Trane TUHMB060ACV3VA, TUHMB080ACV3VA, TUHMC100ACV4VA, TUHMD120ACV5VA, TDHMB060BCV3VA Installer's Manual

...

18- CD30D1- 9

Installer’s Guide

Upflow/ Horizontal and Downflow/ Horizontal, Gas-Fired, Direct Vent, Variable Speed Inducer, Modulating Condensing Communicating Furnaces

*UHMB060ACV3VA *UHMB080ACV3VA *UHMC100ACV4VA *UHMD120ACV5VA

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.

NOTE:

This furnace can be configured for Communicating or 24 VAC modes. Using fully Communicating or 24 VAC modes, the furnace can support single or multi-stage heat pump, AC, or heating only applications. Combined with a communicating Comfort Control only, the furnace will support a single stage 24 VAC cooling outdoor unit only.

*UHM

*DHMB060BCV3VA *DHMB080ACV3VA *DHMC100ACV4VA *DHMD120BCV5VA

*DHM

* First letter may be “A” or “T"

DOWNFLOW

UPFLOW

UPFLOW/HORIZONTAL

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.

DOWNFLOW/HORIZONTAL

A341624P14

SAFETY SECTION

▲

Installer’s Guide

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

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

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.

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

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

WARNING

and these

Natural

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

EXPLOSION HAZARD!

PROPANE GAS IS HEAVIER THAN AIR AND MAY COLLECT IN ANY LOW AREAS OR CONFINED SPACES. IN ADDITION, ODORANT FADE MAY MAKE THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE. IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO CONTACT A GAS SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOT test

any detectors and makes no representations regarding any brand or type of detector.

WARNING

SAFETY HAZARD THIS INFORMATION 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 INTERPRETATION OF THIS INFORMATION, NOR CAN IT ASSUME ANY LIABILITY IN CONNECTION WITH ITS USE.

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.

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.

Installer’s Guide

▲

WARNING

EXPLOSION HAZARD! NEVER USE AN OPEN FLAME TO DETECT GAS

LEAKS. EXPLOSIVE CONDITIONS MAY OCCUR. USE A LEAK TEST SOLUTION OR OTHER APPROVED METHODS FOR LEAK TESTING. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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-h 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

SAFETY 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.

CAUTION

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

NOTE: 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.

WARNING

SAFETY HAZARD DO NOT INSTALL THE FURNACE DIRECTLY ON CARPETING, TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING. FOR VERTICAL DOWNFLOW APPLICATIONS, 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. FAILURE TO FOLLOW THE WARNING EXACTLY COULD RESULT IN SERIOUS PERSONAL INJURY, PROPERTY DAMAGE OR DEATH.

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” on page 6 of these instructions.

Contents

Safety Section ................................................................................... 2

Installation Instructions .......................................... 6

Outline Drawing ................................................................................. 4

Locations and Clearances ................................................................ 6

General Installation Instructions ....................................................... 6

Upflow Installation ............................................................................. 7

Downflow Installations ...................................................................... 7

Horizontal Installation ....................................................................... 7

Air for Combustion and Ventilation ................................................... 8

Duct Connections .............................................................................. 9

Return Air Filters .............................................................................. 11

General Venting Information ........................................................... 15

Venting Materials ............................................................................. 18

Vent Length Table ............................................................................ 19

Venting Through the Roof ............................................................... 20

Horizontal Venting Through the Wall .............................................. 21

Downward Venting .......................................................................... 21

Venting Routed Through a Masonry Chimney .............................. 27

Electrical Connections .................................................................... 28

Field Wiring Diagrams ..................................................................... 28

Condensate Drain Instructions ....................................................... 32

Gas Piping ....................................................................................... 34

Combustion and Input Check ......................................................... 36

High Altitude Derate ........................................................................ 36

Start-up and Adjustment....................................... 39

Preliminary Inspections ................................................................... 39

Lighting Instructions ........................................................................ 39

User Interface Menu ........................................................................ 40

Sequence of Operation ................................................................... 43

Unit Test Mode ................................................................................. 46

Simple ........................................................................................ 4 6

Gas Valve Setup (Manifold Pressure Adjustment).................... 46

Control and Safety Switch Adjustments ......................................... 52

Airflow Adjustment ........................................................................... 52

Conditions Effecting Furnace Operation ........................................ 53

Alert Code Recovery ....................................................................... 54

Furnace Alert Codes ............................................. 55

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

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section (pages 15-

27), 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 starting on page 34.

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.

