Trane TUH2B060A9V3VA, TUH2B080A9V3VA, TUH2B080A9V4VA, TUH2C100A9V4VA, TUH2C100A9V5VA Installer's Manual

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Page 1

18- CD26D1- 1

Available in French Canadian (FC)

Installer’s Guide

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

*UH2B060A9V3VA *UH2B080A9V3VA *UH2B080A9V4VA *UH2C100A9V4VA

*__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.

*UH2

UPFLOW

*UH2C100A9V5VA *UH2D120A9V5VA *DH2B060A9V3VA *DH2B080A9V3VA

*DH2

*DH2B080A9V4VA *DH2C100A9V4VA *DH2D120A9V5VA

DOWNFLOW

UPFLOW/HORIZONTAL

DOWNFLOW/HORIZONTAL

Figure 1

A341624P11

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Installer’s Guide

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H N E S T

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WARNING

CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each

appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1 Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

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

4. Close fireplace dampers.

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

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

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

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

9. After it has been determined that each appliance connected to the venting system properly vents where

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

CAUTION

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

WARNING

FIRE & EXPLOSIVE HAZARD. DO NOT USE SEMI-RIGID METALLIC GAS CONNECTORS (FLEXIBLE GAS LINES)

WITHIN THE FURNACE CABINET. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

2 18-CD26D1-10

SAFETY SECTION

WARNING

Failure to follow safety warnings exactly, could result in a fire or explosion causing property damage, personal injury or loss of life.

— Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

— Installation and service must be performed by

a qualified installer, service agency or the gas supplier.

WARNING

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

WARNING

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AZARD OF EXPLOSION! EVER USE AN OPEN FLAME TO DETECT GAS LEAKS. XPLOSIVE CONDITIONS MAY OCCUR. USE A LEAK TEST

OLUTION OR OTHER APPROVED METHODS FOR LEAK ESTING. FAILURE TO FOLLOW RECOMMENDED SAFE LEA EST PROCEDURES COULD RESULT IN DEATH OR SERIOU

NJURY OR EQUIPMENT OR PROPERTY-ONLY-DAMAGE.

WARNING

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

CAUTION

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

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Installer’s Guide

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The following warning complies with State of California law, Proposition 65

WARNING

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.

Skin Contact – Wash affected areas gently with soap

If symptoms persist, seek medical attention.

and warm water after handling.

Careful consideration must be taken in the installation process to avoid personal injury, property damage or equipment damage. These instructions do not cover all variations in systems or provide for every possible contingency. Should further information be desired or particular problems arise which are not covered sufficiently by this manual, contact your local distributor or the manufacturer as listed on the Furnace nameplate. In addition, these Furnaces are suitable for installation in an attic, garage or crawl space with ducted supply and return air.

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

a. WARNING indicates a potentially hazardous situation

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

b. CAUTION indicates a potentially hazardous situation

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

WARNING

▲

WARNING 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. THE MANUFACTURER OF YOUR FURNACE DOES NOT TEST ANY DETECTORS AND MAKES NO REPRESENTATIONS REGARDING ANY BRAND OR TYPE OF DETECTOR.

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Installer’s Guide

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

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

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

3. Provide adequate combustion and ventilation air to the Furnace space as specified in “Air for Combustion and Ventilation” (page 9), of these instructions.

4. Combustion products must be discharged outdoors. Connect this Furnace to an approved vent system only, as specified in the “Venting” section (page 15), of these instructions.

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

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

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

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

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

a. The Furnace venting system must be complete and installed per manufacturers instructions.

b. The Furnace is controlled only by a room Comfort Control (no field jumpers).

c. The Furnace return air duct must be complete and sealed to the Furnace.

d. The Furnace input rate and temperature rise must be verified to be within nameplate marking.

e. 100% of the Furnace combustion air requirement must come from outside the structure.

f. The Furnace return air temperature range is between 550 and 800 Fahrenheit.

g. Clean the Furnace, duct work, and components upon substantial completion of the construction process, and verify Furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer's instructions.

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

only when the

Contents

Safety Section 2

Installation Instructions 5

General 5 Location and Clearances 5

Outline Drawings 6

Upflow Installation 8 Downflow Installation 8 Horizontal Installation 8 Air For Combustion and Ventilation 9 Duct Connections 10 Return Air Filters 11 General Venting 15 Vent Tables 19 Horizontal Venting 20 Horizontal Venting Through a Wall 21 Venting Through The Roof 23 Venting Routed Through a Masonry Chimney 24 Downward Venting 26 Condensate Drain Instructions 27 Gas Piping 32 Combustion and Input Check 32 High Altitude Derate 35 Electrical Connections 36 Field Wiring Diagrams 36

Start-up and Adjustment 41

Preliminary Inspections 41 Lighting Instructions 41 Sequence of Operation 41 Control and Safety Switch Adjustments 42

Conditions Affecting System Operation 43

IFC Error Flash Codes 44

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Installer’s Guide

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GENERAL INSTALLATION INSTRUCTIONS

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

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

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

Codes and local utility requirements governing the installation of gas fired equipment, wiring, plumbing, and flue connections must be adhered to. In the absence of local codes, the installation must conform with latest edition of the National Fuel Gas Code ANSI Z223.1• National Installation Code, CAN/CGA B149.1. The latest code may be obtained from the American Gas Association Laboratories, 400 N. Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or www.aga.org.

These Furnaces have been classified as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21.47 standards • CSA 2.3. Category IV furnaces operate with positive vent static pressure and with a flue loss less than 17 percent. These conditions require special venting systems, which must be gas tight and water tight. These Category IV Direct Vent Furnaces are approved for installation in Manufactured/ Mobile housing when used with BAYMFGH001A.

LOCATION AND CLEARANCES

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

5. Are the ventilation and combustion air openings large enough and will they remain unobstructed? If outside air is used, are the openings set 12" above the highest snow accumulation level (18" minimum in Canadian applications)?

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

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

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

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

WARNING

FIRE HAZARD. DO NOT INST ALL THE FURNACE DIRECTLY ON CARPETING, TILE OR OTHER COMBUSTIBLE MA TERIAL OTHER THAN WOOD FLOORING.

CAUTION

Do NOT install the Furnace in a corrosive or contaminated atmosphere. Failure to follow this caution could result in early equipment failure.

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

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

2. Do all clearances between the Furnace and enclosure equal or exceed the minimums stated in Clearance Table on the Outline Drawings?

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

18-CD26D1-10 5

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Installer’s Guide

Figure 2. Upflow Outline Drawing

6 18-CD26D1-10

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Installer’s Guide

Figure 3. Downflow Outline Drawing

18-CD26D1-10 7

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Installer’s Guide

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)

INSTALLATION INSTRUCTIONS

WARNING

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

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

installations.

UPFLOW INSTALLATION

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

FOR VERTICAL

CASED

UPFLOW

FURNACE

COIL

STANDOFFS

(BOTH SIDES)

TANDOFFS (4)

SCREW

(BOTH SIDES

Figure 4

DOWNFLOW INST ALLATION

Figure 5

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/ HORIZONTAL FURNACES

FURNACE SURFACE

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

NOTE

8 18-CD26D1-10

VERTICAL

CLOSET

Table 2

DRILL SCREWS (

UNIT LOCATION

HORIZONTAL

CLOSET

Table 1 Required floor opening: (DOWNFLOW)

CABINET

WIDTH

RETURN

DUCT 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"

2345678901234567890123456789012123456789012345

FURNACE

2345678901234567890123456789012123456789012345

FRONT

2345678901234567890123456789012123456789012345

FLOOR OPENING PLENUM OPENING

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

A (width)

B (depth)

Figure 6

HORIZONTAL INSTALLATION

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

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

The Furnace and the cased coil must be properly supported. The Furnace may be installed in an attic or crawl space in the

horizontal position by placing the Furnace on the left side (as viewed from the front in the vertical position). The horizontal Furnace installation in an attic should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of the Furnace (See Figure 6 & Table 1). Line contact is only permissible between lines formed by intersections of the top and two sides of the furnace casing and building joists, studs, or framing. The Furnace may be placed horizontally in a crawl space on a pad or other noncombustible material which will raise the unit for sufficient protection from moisture.

