Trane UHMB060ACV3VB, UHMD120ACV5VB, DHMB060BCV3VB, DHMB080ACV3VB, DHMC100ACV4VB Installer's Manual

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Page 1

18-CD30D1-12

Installer’s Guide

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

*UHMB060ACV3VB *UHMB080ACV3VB *UHMC100ACV4VB *UHMD120ACV5VB

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

*DHMB060BCV3VB *DHMB080ACV3VB *DHMC100ACV4VB *DHMD120BCV5VB

*DHM

* First letter may be “A” or “T"

DOWNFLOW

UPFLOW

UPFLOW/HORIZONTAL

1. Safety signal words are used to designate a degree or level of seriousness associated with a particular hazard.

2. The signal words for safety markings are WARNING, and CAUTION.

3. a. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

4. 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

Page 2

Installer’s Guide

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

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

1. Seal any unused openings in the venting system.

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

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

4. Close fireplace dampers.

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

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

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

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

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

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

▲

WARNING

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

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

Hazardous Gases!

Exposure to fuel substances or by-products of incomplete fuel combustion is believed by the state of California to cause cancer, birth defects, or other reproductive harm.

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WARNING

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WARNING

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CAUTION

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WARNING

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WARNING

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.

SAFETY SECTION

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.

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.

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.

Page 3

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CAUTION

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WARNING

▲

WARNING

▲

CAUTION

▲

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.

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 .

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.

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.

Installer’s Guide

Contents

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

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 ................................................................................ 46

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

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.

18-CD30D1-12 3

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.

continued on page 6

Page 4

Installer’s Guide

(ALL DIMENSIONS ARE IN INCHES)

*UHM-ACV OUTLINE DRAWING

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

MODEL

(SEE NOTE 1)

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

*UHMB060ACV3VB

*UHMB080ACV3VB

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.

*UHMC100ACV4VB 21" 2-1/2" 19-3/4" 19-1/2" 9" 3"

*UHMD120ACV5VB 24-1/2" 2-15/16" 23-1/4" 23" 10" 3"

4 18-CD30D1-12

Page 5

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)

*DHMB080ACV3VB

*DHMB060BCV3VB

*DHMC100ACV4VB 21" 2-1/2" 19-3/4" 19-1/2"

*DHMD120BCV5VB 24-1/2" 2-15/16" 23-1/4" 23"

18-CD30D1-12 5

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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 only when the following conditions have been met:

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

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

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

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

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

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

g. Clean the Furnace, duct work, and components upon substantial completion of the construction process, and verify Furnace operating 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.

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 provided in this document?

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-CD30D1-12

Page 7

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WARNING

SAFETY HAZARD

UPFLOW

FURNACE

CASED

COIL

SCREWS

(BOTH SIDES)

STANDOFFS

(BOTH SIDES)

STANDOFFS (4)

DRILL SCREWS (4)

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.

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.

FOR VERTICAL

INSTALLATIONS:

Installer’s Guide

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 position. 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

DOWNFLOW ONLY

A (width)

FURNACE

FRONT

TABLE 1

CABINET

WIDTH

17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"

21" 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8"

24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8"

RETURN

DUCT WIDTH

FLOOR OPENING PLENUM OPENING

B (depth)

"A" "B"

"C" "D"

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.

18-CD30D1-12 7

Page 8

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 open ings 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 con sidered to avoid unsatisfactory furnace operation.

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

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:

1. * Commercial buildings

2. * Buildings with indoor pools

3. * Furnaces installed in “conﬁned” laundry rooms

4. * Furnaces installed in “conﬁned” hobby or craft rooms

5. * Furnaces installed near chemical storage areas.

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

1. * Permanent wave solutions

2. * Chlorinated waxes and cleaners

3. * Chlorine based swimming pool chemicals

4. * Water softening chemicals

5. * Deicing salts or chemicals

6. * Carbon Tetrachloride

7. * Halogen type refrigerants

8. * Cleaning solvents (such as perchloroethylene)

9. * Printing inks, paint removers, varnish, etc.

10. * Hydrochloric acid

11. * Cements and glues

12. * Antistatic fabric softeners for clothes dryers

13. * 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

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE MAXI-

MUM BTUH INPUT

RATING

60,000

80,000 100,000 120,000

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE FEET

OF UNCONFINED SPACE

375 500 625 875

UNCONFINED

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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.

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

2. All air from outdoors as in Figure 9: The conﬁned space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 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-CD30D1-12 9

Air From Outside

Horizontal

15 20 25 30

Duct

30 40 50 60

Page 10

Installer’s Guide

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CAUTION

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

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.

NOTE: Minimum return air temperature is 55°F.

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.

UPFLOW FURNACE ONLY

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.

CUT OUT FOR SIDE FILTER

FRONT of Furnace

10 18-CD30D1-12

Page 11

Rotate the channel downward (or remove by lowering

VIEW

ENGAGEMENT

HOLE DETAIL

(Typical both sides and blower deck)

Blower Deck Engagement

Hole

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 con nectors are recommended to connect both supply and return air ducts to the furnace. If only the front of the furnace is accessible, it is recommended that both supply and return air plenums are removable.

RETURN AIR FILTERS

TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS

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

*UHMB060BCV3VB *UHMB080ACV3VB

*UHMC100ACV4VB 21" 1 - 20" X 25" X 1"

*UHMD120BCV5VB 24-1/2" 1 - 24" X 25" X 1"

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

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

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.

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-CD30D1-12 11

Page 12

Installer’s Guide

Bottom Panel

Filter Rack

Furnace

Cabinet

Side

Filter Rack Retaining Screw/Pin

Engagement Hole

For

Bottom Return

Filter Rack

Installation With

RETAINING

(Both Sides)

SPRINGS

SIDE

CUTOUT

FILTER

RACK

RAILS

BOTTOM

PANEL

INSTALLED

Airflow

RETAINING

(Both Sides)

SPRINGS

SIDE

CUTOUT

FILTER

RACK

RAILS

BOTTOM

PANEL

INSTALLED

Airflow

Filter Rack

Furnace

Cabinet

Side

Filter Rac

k Retaining Screw/Pin

Engagement Hole For

Bottom Return

Filter Rack

Installation With

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

Typical Upﬂow Left Side Return Filter Rack Installation

12 18-CD30D1-12

SIDE ENGAGEMENT

Typical Upﬂow Right Side Return Filter Rack Installation

Page 13

Filter Rack Assembly

Furnace Blower Deck

Filter Rack Retaining Screw/Pin

Engagement Hole For

Return

Filter Rack Installation With Side

Furnace

Cabinet

Side

CHAMFER

END OF

FILTER GOES

INTO FILTER RACK FIRST

SIDE

CUT-OUT

ALTERNATE SIDE

FILTER CLIPS

LOCATIONS

ALTERNATE BOTTOM

FILTER CLIPS LOCATIONS

BLOWER DECK

Airflow

Installer’s Guide

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. See Figure 20.

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 predrilled. 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.

Accessory ﬁlter kit BAYFLTR203, 204, or 205 used for Upﬂow Horizontal furnaces.

Typical Horizontal Filter Installation

Table 4A CONVERSION KITS FOR HORIZONTAL FILTERS

MODEL NUMBERS

*UHMB060ACV3VB *UHMB080ACV3VB

*UHMC100ACV4VB

*UHMD120ACV5VB

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

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

18-CD30D1-12 13

CABINET

WIDTH

17-1/2" BAYFLTR203

21" BAYFLTR204

24-1/2" BAYFLTR205

Airﬂow

CONVERSION

KIT NUMBER

Page 14

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.

UNIT SIZE

TABLE 5

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

*DHMB060BCV3VB *DHMB080ACV3VB

*DHMC100ACV4VB 21" 2 - 16" X 20" X 1"

*DHMD120BCV5VB 24-1/2" 2 - 16" X 20" X 1"

*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"

TABLE 7

DIMENSION

"A"

DIMENSION

FILTER

QTY & SIZE

"B"

FILTER

BRACKET

LOCATION*

DOWNFLOW

Airﬂow

TABLE 8

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/ HORIZONTAL FURNACES

FURNACE SURFACE

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

VERTICAL

CLOSET

DOWNFLOW/ HORIZONTAL

Airﬂow

UNIT LOCATION

HORIZONTAL

CLOSET

HORIZONTAL

ALCOVE / ATTIC

14 18-CD30D1-12

Page 15

GENERAL VENTING INFORMATION

▲

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.

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.

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

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

▲

WARNING

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

#CPL00938

LABEL SAYS "TOP"

STRAIGHT SIDE MUST BE ON BOTTOM FOR PROPER CONDENSATE DRAINAGE.

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.

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.

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 and water tight.

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

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

18-CD30D1-12 15

Installer’s Guide

Page 16

Installer’s Guide

▲

WARNING

▲

WARNING

Furnace

Air Inlet

Vent

2" TO 3" COUPLING

FURNACE VENT OUTLET

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

#CPL00938

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.

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 gasburning 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 Devices, CSA 6.19

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

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

result in carbon monoxide poisoning or death.

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 ex. 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.

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-CD30D1-12

Page 17

Installer’s Guide

Furnace

Air

Inlet

Vent

Attic Vent

(See Note)

Furnace

Air Inlet

Vent

Furnace

Vent

Air

Inlet

(See Note)

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.

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.

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.

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.

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-CD30D1-12 17

Page 18

Installer’s Guide

KIT02281

KIT02282

Seal VENT PIPE with RTV sealant

Seal INLET AIR PIPE

with RTV sealant

Front of Furnace

TABLE 9

PVC VENT FITTING MATERIAL These ﬁttings are available from your Gas Furnace Distributors for U.S. appli-

cations only.

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)]

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.

IMPORTANT:

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

18 18-CD30D1-12

VENT AND INLET AIR CONNECTIONS

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.

Page 19

Installer’s Guide

ALTITUDE

NATURAL GAS PROPANE NATURAL GAS PROPANE NATURAL GAS PROPANE

UHMB060ACV3V DHMB060BCV3V

200 Not Allowed 200 Not Allowed 200 150

UH/DHMB080ACV3V 50 Not Allowed 120 Not Allowed 200 150 UH/DHMC100ACV4V Not Allowed Not Allowed 60 Not Allowed 200 150

DHMD120BCV5V

UHMB060ACV3V DHMB060BCV3V

UH/DHMB080ACV3V UH/DHMC100ACV4V

DHMD120BCV5V

UHMB060ACV3V DHMB060BCV3V UH/DHMB080ACV3V

UH/DHMC100ACV4V

DHMD120BCV5V

Not Allowed Not Allowed Not Allowed Not Allowed 200 100

NATURAL GAS PROPANE NATURAL GAS PROPANE NATURAL GAS PROPANE

100 Not Allowed 100 Not Allowed 100 100

25 Not Allowed 60 Not Allowed 100 100

Not Allowed Not Allowed 30 Not Allowed 100 100

Not Allowed Not Allowed Not Allowed Not Allowed 100 50

NATURAL GAS PROPANE NATURAL GAS PROPANE NATURAL GAS PROPANE

50 Not Allowed 50 Not Allowed 50 38

Not Allowed Not Allowed 30 Not Allowed 50 38 Not Allowed Not Allowed Not Allowed Not Allowed 50 38

Not Allowed Not Allowed Not Allowed Not Allowed 50 25

Notes: * - First letter may be "A" or "T", ** - Last two digits may be "A" thru "Z"

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

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

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

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

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

6. Pipe adapters are field supplied. Downflow models, UHM 100 and UHM 120 models include the 2" x 3" adapter.

3 or 4 INCH PIPE

3 or 4 INCH PIPE2.5 INCH PIPE2 INCH PIPE

VENT LENGTH TABLE - MODULATING FURNACE

0-7000 Feet

7000-9500 Feet

9500-12000 Feet

3 or 4 INCH PIPE2.5 INCH PIPE2 INCH PIPE

2 INCH PIPE 2.5 INCH PIPE

MAXIMUM TOTAL EQUIVALENT LENGTH IN FEET FOR VENT AND INLET

AIR (SEE NOTES)

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

UHMD120ACV5V

Not Allowed Not Allowed Not Allowed Not Allowed 200 150

Not Allowed Not Allowed Not Allowed Not Allowed 100 100

Not Allowed Not Allowed Not Allowed Not Allowed 50 38

TABLE 10

Connection of the vent pipe to the vent collar should also be accomplished using RTV type sealant. This type sealant provides a connection which remains ﬂexible and can be separated in the future if service needs require the removal of the Vent Pipe for service or clearance.