18-CD30D1-9 3

Installer’s Guide

MODEL

(SEE NOTE 1)

DIM "A" DIM "B" DIM "C" DIM "D" DIM "E" DIM "F"

*UHMB060ACV3VA

*UHMB080ACV3VA

17-1/2" 2-1/4" 16-1/4" 16" 7-1/2" 2"

*UHMC100ACV4VA 21" 2-1/2" 19-3/4" 19-1/2" 9" 3"

*UHMD120ACV5VA 24-1/2" 2-15/16" 23-1/4" 23" 10" 3"

(ALL DIMENSIONS ARE IN INCHES)

NOTES:

1. DIAMETER OF VENT PIPE MAY BE LIMITED

TO 2-1/2" OR 3" ON SOME MODELS AT DIFFERENT

ALTITUDES. REFER TO THE VENT LENGTH TABLE

FOR PROPER APPLICATION.

*UHM-ACV OUTLINE DRAWING

4 18-CD30D1-9

Installer’s Guide

(ALL DIMENSIONS ARE IN INCHES)

*DHM-ACV DOWNFLOW/ HORIZONTAL OUTLINE DRAWING

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

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

MODEL

(SEE NOTE 1)

*DHMB060ACV3VB

*DHMB080ACV3VA

*DHMB060BCV3VA

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

*DHMC100ACV4VA 21" 2-1/2" 19-3/4" 19-1/2"

*DHMD120BCV5VA

*DHMD120ACV5VB

18-CD30D1-9 5

Installer’s Guide

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 of these instructions.

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

a. The furnace venting system must be complete

and installed per manufacturers instructions.

b. The furnace is controlled only by a room Com-

fort 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 require-

ment must come from outside the structure.

f. The Furnace return air temperature range is

between 55

g. Clean the Furnace, duct work, and components

upon substantial completion of the construction process, and verify Furnace operating condition including ignition, input rate, temperature rise and venting, according to the manufacturer's instructions.

h. An external field supplied air filter must be

used during construction.

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

and 800 Fahrenheit.

only

LOCATION AND CLEARANCES

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

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

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

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

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

5. Are the ventilation and combustion air openings large enough and will they remain unobstructed? If outside air is used, are the openings at least 12" above the highest expected snow accumulation level (18" minimum for 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.

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

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

GENERAL INSTALLATION INSTRUCTIONS

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

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

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

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

These furnaces have been classified as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21.47 standards • CAN/CGA 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 not approved for installation in Manufactured/ Mobile housing.

6 18-CD30D1-9

Installer’s Guide

▲

WARNING

UPFLOW INSTALLATION

Standoffs and screws (See Figure 1) are included with the cased coils for attachment to the furnace. There are clearance alignment holes near the bottom of the coil wrapper. Drill screws are used to engage the furnace top flanges. The standoff is inserted into the cabinet alignment hole. The drill screws are inserted through the standoffs then screwed into the furnace flange. The coil is always placed downstream of the furnace airflow.

STANDOFFS (4)

DRILL SCREWS (4)

CASED

COIL

FOR VERTICAL

INSTALLATIONS:

DOWNFLOW INSTALLATIONS

REQUIRED FLOOR OPENING: (DOWNFLOW) SEE FIGURE 2 AND FIGURE 3, AND TABLE 1

HORIZONTAL INSTALLATION

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

The 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% or greater Gas Furnace. Connect the auxiliary drain line to a separate drain line (no trap is needed in this line).

Three brackets (with screws) are included with downflow furnaces for installation to stabilize and secure the furnace and TXC cased coil in the horizontal posi- tion. See Figure 4. The coil is placed downstream of the furnace, with the apex of the coil pointing in either direction of the airflow for horizontal installation. The cased coil is secured to the furnace and both the furnace and the cased coil must be properly supported.

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

SCREWS

STANDOFFS

(BOTH SIDES)

2345678901234567890123456789012123456789012345

FURNACE

2345678901234567890123456789012123456789012345

CABINET

WIDTH

FRONT

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"

18-CD30D1-9 7

A (width)

B (depth)

TABLE 1

FLOOR OPENING PLENUM OPENING

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

DOWNFLOW ONLY

The brackets mount using the rear screws on the coil case and use the screws provided to secure the bracket to the furnace. The remaining bracket is placed as close to center as possible (horizontally) between the coil case front and the furnace bottom channel (for downflow/ horizontal furnace). Use four of the screws provided to secure the bracket. The coil requires additional support.

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 5 & Clearance

Tables, on the Outline drawings on pages 4-5). 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.

Installer’s Guide

UPFLOW/ HORIZONTAL SHOWN WITH DIRECT VENT

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

The horizontal furnace may also be suspended from the joists using 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.

