Trane AUD1A040A9241A, AUD1A040A9301A, AUD1A060A9241A, AUD1A060A9361A, AUD1B060A9361A Installer's Manual

18- CD19D7- 22

Installer’s Guide

Upflow / Horizontal — Downflow / Horizontal,
Gas-Fired Furnaces, “Fan Assisted
Combustion System”

*UD1A040A9241A
*UD1A040A9301A
*UD1A060A9241A
*UD1A060A9361A
*UD1B060A9361A

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

*UD1B080A9241A
*UD1B080A9361A
*UD1B080A9481A
*UD1C080A9601A
*UD1B100A9361A

*First letter may be “A” or “T”

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

Please return to service information pack upon completion of work.

USA —

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

CANADA —

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

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

USA/CANADA ALTERNATE —

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

*UD1B100A9451A
*UD1C100A9481A
*UD1C100A9601A
*UD1D100A9721A
*UD1C120A9541A

For VENT SIZING INFORMATION see:

*UD1D120A9601A
*UD1D140A9601A
*DD1A040A9241A
*DD1A060A9241A
*DD1A060A9361A

*DD1B060A9361A
*DD1B080A9361A
*DD1B080A9451A
*DD1B100A9451A
*DD1C100A9481A

*DD1C100A9541A
*DD1C120A9541A
*DD1D120A9601A
*DD1D140A9601A

Upflow / Horizontal* Downflow / Horizontal*

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

A341789P01

Installer’s Guide

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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 the Location and Clearances section (page

3), of these instructions.

3. Provide adequate combustion and ventilation air to the
furnace space as specified in the Air for Combustion and
Ventilation section (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 13-14), 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 (page 17), 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 the Location and
Clearances section (page 3), 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 manufacturer’s instructions.

b. The furnace is controlled only by a room thermostat

(no field jumpers).

c. The furnace return air duct must be complete and

sealed to the furnace and clean air filters are in
place.

d. The furnace input rate and temperature rise must be

verified to be within nameplate marking.

e. 100% of the furnace combustion air requirement must

come from outside the structure.

f. The furnace return air temperature range is between

55 and 80 degrees Fahrenheit.

g. Clean the furnace, duct work, and components upon

substantial completion of the construction process,
and verify furnace operating conditions including
ignition, input rate, temperature rise and venting,
according to the manufacturer’s instructions.

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

!

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.

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

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.

© 2011 Trane All Rights Reserved 18-CD19D7-22

Installer’s Guide

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GENERAL

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 High Altitude
Derate, page 19).

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 Fan Assisted
Combustion system CATEGORY I furnaces as required by
ANSI Z21.47 “latest edition” and CAN/CGA 2.3. Therefore
they do not require any special provisions for venting
other than what is indicated in these instructions.
(Category I defined on page 13).

These furnaces may be twinned. They shall have
common returns with equal pressure drops or ducts
with equivalent lengths and sizes. See Field Wiring
Diagrams for Twinning on page 16 for proper hookup.

!

CAUTION

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.

!

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.

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?

Contents

Installation Instructions 3

General 3
Location and Clearances 3
Outline Drawings 4-5
Upflow Installation 6
Downflow Installation 6
Horizontal Installation 6
Air for Combustion and Ventilation 7
Duct Connections 8
Return Air Filters 9-13
General Venting Instructions 13
Venting into a Masonry Chimney 13
Electrical Connections 14
Field Wiring Diagrams 15
Twinning Connection Diagrams 16
Gas Piping 17
Sequence of Operation 17

Start-up and Adjustment 18

Preliminary Inspections 18
Combustion and Input Check 18
High Altitude Derate 19
Lighting Instructions 20
Control and Safety Switch Adjustment 20

Abnormal Conditions 21

IFC Error Flash Codes 21

2. Do all clearances between the furnace and enclosure
equal or exceed the minimums stated in the Clearance
Table on the Outline Drawings (see pages 4&5).

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

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

5. Are the ventilation and combustion air openings large
enough and will they remain unobstructed? If outside
air is used, are the openings set above the highest snow
accumulation level? (See the Air for Combustion and
Ventilation section on pages 7&8.)

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.

18-CD19D7-22 3

Installer’s Guide

From Dwg. 21C341699 Rev. 7

(ALL DIMENSIONS ARE IN INCHES)

*UD-A-1A OUTLINE DRAWING

4 18-CD19D7-22

Installer’s Guide

From Dwg. 21C341700 Sh. 1 Rev. 3

(ALL DIMENSIONS ARE IN INCHES)

*DD-A-1A OUTLINE DRAWING

18-CD19D7-22 5

Installer’s Guide

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6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

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 and
drill screws are used to engage the furnace top flange. 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. These instructions apply only if the coil
is on top of an upflow furnace.

1

STANDOFFS (4)

CASED

COIL

DRILL SCREWS (4)

FOR VERTICAL

INSTALLATIONS

TABLE 1

CABINET

WIDTH

RETURN

DUCT WIDTH

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"

FLOOR OPENING PLENUM OPENING

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

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used in the
horizontal position.

Three brackets (with screws) are included with downflow
furnaces for installation to stabilize and secure the furnace
and TXC cased coil in the horizontal position. See Figure 4.

IMPORTANT:
The 2/4TXC cased coil must be placed downstream of the
furnace. In horizontal installations, the apex of the coil
may point either toward or away from the furnace. See
the 2/4TXC coil Installer's Guide for more details.

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

SCREWS

UPFLOW

FURNACE

STANDOFFS

(BOTH SIDES)

(BOTH SIDES)

DOWNFLOW INSTALLATION

!

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

4

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

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.

This furnace may be installed in an attic or crawl space in the
horizontal position by placing the furnace on the left or right
side (as viewed from the front in the upright 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
Clearance Table on Outline Drawings, pages 4&5, and
Figure 5 below).

If the furnace is suspended using perforated steel strap
(plumber’s strap), it must be supported at all four corners
and in the middle at the front of the furnace. The forward
most screw on the side of the furnace may be used to connect
the strapping (See Figure 6 on page 7).

5

REQUIRED FLOOR OPENING: (DOWNFLOW)

See Figure 2 and Table 1

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2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

3

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

FURNACE

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

FRONT

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

2345678901234567890123456789012123456789012345

A (width)

B (depth)

6 18-CD19D7-22

D

C

TYPICAL ATTIC PLATFORM INSTALLATION

(UPFLOW/HORIZONTAL FURNACE SHOWN)

Installer’s Guide

Line contact is only permissible between lines formed by
the intersection of the top and two sides of the furnace
casing and the building joists, studs, or framing.

A cutout is provided on both sides of the downflow furnace
cabinet to allow a 90° elbow to be attached inside the cabinet
and the vent piping to connect there. In horizontal, the
downflow furnace may be vented through the top of the
cabinet if needed. In vertical configuration, the downflow
furnace may be vented using the side cabinet cutouts. This
venting configuration could be used if an electronic air
cleaner is installed.

When the downflow furnace is vented through the left
side of the furnace cabinet in horizontal or vertical
configuration, Type B vent pipe must be used within the
cabinet.

6

TYPICAL SUSPENDED INSTALLATION

(UPFLOW/HORIZONTAL FURNACE SHOWN)

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 7.
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.

7

UNCONFINED

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

8

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

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 9 (page 8), or
from the outdoors, as in Figure 10 (page 8).

1.

2.

3. The following types of installations will require use of

FURNACE MAXIMUM

BTUH / INPUT RATING

CONFINED

All air from inside the building as in Figure 9 (page 8):
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 3 (page 8), for
minimum open areas required.

All air from outdoors as in Figure 10 (page 8): 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 3 (page 8), for minimum open areas required.

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

WITH 8 FOOT CEILING

MINIMUM AREA IN SQUARE FEET

OF UNCONFINED SPACE

40,000
60,000

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

250
375
500
625
750
875

18-CD19D7-22 7

Installer’s Guide

TABLE 3

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
140,000

Air From

Inside

100
100
100
100
120
140

Vertical

Duct

20
25
30
35

9

0

Air From Outside

Horizontal

10
15

Duct

20
30
40
50
60
70

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. Check controls to make certain they are correct
for the electrical supply.

Central furnaces, when used in connection with cooling units,
shall be installed in parallel or on the upstream side of the
cooling units to avoid condensation in the heating element,
unless the furnace has been 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 “entering temperature” for the
furnace is 55° 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.

8 18-CD19D7-22

RETURN AIR DUCT CONNECTION

NOTE:
On upflow 5 or 6 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.

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 connect to the existing supply and return
ductwork.

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