The vent length Table 10 above shows the required vent lengths for installations at various altitudes. Optional high altitude kits are available for installations above 5000 feet (Installations above 12,000 feet are not allowed) as follows:

18-CD30D1-12 19

For *UHM/DHMB060 use BAYSWT07AHALTA.

For *UHM/DHMB080, C100 use BAYSWT09AHALTA.

For *UHM/DHMD120 use BAYSWT08AHALTA.

For Canadian applications, use the appropriate tables in the latest edition of the National Fuel Gas Code (ANSI

Z223.1 • CAN/CGA B149.1 Installation Codes or “Exhibit J” of ANSI Z21.47 • CAN/CGA-2.3 Standards. “Exhibit

J” includes examples and drawings of typical venting systems.

Page 20

Installer’s Guide

▲

CAUTION

9" MINIMUM

▲

WARNING

CARBON MONOXIDE POISONING HAZARD DO NOT REPLACE ANY OF THE FACTORY SUPPLIED VENTING COMPONENTS WITH FIELD FABRICATED PARTS. FAILURE TO FOLLOW THIS SAFETY WARNING EXACTLY COULD RESULT IN DAMAGED VENTS, DAMAGED COMPONENTS, CARBON MONOXIDE POISONING, OR DEATH.

HORIZONTAL VENTING

NOTE: Vent termination kit BAYAIR30AVENTA or BAYVENT200B may be used in addition to the horizontal and vertical termination options shown in Figure 26. See Figure 31. For Canadian applications ONLY: IPEX 196006 may be used for horizontal and vertical terminations. IPEX 081216, IPEX 081218, and IPEX 081219 may only be used for horizontal vent terminations.

When the vent pipe is exposed to temperatures below freezing, i.e., when it passes through unheated spaces, etc., the pipe must be insulated with 1/2 inch (22.7 mm) thick Armaﬂex-type insulation or equal. If the space is heated sufﬁciently to prevent freezing, then the insulation would not be required. If domestic water pipes are not protected from freezing then the space meets the condition of a heated space.

VENTING THROUGH THE ROOF

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

NOTE: No Vent Cap as shown in Figure 35 is the preferred method for vertical Vent Termination in extremely cold climates. In extreme climate conditions, insulate the exposed pipe above the roof line with Armaﬂex type insulation.

ELBOW AND TEE MUST BE AS CLOSE TOGETHER AS POSSIBLE

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

20 18-CD30D1-12

Page 21

Installer’s Guide

6" Min.

40 Inch Upflow or Downflow

Furnace

Slope 1/4" per ft.

▲

CAUTION

HORIZONTAL VENTING THROUGH WALL

IMPORTANT:

The building owner/maintenance provider must keep the area around the vent clear from snow. These furnaces may be installed as direct vent (as shipped) or as non-direct vent. Installation must conform to national, state, and local codes.

The vent & inlet terminals must be located at least 12" minimum above normally expected snow accumulation level. See Figure 29.

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

Location of the vent/ wind terminal should be chosen to meet the requirements of Figure 30 and Tables 11 and 12 for either direct or non-direct vent applications.

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

FLUE GAS DEGRADATION – The moisture content of the ﬂue gas may have a detrimental effect on some building materials. This can be avoided by using the roof or

chimney venting option. When wall venting is used on any surface that can be affected by this moisture, it is recommended that a corrosion resistant shield (24 inches square) be used behind the Vent Terminal. This shield can be wood, plastic, sheet metal, etc. Also, silicone caulk all cracks, seams and joints within 3 feet of the Vent Terminal.

The vent for this appliance shall not terminate

(1) Over public walkways; or

(2) Near sofﬁt vents or crawl space vents or other ar-

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

(3) Where condensate vapor could cause damage or

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

NOTES:

A) Condensate trap for Vent Pipe must be a minimum of 6 inches in height. B) Condensate trap for Vent and Inlet Pipe must be connected into a condensate drain pump; an open or vented

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

DOWNWARD VENTING

Furnace may be in vertical or horizontal conﬁguration.

All horizontal pipes must be

supported at a maximum of

3 foot intervals

DOWNWARD VENT

LENGTH IS LIMITED

TO A MAXIMUM OF

15 EQUIVALENT

FEET.

drain; or it can be connected to the outlet hose of the Furnace's condensate trap. Outdoor draining of the Furnace and coil condensate is permissible if allowed by local codes. Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants.

18-CD30D1-12 21

Page 22

Installer’s Guide

IMPORTANT:

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows:

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

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasﬁtter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the ﬂoor level where the gas equipment is to be installed. In addition, the installing plumber or gasﬁtter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualiﬁed licensed professionals for the installation of hard wired carbon monoxide detectors a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery backup may be installed on the next adjacent ﬂoor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁed. The manufacturer of the furnace does not test any carbon monoxide detectors and makes no representation regarding any brand of carbon monoxide detector.

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

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. This appliance requires a special venting system. If BAYAIR30AVENTA or BAYVENT200B are used, a copy of the installation instructions for the kit shall remain with the appliance or equipment at the completion of installation. The venting system installation instructions can be obtained from the manufacturer by writing to the following address:

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

IMPORTANT:

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

22 18-CD30D1-12

Page 23

Installer’s Guide

VENT

COMBUSTION AIR

VENT

VENT PLATE

VENT CAP

12" MINIMUM TO OVERHANG

MAINTAIN 12" MINIMUM CLEARANCE

ABOVE HIGHEST ANTICIPATED SNOW LEVEL

OR GRADE WHICHEVER IS GREATER

SCREWS (4 req.)

ANCHORS (4 req.)

7.2"

3.2"

COMBUSTION AIR

12" MIN TO OVERHANG

1" + "

VENT

MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SHOW LEVEL OR GRADE WHICH EVER IS GREATER

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

FIXED

CLOSED

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

OPERABLE

BAYVENT200B

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

;

HORIZONTAL VENT CLEARANCES

(See clearance tables 11 and 12 on page 24)

BAYAIR30AVENTA

(Side wall)

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

CONCENTRIC VENT

SIDE WALL INSTALLATION

VENT FITTING MATERIAL – STAINLESS STEEL

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

These ﬁttings and ﬁtting accessories are to be supplied locally.

18-CD30D1-12 23

DIRECTION OF STAINLESS STEEL FITTING

All stainless steel ﬁtting must be installed with male end towards the Furnace. All horizontal stainless steel sections must be positioned with the seam on top. All long horizontal sections must be supported to prevent sagging. All pipe joints must be fastened and sealed to prevent escape of combustion products into the building.

Page 24

Installer’s Guide

Table 11 Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch, deck,

or balcony

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

B= Clearance to window or door that may be opened

C= Clearance to permanently closed window * *

Vertical clearance to ventilated sofﬁt located

above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

E= Clearance to unventilated sofﬁt * *

F= Clearance to outside corner * *

G= Clearance to inside corner * *

Clearance to each side of center line extended above

meter/regulator assembly

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

Clearance to nonmechanical air supply inlet to building or

the combustion air inlet to any other appliance

K= Clearance to a mechanical air supply inlet 6 feet (1.83m)

Clearance above a paved sidewalk or paved driveway

located on public property

M= Clearance under veranda, porch, deck, or balcony 12 inches (30 cm) ‡ *

Notes:

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

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

Table 12 Direct Vent Terminal Clearances

Clearance above grade, veranda, porch, deck,

or balcony

Clearance to window or door that may be

opened

C= Clearance to permanently closed window * *

Vertical clearance to ventilated sofﬁt located above the terminal within a horizontal distance

of 2 feet (61 cm) from the center line of the terminal

E= Clearance to unventilated sofﬁt * *

F= Clearance to outside corner * *

G= Clearance to inside corner * *

Clearance to each side of center line extended

above meter/regulator assembly

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

Clearance to nonmechanical air supply inlet to

building or the combustion air inlet to any other appliance

Clearance to a mechanical

air supply inlet

Clearance above a paved sidewalk

or paved driveway located on public property

Clearance under veranda,

porch, deck, or balcony

Notes:

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

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

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

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

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

Canadian Installations US Installations

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

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

regulator assembly

7 feet (2.13 m) † *

12 inches (30 cm) ‡ *

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

4 feet (1.2m) below or to the side of opening; 1 foot

* *

the meter/regulator assembly

7 feet (2.13 m) † 7 feet (2.13 m)

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

* *

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

6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally

(0.3m) above opening.

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

1 foot (300 m) above opening

3 feet (91 cm) above if within

10 feet (3m) horizontally

Page 25

Installer’s Guide

COUPLING (PLASTIC VENTING)

STUD

PVC WALL MOUNT FLANGE (OPTIONAL)

APPROVED TERMINATION

1” CLEARANCE (AIR SPACE)

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

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

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

6 IN. MIN. (TO JOINT)

COUPLING (PLASTIC VENTING)

PVC WALL MOUNT FLANGE (OPTIONAL)

APPROVED TERMINATION

CEMENT MORTAR SEAL INSIDE & OUTSIDE

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

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

6 IN. MIN. (TO JOINT)

3" PIPING

2", 2-1/2"

or 3" PIPING

REDUCING COUPLING, FIELD SUPPLIED IF NEEDED

SEAL ALL

WALL CAVITIES

RAIN CAP

COMBUSTION AIR

STRAP (FIELD SUPPLIED)

COMBUSTION AIR

VENT

ELBOW (FIELD SUPPLIED)

VENT

1" + 1/2"

STRAPS OR OTHER SUITABLE SUPPORTS AT A MAXIMUM OF 3' 0" INTERVALS

TEE

NOTE: VENT AND INLET MUST BE SUPPORTED AT A MAXIMUM OF 3' INTERVALS

BAYAIR30AVENTA

CONCENTRIC VENT

SIDE WALL INSTALLATION

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

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials must be maintained when using single wall stainless steel venting. See Figure 32. Shield material to be a minimum of 24 gauge stainless or aluminized sheet metal. Minimum dimensions are

12"x12". Shield must be fastened to both inside and outside of wall. Use screws or anchor type fasteners suited to the outside or inside wall surfaces.

18-CD30D1-12 25

BAYVENT200B

NONCOMBUSTIBLE MATERIAL WALL

The hole through the wall must be large enough to maintain pitch of vent and properly seal. Use cement mortar seal on inside and outside of wall. See Figure 33.

