Trane AUX2B060AFV3VA, AUX2C100AFV4VA, TUX2B060AFV3VA, AUX2D120AFV5VA, AUX2B080AFV3VA Installer's Manual
...
18- CD25D1- 2
Installer’s Guide
Upflow/ Horizontal, Gas-Fired, Direct Vent,
2-Stage Condensing Furnaces with Variable
Speed Inducer and Whole House Air Cleaner
*UX2B060AFV3VA *UX2C100AFV4VA
*UX2B080AFV3VA *UX2D120AFV5VA
*__First letter may be “A” or “T”
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
Available in French Canadian (FC)
IMPORTANT — This Document is customer property and is to remain with this unit.
Please return to service information pack upon completion of work.
UPFLOW/ HORIZONTAL
UPFLOW
Bottom Return ONLY
This unit is equipped with an integrated high efficiency
Whole House Air Cleaner. 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 situa-
tion 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.
A341624P10
Installer’s Guide
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SAFETY SECTION
!
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 serious 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 instruction. 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 dryer 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 running continuously.
7. Test for spillage from draft hood equipped appliances at the draft hood relieve 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 tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any
other gas-fired appliances to their previous condition of use.
!
WARNING
Failure to follow the 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 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 exactly could result in serious injury, death or property damage.
Improper servicing could result in dangerous operation, serious injury, death, or property damage.
The following safety practices and precautions must be
followed during the installation, servicing, and operation
of this Furnace.
1. Use only with the type of gas approved for this Furnace. Refer to the Furnace rating plate.
2. Install this Furnace only in a location and position
as specified in “Location and Clearances” (page 4) of
these instructions.
3. Provide adequate combustion and ventilation air to
the Furnace space as specified in “Air for Combustion and Ventilation” (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 (pages 11-
23), 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.
© 2008 Trane All Rights Reserved 18-CD25D1-2
Installer’s Guide
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7. When a Furnace is installed so that supply ducts
carry air circulated by the Furnace to areas outside
the space containing the Furnace, the return air
shall also be handled by a duct(s) sealed to the Furnace casing and terminating outside the space containing the Furnace.
8. A gas-fired Furnace for installation in a residential
garage must be installed as specified in “Location
and Clearances” section (page 4) , of these instructions.
9. The Furnace may be used for temporary heating of
buildings or structures under construction
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 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 55
g. Clean the Furnace, duct work, and components
upon substantial completion of the construction process, and verify Furnace and whole house air
cleaner operating conditions including ignition, input rate, temperature rise and venting, according to
the manufacturer's instructions.
h. Remove the Whole House Air Cleaner and
store in clean dry location during the construction
process. To be reinstalled when construction is complete. See page 39 for proper air cleaner removal.
i. An external field supplied air filter must be
used during construction.
0
and 800 Fahrenheit.
only
Contents
Safety Section 2
Installation Instructions 4
General 4
Location and Clearances 4
Outline Drawings 6
Upflow Installation 7
Horizontal Installation 7
Air For Combustion and Ventilation 9
Duct Connections 10
General Venting 11
Venting Materials 12
Vent Tables 15
Horizontal Venting Through Wall 17
Venting Through The Roof 19
Venting Routed Through a Masonry Chimney 20
Downward Venting 22
Condensate Drain Instructions 24
Field Wiring Diagrams 26
Electrical Connections 31
Gas Piping 31
Combustion and Input Check 33
High Altitude Derate 34
Start-up and Adjustment 35
Preliminary Inspections 35
Lighting Instructions 35
Sequence of Operation 36
Control and Safety Switch Adjustments 36
Conditions Affecting System Operation 38
Whole House Air Cleaner Maintenance 39
IFC Error Flash Codes 41
Checkout Procedure 43
10. This product must be gas piped by a Licensed
!
Plumber or Gas Fitter in the Commonwealth of
Massachusetts.
!
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-i 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.
!
CAUTION
Chemicals used to during construction may cause
damage to the COLLECTION CELL.
18-CD25D1-2 3
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.
WARNING
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
!
WARNING
Do NOT install the Furnace directly on carpeting, tile or
other combustible material other than wood flooring.
!
CAUTION
Do NOT install the Furnace in a corrosive or contaminated atmosphere.
Failure to follow this warning 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.
4. Are there at least 3 inches of clearance between the
Furnace combustion air openings in the front panel
and any closed panel or door provided?