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

IMPORTANT: The 2/4TXC cased coil must

HORIZONTAL

ALCOVE / ATTIC

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

Page 9

The horizontal Furnace may also be suspended from the

▲

joists using all-thread rods with a substantial metal support frame that supports the entire length of the furnace. The rods need to be of sufficient length to allow for proper clearances from combustible materials. The frame needs to be at least 32" in length to allow for access to service panels.

If the Furnace is suspended using steel strap, it must be supported at all four corners and in the middle at the front of the Furnace.

UPFLOW/ HORIZONTAL SHOWN WITH DIRECT VENT

Figure 7

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

Figure 8

AIR FOR COMBUSTION AND VENTILATION

The following warning complies with State of California law, Proposition 65

WARNING

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.

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

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

UNCONFINED

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

Figure 9

Furnace locations may be in a confined space (see Figure 10) or an unconfined space (See Figure 9).

Installer’s Guide

Table 3

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE

MAXIMUM BTUH

INPUT RATING

60,000

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

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

All air from inside the building as in Figure 11: The con-

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

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

The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 4, for minimum open areas required.

CONFINED

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

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000

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

Confined spaces are installations with less than 50 cu. ft. of space per 1000 BTU/ hr input from all equipment installed. Confined space is defined in Figure 10. Air for combustion and ventilation requirements can be supplied from inside the building as in Figure 11 or from the outdoors, as in Figure 12.

3. The following types of installations will require use of OUTDOOR AIR for combustion, due to chemical exposures: * Commercial buildings * Buildings with indoor pools * Furnaces installed in commercial laundry rooms * Furnaces installed in hobby or craft rooms

From

Inside

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE

FEET OF UNCONFINED SPAC

375 500 625 750 875

Figure 10

Table 4

Air

100 100 100 120 140

Air From Outside

Vertical

Duct

15 20 25 30 35

Horizontal

Duct

30 40 50 60 70

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Installer’s Guide

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* 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

NOTE: Extended warranties are not available in some instances. Extended warranty does not cover repairs to equipment installed in establishments with corrosive atmospheres, including but limited to, dry cleaners, beauty shops, and printing facilities.

DUCT CONNECTIONS

Figure 11

CAUTION

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

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

Central Furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling coil to avoid condensation in the heat exchanger. With a parallel flow arrangement, the dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering the Furnace, and if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in full heat or cool position.

Flexible connections of nonflammable material may be used for return air and discharge connections to reduce the transmission of vibration. Though these units have been specifically designed for quiet, vibration free operation, air ducts can act as sounding boards and could, if poorly installed, result in vibration to the annoyance level.

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

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

Figure 12

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Installer’s Guide

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

Do Not install return air through the back of the Furnace

cabinet. Carbon monoxide, fire or smoke can cause serious bodily

injury, death, and/or property damage. A variety of potential sources of carbon monoxide can be found

in a building or dwelling such as gas-fired clothes dryers, gas cooking stoves, water heaters, furnaces and fireplaces. The U.S. Consumer Product Safety Commission recommends that users of gas-burning appliances install carbon monoxide detectors as well as fire and smoke detectors per the manufactures installation instructions to help alert dwelling occupants of the presence of fire, smoke or unsafe levels of carbon monoxide. These devices should be listed by Underwriters Laboratories, Inc. Standards for Single and Multiple Station Carbon Monoxide Alarms, UL 2034 or CSA International Standard, Residential Carbon Monoxide Alarming Devices, CSA 6.19.

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

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

PREPARATION FOR UPFLOW BO TTOM AND SIDE RETURN AIR FILTER INST ALLATION

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 and rack are shipped in either the bottom or side location. Remove the filter and filter rack by first turning the two latches on the blower door and tilting the door forward to remove. Remove the filter by sliding it out of the rack. Compress the spring loaded filter rack to disengage the retaining pins/screws from the furnace sides and slide the filter rack out.

The filter rails are spring loaded for automatic adjustment to allow standard size, locally obtainable replacement filters. The filter rack itself slides to adjust to the required width needed for bottom or side return (See Figure 15).

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

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

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

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

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

Slide the bottom return air panel out of the cabinet. Rotate the front channel to its original position and reinstall the two 5/16” screws.

8. The horizontal installation of the upflow furnace

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

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

Return Air Filters

TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS

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

Table 5

MODELS

NUMBERS

*UH2B060A9V3VA *UH2B080A9V3VA *UH2B080A9V4VA

*UH2C100A9V4VA *UH2C100A9V5VA

*UH2D120A9V5VA 24-1/2" 1 - 24" X 25 X 1"

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

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

UPFLOW FURNACE ONLY

LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT

SEE OUTLINE DRAWING

CABINET

WIDTH

17-1/2" 1 - 17" X 25" X 1"

21" 1 - 20" X 25" X 1"

FILTER

QTY & SIZE

FRONT of Furnace

Figure 13

18-CD26D1-10 11

Page 12

Installer’s Guide

( a

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

Airflow

Blower Door Hinge and Bottom Filter Rack Installation

Figure 14

OPTIONAL FILTER RACK INSTALLATION FOR BOTTOM RETURN

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

a. Remove the filter. b. Remove the filter rack.

c. Remove the bottom panel.

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

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

f. Reinstall the furnace filter in the bottom position by

inserting the chamfer end first into the filter rack.

FILTER RACK INST ALLATION FOR SIDE RETURN AIR ON UPFLOW FURNACES (Left or Right)

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

a. Remove the filter. b. Remove the filter rack.

c. Leave the bottom panel in place. e. Make side cutout by following the directions in the

“Return Air Duct Connections” section on page 11.

e. Compress the filter rack and reinstall in the side

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

f. Reinstall the furnace filter in the side position by

inserting the chamfer end first into the filter rack.

Filter Rack Assembly

Figure 15

Blower Deck Engagement

Hole

VIEW

NGAGEMENT

HOLE DETAIL

Typical both sides

nd blower deck)

Figure 16

12 18-CD26D1-10

Filter

urnace

Rack

Cabinet

Side

Filter Rac Retaining Screw/Pi

Engagement Hole For

Filter Rack Installation With Bottom Return

Figure 17

Conversion kits for horizontal filters are BAYFLTR203 for 17 1/2" width cabinets, BAYFLTR204 for 21" width cabinets, and BAYFLTR205 for 24" width cabinets. These include filters and brackets necessary for horizontal filters. In addition, optional door kit BAYFLTR206 is also available. See Figures 23 and 25.

Page 13

Installer’s Guide

CHAMFER

END OF

FILTER GOES

INTO FILTER RACK FIRST

(

SIDE

Airflow

Furnace

Cabinet

Side

ngagement Hole

For

Filter Rack

Installation With

Bottom Return

BOTTOM ENGAGEMENT

BLOWER DECK

urnace

Cabinet

Side

Filter Rack Retaining Screw/Pin

Figure 18

Engagement Hole For

Filter Rack

Installation With

Return

Side

Filt Rac

Bottom Pane

Furnace Blower Deck

SIDE

CUTOUT

Airflow

BOTTOM

PANEL

INSTALLED

SPRINGS

FILTER

RACK

RAILS

RETAINING

(Both Side

Figure 21

Typical Upflow Right Side Return Filter Rack Installation

Airflow

Filter Rack Retaining Screw/Pin

Filter Rack Assemb

Figure 19

Figure 22

CUTOUT

Airflow

RETAINING

Both Sides)

Typical Upflow Left Side Return Filter Rack Installation

SPRINGS

FILTER

RACK

RAILS

Figure 20

BOTTOM

PANEL

INSTALLED

RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in the horizontal configuration, the return air filters must be installed exterior to the furnace cabinet. Remote filter grilles may be used for homeowner convenience or the filters may be installed in the duct work upstream of the furnace. See Figure 23.

