Trane ADC040C924, ADC060C936, ADC080C942, AUC100C948, AUC100C960 Installer's Manual

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Page 1

18-CD19D5-10

Installer’s Guide

Upflow / Horizontal and Downflow / Horizontal Gas-Fired Condensing Furnaces

*UC040C924 *UC060C936 *UC080C942

*__First letter may be “A” or “T”

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT — This Document is customer property and is to remain with this unit.

Please return to service information pack upon completion of work.

*UC-C

*UC100C948 *UC100C960 *UC120C960

*DC040C924 *DC060C936 *DC080C942

*DC-C

*DC100C948 *DC120C960

DOWNFLOW

UPFLOW/HORIZONTAL

UPFLOW

DOWNFLOW/HORIZONTAL

A341624P01

Page 2

Installer’s Guide

SAFETY SECTION

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

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

2. Install this furnace only in a location and position as specified in “Location and Clearances” (page 3), of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” (pages 7-8), 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 10-18), of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in “Gas Piping” (page 20), of these instructions.

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

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

8. A gas-fired furnace for installation in a residential garage must be installed as specified in “Location and Clearances” section (page 3), of these instructions.

9. The furnace is not to be used for temporary heating of buildings or structures under construction.

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

a. DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury. This signal word is limited to the most extreme situations.

b. WARNING indicates a potentially hazardous situation

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

c. CAUTION indicates a potentially hazardous situation which,

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

WARNING

▲

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

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

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

1. Seal any unused openings in the venting system.

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

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

4. Close fireplace dampers.

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

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

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

8. After it has been determined that each appliance connected to the venting system properly vents where tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

WARNING

▲

FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in

serious injury, death or property damage. Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

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Installer’s Guide

GENERAL INSTALLATION INSTRUCTIONS

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

It is recommended that Manual J of the Air Conditioning Contractors Association (ACCA) or A.R.I. 230 be followed in estimating heating requirements. When estimating heating requirements for installation at altitudes above 2000 ft., remember the gas input may need to be reduced (See High Altitude Installation).

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

Codes and local utility requirements governing the installation of gas fired equipment, wiring, plumbing, and flue connections must be adhered to. In the absence of local codes, the installation must conform with latest edition of the National Fuel Gas Code ANSI Z223.1 • National Installation Code, CAN/CGA B149.1. The latest code may be obtained from the American Gas Association Laboratories, 8501 E. Pleasant Valley Rd., Cleveland, Ohio 44131.

These furnaces have been classified as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21.47 • CAN/CGA 2.3 standards. Category IV furnaces operate with positive vent static pressure and with a flue loss less than 17 percent.

CAUTION

▲

To prevent shortening its service life, the furnace should not be used as a “Construction Heater” during the finishing phases of construction. The low return air temperatures can lead to the formation of condensate even though this is a noncondensing model. Condensate in the presence of chlorides and fluorides from paint, varnish stains, adhesives, cleaning compounds, and cement create a corrosive condition which may cause rapid deterioration of the heat exchanger.

WARNING

▲

These furnaces are not approved or intended for installation in manufactured (mobile) housing, trailers, or recreational vehicles. Failure to follow this warning could result in property damage, personal injury, or death.

CAUTION

▲

Do not install the furnace in a corrosive or contaminated atmosphere.

These conditions require special venting systems, which must be gas tight and water tight.

These furnaces may be twinned using BAYTWIN300A. They shall have common returns with equal pressure drops or ducts with equivalent lengths and sizes.

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.

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.

Contents

Installation Instructions 3

General Installation Instructions 3 Location and Clearances 3 Upflow Installation 3 Outline Drawings 4-5 Downflow Installation 6 Horizontal Installation 6 Air for Combustion and Ventilation 7 Duct Connections 8 Return Air Filters 9-10 General Venting Instructions 10-18 Venting Tables 11-12 IFC Error Flash Codes 12 Downward Venting 13 Condensate Drain Instructions 14 Electrical Connections 18 Field Wiring Diagrams 19 Gas Piping 20-22 Combustion and Input Check 20 High Altitude Derate 22

Start-up and Adjustment 22

Preliminary Inspections 22 Lighting Instructions 22 Sequence of Operation 23 Control and Safety Switch Adjustments 23

Abnormal Conditions 24

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

5. Are the ventilation and combustion air openings large enough and will they remain unobstructed? If outside air is used, are the openings set above the highest snow accumulation level? (See the Air for Combustion and Ventilation section)

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.

IMPORTANT:

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

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.

18-CD19D5-10 3

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4 18-CD19D5-10

Installer’s Guide

MODEL A B C D

*UC040C924 *UC060C936 *UC080C942

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

*UC100C948 21" 2-1/2" 19-3/4" 19-1/2" *UC100C960

*UC120C960

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

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

From Dwg. 21C340386 Rev. 7

*UC-C OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

Page 5

18-CD19D5-10 5

Installer’s Guide

MODEL A B C D

*DC040C924 *DC060C936 *DC080C942

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

*DC100C948 21" 2-1/2" 19-3/4" 19-1/2" *DC120C960 24-1/2" 2-15/16" 23-1/4" 23"

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

From Dwg. 21C340462 Rev. 7

*DC-C DOWNFLOW / HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

Page 6

Installer’s Guide

STANDOFFS (4)

DRILL SCREWS (4)

CASED

COIL

FOR VERTICAL

INSTALLATIONS:

SCREWS

UPFLOW

FURNACE

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

WARNING

▲

Do not install the furnace directly on carpeting, tile or other combustible material other than wood flooring. For vertical downflow application, subbase (BAYBASE205) must be used between the furnace and combustible flooring. When the downflow furnace is installed vertically with a cased coil, a subbase is not required.