Page 26

Installer’s Guide

MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

VENT

COMBUSTION AIR

REMOVE RIBS FROM CAP

COMBUSTION AIR

ROOF BOOT (FIELD SUPPLIED)

COMBUSTION AIR

VENT

ELBOW (FIELD SUPPLIED)

MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF

SUPPORT (FIELD SUPPLIED)

VENT

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

SUPPORT HORIZONTAL PIPE EVERY

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

BAYAIR30AVENTA (VERTICAL)

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

26 18-CD30D1-12

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

CONCENTRIC VENT

ROOF INSTALLATION

CONCENTRIC VENT

ROOF TOP APPLICATION

Page 27

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

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

6 IN. MIN.

SEE CAUTION

STAINLESS STEEL VENT CAP (OPTIONAL)

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

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

6 IN. MIN.

STAINLESS STEEL VENT CAP (OPTIONAL)

SEE CAUTION

FLUE PIPE

COUPLING AS REQUIRED

FLUE PIPE

COUPLING TO SUPPORT PIPE FROM ANGLES OR OTHER SUITABLE SUPPORT METHOD

Installer’s Guide

IMPORTANT – Refer to Section 12.6.8 of NFPA 54 / ANSI 223.1 2012 when routing vent piping through a chimney.

IMPORTANT –

The single wall ﬂue pipe joints must be sealed. The 90° elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of

THROUGH UNUSED CHIMNEY

masonry chimney.

PVC PLASTIC VENTING

TYPE 29-4C STAINLESS STEEL VENTING

IMPORTANT – Refer to Section 12.6.8 of NFPA 54 / ANSI 223.1 2012 when routing vent piping through a chimney.

THROUGH UNUSED CHIMNEY

IMPORTANT – The single wall ﬂue pipe joints must be sealed. The 90° elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of masonry chimney.

18-CD30D1-12 27

Page 28

Installer’s Guide

▲

CAUTION

ELECTRICAL CONNECTIONS

Protect from Property Damage Do NOT connect the furnace line voltage to a GFCI protected circuit. Failure to follow this warning could result in property damage.

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

furnace control is polarity sensitive.

The hot leg of the 120V power supply must be connected to the Black power lead as indicated on the wiring diagram. Provision for hooking up an Electronic Air Cleaner and/ or Humidiﬁer is provided on the Integrated Control.

Refer to the Service Facts literature and unit wiring diagram attached to the furnace.

WHOLE HOUSE AIR CLEANER CONNECTION

NOTE: The B/C terminal will require three wires to be connected to the low voltage terminal strip. To make this easier, create a pigtail using a short length of thermostat wire to connect the three wires to the B/C terminal.

NOTE: *FD whole house air cleaners with "D" or later in the 14th digit of the model number must use the BAYACCECOMM101 kit when connected for 24 volt mode. *FD whole house air cleaners with "A", "B", or "C" in the 14th digit of the model number must use the BAYACCECOMM101 kit when connected for 24 volt or communicating modes. See the BAYACCECOMM101 Installer's Guide for ﬁeld wiring.

Field Wiring Diagrams

41A -Communicating Indoor Unit with Communicating Comfort Control and Communicating Outdoor Unit

28 18-CD30D1-12

Page 29

Installer’s Guide

41B - Communicating Indoor Unit with Communicating Comfort Control and 24VAC Single Stage Cooling

41C - 24 VAC Mode Indoor Unit with 24 VAC Comfort Control and 24VAC Single Stage Cooling

18-CD30D1-12 29

FIELD WIRING DIAGRAMS

Page 30

Installer’s Guide

Field Wiring Diagrams continued

41D - 24 VAC Mode Indoor Unit with 24 VAC Comfort Control and 24VAC 2-Stage or 2-Step Cooling

41E - 24 VAC Mode Indoor Unit with 24 VAC Comfort Control and 24VAC Single Stage Heat Pump

30 18-CD30D1-12

Page 31

Installer’s Guide

BK Jumper

41F - 24 VAC Mode Indoor Unit with 24 VAC Comfort Control and 24VAC 2-Stage or 2-Step Heat Pump

41G - Humidistat Hookup - 24 V Mode ONLY

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

HUMIDISTAT HOOKUP - 24 V ONLY

If an optional humidistat for humidity control in cooling is used, the factory installed "BK Jumper" must be cut.

The BK Jumper must also be cut if a multi-zone

controller is connected to *CONT402 is installed and using the BK enabled feature.

See the 24VAC ﬁeld wiring diagrams for mor information.

18-CD30D1-12 31

Page 32

Installer’s Guide

▲

CAUTION

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

To drain opening

If upflow furnace is installed over a finished ceiling, overflow from the primary drain vent stack must flow into an auxillary drain pan to prevent damage to the finished ceiling below.

CONDENSATE DRAIN INSTRUCTIONS

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

Evaporator and furnace condensate drain piping may be manifolded together. A primary drain vent stack must be installed and terminated below the outlet of the secondary heat exchanger drain connection to prevent water from damaging furnace controls if the primary drain outlet plugs up. Where the furnace is installed above a ﬁnished ceiling, the primary drain vent stack must be installed such that overﬂow from the vent stack opening will ﬂow into an auxiliary drain pan in order to prevent water damage to the ﬁnished ceiling below. See Figure 42.

VERTICAL APPLICATIONS

Upﬂow Vertical Furnace - The connection tubing for left

and right side drainage is shipped in the blower compartment. Install the connection tubing from the trap to the side of the unit and trim all excess tubing to avoid kinks. See Figures 43 & 44.

NOTE: The condensate trap must be primed before operation.

Condensate trap

Left side

Condensate

Trap

UPFLOW (VERTICAL)

Condensate

Trap

UPFLOW (VERTICAL)

Right side

32 18-CD30D1-12

Page 33

Installer’s Guide

Downﬂow Vertical Furnace - Downﬂow furnace - Use

RTV silicon sealant to connect the ﬁtting to the trap for ease of removal when cleaning the trap.

For left side drain a 1/2" slip PVC ﬁtting is needed. See Fig 45.

To change to a right side drain, remove the drain lines from the trap, rotate the trap 180° so it exits to the right, then reconnect the lines. Start with a 1/2" 90° CPVC street elbow connected to the trap using RTV silicon sealant. Run 1/2" CPVC pipe to a CPVC elbow. Run 1/2" CPVC pipe from the elbow out through the right side

knock-out. See Figure 46.

Left

side

The furnace trap must be repositioned to the exterior of the cabinet. Remove the trap from its present location and reposition the trap outside of the unit, through the long circular hole, next to the secondary recuperative cell. Remove the larger drain line (from the secondary cell) and trim to ﬁt between the secondary cell and the new trap location. On upﬂow units, plug the hole in the blower deck where the tube went through with factory supplied cap. Remove the hose from the induced blower and reposition into the other drain tap of the inducer, which is located 90° clockwise around the inducer. Move the cap from that drain tap to the unused drain tap. On upﬂow units, plug the hole in the blower deck where the tube went through with factory supplied cap.

DOWNFLOW (VERTICAL)

Right

side

DOWNFLOW (VERTICAL)

HORIZONTAL APPLICATIONS Upﬂow and Downﬂow Horizontal Furnaces - See

Figures 47 and 48. All horizontal applications are left side only. It is always recommended that the auxiliary drain pan be installed under a horizontally installed evaporator and/or 95% Gas Furnace. Connect the auxiliary drain pan to a separate drain line (no trap is needed in this line).

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

Use exten-

sion hose

here

UPFLOW HORIZONTAL 21" & 24" UNITS

(LEFT SIDE ONLY)

Use Inducer Drain

hose without

extension

UPFLOW HORIZONTAL 17" UNITS

(LEFT SIDE ONLY)

18-CD30D1-12 33

Page 34

Installer’s Guide

▲

CAUTION

▲

WARNING

▲

CAUTION

(

Cut off curved end of

Inducer drain hose

DOWNFLOW (HORIZONTAL)

This tube on downﬂow units will need to be cut to ﬁt between the Inducer and the trap. On upﬂow units, this tube may need to be extended, using the tubing shipped with the furnace.

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

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

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

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

IMPORTANT:

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

GAS PIPING

FIRE - EXPLOSION HAZARD DO NOT RUN FLEXIBLE GAS LINE THROUGH THE FURNACE CABINET WALL OR WITHIN THE FURNACE CABINET. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

Use a backup wrench on the Gas Valve when installing Gas Piping to prevent damage to the Gas Valve and Manifold Assembly.

The upﬂow/ horizontal furnace is shipped standard for left side installation of Gas Piping. A knockout is provided on the right side for an alternate Gas Piping arrangement. The installation of piping shall be in accordance with piping codes and the regulations of the local gas company. Pipe joint compound must be resistant to the chemical reaction with liqueﬁed petroleum gases. Flexible gas connections, if applied, must not be routed through the cabinet of the furnace. Refer to Natural Gas Piping Table 13 for delivery sizes.

NOTE: Refer to local codes and the National Fuel Gas Code, current edition, for gas pipe requirements.

The furnace and its individual shut-off valve must be disconnected from the Gas Supply Piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa). The furnace must be isolated from the Gas Supply Piping by closing its individual manual shut-off valve during any pressure testing of the Gas Supply Piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).

NOTE: Maximum pressure to the Gas Valve for natural gas is

13.8" W.C. Minimum pressure is 5.0" W.C. Maximum pressure to the Gas Valve for Propane is 13.8" W.C. Minimum pressure is 11.0" W.C.

TABLE 13

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE SIZE

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

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

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

10 20 30 40 50 60 70

1 520 350 285 245 215 195 180

LENGTH OF PIPE

NOTE: All supplied ﬂexible condensate piping is for internal use only. All condensate piping external to the unit must be CPVC or PVC piping.

34 18-CD30D1-12

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

WITH AN OPEN FLAME!

Page 35

Installer’s Guide

DRIP LEG

)

DRIP

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

UPFLOW MAY BE LEFT OR RIGHT HAND GAS PIPING

DRIP

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

DRIP

LEG

DRIP

LEG

IMPORTANT:

A sediment trap must be installed in the gas line before the furnace gas valve. The sediment trap must be located as close to the furnace cabinet as practical.

IMPORTANT:

A sediment trap must be installed in the gas line before the furnace gas valve. The sediment trap must be located as close to the furnace cabinet as practical.

THE DOWNFLOW (VERTICAL) MAY BE INSTALLED LEFT OR RIGHT SIDE GAS PIPING

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

DRIP LEG

AUTOMATIC GAS VALVE WITH MANUAL SHUT-OFF

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

(TYPICAL UPFLOW FURNACE IN HORIZONTAL CONFIGURATION SHOWN)

IMPORTANT:

A sediment trap must be installed in the gas line before the furnace gas valve. The sediment trap must be located as close to the furnace cabinet as practical.

18-CD30D1-12 35

Page 36

Installer’s Guide

▲

CAUTION

COMBUSTION AND INPUT CHECK

(SEE ALSO HIGH ALTITUDE DERATE)

NOTE: Before checking or adjusting the gas pressure, make sure the condensate trap has been primed.

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

2. Clock the Gas Meter with the furnace operating on high heat for one revolution. Table 18 shows the ﬂow rate in cubic feet per hour for a measured time of one revolution for a meter on which one revolution indicates 2 cubic feet per hour of gas ﬂow. For other meters, use the following conversions:

a. For 1 Cu. Ft. Dial Gas Flow CFH = Chart Flow

Reading ÷ 2

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

Reading ÷ 4

c. For 5 Cu. Ft. Dial Gas Flow CFH = 10X Chart Flow

Reading ÷ 4

3. Multiply the ﬁnal ﬁgure by the heating value of the

gas obtained from the utility company and compare to the nameplate rating. This must not exceed the nameplate rating.

4. Repeat steps 2 and 3 with the furnace operating on low heat.

5. Changes can be made by adjusting the manifold

pressure (See Table 15), or changing oriﬁces (oriﬁce change may not always be required).