Airflow

Optional door kit BAYFLTR206

Figure 23

18-CD26D1-10 13

Typical Horizontal Filter Installation

Page 14

Installer’s Guide

ALTERNATE UPFLOW FILTER CLIP / BRACKET INSTALLATION - KIT09224

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.

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

REAR

SIDE

CUT-OUT

ALTERNATE FILTE CLIPS LOCATION

Figure 24

INSTALLING THE FILTER

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

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

Table 6

UNIT SIZE

RETURN AIR

BOTTOM SIDE

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

21" DO NOT CUT CUT ON LINE

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

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS

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

Table 7

MODELS

NUMBERS

*DH2B060A9V3VA *DH2B080A9V3VA *DH2B080A9V4VA

*DH2C100A9V4VA 21" 2 - 16" X 20" X 1" *DH2D120A9V5VA 24-1/2" 2 - 16" X 20 X 1"

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

CABINET

WIDTH

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

FILTER

QTY & SIZE

Optional

BAYFLTR206

Door Kit

DOWNFLOW

Table 8

LOCATING FILTER RETAINER BRACKETS IN DUCTWORK

CABINET

WIDTH

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

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

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

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

RETURN

DUCT

WIDTH

DIMENSION

"A"

DIMENSION

"B"

FILTER

BRACKET

LOCATION

Optional door kit BAYFLTR206

Figure 25

DOWNFLOW/ HORIZONTAL

14 18-CD26D1-10

Page 15

Installer’s Guide

▲

GENERAL VENTING

WARNING

CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each

appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and

horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1 Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3. As far as practical, close all building doors and

windows and all doors between the space in which the appliance(s) connected to the venting system are located and other deficiencies which could cause an unsafe condition.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not

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

6. Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances

at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above

tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z221.1/NFPA 54 and/or CSA B149.1 Natural Gas and Propane Installation Code.

9. After it has been determined that each appliance

connected to the venting system properly vents where when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous condition of use.

WARNING

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.

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

NOTE: Minimum return air temperature is 55° F.

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

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

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

The recommended system is assembled from 2", 2-1/2", or 3" plastic pipe and fittings (See Table 10, page 19). Where the system is routed to the outdoors through an existing masonry chimney containing flue products from another gas appliance, or where required by local codes, then 3" venting of Type 29-4C stainless steel must be used in place of PVC material.

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

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

The following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

3. In so far as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan, close fireplace dampers.

4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust Comfort Control so appliance will operate continuously.

5. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return door, windows, exhaust fans, fireplace dampers and any other gasburning appliance to their previous conditions of use.

If improper venting is observed during any of the above tests, the remaining common venting system must be corrected. Correction could require rerouting or resizing the remaining vent system.

IMPORTANT: These Furnaces may be installed as Direct Vent (sealed combustion) or as Nondirect Vent (single pipe). The Furnaces are shipped DIRECT VENT with sealed combustion.

18-CD26D1-10 15

Page 16

Installer’s Guide

A I

Vent

(

A I

Attic

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

NOTE: BAYVENT200* accessories can be used for inlet and outlet terminals when the pipes do not exit the structure together. For Canadian applications ONLY, IPEX 196006 may be used for horizontal and vertical terminations. IPEX 081216, IPEX 081218, and IPEX 081219 may only be used for horizontal vent terminations.

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

FURNACE VENT / INLET PIPE INST ALLATION

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

1. The Furnace must vent outside the structure.

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

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

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

Air

Inlet

See Note)

Furnace

Example 2

EX. 3 —

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

NOTE: Vent termination kit BA YAIR30AVENTA or BAYVENT200B may be used in addition to the horizontal and vertical termination options shown in the following examples. For Canadian applications ONLY, IPEX 196006 may be used for horizontal and vertical terminations. IPEX 081216, IPEX 081218, and IPEX 081219 may only be used for horizontal vent terminations.

The following are EXAMPLES ONLY:

EX. 1 —

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

Example 1

nlet

Furnace

Example 3

EX. 4 —

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

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

Vent

EX. 2 —

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

16 18-CD26D1-10

nlet

Furnace

Air

Inlet

(See Note)

Furnace

Example 4

Page 17

Installer’s Guide

VENT FITTING MATERIAL – PLASTIC

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

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

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

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

Be sure to properly support these joints.

BONDING OF PVC

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

Pipe and Fitting – ASTM D1785, D2466, D2661, & D2665 PVC Primer and Solvent Cement – ASTM D2564 Procedure for Cementing Joints – Ref ASTM D2855

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

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

DO NOT ALLOW PRIMER TO DRY BEFORE APPLYING CEMENT.

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

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

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

NOTE: Follow venting instructions carefully when using PVC cement.

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

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

NOTE: Vent termination kit BA YAIR30AVENTA or BA YVENT200B may be used in addition to the horizontal and vertical termination options shown in the following figures. For Canadian applications ONLY, IPEX 196006 may be used for horizontal and vertical terminations. IPEX 081216, IPEX 081218, and IPEX 081219 may only be used for horizontal vent terminations.

VENT AND INLET AIR CONNECTIONS

Seal VENT PIP with RTV seala

Front of Furnace

eal INLET AIR PIPE

with RTV sealant

Figure 26

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

18-CD26D1-10 17

Page 18

Installer’s Guide

Table 9

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

PLASTIC PIPE DESIGNATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

F891 CELLULAR CORE *158 ASTM F891 D2665 DWV PIPE **158 ASTM D2665 D1785 SCH 40, 80, 120 **158 ASTM D1785 D2241 SDR SERIES **158 ASTM D2241

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41 **212 ASTM D2846

F441 SCH 40, 80 **212 ASTM F441

F442 SDR SERIES **212 ASTM F442

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV ***180 ASTM D2661

F628 SCH 40 DWV CELLULAR CORE ***180 ASTM F628

* - Allowable temperatures based on classifications covered in ASTM D4396 [Deflection Temps Under Load (264 PSI)] ** - Allowable temperatures based on classifications covered in ASTM D1784 [Deflection Temps Under Load (264 PSI)] *** - Allowable temperatures based on classifications covered in ASTM D3965 [Deflection Temps Under Load (264 PSI)]

18 18-CD26D1-10

Page 19

Installer’s Guide

Table 10

ALTITUDE

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

*UH/DH2B060A9V3VA 200 200 200 *UH/DH2B080A9V3VA

*UH/DH2B080A9V4VA *UH/DH2C100A9V4VA

*UH2C100A9V5VA

50 120 200

Not Allowed 60 200

*UH/DH2D120A9V5VA Not Allowed Not Allowed 200

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

*UH/DH2B060A9V3VA 100 100 100 *UH/DH2B080A9V3VA

*UH/DH2B080A9V4VA *UH/DH2C100A9V4VA

*UH2C100A9V5VA

25 60 100

Not Allowed 30 100

*UH/DH2D120A9V5VA Not Allowed Not Allowed 100

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

*UH/DH2B060A9V3VA 50 50 50 *UH/DH2B080A9V3VA

*UH/DH2B080A9V4VA *UH/DH2C100A9V4VA

*UH2C100A9V5VA

Not Allowed 30 50

Not Allowed Not Allowed 50

*UH/DH2D120A9V5VA Not Allowed Not Allowed 50

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

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

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

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

4. One SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is equivalent to 6' of 3" pipe. One 90° elbow is equivalent to 7½' of 2½" pipe or 5' of 2" pipe. Two 45° elbows equal one 90°elbow.

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

6. Pipe adapters are field supplied (except for the *UH/DH2D120 models).

7. For Canadian applications ONLY, IPEX 196006 may be used for horizontal and vertical ter minations. IPEX 081216, IPEX 081218, and IPEX 081219 may only be used for horizontal vent terminations. Equivalent lengths are IPEX 196009 = 5 feet, IPEX 081216 = 11 feet, IPEX 081218 = 16 feet, and IPEX 081219 = 21 feet

Table 11

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

44 45 46 47 48 49 50

PART

NUMBER

ORF00501 ORF00644 ORF00909 ORF00910 ORF01099 ORF00503 ORF00493

DRILL

SIZE

54 55 56 57 58 59

PART

NUMBER

ORF00555 ORF00693 ORF00907 ORF00908 ORF01338 ORF01339

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.