Required floor opening: (DOWNFLOW)

2345678901234567890123456789012123456789012345

See Figure 3 and Table 1

FURNACE

FRONT

A (width)

B (depth)

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used in the horizontal position. It is always recommended that an auxiliary drain pan be installed under a horizontally installed evaporator coil or 90% gas furnace. Connect the auxiliary drain line to a separate drain line (no trap is needed in this line).

Three brackets (with screws) are included with downflow furnaces for installation to stabilize and secure the furnace and TXC cased coil in the horizontal position. See Figure 4. The coil is placed downstream of the furnace, with the apex of the coil pointing in the direction of the airflow for horizontal installa- tion. The cased coil is secured to the furnace and both the furnace and the cased coil must be properly supported. The brackets mount using the rear screws on the coil case and use the screws provided to secure the bracket to the furnace. The remaining bracket is placed as close to center as possible (horizontally) between the coil case front and the furnace bottom channel (for downflow/horizontal furnace). Use four of the screws provided to secure the bracket. The upflow furnace, converted to horizontal, aligns and attaches the TXC coil as in Figure 1. However, the coil requires additional support.

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

The furnace may be installed in an attic or crawl space in the horizontal position by placing the furnace on the left side (as viewed from the front in the vertical position). The horizontal furnace installation in an attic should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of the furnace (See Outline Drawings). Line contact is only permissible between lines formed by intersections of the top and two sides of the furnace casing and building joists, studs, or framing.

The furnace may be placed horizontally in a crawl space on a pad or other noncombustible material which will raise the unit for sufficient protection from moisture. The furnace must be

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

The horizontal furnace may also be suspended from the joists using 3/8" all-thread rods with pieces of angle iron underneath the furnace to form a hanging rack at both ends and the midpoint. The rods need to be of sufficient length to allow for proper clearances from combustible materials. The angle iron needs to be at least 32" in length to allow for access to service panels.

The upflow furnace, converted to horizontal, aligns and attaches the TXC coil to the same flanges used in vertical. The coil needs to have additional support.

TABLE 1

CABINET

WIDTH

RETURN

DUCT WIDTH

FLOOR OPENING PLENUM OPENING

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

14-1/2" 13-1/4" 13-5/8" 20-1/8" 12-5/8" 19-3/8" 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"

6 18-CD19D5-10

UPFLOW/ HORIZONTAL SHOWN

Page 7

UNCONFINED

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

AIR FOR COMBUSTION AND VENTILATION

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

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

Furnace locations may be in “confined space” or “unconfined space”. Unconfined space is defined in Table 2 and Figure 6. These spaces may have adequate air by infiltration to provide air for combustion, ventilation, and dilution of flue gases. Buildings with tight construction (for example, weather stripping, heavily

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

insulated, caulked, vapor barrier, etc.), may need additional air provided as described for confined space.

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

All air from inside the building as in Figure 8: The confined

1. space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Refer to Table 3, for minimum open areas required.

All air from outdoors as in Figure 9: The confined space

2. shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure.

The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 3, for minimum open areas required.

CONFINED

Installer’s Guide

3. The following types of installations will require use of

OUTDOOR AIR for combustion, due to chemical exposures:

* Commercial buildings * Buildings with indoor pools * Furnaces installed in commercial laundry rooms * Furnaces installed in hobby or craft rooms * Furnaces installed near chemical storage areas.

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

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

TABLE 2

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE

MAXIMUM BTUH

INPUT RATING

40,000 60,000

80,000 100,000 120,000

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

40,000 60,000

80,000 100,000 120,000

Carbon monoxide, fire or smoke can cause serious bodily injury, death, and/or property damage.

A variety of potential sources of carbon monoxide can be found in a building or dwelling such as gas-fired clothes dryers, gas cooking stoves, water heaters, furnaces and fireplaces. The U.S. Consumer Product Safety Commission recommends that users of gas-burning appliances install carbon monoxide detectors as well as fire and smoke detectors, listed by a nationally recognized agency (e.g. Underwriters Laboratories or International Approval Services), to help alert dwelling occupants of the presence of fire, smoke or unsafe levels of carbon monoxide.

From

Inside

NOTE: The manufacturer of your furnace does not test any detectors and makes no representations regarding any brand or type of detector.