AIR FOR COMBUSTION AND VENTILATION

If these furnaces are installed in a nondirect vent capacity then the adequate flow of combustion and ventilating air must not be obstructed from reaching the furnace. Air openings provided for combustion air must be kept free of obstructions which restrict the flow of air. Airflow restrictions affect the efficiency and safe operation of the furnace. Keep this in mind should you choose to remodel or change the area which contains your furnace. Furnaces must have a free flow of air for proper performance.

Provisions for combustion and ventilation air shall be made in accordance with latest edition of Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1 — CAN/CGA B149.1 or applicable provisions of the local building codes. Special conditions created by mechanical exhausting of air and

fireplaces must be considered to avoid unsatisfactory furnace operation.

OUTSIDE AIR IS RECOMMENDED

The use of indoor air for most applications is acceptable, unless there is the presence of corrosive chemicals or contamination. Certain types of installation will require the use of outside air for combustion.

The following types of installations will require use of OUTDOOR AIR for combustion, due to chemical exposures:

* Commercial buildings * Buildings with indoor pools * Furnaces installed in “confined” laundry rooms * Furnaces installed in “confined” hobby or craft

rooms

* Furnaces installed near chemical storage areas.

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

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

Furnace locations may be in a “confined space” or an “unconfined space”.

Unconfined space is defined in Figure 6. These spaces may have adequate air by infiltration to provide air for combustion and ventilation. Buildings with tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), may need additional air to be provided as described for confined space. See Table 2 for minimum area.

TABLE 2

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

UNCONFINED

8 18-CD30D1-9

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE

MAXIMUM BTUH

INPUT RATING

60,000

80,000 100,000 120,000

MINIMUM AREA IN SQUARE FEET

WITH 8 FT. CEILING

OF UNCONFINED SPACE

375 500 625 875

Installer’s Guide

CONFINED

SPACE

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

All air from inside the building as in Figure 8: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Refer to Table 3 for minimum open areas requirements.

All air from outdoors as in Figure 9: The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 3, for minimum open areas requirements.

TABLE 3

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000

80,000 100,000 120,000

Air

From

Inside

100 100 100 120

Vertical

Duct

DUCT CONNECTIONS

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

Central furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling coil to avoid condensation in the heat exchanger.

18-CD30D1-9 9

Air From Outside

Horizontal

15 20 25 30

Duct

30 40 50 60

Installer’s Guide

▲

With a parallel flow arrangement, the dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering the Furnace, and if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in full heat or cool position.

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

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

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

RETURN AIR DUCT SYSTEMS

CAUTION

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.

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

Do NOT install return air through the back of the furnace cabinet.

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

PREPARATION FOR UPFLOW BOTTOM AND SIDE RETURN AIR FILTER INSTALLATION

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

1. Determine the appropriate position to set the furnace in order to connect to existing supply and return ductwork.

2. The return air filter is shipped in either the bottom or side location. Remove the filter by first turning the two latches on the blower door and tilting the door forward to remove. Remove the filter by sliding it out.

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

4. The side panels of the upflow furnace include locating notches that are used as guides for cutting an opening for return air, refer to Figure 10 and the outline drawing on page 4 for duct connection dimensions for various furnaces.

LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT

SEE OUTLINE DRAWING

5. If a 3/4" flange is to be used for attaching the air

inlet duct, add to cut where indicated by dotted lines in Figure 10. Cut corners diagonally and bend outward to form flange.

6. If flanges are not required, and a filter frame is

installed, cut between locating notches (See Figure

10).

7. The bottom panel of the upflow furnace must be

removed for bottom return air. After removing the filter, lay the furnace on its back. Remove the two 5/16" hex screws securing the front of the bottom channel to the cabinet.

UPFLOW FURNACE ONLY

CUT OUT FOR SIDE FILTER

FRONT of Furnace

NOTE: Minimum return air temperature is 55°F.

10 18-CD30D1-9

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 4

MODELS

NUMBERS

*UHMB060ACV3VA *UHMB080ACV3VA

*UHMC100ACV4VA 21" 1 - 20" X 25" X 1" *UHMD120ACV5VA 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 - Models will require return air openings and filters on: (1) both sides, or (2) one side and the bottom, or (3) just the bottom. The filter rack installation is not allowed for right side return on the following models: *UHMB060ACV3V, *UHMB080ACV3V & *UHMC100ACV4V.

CABINET

WIDTH

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

FILTER

QTY & SIZE

Installer’s Guide

Airflow

BOTTOM FILTER RACK INSTALLATION

FILTER RACK ASSEMBLY

Blower Deck Engagement

Hole

The furnace and the bottom filter rack, BAYRACK960, installation can be seen in Figure 11.