HIGH ALTITUDE DERATE

CAUTION

Maintain manifold pressure as speciﬁed in Table 15 in high altitude installations. Failure to do so may result in poor ignition characteristics.

Input ratings (BTUH) of these furnaces are based on sea level operation and should not be changed at elevations up to 2,000 ft. (610m).

If the installation is 2,000 ft. (610m) or above, the furnace input rate (BTUH) shall be reduced 4% for each 1,000 ft. above sea level.

Installation of this furnace at altitudes above 2,000 ft. (610m) shall be in accordance with local codes, or in the absence of local codes, the National Fuel Gas Code,

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

The furnace input rate shall be checked by using the methods of Combustion and Input Check. High altitude kits are listed in Table 15A.

Table 15A

High Altitude Kit Used with Model:

BAYSWT07AHALTA *UHMB060ACV3V

*DHMB060BCV3V

TABLE 15

Furnace Input rate

(KBTU/hr)

60 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2 80 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

100 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

Downﬂow 120 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

Upﬂow 120 0.9 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2 For upﬂow 120KBTU/hr model, 1st stage is 45% Manifold pressures apply for Natural Gas applications ONLY

Furnace Input rate

(KBTU/hr)

60 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5 80 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

100 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

Downﬂow 120 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

Upﬂow 120 2.9 ± 0.5 Not Adjustable 10.0 ± 0.5

For upﬂow 120KBTU/hr model, 1st stage is 45% Manifold pressures apply for Propane applications ONLY

FINAL NG MANIFOLD PRESSURE SETTINGS (inches w.c.)

40% 65% 100%

FINAL LP MANIFOLD PRESSURE SETTINGS (inches w.c.)

40% 65% 100%

BAYSWT09AHALTA *UHMB080ACV3V

*DHMB080ACV3V *UHMC100ACV4V *DHMC100ACV4V

BAYSWT08AHALTA *UHMD120ACV5V

*DHMD120BCV5V

* May be "A" or "T"

36 18-CD30D1-12

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Installer’s Guide

If the desired input rate cannot be achieved with a change in manifold pressure, then the oriﬁces must be changed. See Table 16 for replacement oriﬁce part numbers.

LP installations will require an oriﬁce and gas valve change. Order kit BAYLPKT220B or BAYLPSS220B.

IMPORTANT:

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

See Table 17 for help in selecting oriﬁces if oriﬁce change is required. Furnace input rate and temperature rise should be checked again after changing oriﬁces to conﬁrm the proper rate for the altitude. The vent length table on page 19 shows the required vent lengths for installations at various altitudes. An optional high altitude kit is available for installations above 4000 feet (Installations above 12,000 feet are not allowed). Use Table 15A to select the appropriate high altitude kit for your furnace model.

TABLE 16

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

44 45 46 47 48 49 50 51

PART

NUMBER

ORF00501 ORF01427 ORF00909 ORF01429 ORF01099 ORF00503 ORF00493 ORF00494

DRILL

SIZE

52 53 54 55 56 57 58 59

PART

NUMBER

ORF00495 ORF00504 ORF00555 ORF00693 ORF01428 ORF00908 ORF01338 ORF01339

TABLE 17

Oriﬁce

Twist

Drill

Size If

Installed At Sea

2000 3000 4000 5000 6000 7000 8000 9000 10000

Level

42 43 44 45 46 47 48 49

50 51 52 53 54 55 56 57 58

42 44 45 46 47 48 49 50

51 51 52 54 54 55 56 58 59

From National Fuel Gas Code - Table F-4

ALTITUDE ABOVE SEA LEVEL

and Oriﬁce Required At Other Elevations

45 44 45 47 47 48 49 50

51 52 53 54 55 55 56 59 60

44 45 47 47 49 49 50

51 52 53 54 55 55 57 59 60

45 46 47 48 49 50 51

51 52 53 54 55 56 57 60 61

45 47 48 48 49 50 51

52 52 53 54 55 56 57 60 62

46 47 48 49 50 50 51

52 53 53 54 55 56 58 61 62

46 47 48 49 50 51 51 52

53 53 54 55 56 56 59 63 63

47 48 50 50 51 52 52 52

53 54 54 55 56 57 60 63 64

TABLE 18

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

8 900 29 248 50 144 82 88

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

Note: Natural gas input rate should be clocked at gas meter in high heat when the gas valve is replaced or gas valve pressure adjustments are made.

Table 19 lists the main burner oriﬁces used with the Furnace.

Table 19 ORIFICE SIZES

INPUT

RATING

BTUH

60,000

80,000 100,000 120,000

NUMBER

BURNERS

3 4 5 6

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 45 45 45

56 56 56 56

Note: The LP Conversion Kit used with the modulating furnace is BAYLPSS220B or BAYLPKT220B.

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Installer’s Guide

Heat Exchanger (Cold Header)

Burner Box

H-Fitting

Pressure Switch PS-1

Tee

Pressure Switch PS-3

Pressure Switch PS-2

Negative Control Pressure Post

Positive Control Pressure Post

Modulating Gas Valve

Orifice in H fitting must be pointing away from PS1

To Pressure Switch PS-1

! Important !

Brass orifices located in these two legs.

H-Fitting must be installed in this orientation.

VACUUM HOSE

ROUTING

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Installer’s Guide

▲

WARNING

▲

WARNING

▲

CAUTION

▲

CAUTION

REINSTALLATION OF THE BURNER BOX COVER

Figure 55 shows the correct way to reinstall the Burner Box cover if adjustment or replacement of the Flame Sensor, Hot Surface Igniter, or Main Burner oriﬁces have required removal of the cover.

ROTATE THE FRONT COVER AS SHOWN

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

ALL SIDE FLANGES MUST BE OUTSIDE OF THE BOX

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

START-UP AND ADJUSTMENT PRELIMINARY INSPECTIONS

ELECTRICAL SHOCK HAZARD Disconnect power to the unit before removing the blower door. Allow a minimum of 10 seconds for IFC power supply to discharge to 0 volts. Failure to follow this warning could result in property damage, personal injury or death.

for any gas that might have escaped to dissipate. LP Gas being heavier than air may require forced ventilation. Turn the toggle switch on the Gas Valve in the unit to the “ON” position.

All soap solution should be cleaned off gas piping after gas leak testing is complete.

LIGHTING INSTRUCTIONS

FIRE OR EXPLOSION HAZARD Do NOT attempt to manually light the burner. Failure to follow this warning could result in property damage, personal injury or death.

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

Lighting instructions appear on each unit. Each installation must be checked out at the time of initial start up to insure proper operation of all components. Check out should include putting the unit through one complete cycle as outlined below. Turn on the main electrical supply and set the Comfort Control above the indicated temperature. The Ignitor will automatically heat, then the Gas Valve is energized to permit the ﬂow of gas to the burners. After ignition and ﬂame is established, the Flame Control Module monitors the ﬂame and supplies power to the Gas Valve until the Comfort Control is satisﬁed.

TO SHUT OFF

For complete shutdown: Turn the Gas Valve toggle switch on the main Gas Valve to the “OFF” position (See Figures

59). Disconnect the electrical supply to the unit.

NOTE: The condensate trap must be primed before operation.

With gas and electrical power “OFF”

1. Duct connections are properly sealed.

2. Filters are in place.

3. Venting is properly assembled.

4. Blower door is in place.

Turn the main Gas Valve toggle switch (See Figure 59) within the unit to the “OFF” position. Turn the external shutoff valve to the “OPEN” position (See Figures 50 and

52). Purge the air from the gas lines. After purging, check all gas connections for leaks with a soapy solution — DO NOT CHECK WITH AN OPEN FLAME. Allow 5 minutes

18-CD30D1-12 39

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

NOTE: Natural gas units should not have any yellow tipped ﬂames. This condition indicates that a service call is required. For best operation, burners must be cleaned annually using brushes and vacuum cleaner.

Page 40

Installer’s Guide

▲

WARNING

▲

WARNING

ENTER

USER INTERFACE MENU

SERVICE PROCEDURE TO ACCESS USER INTERFACE FOR THE MODULATING FURNACE

This procedure should only be performed by trained service personnel.

ELECTRICAL SHOCK HAZARD DO NOT BYPASS THE DOOR SWITCH BY ANY PERMANENT MEANS. FAILURE TO FOLLOW WARNING COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

ELECTRICAL SHOCK HAZARD DO NOT TOUCH ANY COMPONENTS OTHER THAN THE DISPLAY ASSEMBLY AND THE DOOR SWITCH DURING THIS PROCEDURE. FAILURE TO FOLLOW WARNING COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

1. Remove Blower Door panel by turning the two door latches.

2. Lower door panel and remove from service access area.

3. Use one hand depress the door switch (there must be power to the control system for the display assembly to function) and keep the door switch depressed during programming.

4. Using the other hand move through the Display Assembly menu using the arrow buttons.

5. The User Interface menu on pages 41-42 is a guide to the menu options.

6. When programming is complete release Door Switch and replace the Blower Door.

NOTE: If power is lost during programming, all changes made will be saved.

USER INTERFACE

Push left & right

Viewing Window

Push ENTER

to make selection

User Interface pictured above adjusts Variable Speed Airﬂow options and is used

for custom setup of Furnace operations- See menu options in User Interface on pages 45-46.

to scroll through

menu options

Push up & down

to scroll through

setup menu

40 18-CD30D1-12

Page 41

TABLE 20 - USER INTERFACE MENU

Power Up

== WAIT ==

A/TCONT900 Variable Speed

Standy Screen System Status Setup Options [ ] = Current Setting

MODEL NUMBER CMFRT CNT MODE SERIAL NUMBER COMM [COMM] 24VAC

* Unit specific

COOLING CFM 2

COOLING CFM A/TUHMB060 3T [3T] 1.5T 2T 2.5T * A/TUHMB080 3T [3T] 3.5T 2T 2.5T

A/TUHMC100 4T [4T] 2.5T 3T 3.5T

CFM PER TON CFM PER TON A/TUHMD120 5T [5T] 3.5T 4T

400 [ 400 ] 430 450 290 310 330 350 370 A/TDHMB060 3T [3T] 1.5T 2T 2.5T

A/TDHMB080 3T [3T] 3.5T 2T 2.5T

HEAT CFM HEAT CFM A/TDHMC100 4T [4T] 2.5T 3T 3.5T

** A/TDHMD120 5T [5T] 3.5T 4T

HT OFF DELAY HEAT OFF DLY ** Unit specific

100s [100s] 140s 180s 60s A/TUHMB060 960 [960] 1080 830 900

A/TUHMB080 1400 [1400] 1610 1120 1260

FACTORY DEFLTS FACTORY DEFLTS A/TUHMC100 1620 [1620] 1790 1460 1540

NO [NO] YES A/TUHMD120 1890 [1890] 2000 1700 1790

A/TDHMB060 1040 [1040] 1160 900 950

EXIT EXIT A/TDHMB080 1400 [1400] 1610 1300 1350

NO [NO] YES A/TDHMC100 1650 [1650] 1700 1500 1600

A/TDHMD120 1850 [1850] 2040 1660 1760

Information Menu Information Options

MODEL NUMBER MODEL

A/TUHM####

SERIAL NUMBER SERIAL

#####

SW REV NUMBER SW REV NUMBER

#####

SYSTEM STATUS SYSTEM STATUS

OFF

REQUESTED CFM REQUESTED CFM

0 CFM

LAST 4 FAULTS LAST 4 FAULTS

NO ALERTS

INDOOR ALERTS INDOOR ALERTS

NO ALERTS

UNIT TEST UNIT TEST UNIT TEST UNIT TEST

SIMPLE GAS VAL SETUP

TEMP SENSOR TEMP SENSOR

SNSR1 [SNSR1] SNSR2 DLT2-1

UNIT TEST SIMPLE GAS VAL SETUP

MOTOR RPM MOTOR RPM NO [NO] YES MIN [MIN] MAX

0 RPM

INDUCER RPM INDUCER RPM

0 RPM ARE YOU SURE ARE YOU SURE

NO [NO] YES NO [NO] YES

RESET LST FAULT RESET LST FAULT

NO [NO] YES

PART LIST PART LIST

CNT*****

PM SERIAL NUM PM SERIAL NUM

#####

CNTNGNCY MODE CNTNGNCY MODE OR

CNTNGNCY MODE 1

NOT AVAILABLE (with data line connected and active) NO [YES] YES (no data line connected)