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE

FEET OF UNCONFINED SPACE

250 375 500 625 750

TABLE 3

Air

100 100 100 100 120

Air From Outside

Ver tical

Duct

10 15 20 25 30

Horizontal

Duct

20 30 40 50 60

18-CD19D5-10 7

Page 8

Installer’s Guide

DUCT CONNECTIONS

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

Central furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling units to avoid condensation in the heating element, unless the furnace has been specifically approved for downstream installation. 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 which minimize noise transmission through the return air grille. Although these winter air conditioners 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.

Minimum return air/“air entering” temperature for the furnace is 50° F.

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.

RETURN AIR DUCT CONNECTION

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

1. Set the furnace in place.

2. For side return installations on upflow models, remove the insulation around the opening in the blower compartment.

3. The side panels on upflow furnaces include locating notches which may be 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.

4. If a 3/4" flange is to be used for attaching the air inlet duct, add to cut where indicated by solid lines in Figure 10. Cut corners diagonally and bend outward to form flange.

5. If flanges are not required, and a filter frame is installed, cut along knockout guidelines.

6. Upflow furnaces: filter retainer brackets are factory supplied for bottom return. Use the filter retainer brackets on either side or on bottom if filter is to be used within the furnace cabinet.

Downflow Furnaces: Brackets are factory supplied to mount filters in the return air ductwork.

8 18-CD19D5-10

Page 9

Installer’s Guide

TYPICAL UPFLOW FURNACE RETURN AIR FILTER INSTALLATIONS

CUT OUT FOR SIDE FILTER

LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT

SEE OUTLINE DRAWING

7. Connect duct work to furnace. See Outline Drawing for supply and return duct size and location. Flexible duct connectors are recommended to connect both supply and return air ducts to the furnace. If only the front of the furnace is accessible, it is recommended that both supply and return air plenums are removable.

8. When replacing a furnace, old duct work should be cleaned out. Thin cloths should be placed over the registers and the furnace fan should be run for 10 minutes. Don’t forget to remove the cloths before you start the furnace.

FRONT of Furnace

RETURN AIR FILTER

Filters are factory supplied for these furnaces. These furnaces require high velocity cleanable type air filters which may be located within the furnace blower compartment for UPFLOW furnaces in either a BOTTOM or SIDE (left side or right side) return air inlet. See Figure 11. Some filters may need to be trimmed for side or bottom filter use.

Downflow furnace filters must be located outside the furnace cabinet. Typical installations are shown in Figure 13. Table 5 provides information for installation of the filter retaining brackets shipped with downflow furnaces.

TABLE 4

MODELS

NUMBERS

*UC040C924 *UC060C936 *UC080C942

*UC100C948 21" 1 - 20" X 25" X 1"

*UC100C960 ## *UC120C960 ##

*DC040C924 *DC060C936 *DC080C942

*DC100C948 21" 2 - 16" X 20" X 1" *DC120C960 24-1/2" 2 - 16" X 20" X 1"

* - First letter may be "A" or "T" ## - Requires filters on 2 sides OR 1 side and bottom filte OR just the bottom

CABINET

WIDTH

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

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

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

FILTER

QTY & SIZE

Airflow

TYPICAL BOTTOM RETURN FILTER

Airflow

TYPICAL SIDE RETURN FILTER

FILTER RETAINER BRACKETS FOR SIDE AIR RETURN ON UPFLOW FURNACES

If side air return is desired, it is necessary to move the 2 filter retainer brackets from the bottom of the furnace and reinstall them on the side. The following instructions should be used:

a. Remove the front doors. b. Remove the filter.

c. Carefully place the unit on its back.

d. Using a 5/16" nut driver, remove the 4 screws holding the

filter retainer brackets.

e. Reinstall the filter retainer brackets on the desired side.

(See Figure 11 “Typical Side Return Filter”).

Airflow

18-CD19D5-10 9

TYPICAL FILTERS OF UPFLOW IN HORIZONTAL

Page 10

Installer’s Guide

Airflow

DOWNFLOW

Airflow

DOWNFLOW / HORIZONTAL

RETURN AIR FILTER FOR DOWNFLOW/HORIZONTAL

After the return air plenum has been connected to the downflow furnace in either downflow or horizontal position the return air filters may be installed in the plenum using the brackets (and screws) supplied with the furnace. See Table 5. It is recommended that BAYFLTR206 be installed in the return air plenum. See Figure 12 and Table 5 for typical installation. The BAYFLTR206 Kit includes the filter door, instructions, and the necessary hardware for installation.

To replace filters, remove the filter access door, lift the filter from the lower bracket and shift the filter to the side to free the top bracket and slide the filter out through the filter access door. Replace the filters in the same manner, making sure that the filter is secured in both top and bottom brackets. Replace the filter access door.

Use high velocity replacement filters only.

GENERAL VENTING INSTRUCTIONS

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.

TABLE 5

LOCATING FILTER RETAINER

BRACKETS WITHIN RETURN DUCT

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.

10 18-CD19D5-10

RETURN

DUCT

WIDTH

DIMENSION

"A"

DIMENSION

"B"

FILTER

BRACKET

LOCATION*

Page 11

GENERAL VENTING

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.

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

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

The recommended system is assembled from 2", 2-1/2", 3", or 4" pipe and fittings. 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 plastic materials.