Important: Reinstall the propane orifices to the same depth as the orifices supplied with the equipment.

See Table 11 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. For information on high altitude derating, refer to page 34.

VENT LENGTH TABLE

MAXIMUM TOTAL EQUIVALENT LENGTH IN FEET

FOR VENT AND INLET AIR (SEE NOTES)

The Vent Length Table (Table 10) above shows the required vent lengths for installations at various altitudes. An optional high altitude kit is available for installations above 5000 feet (Installations above 12,000 feet are not allowed).

Table 12

Orifice

Tw ist D r ill

Size If

Installed

At Sea

Level

42 43 44 45 46 47 48 49

51 52 53 54 55 56 57 58

2000 3000 4000 5000 6000 7000 8000 9000 1000

42 44 45 46 47 48 49 50

51 51 52 54 54 55 56 58 59

From National Fuel Gas Code - Table F-4

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

44 44 45 47 47 48 49 50

51 52 53 54 55 55 56 59 60

44 45 47 47 49 49 50

51 52 53 54 55 55 57 59 60

45 46 47 48 49 50 51

51 52 53 54 55 56 57 60

45 47 48 48 49 50

52 52 53 54 55 56 57 60 62

46 47 48 49 50 50

52 53 53 54 55 56 58

45 47 48 49 49 50

52 52

53 54 55 56 56 59 62 63

46 47 48 49 50

51 51

52 53

53 54 55 56 56 59 63 63

47 48 50 50 51 52 52 52

53 54 54 55 56 57 60 63 64

18-CD26D1-10 19

Page 20

Installer’s Guide

▲

HORIZONTAL VENTING

(Upflow/ Horizontal)

CAUTION

When the vent pipe is exposed to temperatures below freezing, e.g., when it passes through unheated spaces, etc., the pipe must be insulated with 1/2 inch (22.7 mm) thick Armaflex-type insulation or equal.

If the space is heated sufficiently to prevent freezing, then the insulation will not be required. If domestic water pipes are not protected from freezing then the space meets the condition of a heated space.

Figure 27

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

Horizontal Venting

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

For Canadian applications ONLY: IPEX 196006 may be used for horizontal and vertical terminations. IPEX 081216, IPEX 081218, and IPEX 081219 may only be used for horizontal vent terminations.

9" MINIMUM

Figure 28

FURNACE VENT OUTLET

9" MINIMUM

2" TO 3" COUPLING

#CPL00938

FACTORY SUPPLIED ONLY WITH THE FOLLOWING MODELS: ALL 100,000 BTUH UPFLOW MODELS, ALL 120,000 BTUH UPFLOW MODELS, THE UX1C080A9601 MODEL, AND ALL DOWNFLOW MODELS

9" MINIMUM

POSSIBLE CONFIGURA TIONS FOR TWO PIPE VENTING SYSTEMS

20 18-CD26D1-10

ELBOW AND TEE MUST BE AS CLOSE TOGETHER AS POSSIBLE

9" MINIMUM

Figure 30

Page 21

7.2"

▲

3.2"

COMBUSTION AIR

ANCHORS (4 req.)

VENT

VENT PLATE

12" MINIMUM TO OVERHANG

SCREWS (4 req.)

Installer’s Guide

CAUTION

The vent for this appliance shall not terminate (1) Over public walways; or (2) Near sofit vents or crawl space vents or other areas

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

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

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

VENT

VENT CAP

MAINTAIN 12" (18" FOR CANADA) MINIMUM

CLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

Figure 32. BA YVENT200B

For Canadian applications only, IPEX 196006, IPEX 081216, IPEX 081218, and IPEX 081219 may be used for horizontal vent terminations.

BA YAIR30A VENTA

(Sidewall)

STRAP (FIELD SUPPLIED)

VENT

COMBUSTION AIR

For Canadian applications only, IPEX 196006, IPEX 081216, IPEX 081218, and IPEX 081219 may be used for horizontal vent terminations.

ELBOW (FIELD SUPPLIED)

Figure 33

COMBUSTION

AIR

RAIN CA

VENT

1" + 1/2"

HORIZONT AL VENTING THROUGH WALL

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

The vent & inlet terminals must be located at least 12" minimum (18" minimum in Canadian applications) above normally expected snow accumulation level.

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

Location of the vent/wind terminal should be chosen to meet the requirements of Figure 42 for either direct or non-direct vent applications.

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

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

Important: The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and

5.00 for installation of through – the – wall vented gas appliances as follows:

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

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

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

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

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

18-CD26D1-10 21

Page 22

VENT TABLES

Installer’s Guide

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

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

5.08(2)(a)1 through 4.

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

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

COMBUSTIBLE MA TERIAL WALL

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

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

NONCOMBUSTIBLE MA TERIAL WALL

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

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

COUPLING (PLASTIC VENTING)

6 IN. MIN. (TO JOINT)

1” CLEARANCE (AIR SPACE)

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

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

STUD

PVC WALL MOUNT FLANGE (OPTIONAL)

APPROVED TERMINATION

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

Figure 34

COUPLING (PLASTIC VENTING)

6 IN. MIN. (TO JOINT)

CEMENT MORTAR SEAL INSIDE & OUTSIDE

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

PVC WALL MOUNT FLANGE (OPTIONAL)

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

Figure 35

APPROVED TERMINATION

22 18-CD26D1-10

Page 23

R (

)

MAINTAIN 12 IN.

M ( M A A

SUPPORT HORIZONTAL PIPE EVERY 3' 0" WITH THE FIRST SUPPORT AS CLOSE TO THE FURNACE AS POSSIBLE. INDUCED DRAFT BLOWER, HOUSING, AND FURNACE MUST NOT SUPPORT THE WEIGHT OF THE FLUE PIPE.

Installer’s Guide

Figure 36

REMOVE RIBS FROM CAP

COMBUSTION AIR

OOF FLASHING BOOT

FIELD SUPPLIED)

VENT

SUPPORT (FIELD SUPPLIED)

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

AINTAIN 12 IN.

18 IN. FOR CANADA)

INIMUM CLEARANCE BOVE HIGHEST NTICIPATED SNOW

LEVEL. MAXIMUM OF

4 IN. ABOVE ROOF.

Figure 37 BAYAIR30AVENTA (VERTICAL)

For Canadian applications only, IPEX 196006 may be used for vertical vent terminations.

SEAL BETWEEN FLANGE, PIPE, COUPLING AND METAL PANEL

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

WITH HI TEMP RTV SILICONE SEALANT

SUPPORT

FLANGE

VENT

COMBUSTION AIR

FLUE PIPE

COUPLING

VENT

Figure 38. BAYAIR30AVENTA (VERTICAL)

For Canadian applications only, IPEX 196006 may be used for vertical vent terminations.

18-CD26D1-10 23

ELBOW (FIELD SUPPLIED

COMBUSTION AIR

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

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

CEILING

VENTING THROUGH CEILING

Figure 39

Page 24

Installer’s Guide

C P O S

▲

CAUTION

VENTING THROUGH THE ROOF

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

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

VENT FITTING MATERIAL – STAINLESS STEEL

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

These fittings and fitting accessories are to be field supplied.

DIRECTION OF STAINLESS STEEL FITTING

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

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

All long horizontal sections must be supported to prevent sagging.

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

PVC PLASTIC VENTING - ONLY THROUGH UNUSED CHIMNEY

STAINLESS STEEL VENT CAP

FLUE PIPE

OUPLING TO SUPPORT IPE FROM ANGLES R OTHER SUITABLE UPPORT METHOD

STAINLESS STEEL

(OPTIONAL)

VENT CAP

SEE CAUTION

FLUE PIPE

6 IN. MIN.

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

COUPLING AS REQUIRED

Figure 40

TYPE 29-4C ST AINLESS STEEL VENTING - USED

THROUGH CHIMNEY THA T VENTS ANOTHER GAS

APPLIANCE

STAINLESS

STAINLESS STEEL VENT CAP

STEEL VENT CAP

(OPTIONAL)

EE CAUTION

6 IN. MIN.

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

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

Do NOT run vent through chimney for wood burning or oil Furnaces or incinerators or any other gas appliance.