The furnace filter in the bottom or side configuration can be removed by simply turning the two latches on the blower door and tilting the door forward.

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 12).

18-CD30D1-9 11

VIEW

ENGAGEMENT

HOLE DETAIL

(Typical both sides and blower deck)

Installer’s Guide

Airfl

Airflow

ALTERNATE FILTER RACK INSTALLATION FOR BOTTOM RETURN - BAYRACK960

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

a. Remove the filter. b. Remove the bottom panel. c. With the filter removed, the filter rack is

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

14.

d. Reinstall the furnace filter in the bottom

position by inserting the chamfer end first into the filter rack. See Figure 19.

ALTERNATE FILTER RACK INSTALLATION FOR SIDE RETURN AIR ON UPFLOW FURNACES (LEFT OR RIGHT) - BAYRACK960

NOTE: The filter rack installation is not allowed for right side return on the following models: *UHMB060ACV3V, *UHMB080ACV3V & *UHMC100ACV4V. See Figure 21 for alternate upflow filter clip/ bracket installation.

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

a. Remove the filter. b. Leave the bottom panel in place. c. Make side cutout by following the directions in

the “Return Air Duct Connections” section on page 10,

d. Compress the filter rack and reinstall in the side

position on the furnace. Confirm that the upper retaining pin/screw locks into the engagement hole in the blower deck and the lower pin/screw rests against the side of the bottom panel. See Figures 13, 15-18.

e. Reinstall the furnace filter in the side position by

inserting the chamfer end first into the filter rack.

BOTTOM ENGAGEMENT

Filter Rack Retaining

Furnace

Cabinet

Side

Engagement Hole

For

Filter Rack

Installation With

Bottom Return

Screw/Pin

Filter Rack

Bottom Panel

Typical Upflow Left Side Return Filter Rack Installation

SIDE

CUTOUT

RETAINING

(Both Sides)

SPRINGS

FILTER

RACK

RAILS

Airflow

BOTTOM

PANEL

INSTALLED

SIDE

CUTOUT

SIDE ENGAGEMENT

Furnace

Cabinet

Side

Engagement Hole For

Filter Rack Installation With Bottom Return

12 18-CD30D1-9

Filter Rack

Filter Rac Retaining Screw/Pin

Airflow

SPRINGS

BOTTOM

PANEL

INSTALLED

Typical Upflow Right Side Return Filter Rack Installation

FILTER

RACK RAILS

RETAINING

(Both Sides)

Installer’s Guide

SIDE

CUT-OUT

ALTERNATE SIDE

FILTER CLIPS

LOCATIONS

ALTERNATE BOTTOM

FILTER CLIPS LOCATIONS

BLOWER DECK

Furnace

Cabinet

Side

Engagement Hole For

Filter Rack Installation With Side

Return

Filter Rack Retaining Screw/Pin

Airflow

Furnace Blower Deck

Filter Rack Assembly

CHAMFER

END OF

FILTER GOES

INTO FILTER RACK FIRST

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 20. Conversion kits for horizontal filter installation are shown in Table 4A.

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 20 and 22.

UPFLOW FILTER CLIP/ BRACKET INSTALLATION

1. Determine the location to be used. The furnace cabinet has dimples for location of the alternate furnace clips (Side return only). Pre-drill clearance holes with a 3/16" drill. Bottom return holes are pre-drilled. Attach clip to bottom channel and rear of unit with screws provided for bottom return.

2. Install the clips in front and rear of the desired location using the screws provided. The filter clip with the leaf spring mounts in the rear of the cabinet. See Figure 21.

Optional door kit BAYFLTR206

Typical Horizontal Filter Installation

Table 4A CONVERSION KITS FOR HORIZONTAL FILTERS

MODEL NUMBERS

*UHMB060ACV3VA *UHMB080ACV3VA

*UHMC100ACV4VA

*UHMD120ACV5VA

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

2. Kit includes Filters and Brackets necessary for Horizontal Filters.

3. Optional Door Kit BAYFLTR206 is also available.

18-CD30D1-9 13

CABINET

WIDTH

17-1/2" BAYFLTR203

21" BAYFLTR204

24-1/2" BAYFLTR205

Airflow

CONVERSION

KIT NUMBER

Installer’s Guide

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 5

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 22. Tables 6 and 7 provide information for installation of the filter retaining brackets shipped with downflow furnaces.

TABLE 6

MODELS

NUMBERS

*DHMB060ACV3VB *DHMB060BCV3VA *DHMB080ACV3VA

*DHMC100ACV4VA 21" 2 - 16" X 20" X 1" *DHMD120ACV5VB

*DHMD120BCV5VA

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

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

CABINET

WIDTH

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

24-1/2" 2 - 16" X 20" X 1"

TABLE 7

DIMENSION

"A"

FILTER

QTY & SIZE

DIMENSION

"B"

FILTER

BRACKET

LOCATION*

Optional

BAYFLTR206

Door Kit

Airflow

DOWNFLOW

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/ HORIZONTAL FURNACES

FURNAC E 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

VERTICAL

CLOSET

TABLE 8

Optional

BAYFLTR206

Door Kit

Airflow

UNIT LOCATION

HORIZONTAL

CLOSET

DOWNFLOW/ HORIZONTAL

HORIZONTAL

ALCOVE / ATTIC

14 18-CD30D1-9

Installer’s Guide

▲

GENERAL VENTING INFORMATION

THIS FURNACE 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.

WARNING

CARBON MONOXIDE HAZARD FURNACE MUST BE VENTED PROPERLY. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN CARBON MONOXIDE, FIRE OR SMOKE THAT CAN CAUSE SERIOUS BODILY INJURY, DEATH OR PROPERTY DAMAGE.

IMPORTANT:

The building owner/maintenance provider must keep the area around the vent clear from snow.

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. See Table 8.

The recommended system is assembled from 2", 2-1/ 2", or 3" plastic pipe and fittings (See Table 9, page

18) for material specifications. 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 t maining 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.

he re-

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

instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

4. Close fireplace dampers.

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

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.

WHEN THE FACTORY SUPPLIED "OFF-SET" (2X3 REDUCING COUPLING) IS USED FOR 3" VENT PIPE INSTALLATION, MAKE SURE THE MARKING "TOP" IS

#CPL00938

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

LOCATED ON THE TOP SIDE OF THE PIPE.

LABEL SAYS "TOP"

STRAIGHT SIDE MUST BE ON BOTTOM FOR PROPER CONDENSATE DRAINAGE.

and these

Natural

18-CD30D1-9 15

Installer’s Guide

▲

Furnace

Air Inlet

Vent

2" TO 3" COUPLING

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

FURNACE VENT

HORIZONTAL INSTALLATION

(UPFLOW/ HORIZONTAL OR DOWNFLOW/ HORIZONTAL)

NOTE: See Figures 23 & 24. In horizontal venting when the factory supplied “off-set” (2X3 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 must be on bottom for proper condensate drainage. This coupling is factory supplied with the following models: *UHMC100, *UHMD120, & all downflow

models.

WARNING

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 manufacturer’s installation instructions to help alert dwelling occupants of the presence of fire, smoke or unsafe levels of carbon monoxide. These devices should meet Underwriters Laboratories, Inc. Standards for Single and Multiple Station Carbon Monoxide Alarms, UL 2034 or CSA International Standard, Residential Carbon Monoxide Alarming De- vices, 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.

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. 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. The pipes DO NOT have to exit the

exterior of the house together or on the same side of the house.

16 18-CD30D1-9

#CPL00938

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 INSTALLATION

WARNING

CARBON MONOXIDE POISONING HAZARD Failure to follow the installation instructions for the venting system being placed into operation could re-

sult in carbon monoxide poisoning or death.

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 nondirect, single pipe applications (See example 2 ).

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.

NOTE: BAYVENT200B 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 be only 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.

Installer’s Guide

EX. 2 —

Example 2 shows the vent pipe exhausting through the roof and the inlet air coming from the interior of the house (See Note). 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.

Vent

Air

Inlet

(See Note)

Furnace

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: 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 equivalent feet) installed on the end to prevent dust and debris from falling directly into the Furnace.

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 are materials that meet these requirements. The materials listed are various grades of PVC and ABS plastic.

PIPE JOINTS: All joints must be fastened and sealed to prevent escape of combustion products into the building. These materials are acceptable for U.S. applications only. All Canadian installations must conform to ULC S636.

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.

Air

Vent

Inlet

Furnace

EX. 4 —

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

Attic Vent

Vent

Air

Inlet

(See Note)

Furnace

BONDING OF PVC

Commercially available solvent cement for PVC must be used to join PVC pipe fittings. Follow instructions on container carefully for U.S. applications only. Canadian applications require primer and cement that are from a single system manufacturer.

For U.S. applications only:

Pipe and Fittings – 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.

18-CD30D1-9 17

+ 39 hidden pages

Trane TUHMB060ACV3VA, TUHMB080ACV3VA, TUHMC100ACV4VA, TUHMD120ACV5VA, TDHMB060BCV3VA Installer's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual