Trane ADC040C924, ADC060C936, ADC080C942, AUC100C948, AUC100C960 Installer's Manual

18-CD19D5-10

Installer’s Guide

Upflow / Horizontal and Downflow / Horizontal
Gas-Fired Condensing Furnaces

*UC040C924
*UC060C936
*UC080C942

*__First letter may be “A” or “T”

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

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

Please return to service information pack upon completion of work.

*UC-C

*UC100C948
*UC100C960
*UC120C960

*DC040C924
*DC060C936
*DC080C942

*DC-C

*DC100C948
*DC120C960

DOWNFLOW

UPFLOW/HORIZONTAL

UPFLOW

DOWNFLOW/HORIZONTAL

A341624P01

Installer’s Guide

SAFETY SECTION

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

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

2. Install this furnace only in a location and position as
specified in “Location and Clearances” (page 3), of these
instructions.

3. Provide adequate combustion and ventilation air to the
furnace space as specified in “Air for Combustion and
Ventilation” (pages 7-8), 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 (pages 10-18), of these instructions.

5. Never test for gas leaks with an open flame. Use a commer­cially available soap solution made specifically for the
detection of leaks to check all connections, as specified in
“Gas Piping” (page 20), of these instructions.

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

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

8. A gas-fired furnace for installation in a residential garage
must be installed as specified in “Location and Clearances”
section (page 3), of these instructions.

9. The furnace is not to be used for temporary heating of
buildings or structures under construction.

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

a. DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.
This signal word is limited to the most extreme situations.

b. WARNING indicates a potentially hazardous situation

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

c. CAUTION indicates a potentially hazardous situation which,

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

!

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 CAN/CGA B149
Installation Codes and these instructions. Determine
that there is no blockage or restriction, leakage,
corrosion and other deficiencies which could cause an
unsafe condition.

3. As far as practical, close all building doors and
windows and all doors between the space in which the
appliance(s) connected to the venting system are
located and other deficiencies which could cause an
unsafe condition.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they are operating at maximum speed. Do not operate
a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.

7. If improper venting is observed during any of the above
tests, the venting system must be corrected in
accordance with the National Fuel Gas Code,
ANSI Z221.1/NFPA 54 and/or CAN/CGA B149
Installation Codes.

8. After it has been determined that each appliance
connected to the venting system properly vents where
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas-fired
burning appliance to their previous conditions of use.

!

WARNING

▲

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.

© 2003 American Standard Inc. All Rights Reserved 18-CD19D5-10

Installer’s Guide

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 may need to be reduced (See High Altitude Installation).

Material in this shipment has been inspected at the
factory and released to the transportation agency with­out known damage. Inspect exterior of carton for evi­dence of rough handling in 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,
8501 E. Pleasant Valley Rd., Cleveland, Ohio 44131.

These furnaces have been classified as CATEGORY IV furnaces
in accordance with latest edition of ANSI Z21.47 • CAN/CGA 2.3
standards. Category IV furnaces operate with positive vent
static pressure and with a flue loss less than 17 percent.

!

CAUTION

▲

To prevent shortening its service life, the furnace should not
be used as a “Construction Heater” during the finishing
phases of construction. The low return air temperatures can
lead to the formation of condensate even though this is a non­condensing model. 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.

!

WARNING

▲

These furnaces are not approved or intended for installation in
manufactured (mobile) housing, trailers, or recreational
vehicles. Failure to follow this warning could result in property
damage, personal injury, or death.

!

CAUTION

▲

Do not install the furnace in a corrosive or contaminated
atmosphere.

These conditions require special venting systems, which must be
gas tight and water tight.

These furnaces may be twinned using BAYTWIN300A. They
shall have common returns with equal pressure drops or ducts
with equivalent lengths and sizes.

LOCATION AND CLEARANCES

The location of the furnace is normally selected by the architect,
the builder, or the installer. However, before the furnace is
moved into place, be sure to consider the following requirements:

1. Is the location selected as near the chimney or vent and as
centralized for heat distribution as practical?

2. Do all clearances between the furnace and 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.

Contents

Installation Instructions 3

General Installation Instructions 3
Location and Clearances 3
Upflow Installation 3
Outline Drawings 4-5
Downflow Installation 6
Horizontal Installation 6
Air for Combustion and Ventilation 7
Duct Connections 8
Return Air Filters 9-10
General Venting Instructions 10-18
Venting Tables 11-12
IFC Error Flash Codes 12
Downward Venting 13
Condensate Drain Instructions 14
Electrical Connections 18
Field Wiring Diagrams 19
Gas Piping 20-22
Combustion and Input Check 20
High Altitude Derate 22

Start-up and Adjustment 22

Preliminary Inspections 22
Lighting Instructions 22
Sequence of Operation 23
Control and Safety Switch Adjustments 23

Abnormal Conditions 24

4. Are there at least 3 inches of clearance between the furnace
combustion air openings in the front panel and any closed
panel or door provided?