CAUTION

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

IMPORTANT –

The single wall flue pipe joints must be sealed. The 90° elbow connection to vertical pipe must be sealed to

prevent condensate leakage to base of masonry chimney.

Figure 41. VENTING ROUTED THROUGH A MASONRY CHIMNEY

24 18-CD26D1-10

Do NOT run vent through chimney for wood burning or oil Furnaces or incinerators.

If remaining free area between single wall flue pipe and masonry chimney is to be used for another gas appliance venting area must be sufficient to vent that appliance and that appliance must be connected to chimney with separate entry openings.

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

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

Page 25

INSIDE

VENT TERMINAL

AIR SUPPLY INLET

CORNER DETAIL

Installer’s Guide

FIXED

CLOSED

FIXED

CLOSED

OPERABLE

AREA WHERE TERMINAL IS NOT PERMITTED

Figure 42. HORIZONT AL VENT CLEARANCES

Table 13

Non-Direct Vent Terminal Clearances

Canadian Installations US Inst allati ons

Clearance above grade, veranda, porch, deck, or

balcony

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

B= Clearance to window or door that may be opened

C= Clearance to permanently closed window * *

Vertical clearance to ventilated soffit located above

the terminal within a hor izontal dist ance of 2 feet

(61 cm) from the center line of the ter mi nal

E= Clearance to unventilated soffit * * F= Clearance to outside corner * * G= Clearance to inside corner * *

Clearance to each side of center line extended

above meter/regulator assembly

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

Clearance to nonmechanical air supply inlet t o

building or the combustion air inlet to any other

appliance

K= Clearance to a mechanical air su pply in let 6 feet (1.83m)

Clearance above a paved sidewalk or paved

driveway located on public property M= Clearance under veranda, porch, deck, or balcony 12 inches (30 cm) ‡ * Notes:

1. In accordance with the current CSA B149.1 Natural Gas and Propan e Instal lation C ode.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code. †. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. ‡. Pemitted only if veranda, porch, deck, or balcony is fu lly open on a minimum of t wo sides beneat h the floor. * Clearance in accordance with local installation codes and t he requirements of the gas supplier an d the manufacturer's Installat ion Ins truc tions.

12 inches (30 cm) for appliances > 10,000 Btuh (3 kw)

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

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

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

12 inches (30 cm) for appliances > 10,000 Btuh (3 kw)

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

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

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

1 foot (0.3m) above opening.

meter/regulator assembly

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

1 foot (300 m) above opening

3 feet (91 cm) above if within

10 feet (3m) horizontally

7 feet (2.13 m) † 7 feet (2.13 m)

18-CD26D1-10 25

Page 26

Installer’s Guide

▲

Table 14

Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch,

deck, or balcony

Clearance to window or door that may be

opened

C= Clearance to permanently closed window * *

Vertical clearance to ventilated soffit located above the terminal within a

horizontal dist anc e of 2 feet (61 cm)

from the center line of the terminal E= Clearance to unventilated soffit * * F= Clearance to outside corner * * G= Clearance to inside corner * *

Clearance to each side of center line H=

extended above meter/regulator assembly I= Clearance to service regulator vent outlet 3 feet (91 cm) *

Clearance to nonmechanical air supply J=

inlet to building or the combustion air

inlet to any other appliance

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

Clearance above a paved sidewalk or L=

paved driveway located on public property

Clearance under veranda, porch, deck, M=

or balcony Notes:

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

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

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

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

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

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

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

meter/regulator assembly

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

7 feet (2.13 m) † *

12 inches (30 cm) ‡ *

DOWNWARD VENTING

Furnace may be in vertical or horizontal configuration.

All horizontal pipes must be supported at maximum of 3

foot intervals

Slope 1/4" per ft.

lope 1/4" per ft.

NOTES:

A) Condensate trap for vent pipe must be a minimum of 6 inches in height. B) Condensate trap for vent and inlet pipe must be connected into a condensate drain pump; an open or

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

CAUTION

Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants.

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

Figure 43

DOWNWARD VENT LENGTH IS LIMITED TO A MAXIMUM OF

EQUIVALENT FEET.

40 Inch Upflow or Downflow

Furnace

6" Min.

26 18-CD26D1-10

Page 27

CONDENSATE DRAIN INSTRUCTIONS

▲

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

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

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

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

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

Installer’s Guide

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

Connections must be made to an OPEN/ VENTED DRAIN.

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

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

CAUTION

▲

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

THE UPFLOW (VERTICAL) MA Y BE INSTALLED

LEFT OR RIGHT SIDE CONDENSA TE DRAIN

UPFLOW FURNACE

(Vertical)

HEADER

TO DRAIN

LEFT SIDE

18-CD26D1-10 27

TO DRAIN

RIGHT SIDE

Figure 44

Page 28

Installer’s Guide

I o f s d t

ALL HORIZONT AL APPLICATIONS

ARE LEFT SIDE DRAIN ONLY

UPFLOW FURNACE ON LEFT SIDE WITH LEFT DRAIN SHOWN

Figure 45

HEADER

OPEN/

VENTED

DRAIN

f upflow furnace is installed

ver a finished ceiling, overflow

rom the primary drain vent

tack must flow into an auxillary rain pan to prevent damage to

he finished ceiling below.

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

Typical sources of UL listed heat tapes are W.W. Granger, Inc. (Wintergard Plus

Series), McMaster Carr Supply Co.

(3554 Series), or your equipment supplier. The condensate drain may be cleaned or inspected by re-

moval of the drain tube at the header.

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

To drain opening

Figure 46

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

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

28 18-CD26D1-10

Page 29

Installer’s Guide

VERTICAL APPLICATIONS

Upflow furnace - The connection tubing for left and right side drainage is shipped in the blower compartment. Install the connection tubing from the trap to the side of the unit and trim all excess tubing to avoid kinks.

Downflow furnace - The furnace is shipped with the left side drainage setup. To change the right side drain, remove the drain lines from the trap, rotate the trap 180° so it exits to the right, reconnect the lines, and run a 1/2" CPVC pipe from the trap out through the right side knock-out. Use RTV silicone sealant to connect the CPVC pipe to the trap for ease of removing to clean the trap.

HORIZONTAL APPLICATIONS

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

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

Right side

Figure 47. UPFLOW (VERTICAL)

Use Inducer Drain

hose without

extension

Figure 48. UPFLOW HORIZONT AL 17" UNITS

(Left side only)

Left side

Figure 49. UPFLOW (VERTICAL)

Use extension hose here

Figure 50. UPFLOW HORIZONT AL 21" & 24" UNITS

(Left side only)

18-CD26D1-10 29

Page 30

Installer’s Guide

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

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

Connections must be made to an OPEN/VENTED DRAIN. Outdoor draining of the furnace and coil condensate is permissible if allowed by local codes. Caution should be taken

Cut off curved end of

Inducer drain hose

Figure 53. DOWNFLOW (HORIZONT AL)

to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants.

Left

side

Figure 51. DOWNFLOW (VERTICAL)

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

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

IMPORTANT: The condensate drain should be installed with

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

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

Figure 52. DOWNFLOW (VERTICAL)

30 18-CD26D1-10

Right

side

Page 31

Installer’s Guide

▲

MAIN MANUAL

SHUT-OFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

AUTOMA TIC GAS VALVE

WITH MANUAL SHUT-OFF

AUTOMA TIC GAS VALVE

WITH MANUAL SHUT-OFF

Figure 54. UPFLOW MA Y BE LEFT OR RIGHT HAND GAS PIPING

AUTOMA TIC GAS V ALVE WITH MANUAL SHUT-OFF

MAIN MANUAL

SHUT-OFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

AUTOMATIC GAS VALVE WITH MANUAL SHUT-OFF

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

AUTOMA TIC GAS VALVE WITH MANUAL SHUT-OFF

MAIN MANUAL SHUT-OFF VALVE

GROUND UNION JOINT

DRIP LEG

Figure 56. HORIZONT AL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

(Typical UPFLOW Furnace in horizontal configuration shown)

CAUTION

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

MAIN MANUAL SHUT-OFF VALVE

AUTOMA TIC GAS VALVE WITH MANUAL SHUT-OFF

GROUND UNION JOINT

DRIP LEG

18-CD26D1-10 31

Page 32

Installer’s Guide

▲

H N E S T

▲

Gas Piping

WARNING

▲

AZARD OF EXPLOSION!