These furnaces have been classified as CATEGORY IV furnaces in accordance with the latest edition of ANSI Z21.47 • CAN/CGA 2.3 standards. Category IV furnaces operate with positive vent pressure and with a vent gas temperature less than 140° F. above the dewpoint. These conditions require special venting systems, which must be gas tight and water tight.

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

The following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances

Installer’s Guide

remaining connected to the common venting system are not in operation:

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

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

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

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

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

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

If improper venting is observed during any of the above tests, the common venting system must be corrected.

Refer to latest edition of National Fuel Gas Code (ANSI 223.1) • CAN/CGA B149 or Exhibit J of ANSI Z21.47 • CAN/CGA 2.3 for vent sizing instructions.

VENT FITTING MATERIAL

These fittings are available from your Gas Furnace Distributors. Straight Pipe Sections, Couplings, 45° Elbows, 60° Elbows, 90° Elbows, Vent or Sanitary Tee, or other necessary fittings may be

2", 2-1/2", 3", or 4" diameter. The allowable materials are shown in Table 6. A vent screen is optional, but recommended. The vent screen must be 3/8" open mesh weave (minimum 70% open), made of any noncorrosive material having at least 3/8" open mesh weave.

TABLE 6

PLASTIC PIPE DESIGNATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

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

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41 **212 ASTM D2846

F441 SCH 40, 80 **212 ASTM F441

F442 SDR SERIES **212 ASTM F442

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV ***180 ASTM D2661

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

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

18-CD19D5-10 11

Page 12

Installer’s Guide

VENT FITTING MATERIAL – PLASTIC

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

Listed in Table 7 are fittings that meet these requirements. The materials listed are various grades of PVC and ABS plastic.

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

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

Be sure to properly support these joints.

BONDING OF PVC

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

Pipe and Fittings – ASTM D1785, D2466, D2661, & D2665

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

2. After checking pipe and socket for proper fit, wipe socket and pipe with cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe. DO NOT ALLOW PRIMER TO DRY BEFORE APPLYING CEMENT.

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

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

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

NOTE: Follow venting instructions carefully when using PVC cement.

PVC Primer and Solvent Cement – ASTM D2564 Procedure for Cementing Joints – Ref ASTM D2855

IMPORTANT:

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

MAXIMUM VENT LENGTHS

UPFLOW / HORIZONTAL and DOWNFLOW / HORIZONTAL VENTING TABLE

TABLE 7

MAXIMUM VENT LENGTH:

MAXIMUM TOTAL EQUIVALENT FEET

MODEL

*UC/*DC040C

*UC/*DC060C

2" PIPE & FITTINGS 2-1/2" PIPE & FITTINGS 3" PIPE & FITTINGS 4" PIPE & FITTINGS

50 80 80 130

*UC/*DC080C

*UC/*DC100C 30 80 80 130

*UC/*DC120C

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

NOTES:

DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET

1. (Except adapters at top of furnace).

MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! One 90° elbow is equivalent to 12' of 4" pipe. One SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one

3. LONG radius elbow is equivalent to 6' of 3" pipe. One SHORT/LONG radius 90° elbow is equivalent to 7½' of 2½" pipe, & 5' of 2" pipe. Two 45° elbows equal one 90° elbow.

The termination tee or bend must be included in the total number of elbows.

Pipe adapters are field supplied. Downflow models and *UC120 include 2" X 3" adapter.

4" pipe may be reduced to 3" for termination with BAYVENT100 or BAYVENT200 without length restriction

Flashing Slow --- Normal - No call for Heat Flashing Fast --- Normal - Call for Heat Continuous ON --- Replace IFC Continuous OFF --- Check Power 2 Flashes --- System Lockout (Retries or Recycles exceeded)

3 Flashes ---

4 Flashes --- Open Temperature Limit Circuit 5 Flashes --- Flame sensed when no flame should be present 6 Flashes --- 115 volt AC power reversed, poor grounding or system voltage too low 7 Flashes --- Gas valve circuit error 8 Flashes --- Low flame sense signal

40 80 80 130

NOT ALLOWED 25 70 130

INTEGRATED FURNACE CONTROL ERROR FLASH CODES

Draft Pressure Error - Possible problems:

a) Venting problem b) Pressure switch problem c) Inducer problem

12 18-CD19D5-10

Page 13

HORIZONTAL AND VERTICAL VENTING

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

Installer’s Guide

CAUTION

▲

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 it is assumed the space meets the condition of a heated space.

DOWNWARD VENTING

Furnace may be in vertical or horizontal configuration.

All horizontal pipes must be supported

at a maximum of 3 foot intervals

40 Inch Upflow or Downflow

Furnace

Slope 1/4" per ft.

6" Min.

NOTES:

A) CONDENSATE TRAP FOR VENT PIPE MUST BE A MINIMUM OF

6 INCHES IN HEIGHT.

B) CONDENSATE TRAP FOR VENT AND INLET PIPE MUST BE CONNECTED INTO A CONDENSATE DRAIN PUMP; AN OPEN OR

VENTED DRAIN; OR IT CAN BE CONNECTED TO THE OUTLET HOSE OF THE FURNACE'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.