5. Are the ventilation and combustion air openings
large enough and will they remain unobstructed? If
outside air is used, are the openings set above the
highest snow accumulation level? (See the Air for
Combustion and Ventilation section, page 8)
6. A heavy gauge steel plate is attached to the
bottom of the unit for protection during shipping and handling prior to the unit installation. Leave this plate in place until the unit is
ready to be connected to the ductwork.
7. A Pre-filter is
the furnace containing a Whole House Air Cleaner. If the use of a Pre-Filter is desired, it must be
installed at least 6" away from the Whole House
Air Cleaner. The additional pressure drop of the
Pre-Filter must be considered during duct design
or evaluation to ensure proper airflow.
8. 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.
9. A Furnace shall be installed so electrical components are protected from water.
10. DO NOT use silicon based sealant in the airstream.
This causes a coating on the FIELD CHARGER pins
that will decrease the efficiency of the air cleaner.
11. Allow a minimum of 24 inches clearance in front of
the air cleaner to permit removal of COLLECTION
CELL and FIELD CHARGER.
12. Do Not install furnace where the air cleaner can be
exposed to UV light.
not required to be installed with
4 18-CD25D1-2
Installer’s Guide
NOTE: Do NOT install an atomizing style humidifier in
the return plenum of this unit.
13. Flow-through Bypass Humidifiers
Excessive bypass air may cause water blow-off,
which will adversely affect system operation and air
cleaner performance. To verify bypass airflow, follow the Bypass Humidifier Pre-Installation Checkout and Set-Up Procedures available through your
local distributor. Ask for publication number 18CH37D1-1.
Steam and Flow-through Fan Power Ductmounted Humidifiers
Follow the humidifier installation instructions.
These should only be installed on the supply air
side of the system.
Other Duct Mounted Humidifiers are not recommended for installation with the air
cleaner.
Figure 1. COMPONENTS OF THE INTEGRATED WHOLE HOUSE AIR CLEANER
14. 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.
15. The whole house air cleaner is designed to run at a
maximum indoor relative humidity of 65%.
1
Components of the integrated Whole House Air Cleaner:
1) FIELD CHARGER - Charges the contaminants
2) COLLECTION CELL - removes and collects very small
impurities from the air.
3) Power Supply - the solid state power supply converts
the 24 Volt AC to the high-voltage, direct current required
to power the FIELD CHARGER and COLLECTION CELL.
Check carefully for any shipping damage. This must
be reported to and claims made against the transportation company immediately. Check to be sure all
major components are in the unit. Any missing parts
should be reported to your supplier at once, and
replaced with authorized parts only.
3
2
18-CD25D1-2 5
Installer’s Guide
(ALL DIMENSIONS ARE IN INCHES)
*UX2 UPFLOW/ HORIZONTAL OUTLINE DRAWING
6 18-CD25D1-2
Installer’s Guide
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INSTALLATION INSTRUCTIONS
!
CAUTION
Bottom panel for furnace to remain in place until
unit reaches final installation location. If bottom
panel is removed before installation the COLLECTION CELL and FIELD CHARGER must also be removed to protect installation personnel.
!
CAUTION
Remove the COLLECTION CELL and remove and discard the cardboard over the cell.
NOTE: No sheetmetal screws may be used from 0-4"
from the bottom of the unit. Screws will interfere with
the Air Cleaner. See Figure 4.
REMOVING THE BOTTOM PLATE
a. Once the furnace is in place, remove the two screws
located at the front bottom corners of the furnace.
b. Lean the furnace back slightly and remove the bot-
tom panel.
c. Replace the two screws removed in step a.
REMOVING THE COLLECTION CELL
AND FIELD CHARGER
When COLLECTION CELLS and FIELD CHARGER
must be removed, follow the steps below.
a. Remove the lower furnace door.
b. Remove the four screws holding the inner blower
panel and remove panel. Set aside in a safe place
until the unit is set in place and ready to start up.
d. Remove the COLLECTION CELL by sliding for-
ward.
TION CELL and discard. Set aside in a safe place
until the unit is set in place and ready to start up.
e. Disconnect the Green return wire and the Red high
voltage wire. Twist and pull the connector on the
Red wire to release.
f. Remove the two hold down screws on the bottom of
the FIELD CHARGER and retain.
g. Remove the Field Charger. Set aside in a safe place
until the unit is set in place and ready to start up.
h. Set furnace in place. Repeat step a-g in reverse or-
der. Do Not put cardboard back in furnace. Inner
blower door MUST be put back into place.
UPFLOW INSTALLATION
Standoffs and screws (See Figure 2) 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.
