Trane AUD1B060A9H31B, TUD1A040A9H21B, TUD1B060A9H31B, AUD1B060G9H31A, TUD1B060G9H31A Installer's Manual
...Page 1
18-CD21D1-12
Installer’s Guide
High Efficiency Single Stage Upflow/ Horizontal
and Downflow/ Horizontal Gas-Fired Furnaces,
“Fan Assisted Combustion System”
*UD1A040A9H21B
*UD1A040G9H21A
*UD1B060A9H31B
*UD1B060G9H31A
*UD1B080A9H31B
*UD1B080G9H31A
*UD1C080A9H41B
*UD1C080G9H41A
*__First letter may be “A” or “T”
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT — This Document is customer property and is to remain with this unit.
Please return to service information pack upon completion of work.
For VENT SIZING INFORMATION see:
USA —
National Fuel Gas Code ................ ANSI Z223.1/NFPA 54 (latest version)
CANADA —
Natural Gas Installation Code ..............CAN/CGA-B149.1 (latest version)
Propane Installation Code ....................CAN/CGA-B149.2 (latest version)
USA/CANADA ALTERNATE —
Category I Venting Guide ......................................Pub. No. 18-CH23D1-2
*UD1B100A9H31B
*UD1B100G9H31A
*UD1C100A9H51B
*UD1C100G9H51A
*UD1D120A9H51B
*UD1D120G9H51A
*UD1D140A9H51B
*UD1D140G9H51A
*DD1B060A9H31B
*DD1B080A9H31B
*DD1C100A9H51B
*DD1D120A9H51B
*UD1-H
Upflow/ Horizontal* Downflow/ Horizontal*
*Horizontal Conversion for these furnaces may be left or right side rotation.
*DD1-H
A341789P07
Page 2
Installer’s Guide
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
!
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 4),
of these instructions.
3. Provide adequate combustion and ventilation air to
the furnace space as specified in “Air for Combustion and Ventilation” (pages 8-9), 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 (pages
13-15), 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 “Gas Piping” (page 618), of
these instructions.
6. Always install the furnace to operate within the
7. When a furnace is installed so that supply ducts
8. A gas-fired furnace for installation in a residential
9. The furnace may be used for temporary heating
a. The furnace venting system must be complete
b. The furnace is controlled only by a room thermo-
c. The furnace return air duct must be complete
d. The furnace input rate and temperature rise
e. 100% of the furnace combustion air requirement
© 2013 Trane All Rights Reserved 18-CD21D1-12
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.
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.
garage must be installed as specified in “Location
and Clearances” section (page 4), of these instructions.
of buildings or structures under construction only
when the following conditions have been met:
and installed per manufacturer’s instructions.
stat (no field jumpers).
and sealed to the furnace and clean air filters are
in place.
must be verified to be within nameplate marking.
must come from outside the structure.
f. The furnace return air temperature range is be-
tween 55 and 80 degrees Fahrenheit.
g. Clean the furnace, duct work, and components
upon substantial completion of the construction
process, and verify furnace operating conditions
including ignition, input rate, temperature rise
and venting, according to the manufacturer’s instructions.
10. This product must be gas piped by a Licensed
Plumber or Gas Fitter in the Commonwealth of
Massachusetts.
Page 3
Installer’s Guide
▲
WARNING
!
▲
CAUTION
!
▲
WARNING
!
▲
CAUTION
!
Safety signal words are used to designate a degree
or level of seriousness associated with a particular
hazard. The signal words for safety markings are
WARNING, and CAUTION.
a. WARNING indicates a potentially hazardous situa-
tion which, if not avoided, could result in death or
serious injury.
b. CAUTION indicates a potentially hazardous situa-
tion 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.
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.
Contents
Installation Instructions 3
General Installation Instructions 4
Location and Clearances 4
Outline Drawing 5
Upflow Installation 7
Downflow Installation 7
Air For Combustion and Ventilation 8
Duct Connections 10
Return Air Filters 11
Typical Upflow Return Air Filter Installations 11
Alternate Upflow Filter Clip / Bracket Installation 13
Typical Downflow Furnace Return Air Filter Installations 13
General Venting Instructions 14
Venting Into a Masonry Chimney 15
Electrical Connections 16
Field Wiring Diagrams 17
Gas Piping 19
Sequence of Operation 19
Start Up and Adjustment 20
Preliminary Inspections 20
Combustion and Input Check 20
High Altitude Derate 21
Lighting Instructions 22
Control and Safety Switch Adjustment 23
Abnormal Conditions 23
IFC Error Flash Codes 24
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.
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.
18-CD21D1-12 3
Do NOT install the furnace in a corrosive or contaminated atmosphere.
Page 4
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 must be
reduced (See GAS INPUT ADJUSTMENT).
Material in this shipment has been inspected at
the factory and released to the transportation
agency without known damage. Inspect exterior
of carton for evidence of rough handling in 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 re-
quired 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 14).
These furnaces may be twinned. They shall have
common returns with equal pressure drops or
ducts with equivalent lengths and sizes. See
Field Wiring Diagrams for Twinning on page 17
for proper hookup.
LOCATION AND CLEARANCES
The location of the furnace is normally selected by the
architect, the builder, or the installer. However, before
the furnace is moved into place, be sure to consider the
following requirements:
1. Is the location selected as near the chimney or vent
and as centralized for heat distribution as practical?
2. Do all clearances between the furnace and 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.
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.