EVER USE AN OPEN FLAME TO DETECT GAS LEAKS. XPLOSIVE CONDITIONS MAY OCCUR. USE A LEAK TEST OLUTION OR OTHER APPROVED METHODS FOR LEAK ESTING. FAILURE TO FOLLOW RECOMMENDED SAFE LEA EST PROCEDURES COULD RESULT IN DEATH OR SERIOU

NJURY OR EQUIPMENT OR PROPERTY-ONLY-DAMAGE.

WARNING

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

WARNING

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

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

54. The installation of piping shall be in accordance with piping

codes and the regulations of the local gas company. Pipe joint compound must be resistant to the chemical reaction with liquefied petroleum gases.

Refer to piping Table 15, for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve as shown in Figures 43 & 44. National codes require a condensation drip leg to be installed ahead of the controls as shown in Figures 55 & 56.

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

The furnace must be isolated from the gas supply piping by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).

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

Table 15

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE

SIZE

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

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

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

32 18-CD26D1-10

10 20 30 40 50 60 70

1 520 350 285 245 215 195 180

LENGTH OF PIPE

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

OPEN FLAME!

Table 16

ORIFICE SIZES

INPUT

RATING

BTUH

60,000

80,000 100,000 120,000

NUMBER

BURNERS

3 4 5 6

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 45 45 45

56 56 56 56

Combustion and Input Check

(See also High Altitude Derate, page 34)

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

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

3. Match the “Sec” column in the gas flow (in cfh) Table 13 with the time clocked.

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

5. Use the following factors For 1 Cu. Ft. Dial Gas Flow CFH =

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

For 5 Cu. Ft. Dial Gas Flow CFH =

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.

if necessary:

Chart Flow Reading ÷ 2

Chart Flow Reading ÷ 4

10X Chart Flow Reading ÷ 4

Gas Valve Adjustment

Changes can be made by adjusting the manifold pressure

(See Table 17), or changing orifices (orifice change may not always be required). To adjust the manifold pressure:

1. Turn off all electrical power to the system.

2. Attach a manifold pressure gauge with flexible tubing to the outlet pressure boss marked “OUT P” on WhiteRodgers gas valve model 36G or 36J. See Figure 57A for White-Rodgers gas valve model 36J. See Figure 57B for White-Rodgers gas valve model 36G.

3. Loosen (Do Not remove) the pressure tap test set screw one turn with 3/32" hex wrench.

a. The pressure tap adjustment kit (KIT07611)

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

4. Turn on system power and energize valve.

Page 33

Installer’s Guide

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

a. To increase outlet pressure, turn the regulator adjust

screw clockwise.

b. To decrease outlet pressure, turn the regulator adjust

screw counterclockwise.

c. Adjust regulator until pressure shown on manometer

matches the pressure specified in Table 17.

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

d. Replace and tighten the regulator cover screw securely.

6 . Adjust 2nd stage gas heat by removing the high (HI)

adjustment regulator cover screw.

a. To increase outlet pressure, turn the regulator adjust

screw clockwise.

b. To decrease outlet pressure, turn the regulator adjust

screw counterclockwise.

c. Adjust regulator until pressure shown on manometer

matches the pressure specified in Table 17.

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

d. Replace and tighten the regulator cover screw securely.

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

a. Repeat steps 5-7 if needed.

8. Turn off all electrical power to the system.

9. Remove the manometer and flexible tubing and tighten

the pressure tap screw.

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

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

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

2nd Stage (HI) Manifold Pressure Adjustment

1st Stage (LO) Gas Valve On / Off Toggle Switch

Figure 57B. White-Rodgers 36G

Table 17

FINAL MANIFOLD PRESSURE SETTINGS (inches w.c.)

FUEL 2nd Stage Ma x. 1st Stage Max.

NATURAL GAS 3.5" W.C. 1.7" W.C.

LP GAS 10.5" W.C. 6.0" W.C.

ROT ATE THE FRONT COVER AS SHOWN

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

Manifold Pressure

Adjustment

2nd Stage (HI) Manifold

Outlet Pressure Boss

Inlet Pressure Boss

18-CD26D1-10 33

Pressure Adjustment

Gas Valve On / Off Toggle Switch

Figure 57A. White-Rodgers 36J

1st Stage (LO) Manifold Pressure Adjustment

ALL SIDE FLANGES MUST BE OUTSIDE OF THE BOX

ROT ATE THE FRONT COVER INWARD MAKING SURE THAT ALL SIDE FLANGES ARE OUTSIDE OF THE BOX.

Figure 58

Page 34

Installer’s Guide

▲

Figure 59

WARNING

NOTE: The manifold pressure must be referenced to the burner box. The burner box pressure tap equalizes the gas valve pressure regulator. Manifold pressure is checked by installing a tee (field supplied) in the tubing, between the tee coming from the burner box tube and the gas valve, addition to the regular gas valve pressure tap on the outlet side of the gas valve. See Figure 59.

Table 21 lists the main burner orifices used with the furnace. If a change of orifices is required to correct the furnace input rating refer to Table 19.

REINSTALLATION OF THE BURNER BOX COVER

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

Table 18

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

8 900 29 248 50 144 82 88

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

34 18-CD26D1-10

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Installer’s Guide

HIGH ALTITUDE DERATE

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

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

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

If the desired input rate can not be achieved with a change in Manifold Pressure, then the orifices must be changed. LP installations will require an orifice change.

IMPORTANT: Reinstall the replacement orifices to the same depth as the orifices supplied with the equipment.

See Table 19 for help in selecting orifices if orifice change is required. Furnace input rate and temperature rise should be checked again after changing orifices to confirm the proper rate for the altitude.

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

Table 19

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

44 45 46 47 48 49 50

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

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

PART

NUMBER

ORF00501 ORF00644 ORF00909 ORF00910 ORF01099 ORF00503 ORF00493

DRILL

SIZE

54 55 56 57 58 59

PART

NUMBER

ORF00555 ORF00693 ORF00907 ORF00908 ORF01338 ORF01339

Table 21

Orific e

Twist D rill

Size If

Installed

At Sea

Level

42 43 44 45 46 47

54 55 56 57 58

2000 3000 4000 5000 6000 7000 8 000 9000 1000

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 44 45 47 47 48

55 55 56 59 60

44 45 47 47 49

55 55 57 59 60

45 46 47 48 49

55 56 57 60

45 47 48 48 49

55 56 57 60 62

46 47 48 49 50

55 56 58 61 62

47 48 49 49 50

56 56 59

47 48 49 50 51

56 56 59 63 63

47 48 50 50 51 52

56 57 60 63 64

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

Z223.1/NFPA 54 or National Standard of Canada, Natural Gas and Propane Installation Code, CSA B149.1.

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

If your application requires a high altitude pressure switch use Table 20 to select the appropriate kit for your model furnace.

Table 20

High Altitude Kits Used With

*UH2B/*DH2B080A9V3VA *UH2B/*DH2B080A9V4VA

BAYSWT08AHALTA

*UH2C/*DH2C100A9V4VA

*UH2C100A9V5VA

*UH2D/*DH2D120A9V5VA

BAYSWT10AHALTA *UH2B/*DH2B060A9V3VA

18-CD26D1-10 35

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Installer’s Guide

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

Electrical Connections

Make wiring connections to the unit as indicated on enclosed wiring diagram. As with all gas appliances using electrical power, this furnace shall be connected into a permanently live electric circuit. It is recommended that furnace be provided with a separate “circuit protection device” electric circuit. The furnace must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code, ANSI/NFPA 70 or CSA C22.1 Electrical Code, if an external electrical source is utilized. The integrated furnace control is polarity sensitive. The hot leg of the 120V power supply must be connected to the black power lead as indicated on the wiring diagram.