EXIT EXIT

NO [NO] YES CNTNGNCY MODE <STAGE> CNTNGNCY MODE <STAGE>

STAGE [OFF] OFF 1 2

DUTY CYCLE [10] 10 20 30 40 50

START [NO] NO YES

NOTES: EXIT [NO] NO YES 1 This menu will only display at comfort control mode when A/TCONT900 is NOT connected

ARE YOU SURE [NO] NO YES

ENTER

2 Shown only when Communicating Outdoor Unit is not detected

ENTER

Installer’s Guide

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Installer’s Guide

24V Variable Speed

System Status Setup Options [ ] = Current Setting

CMFRT CNT MODE

COMM [24VAC] 24VAC

* Unit specific A/TUHMB060 3T [3T] 1.5T 2T 2.5T

COOLING CFM 2

COOLING CFM A/TUHMB080 3T [3T] 3.5T 2T 2.5T * A/TUHMC100 4T [4T] 2.5T 3T 3.5T

A/TUHMD120 5T [5T] 3.5T 4T

CFM PER TON CFM PER TON A/TDHMB060 3T [3T] 1.5T 2T 2.5T

400 [ 400 ] 430 450 290 310 330 350 370 A/TDHMB080 3T [3T] 3.5T 2T 2.5T

A/TDHMC100 4T [4T] 2.5T 3T 3.5T

CLG STAGES CLG STAGES A/TDHMD120 5T [5T] 3.5T 4T

1 STG [1 STG] 2 STGS

** Unit specific

CLG 1ST STG CFM 3 CLG 1ST STG CFM 2

A/TUHMB060 960 [960] 1080 830 900

50% [50%] 55% 65% 80% A/TUHMB080 1400 [1400] 1610 1120 1260

A/TUHMC100 1620 [1620] 1790 1460 1540

CONT FAN CFM CONT FAN CFM A/TUHMD120 1890 [1890] 2000 1700 1790

50% [50%] 75% 100% 25% A/TDHMB060 1040 [1040] 1160 900 950

A/TDHMB080 1400 [1400] 1610 1300 1350

FAN PRERUN DLY FAN PRERUN DLY A/TDHMC100 1650 [1650] 1700 1500 1600

NONE [NONE] 1m@50% A/TDHMD120 1850 [1850] 2040 1660 1760

FAN SHRTRUN DLY FAN SHRTRUN DLY

NONE [NONE] 4m@80% 7.5m@80%

FAN OFF DLY FAN OFF DLY

1.5m@100% [1.5m@100%] NONE 1m@50% 2m@50% 3m@50%

HEAT CFM HEAT CFM

HT OFF DELAY HT OFF DELAY

100s [100s] 140 180 60

W1 W2 STG DLY W1 W2 STG DLY

00m [00m] 5m 10m 15m

FACTORY DEFLTS FACTORY DEFLTS

NO [NO] YES

EXIT EXIT

NO [NO] YES

NOTES:

3 This menu will only display when 2 STGS is chosen in previous menu.

2 Shown only when Communicating Outdoor Unit is not detected

TABLE 20 - USER INTERFACE MENU - 24VOLT MENU (CONTINUED)

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Installer’s Guide

SEQUENCE OF OPERATION

SEQUENCE OF OPERATION – COMMUNICATING

MODE

1. This furnace is fully modulating between 40% and 100% of capacity in 1% increments. The furnace always lights at approximately 65% and will modulate up or down; depending on the communicating comfort control demand. Requested capacity can be seen in the “STATUS” section of the User Interface menu.

Note:

Pressure Switch 1 closes at approximately 40% of capacity. Pressure Switch 2 closes at approximately 65% of capacity. Pressure Switch 3 closes at approximately 95% of capacity.

2. The communicating comfort control signals the furnace IFC for heat.

3. The IFC then checks all safeties, thermostats, and pressure switches PS1, PS2, and PS3.

4. The IFC signals the variable speed inducer drive to start the vent motor at the speed needed to close pressure switches PS1 and PS2.

5. PS1 and PS2 close.

6. The IFC receives a 24 VAC signal from PS1 and PS2 when they close. This veriﬁes the vent motor is moving the correct amount of combustion air through the furnace and the vent system.

7. IFC starts the hot surface ignitor learning routine warm-up time cycle.

8. IFC turns on the gas valve. Trial time for ignition is 5 seconds.

Note: The furnace lights at approximately 65% of capacity.

9. The IFC veriﬁes ignition by the ﬂame current sensing method. If a ﬂame is not detected, the IFC will cycle the furnace three times to try and verify a ﬂame. If no ﬂame is detected, the IFC will lockout for one hour. The IFC will send an alert code to the communicating comfort control (ERR 22) and User Interface (RETRY LO). The Red alert LED two times repeatedly.

10. If a ﬂame is detected, the IFC will start the heat exchanger warm-up time delay for the indoor blower.

11. “IGNITION” will now be displayed in the “STATUS” section of the User Interface menu.

12. After 45 seconds, the IFC signals the indoor blower motor and run at the programmed ignition sequence speed.

13. Depending on the communicating comfort control demand, the IFC will then signal the variable speed inducer motor drive board and the indoor blower motor to ramp up or down.

14. With a heat demand less than 65% from the communicating comfort control, the IFC signals the variable speed inducer motor drive board to ramp down to that corresponding demand speed. The

reduction of the vent motor speed in steps allows the gas ﬂow through the gas valve to also be reduced in steps, decreasing the chance of burner ﬂame out. The minimum capacity change is 1%.

15. The minimum capacity of all furnaces is 40%, with the exception of the *UHMC120. The minimum capacity for this furnace is 45%.

16. The communicating comfort control will continue to call for the requested capacity demand until the indoor temperature is back at the set point OR,

17. If the communicating comfort control does not detect that the indoor temperature is moving back towards its set point or the indoor temperature is still moving away from the set point, it will signal the IFC to go to a higher capacity of heat.

18. The IFC then signals the variable speed inducer drive to ramp up the vent motor in steps. As the vent motor speed increases the amount of gas coming through the gas valve will increase. The IFC will also increase the indoor blower motor speed.

19. The communicating comfort control will continue to monitor the indoor temperature and send signals to the IFC to modulate the heating capacity or turn off to maintain the homeowner's set point.

20. Once the communicating comfort control senses that the heating requirements have been satisﬁed, the gas valve will be de-energized and gas ﬂow will cease. The variable speed vent motor will deenergize approximately after a 5 second post purge. All pressure switches will open and the indoor blower motor will then run the heat off delay that is selected in the User Interface menu.

Indoor Blower motor operation thermostat fan switch “ON” (Communicating Mode)

The communicating comfort control signals a continuous fan call. The factory setting is 50% of the cooling cfm selected but can be adjusted from 25% - 100% through the Installer Setup menu on the communicating comfort control. If the outdoor unit is a 2 stage system, the factory setting is 50% of the 2nd stage cooling cfm. If the outdoor unit is a 24 volt single stage cooling system, the factory setting is 50% of the cooling cfm.

NOTE: If the actual relative humidity (RH) is at or below the set-point, the fan will run until the continuous fan call is removed or the actual RH exceeds the set-point. If the actual RH is above the set-point, the fan will not turn on.

See the communicating comfort control Installer's Guide for additional information.

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Installer’s Guide

SEQUENCE OF OPERATION – 24VAC Mode

1. This furnace modulates between 40% and 100% of capacity, in 3% increments, every 1 minute. The furnace always lights at approximately 65% and will modulate up or down; depending on the 24VAC thermostat signal. Requested capacity can be seen in the “STATUS” section of the User Interface menu.

Note:

Pressure Switch 1 closes at approximately 40% of capacity. Pressure Switch 2 closes at approximately 65% of capacity. Pressure Switch 3 closes at approximately 95% of capacity.

Thermostat call for W1 (2 stage heating thermostat)

2. R and W1 contacts close signaling the control board (IFC) to run its self- check routine. After the control has veriﬁed that all safeties are closed and PS1, PS2, and PS3 pressure switch contacts are open, the IFC signals the variable speed inducer drive to start the vent motor at the speed needed to close pressure switches PS1 and PS2.

Note: The furnace lights at approximately 65% of capacity.

3. PS1 and PS2 close.

4. The IFC receives a 24 VAC signal from PS1 and PS2 when they close. This veriﬁes the vent motor is moving the correct amount of combustion air through the furnace and the vent system.

5. IFC starts the hot surface ignitor learning routine warm-up time cycle.

6. IFC turns on the gas valve. Trial time for ignition is 5 seconds.

7. The IFC veriﬁes ignition by the ﬂame current sensing method. If a ﬂame is not detected, the IFC will cycle the furnace three times to try and verify a ﬂame. If no ﬂame is detected, the IFC will lockout for one hour. The IFC will send an alert code to the communicating comfort control (ERR 22) and User Interface (RETRY LO) as well as ﬂash its Red alert LED two times repeatedly.

8. If a ﬂame is detected, the IFC will start the heat exchanger warm-up time delay for the indoor blower.

9. “IGNITION” will now be displayed in the “STATUS” section of the User Interface menu.

10. After 45 seconds, the IFC signals the indoor blower motor to run at the programmed ignition sequence speed.

11. The IFC then signals the variable speed inducer motor drive board to ramp down to the corresponding speed to keep PS1 closed. The reduction of the vent motor speed in steps allows the gas ﬂow through the gas valve to also be reduced in steps, decreasing the chance of burner ﬂame out. The W1 heating capacity is 40%. The IFC will also decrease the indoor blower motor speed.

Thermostat call for W2 after W1

12. R and W2 thermostat contacts close signaling a call for W2 heat. The IFC then signals the variable speed inducer drive to ramp up the vent motor allowing ﬂow through the gas valve to also be increased in 3% steps.

13. If the call for W2 remains, this 3% increase will be repeated every 1 minute until the capacity requested is 100%. The IFC will also increase the indoor blower motor speed in appropriate steps.

W2 satisﬁed, W1 still called for

14. R and W2 thermostat contacts open signaling that W2 heating requirements have been satisﬁed. The IFC will signal the variable speed vent motor to slow down to its learned W1 speed. The gas valve will reduce the gas ﬂow to 40% capacity and the indoor blower motor speed will be reduced.

W1 satisﬁed

15. R and W1 thermostat contacts open signaling that W1 heating requirements have been satisﬁed. The gas valve will be de-energized and gas ﬂow will cease. The variable speed vent motor will de-energize approximately after a 5 second post purge. The indoor blower motor will be de-energized after the fan off delay period has ended. (The indoor blower heat fan off delay is ﬁeld selectable and can be adjusted using the User Interface menu. It is factory set at 100 seconds but can be set to 60, 140, or 180 seconds)

Thermostat call for heat (1 stage heating thermostat)

Note: The inter-stage delay is ﬁeld selectable and can be adjusted through the User interface menu. It is factory set at 0 minutes but can be adjusted to 5, 10, or 15 minutes. This option can help optimize the furnace to try to satisfy the heating requirement during low heating load conditions.