4 18-CD21D1-12
Page 5
Installer’s Guide
From Dwg. 21C341699 Sh. 1 Rev. 4
(ALL DIMENSIONS ARE IN INCHES)
*UD1-H OUTLINE DRAWING
MODEL DIM "A" DIM "B" DIM "C" DIM "D"
TUD1A040A9H21B, TUD1A040G9H21A 14-1/2" 9-5/8" 13-1/4" 13"
17-1/2" 9-5/8" 16-1/4" 16"
TUD1B060A9H31B, TUD1B060G9H31A
TUD1B080A9H31B, TUD1B080G9H31A
21" 13-1/16" 19-3/4" 19-1/2"
TUD1B100A9H31B, TUD1B100G9H31A
TUD1C080A9H41B, TUD1C080G9H41A
TUD1C100A9H51B, TUD1C100G9H51A
TUD1D120A9H51B, TUD1D120G9H51A
24-1/2" 15-5/16" 23-1/4" 23"
TUD1D140A9H51B, TUD1D140G9H51A
18-CD21D1-12
Page 6
Installer’s Guide
From Dwg. 21C341700 Sh. 1 Rev. 0
(ALL DIMENSIONS ARE IN INCHES)
*DD1-HF OUTLINE DRAWING
6 18-CD21D1-12
Page 7
Installer’s Guide
▲
WARNING
!
UPFLOW
FURNACE
CASED
COIL
SCREWS
(BOTH SIDES)
STANDOFFS
(BOTH SIDES)
STANDOFFS (4)
DRILL SCREWS (4)
UPFLOW INSTALLATION
Standoffs and screws (See Figure 1 on page 6) 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
FOR VERTICAL
INSTALLATIONS:
REQUIRED FLOOR OPENING: (DOWNFLOW)
SEE FIGURE 3 AND TABLE 1
3
A (width)
FURNACE
FRONT
TABLE 1
CABINET
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"
RETURN
DUCT WIDTH
FLOOR OPENING PLENUM OPENING
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 posi-
tion. 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.
B (depth)
D
C
"A" "B" "C" "D"
DOWNFLOW INSTALLATION
Do NOT install the furnace directly on carpeting, tile
or other combustible material other than wood flooring. For vertical downflow application, subbase (BAYBASE205) must be used between the furnace and
combustible flooring. When the downflow furnace is
installed vertically with a cased coil, a subbase is not
required.
2
18-CD21D1-12
4
CASED COIL CONNECTION
BRACKET FOR DOWNFLOW
FURNACE IN HORIZONTAL
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
downow/ 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 and Figure 5).
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
Page 8
Installer’s Guide
forward most screw on the side of the furnace may be
used to connect the strapping (See Figure 6). Line contact is only permissible between lines formed by the
intersection of the top and two sides of the 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.
7
UNCONFINED
50 CU. FT. OR MORE
PER 1000 BTU/ HR.
INPUT ALL EQUIP-
MENT INSTALLED
5
TYPICAL ATTIC PLATFORM INSTALLATION
(UPFLOW/HORIZONTAL FURNACE SHOWN)
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.
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 ue 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.
6
Typical Suspended Installation
(Upflow/Horizontal Furnace Shown)
8 18-CD21D1-12
8
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 or from the outdoors, as in Figure 10.
CONFINED
LESS THAN 50 CU. FT.
PER 1000 BTU/ HR.
INPUT ALL EQUIP-
MENT INSTALLED
Page 9
Installer’s Guide
1. All air from inside the building as in Figure 9: 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, for minimum open areas
required.
2. All air from outdoors as in Figure 10: 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, for minimum
open areas required.
3. The following types of installations will require use
of OUT DOOR 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 combus-
tion air supply will also require OUTDOOR AIR for
combustion:
* Permanent wave solutions
* Chlorinated waxes and cleaners
* Chlorine based swimming pool chemicals
* Water softening chemicals
* Deicing salts or chemicals
* Carbon Tetrachloride
* Halogen type refrigerants
* Cleaning solvents (such as perchloroethylene)
* Printing inks, paint removers, varnish, etc.
* Hydrochloric acid
* Cements and glues
* Antistatic fabric softeners for clothes dryers
* Masonry acid washing materials
TABLE 2
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
Insid
100
100
100
100
120
140
Vertical
Duct
9
0
Air From Outside
Horizontal
Duct
10
15
20
25
30
35
20
30
40
50
60
70
MINIMUM AREA IN SQUARE FEET FOR
UNCONFINED SPACE INSTALLATIONS
FURNACE MAXIMUM
BTUH / INPUT RAT-
ING
40,000
60,000
80,000
100,000
120,000
140,000
18-CD21D1-12
WITH 8 FOOT CEILING
MINIMUM AREA IN SQUARE FEET
OF UNCONFINED SPACE
250
375
500
625
750
875
Page 10
Installer’s Guide
▲
WARNING
!
TO PREVENT INJURY OR DEATH DUE TO CONTACT
WITH MOVING PARTS, TURN THE POWER TO THE
FURNACE OFF BEFORE SERVICING FILTERS.
▲
WARNING
!
Do NOT install the filter in the return duct directly
above the furnace in horizontal applications. Install
the filter remotely. Installing the filter directly above
the furnace in horizontal applications may cause
property damage, serious injury or death.
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 on controls to make
certain they are correct for the electrical supply.
Central furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling units to avoid condensation
in the heating element, unless the furnace has been
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.
NOTE: DO NOT install return air through the
back of the furnace cabinet.
RETURN AIR DUCT CONNECTION
NOTE:
On upflow 5 or 6 ton airflow models, if the airflow requirement exceeds 1800 CFM, these models will re-
quire return air openings and filters on both sides; OR
1 side and the bottom; OR just the bottom.
10 18-CD21D1-12
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 postion to set the furnace in order to connect to the supply and return
ductwork.
2. The return air filter are 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 12 and
the outline drawing on page 5 for duct connection
dimensions for various furnaces.
5. If a 3/4" ange is to be used for attaching the air
inlet duct, add to cut where indicated by solid lines
in Figure 12. Cut corners diagonally and bend outward to form flange.
6. If flanges are not required, and a filter frame is
installed, cut between the locating notches. See
Figure 12.
7. Upflow Furnaces: Two clips are factory supplied
for bottom or side return. Use the filter rack on either side or on the bottom if the filter is to be used
within the furnace cabinet.
Page 11
Installer’s Guide
REMOVE FILTER FROM UPFLOW
FURNACE WHEN RETURN DUCT IS
ATTACHED TO FURNACE TOP SIDE
(HORIZONTAL LEFT OR RIGHT APPLICATIONS) AS SHOWN.
Close coupled (less than 36")
return (filter directly beneath bottom
side return) not recommended due to
noise considerations. If used, securely
attach 1/2" mesh metal hardware cloth
protective screen to the inside bottom
of filter grill.
When the upflow furnace is installed in the hori-
zontal right or left application and a return duct
is attached to the top side as shown in Figure 11,
remove the filter from the furnace and install in a
remote location.
Do not install the filter in the return duct directly
above the furnace in horizontal applications.
When the upflow furnace is installed in the hori-
zontal right or left application and a close coupled
(less than 36") return duct is attached to the bottom side of the furnace as shown in Figure 11, se-
curely attach a 1/2" mesh metal hardware cloth
protective screen to the inside bottom of the filter
grill to prevent personal injury from contact-
ing moving parts when reaching into the return opening to replace the filter.
Close coupled (less than 36") return (lter directly
beneath bottom side return) is not recommended
due to noise considerations.
Downflow Furnaces: Brackets are factory sup-
plied to mount filters in the return air duct work.
8. Connect the duct work to the furnace. See Outline
Drawing for supply and return duct size and location. Flexible duct connectors are recommended
to connect both supply and return air ducts to the
furnace.
If only the front of the furnace is accessible, it is
recommended that both supply and return air plenums are removable.
9. The horizontal installation of the upflow fur-
nace requires an external filter section. Do
NOT use the bottom return filter within the
furnace. Filter kits are available for horizontal applications.
10. When replacing a furnace, old duct work should
be cleaned out. Thin cloths should be placed over
the registers and the furnace fan should be run for
10 minutes. Don’t forget to remove the cloths before you start the furnace.
18-CD21D1-12
FILTER
q
w
LOCATING
NOTCHES
PROVIDED
FOR SIDE
RETURN
CUTOUT
*SEE OUTLINE DRAWING
*
*
*
*
CUT OUT
FOR
SIDE
FILTER
FRONT
of Furnace
e
Airflow
BOTTOM FILTER RACK INSTALLATION
11. 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.
RETURN AIR FILTERS
TYPICAL UPFLOW RETURN AIR
FILTER INSTALLATIONS
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.
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.
The furnace and the bottom lter rack, BAYRACK960,
installation can be seen in Figure 13.
Page 12
Installer’s Guide
RETAINING
PIN
(Both Sides)
SPRINGS
SIDE
CUTOUT
FILTER
RACK
RAILS
BOTTOM
PANEL
INSTALLED
Airflow
RETAINING
PIN
(Both Sides)
SPRINGS
SIDE
CUTOUT
FILTER
RACK
RAILS
BOTTOM
PANEL
INSTALLED
Airflow
TABLE 4
UPFLOW FURNACE RETURN AIR FILTERS
CABINET
WIDTH
14-1/2" 1 14" X 25" X 1" 17-1/2" X 25" X 1"
17-1/2" 1 17" X 25" X 1" 17-1/2" X 25" X 1"
21" 1 20" X 25" X 1" 17-1/2" X 25" X 1"
24-1/2" 1 24" X 25" X 1" 17-1/2" X 25" X 1"
**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
QTY*
CABINET
BOTTOM FILTER
CABINET
SIDE FILTER
ALTERNATE FILTER RACK INSTALLATION FOR BOTTOM RETURN - BAYRACK960
The following checklist should be used when installing
a bottom return filter on an upflow furnace:
a. Remove the filter.
b. Remove the bottom panel.
c. With the filter removed, the filter rack is com-
pressed 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 18.
d. Reinstall the furnace filter in the bottom position
by inserting the chamfer end first into the filter
rack.
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 10.
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 15-16, 19-20.
e. Reinstall the furnace filter in the side position
by inserting the chamfer end first into the filter
rack.
Optional conversion kits for horizontal lters 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 17.
y
r
Airflow
t
Typical Upflow Left Side Return Filter Rack Installation
12 18-CD21D1-12
Typical Upflow Right Side Return Filter Rack Installation
u
Airflow
Accessory lter kit BAYFLTR203, 204, 205 used
for Upflow Horizontal
furnaces.
Typical Horizontal Filter Installation
Page 13
Installer’s Guide
Bottom Panel
Filter
Rack
Furnace
Cabinet
Side
Filter Rack
Retaining
Screw/Pin
Engagement Hole
For
Bottom Return
Filter Rack
Installation With
Filter
Rack
Furnace
Cabinet
Side
Filter Rack
Retaining
Screw/Pin
Engagement Hole
For
Bottom Return
Filter Rack
Installation With
Filter
Rack
Assembly
Furnace
Blower
Deck
Filter Rack
Retaining
Screw/Pin
Engagement Hole
For
Return
Filter Rack
Installation With
Side
Furnace
Cabinet
Side
SIDE
CUT-OUT
ALTERNATE SIDE
FILTER CLIPS
LOCATIONS
ALTERNATE BOTTOM
FILTER CLIPS LOCATIONS
i
o
p
BLOWER
DECK
a
s
Airflow
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 17.
UPFLOW FILTER CLIP/ BRACKET INSTALLATION
1. Determine the location to be used. The furnace
cabinet has dimples for location of the alternate furnace clips (Side return only). Pre-drill
clearance holes with a 3/16" drill. Bottom
return holes are pre-drilled. See Figure 21.
Attach clip to bottom channel and rear of unit
with screws provided for bottom return.
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.
TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS
These furnaces require high velocity type air filters.
Downflow furnace filters must be located outside the
furnace cabinet. Typical installations are shown in
Figure 22. Tables 5 and 6 provide information for installation of the filter retaining brackets shipped with
downflow furnaces.
18-CD21D1-12
Page 14
Installer’s Guide
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon
monoxide poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 or the CAN/CGA
B149 Installation Codes and these instructions.
Determine that there is no blockage or restriction,
leakage, corrosion and other deficiencies which
could cause an unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system
are located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts, so they are operating at maximum speed.
Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the
thermostat so appliance is operating continuously.
7. If improper venting is observed during any of the
above tests, the venting system must be corrected
in accordance with the National Fuel Gas Code,
ANSI Z221.1/NFPA 54 and/or CAN/CGA B149
Installation Codes.
8. After it has been determined that each appliance
connected to the venting system properly vents
where tested as outlined above, return doors,
windows, exhaust fans, fireplace dampers and any
other gas-fired burning appliance to their previous
conditions of use.
▲
WARNING
!
TABLE 5
CABINET
WIDTH
14-1/2" 2 - 14X20X1 12-7/8"
17-1/2" 2 - 16X20X1 14-3/8"
21" 2 - 16X20X1 13-1/8"
24-1/2" 2 - 16X20X1 11-5/8"
* Location dimension is from end of duct to the screw holes for the bracket.
CABINET
WIDTH
14-1/2" 13-1/4" 12" 14"
17-1/2" 16-1/4" 15" 14"
21" 19-3/4" 19-1/2" 14"
24-1/2" 23-1/4" 22" 14"
14 18-CD21D1-12
RETURN
DUCT
WIDTH
FILTER
SIZE
TABLE 6
FILTER ACCESS
OPENING - DI-
MENSION "A"
FILTER BRACKET
GENERAL VENTING INSTRUCTIONS
LOCATION *
FILTER ACCESS
OPENING -
DIMENSION "B"
Page 15
Installer’s Guide
▲
WARNING
!
▲
WARNING
!
▲
WARNING
!
VENT PIPING
These furnaces have been classified as Fan-Assisted
Combustion System, Category I furnaces under the
“latest edition” provisions of ANSI Z21.47 and CAN/
CGA 2.3 standards. Category I furnaces operate with a
non-positive vent static pressure and with a flue loss of
not less than 17 percent.
NOTE:
If desired, a side wall termination can be accomplished
through the use of an “add-on” draft inducer. The inducer must be installed according to the inducer manufacturer’s instructions. Set the barometric pressure
relief to achieve -0.02 inch water column.
NOTE: When the downflow furnace is vented through
the left side of the furnace cabinet using the provided
cutout, Type B vent piping must be used.
The furnace shall be connected to a factory built chimney or vent complying with a recognized standard, or a
masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction.
Furnace venting into an unlined masonry chimney or
concrete chimney is prohibited.
Failure to follow this warning could result in property
damage, personal injury, or death.
VENTING INTO A MASONRY CHIMNEY
If the chimney is oversized, the liner is inadequate, or
flue-gas condensation is a problem in your area, consider using the chimney as a pathway or chase for type
“B” vent or exible vent liner. If exible liner material
is used, size the vent using the “B” vent tables, then
reduce the maximum capacity by 20% (multiply 0.80
times the maximum capacity). Masonry Chimney Kit
BAYVENT800B may be used with these furnaces (Up-
flow model furnaces only) to allow venting into a
masonry chimney. Refer to the BAYVENT800B Installer’s Guide for application requirements.
INTERNAL MASONRY CHIMNEYS
Venting of fan assisted appliances into a lined, internal masonry chimney is allowed only if it is common
vented with at least one natural draft appliance; OR,
if the chimney is lined with type “B”, double wall vent
or suitable flexible liner material (See Table 7).
The chimney liner must be thoroughly inspected to
insure no cracks or other potential areas for flue gas
leaks are present in the liner. Liner leaks will result in
early deterioration of the chimney.
Failure to follow this warning could result in carbon
monoxide poisoning or death.
TABLE 7
MASONRY CHIMNEY VENTING
Tile Lined Chimney Chimney Lining
Type Furnace
Internal External “B” Vent
Single Fan
Assist
Fan Assist
+
Fan Assist
Fan Assist
+
Natural
* Flexible chimney liner size is determined by using the type “B” vent size
for the available BTUH input, then reducing the maximum capacity by 20%
(multiply maximum capacity times 0.80). The minimum capacity is the same
as shown in the “B” vent tables.