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

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

1. Be sure power agrees with equipment nameplates.

2. Low voltage (24 volt wiring) to be No. 18 A.W.G. min.

3. Grounding of equipment must comply with local codes.

4. Set thermostat heat anticipator per unit wiring diagram.

5. These leads provide 115V. power for connection of electronic

W14

W14 JUMPER SEE NOTE 11

Y1/Ylo

SEE

NOTE 6

NOTE 9

FIELD ADDED JUMPER

SEE FURNACE WIRING DIAGRAM

FOR 2ND STAGE TIMING.

air cleaner and humidifier MAX. load 1.0 amps each.

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

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

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

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

10. This wire is only for thermostats requiring connection to transformer common terminal.

11. Optional humidistat is to be connected between R and BK. Factory installed jumper R to BK on the circuit board must be cut if optional humidistat is used. The jumper must also be cut when applying an airflow command signal to the BK input such as with the variable speed single-zone and multi-zone system controllers. On single speed cooling only/non-heat pump systems, jumper Y to O for proper operation of the delay profiles and the humidistat. For two compressor or two speed systems, jumper YLo to O.

W1 TO W2.

SEE

B/C

NOTE 10

B/C

36 18-CD26D1-10

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

HUM SEE NOTE 5

EAC SEE NOTE 5

From Dwg. B342027 Rev. 1

Figure 60

Page 37

Installer’s Guide

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTAT

NO COOLING

1. Be sure power agrees with equipment nameplates.

2. Low voltage (24 volt wiring) to be No. 18 A.W.G. min.

3. Grounding of equipment must comply with local codes.

4. Set thermostat heat anticipator per unit wiring diagram.

5. These leads provide 115V. power for connection of electronic air cleaner and humidifier MAX. load 1.0 amps each.

6. This wire is only for thermostats requiring connection to transformer common terminal.

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

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

9. Optional humidistat is to be connected between R and BK. Factory installed jumper R to BK on the circuit board must be cut if optional humidistat is used. The jumper must also be cut when applying an airflow command signal to the BK input such as with the variable speed single-zone and multi-zone system controllers. On single speed cooling only/non-heat pump systems, jumper Y to O for proper operation of the delay profiles and the humidista For two compressor or two speed systems, jumper YLo to O.

Y1/Ylo

W14

W14 JUMPER

SEE NOTE 9

SEE

NOTE 7

B/C

SEE

NOTE 6

B/C

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

HUM SEE NOTE 5

EAC SEE NOTE 5

From Dwg. B342025 Rev. 0

Figure 61

18-CD26D1-10 37

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Installer’s Guide

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

OUTDOOR UNIT

(NO TRANSFORMER)

B/C

SEE

NOTE 7

SEE

NOTE 6

Y1/Ylo

B/C

1 STAGE HEATING, 1 STAGE COOLING

W14

W14 JUMPER

SEE NOTE 9

FIELD ADDED JUMPER

W1 TO W2.

SEE FURNACE WIRING DIAGRAM

FOR 2ND STAGE TIMING.

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

HUM SEE NOTE 5

EAC SEE NOTE 5

Figure 62

From Dwg. B342022 Rev. 1

38 18-CD26D1-10

Page 39

OUTDOOR UNIT

(NO TRANSFORMER)

Installer’s Guide

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

2 STAGE HEATING, 1 STAGE COOLING

USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

W14

SEE

NOTE 9

SEE

NOTE 7

Y1/Ylo

W14 JUMPER

SEE NOTE 9

B/C

SEE

NOTE 6

B/C

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

HUM SEE NOTE 5

EAC SEE NOTE 5

Figure 63

From Dwg. B342020 Rev. 0

18-CD26D1-10 39

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Installer’s Guide

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE

(OUTDOOR SECTION WITHOUT TRANSFORMER)

OUTDOOR UNIT NO. 1

(NO TRANSFORMER)

SEE NOTE 3

SEE

NOTE 7

OUTDOOR UNIT NO. 2

(NO TRANSFORMER)

SEE

NOTE 6

B/C

2 STAGE HEATING, 2 STAGE COOLING

W14

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

B/C

HUM SEE NOTE 5

EAC SEE NOTE 5

Figure 64

HUMIDISTAT HOOKUP

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

From Dwg. B342018 Rev. 0

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

BLK

40 18-CD26D1-10

BLK

Figure 65

Page 41

Installer’s Guide

▲

Start-up and Adjustment Preliminary Inspections

WARNING

ELECTRIC SHOCK HAZARD DISCONNECT POWER TO THE UNIT BEFORE REMOVING THE BLOWER DOOR. ALLOW A MINIMUM OF 10 SECONDS FOR IFC POWER SUPPLY TO DISCHARGE TO 0 VOLTS. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

With gas and electrical power “OFF”

1. Duct connections are properly sealed

2. Filters are in place

3. Venting is properly assembled

4. Blower door is in place

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

Lighting Instructions

WARNING

BURN HAZARD DO NOT ATTEMPT TO MANUALLY LIGHT THE BURNER. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Lighting instructions appear on each unit. Each installation must be checked out at the time of initial start up to insure proper operation of all components. Check out should include putting the unit through one complete cycle as outlined below.

Turn on the main electrical supply and set the comfort control above the indicated temperature. The ignitor will automatically heat, then the gas valve is energized to permit the flow of gas to the burners. After ignition and flame is established, the flame control module monitors the flame and supplies power to the gas valve until the comfort control is satisfied.

To shut off

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

CAUTION

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

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

Control and Safety Switch Adjustments

LIMIT SWITCH CHECK OUT

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

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

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

SEQUENCE OF OPERATION

Comfort Control call for heat (2-Stage Comfort Control)

Call for 1st Stage only:

W1 Comfort Control contacts close signaling the control module to run its self-check routine. After the control module has verified that the 1st Stage Pressure Switch contacts are open and the Limit Switch(es) contacts are closed, the draft blower will be energized.

As the induced draft blower comes up to speed, the Pressure Switch contacts will close and the ignitor warm up period will begin. The ignitor will heat for approx. 20 seconds, then the Gas Valve is energized in 1st Stage to permit gas flow to the burners.

The flame sensor confirms that ignition has been achieved within the 4 second ignition trial period.

As the flame sensor confirms that ignition has been achieved, the delay to fan ON period begins timing and after approx. 45 seconds the indoor blower motor will be energized at low speed and will continue to run during the heating cycle.

Call for 2nd Stage after 1st Stage:

W2 Comfort Control contacts close signaling a call for 2nd Stage Heat. After a 30 second delay, the induced draft blower will be energized on high speed and the 2nd Stage Pressure Switch contacts will close. The Gas Valve is energized in 2nd Stage and the indoor blower motor in high speed.

2nd Stage satisfied, 1st Stage still called:

W2 Comfort Control contacts open signaling that 2nd Stage Heating requirements are satisfied. The induced draft blower is reduced to low speed allowing the 2nd Stage Pressure Switch contacts to open and the Gas Valve is reduced to 1st Stage. The indoor blower motor is reduced to low speed.

1st stage satisfied:

W1 Comfort Control contacts open signaling that 1st Stage heating requirements are satisfied. The Gas Valve will close and the induced draft blower. The indoor blower motor will continue to run for the fan off period (Field selectable at 60, 100, 140 or 180 seconds), then will be de-energized by the control module.

Comfort Control call for heat (1-Stage Comfort Control)

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

Comfort Control satisfied:

W1/ W2 (jumpered) contacts close signaling the control module to close the Gas Valve. The induced draft blower is switched to low speed and de-energized after the post purge timer has expired. The indoor blower motor will continue to operate after the flames are extinguished and then is switched to low heat speed for the FAN-OFF period.

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Installer’s Guide

▲

NOTE TO INSTALLER Review warnings and the contents of USER’S INFORMATION MANUAL with the homeowner when installation is complete and equipment is ready to be turned over to the homeowner for normal operation.

CONTROL AND SAFETY SWITCH ADJUSTMENT

LIMIT SWITCH CHECK OUT

The limit switch is a safety device designed to close the Gas Valve should the Furnace become overheated. Since proper operation of this switch is important to the safety of the unit, it must be checked out on initial start up by the installer.

To check for proper operation of the Limit Switches, set the Comfort Control to a temperature higher than the indicated temperature to bring on the Gas Valve. Restrict the airflow by blocking the return air or by disconnecting the blower. When the Furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and overheating is evident, a faulty Limit Switch is probable and the Limit Switch must be replaced. After checking the operation of the Limit Control, be sure to remove the paper or cardboard from the return air inlet, or reconnect the blower. Refer to the Service Facts for additional instructions.

INDOOR BLOWER TIMING

Table 22. FAN OFF -- DELAY OPTIONS

SWITCH SETTINGS SELECTION

5 - OFF 6 - OFF NON E SAME

5 - ON 6 - OFF 1.5 MINUTES 100 % *

5 - OFF 6 - ON 3 MINUTES 50%

5 - ON 6 - ON

Enhanced

Mode**

NOMINAL AIRFLOW

50 - 100%

* - This setting is equivalent to BA Y24X045 relay benefit.

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

See Wiring Diagram on the unit or in the Service Facts for complete wiring setup for Enhanced Mode.

WARNING

Heating: The Integrated Furnace Control (IFC) controls the Variable Speed Indoor Blower. The blower “on” time is fixed at 45 seconds after ignition. The FAN-OFF period is field selectable by dip switches #1 and #2 located on the Integrated Furnace Control between the 5-pin and 9-pin wire connectors. The delay may be set at 60, 100, 140, or 180 seconds. The factory setting is 100 seconds (See unit wiring diagram).

Cooling: The fan delay-off period is set by dip switches on the Integrated Furnace Control. The options for cooling delay off is field selectable by dip switches #5 and #6.

The following table and graph explain the delay-off settings: This unit is equipped with a blower door switch which cuts

power to the blower and Gas Valve causing shutdown when the door is removed.

ROOM AIR COMFORT CONTROL HEAT ANTICIPATOR ADJUSTMENT

Set the Comfort Control heat anticipator according to the current flow measured, or the settings found in the notes on the Furnace wiring diagram (found in the SERVICE FACTS or inside the furnace casing).

100% if necessary

80%

Fast Cooling

minute

Dehumidify

7.5

minutes

Figure 66

WARNING

50%

Efficiency

OFF

minutes

50%

OFF

AIRFLOW ADJUSTMENT

CARBON MONOXIDE HAZARD OPERATION WITH THE DOOR REMOVED OR AJAR CAN PERMIT THE ESCAPE OF DANGEROUS FUMES. ALL PANELS MUST BE SECURELY CLOSED AT ALL TIMES FOR SAFE OPERATION OF THE FURNACE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Check inlet and outlet air temperatures to make sure they are within the ranges specified on the Furnace rating nameplate. If the airflow needs to be increased or decreased, see the Service Facts for information on changing the speed of the blower motor.

42 18-CD26D1-10

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Installer’s Guide

▲

INSTRUCTIONS TO THE OWNERS

WARNING

EXPLOSION HAZARD

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

BURNER BOX TEMPERATURE LIMIT DEVICE

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

CONDITIONS THAT AFFECT SYSTEM OPERA TION

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN EXCESS OF 40 M.P.H.) VENT OR FLUE BLOCKAGE On a call for heat, the Variable Speed Draft Inducer must first ramp up to speed and close the Pressure Switch before the ignition sequence is allowed to begin. If the Pressure Switch does not close, the motor will ramp up to maximum speed and continue to operate there for about 1 minute. After one minute, the Integrated Furnace Control will turn the motor off for about 30 seconds and then back on in an attempt to reestablish proper operation. This condition is indicative of a highly restricted or blocked inlet or outlet vent pipe or a failed Pressure Switch. If pressure against induced draft blower outlet becomes excessive, the Pressure Switch will open. If the Pressure Switch is open for more than 3.5 seconds, the variable speed draft inducer will speed up and attempt to close the Pressure Switch. If the Pressure Switch is not closed within 12 seconds or if the maximum speed of the motor is reached, the draft inducer sends a Fault signal to the Integrated Furnace Control. If the unit is operating in Second Stage, an Inducer Fault will cause the Furnace Control to transition the system to First Stage and it will operate there for 10 minutes before attempting to run again in Second Stage. If the unit is operating in First Stage, an Inducer Fault will cause the Furnace Control to shut the system down and wait 30 seconds before attempting to reestablish operation in First Stage.

2. LOSS OF FLAME If loss of flame occurs during a heating cycle, or flame is not present at the sensor, the flame control module will close the Gas Valve. The Integrated Furnace Control will then recycle the ignition sequence, then if ignition is not achieved, it will shut off the Gas Valve and lock out the system.

3. POWER FAILURE If there is a power failure during a heating cycle, the system will restart the ignition sequence automatically when power is restored, if the Comfort Control still calls for heat.

4. GAS SUPPLY FAILURE If loss of flame occurs during a heating cycle, the system Integrated Control Module will recycle the ignition sequence, then if ignition is not achieved, the Integrated Control Module will shut off the Gas Valve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE Please refer to the Variable Speed Draft Inducer troubleshooting manual for diagnostic assistance.

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

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

8. RESET AFTER BURNER BOX LIMIT SHUTDOWN If the furnace shuts down, one thing that can be checked is the burner box temperature limit switch. It is located on the bottom of the burner box. The vent and combustion air inlet terminations should be checked for blockage. If blockage exists, clear the problem and then the reset button may be depressed. If there is no blockage

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

INDOOR MOTOR MAINTENANCE

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

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Installer’s Guide

IFC Error Flash Codes

Table 23

INTEGRATED F URNACE CONTROL LED FLASH CODES

RED LED - LitePort

DATA - 1 FLASH EVERY 20 SECONDS

2 Flashes --- RETRIES OR RECYCLES EXCEEDED 3 Flashes --- INDUCER OR PRESSURE SWITCH ERROR 4 Flashes --- OPEN LIMIT OR ROLLOUT SWITCH

5 Flashes --- FLAME SENSED WHEN NO FLAME SHOULD BE PRESENT 6 Flashes --- LINE REVERSE POLARITY 7 Flashes --- GAS VALVE CIRCUIT ERROR 8 Flashes --- WEAK FLAME 9 Flashes --- OPEN INDUCER LIMI T ERROR

GREEN LED - STATUS

Slow Flash NORMAL, NO CALL FOR HEAT Fast Flash NORMAL, CALL FOR HEAT PRESENT GREEN and RED

LED's on Continuously

FUSE OPEN OR INTERNAL CONTROL FAILURE

Fault Code Recovery

On power up, last 4 faults, if any, will be flashed on the red LED. The newest fault detected will flash first and the oldest last. There will be a 2 second delay between fault code flashes. Solid red LED error codes will not be displayed.

The Green LED will be on solid during last fault recovery. At any other time the control is powered, the Green LED indicator light will operate as shown in Table 14 and the red LED will flash LitePort data (one flash) every 20 seconds.

Table 25

INTEGRATED FURNACE CONTROL

GREEN "STATUS" LED FLASH CODES

Flashing Slow --- Normal - No call for Heat Flashing Fast --- Normal - Call for Heat

Fault Code Reset

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

Red LitePort Green Status LED

LED

Figure 67

44 18-CD26D1-10

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Notes

Installer’s Guide

18-CD26D1-10 45

Page 46

Trane 6200 Troup Highway Tyler, TX 75707

For more information contact your local dealer

Literature Order Number 18-CD26D1-10 File Number 18-CD26D1-10 Supersedes 18-CD26D1-9 Date 09/10

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

Trane TUH2B060A9V3VA, TUH2B080A9V3VA, TUH2B080A9V4VA, TUH2C100A9V4VA, TUH2C100A9V5VA Installer's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual