIPE

COUPLING

SEAL BETWEEN FLANGE, PIPE, COUPLING AND METAL PANEL WITH HI TEMP RTV SILICONE SEALANT

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

VENT

COMBUSTION AIR

SUPPORT HORIZONTAL PIPE EVERY 3' 0"

12 INCHES MIN. CLEARANCE MUST BE MAINTAINED ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM NOT TO EXCEED 24 INCHES ABOVE ROOF.

WITH THE FIRST SUPPORT AS CLOSE TO THE FURNACE AS POSSIBLE. INDUCED DRAFT BLOWER, HOUSING, AND FURNACE MUST NOT SUPPORT THE WEIGHT OF THE FLUE PIPE.

Installer’s Guide

Figure 36

18-CD37D1-2-EN 23

Figure 38. BAYAIR30AVENTA (VERTICAL)

For Canadian applications, vertical vent termination kits must meet ULC-S636.

Figure 37 BAYAIR30AVENTA (VERTICAL)

For Canadian applications, vertical vent termination kits must meet ULC-S636.

Figure 39

Page 24

Installer’s Guide

SUPPORT THE SINGLE WALL FLUE PIPE AND CENTER IT IN THE CHIMNEY OPENING WITH ANGLES AS SHOWN OR ANOTHER EQUIVALENT MANNER.

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

6 IN. MIN.

STAINLESS STEEL VENT CAP (OPTIONAL)

SEE CAUTION

FLUE PIPE

COUPLING AS REQUIRED

FLUE PIPE

COUPLING TO SUPPORT PIPE FROM ANGLES OR OTHER SUITABLE SUPPORT METHOD

STAINLESS

VENTING THROUGH THE ROOF

When penetrating roof with a 2" PVC vent pipe, a 2" electrical conduit ﬂashing may be used for a weather tight seal. Lubricate ﬂexible seal on ﬂashing before PVC pipe is pushed through the seal. (Field Supplied)

NOTE: No vent cap as shown in Figure 37 is the preferred method for vertical vent termination in extremely cold climates. In extreme climate conditions, insulate the exposed pipe above the roof line with Armaﬂex type insulation.

VENT FITTING MATERIAL – STAINLESS STEEL

Gas and liquid tight single wall metal vent ﬁtting, designed for resistance to corrosive ﬂue condensate such as Type 29-4C MUST be used throughout.

These ﬁttings and ﬁtting accessories are to be ﬁeld supplied.

DIRECTION OF STAINLESS STEEL FITTING

All stainless steel ﬁtting must be installed with male end towards the Furnace.

All horizontal stainless steel sections must be positioned with the seam on top.

All long horizontal sections must be supported to prevent sagging.

All pipe joints must be fastened and sealed to prevent escape of combustion products into the building.

Figure 40

TYPE 29-4C STAINLESS STEEL VENTING

THROUGH UNUSED CHIMNEY

IMPORTANT – Refer to Section 12.6.8 of NFPA 54 / ANSI 223.1 2012 when routing vent piping through a chimney.

IMPORTANT – The single wall ﬂue pipe joints must be sealed. The 90° elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of masonry chimney.

PVC PLASTIC VENTING

THROUGH UNUSED CHIMNEY

Figure 41. VENTING ROUTED THROUGH A MASONRY CHIMNEY

STEEL VENT CAP (OPTIONAL)

SEE CAUTION

6 IN. MIN.

SUPPORT THE SINGLE WALL STAINLESS STEEL GAS VENTING AND CENTER IT IN THE CHIMNEY OPENING WITH ANGLES AS SHOWN OR ANOTHER EQUIVALENT MANNER.

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

IMPORTANT – The single wall ﬂue pipe joints must be sealed.

The 90° elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of masonry chimney.

24 18-CD37D1-2-EN

Page 25

Installer’s Guide

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

FIXED

CLOSED

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

OPERABLE

Figure 42. HORIZONTAL VENT CLEARANCES

Table 11

Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch, deck, or

balcony

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

B= Clearance to window or door that may be opened

C= Clearance to permanently closed window * *

Vertical clearance to ventilated sofﬁt located above

the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

E= Clearance to unventilated sofﬁt * *

F= Clearance to outside corner * *

G= Clearance to inside corner * *

Clearance to each side of center line extended above

meter/regulator assembly

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

Clearance to nonmechanical air supply inlet to build-

ing or the combustion air inlet to any other appliance

K= Clearance to a mechanical air supply inlet 6 feet (1.83m)

Clearance above a paved sidewalk or paved drive-

way located on public property

M= Clearance under veranda, porch, deck, or balcony 12 inches (30 cm) ‡ *

Notes:

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

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code. †. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. ‡. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the ﬂoor. * Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/< 100,000 Btuh (30 kw), 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

3 feet (91 cm) with a height 15 feet (4.5 m) above the

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/< 100,000 Btuh (30 kw), 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

12 inches (30 cm) 12 inches (30 cm)

4 feet (1.2m) below or to the side of opening;

1 foot (0.3m) above opening.

* *

meter/regulator assembly

4 feet (1.2 m) below or to side of opening;

1 foot (300 m) above opening

7 feet (2.13 m) † 7 feet (2.13 m)

3 feet (91 cm) above if within

10 feet (3m) horizontally

18-CD37D1-2-EN 25

Page 26

Installer’s Guide

6" Min.

40 Inch

Upflow or

Downflow

Furnace

Slope 1/4" per ft.