Remove the cardboard from the COLLEC-
C
UPFLOW
FURNACE
A
S
E
D
C
O
IL
SCREWS
(BOTH SIDES)
STANDOFFS
(BOTH SIDES)
FOR VERTICAL
STANDOFFS (4)
DRILL SCREWS (4)
Figure 2
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).
IMPORTANT:
The 2/4TXC cased coil must be placed downstream of the
furnace. In horizontal installations, the apex of the coil
may point either toward or away from the furnace. See
the 2/4TXC coil Installer's Guide for more details.
The cased coil is secured to the Furnace and both the
Furnace and the cased coil must be properly supported.
The brackets mount using the rear screws on the coil
case and use the screws provided to secure the bracket
to the Furnace. The remaining bracket is placed as
close to center as possible (horizontally) between the
coil case front and the upflow Furnace, converted to
horizontal, aligns and attaches to the TXC coil. However, 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 3 & Clearance
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.
Figure 3
UPFLOW/
HORIZONTAL
SHOWN WITH
DIRECT VENT
18-CD25D1-2 7
Installer’s Guide
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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.
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.
NOTE: No sheetmetal screws may be
used from 0-4" from
the bottom of the
unit. Screws will interfere with the air
cleaner.
2. Attach flanges 1, 2, and 3 (Fig 7) to the unit using
the factory provided screws and the pre-drilled
holes in the wrapper. Flanges 1 and 2 are the
23.5" flanges that are generic to all units. Flange
3 will be one of two short flanges and the length
of which is dependent on the cabinet size.
3. Attach flange 4 (Fig 7) to the duct work (Flanges
should be inside duct work). Flange 4 is the
remaining short flange.
4. Place duct work with single flange over the
flanges that are currently attached to the unit
5. Attach duct work to remaining 3 flanges.
6. Attach the front flange from step 3 to the unit by
drilling 1/8" holes into the bottom channel. Use
the factory provided 5/16" blunt tip screws to
attach.
7. Use field supplied material to make an adequate
seal.
DO NOT use silicon based sealant in the
airstream.
Figure 5: Horizontal Left
Figure 4
NOTE: Do NOT install screws to the bottom of the
unit except with Duct Flanges and Screws provided.
GUIDE FOR THE INSTALLATION OF DUCT FLANGES
Failure to use pre-drilled holes and the factory
provided screws can potentially damage air cleaner
components.
Materials
• Duct Flanges
Two 23.5" Flanges
Two Additional Flanges
15.92" (for 17.5" cabinet)
19.42" (for 21" cabinet)
21.92" (for 24.5" cabinet)
• Screws
Eight 5/16" Blunt Tip Screws with 5/16" Hex
Head
Steps
1. See Figures 5, 6, and 7 for flange orientation.
"
!
CAUTION
Use pre-drilled
holes
1
4
Figure 6: Bottom View - Pre-drilled holes
Use predrilled
holes
3
2
Use predrilled
holes
8 18-CD25D1-2
1
3
4
2
Figure 7: Bottom View Flange Attachment
Tab le 1
Minimum Clearance to Cumbustible Materials
Upflow Closet
Left Side 0 inches Front 3 inches (note 1)
Right Side 0 inches Back 0 inches
Flue 6 inches * Top 1 inch
Horizontal Closet
(see note 2)
Top 2 inches Back 3 inches
Flue 6 inches * Sides 1 inch
Front 18 inches (note 1)
Horizontal Alcove
(see note 2)
To p 1 i n c h B a c k 0 i n c h e s
Flue 6 inches Sides 0 inches
Front 18 inches
* May be 1" when type B-1 vent is used
NOTES:
1) Minumum clearance to front on *UD2D120 is 6 inches
2) May be installed on combustible floor when type B-1 vent is used.
AIR FOR COMBUSTION AND VENTILATION
Adequate flow of combustion and ventilating air must
not be obstructed from reaching the Furnace. Air openings provided in the Furnace casing must be kept free
of obstructions which restrict the flow of air. Airflow restrictions affect the efficiency and safe operation of the
Furnace. Keep this in mind should you choose to remodel or change the area which contains your Furnace.
Furnaces must have a free flow of air for proper performance.
Installer’s Guide
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.
Furnace locations may be in “confined space” or “unconfined space”. Unconfined space is defined in Table 2 and
Figure 8. 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.
UNCONFINED
50 CU. FT. OR MORE
PER 1000 BTU/ HR. INPUT
ALL EQUIP. INSTALLED
Figure 8
TABLE 2
MINIMUM AREA IN SQUARE FEET
FOR UNCONFINED SPACE INSTALLATIONS
FURNACE
MAXIMUM BTUH
INPUT RATING
60,000
80,000
100,000
120,000
140,000
All air from inside the building as in Figure 10: The
1.
confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an
unconfined space. The total input of all gas utilization equipment installed in the combined space
shall be considered in making this determination.
Refer to Table 3, for minimum open areas required.
2.
All air from outdoors as in Figure 11: The confined
space shall be provided with two permanent openings, one commencing within 12 inches of the top
and one commencing within 12 inches of the bottom of the enclosure.
The openings shall communicate directly, or by
ducts, with the outdoors or spaces (crawl or attic)
that freely communicate with the outdoors. Refer to
Table 3, for minimum open areas required.
WITH 8 FT. CEILING
MINIMUM AREA IN SQUARE
FEET OF UNCONFINED SPACE
375
500
625
750
875
18-CD25D1-2 9
Installer’s Guide
CONFINED
LESS THAN 50 CU. FT.
PER 1000 BTU/ HR. INPUT
ALL EQUIP INSTALLED
Figure 9
Air
From
Inside
100
100
100
120
140
TABLE 3
Air From Outside
Vertical
Duct
15
20
25
30
35
Horizontal
Duct
30
40
50
60
70
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 9. Air for
combustion and ventilation requirements can be supplied from inside the building as in Figure 10 or from
the outdoors, as in Figure 11.
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
* 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
DUCT CONNECTIONS
Air duct systems should be installed in accordance with
standards for air conditioning systems, National Fire
Protection Association Pamphlet No. 90. They should
be sized in accordance with ACCA Manual D or whichever is applicable.
Central Furnaces, when used in connection with cooling
units, shall be installed in parallel or on the upstream
side of the cooling coil to avoid condensation in the heat
exchanger. With a parallel flow arrangement, the dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering the Furnace,
and if manually operated, must be equipped with means
to prevent operation of either unit unless the damper is
in full heat or cool position.
On any job, flexible connections of nonflammable material
may be used for return air and discharge connections to
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, 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.
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 Fur-
nace cabinet.
Bottom Return Only
NOTE: Minimum return air temperature is 55° F.
NOTE: Extended warranties are not available in some
instances. Extended warranty does not cover repairs to
equipment installed in establishments with corrosive
NOTE: No sheetmetal screws may be used from 0-4"
from the bottom of the unit. Screws will interfere with
the air cleaner. See Figure 4.
atmospheres, including but limited to, dry cleaners,
beauty shops, and printing facilities.
10 18-CD25D1-2
Installer’s Guide
▲
Figure 10
Figure 11
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.
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 manufacturers installation instructions to help alert dwelling occupants of the presence of fire, smoke or unsafe levels of carbon monoxide.
These devises 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.
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.
GENERAL VENTING
THIS 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.
18-CD25D1-2 11
Installer’s Guide
The recommended system is assembled from 2", 2-1/2",
or 3" plastic pipe and fittings (See Table 4, page 12).
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
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 gas-burning 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.
the
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.
NOTE: BAYVENT200* accessories can be used for inlet
and outlet terminals when the pipes do not exit the
structure together.
For NON-DIRECT VENT APPLICATION: The Fur-
nace 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
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 14.
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.
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 4 are 2" and 3" size fittings 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.
12 18-CD25D1-2
ent
V
Air
Inlet
Furnace
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 1). 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
Installer’s Guide
EX. 4 —
The inlet air does not have to come from outside the
structure. Example 4 shows the inlet air (See Note 1),
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.
Attic
Vent
s
Air
Inlet
(See Note)
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.
V
Air
ent
Inlet
Furnace
Furnace
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.
18-CD25D1-2 13
Installer’s Guide
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 12.
TABLE 4
PVC VENT FITTING MATERIAL These fittings are available from your Gas Furnace Distributors.
NOTE: Vent termination kit BAYAIR30AVENTA or
BAYVENT200B may be used in addition to the horizontal and vertical termination options shown in the following figures.
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, listed by a nationally recognized
agency (e.g. Underwriters Laboratories or International
Approval Services), to help alert dwelling occupants of
the presence of fire, smoke or unsafe levels of carbon
monoxide.
NOTE: The manufacturer of your furnace does not test
any detectors and makes no representations regarding
any brand or type of detector.
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)]
14 18-CD25D1-2
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