No No Ye s Yes*
No No Ye s Yes*
Ye s No Ye s Yes*
Flexible
Metal Liner
External Masonry Chimney
Venting of fan assisted appliances into external chimneys (one or more walls exposed to outdoor tempera-
tures), requires the chimney be lined with type “B”,
double wall vent or suitable flexible chimney liner
material. This applies in all combinations of common
venting as well as for fan assisted appliances vented
alone.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the installation instructions for the
venting system being placed into operation could result in carbon monoxide poisoning or death.
The following installation practices are recommended
to minimize corrosion caused by condensation of flue
products in the furnace and flue gas system.
1. Avoid an excessive number of bends.
2. Horizontal runs should pitch upward at least 1/4"
per foot.
3. Horizontal runs should be as short as possible.
4. All vent pipe or connectors should be securely supported and must be inserted into, but not beyond
the inside wall at the chimney vent.
5. When vent connections must pass through walls or
partitions of combustible material, a thimble must
be used and installed according to local codes.
6. Vent pipe through the roof should be extended to
a height determined by National Fuel Gas Code or
local codes. It should be capped properly to prevent
rain water from entering the vent. Roof exit should
be waterproofed.
7. Use type “B” double wall vent when vent pipe is
routed through cool spaces (below 60° F.).
NOTE:
The following section does not apply if BAYVENT800B
(Masonry Chimney Vent Kit) is used. All instructions
with the kit must be followed.
18-CD21D1-12
Page 16
Installer’s Guide
▲
WARNING
!
▲
CAUTION
!
▲
WARNING
!
TABLE 8
GAS VENT TERMINATION
ROOF PITCH MINIMUM HEIGHT
FLAT TO 7/12
OVER 7/12 TO 8/12
OVER 8/12 TO 9/12
OVER 9/12 TO 10/12
OVER 10/12 TO 11/12
OVER 11/12 TO 12/12
OVER 12/12 TO 14/12
OVER 14/12 TO 16/12
OVER 16/12 TO 18/12
OVER 18/12 TO 20/12
OVER 20/12 TO 22/12
* THIS REQUIREMENT COVERS MOST INSTALLATIONS
1.0 FEET *
1.5 FEET
2.0 FEET
2.5 FEET
3.25 FEET
4.0 FEET
5.0 FEET
6.0 FEET
7.0 FEET
7.5 FEET
8.0 FEET
d
8. Where long periods of airflow are desired for com-
fort, use long fan cycles instead of continuous airflow.
9. Apply other good venting practices as stated in
the venting section of the National Fuel Gas Code
ANSI Z223.1 “latest edition”.
10. Vent connectors serving appliance vented by
natural draft or non-positive pressure shall
not be connected into any portion of a mechanized draft system operating under positive
pressure.
11. Horizontal pipe runs must be supported by hangers, straps or other suitable material in intervals
at a minimum of every 3 feet of pipe.
12. A furnace shall not be connected to a chimney or
flue serving a separate appliance designed to burn
solid fuel.
13. The flow area of the largest section of vertical
vent or chimney shall not exceed 7 times the smallest listed appliance categorized vent area, flue collar area, or draft hood outlet area unless designed
in accordance with approved engineering methods.
Maximum Vent or Tile
Lined Chimney Flow Area
*Drafthood outlet diameter, flue collar diameter, or listed appliance categorized vent diameter.
= X 7
π(D*)
4
2
ELECTRICAL CONNECTIONS
The cabinet must have an uninterrupted or unbroken
ground according to National Electrical Code, ANSI/
NFPA 70 – “latest edition” and Canadian Electrical
Code, CSA C22.1 or local codes to minimize personal
injury if an electrical fault should occur.
Failure to follow this warning could result in an electrical shock, fire, injury, or death.
The integrated furnace control is polarity sensitive. The
hot leg of the 115 VAC power must be connected to the
BLACK field lead.
To prevent injury or death due to electrical shock or
contact with moving parts, lock unit disconnect switch
in the open position before servicing the unit.
Failure to follow this warning could result in electrical
shock, personal injury, or death.
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 it be provided with a separate “circuit
protection device” electric circuit. The furnace must be
electrically grounded in accordance with local codes or
in the absence of local codes with the National Electri-
cal Code, ANSI/NFPA 70 “latest edition” or Canadian
Electrical Code, CSA C22.1, if an external electrical
source is utilized.
All field supplied wiring must conform with the temperature limitation for Type T wire [63° F. (35° C)],
when installed in accordance with these instructions
and wiring diagrams supplied with the furnace. A disconnecting means must be located within sight from,
and readily accessible to, the furnace.
Refer to the SERVICE FACTS literature for unit wiring diagrams in addition to the diagram inside the
blower door.
16 18-CD21D1-12
Page 17
Installer’s Guide
SEE
NOTE 6
From Dwg. B341437 Rev. 1
FURNACE
TWIN
SEE
NOTE 7
B/C
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 1 STAGE FURNACE
1 STAGE HEATING
USING A 1 STAGE HEATING THERMOSTAT
NO COOLING
OUTDOOR UNIT
(NO TRANSFORMER)
SEE
NOTE 6
From Dwg. B341436 Rev. 1
SEE
NOTE 8
FURNACE
TWIN
SEE
NOTE 7
B/C
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 1 STAGE FURNACE
1 STAGE HEATING, 1 STAGE COOLING
USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT
(OUTDOOR SECTION WITHOUT TRANSFORMER)
18-CD21D1-12
From Dwg. 21B341437 P01
From Dwg. 21B341436 P01
Page 18
Installer’s Guide
TWIN
TWIN
R1
R1
TWINNING CONNECTION DIAGRAM
FOR TWINNING 1 STAGE FURNACES WITH
SINGLE WIRE TWINNING FEATURE
1 STAGE HEATING ONLY THERMOSTAT
1 STAGE HEAT
ONLY
THERMOSTAT
(WITH FAN SWITCH) FURNACE NO. 1
FURNACE NO. 2
BLOWER OPERATION OF
UNIT NO. 2 IS SYNCRONIZED
WITH UNIT NO. 1 VIA SIGNALS
FROM TWIN CONNECTION.
SEE NOTE 4
SEE NOTE 3
ISOLATION RELAY
(FIELD SUPPLIED)
SEE NOTE 4
ISOLATION RELAY
SEE NOTE 4
B/C
B/C
B/C
From Dwg. 21B341422 Rev. 3
TWIN
TWIN
R1
R1
TWINNING CONNECTION DIAGRAM
FOR TWINNING 1 STAGE FURNACES WITH
SINGLE WIRE TWINNING FEATURE
1 STAGE HEAT / 1 STAGE COOL THERMOSTAT
1 STAGE
HEATING / COOLING
THERMOSTAT FURNACE NO. 1
FURNACE NO. 2
BLOWER OPERATION OF
UNIT NO. 2 IS SYNCRONIZED
WITH UNIT NO. 1 VIA SIGNALS
FROM TWIN CONNECTION.
SEE NOTE 4
SEE NOTE 5
ISOLATION RELAY
(FIELD SUPPLIED)
SEE NOTE 4
ISOLATION RELAY
SEE NOTE 4
OUTDOOR UNIT
(NO TRANSFORMER)
OUTDOOR UNIT
(WITH TRANSFORMER)
RC
ISOLATION RELAY
(FIELD SUPPLIED)
SEE NOTE 3
B/C
B/C
B/C
From Dwg. 21B341423 Rev. 2
TWINNING
These furnaces may be twinned. Twinning requires
that two furnaces with the same configuration, capacity, and airflow must be used. They shall have common
returns with equal pressure drops or ducts with equivalent lengths and sizes. See Field Wiring Diagrams below for proper hookup.
18 18-CD21D1-12
Page 19
TOP VIEW
AUTOMATIC GAS VALV E
WITH MANUAL SHUTOFF
▲
WARNING
!
FIRE OR EXPLOSION HAZARD
▲
WARNING
!
▲
CAUTION
!
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.
▲
WARNING
!
▲
WARNING
!
DRIP LEG
DRIP LEG
Failure to follow the safety warnings exactly could result in serious injury, death or property damage. 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. A fire or explosion may result causing property damage, personal
injury, or loss of life.
IMPORTANT:
A sediment trap must be installed in the gas line
before the furnace gas valve. The sediment trap
must be located as close to the furnace cabinet
as practical.
LEFT SIDE PIPING (STANDARD)
f
Installer’s Guide
GAS PIPING
FIRE - EXPLOSION HAZARD
DO NOT RUN FLEXIBLE GAS LINE THROUGH THE
FURNACE CABINET WALL. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN PROPERTY DAMAGE,
SERIOUS PERSONAL INJURY, OR DEATH.
This unit is shipped standard for left side installation
of gas piping. A piping knockout is also provided in the
right side for an alternate piping arrangement. The
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 9 for delivery sizes.
NOTE: Refer to local codes and the National
Fuel Gas Code, current edition, for gas pipe requirements.
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.
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 sys-
tem at test pressures equal to or less than 1/2 psig.
RIGHT SIDE PIPING (OPTIONAL)
TOP VIEW OF RIGHT SIDE PIPING
TO PREVENT AN EXPLOSION OR POSSIBLE INJURY,
DEATH AND EQUIPMENT DAMAGE, DO NOT STORE
COMBUSTIBLE MATERIALS, GASOLINE OR OTHER
FLAMMABLE VAPORS OR LIQUIDS NEAR THE UNIT.
18-CD21D1-12
Use a backup wrench on the gas valve when installing gas piping to prevent damage to the gas valve and
manifold assembly.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.
All gas fittings must be checked for leaks using a soapy
solution before lighting the furnace.
DO NOT CHECK WITH AN OPEN FLAME!
SEQUENCE OF OPERATION
THERMOSTAT CALL FOR HEAT
R and W thermostat contacts close signaling the control module to run its self-check routine. After the
control module has verified that the pressure switch
contacts are open and the limit switch(es) contacts are
closed, the draft blower will be energized.
Page 20
Installer’s Guide
▲
WARNING
!
As the induced draft blower comes up to speed, the
pressure switch contacts will close and the ignitor
warm up period will begin. The ignitor will heat for
approx. 20 seconds, then the gas valve is energized to
permit gas flow to the burners. The flame sensor confirms that ignition has been achieved within the 6 second ignition trial period.
After the flame sensor confirms that ignition has been
achieved, the delay fan ON period (fixed at 45 seconds)
begins timing. After the delay of 45 seconds, the indoor blower motor will be energized and will continue
to run during the heating cycle.
When the thermostat is satisfied, R and W thermostat
contacts open, the gas valve will close, the flames will
extinguish, and the induced draft blower will be de-energized. The indoor blower motor will continue to run
for the fan off period (fixed at 100 seconds), then will
be de-energized by the control module.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death or property damage. 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. A fire or explosion may result causing property damage, personal
injury, or loss of life.
START-UP AND ADJUSTMENT
PRELIMINARY INSPECTIONS
With gas and electrical power “OFF”
1. Duct connections are properly sealed
2. Filters are in place
3. Venting is properly assembled
4. Blower door is in place
Turn knob on main gas valve within the unit to the
“OFF” position. Turn the external gas valve to “ON”.
Purge the air from the gas lines. After purging, check
all gas connections for leaks with a soapy solution –
DO NOT CHECK WITH AN OPEN FLAME. Allow
5 minutes for any gas that might have escaped to dissipate. LP Gas, being heavier than air, may require
forced ventilation. Turn the knob on the gas valve in
the unit to the “ON” position.
COMBUSTION AND INPUT CHECK
1. Make sure all gas appliances are off except the 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 13 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 pres-
sure (See Table 12), 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 White-Rodgers gas valve model 36G or 36J.
See Figure 26 for White-Rodgers gas valve model
36J. See Figure 25 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 wrence, a 5/16" hose and
a connector and can be ordered through Global
Parts.
4. Turn on system power and energize valve.
5. Adjust gas heat by removing the adjustment regu-
lator 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
12.
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. Cycle the valve several times to verify regulator
setting.
a. Repeat steps 5-6 if needed.
7. Turn off all electrical power to the system.
8. Remove the manometer and flexible tubing and
tighten the pressure tap screw.
20 18-CD21D1-12
Page 21
Installer’s Guide
▲
CAUTION
!
▲
WARNING
!
9. Using a leak detection solution or soap suds, check
for leaks at the pressure outlet boss and pressure
tap test screw.
10. Turn on system power and check operation of the
unit.
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, or property damage.
Table 10 lists the main burner orifices shipped with
the furnace. If a change of orifices is required to correct the input rate, refer to Table 11.
TABLE 9
NATURAL GAS ONLY
TABLE OF CUBIC FEET PER HOUR OF GASFOR VARIOUS PIPE
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
10 20 30 40 50 60 70
1 520 350 285 245 215 195 180
SIZES AND LENGTHS
LENGTH OF PIPE
TABLE 10
ORIFICE SIZES
INPUT
RATING
BTUH
40,000
60,000
80,000
100,000
120,000
140,000
NUMBER
OF
BURNERS
2
3
4
5
6
7
TABLE 11
MAIN BURNER ORIFICE
DRILL SIZE
NAT. GAS LP GAS
45
45
45
45
45
45
56
56
56
56
56
56
PART NUMBERS FOR REPLACEMENT ORIFICES
DRILL
SIZE
44
45
46
47
48
49
50
PART
NUMBER
ORF00501
ORF00644
ORF00909
ORF00910
ORF01099
ORF00503
ORF00493
TABLE 12
FINAL MANIFOLD PRESSURE SET-
TINGS (inches w.c.)
FUEL PRESSURE
NATURAL GAS 3.5" W.C.
LP GAS 10.5" W.C.
DRILL
SIZE
54
55
56
57
58
59
PART
NUMBER
ORF00555
ORF00693
ORF00907
ORF00908
ORF01338
ORF01339
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 in-
put 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
cannot be achieved with a change in manifold pressure,
then the orifices must be changed. LP installations will
require an orifice change.
Installation of this furnace at altitudes above 2,000 ft.
(610m) shall be in accordance with local codes, the Na-
tional Fuel Gas Code, ANSI Z223.1/ NFPA 54 or National Standard of Canada, Natural Gas and Propane
Installation Code, CSA B149.1. Installation of this fur-
nace at altitudes above 2,000 ft. (610m) shall be made
in accordance with the listed high Altitude Conversion
Kit available with this furnace.
IMPORTANT:
Re-install the propane orifices to the same depth as the
orifices supplied with the equipment.
See Table 14 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.
Installations above 4,000 feet may require a pressure
switch change. If required, use the BAYHALT*** Kit
(High Altitude Accessory Kit) listed in PRODUCT
DATA.
EXPLOSION HAZARD!
PROPANE GAS IS HEAVIER THAN AIR AND MAY
COLLECT IN ANY LOW AREAS OR CONFINED SPACES. IN ADDITION, ODORANT FADE MAY MAKE THE
GAS UNDETECTABLE EXCEPT WITH A 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.
18-CD21D1-12
Page 22
Installer’s Guide
▲
WARNING
!
▲
CAUTION
!
Outlet Pressure Boss
On/Off Switch
Inlet Pressure
Boss (opt.)
Regulator
Adjust
TABLE 13
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
g
White-Rodgers 36G gas valve
h
Outlet Pressure Boss
Regulator
Adjustment
TABLE 14
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 10000
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
43
43
43
44
44
45
46
44
44
45
45
46
47
47
45
45
46
47
47
48
48
47
47
47
48
48
49
49
47
47
48
48
49
49
50
48
49
49
49
50
50
51
55
55
55
55
55
56
56
55
55
56
56
56
56
56
56
57
57
57
58
59
59
59
59
60
60
61
62
63
60
60
61
62
62
63
63
47
48
50
50
51
52
56
57
60
63
64
LIGHTING INSTRUCTIONS
DO NOT attempt to manually light the burner.
Failure to follow this warning could result in property
damage, personal injury or death.
Lighting instructions appear on each unit. Each
installation must be checked out at the time of
initial start up to insure proper operation of all
components. Check out should include putting
the unit through one complete cycle as outlined
below.
Turn on the main electrical supply and set the thermostat above the indicated temperature. The ignitor will
automatically heat, then the gas valve is energized to
permit the flow of gas to the burners. After ignition
and flame is established, the flame control module
monitors the flame and supplies power to the gas valve
until the thermostat is satisfied.
TO SHUT OFF
For complete shutdown: Move the control switch on the
main gas valve to the “OFF” position (See Figures 25
and 26). Disconnect the electrical supply to the unit.
Inlet Pressure
Boss (opt.)
White-Rodgers 36J gas valve
22 18-CD21D1-12
On/Off Switch
If this is done during the cold weather months, provisions must be taken to prevent freeze-up of all water
pipes and water receptacles.
Failure to follow this warning could result in property
damage.
Whenever your house is to be vacant, arrange
to have someone inspect your house for proper
temperature. This is very important in below
freezing weather. If for any reason your furnace
should fail to operate damage could result, such
as frozen water pipes.
Page 23
Installer’s Guide
▲
WARNING
!
▲
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
!
CONTROL AND SAFETY SWITCH
ADJUSTMENT
LIMIT SWITCH CHECK OUT
The limit switch is a safety device designed to close the
gas valve should the furnace become overheated. Since
proper operation of this switch is important to the
safety of the unit, it must be checked out on initial
start up by the installer.
To check for proper operation of the limit switches, set
the thermostat to a temperature higher than the 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.
AIRFLOW ADJUSTMENT
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 wiring diagram for information on
changing the speed of the blower motor.
INSTRUCTIONS TO THE OWNERS
In the event that electrical, fuel, or mechanical
failures occur, the owner should immediately
turn the gas supply off at the manual gas valve,
located in the burner compartment (See Figure
24). Also turn off electrical power to the furnace
and contact the service agency designated by
your dealer.
Should overheating occur, or the gas supply fail to shut
off, shut off the gas valve to the unit before shutting off
the electrical supply.
Failure to follow this warning could result in property
damage, personal injury or death.
Disconnect power to the unit before removing the
blower door.
Failure to follow this warning could result in property
damage, personal injury or death.
This unit is equipped with a blower door switch which
cuts power to the blower and gas valve causing shutdown when the door is removed. 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.
NOTE:
Direct drive motors have bearings which are permanently lubricated and under normal use, lubrication is
not recommended.
INDOOR BLOWER TIMING
The control module controls the indoor blower. The
blower starts approximately 45 seconds after ignition.
The FAN-OFF period is approximately 100 seconds
from the interruption of gas flow.
ROOM AIR THERMOSTAT HEAT ANTICIPATOR
ADJUSTMENT
Set the thermostat heat anticipator according to the
current flow measured, or the settings found in the
notes on the furnace wiring diagram (found inside the
furnace casing).
18-CD21D1-12
OPERATING INFORMATION
FLAME ROLL-OUT DEVICE
All models are equipped with a thermal control device
on the burner cover. In case of flame roll-out, the device will cause the circuit to open which shuts off all
flow of gas.
ABNORMAL CONDITIONS
1. EXCESSIVE COMBUSTION VENT PRESSURE
OR FLUE BLOCKAGE
If pressure against the induced draft blower outlet
becomes excessive, the pressure switch will shut
off the gas valve until acceptable combustion pressure is again available.
Page 24
Installer’s Guide
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.
▲
WARNING
!
2. LOSS OF FLAME OR GAS SUPPLY FAILURE
If loss of flame occurs during a heating cycle
(when flame is not present at the sensor), the control module will retry the ignition sequence up to
two times after the sensor cools. If ignition is not
achieved, it will lockout the furnace.
3. POWER FAILURE
If there is a power failure during a heating cycle,
the system will restart the ignition sequence automatically when power is restored, if the thermostat
still calls for heat.
4. INDUCED DRAFT BLOWER FAILURE
If pressure is not sensed by the pressure switch, it
will not allow the gas valve to open, therefore the
unit will not start. If failure occurs during a running cycle, the pressure switch will cause the gas
valve to close and shut the unit down.
Carbon monoxide, fire or smoke can cause serious bodi-
ly 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 gasburning appliances install carbon monoxide detectors
as well as fire and smoke detectors per the manufacturers installation instructions to help alert dwelling
occupants of the presence of fire, smoke or unsafe lev-
els of carbon monoxide. These devises should be listed
by Underwriters Laboratories, Inc. Standards for Sin-
gle 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.
INTEGRATED FURNACE CONTROL ERROR FLASH CODES
Flashing Slow --- Normal - No call for Heat
Flashing Fast --- Normal - Call for Heat
Continuous ON --- Replace IFC
Continuous OFF --- Check Power
2 Flashes --- System Lockout (Retries or Recycles exceeded)
Draft Pressure Error - Possible problems:
3 Flashes ---
4 Flashes --- Open Temperature Limit Circuit
5 Flashes --- Flame sensed when no flame should be present
6 Flashes --- 115 volt AC power reversed, poor grounding or system voltage too low
7 Flashes --- Gas valve circuit error
8 Flashes --- Low flame sense signal
9 Flashes --- Check Ignitor Circuit and Line "N" to 24VAC "Common" voltage (< 2 volts) [possible grounding problem]
Trane
6200 Troup Highway
Tyler, TX 75707
For more information contact
your local dealer (distributor)
24 18-CD21D1-12
a) Venting problem
b) Pressure switch problem
c) Inducer problem
File Number 18-CD21D1-12
Supersedes 18-CD21D1-11
Date 08/13
The manufacturer has a policy of continuous product and product data improvement and reserves the right to
change design and specifications without notice.
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