C) THE CONDENSATE TRAP SHOULD BE PRIMED AT INITIAL START UP PRIOR TO HEATING SEASON OPERATION.

18-CD19D5-10 13

Page 14

Installer’s Guide

▲

CONDENSATE DRAIN INSTRUCTIONS

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

The upflow (vertical application) has provisions for right side drain connections by turning the trap and extending the tubing to the lower right front corner of the furnace. Trim all excess tubing to avoid kinking. The connecting tubing for left or right side condensate drain shown in Figures 16 & 17 is shipped in the blower compartment.

The downflow (vertical application) may be right side drain by removing the drain lines and rotating the trap from left to right, reconnecting the lines, and running 1/2" CPVC pipe from the trap to the right side knock out just over and above the burner section ( Use RTV high temperature silicone sealant to connect the CPVC pipe to the trap for ease of removing and cleaning the trap). See Figure 19.

CAUTION

▲

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

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

All horizontal applications are left side only and require repositioning the condensate canister trap to the exterior of the cabinet. Additionally the drain tubing connected to the inducer housing must be repositioned for removing the plug and reconnecting the tubing to the lower connection on the inducer housing. See Figure 18.

For horizontal installation, remove the condensate trap and position the trap outside the cabinet through the slotted opening next to the secondary cell. On upflow/horizontal models, remove lines from the blower section and pull through the blower deck. Cut and reattach the line from the secondary cell (use the spring to prevent kinking). The inducer housing has a secondary drain opening at its 9 o’clock position. Remove the plug and use the

TO DRAIN

RIGHT SIDE

VERTICAL UPFLOW – RIGHT SIDE CONDENSATE

DRAIN CONNECTION

plug to cover the hole at the 6 o’clock position. Reposition the inducer drain tube from 6 o’clock to the 9 o’clock location. Cut and reattach the tube to the canister trap. Plug openings in blower deck, inducer and blower section. See Figure 18.

Connections must be made to an OPEN/VENTED DRAIN. Refer to illustrations of typical connections. 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" size PVC pipe and fittings throughout for drain connections (fittings, pipe and PVC solvent cement not provided).

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

TO DRAIN

LEFT SIDE

VERTICAL UPFLOW – LEFT SIDE CONDENSATE

14 18-CD19D5-10

DRAIN CONNECTION

OPEN/

VENTED

DRAIN

ALL HORIZONTAL APPLICATIONS ARE LEFT SIDE DRAIN ONLY

(TYPICAL UPFLOW FURNACE SHOWN IN HORIZONTAL)

Page 15

Installer’s Guide

TO DRAIN

VERTICAL DOWNFLOW – LEFT SIDE

CONDENSATE DRAIN CONNECTION

IMPORTANT:

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

Typical sources of UL listed heat tapes are W.W. Granger, Inc. (Wintergard Plus™ Series), McMaster Carr Supply Co. (3554 Series), or your equipment supplier.

The condensate drain may be cleaned or inspected by removal of the drain tube at the header as shown in the illustrations.

HORIZONTAL VENTING THROUGH WALL

CPVC PIPE REQUIRED

TO OPEN/VENTED DRAIN

VERTICAL DOWNFLOW – RIGHT SIDE

CONDENSATE DRAIN CONNECTION

HORIZONTAL VENTING THROUGH WALL

CAUTION

▲

If the furnace is to be vented through the wall, the preferred application is to avoid installation through the wall exposed to the prevailing winter wind, where possible.

A wall sheltered from the prevailing wind is least likely to experience excessive wind pressure and possible nuisance induced draft blower pressure switch trips.

The vent/wind terminal must be located at least 12" minimum above normally expected snow accumulation level.

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

TEE

18-CD19D5-10 15

OUTSIDE

WALL

STUB CUT AT

45˚ ANGLE

45˚ ELBOW

6" MAX.

45˚

Page 16

Installer’s Guide

The vent/wind terminal must terminate at least 3' above any forced air inlet into the building that is within 10' of the terminal. The terminal must also terminate 4' below, 4' horizontal from or 1' above any door, window or other air inlet into building.

The vent/wind terminal shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

The vent/wind terminal shall have a minimum horizontal clearance of 4' from electrical meters, gas meters, regulators, and relief equipment.

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

COUPLING ( PLASTIC VENTING )

6 IN. MIN.

(TO JOINT)

1" CLEARANCE ( AIR SPACE )

STUD

PVC WALL MOUNT

FLANGE

12" MIN.

12" MIN. ABOVE NORMALLY EXPECTED SNOW ACCUMULATION

90˚ ELBOW

VENTING THROUGH COMBUSTIBLE WALLS

Pitch -- 1/4 Inch Per Ft.

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

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 23.

HORIZONTAL VENT CAP BAY69X146

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials must be maintained when using single wall stainless steel venting. See Figure 22.

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. See example in Figure 21.

COUPLING

( PLASTIC

VENTING )

MORTAR SEAL

6 IN. MIN.

( TO JOINT )

CEMENT

INSIDE &

OUTSIDE

PVC WALL MOUNT

FLANGE

12" MIN.

12" MIN. ABOVE NORMALLY EXPECTED SNOW ACCUMULATION

VENTING THROUGH NON-COMBUSTIBLE WALLS

Pitch – 1/4 Inch Per Ft.

90˚ ELBOW

16 18-CD19D5-10

Page 17

90˚ ELBOW

3" MIN.

MIN. 12" CLEARANCE ABOVE SNOW ACCUMULATION

SECURE STAINLESS STEEL VENT CAP TO COUPLING WITH THREE STAINLESS STEEL SCREWS (CLEARANCE HOLES DRILLED THROUGH COUPLING FOR SCREWS MUST BE LARGER THAN SCREW DIAMETER)

Used with type 29-4C stainless steel optional on 3" PVC pipe only.

VENTING THROUGH ROOF

STAINLESS STEEL VENT CAP

COUPLING (PLASTIC VENTING)

VENTING (FLUE PIPE)

STORM COLLAR

ADJUSTABLE ROOF FLASHING

Installer’s Guide

RIDGE

NOTE: MINIMUM OF 12" ABOVE EXPECTED SNOW ACCUMULATION.

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: Vertical vent termination can be done by:

1. Stainless steel vent cap Figure 24 or

2. Two (2) 90° elbows as shown in Figure 24.

3. No vent cap as shown in Figure 25 (preferred method for extremely cold climates.)

In extreme climate conditions, insulate the exposed pipe above roof line with Armaflex type insulation.

18" MIN.

SEAL BETWEEN FLANGE, PIPE, COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT

FLUE PIPE

SUPPORT

FLANGE

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

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

COUPLING

CEILING

18-CD19D5-10 17

VENTING THROUGH CEILING

Page 18

Installer’s Guide

FLUE PIPE

COUPLING TO SUPPORT PIPE FROM ANGLES OR OTHER SUITABLE SUPPORT METHOD

PVC PLASTIC VENTING - ONLY

THROUGH UNUSED CHIMNEY

STAINLESS STEEL

VENT CAP

STAINLESS

(OPTIONAL)

STEEL VENT CAP

SEE CAUTION

FLUE PIPE

CAUTION

▲

6 IN. MIN.

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

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

COUPLING AS REQUIRED

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

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.

TYPE 29-4C STAINLESS STEEL VENTING -

USED THROUGH CHIMNEY THAT VENTS

ANOTHER GAS APPLIANCE

STAINLESS STEEL

STAINLESS

VENT CAP

STEEL

(OPTIONAL)

VENT CAP

SEE CAUTION

▲

Do not run vent through chimney for wood burning or oil furnaces or incinerators.

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

6 IN. MIN.

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

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

CAUTION

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.

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.

WARNING

▲

CARBON MONOXIDE POISONING HAZARD Failure to follow the service and/or periodic maintenance

instructions for the furnace and venting system, could result in carbon monoxide poisoning or death.

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.

ELECTRICAL CONNECTIONS

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

WARNING

▲

The cabinet must have an uninterrupted or unbroken ground according to National Electrical Code, ANSI/NFPA 70 - “latest edition” and Canadian Electrical Code, CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. A failure to follow this warning could result in an electrical shock, fire, injury, or death.

18 18-CD19D5-10

Page 19

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

HUM SEE NOTE 5

EAC SEE NOTE 5

Installer’s Guide

FIELD WIRING DIAGRAM FOR HEATING ONLY

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

HUM SEE NOTE 5

EAC SEE NOTE 5

From Dwg. 21B340387 Rev. 1

FIELD WIRING DIAGRAM FOR SINGLE STAGE HEATING/COOLING

(OUTDOOR SECTION WITHOUT TRANSFORMER)

18-CD19D5-10 19

From Dwg. 21B340388 Rev. 1

Page 20

Installer’s Guide

WARNING

▲

FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in

serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commer-

cially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury, or loss of life.

GAS PIPING

The upflow/horizontal furnace is shipped standard for left side installation of gas piping. A knockout is provided on the right side for an alternate gas piping arrangement. See Figures 29-31 on page 21.

The installation of piping shall be in accordance with piping codes and the regulations of the local gas company. Pipe joint compound must be resistant to the chemical reaction with liquefied petroleum gases.

Refer to piping Table 8, for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve as shown in Figures 29-31. National codes require a condensation drip leg to be installed ahead of the controls as shown in Figures 29-31.

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. All gas fittings must be checked for leaks using a soapy

solution before lighting the furnace. OPEN FLAME!

TABLE 8

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

TABLE 9

DO NOT CHECK WITH AN

ORIFICE SIZES

INPUT

RATING

BTUH

40,000 60,000

80,000 100,000 120,000

NUMBER

BURNERS

2 3 4 5 6

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 45 45 45 45

56 56 56 56 56

COMBUSTION AND INPUT CHECK

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

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

3. Match the “Sec” column in the gas flow (in cfh) Table 10 with the time clocked.

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

5. Use the following factors For 1 Cu. Ft. Dial Gas Flow CFH = Chart Flow Reading ÷2 For 1/2 Cu Ft. Dial Gas Flow CFH = Chart Flow Reading ÷4 For 5 Cu. Ft. Dial Gas Flow CFH =

6. Multiply the final figure by the heating value of the gas obtained from the utility company and compare to the nameplate rating. This must not exceed the nameplate rating.