Table 12

Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch,

deck, or balcony

Clearance to window or door that may be

opened

C= Clearance to permanently closed window * *

Vertical clearance to ventilated sofﬁt located above the terminal within a hori-

zontal distance of 2 feet (61 cm) from the center line of the terminal

E= Clearance to unventilated sofﬁt * *

F= Clearance to outside corner * *

G= Clearance to inside corner * *

Clearance to each side of center line ex-

tended above meter/regulator assembly

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

Clearance to nonmechanical air supply

inlet to building or the combustion air inlet to any other appliance

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally

Clearance above a paved sidewalk or

paved driveway located on public property

Clearance under veranda, porch, deck,

or balcony

Notes:

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

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/< 100,000 Btuh (30 kw), 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

3 feet (91 cm) with a height 15 feet (4.5 m) above the

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/< 100,000 Btuh (30 kw), 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

12 inches (30 cm) 12 inches (30 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/< 50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)

* *

meter/regulator assembly

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/< 50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)

7 feet (2.13 m) † *

12 inches (30 cm) ‡ *

DOWNWARD VENTING

Furnace may be in vertical or horizontal conﬁguration.

Figure 43

All horizontal pipes must be

supported at maximum of 3

foot intervals

NOTES:

DOWNWARD VENT LENGTH

IS LIMITED TO A MAXIMUM

OF 15 EQUIVALENT FEET.

A) Condensate trap for vent pipe must be a

minimum of 6 inches in height.

B) Condensate trap for vent and inlet pipe

must be connected into a condensate drain pump; an open or vented drain; or it can be connected to the outlet hose of the Furnace condensate trap. Outdoor draining of the Furnace and coil condensate is permissible if allowed by local codes.

CAUTION

▲

Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to

personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants.

C) The condensate trap should be primed at initial start up prior to heating season operation.

26 18-CD37D1-2-EN

Page 27

CONDENSATE DRAIN INSTRUCTIONS

▲

CAUTION

It is recommended that a drain pan be installed under the furnace to prevent property damage or personal injury from leaking condensate.

Knock outs are provided on the left and right hand side of both furnace cabinets for drain connections IN VERTICAL APPLI- CATIONS. The standard arrangement is for the drain connection on the left side. The tubing may have to be trimmed in this application to avoid kinking.

The upﬂow (vertical application) has provisions for right side drain connections by turning the trap and extending the tubing to the lower right front corner of the Furnace. Trim all excess tubing to avoid kinking. The connecting tubing for left or right side condensate drain shown in Figure 44 is shipped in the blower compartment.

It is always recommended that an auxiliary drain pan be installed under a horizontally installed evaporator or 90% Gas Furnace. Connect the auxiliary drain line to a separate drain line (no trap is needed in this line).

All horizontal applications are left side only and require repositioning the condensate canister trap to the exterior of the cabinet. Additionally the drain tubing connected to the inducer housing must be repositioned for removing the plug and reconnecting the tubing to the lower connection on the inducer housing. See Figure 45.

For horizontal installation, remove the condensate trap and position the trap outside the cabinet through the slotted opening next to the secondary cell. On upﬂow/ horizontal models, remove lines from the blower section and pull through the blower deck. Cut and reattach the line from the secondary cell (use the spring to prevent kinking).

Installer’s Guide

The inducer housing has a secondary drain opening at its 9 o’clock position. Remove the plug and use the plug to cover the hole at the 6 o’clock position. Reposition the Inducer drain tube from 6 o’clock to the 9 o’clock location. Cut and reattach the tube to the canister trap. Plug openings in Blower deck, Inducer and Blower section. See Figure 45.

Connections must be made to an OPEN/ VENTED DRAIN.

NOTE: All condensate drain piping supplies included with the furnace are intended for internal piping only and should not be applied external to the furnace. All external piping should use 1/2" size PVC pipe and ﬁttings throughout for drain connections (ﬁttings, pipe and PVC solvent cement not provided with furnace, must be ﬁeld supplied).

NOTE: A corrosion resistant condensate pump must be used if a pump is required for a speciﬁc drain system.

THE UPFLOW (VERTICAL) MAY BE INSTALLED

LEFT OR RIGHT SIDE CONDENSATE DRAIN

HEADER

TO DRAIN

LEFT SIDE

18-CD37D1-2-EN 27

UPFLOW FURNACE

(Vertical)

Figure 44

HEADER

TO DRAIN

RIGHT SIDE

Page 28

Installer’s Guide

ALL HORIZONTAL APPLICATIONS

ARE LEFT SIDE DRAIN ONLY

HEADER

OPEN/

VENTED

DRAIN

UPFLOW FURNACE ON LEFT SIDE WITH LEFT DRAIN SHOWN

Figure 45

IMPORTANT: The condensate drain should be installed with provisions to prevent winter freeze-up of the condensate drain line. Frozen condensate will block drains, resulting in furnace shutdown. If the drain line cannot be installed in a conditioned space and/ or its surrounding ambient temperature is expected to fall below freezing, then heat tape should be applied as required to prevent freezing (per manufacturer’s instructions). The heat tape should be rated at 5 or 6 watts per foot at 120 volts. Self-regulating (preferred) or thermostatically controlled heat tape is required.

Typical sources of UL listed heat tapes are W.W. Granger, Inc. (Wintergard PlusTM Series), McMaster Carr Supply Co. (3554 Series), or your equipment supplier.