5. Are the ventilation and combustion air openings large enough
and will they remain unobstructed? If outside air is used, are
the openings set above the highest snow accumulation level?
(See the Air for Combustion and Ventilation section)

6. Allow sufficient height in supply plenum above the furnace
to provide for cooling coil installation, if the cooling coil is
not installed at the time of this furnace installation.

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

8. If the furnace is installed in a residential garage, it must
be installed so that the burners, and the 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.

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.

UPFLOW INSTALLATION

Standoffs and screws (See Figure 1) 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.

18-CD19D5-10 3

4 18-CD19D5-10

Installer’s Guide

MODEL A B C D

*UC040C924
*UC060C936
*UC080C942

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

*UC100C948 21" 2-1/2" 19-3/4" 19-1/2"
*UC100C960

*UC120C960

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

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

From Dwg. 21C340386 Rev. 7

*UC-C OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

18-CD19D5-10 5

Installer’s Guide

MODEL A B C D

*DC040C924
*DC060C936
*DC080C942

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

*DC100C948 21" 2-1/2" 19-3/4" 19-1/2"
*DC120C960 24-1/2" 2-15/16" 23-1/4" 23"

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

From Dwg. 21C340462 Rev. 7

*DC-C DOWNFLOW / HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

Installer’s Guide

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

1

STANDOFFS (4)

DRILL SCREWS (4)

CASED

COIL

FOR VERTICAL

INSTALLATIONS:

SCREWS

UPFLOW

FURNACE

STANDOFFS

(BOTH SIDES)

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

!

WARNING

▲

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.

2

Required floor opening: (DOWNFLOW)

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3

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See Figure 3 and Table 1

FURNACE

FRONT

A (width)

B (depth)

D

C

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 furnace and
TXC cased coil in the horizontal position. See Figure 4. The
coil is placed downstream of the furnace, with the apex of the coil
pointing in the direction of the airflow for horizontal installa-
tion. The cased coil is secured to the furnace and both the
furnace and the cased coil must be properly supported. The
brackets mount using the rear screws on the coil case and use
the screws provided to secure the bracket to the furnace. The
remaining bracket is placed as close to center as possible
(horizontally) between the coil case front and the furnace bottom
channel (for downflow/horizontal furnace). Use four of the
screws provided to secure the bracket. The upflow furnace,
converted to horizontal, aligns and attaches the TXC coil as in
Figure 1. However, the coil requires additional support.

4

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

The furnace may be installed in an attic or crawl space in the
horizontal position by placing the furnace on the left side (as
viewed from the front in the vertical 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 Outline Drawings).
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.

The horizontal furnace may also be suspended from the joists
using 3/8" all-thread rods with pieces of angle iron underneath
the furnace to form a hanging rack at both ends and the mid­point. The rods need to be of sufficient length to allow for proper
clearances from combustible materials. The angle iron needs to
be at least 32" in length to allow for access to service panels.

The upflow furnace, converted to horizontal, aligns and attaches
the TXC coil to the same flanges used in vertical. The coil needs
to have additional support.

5

TABLE 1

CABINET

WIDTH

RETURN

DUCT WIDTH

FLOOR OPENING PLENUM OPENING

"A" "B" "C" "D"

14-1/2" 13-1/4" 13-5/8" 20-1/8" 12-5/8" 19-3/8"
17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"

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

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

6 18-CD19D5-10

UPFLOW/
HORIZONTAL
SHOWN

6

UNCONFINED

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

AIR FOR COMBUSTION AND VENTILATION

Adequate flow of combustion and ventilating air must not be
obstructed from reaching the furnace. Air openings provided in
the furnace casing must be kept free of obstructions which
restrict the flow of air. Airflow restrictions 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 CAN/CGA B149
Installation Codes, and applicable provisions of the local building
codes. Special conditions created by mechanical exhausting of
air and fireplaces must be considered to avoid unsatisfactory
furnace operation.

Furnace locations may be in “confined space” or “unconfined
space”. Unconfined space is defined in Table 2 and Figure 6.
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

7

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

insulated, caulked, vapor barrier, etc.), may need additional air
provided as described for confined space.