7. Changes can be made by adjusting the manifold pressure or changing orifices (orifice change may not always be required). To adjust the manifold pressure:

a. Turn off all electrical power to the system. b. Attach a manifold pressure gauge to the outlet pressure

tap marked “OUT PRESS TAP” on White-Rodgers gas valve model 36F or boss marked “OUT P” on White-Rodgers gas valve model 36G. (See Figure 33 for White-Rodgers gas valve model 36F and Figure 32 for White-Rodgers gas valve model 36G.). For the gas valve model 36F, measurement requires removal of the plug and installation of a barbed fitting. Attach flexible tubing and a manometer to the barbed fitting. For the gas valve model 36G, do not remove the pressure tap test screw. Loosen the pressure tap test screw one turn and install 5/16" flexible tubing and a manometer directly onto the outlet pressure boss.

c. Turn on system power and energize valve.

d. Remove the regulator adjustment screw cap on the gas

valve for manifold pressure adjustment.

e. Turn the adjustment nut clockwise to increase the gas

flow rate, and counterclockwise to decrease the gas flow rate using a 3/32" hex wench.

f. The final manifold pressure setting shall be 3.5" W.C.

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

g. Replace the regulator adjustment screw cap and tighten

securely.

h. Turn off all electrical power to the system.

i. Remove the manometer and flexible tubing. Remove the

barbed fitting and replace the plug or tighten the pressure test screw.

j. Turn on electrical power to the system and energize

valve.

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

leaks at plug or pressure boss screw.

▲

Replace and/or tighten all plugs removed or loosened when adjusting gas pressure. Leak check the fittings before placing the furnace into regular service. Failure to follow this warning could result in fire, explosion, or property damage.

Table 9 lists the main burner orifices used with the furnace. If a change of orifices is required to correct the furnace input rating refer to Table 12.

if necessary:

10X Chart Flow Reading ÷4

CAUTION

20 18-CD19D5-10

Page 21

Installer’s Guide

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

;

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

UPFLOW MAY BE LEFT OR RIGHT HAND GAS PIPING

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION JOINT

DRIP

LEG

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

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION JOINT

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

18-CD19D5-10 21

MAIN MANUAL

SHUTOFF

VALVE

DRIP LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

(Typical upflow furnace shown in horizontal)

GROUND UNION JOINT

DRIP

LEG

Page 22

Installer’s Guide

TABLE 10

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

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

WARNING

▲

Hazardous Gases! Exposure to fuel substances or by-products of incomplete

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

TABLE 11

FINAL MANIFOLD PRESSURE SETTINGS

FUEL PRESSURE

NATURAL GAS 3.5" W.C.

LP GAS 11.0" W.C.

TABLE 12

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

44 45 46 47 48 49 50

HIGH ALTITUDE DERATE

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

If the installation is 2,000 ft. or above, the furnace input rate (BTUH) shall be reduced 4% for each 1,000 ft. above sea level. The furnace input rate shall be checked by clocking the gas flow rate (CFH) and multiplying by the heating value obtained from the local utility supplier for the gas being delivered at the installed altitude. Input rate changes can be made by adjusting the manifold pressure (min 3.0 - max 3.7 in. W.C. - Natural Gas) or changing orifices (orifice change may not always be required).

PART

NUMBER

ORF00501 ORF00644 ORF00909 ORF00910 ORF01099 ORF00503 ORF00493

DRILL

SIZE

54 55 56 57 58 59

PA RT

NUMBER

ORF00555 ORF00693 ORF00907 ORF00908 ORF01338 ORF01339

If the desired input rate cannot be achieved with a change in manifold pressure, then the orifices must be changed. LP installations will require an orifice change. See Table 13 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.

Installations above 4,000 feet may require a pressure switch change. If required, use the BAYHALT*** Kit (High Altitude Accessory Kit) listed in PRODUCT DATA.

TABLE 13

Orifice

Twist Drill

Size If

Installed

At Sea

Level

44 45 46

2000 3000 4000 5000 6000 7000 8000 9000 10000

42 44 45 46 47 48

54 55 56 58 59

From National Fuel Gas Code - Table F-4

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

45 44 45 47 47 48

55 55 56 59 60

44 45 47 47 49

55 55 57 59 60

45 46 47 48 49

55 56 57 60

45 47 48 48 49

55 56 57 60 62

46 47 48 49 50

55 56 58 61 62

46 47 48 49 50

56 56 59 63 63

47 48 50 50 51 52

56 57 60 63 64

START-UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

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

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

LIGHTING INSTRUCTIONS

WARNING

▲

DO NOT attempt to manually light the burner. Failure to follow this warning could result in property damage, personal injury, or death.

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

Turn on the main electrical supply and set the thermostat 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 thermostat is satisfied.

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Installer’s Guide

Outlet Pressure Boss

Swi

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Boss

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Adj

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Inlet Pressure

Boss

(opt.)