The condensate drain may be cleaned or inspected by removal of the drain tube at the header.

If upflow furnace is installed over a finished ceiling, overflow from the primary drain vent stack must flow into an auxillary drain pan to prevent damage to the finished ceiling below.

Primary drain vent stack must terminate below secondary heat exchanger condensate drain outlet.

To drain opening

Figure 46

Evaporator and Furnace condensate drain piping may be manifolded together as shown in Figure 46. A primary drain vent stack must be installed and terminated below the outlet of the secondary heat exchanger drain connection to prevent water from damaging Furnace controls if the primary drain outlet plugs up.

Where the Furnace is installed above a ﬁnished ceiling, the primary drain vent stack must be installed such that overﬂow from the vent stack opening will ﬂow into an auxiliary drain pan in order to prevent water damage to the ﬁnished ceiling below.

28 18-CD37D1-2-EN

Page 29

VERTICAL APPLICATIONS

Upﬂow furnace - The connection tubing for left and right side

drainage is shipped in the blower compartment. Install the connection tubing from the trap to the side of the unit and trim all excess tubing to avoid kinks.

Downﬂow furnace - Use RTV silicon sealant to connect the ﬁtting to the trap for ease of removal when cleaning the trap.

For left side drain a 1/2" slip PVC ﬁtting is needed. See Figure

51.

To change to a right side drain, remove the drain lines from the trap, rotate the trap 180° so it exits to the right, then reconnect the lines. Start with a 1/2" 90° CPVC street elbow connected to the trap using RTV silicon sealant. Run 1/2" CPVC pipe to a CPVC elbow. Run 1/2" CPVC pipe from the elbow out through

the right side knock-out. See Figure 52.

HORIZONTAL APPLICATIONS

Installer’s Guide

Upﬂow and Downﬂow furnaces - All horizontal applications are left side only. It is always recommended that the auxiliary drain pan be installed under a horizontally installed evaporator and/or 90% gas furnace. Connect the auxiliary drain pan to a separate drain line (no trap is needed in this line).

The trap must be repositioned to the exterior of the cabinet. Remove the trap from its present location and reposition the trap outside of the unit, through the long circular hole, next to

Figure 47. UPFLOW (VERTICAL)

Right side

Left side

Figure 49. UPFLOW (VERTICAL)

Use extension hose here

Figure 48. UPFLOW HORIZONTAL

17" UNITS (Left side only)

18-CD37D1-2-EN 29

Use Inducer Drain

hose without

extension

Figure 50. UPFLOW HORIZONTAL 21" & 24" UNITS

(Left side only)

Page 30

Installer’s Guide

the secondary recuperative cell. Remove the larger drain line (from the secondary cell) and trim to ﬁt between the secondary cell and the new trap location. On upﬂow units, plug the hole in the blower deck where the tube went through.

Remove the hose from the induced blower and reposition into the other drain tap of the inducer, which is located 90° clockwise around the inducer. Move the cap from that drain tap to the unused drain tap. On upﬂow units, plug the hole in the blower deck where the tube went through. This tube on downﬂow units will need to be cut to ﬁt between the inducer and the trap. On upﬂow units, this tube may need to be extended, using the tubing shipped with the furnace.

Connections must be made to an OPEN/VENTED DRAIN. Outdoor draining of the furnace and coil condensate is permissible if allowed by local codes. Caution should be taken to prevent drains from freezing or causing slippery conditions that

Cut off curved end of

Inducer drain hose

Figure 53. DOWNFLOW (HORIZONTAL)

could lead to personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants.

NOTE: Use 1/2" or larger PVC or CPVC pipe and ﬁttings as required for drain connections (ﬁttings, pipe and solvent cement not provided).

Left

side

Figure 51. DOWNFLOW (VERTICAL)

NOTE: A corrosion resistant condensate pump must be used if a pump is required for a speciﬁc drain system.

IMPORTANT: The condensate drain should be installed with

provisions to prevent winter freeze-up of the condensate drain line. Frozen condensate will block drains, resulting in fur nace shutdown. If the drain line cannot be installed in a conditioned space, then UL listed heat tape should be applied as required to prevent freezing (per manufacturer’s instructions). The heat tape should be rated at 5 or 6 watts per foot at 120 volts. Selfregulating (preferred) or thermostatically controlled heat tape is required.

Right

side

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

Figure 52. DOWNFLOW (VERTICAL)

30 18-CD37D1-2-EN

Page 31

Installer’s Guide

▲

CAUTION

MAIN MANUAL

SHUT-OFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

Figure 54. UPFLOW MAY BE LEFT OR RIGHT HAND GAS PIPING

AUTOMATIC GAS VALVE WITH MANUAL SHUT-OFF

MAIN MANUAL

SHUT-OFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

AUTOMATIC GAS VALVE WITH MANUAL SHUT-OFF

Figure 55. THE DOWNFLOW (VERTICAL) MAY BE INSTALLED LEFT OR RIGHT SIDE GAS PIPING

AUTOMATIC GAS VALVE WITH MANUAL SHUT-OFF

MAIN MANUAL SHUT-OFF VALVE

GROUND UNION JOINT

DRIP LEG

MAIN MANUAL SHUT-OFF VALVE

AUTOMATIC GAS VALVE WITH MANUAL SHUT-OFF

GROUND UNION JOINT

Figure 56. HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

(Typical UPFLOW Furnace in horizontal conﬁguration shown)

Use a backup wrench on the gas valve when installing gas piping to prevent damage to the gas valve and manifold assembly.