Confined spaces are installations with less than 50 cu. ft. of
space per 1000 BTU/hr input from all equipment installed. Air
for combustion and ventilation requirements can be supplied
from inside the building as in Figure 8 or from the outdoors, as
in Figure 9.

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

1.
space shall be provided with two permanent openings
communicating directly with an additional room(s) of
sufficient volume so that the combined volume of all spaces
meets the criteria for an unconfined space. The total input
of all gas utilization equipment installed in the combined
space shall be considered in making this determination.
Refer to Table 3, for minimum open areas required.

All air from outdoors as in Figure 9: The confined space

2.
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 3, for minimum open
areas required.

CONFINED

Installer’s Guide

3. The following types of installations will require use of

OUTDOOR AIR for combustion, due to chemical exposures:

* Commercial buildings
* Buildings with indoor pools
* Furnaces installed in commercial laundry rooms
* Furnaces installed in hobby or craft rooms
* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion air
supply will also require OUTDOOR AIR for combustion:

* Permanent wave solutions
* Chlorinated waxes and cleaners
* Chlorine based swimming pool chemicals
* Water softening chemicals
* Deicing salts or chemicals
* Carbon Tetrachloride
* Halogen type refrigerants
* Cleaning solvents (such as perchloroethylene)
* Printing inks, paint removers, varnish, etc.
* Hydrochloric acid
* Cements and glues
* Antistatic fabric softeners for clothes dryers
* Masonry acid washing materials

TABLE 2

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE

MAXIMUM BTUH

INPUT RATING

40,000
60,000

80,000
100,000
120,000

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

40,000
60,000

80,000
100,000
120,000

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, listed by a nationally recognized
agency (e.g. Underwriters Laboratories or International Ap­proval Services), to help alert dwelling occupants of the presence
of fire, smoke or unsafe levels of carbon monoxide.

From

Inside

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

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE

FEET OF UNCONFINED SPACE

250
375
500
625
750

TABLE 3

Air

100
100
100
100
120

Air From Outside

Ver tical

Duct

10
15
20
25
30

Horizontal

Duct

20
30
40
50
60

18-CD19D5-10 7

Installer’s Guide

8

9

DUCT CONNECTIONS

Air duct systems should be installed in accordance with stan­dards for air conditioning systems, National Fire Protection
Association Pamphlet No. 90. They should be sized in accor­dance with ACCA Manual D or whichever is applicable.

Central furnaces, when used in connection with cooling units,
shall be installed in parallel or on the upstream side of the
cooling units to avoid condensation in the heating element,
unless the furnace has been specifically approved for down­stream installation. With a parallel flow arrangement, the
dampers or other means used to control flow of air shall be
adequate to prevent chilled air from entering the furnace, and if
manually operated, must be equipped with means to prevent
operation of either unit unless the damper is in full heat or cool
position.

On any job, flexible connections of nonflammable material may
be used for return air and discharge connections to prevent
transmission of vibration. Though these units have been
specifically designed for quiet, vibration free operation, air ducts
can act as sounding boards and could, if poorly installed, amplify
the slightest vibration to the annoyance level.

When the furnace is located in a utility room adjacent to the
living area, the system should be carefully designed with returns
which minimize noise transmission through the return air grille.
Although these winter air conditioners are designed with large
blowers operating at moderate speeds, any blower moving a high
volume of air will produce audible noise which could be objection­able when the unit is located very close to a living area. It is
often advisable to route the return air ducts under the floor or
through the attic. Such design permits the installation of air
return remote from the living area (i.e. central hall).

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

Minimum return air/“air entering” temperature for the
furnace is 50° F.

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

Do Not install return air through the back of the furnace
cabinet.
Do Not install return air through the side of the furnace cabinet

on horizontal applications.

RETURN AIR DUCT CONNECTION

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

1. Set the furnace in place.

2. For side return installations on upflow models, remove the
insulation around the opening in the blower compartment.

3. The side panels on upflow furnaces include locating notches
which may be used as guides for cutting an opening for
return air. Refer to Figure 10 and the outline drawing on
page 4 for duct connection dimensions for various furnaces.

4. If a 3/4" flange is to be used for attaching the air inlet duct,
add to cut where indicated by solid lines in Figure 10. Cut
corners diagonally and bend outward to form flange.

5. If flanges are not required, and a filter frame is installed,
cut along knockout guidelines.

6. Upflow furnaces: filter retainer brackets are factory
supplied for bottom return. Use the filter retainer brackets
on either side or on bottom if filter is to be used within the
furnace cabinet.

Downflow Furnaces: Brackets are factory supplied to
mount filters in the return air ductwork.

8 18-CD19D5-10