Outlet Pressure Boss

On/Offff Swi

White-Rodgers 36G gas valve

On/Off Switch

tch

Regululator

Adj

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

When the thermostat is satisfied, R and W thermostat contacts open, the gas valve will close, the flames will extinguish, and the induced draft blower will be de-energized. The indoor blower motor will continue to run for the fan off period (Field selectable at 60, 100, 140 or 180 seconds), then will be de-energized by the control module.

CONTROL AND SAFETY SWITCH ADJUSTMENTS LIMIT SWITCH CHECK OUT

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

To check for proper operation of the limit switches, set the thermostat to a temperature higher than the indicated temperature to bring on the gas valve. 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 paper or cardboard from the return air inlet. Refer to Service Facts for additional instructions.

NOTE TO INSTALLER Review the following warnings with the owner. Review contents of USER’S INFORMATION MANUAL with the owner.

White-Rodgers 36F gas valve

To shut off.

For complete shutdown: Flip the switch on the main gas valve to the “OFF” position (See Figures 32 & 33). Disconnect the electrical supply to the unit.

CAUTION

▲

If this is done during the cold weather months, provisions must be taken to prevent freeze-up of all water pipes and water receptacles. Failure to follow this warning could result in property damage.

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.

SEQUENCE OF OPERATION Thermostat call for heat

R and W thermostat contacts close signaling the control module to run its self-check routine. After the control module has verified that the pressure switch contacts are open and the limit switch(es) contacts are closed, the draft blower will be energized.

As the induced draft blower comes up to speed, the pressure switch contacts will close and the ignitor warm up period will begin. The ignitor will heat for approximately 20 seconds, then the gas valve is energized to permit gas flow to the burners. The flame sensor confirms that ignition has been achieved within the 4 second ignition trial period.

AIRFLOW ADJUSTMENT

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

WARNING

▲

Disconnect power to the unit before removing the blower door. Failure to follow this warning could result in property damage, personal injury or death.

This unit is equipped with a blower door switch which cuts power to the blower and gas valve causing shutdown when the door is removed. 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.

INDOOR BLOWER TIMING

Heating: The integrated furnace control controls the indoor blower. The blower start is fixed at 45 seconds after ignition. The FAN-OFF period is field selectable by dip switches at 60, 100, 140, or 180 seconds. The factory setting is 100 seconds (See wiring diagram).

Cooling: The fan delay off period is factory set at 0 seconds. The option for 80 second delay off is field selectable (See wiring diagram).

ROOM AIR THERMOSTAT HEAT ANTICIPATOR ADJUSTMENT

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

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Installer’s Guide

INSTRUCTIONS TO THE OWNERS

In the event that electrical, fuel, or mechanical failures occur, the owner should immediately turn the gas supply off at the manual gas valve, located in the burner compartment. Also turn off electrical power to the furnace and contact the service agency designated by your dealer.

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.

ABNORMAL CONDITIONS

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN EXCESS OF 40 M.P.H.) VENT OR FLUE BLOCKAGE If pressure against induced draft blower outlet becomes excessive, the pressure switch will open and shut off the gas valve until acceptable combustion pressure is again available.

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

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

4. GAS SUPPLY FAILURE If loss of flame occurs during a heating cycle, the system integrated control module will recycle the ignition sequence, than if ignition is not achieved, the integrated control module will shut off the gas valve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE If pressure is not sensed by the pressure switch, the contacts will remain open and not allow the gas valve to open, therefore the unit will not start. If failure occurs during a running cycle, the pressure switch contacts will open and the gas valve will close to shut the unit down.

6. CONDENSATE DRAIN BLOCKAGE If the condensate drain is blocked, either by debris, improper draining, or by freezing condensate, the pressure switch will sense the accumulation of condensate in the furnace drain pan. 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 control module has shut the system down and gone into lockout, the system must be manually reset before the unit will restart. To reset, turn the system power off, then on, then off and then on again within 30 seconds. This may be done at the unit’s power source or at the thermostat. The system will not reset unless the

procedure off-on-off-on is completed within 30 seconds.

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

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

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

WARNING

▲

This product contains fiberglass wool insulation! Fiberglass dust and ceramic fibers are believed by the

State of California to cause cancer through inhalation. Glasswool fibers may also cause respiratory, skin, or eye irritation.

PRECAUTIONARY MEASURES

●

Avoid breathing fiberglass dust.

●

Use a NIOSH approved dust/mist respirator.

●

Avoid contact with the skin or eyes. Wear long-sleeved, loose-fitting clothing, gloves, and eye protection.

●

Wash clothes separately from other clothing: rinse

washer thoroughly.

●

Operations such as sawing, blowing, tear-out, and spraying may generate fiber concentrations requiring additional respiratory protection. Use the appropriate NIOSH approved respirator in these situations.

FIRST AID MEASURES Eye Contact – Flush eyes with water to remove dust.

If symptoms persist, seek medical attention.

Skin Contact – Wash affected areas gently with soap

and warm water after handling.

American Standard Inc. 6200 Troup Highway Tyler, TX 75707

For more information contact your local dealer (distributor)

P.I. 11/02

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

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