16. W1 and W2 must be jumpered at the IFC. R and W1 contacts close signaling the control board (IFC) to run its self- check routine. After the control has veriﬁed that all safeties are closed and PS1, PS2, and PS3 pressure switch contacts are open, the IFC signals the variable speed inducer drive to start the vent motor at the speed needed to close pressure switches PS1 and PS2.

Note: The furnace lights at approximately 65% of capacity.

17. PS1 and PS2 close.

18. The IFC receives a 24 VAC signal from PS1 and PS2 when they close. This veriﬁes the vent motor is moving the correct amount of combustion air through the furnace and the vent system.

19. IFC starts the hot surface ignitor learning routine warm-up time cycle.

20. IFC turns on the gas valve. Trial time for ignition is 5 seconds.

21. The IFC veriﬁes ignition by the ﬂame current sensing method. If a ﬂame is not detected, the IFC will cycle

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Installer’s Guide

15 16

Communicating Comfort Control

the furnace three times to try and verify a ﬂame. If no ﬂame is detected, the IFC will lockout for one hour. The IFC will send an alert code to the communicating comfort control (ERR 22) and User Interface (RETRY LO) as well as ﬂash its Red alert LED two times repeatedly.

22. If a ﬂame is detected, the IFC will start the heat exchanger warm-up time delay for the indoor blower.

23. “IGNITION” will now be displayed in the “STATUS” section of the User Interface menu.

24. After 45 seconds, the IFC signals the indoor blower motor to run at the programmed ignition sequence speed.

25. Every 1 minute, the IFC will signal the vent motor to ramp up. The increase of the vent motor speed allows the gas ﬂow through the gas valve to also be increased in 3% steps. This 3% increase will be repeated every 1 minute until the capacity requested is 100%. Pressure switch 3 closes at approximately 95% of capacity.

26. The IFC will also increase the indoor blower motor speed in appropriate steps.

Indoor Blower motor operation thermostat fan switch “CONTINUOUS” (24V Mode)

R and G comfort control contacts close signaling a continuous fan call. The continuous fan cfm is ﬁeld selectable and can be adjusted through the User Interface menu. The factory setting is 50% of the cooling cfm selected but can be set at 25%, 50%, 75%, or 100%. If the system has a 2 stage outdoor unit, the setting is 50% of the 2nd stage cooling cfm.

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Installer’s Guide

UNIT TEST MODE

A) SIMPLE

Note: Stage 1 = 40% (low) heat, Stage 2 = 100% (high) heat

A qualiﬁed technician can cycle the Variable Speed Indoor Blower and the Modulating Gas Furnace through its operation at the User Interface.

• The unit test cycle is entered at the user interface.

• The test cycle can only be entered when the comfort

control has no demand and the furnace IFC is not reporting a fault. Turn the comfort control to the Off

position and turn the fan control to Auto. This will ensure the unit test cycle will not be interrupted.

• Scroll down using the button at the user interface until the display reads:

• UNIT TEST. Press the Enter button.

• UNIT TEST and NO (NO) will now be displayed. Use

the  or  arrow button to change the NO to a YES and then press ENTER.

• ARE YOU SURE and NO (NO) will now be displayed. Use the  or  arrow button to change the NO to a YES and then press ENTER.

• UNIT TEST and Y1 ON FAN ON will now be displayed. The variable speed indoor blower will then be turned on by the IFC for 10 seconds and then off.

• Furnace will then transition to the ignition sequence. STAGE OFF will now be displayed. After a 45 second heat fan on delay, Stage 1 will be displayed and 40% (low) heat inducer speed will be energized for 10 seconds.

• Stage 2 will be displayed and 100% (high) heat inducer speed will be energized for 10 seconds.

• The control transitions to off.

• The Model and Serial Number will be displayed.

• The variable speed indoor blower will now operate for the

heat exchanger cool down cycle and then shut off at the end of the cycle.

• The comfort control can now be returned to the

homeowner’s desired settings.

B) GAS VALVE SETUP (MANIFOLD PRESSURE

ADJUSTMENT)

NOTE: To obtain an accurate manifold pressure measurement ,the manifold pressure must be referenced to the burner box, since the burner box pressure tap equalizes the gas valve pressure regulator. To do so, install a tee and section of tube (ﬁeld supplied) in the tubing between the tee coming from the burner box tube and the gas valve manifold pressure measurement ﬁtting. This tube and tee is in addition to the tube attached to the gas valve pressure tap on the

outlet side of the gas valve. See Figure 58.

NOTE: In order to properly set the manifold gas pressure, the incoming line gas pressure should be tested with the unit off and again with the unit operating at the high heat setting to ensure adequate fuel supply to the furnace. The incoming gas pressure should be 5" W.C. minimum and 13.8" W.C. maximum for natural gas.

1) Before Setting Manifold Gas Pressure

Setting the manifold gas pressures is critical for the cor-

rect operation of this furnace.

Before entering the Gas Valve Setup mode:

a. Turn comfort control system switch to the OFF position

and fan switch to the AUTO position.

b. Prime the furnace condensate trap.

Any call for heat or fan by the comfort control will abort

or cancel the Gas Valve Setup mode. The unit will stay in Gas Valve Setup mode for a maximum of 20 minutes.

c. Connect dual port manometer & ﬁeld tubing per Figure

58 on page 47.

Note: MIN = 40% (low) heat, MAX = 100% (high) heat

Setting Manifold Gas Pressure

2) Setting “MIN” manifold gas pressure

To enter the Gas Valve Setup mode:

a. Scroll down on the user interface to Unit Test.

b. Scroll to the right and select “Gas Val Setup”.

c. Push the Enter button.

d. Select “MIN” and push the Enter button.

e. When asked “Are You Sure”, select Yes, and push the

Enter button.

f. The furnace will now begin the ignition sequence.

g. If pressure switch 1 & 2 learning routines have not

been performed; after successful ignition, the inducer will go through this operation. (see Inducer Learning Routine section).

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Installer’s Guide

Manifold Pressure

Measurement

Fitting

CORRECT METHOD OF CHECKING DIRECT VENT MANIFOLD PRESSURE

WITH BURNER BOX REFERENCED

WARNING

▲

EXPLOSION HAZARD

REPLACE AND/OR TIGHTEN ALL PLUGS REMOVED OR LOOSENED WHEN ADJUSTING GAS PRESSURE. LEAK CHECK THE FITTINGS

Slope Gauge

BEFORE PLACING INTO REGULAR SERVICE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY, PROPERTY DAMAGE, OR

Connects to Burner Box Pressure Hose

Field Supplied

DEATH

A Field Supplied barb ﬁtting must be used on the gas valve to attach the hose

TABLE 21

Furnace Input

rate (KBTU/hr)

60 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

80 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

100 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

Downﬂow 120 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

Upﬂow 120 0.9 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

For upﬂow 120KBTU/hr model, 1st stage is 45% Manifold pressures apply for Natural Gas applications ONLY

Furnace Input

rate (KBTU/hr)

60 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

80 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

100 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

Downﬂow 120 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

Upﬂow 120 2.9 ± 0.5 Not Adjustable 10.0 ± 0.5

For upﬂow 120KBTU/hr model, 1st stage is 45% Manifold pressures apply for Propane applications ONLY

FINAL NG MANIFOLD PRESSURE SETTINGS

(inches w.c.)

40% 65% 100%

FINAL LP MANIFOLD PRESSURE SETTINGS

(inches w.c.)

40% 65% 100%

Negative Control

Pressure Post

Gas Valve

On/ Off Toggle Switch

Inlet Pressure

Measurement Fitting

Low Heat Manifold

Pressure

(Adjustment under

cover)

Positive Control

Pressure Post

High Heat

Manifold Pressure

(Adjustment

under cover)

Flow

Manifold

Pressure

Measurement

Fitting

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Installer’s Guide

▲

WARNING

h. Allow 5 minutes to pass before attempting to adjust

the 40% manifold pressure. This will insure that the learning routine is complete and that the heat rise is stable.

j. Read the 40% manifold pressure.

k. If needed, remove the low heat manifold adjustment

cover and adjust to obtain the correct manifold pressure. See Figure 59.

40% (LOW) HEAT ADJUSTMENT: TURN CLOCKWISE TO DECREASE MANIFOLD PRESSURE OR COUNTERCLOCKWISE TO INCREASE MANIFOLD PRESSURE.

l. Use Manifold Pressure Settings Table 21 for the correct

manifold pressure setting in Inches of Water Column.

m. Once the 40% manifold pressure has been adjusted;

push the Enter button on the user interface. This will stop the gas valve setup mode and take you back to the home screen.

3) Setting “MAX” manifold gas pressure

To enter the Gas Valve Setup mode:

a. Scroll down on the user interface to Unit Test.

b. Scroll to the right and select “Gas Val Setup”.

c. Push the Enter button.

d. Scroll to the right and select MAX; then push the Enter

button.

e. Select “MAX” and push the Enter button.

f. When asked “Are You Sure”, select Yes, and push the

Enter button.

g. The furnace will now begin another ignition sequence.

h. If pressure switch 2 & 3 learning routines have not

been performed; after successful ignition, the inducer will go through this operation. (see Inducer Learning Routine section).

i. Allow 5 minutes to pass before attempting to adjust

the 100% manifold pressure. This will insure that the learning routine is complete and that the heat rise is stable.

j. Read the 100% manifold pressure.

k. If needed, remove the high heat manifold adjustment

cover and adjust to obtain the correct manifold pressure. See Figure 59.

100% (HIGH) HEAT ADJUSTMENT: COUNTERCLOCKWISE TO DECREASE MANIFOLD PRESSURE OR CLOCKWISE TO INCREASE MANIFOLD PRESSURE.

l. Use Manifold Pressure Settings Table 22 for the correct

manifold pressure setting in Inches of Water Column.

m. Replace and tighten the adjustment cover for the high

heat and read the manifold pressure again. This procedure may need to be repeated until the correct manifold pressure is obtained.

NOTE: The adjustment cover over the high heat must be in place during manifold gas pressure readings. See Figure 53.

n. If the ﬁring rate cannot be obtained with the manifold

pressures speciﬁed in Table 22, the oriﬁces must be changed. If a change of oriﬁces is required to correct the furnace input rating, refer to Table 17 on page 37.

o. Once the 100% manifold pressure has been adjusted;

push the Enter button on the user interface. This will stop the gas valve setup mode and take you back to the home screen.

EXPLOSION HAZARD

REPLACE AND/OR TIGHTEN ALL PLUGS REMOVED OR LOOSENED WHEN ADJUSTING GAS PRESSURE. LEAK CHECK THE FITTINGS BEFORE PLACING INTO REGULAR SERVICE. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY, PROPERTY DAMAGE, OR DEATH.

p. Remove all ﬁeld supplied tubing and measurement

devices. Reinstall and tighten all covers and outlet pressure tap screw.

q. Leak test all gas ﬁttings using a leak detection solution

or soap suds.

r. Turn comfort control to home owners desired

temperature.

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Installer’s Guide

TABLE 22

Furnace

Input rate

(KBTU/

hr)

100 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

Downﬂow

120

Upﬂow

120

For upﬂow 120KBTU/hr model, 1st stage is 45% Manifold pressures apply for Natural Gas applications ONLY

Furnace

Input rate

(KBTU/hr)

100 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

Downﬂow

120

Upﬂow 120 2.9 ± 0.5 Not Adjustable 10.0 ± 0.5

For upﬂow 120KBTU/hr model, 1st stage is 45% Manifold pressures apply for Propane applications ONLY

FINAL NG MANIFOLD PRESSURE SETTINGS (inches

w.c.)