DRIP LEG

18-CD37D1-2-EN 31

Page 32

Installer’s Guide

▲

WARNING

▲

WARNING

▲

WARNING

Gas Piping

HAZARD OF EXPLOSION REPLACE AND/ OR TIGHTEN ALL PLUGS REMOVED OR LOOSENED WHEN ADJUSTING GAS PRESSURE. LEAK CHECK THE FITTINGS BEFORE PLACING THE FURNACE INTO REGULAR SERVICE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE, OR DEATH.

HAZARD OF EXPLOSION DO NOT USE SEMI-RIGID METALLIC GAS CONNECTORS (FLEXIBLE GAS LINES) WITHIN THE FURNACE CABINET. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

The upﬂow/horizontal furnace is shipped standard for left side installation of gas piping. A knockout is provided on the right side for an alternate gas piping arrangement. See Figure 54.

The installation of piping shall be in accordance with piping codes and the regulations of the local gas company. Pipe joint compound must be resistant to the chemical reaction with liqueﬁed petroleum gases.

Refer to piping Table 13, for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve as shown in Figures 43 & 44. National codes require a condensation drip leg to be installed ahead of the controls as shown in Figures 55 & 56.

The furnace and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).

The furnace must be isolated from the gas supply piping by 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 (3.5 kPa).

NOTE: Maximum pressure to the gas valve for natural gas is 13.8" W.C. Minimum pressure is 5.0" W.C. Maximum pressure to the gas valve for propane is 13.8" W.C. Minimum pressure is 11.0" W.C.

Table 13

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE SIZE

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

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

This table is based on Pressure Drop of 0.3 inch W.C. and 0.6 SP.GR. Gas

32 18-CD37D1-2-EN

10 20 30 40 50 60 70

1 520 350 285 245 215 195 180

LENGTH OF PIPE

All gas ﬁttings must be checked for leaks using a soapy solution before lighting the furnace. DO NOT CHECK WITH AN

OPEN FLAME!

Table 14

ORIFICE SIZES

INPUT

RATING

BTUH

60,000

80,000 100,000 120,000

NUMBER

BURNERS

3 4 5 6

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 45 45 45

56 56 56 56

Combustion and Input Check

(See also High Altitude Derate, page 34)

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

2. Clock the gas meter with the furnace operating (determine the dial rating of the meter) for one revolution.

3. Match the “Sec” column in the gas ﬂow (in cfh) Table 16 with the time clocked.

4. Read the “Flow” column opposite the number of seconds clocked.

5. Use the following factors if necessary:

For 1 Cu. Ft. Dial Gas Flow CFH =

Chart Flow Reading ÷ 2

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

Chart Flow Reading ÷ 4

For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading ÷ 4

6. Multiply the ﬁnal ﬁgure by the heating value of the gas obtained from the utility company and compare to the nameplate rating. This must not exceed the nameplate rating.

Gas Valve Adjustment

Changes can be made by adjusting the manifold pressure

(See Table 15), or changing oriﬁces (oriﬁce change may not always be required). To adjust the manifold pressure:

1. Turn off all electrical power to the system.

2. Attach a manifold pressure gauge with ﬂexible tubing

to the outlet pressure boss marked “OUT P” on WhiteRodgers gas valve model 36G or 36J. See Figure 57A for White-Rodgers gas valve model 36J. See Figure 57B for White-Rodgers gas valve model 36G.

3. Loosen (Do Not remove) the pressure tap test set screw

one turn with 3/32" hex wrench.

a. The pressure tap adjustment kit (KIT07611) contains

a 3/32" hex wrench, a 5/16" hose and a connector and can be ordered through Global Parts.

4. Turn on system power and energize valve.

Page 33

Installer’s Guide

5. Adjust 1st stage gas heat by removing the low (LO) adjustment regulator cover screw.

a. To increase outlet pressure, turn the regulator adjust

screw clockwise.

b. To decrease outlet pressure, turn the regulator adjust

screw counterclockwise.

c. Adjust regulator until pressure shown on mano meter

matches the pressure speciﬁed in Table 15.

1. The input of no more than nameplate rating and no less than 93% of the nameplate rating, unless the unit is derated for high altitude.

d. Replace and tighten the regulator cover screw securely.

6. Adjust 2nd stage gas heat by removing the high (HI) adjustment regulator cover screw.

a. To increase outlet pressure, turn the regulator adjust

screw clockwise.

b. To decrease outlet pressure, turn the regulator adjust

screw counterclockwise.

c. Adjust regulator until pressure shown on mano meter

matches the pressure speciﬁed in Table 15.

1. The input of no more than nameplate rating and no less than 93% of the nameplate rating, unless the unit is derated for high altitude.

d. Replace and tighten the regulator cover screw securely.

7. Cycle the valve several times to verify regulator setting.

a. Repeat steps 5-7 if needed.

8. Turn off all electrical power to the system.

9. Remove the manometer and ﬂexible tubing and tighten the

pressure tap screw.

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

leaks at the pressure outlet boss and pressure tap test screw.

11. Turn on system power and check operation of the unit.

2nd Stage (HI) Manifold Pressure Adjustment

1st Stage (LO)

Gas Valve On / Off Toggle Switch

Figure 57B. White-Rodgers 36G

Table 15

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.

ROTATE THE FRONT COVER AS SHOWN

INSERT THE TOP FLANGE OF THE FRONT COVER UNDER THE LIP INSIDE THE BOX

Manifold Pressure Adjustment

2nd Stage (HI) Manifold

Outlet Pressure Boss

Inlet Pressure Boss

18-CD37D1-2-EN 33

Pressure Adjustment

Gas Valve On / Off Toggle Switch

Figure 57A. White-Rodgers 36J

1st Stage (LO) Manifold Pressure Adjustment

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.

Figure 58

Page 34

Installer’s Guide

▲

WARNING

CORRECT METHOD OF CHECKING DIRECT VENT MANIFOLD

PRESSURE WITH BURNER BOX REFERENCED

Separate the tube at the unit Tee and reconnect with a short piece of field supplied tube and

See inset

another Tee with the “U” Manometer attached. Be sure to reconnect unit tubing to original position after testing the manifold pressure!

Field supplied barb fitting with manometer tube is attached to the “OUTLET PRESSURE TAP” on the outlet side of the gas valve.

Figure 59

NOTE: The manifold pressure must be referenced to the burner box. The burner box pressure tap equalizes the gas valve pressure regulator. Manifold pressure is checked by installing a tee (ﬁeld supplied) in the 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 59.

Table 19 lists the main burner oriﬁces used with the furnace. If a change of oriﬁces is required to correct the furnace input rating refer to Table 17.

REINSTALLATION OF THE BURNER BOX COVER

Figure 59 shows the correct way to reinstall the burner box cover if adjustment or replacement of the ﬂame sensor, hot surface igniter, or main burner oriﬁces have required removal of the cover.

Table 16

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

8 900 29 248 50 144 82 88

9 800 30 240 51 141 84 86 10 720 31 232 52 138 86 84 11 655 32 225 53 136 88 82 12 600 33 218 54 133 90 80 13 555 34 212 55 131 92 78 14 514 35 206 56 129 94 76 15 480 36 200 57 126 96 75 16 450 37 195 58 124 98 73 17 424 38 189 59 122 100 72 18 400 39 185 60 120 104 69 19 379 40 180 62 116 108 67 20 360 41 176 64 112 112 64 21 343 42 172 66 109 116 62 22 327 43 167 68 106 120 60 23 313 44 164 70 103 124 58 24 300 45 160 72 100 128 56 25 288 46 157 74 97 132 54 26 277 47 153 76 95 136 53 27 267 48 150 78 92 140 51 28 257 49 147 80 90 144 50

34 18-CD37D1-2-EN

Page 35

Installer’s Guide

HIGH ALTITUDE DERATE

Input ratings (BTUH) of these Furnaces are based on sea level operation and should not be changed at elevations up to 2,000 ft.

If the installation is 2,000 ft. or above, the Furnace input rate (BTUH) shall be reduced 4% for each 1,000 ft. above sea level.

The Furnace input rate shall be checked by clocking the gas ﬂow rate (CFH) and multiplying by the heating value obtained from the local utility supplier for the gas being delivered at the installed altitude. Input rate changes can be made by adjusting the Manifold Pressure (min 3.0 - max 3.7 in. W.C. - Natural Gas) or changing oriﬁces (oriﬁce change may not always be required).

If the desired input rate 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 replacement oriﬁces to the same depth as the oriﬁces supplied with the equipment.

See Table 17 for help in selecting oriﬁces if oriﬁce change is required. Furnace input rate and temperature rise should be checked again after changing oriﬁces to conﬁrm the proper rate for the altitude.

The vent length table on page 19 shows the required vent lengths for installations at various altitudes. An optional high altitude kit is available for installations above 5000 feet. Installations above 12,000 feet are not allowed.

Table 17

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

44 45 46 47 48 49 50

PART

NUMBER

ORF00501 ORF00644 ORF00909 ORF00910 ORF01099 ORF00503 ORF00493

DRILL

SIZE

54 55 56 57 58 59

PART

NUMBER

ORF00555 ORF00693 ORF00907 ORF00908 ORF01338 ORF01339

Table 19

Oriﬁce

Twist

Drill

Size If

Installed

At Sea

Level

42 43 44 45 46 47

54 55 56 57 58

2000 3000 4000 5000 6000 7000 8000 9000

42 44 45 46 47 48

54 55 56 58 59

From National Fuel Gas Code - Table F-4

ALTITUDE ABOVE SEA LEVEL

and Oriﬁce Required At Other Elevations

45 44 45 47 47 48

55 55 56 59 60

44 45 47 47 49

55 55 57 59 60

45 46 47 48 49

55 56 57 60 61

45 47 48 48 49

55 56 57 60 62

46 47 48 49 50

55 56 58 61 62

46 47 48 49 50 51

56 56 59 63 63

10000

47 48 50 50 51 52

56 57 60 63 64

Installation of this furnace at altitudes above 2000 ft (610m) shall be in accordance with local codes, or in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1/NFPA

54 or National Standard of Canada, Natural Gas and Propane Installation Code, CSA B149.1. Installation of this furnace at

altitudes above 2000 ft (610 m) shall be made in accordance with the listed high Altitude Conversion Kit available with this furnace.

Turn the main Gas Valve toggle switch (See Figures 30 & 31) within the unit to the “OFF” position. Turn the external gas valve to “ON”. Purge the air from the gas lines. After purging, check all gas connections for leaks with a soapy solution -- DO NOT CHECK WITH AN OPEN FLAME. Allow 5 minutes for any gas that might have escaped to dissipate.

LP Gas being heavier than air may require forced ventilation. Turn the toggle switch on the Gas Valve in the unit to the “ON” position.

If your application requires a high altitude pressure switch use Table 18 to select the appropriate kit for your model furnace.

Table 18

High Altitude Kits Used With

M952V080BU36A M952V100CU48A

BAYSWT08AHALTA

M952V120DU60A M952V080BD36A M952V100CD48A M952V120DD60A

BAYSWT10AHALTA

M952V060BU36A, M952V060BD36A

18-CD37D1-2-EN 35

Page 36

Installer’s Guide

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 electronic air cleaner and humidifier MAX. load 1.0 amps each.

6. When a single stage heating thermostat without fan switch is used, no wiring on "G" terminal is used.

7. W1 and W2 must be jumpered together for proper operation. Second stage heat will begin based on IFC switch setting.

8. Set dip switches with power off per installation instructions to set airflow and indoor fan off delays.

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

10. This 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 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.

W14

SEE

NOTE 10

SEE

NOTE 9

Y1/Ylo

W14 JUMPER SEE NOTE 11

FIELD ADDED JUMPER

W1 TO W2.

SEE FURNACE WIRING DIAGRAM

FOR 2ND STAGE TIMING.

From Dwg. B342027 Rev. 1

SEE

NOTE 6

B/C

TO 115 V 1 PH., 60 HZ., POWER SUPPLY PER LOCAL CODES

HUM SEE NOTE 5

EAC SEE NOTE 5

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

Electrical Connections

Make wiring connections to the unit as indicated on enclosed wiring diagram. As with all gas appliances using electrical power, this furnace shall be connected into a permanently live electric circuit. It is recommended that furnace be provided with a separate “circuit protection device” electric circuit. The furnace must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code, ANSI/NFPA 70 or CSA C22.1 Electrical Code, if an external electrical source is utilized. The integrated 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 diagram.

Refer to the SERVICE FACTS literature and unit wiring diagram attached to furnace.

Figure 60

36 18-CD37D1-2-EN

Page 37

Installer’s Guide

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 electronic

air cleaner and humidifier MAX. load 1.0 amps each.

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.

W14

SEE

NOTE 6

From Dwg. B342025 Rev. 0

Y1/Ylo

W14 JUMPER

SEE NOTE 9

SEE

NOTE 7

B/C

TO 115 V 1 PH., 60 HZ., POWER SUPPLY PER LOCAL CODES

HUM SEE NOTE 5

EAC SEE NOTE 5

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTAT

NO COOLING

Figure 61

18-CD37D1-2-EN 37

Page 38

Installer’s Guide

W14

OUTDOOR UNIT

(NO TRANSFORMER)

SEE

NOTE 6

SEE

NOTE 7

From Dwg. B342022 Rev. 1

Y1/Ylo

W14 JUMPER

SEE NOTE 9

B/C

TO 115 V 1 PH., 60 HZ., POWER SUPPLY PER LOCAL CODES

HUM SEE NOTE 5

EAC SEE NOTE 5

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)

FIELD ADDED JUMPER

W1 TO W2.

SEE FURNACE WIRING DIAGRAM

FOR 2ND STAGE TIMING.

Figure 62

38 18-CD37D1-2-EN

Page 39

Installer’s Guide

W14

OUTDOOR UNIT

(NO TRANSFORMER)

SEE

NOTE 6

SEE

NOTE 7

Y1/Ylo

SEE

NOTE 9

W14 JUMPER

SEE NOTE 9

From Dwg. B342020 Rev. 0

B/C

TO 115 V 1 PH., 60 HZ., POWER SUPPLY PER LOCAL CODES

HUM SEE NOTE 5

EAC SEE NOTE 5

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)

Figure 63

18-CD37D1-2-EN 39

Page 40

Installer’s Guide

BLK/TWIN W2

W1 R

YLO

BLK/TWIN

BK JUMPER

W14

W1 R

YLO

OFF

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING, 2 STEP STAGED COOLING

(OUTDOOR SECTION WITHOUT TRANSFORMER)

SEE

NOTE 7

SEE

NOTE 6

B/C

W14 R-BK

JUMPER

SEE NOTE 9

OUTDOOR UNIT

(NO TRANSFORMER)

TO 115 V 1 PH., 60 HZ., POWER SUPPLY PER LOCAL CODES

HUM SEE NOTE 5

Figure 64

HUMIDISTAT HOOKUP

If an optional Humidistat is to be connected between “R” and “BK”, the factory installed jumper between “R” and “BK” on the circuit board must be cut. If an optional Humidistat is used, the jumper must also be cut when applying an airﬂow command signal to the “BK” input such as with the variable speed single-zone and multi-zone system controller. On single speed cooling only/ non-heat pump systems, jumper “Y” to “O” for proper operation of the delay proﬁles and the Humidistat. For two compressor or two speed systems, jumper “YLO” to “O”.

EAC SEE NOTE 5

The factory installed jumper between “R” and “BK” on the circuit board must be cut if an optional Humidistat is installed.

Figure 65

40 18-CD37D1-2-EN

Page 41

Installer’s Guide

▲

WARNING

▲

WARNING

▲

CAUTION

Start-up and Adjustment Preliminary Inspections

ELECTRIC SHOCK HAZARD DISCONNECT POWER TO THE UNIT BEFORE REMOVING THE BLOWER DOOR. ALLOW A MINIMUM OF 10 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. Filters are in place

3. Venting is properly assembled

4. Blower door is in place

Turn the toggle switch on the main gas valve within the unit to the “OFF” position (See Figures 54 - 56) . Turn the exter- nal main gas shutoff valve to “ON”. Purge the air from the gas lines. After purging, Check all gas connections for leaks with a soapy solution — DO NOT CHECK WITH AN OPEN FLAME. Allow 5 minutes for any gas that might have escaped to dissipate. LP Gas being heavier than air may require forced ventilation. Turn the toggle switch on the main gas valve within the unit to the “ON” position.

Lighting Instructions

BURN HAZARD 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 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

For complete shutdown: Turn the toggle switch located on the main gas valve inside the unit to the "OFF" position and the external main gas shutoff valve to the “OFF” position (See Figures 54-56). Disconnect the electrical supply to the unit.

If shutoff is done during the cold weather months, provisions must be taken to prevent freeze-up of all water pipes and water receptacles.

Whenever your house is to be vacant, arrange to have someone inspect your house for proper temperature. This is very important during freezing weather. If for any reason your furnace should fail to operate damage could result, such as frozen water pipes.

Control and Safety Switch Adjustments

LIMIT SWITCH CHECK OUT

The limit switch is a safety device designed to close the gas valve should the furnace become overheated. Since proper operation of this switch is important to the safety of the unit, it

must be checked out on initial start up by the installer.

To check for proper operation of the limit switches, set the thermostat to a temperature higher than the indicated temperature to bring on the gas valve.

SEQUENCE OF OPERATION

Comfort Control call for heat (2-Stage Comfort Control) Call for 1st Stage only:

W1 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.

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 allowing 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: W1 Comfort Control contacts open signaling that 1st Stage heating requirements are satisﬁed. The Gas Valve will close and the induced draft blower. The indoor 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)

W1/ W2 (jumpered) Comfort Control contacts close signaling a call for heat. 1st Stage sequence of operation remains the same as above. 2nd Stage Heat will energize after the Stage delay timer (10 minutes) has expired.

Comfort Control satisﬁed: W1/ 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.

18-CD37D1-2-EN 41

Page 42

Installer’s Guide

▲

WARNING

▲

WARNING

NOTE TO INSTALLER Review warnings and the contents of USER’S INFORMATION MANUAL with the homeowner when installation 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. Restrict the airﬂow by blocking the return air or by disconnecting the blower. When the Furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and overheating is evident, a faulty Limit Switch is probable and the Limit Switch must be replaced. After checking the operation of the Limit Control, be sure to remove the paper or cardboard from the return air inlet, or reconnect the blower. Refer to the Service Facts for additional instructions.

INDOOR BLOWER TIMING

Heating: The Integrated Furnace Control (IFC) controls the

Variable Speed Indoor Blower. The blower “on” time is ﬁxed at 45 seconds after ignition. The FAN-OFF period is ﬁeld selectable by dip switches #1 and #2 located on the Integrated Furnace Control between 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 settings:

This unit is equipped with a blower door switch which cuts power to the blower and Gas Valve causing shutdown when the door is removed.

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 SERVICE FACTS or inside the furnace casing).

Table 20. FAN OFF -- DELAY OPTIONS

SWITCH SETTINGS SELECTION

5 - OFF 6 - OFF NONE SAME

5 - ON 6 - OFF

5 - OFF 6 - ON 3 MINUTES 50%

5 - ON 6 - ON

1.5 MINUTES

Enhanced

Mode**

NOMINAL

AIRFLOW

100% *

50 - 100%

* - This setting is equivalent to BAY24X045

relay beneﬁt.

** - This selection provides ENHANCED MODE,

which is a ramping up and ramping down of the blower speed to provide improved comfort, quietness, and potential energy savings. See Wiring Diagram notes on the unit or in the Service Facts for complete wiring setup for ENHANCED MODE. The graph which follows, shows the ramping process.

See Wiring Diagram on the unit or in the Service Facts

for complete wiring setup for Enhanced Mode.

100% if necessary

80%

Fast Cooling

minute

Dehumidify

7.5

minutes

Figure 66

50%

Efﬁciency

OFF

minutes

50%

OFF

AIRFLOW ADJUSTMENT

CARBON MONOXIDE HAZARD OPERATION WITH THE DOOR REMOVED OR AJAR CAN PERMIT THE ESCAPE OF DANGEROUS FUMES. ALL PANELS MUST BE SECURELY CLOSED AT ALL TIMES FOR SAFE OPERATION OF THE FURNACE. 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 rating nameplate. If the airﬂow needs to be increased or decreased, see the Service Facts for information on changing the speed of the blower motor.

42 18-CD37D1-2-EN

Page 43

Installer’s Guide

INSTRUCTIONS TO THE OWNERS

WARNING

▲

EXPLOSION HAZARD

IN THE EVENT THAT ELECTRICAL, FUEL OR MECHANICAL FAILURES OCCUR, SHUT OFF THE GAS SUPPLY AT THE MANUAL GAS SHUT OFF VALVE, LOCATED ON THE SUPPLY GAS PIPING COMING INTO THE FURNACE, BEFORE TURNING OFF THE ELECTRICAL POWER TO THE FURNACE. CONTACT SERVICER. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

BURNER BOX TEMPERATURE LIMIT DEVICE

All models are equipped with a manual reset temperature limit located on the Burner Box. In case of excessive temperature, the limit will open and cause the circuit to open which shuts off all ﬂow of gas.

CONDITIONS THAT AFFECT SYSTEM OPERATION

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN EXCESS OF 40 M.P.H.) VENT OR FLUE BLOCKAGE

On a call for heat, the Variable Speed Draft Inducer must

ﬁrst ramp up to speed and close the Pressure Switch before the ignition sequence is allowed to begin. If the Pressure Switch does not close, the motor will ramp up to maximum speed and continue to operate there for about 1 minute.

After one minute, the Integrated Furnace Control will turn

the motor off for about 30 seconds and then back on in an attempt to reestablish proper operation. This condition is indicative of a highly restricted or blocked inlet or outlet vent pipe or a failed Pressure Switch.

If pressure against induced draft blower outlet becomes

excessive, the Pressure Switch will open. If the Pressure Switch is open for more than 3.5 seconds, the variable speed draft inducer will speed up and attempt to close the Pressure Switch. If the Pressure Switch is not closed within 12 seconds or if the maximum speed of the motor is reached, the draft inducer sends a Fault signal to the Integrated Furnace Control. If the unit is operating in Second Stage, an Inducer Fault will cause the Furnace Control to transition the system to First Stage and it will operate there for 10 minutes before attempting to run again in Second Stage. If the unit is operating in First Stage, an Inducer Fault will cause the Furnace Control to shut the system down and wait 30 seconds before attempting to reestablish operation in First Stage.

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 Integrated Furnace Control will then recycle the ignition sequence, then if ignition is not achieved, it will shut off the Gas Valve and lock out the system.

3. POWER FAILURE

If there is a power failure during a heating cycle, the

system will restart the ignition sequence automatically when power is restored, if the 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, then if ignition is not achieved, the Integrated Control Module will shut off the Gas Valve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE Please refer to the Variable Speed Draft Inducer

troubleshooting manual for diagnostic assistance.

6. CONDENSATE DRAIN BLOCKAGE If the condensate drain is blocked, either by debris,

improper draining, or by freezing condensate, the pressure switch will receive a signal warning of the accumulation of condensate in the heat exchanger assembly. The pressure switch contacts will open and remain open, not allowing unit operation. The unit will not operate until the condensate drain has been cleared, and the condensate ﬂows freely.

7. RESET AFTER LOCKOUT When the Integrated Furnace Control has shut the system

down and gone into lockout, the system must be manually reset before the unit will restart. The system can be reset by turning the system power off for more than 1 second, or by removing 24VAC from the control for more than 1 second, or by removing the Comfort Control call for heat for more than 1 second but less than 20 seconds.

8. RESET AFTER BURNER BOX LIMIT SHUTDOWN If the furnace shuts down, one thing that can be checked

is the burner box temperature limit switch. It is located on the bottom of the burner box. The vent and combustion air inlet terminations should be checked for blockage. If blockage exists, clear the problem and then the reset button may be depressed. If there is no blockage of

the terminations, the limit switch must be reset by a qualiﬁed servicer.

INDOOR MOTOR MAINTENANCE

Direct drive motors have bearings which are permanently lubricated and under normal use, lubrication is not recommended.

18-CD37D1-2-EN 43

Page 44

Table 21

INTEGRATED FURNACE CONTROL LED FLASH CODES

RED LED - LitePortTM DATA - 1 FLASH EVERY 20 SECONDS

2 Flashes RETRIES OR RECYCLES EXCEEDED

3 Flashes INDUCER OR PRESSURE SWITCH ERROR

4 Flashes OPEN LIMIT OR ROLLOUT SWITCH

5 Flashes FLAME SENSED WHEN NO FLAME SHOULD BE PRESENT

6 Flashes LINE REVERSE POLARITY

7 Flashes GAS VALVE CIRCUIT ERROR

8 Flashes WEAK FLAME

9 Flashes OPEN INDUCER LIMIT ERROR

GREEN LED - STATUS

Slow Flash NORMAL, NO CALL FOR HEAT

Fast Flash NORMAL, CALL FOR HEAT PRESENT

GREEN and RED LED's on Continuously

FUSE OPEN OR INTERNAL CONTROL FAILURE

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 recovery. At any other time the control is powered, the Green LED indicator light will operate as shown in Table 22 and the red LED will ﬂash LitePort data (one ﬂash) every 20 seconds.

Table 22

INTEGRATED FURNACE CONTROL

GREEN "STATUS" LED FLASH CODES

Flashing Slow ---

Normal - No call for Heat

Flashing Fast --- Normal - Call for Heat

Red LitePort

LED

Green Status LED

Fault Code Reset

The last 4 fault codes can be erased from memory by powering up the control with “G” energized and then applying “R” to the “W1” terminal 3 times within 6 seconds. The control will acknowledge the reset by turning on the red LED for 2 seconds.

Literature Order Number 18-CD37D1-2-EN

File Number 18-CD37D1-2-EN

Supersedes 18-CD37D1-1

Trane 6200 Troup Highway Tyler, TX 75707

For more information contact your local dealer

Date 09/14

The manufacturer has a policy of continuous product and product data improvement and reserves the right to change design and speciﬁcations without notice.

Figure 67