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-
22), 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” (pages 29-
30), 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 4), of these
instructions.
9. The furnace may be used for temporary heating of
buildings or structures under construction only when
the following conditions have been met:
a. The furnace venting system must be complete
and installed per manufacturers instructions.
b. The furnace is controlled only by a room
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 gas piped by a Licensed
Plumber or Gas Fitter in the Commonwealth of
Massachusetts.
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 B149.1 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.
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.
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, 400 N. Capitol St. NW, Washington D.C. 20001.
1-800-699-9277 or www.aga.org
These furnaces have been classified as CATEGORY IV
furnaces in accordance with latest edition of ANSI Z21.47
• CAN/ CGA 2.3 standards.
Contents
INSTALLATION INSTRUCTIONS
General Installation Instructions 3
Location and Clearances 4
Outline Drawings 5
Upflow Installation 7
Downflow Installation 7
Horizontal Installation 7
Air For Combustion and Ventilation 8
Duct Connections 10
Return Air Filters 11
General Venting Instructions 14
Venting Material 15
Venting Tables 15
Horizontal Venting 16
Venting Through The Wall 20
Venting Through The Roof 20
Downward Venting 22
Venting Through a Masonry Chimney 22
Condensate Drain Instructions 25
Electrical Connections 27
Field Wiring Diagrams 27
Gas Piping 29
Combustion Input Checks 31
Start Up and Adjustment 33
Preliminary Inspections 33
Lighting Instructions 34
Sequence Of Operation 34
Control And Safety Switch Adjustments 34
Airflow Adjustment 35
Conditions Affecting Operation 35
IFC Error Flash Code 37
Category IV furnaces operate with positive vent static
pressure and with a flue loss less than 17 percent. These
conditions require special venting systems, which must
be gas tight and water tight. These Category IV Direct
Vent furnaces are approved for installation in Manufactured/Mobile housing when used with BAYMFGH100A.
18-CD33D1-4 3
Installer’s Guide
▲
CAUTION
!
▲
CAUTION
!
▲
WARNING
!
To prevent shortening its service life, the furnace
should not be used as a “Construction Heater” during
the finishing phases of construction until the requirements listed in item 9, a-g of the safety section of this
publication have been met. Condensate in the presence of chlorides and fluorides from paint, varnish,
stains, adhesives, cleaning compounds, and cement
create a corrosive condition which may cause rapid
deterioration of the heat exchanger.
Do NOT install the furnace in a corrosive or contaminated atmosphere.
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.
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 vent and as centralized for heat distribution as practical?
2. Do all clearances between the furnace and enclosure
equal or exceed the minimums shown in the Table 1.
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 front panel and any closed panel or door
provided?
5. Are the ventilation and combustion air openings large
enough and will they remain unobstructed? If outside air is used, are the openings set 12" minimum
above the highest snow accumulation level (18" in
Canadian applications)?
6. Allow sufficient height in supply plenum above or below 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.
4 18-CD33D1-4
Installer’s Guide
From Dwg. 21C341884
APPLICATION.
REFER TO THE VENT LENGTH TABLE FOR PROPER
OR 3” ON SOME MODELS AT DIFFERENT ALTITUDES.
NOTES:
1. *UH1C100A9H41, & *UH1D120A9H51
REQUIRE 3” DIAMETER VENT PIPE.
2. DIAMETER OF VENT PIPE MAY BE LIMITED TO 2-1/2”
(ALL DIMENSIONS ARE IN INCHES)
*UH1-H OUTLINE DRAWING
18-CD33D1-4 5
Installer’s Guide
From Dwg. 21C341885
(ALL DIMENSIONS ARE IN INCHES)
*DH1-H DOWNFLOW/ HORIZONTAL OUTLINE DRAWING
6 18-CD33D1-4
UPFLOW INSTALLATION
▲
WARNING
!
UPFLOW
FURNACE
CASED
COIL
SCREWS
(BOTH SIDES)
STANDOFFS
(BOTH SIDES)
STANDOFFS (4)
DRILL SCREWS (4)
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.
1
FOR VERTICAL
INSTALLATIONS:
DOWNFLOW INSTALLATIONS
FIRE HAZARD
Do NOT install the furnace directly on carpeting, tile
or other combustible material other than wood flooring. For vertical downflow application, subbase (BAYBASE205) must be used between the furnace and
combustible flooring. When the downflow furnace is
installed vertically with a cased coil, a subbase is not
required.
Required floor opening:
Installer’s Guide
2
FURNACE
FRONT
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 3.
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 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.
3
CASED COIL CONNECTION
BRACKET FOR DOWNFLOW FUR-
NACE IN HORIZONTAL
A (width)
B (depth)
D
C
CABINET
WIDTH
17-1/2"16-1/4"16-5/8"20-1/8"15-5/8"19-3/8"
21"19-3/4"20-1/8"20-1/8"19-1/8"19-3/8"
24-1/2"23-1/4"23-5/8"20-1/8"22-5/8"19-3/8"
18-CD33D1-4 7
SUBBASE CROSS SECTION
TABLE 1
RETURN
DUCT WIDTH
FLOOR OPENING PLENUM OPENING
"A" "B""C""D"
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 Figure 4 & Clearance Table). 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.
Installer’s Guide
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.
4
UPFLOW/
HORIZONTAL
SHOWN
The furnace must also be elevated a minimum of 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.
5
50 CU. FT. OR MORE
PER 1000 BTU/HR. INPUT
ALL EQUIP. INSTALLED
made in accordance with latest edition of Section 5.3, Air
for Combustion and Ventilation, of the National Fuel Gas
Code, ANSI Z223.1 — CAN/CGA B149.1 or applicable
provisions of the local building codes. Special conditions
created by mechanical exhausting of air and fireplaces
must be con sidered to avoid unsatisfactory furnace operation.
OUTSIDE AIR IS RECOMMENDED
The use of indoor air for most applications is acceptable,
unless there is the presence of corrosive chemicals
or contamination. Certain types of installation will require the use of outside air for combustion.
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 “confined” laundry rooms
* Furnaces installed in “confined” 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
UNCONFINED
AIR FOR COMBUSTION AND VENTILATION
If these furnaces are installed in a nondirect vent capacity then the adequate flow of combustion and ventilating
air must not be obstructed from reaching the furnace. Air
openings provided for combustion air 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
8 18-CD33D1-4
Furnace locations may be in a “confined space” or an
“unconfined space”.
Unconfined space is defined in Figure 5. These spaces may have adequate air by infiltration to provide air
for combustion and ventilation. Buildings with tight
construction (for example, weather stripping, heavily
insulated, caulked, vapor barrier, etc.), may need additional air to be 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.
Installer’s Guide
6
MINIMUM AREA IN SQUARE FEET
FOR UNCONFINED SPACE INSTALLATIONS
FURNACE MAXI-
MUM BTUH INPUT
RATING
60,000
80,000
100,000
120,000
1. All air from inside the building as in Figure 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 2 for minimum open areas requirements.
WITH 8 FT. CEILING
MINIMUM AREA IN SQUARE FEET
OF UNCONFINED SPACE
375
500
625
875
8
9
7
CONFINED
SPACE
2. All air from outdoors as in Figure 9: 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 2, for minimum open areas requirements.
TABLE 2
MINIMUM FREE AREA IN SQUARE INCHES
EACH OPENING (FURNACE ONLY)
Furnace
Maximum
BTUH/INPUT
Rating
40,000
60,000
80,000
97,000
110,000
Air
From
Inside
100
100
100
100
110
Air From Outside
Vertical
Duct
10
15
20
25
28
Horizontal
Duct
20
30
40
50
55
18-CD33D1-4 9
Installer’s Guide
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 coil to avoid condensation in the heat exchanger. With a parallel flow arrangement, the dampers
or other means used to control flow of air shall be adequate to prevent chilled air from entering the furnace, and
if manually operated, must be equipped with means to
prevent operation of either unit unless the damper is in
full heat or cool position.
On any job, flexible connections of nonflammable material may be used for return air and discharge connections
to pre vent 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 to minimize noise transmission through the
return air grille. Although these furnaces are designed
with large blowers operating at moderate speeds, any
blower moving a high volume of air will produce audible
noise which could be objectionable when the unit is located very close to a living area. It is often advisable to route
the return air ducts under the floor or through the attic.
Such design permits the installation of air return remote
from the living area (i.e. central hall).
When the furnace is installed so that the supply ducts
carry air circulated by the furnace to areas outside the
space containing the furnace, the return air shall also be
handled by a duct(s) sealed to the furnace and terminating outside the space containing the furnace.
RETURN AIR DUCT SYSTEMS
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.
PREPARATION FOR UPFLOW BOTTOM AND SIDE
RETURN AIR FILTER INSTALLATION
All return air duct systems should provide for installation
of return air filters.
1. Determine the appropriate position to set the furnace
in order to existing supply and return ductwork.
2. The return air filter is shipped in either the bottom or
side location. Remove the filter by first turning the
two latches on the blower door and tilting the door
forward to remove. Remove the filter by sliding it out.
3. For upflow side return installations, remove the
insulation around the opening in the blower compartment.
4. The side panels of the upflow furnace include locating notches that are used as guides for cutting an
opening for return air, refer to Figure 10 and the
outline drawing on page 5 for duct connection dimensions for various furnaces.
5. If a 3/4" flange is to be used for attaching the air inlet
duct, add to cut where indicated by dotted lines in
Figure 10. Cut corners diagonally and bend outward
to form flange.
6. If flanges are not required, and a filter frame is
installed, cut between locating notches (See Figure
10).
7. The bottom panel of the upflow furnace must be removed for bottom return air. After removing the filter,
lay the furnace on its back. Remove the two 5/16"
hex screws securing the front of the bottom channel to the cabinet. Rotate the channel downward (or
remove by lowering the front edge of the channel and
pulling forward). Slide the bottom return air panel out
of the cabinet. Rotate the front channel to its original
position and reinstall the two 5/16” screws.
8. The filter retainer is factory supplied for upflow bottom return. Use the filter retainer on side or bottom if
filter is to be used within the furnace cabinet on upflow only installations.
NOTE:
Minimum return air temperature is 55° F.
All return air duct systems should provide for installation
of return air filters.
10 18-CD33D1-4
Installer’s Guide
Filter
Rack
Furnace
Cabinet
Side
Filter Rack
Retaining
Screw/Pin
Engagement Hole
For
Bottom Return
Filter Rack
Installation With
9. The horizontal installation of the upflow furnace
requires an external filter section. Do NOT use
the bottom return filter within the furnace. Filter
kits are available for horizontal applications.
10. Connect duct work to furnace. See Outline Drawing
for supply and return duct size and location. Flexible
duct con nectors are recommended to connect both
supply and return air ducts to the furnace. If only the
front of the furnace is accessible, it is recommended
that both supply and return air plenums are
removable.
RETURN AIR FILTERS
TYPICAL UPFLOW RETURN
AIR FILTER INSTALLATIONS
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.
UPFLOW FURNACE ONLY
0
LOCATING NOTCHES PROVIDED FOR
SIDE RETURN
CUTOUT
CUT OUT FOR
SIDE FILTER
TABLE 3
UPFLOW FURNACE RETURN AIR FILTERS
CABINET
WIDTH
14-1/2"114" X 25" X 1"17-1/2" X 25" X 1"
17-1/2"117" X 25" X 1"17-1/2" X 25" X 1"
21"120" X 25" X 1"17-1/2" X 25" X 1"
24-1/2"124" 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
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)1 side and the bottom, or (3) just the bottom.
QTY*
CABINET
BOTTOM FIL-
TER
CABINET
SIDE FILTER
The furnace and the bottom filter rack, BAYRACK960, installation can be seen in Figure 11.
The furnace filter in the bottom or side configuration can
be removed by simply turning the two latches on the
blower door and tilting the door forward.
ALTERNATE FILTER RACK INSTALLATION FOR
BOTTOM RETURN - BAYRACK960
*SEE OUTLINE DRAWING
q
BOTTOM FILTER RACK INSTALLATION
Airflow
FRONT
of Furnace
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 12.
d. Reinstall the furnace filter in the bottom position
by inserting the chamfer end first into the filter rack.
w
18-CD33D1-4 11
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