40% 65% 100%

60 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

80 0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

0.7 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

0.9 + 0.2 / - 0.0 Not Adjustable 3.5 ± 0.2

FINAL LP MANIFOLD PRESSURE SETTINGS (inches

w.c.)

40% 65% 100%

60 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

80 2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

2.1 ± 0.5 Not Adjustable 10.0 ± 0.5

PERSONALITY MODULE

The Personality Module is a removable memory device, on which is stored model speciﬁc data required for proper furnace operation. The Personality Module is tethered to the unit and must remain with the furnace at all times. The Personality module must remain plugged into the furnace IFC.

STAND ALONE OPERATION (CONTINGENCY MODE)

The Contingency Mode allows the installer to set the equipment to operate in an ON/ OFF Duty Cycle mode. This mode will be activated using the User Interface. Contingency Mode is NOT available in 24VAC mode. The user will select the desired level of capacity required, Stage 1 (40%) or 2 (100%). The user will select the desired ON/ OFF Duty Cycle, 10% minimum to 50% maximum, (10% increments, 10% = 2 minutes On, 18 minutes Off; 50% = 10 minutes on, 10 minutes off).

CONTINGENCY MODE

Note: Stage 1 = 40% (low) heat, Stage 2 = 100% (high) heat

Note: If a communicating comfort control is detected to be present and the contingency mode is selected, NOT AVAILABLE will be displayed on the User Interface.

• Stand alone operation can only be entered at the user interface.

• Stand alone operation can be set up to operate the furnace in Heating Only.

• The contingency mode is used when the communicating comfort Control is not communicating with the furnace or when setting gas manifold pressures.

• Before attempting to enter contingency mode, disconnect the Data wire "D" from the Furnace IFC terminal block.

• The contingency mode will function only when the Furnace IFC is not ﬂashing a fault code at its Fault LED.

• To enter the contingency mode of operation, turn 115 VAC power off. When the Green LED on the variable speed inducer drive goes out, turn 115 VAC power back on.

• Scroll down using the down arrow  at the User Interface until you see CNTNGNCY Mode, then press the Enter button.

• CNTNGNCY MODE and  STAGE  will now be displayed. Press the Enter button.

• STAGE and OFF [OFF] will now be displayed. First or Second heat stage must be selected. Use the or arrows to select the stage of heat wanted and then push the Enter button and then the  button.

• DUTY CYCLE and 10% [10%] will now be displayed.

A duty cycle must now be selected from 10 to 50%. A

10% duty cycle will run the furnace for 2 minutes and then off for 18 minutes. A 50% duty cycle will run the furnace for 10 minutes and then be off for 10 minutes. These duty cycles will be repeated 3 times per hour. Use the or arrows to select a duty cycle and then push the Enter button and then the  button.

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Installer’s Guide

• Start and NO [NO] will now be displayed. With a NO/NO question being asked, use the or arrows to select the YES and then press the ENTER button.

• Are you Sure and NO [NO] will now be displayed. With a NO/ NO question being asked, use the  or arrows to select the YES and then press the ENTER button.

• Turn 115VAC power off. When the Green LED on the variable speed inducer drive goes out, turn 115 VAC power back on.

• When the furnace is operating in the contingency mode (stand alone operating cycle), the user interface will display the following information. The top line will say CNTNGNCY MODE. The bottom line will show the duty cycle stage number STG (1 or 2) selected, and the percent number 10-50 % selected.

• All furnace operating controls, pressure switches and communications between the IFC and the variable speed inducer drive and the variable speed indoor blower will be functional during contingency mode operation of the furnace.

• The  and ENTER buttons do not function in the contingency mode of operation.

• To exit the contingency mode of operation turn off the 115 VAC power to the furnace.

• The contingency mode will stop for any of the following reasons: (1) If the furnace IFC receives a signal from the

communicating comfort control. This will only happen if the data wire "D" from the comfort control has been reconnected to the furnace IFC terminal board terminal "D".

(2) Power is removed from the furnace and then turned

back on.

(3) The Furnace IFC enters a RESET mode of operation.

(4) A fault is detected by the furnace IFC. Fault LED will

be ﬂashing an Alert Code.

24V CONTINGENCY MODE

An alternative method for the contingency mode can be

used by changing the mode of operation in the Use Interface to 24V mode and installing a conventional

24V comfort control. To set this mode of operation: Remove all wiring from the *CONT900 comfort control

and install a 24V comfort control. If the comfort

control requires a 24V common; connect R and B

to respective terminals. Connect a third wire to "W".

At the IFC, connect the same three wires to the

corresponding terminals. Jumper W1 to W2 at the

IFC. The stage delay between W1 and W2 can be set

by scrolling through the User Interface. It is factory

set to zero minutes but can be adjusted to 5, 10, or

15 minutes.

IFC INDUCER LEARNING ROUTINE SEQUENCE

• The furnace IFC will go through an inducer learning routine for three pressure switches.

• The learning routine is done to determine the correct amount of ventilation air for complete combustion.

• The inducer motor speed may be different for each installation due to the different length and size of the ventilation pipe, exhaust vent pipe, number of pipe ﬁttings used, and the type of vent cap installed.

• The inducer learning routine is repeated each time the power to the furnace is interrupted. Once power is restored and the furnace receives a call for heat, the PS-1, PS-2 inducer learning routine will be initiated. The furnace IFC will not go through a PS-3 inducer learning routine until it receives a call for 100% (high) heat.

• To ensure the furnace heating efﬁciency is maintained the furnace IFC will repeat the inducer motor learning routine after :

150 Cycles at 40% (low) heat 100 Cycles at 65% (medium) heat 50 Cycles at 100% (high) heat

PS-1, PS-2 Inducer Learning Routine

• The furnace IFC checks pressure switches PS-1, PS-2, and PS-3. They all have to be open before a heating cycle can begin.

• The furnace IFC sends a digital signal to the variable speed inducer drive to run the inducer motor at the preset factory 65% (medium) heat RPM.

• The furnace IFC waits for the PS-1 and PS-2 pressure switches to close. A 24 Volt AC signal is sent to the furnace IFC when a pressure switch closes.

• If PS-1 and PS-2 do not close at the preset factory 65% (medium) heat RPM, the furnace IFC will continue to signal the variable speed inducer drive to increase the inducer speed in steps until PS-1 and PS-2 close or until the maximum RPM for 65% (medium) heat is reached.

• When PS-1 and PS-2 switches close, the furnace IFC will then start the ignition cycle.

• The IFC now starts the igniter warm up cycle.

• Approximately 20 seconds later, the furnace IFC will turn

on the gas valve.

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NOTE: The furnace lights at approximately 65% of capacity.

• When the burner ﬂame is detected by the furnace IFC, a forty-ﬁve second time delay for indoor blower operation begins. The forty-ﬁve second time delay allows the heat exchanger and the recuperative cell to warm up.

• The furnace IFC will now start its 65% (medium) heat inducer learning routine.

• The furnace IFC will signal the variable speed inducer drive beginning to reduce the inducer motor speed in steps until the furnace IFC detects that PS-2 is open.

• When PS-2 opens, the furnace IFC will NOTE the inducer motor RPM.

• The furnace IFC then adds an additional number of RPM to the 65% (medium) heat inducer motor NOTED RPM until PS-2 closes.

• The additional number of RPM plus this NOTED RPM is the learned 65% (medium) heat inducer operating RPM.

• The furnace IFC now stores this learned operating inducer RPM for 65% (medium) heat in its memory.

• The furnace IFC will use this stored learned operating inducer RPM for 65% (medium) heat calls it receives in the future.

• If the furnace IFC is still receiving a call for low heat operation it will now start the learning routine for 40% (low) heat.

• The furnace IFC will then continue to reduce the inducer motor RPM in steps until the furnace IFC detects that PS-1 is open.

• When PS-1 opens, the furnace IFC will NOTE the inducer motor RPM.

• The furnace IFC then adds an additional number of RPM to the 40% (low) heat inducer motor NOTED RPM until PS-1 closes.

• The additional number of RPM plus this NOTED RPM is the learned 40% (low) heat inducer operating RPM.

• The furnace IFC now stores this learned inducer operating RPM for 40% (low) heat in its memory.

• The furnace IFC will use this stored learned inducer operating RPM for 40% (low) heat calls it receives in the future.

• Whenever the furnace is powered up or after a RESET, the furnace IFC will not go through a learning routine for 100% (high) heat until it receives a call for 100% (high) heat.

PS-3 INDUCER LEARNING ROUTINE

• When the furnace IFC receives a digital signal for 100% (high) heat from the comfort control it will begin the PS-3 inducer learning routine.

• The furnace will start the heating cycle in 65% (medium) heat, if not already on, and then begins the PS-3 inducer learning routine.

• The furnace IFC will send a digital signal to the variable speed inducer drive to run the inducer motor at the preset factory 100% (high) heat RPM.

• The furnace IFC waits for PS-3 pressure switch to close. A 24 Volt AC signal is sent to the furnace IFC when the pressure switch closes.

• If PS-3 does not close at the factory preset 100% (high) heat RPM, the furnace IFC will continue to signal the variable speed inducer drive to increase the inducer speed in steps until PS-3 closes or until the maximum RPM for 100% (high) heat is reached.

• The furnace IFC enters a time delay so that the heat exchanger and the recuperative cell warm up to their high heat operating temperature. At the end of this time delay, the inducer discharge air temperature will be at its high heat operating temperature and the density of the products of combustion will be stabilized.

• The furnace will now signal the variable speed inducer drive to reduce the inducer speed in steps until PS-3 opens.

• When PS-3 opens, the furnace IFC will NOTE the inducer motor RPM.

• The furnace IFC then adds an additional number of RPM to the 100% (high) heat inducer motor NOTED RPM until PS-3 closes.

• The furnace IFC now stores this learned inducer

operating RPM for 100% (high) heat in its memory.

• The furnace IFC will use this stored learned inducer

operating RPM for 100% (high) heat calls it receives in the future.

• If PS-3 is not closed when the inducer reaches its maximum RPM, the furnace IFC will signal the variable speed inducer drive to reduce the inducer Motor speed in steps to its low heat LEARNED SPEED.

• The furnace IFC ﬂashes its Red Fault LED three times repeatedly. The furnace IFC will keep operating at low heat for 10 minutes and then retry the PS-3 learning routine.

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▲

WARNING

▲

WARNING

▲

WARNING

▲

WARNING

CONTROL AND SAFETY SWITCH ADJUSTMENTS

LIMIT SWITCH CHECK OUT

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

start up by the installer.

To check for proper operation of the Limit Switches, set the Comfort Control to a temperature higher than the indicated room temperature to start the furnace. Restrict the airﬂow by blocking the return air (disconnecting the Indoor Blower may trip the Inducer Limit). When the Furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and overheating is evident, a faulty Limit Switch is probable and the Limit Switch must be replaced. After checking the operation of the Limit Control, be sure to remove the restriction from the return air inlet.

AIRFLOW ADJUSTMENT

Check inlet and outlet air temperatures to make sure they are within the range speciﬁed on the Furnace rating nameplate. If the airﬂow needs to be increased or decreased, see the Airﬂow Label on the Furnace or the unit’s Service Facts for information on changing the speed of the Blower Motor for your speciﬁc model. Blower speed changes are made on the User Interface.

ELECTRICAL SHOCK HAZARD

DISCONNECT POWER TO THE UNIT BEFORE REMOVING THE BLOWER DOOR. ALLOW A MINIMUM OF 10 SECONDS FOR IFC POWER SUPPLY TO DISCHARGE TO 0 VOLTS.

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

INDOOR BLOWER TIMING Heating: The Integrated Furnace Control module con-

trols the Indoor Blower. The Blower start is ﬁxed at 45 seconds after ignition. The FANOFF period is ﬁeld selectable via the User Interface menu at 60, 100, 140, or 180 seconds. The factory setting is 100 seconds.

Cooling: Continuous Fan mode is 50% of the cooling

CFM. This is a selectable range on the Comfort Control menu.

When in communicating mode, see Use Interface Menu in furnace Installer's Guide.

SAFETY HAZARD MAKE SURE THAT THE BLOWER DOOR IS IN PLACE AND NOT AJAR. DANGEROUS FUMES COULD ESCAPE. FAILURE TO FOLLOW WARNING COULD RESULT IN

SERIOUS PERSONAL INJURY OR DEATH.

This unit is equipped with a Blower Door Switch which cuts power to the Furnace causing shutdown when the door is removed. Operation with the door removed or ajar can permit the escape of dangerous fumes. All panels must be securely closed at all times for safe operation of the Furnace.

NOTE TO INSTALLER

Review the following instructions with the homeowner. Review contents of USER’S INFORMATION MANUAL with the homeowner.

INSTRUCTIONS TO THE HOMEOWNER

52 18-CD30D1-12

EXPLOSION HAZARD In the event that electrical, fuel, or mechanical failures occur, shut off the gas supply off at the manual gas valve, located on the supply gas piping coming into the furnace, before turning off the electrical power to the furnace. Contact the service agency designated by your dealer.

Page 53

Installer’s Guide

CONDITIONS AFFECTING FURNACE OPERATION

NOTE: CONTINUOUS fan mode during COOLING operation may not be appropriate in humid climates. If the indoor air exceeds 60% relative humidity or simply feels uncomfortably humid, it is recommended that the fan

only be used in the AUTO mode.

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN EXCESS OF 40 M.P.H.) VENT OR FLUE BLOCKAGE

On a call for heat, the Variable Speed Draft Inducer must ﬁrst ramp up to speed and close the Pressure Switch before the Ignition Sequence is allowed to begin. If the Pressure Switch does not close, the Motor will ramp up to maximum speed and continue to operate at maximum speed for about one minute. After one minute, the Integrated Furnace Control will turn the Motor off for about 30 seconds then back on in an attempt to reestablish proper operation. This condition is indicative of a highly restricted or blocked inlet or outlet Vent Pipe or a failed Pressure Switch. If pressure against induced draft Blower outlet becomes excessive, the Pressure Switch will open. If the Pressure Switch is open for more than 3.5 seconds, the Variable Speed Draft Inducer will speed up and attempt to close the Pressure Switch. If the Pressure Switch is not closed within 12 to 15 seconds or if the maximum speed of the Motor is reached, the Draft Inducer sends a Fault Signal to the Integrated Furnace Control. If the unit is operating in high heat, an Inducer Fault will cause the Furnace control to transition the system to medium heat and it will operate there for 10 minutes before attempting to run again in high heat. If the unit is operating in medium heat, an Inducer Fault will cause the Furnace control to transition the system to low heat and it will operate there for 10 minutes before attempting to run again in medium heat. If the unit is operating in low heat, an Inducer Fault will cause the Furnace control to shut the system down and wait 30 seconds before attempting to reestablish operation in low heat.

2. LOSS OF FLAME

If loss of ﬂame occurs during a Heating Cycle, or ﬂame is not present at the sensor, the Integrated Furnace Control (IFC) will close the Gas Valve. The Integrated Furnace Control will then recycle the Ignition Sequence. If Ignition is not achieved, it will shut off the Gas Valve and lock out the system.

3. POWER FAILURE If there is a power failure during a Heating Cycle, the system will restart the Ignition Sequence automatically when power is restored, if the Comfort Control still calls for heat.

4. GAS SUPPLY FAILURE If a gas supply failure occurs during a Heating Cycle, the system Integrated Furnace Control will recycle the Ignition Sequence, then if Ignition is not achieved, the Integrated Furnace Control will shut off the Gas Valve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE Please refer to the "Communicating Controls Service Manual," publication number 34-4093 (latest revision), for diagnostic assistance.

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

7. RESET AFTER LOCKOUT When the Integrated Furnace Control has shut the system down and gone into lockout, the system may be manually reset. The system can be reset by turning the system power off.

8. RESET AFTER BURNER BOX LIMIT SHUT- DOWN

BURNER BOX TEMPERATURE LIMIT DEVICE

All models are equipped with a Manual Reset Temperature Limit located on the Burner Box. In case of excessive temperature, the Limit will open and cause the circuit to open which shuts off all ﬂow of gas. If the Furnace shuts down check the Burner Box Temperature Limit Switch. It is located on the bottom of the Burner Box. The Vent and Combustion Air Inlet terminations must ﬁrst be checked for blockage. If blockage exists, clear the problem and then the Reset Button may be depressed. If there is no

blockage of the terminations, do not reset the Burner Box Limit Switch. A qualiﬁed service professional should be called to determine the problem and reset the Limit Switch.

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Installer’s Guide

ALERT CODE RECOVERY

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

The Green BM LED will be on solid when the control is powered. The Green status LED indicator light will operate as shown in the table and the Red LED will ﬂash (one ﬂash) every 20 seconds.

NOTE:

Use the ﬂash code menu for detail of the alerts. Alert codes also are displayed on the User Interface menu using a descriptive text message and on the comfort control display using an alert code number. A complete list of the alert codes is included with the comfort control.

Line voltage connections

Table 23

LED DESCRIPTION FUNCTION

FAST FLASH - CALL

GREEN STATUS LED

RED ALERT LED

GREEN

(BM)

AMBER COM

BITMASTER

FOR HEAT

SLOW FLASH - NO

CALL FOR HEAT

NO. OF FLASHES

- SEE DIAGNOSTIC

CODES

ON SOLID WHEN UNIT

POWERED

FLASHES DEVICE

COUNT

Neutral connections

"Com" LED (Amber)

Bitmaster (BM) LED (Green)

24V furnace component connections

Low voltage

terminal board

5 Amp control fuse

Motor bus connections

User Interface connection

Status LED (Green)

Personality module connection

Fault LED (Red)

BK jumper

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IFC BOARD

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Installer’s Guide

Furnace Fault Codes D802247P01rev08[1].xls

REVISION: 9 CN: 9108T00 DATE: 2009-6-12

Fault LED COM LED User Interface Display Control Display

RECYCLE

Flame is off when flame should be

detected. Furnace tries to relight

itself.

RETRY

Furnace tries to light, but no flame is

detected.

RECYCLE LO

10 recycles within a single call for

heat will cause 1hr lockout.

RETRY LO

3 ignition attempts in a row within a

single call for heat results in 1 hr

lockout.

PS3 OPEN Open Pressure Switch, third stage

PS3 CLOSED Shorted Pressure Switch, third stage

PS2 OPEN Open Pressure Switch, second stage

PS2 CLOSED

Shorted Pressure Switch, second

stage

PS1 OPEN Open Pressure Switch, first stage

AUX LIMIT

Open Reverse Flow - Heat exchanger

temperature too high. Could be

caused by low airflow or fan failure.

5 Flash Device count FLAME ERROR ERR 34

Flame Detect Fault

Flame detected, should not be

present

POLARITY ERR N/A

Line Polarity Fault Voltage reverse polarity

GND FAULT N/A 88 Ground Fault

Occurs when proper earth ground is

not detected.

IGNITER ERR Igniter fault

TRIAC ERR Triac fault

Control tried to turn on gas valve, but

24V not sensed.

Control senses 24V present at the gas

valve when it should not be present.

8 Flash Device count LO FLAME SNS N/A

Low Flame Signal

Flame current is low, but still strong

enough to allow operation.

9 Flash Device count IND LIMIT ERR 26 26 High Temp Limit Fault

Flue gas temperature too high. Could

be caused by low airflow or fan failure.

SYS COMM CRC

COMM system unrecognized

response

IND COMM CRC Inducer Motor unrecognized response

BLW COMM CRC Blower motor unrecognized response

BLW COMM ERR Blower motor no COMM response ¹

IND COMM ERR Inducer motor no COMM response

SYS COMM ERR Loss of heat/cool demand

NO SYS CLK Loss of clock signal

Device count 24V COMM MSMTCH ERR 139 139

Communication

Failure

Communication Message has been

detected while configured for 24V

Mode

Solid ON Device count CNTRL FAULT ERR 18 18 Control Failure Internal control failure

None Device count TWIN ERROR N/A

Twinning Fault

Twinning Not Allowed with Variable

Speed

PM DATA ERR

Data Section is Corrupt but PM is

useable

CAP MISMATCH

Compressor size does not match

capacity in PM

ID MTR ERR

Blower HP/OEM does not match PM

Data

PM MISSING No PM

PM UNIT ERR N/A

Primary Copy of Unit Data File is

Corrupt.

PM MEM ERROR ERR 114

Primary and Secondary copies of Unit

Data File are Corrupt

AC VOLTS LOW Voltage too low

AC VOLTS HI Voltage too high

None Device count CHECK FUSE N/A 92 Fuse 24V Fuse Open

Y1 OFF ERR Y1 Output OFF when it should be ON

Y1 ON ERR Y1 Output ON when it should be OFF

TS 1 SHORT Temperature sensor 1 shorted.

TS 1 OPEN Temperature sensor 1 open.

TS 2 SHORT Temperature sensor 2 shorted.

TS 2 OPEN Temperature sensor 2 open.

Notes:

D342960P01

PRINTED FROM: D802247P01 Rev 9

Communication FaultERR 91

Fast Flash

¹ Comfort Control will switch system to "OFF" until this fault condition clears

7 Flash

Control senses 24V present at the gas

valve when it should not be present.

EXT GV ERR

None Device count

Device count

None Device count

2 Flash

4 Flash

6 Flash

Device count

3 Flash Device count

Device count

ERR 101

93ERR 93

ERR 10

Alert Description

Alert Group

Shorted Pressure Switch, first stage

Ignition Means Fault

High Temp Limit Fault

Alert Notification

Alert Code

Flame lost or Ignition

failure

N/A

Device count

Y1 Relay Failure

N/A

Communication Busy

Fault

Gas Valve Fault

AC Line Fault

Bad or Missing PM

N/A

HIGH LIMIT

Solid ON INT GV ERR

ERR 87

ERR 26

10 Flash

Device count

Temperature Sensor

Failure

N/A

None Device count N/A

119

None 114

ERR 114

101

Open High Limit - Heat exchanger

temperature too high. Could be

caused by low airflow or fan failure.

ROLLOUT OPEN Open flame rollout

Soft lockout due to

flame lost or ignition

retries

Pressure Switch

Failure

Roll Out Fault

ERR 22

N/A

PS1 CLOSED

TABLE 24- FURNACE ALERT CODES

18-CD30D1-12 55

Page 56

Trane 6200 Troup Highway Tyler, TX 75707

Literature Order Number 18-CD30D1-12

Number 18-CD30D1-12

Supersedes

Date 01/13

For more information contact your local dealer (distributor)

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

Trane UHMB060ACV3VB, UHMD120ACV5VB, DHMB060BCV3VB, DHMB080ACV3VB, DHMC100ACV4VB Installer's Manual

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