Trane TUD2B060A9V3VB, TUD2B080A9V3VB, TUD2C080A9V4VB, TUD2C080B9V4VB, TUD2B100A9V3VB Installer's Manual

...

1 8- CD3 1 D1 - 5

18-CD31D1-5

Installer’s Guide

Variable Speed, 2-Stage Upﬂow / Horizontal and Downﬂow / Horizontal, Gas-Fired Furnaces, “Fan Assisted Combustion System”

*UD2B060A9V3VB *UD2B080A9V3VB *UD2C080A9V4VB *UD2C080B9V4VB *UD2B100A9V3VB

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.

For VENT SIZING INFORMATION see:

USA —

National Fuel Gas Code ........... ANSI Z223.1/NFPA 54 (latest version)

CANADA —

Natural Gas Installation Code ........ CAN/CGA-B149.1 (latest version)

Propane Installation Code ............... CAN/CGA-B149.2 (latest version)

USA/CANADA ALTERNATE —

Category I Venting Guide ........... Pub. No. 18-CH23D1 (latest version)

*DD2-9V

*UD2C100A9V5VB *UD2C100B9V5VB *UD2D120A9V5VB *UD2D120B9V5VB *UD2D140A9V5VB

*UD2-9V

*DD2B060A9V3VA *DD2B080A9V3VA *DD2C100A9V5VA *DD2D120A9V5VA

*__First letter may be “A” or “T”

Downﬂow / Horizontal*

*Horizontal Conversion for these furnaces may be left or right side rotation.

Upﬂow / Horizontal*

A341789P10

Installer’s Guide

▲

WARNING

CARBON MONOXIDE POISONING HAZARD

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

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

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the 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

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 13-14), 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 18) 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 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 manufacturer’s instructions.

b. The furnace is controlled only by a room thermostat

(no ﬁeld jumpers).

c. The furnace return air duct must be complete and

sealed to the furnace and clean air ﬁlters are in place.

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 be-

tween 55 and 80 degrees Fahrenheit.

g. Clean the furnace, duct work, and components upon

substantial completion of the construction process, and verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer’s instructions.

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

SAFETY SECTION

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

a. WARNING indicates a potentially hazardous situation

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

b. CAUTION indicates a potentially hazardous situation

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

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.

Installer’s Guide

▲

CAUTION

▲

CAUTION

▲

WARNING

▲

WARNING

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 Fan Assisted Combustion system CATEGORY I furnaces as required by ANSI Z21.47 “latest edition” and CAN/CGA 2.3. Therefore they do not require any special provisions for venting other than what is indicated in these instructions. (Category I deﬁned on page 13).

Contents

Installation Instructions 3

General Installation Instructions 3 Location and Clearances 3

Outline Drawing 4-5

Upﬂow Installation 6 Downﬂow Installation 6 Horizontal Installation 6 Air for Combustion and Ventilation 7 Duct Connections 8 Return Air Filters 9-13 General Venting Instructions 13 Venting into a Masonry Chimney 13 Electrical Connections 15

Field Wiring Diagrams 16-17

Gas Piping 18 Combustion and Input Check 18 High Altitude Derate 20

Start Up and Adjustment 21

Preliminary Inspections 21 Lighting Instructions 21 Sequence Of Operation 21 Control and Safety Switch Adjustment 22

Abnormal Conditions 23

IFC Error Flash Codes 24

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

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

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.

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.

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.

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.

18-CD31D1-5 3

Installer’s Guide

From Dwg. 21C341699 Rev. 4

(ALL DIMENSIONS ARE IN INCHES)

*UD2-9V OUTLINE DRAWING

17-1/2" 9-5/8" 16-1/4" 16"

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

*UD2B060A9V3VB

*UD2B080A9V3VB

21" 13-1/16" 19-3/4" 19-1/2"

*UD2B100A9V3VB

*UD2C080A9V4VB

*UD2C080B9V4VB

*UD2C100A9V5VB

*UD2C100B9V5VB

24-1/2" 15-5/16" 23-1/4" 23"

*UD2D120A9V5VB

*UD2D120B9V5VB

*UD2D140A9V5VB

* - The First Letter May Be "A" or "T"

4 18-CD31D1-5

Installer’s Guide

From Dwg. 21C341700 Sh. 1 Rev. 0

(ALL DIMENSIONS ARE IN INCHES)

*DD2-9V OUTLINE DRAWING

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

*DD2B060A9V3VA

17-1/2" 9-5/8" 16-1/4" 16"

*DD2B080A9V3VA

*DD2C100A9V5VA 21" 13-1/16" 19-3/4" 19-1/2"

*DD2D120A9V5VA 24-1/2" 15-5/16" 23-1/4" 23"

* - The First Letter May Be "A" or "T"

18-CD31D1-5 5

Installer’s Guide

UPFLOW

FURNACE

CASED

COIL

SCREWS

(BOTH SIDES)

STANDOFFS

(BOTH SIDES)

STANDOFFS (4)

DRILL SCREWS (4)

▲

WARNING

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.

UPFLOW INSTALLATION

Standoffs and screws (See Figure 1, page 6) are included with the cased coils for attachment to the furnace. There are clearance alignment holes near the bottom of the coil wrapper. Drill screws are used to engage the furnace top ﬂanges. The standoff is inserted into the cabinet alignment hole. The drill screws are inserted through the standoffs then screwed into the furnace ﬂange. The coil is always placed downstream of the furnace airﬂow. The above instructions apply only if the coil is on top of an upﬂow furnace.

FOR VERTICAL

INSTALLATIONS:

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"

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used in the horizontal.

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 Fig- ure 4.

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

The cased coil is secured to the furnace and both the furnace and the cased coil must be properly supported. The brackets mount using the rear screws on the coil case and use the screws provided to secure the bracket to the furnace. The remaining bracket is placed as close to center as possible (horizontally) between the coil case front and the furnace bottom channel (for downﬂow/horizontal furnace). Use four of the screws provided to secure the bracket.

RETURN

DUCT WIDTH

FLOOR OPENING PLENUM OPENING

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

DOWNFLOW INSTALLATION

REQUIRED FLOOR OPENING: (DOWNFLOW)

See Figure 3 and Table 1

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW FUR-

NACE IN HORIZONTAL

This furnace may be installed in an attic or crawl space in the horizontal position by placing the furnace on the left or right side (as viewed from the front in the upright 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 Clearance Table on Outline Drawings and Figure 5).

A (width)

FURNACE

FRONT

6 18-CD31D1-5

B (depth)

Typical Upﬂow/Horizontal Attic Installation

If the furnace is suspended using perforated steel strap (plumber’s strap), it must be supported at all four corners

and in the middle at the front of the furnace. The forward most screw on the side of the furnace may be used to connect the strapping (See Figure 5). Line contact is only permissible between lines formed by the intersection of the top and two sides of the furnace casing and the building joists, studs, or framing.

A cutout is provided on both sides of the downﬂow furnace cabinet to allow a 90° elbow to be attached inside the cabinet and the vent piping to connect there. In horizontal, the downﬂow furnace may be vented through the top of the cabinet if needed. In vertical conﬁguration, the downﬂow furnace may be vented using the side cabinet cutouts. This venting conﬁguration could be used if an electronic air cleaner is installed.

When the downﬂow furnace is vented through the left side of the furnace cabinet in horizontal or vertical conﬁguration, Type B vent pipe must be used within the cabinet.

Typical Suspended Upﬂow/Horizontal Furnace

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 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.

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

Installer’s Guide

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

The openings shall communicate directly, or by ducts,

3. The following types of installations will require use

* 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

* 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

UNCONFINED

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

CONFINED

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

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.

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.

with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 3, for minimum open areas required.

of OUTDOOR AIR for combustion, due to chemical exposures:

air supply will also require OUTDOOR AIR for combustion:

TABLE 2

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE

MAXIMUM BTUH

INPUT RATING

60,000

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

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE

FEET OF UNCONFINED SPACE

375 500 625 750 875

18-CD31D1-5 7

Installer’s Guide

TABLE 3

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000

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

Air

From

Inside

100 100 100 120 140

Air From Outside

Vertical

Duct

15 20 25 30 35

Horizontal

Duct

30 40 50 60 70

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. Check on controls to make certain they are correct for the electrical supply.

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 55° 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.

RETURN AIR DUCT CONNECTION

NOTE: On upﬂow 5 or 6 ton airﬂow models, if the airﬂow requirement exceeds 1800 CFM, these models will require return air openings and ﬁlters on both sides; OR 1 side and the bottom; OR just the bottom.

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

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.

8 18-CD31D1-5

Installer’s Guide

▲

WARNING

TO PREVENT INJURY OR DEATH DUE TO CONTACT WITH MOVING PARTS, TURN THE POWER TO THE FURNACE OFF BEFORE SERVICING FILTERS.

▲

WARNING

Do not install the filter in the return duct directly above the furnace in horizontal applications. Install the filter remotely. Installing the filter directly above the furnace in horizontal applications may cause property damage, serious injury or death.

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 12 and the outline drawing on page 4 for duct connection dimensions for various furnaces.

5. 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. Rotate the channel downward (or remove by lowering the front edge of the channel and pulling forward). Slide the bottom return air panel out of the cabinet. Rotate the front channel to its original position and reinstall the two 5/16” screws.

REMOVE FILTER FROM UPFLOW FURNACE WHEN RETURN DUCT IS ATTACHED TO FURNACE TOP SIDE (HORIZONTAL LEFT OR RIGHT APPLICATIONS) AS SHOWN.

FILTER

6. 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 12. Cut corners diagonally and bend outward to form ﬂange.

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

8. Upﬂow Furnaces: Filter clips are factory supplied for bottom or side return. Use the clips on either side or on the bottom if the ﬁlter is to be used within the furnace cabinet.

When the upﬂow furnace is installed in the horizontal

right or left application and a return duct is attached to the top side as shown in Figure 11, remove the ﬁlter from the furnace and install in a remote location. Do not install the ﬁlter in the return duct directly above the furnace in horizontal applications.

When the upﬂow furnace is installed in the horizontal

right or left application and a close coupled (less than 36") return duct is attached to the bottom side of the furnace as shown in Figure 11, securely attach a 1/2" mesh metal hardware cloth protective screen to the inside bottom of the ﬁlter grill to prevent personal

injury from contacting moving parts when reaching into the return opening to replace the ﬁlter.

Close coupled (less than 36") return (ﬁlter directly

beneath bottom side return) is not recommended due to noise considerations.

Downﬂow Furnaces: Brackets are factory supplied

to mount ﬁlters in the return air duct work.

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

LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT

CUT OUT

FOR

SIDE

FILTER

FRONT

of Furnace

*SEE OUTLINE DRAWING

Close coupled (less than 36") return (ﬁlter directly beneath bottom side return) not recommended due to noise considerations. If used, securely attach 1/2" mesh metal hardware cloth protective screen to the inside bottom of ﬁlter grill.

18-CD31D1-5 9

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 recom-

mended that both supply and return air plenums are removable.

10. 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.

11. 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.

Installer’s Guide

VIEW

ENGAGEMENT

HOLE DETAIL

(Typical both sides and blower deck)

Blower Deck Engagement

Hole

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 located 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.

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 furnace and the bottom ﬁlter rack, BAYRACK960, installation can be seen in Figures 13, 14 and 15.

TABLE 4

UPFLOW FURNACE RETURN AIR FILTERS

CABINET

WIDTH

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

21" 1 20" X 25" X 1" 17-1/2" X 25" X 1"

24-1/2" 1 24" X 25" X 1" 17-1/2" X 25" X 1"

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

QTY*

CABINET

BOTTOM FILTER

CABINET

SIDE FILTER

ALTERNATE FILTER RACK INSTALLATION FOR BOTTOM RETURN

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.

d. Reinstall the furnace ﬁlter in the bottom position by

inserting the chamfer end ﬁrst into the ﬁlter rack. See Figures 13-16.

NOTE: There is no internal right side ﬁlter access with the use of the ﬁlter rack on furnace models *UD060R9V3, *UD2C080B9V4VA, and *UD2C100B9V5VA.

Airflow

Filter Rack Assembly

Airflow

BOTTOM FILTER RACK INSTALLATION

10 18-CD31D1-5

ALTERNATE FILTER RACK INSTALLATION FOR SIDE RE-

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 Assembly

Furnace Blower Deck

Filter Rack Retaining Screw/Pin

Engagement Hole For

Return

Filter Rack Installation With Side

Furnace

Cabinet

Side

Bottom Panel

Filter Rack

Furnace

Cabinet

Side

Filter Rack Retaining Screw/Pin

Engagement Hole

For

Bottom Return

Filter Rack

Installation With

TURN AIR ON UPFLOW FURNACES (LEFT OR RIGHT)

The following checklist should be used when installing a right or left side return ﬁlter in 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 8.

d. Compress the ﬁlter rack and reinstall in the side po-

sition 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 17-20.

e. Reinstall the furnace ﬁlter in the side position by

inserting the chamfer end ﬁrst into the ﬁlter rack.

Cabinet Width Left Side Bottom Right Side

17.5 X X X

21 X X X

24.5 X X X

1. UD060C/R936K0 has 10x7 blower which requires use of alternate ﬁlter clips for left side ﬁlter. "K1" and later use the ﬁlter rack.

2. Remove bottom front channel to install or reposition ﬁlter rack. X - All Models

Installer’s Guide

BLOWER DECK

BOTTOM ENGAGEMENT

18-CD31D1-5 11

Typical Upﬂow Left Side Return Filter Rack Installation

Typical Upﬂow Right Side Return Filter Rack Installation

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 21.

Airﬂow

Optional door kit BAYFLTR206

Typical Horizontal Filter Installation

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

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

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

UPFLOW FILTER CLIP / BRACKET INSTALLATION

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

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

22.

SIDE

CUT-OUT

Airﬂow

Optional door kit BAYFLTR206

ALTERNATE BOTTOM

FILTER CLIPS LOCATIONS

12 18-CD31D1-5

ALTERNATE SIDE

FILTER CLIPS

LOCATIONS

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 23. Tables 5 and 6 provide information for installation of the ﬁlter retaining brackets shipped with downﬂow furnaces.

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.

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 spaces of the building.

4. Close fireplace dampers.

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

▲

WARNING

▲

WARNING

▲

WARNING

TABLE 5

CABINET

WIDTH

17-1/2" 2 - 16X20X1 14-3/8"

21" 2 - 16X20X1 13-1/8"

24-1/2" 2 - 16X20X1 11-5/8"

* Location dimension is from end of duct to the screw holes for the bracket.

CABINET

WIDTH

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

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

24-1/2" 23-1/4" 22" 14"

RETURN

DUCT

WIDTH

FILTER

SIZE

TABLE 6

FILTER ACCESS

OPENING - DI-

MENSION "A"

FILTER BRACKET

GENERAL VENTING INSTRUCTIONS

18-CD31D1-5 13

LOCATION *

FILTER ACCESS

OPENING -

DIMENSION "B"

VENT PIPING

These furnaces have been classiﬁed as Fan-Assisted Combustion System, Category I furnaces under the “latest edition” provisions of ANSI Z21.47 and CAN/CGA 2.3 standards. Category I furnaces operate with a non-positive vent static pressure and with a ﬂue loss of not less than 17 percent.

NOTE: If desired, a side wall termination can be accomplished through the use of an “add-on” draft inducer. The inducer must be installed according to the inducer manufacturer’s instructions. Set the barometric pressure relief to achieve

-0.02 inch water column.

NOTE: When the downﬂow furnace is vented through the left side of the furnace cabinet using the provided cutout, Type B vent piping must be used.

The furnace shall be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction.

Furnace venting into an unlined masonry chimney or concrete chimney is prohibited. Failure to follow this warning could result in property damage, personal injury, or death.

VENTING INTO A MASONRY CHIMNEY

If the chimney is oversized, the liner is inadequate, or ﬂue-gas condensation is a problem in your area, consider using the chimney as a pathway or chase for type “B” vent or ﬂexible vent liner. If ﬂexible liner material is used, size the vent using the “B” vent tables, then reduce the maximum capacity by 20% (multiply 0.80 times the maximum capacity). Masonry Chimney Kit BAYVENT800B may be used with these furnaces (Upﬂow model furnaces only) to allow venting into a masonry chimney. Refer to the BAYVENT800B Installer’s Guide for application requirements.

Internal Masonry Chimneys

Venting of fan assisted appliances into a lined, internal masonry chimney is allowed only if it is common vented with at least one natural draft appliance; OR, if the chimney is lined with type “B”, double wall vent or suitable ﬂexible liner material (See Table 7).

The chimney liner must be thoroughly inspected to insure no cracks or other potential areas for ﬂue gas leaks are present in the liner. Liner leaks will result in early deterioration of the chimney.

Failure to follow this warning could result in carbon monoxide poisoning or death.

Installer’s Guide

▲

WARNING

NOTE: The following section does not apply if BAYVENT800B (Masonry Chimney Vent Kit) is used. All instructions with the kit must be followed.

TABLE 7

MASONRY CHIMNEY VENTING

Tile Lined Chimney

Type Furnace Internal External “B” Vent

Single Fan

Assist

Fan Assist

Natural

* Flexible chimney liner size is determined by using the type “B” vent size for the available BTUH input, then reducing the maximum capacity by 20% (multiply maximum capacity times 0.80). The minimum capacity is the same as shown in the “B” vent tables.

No No Ye s Yes*

Ye s No Ye s Yes*

Chimney Lining

Flexible

Metal Liner

EXTERNAL MASONRY CHIMNEY

Venting of fan assisted appliances into external chimneys (one or more walls exposed to outdoor temperatures), requires the chimney be lined with type “B”, double wall vent or suitable ﬂexible chimney liner material. This applies in all combinations of common venting as well as for fan assisted appliances vented alone.

The following installation practices are recommended to minimize corrosion caused by condensation of ﬂue products in the furnace and ﬂue gas system.

TABLE 8

GAS VENT TERMINATION

ROOF PITCH MINIMUM HEIGHT

FLAT TO 7/12 OVER 7/12 TO 8/12 OVER 8/12 TO 9/12

OVER 9/12 TO 10/12 OVER 10/12 TO 11/12 OVER 11/12 TO 12/12 OVER 12/12 TO 14/12 OVER 14/12 TO 16/12 OVER 16/12 TO 18/12 OVER 18/12 TO 20/12 OVER 20/12 TO 22/12

* THIS REQUIREMENT COVERS MOST INSTALLATIONS

1.0 FEET *

1.5 FEET

2.0 FEET

2.5 FEET

3.25 FEET

4.0 FEET

5.0 FEET

6.0 FEET

7.0 FEET

7.5 FEET

8.0 FEET

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.

1. Avoid an excessive number of bends.

2. Horizontal runs should pitch upward at least 1/4" per foot.

3. Horizontal runs should be as short as possible.

4. All vent pipe or connectors should be securely supported and must be inserted into, but not beyond the inside wall at the chimney vent.

5. When vent connections must pass through walls or partitions of combustible material, a thimble must be used and installed according to local codes.

6. Vent pipe through the roof should be extended to a

11. Horizontal pipe runs must be supported by hangers, straps or other suitable material in intervals at a minimum of every 3 feet of pipe.

12. A furnace shall not be connected to a chimney or ﬂue serving a separate appliance designed to burn solid fuel.

13. The ﬂow area of the largest section of vertical vent or chimney shall not exceed 7 times the smallest listed appliance categorized vent area, ﬂue collar area, or draft hood outlet area unless designed in accordance with approved engineering methods.

Maximum Vent or Tile

= X 7

π(D*)

Lined Chimney Flow Area

*Drafthood outlet diameter, ﬂue collar diameter, or listed appliance categorized vent diameter.

height determined by National Fuel Gas Code or local codes. It should be capped properly to prevent rain water from entering the vent. Roof exit should be waterproofed.

7. Use type “B” double wall vent when vent pipe is routed through cool spaces (below 60° F.).

8. Where long periods of airﬂow are desired for comfort, use long fan cycles instead of continuous airﬂow.

9. Apply other good venting practices as stated in the venting section of the National Fuel Gas Code ANSI Z223.1 “latest edition”.

10. Vent connectors serving appliance vented by

natural draft or non-positive pressure shall not be connected into any portion of a mechanized draft system operating under positive pressure.

14 18-CD31D1-5

▲

CAUTION

▲

WARNING

ELECTRICAL CONNECTIONS

▲

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.

The integrated furnace control is polarity sensitive. The hot leg of the 115 VAC power must be connected to the BLACK ﬁeld lead.

To prevent injury or death due to electrical shock or contact with moving parts, lock unit disconnect switch in the open position before servicing the unit. Failure to follow this warning could result in electrical shock, personal injury, or death.

Installer’s Guide

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 it 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 “latest edition” or Canadian Electrical Code, CSA C22.1, if an external electrical source is utilized.

All ﬁeld supplied wiring must conform with the temperature limitation for Type T wire [63° F (35° C)], when installed in accordance with these instructions and wiring diagrams supplied with the furnace. A disconnecting means must be located within sight from, and readily accessible to, the furnace.

Refer to the SERVICE FACTS literature for unit wiring diagrams in addition to the diagram inside the blower door.

18-CD31D1-5 15

Installer’s Guide

FIELD WIRING DIAGRAMS

16 18-CD31D1-5

FIELD WIRING DIAGRAMS

Installer’s Guide

18-CD31D1-5 17

Installer’s Guide

▲

WARNING

▲

WARNING

▲

CAUTION

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.

▲

WARNING

▲

WARNING

TOP VIEW

AUTOMATIC GAS VA LVE WITH MANUAL SHUTOFF

DRIP LEG

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 commercially 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.

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.

LEFT SIDE PIPING (STANDARD)

GAS PIPING

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

This unit is shipped standard for left side installation of gas piping. A piping knockout is also provided in the right side for an alternate 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. Refer to piping Table 10 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.

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.

RIGHT SIDE PIPING (OPTIONAL)

TOP VIEW OF RIGHT SIDE PIPING

TO PREVENT AN EXPLOSION OR POSSIBLE INJURY,

DEATH AND EQUIPMENT DAMAGE, DO NOT STORE COMBUSTIBLE MATERIALS, GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS NEAR THE UNIT.

18 18-CD31D1-5

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

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. DO NOT CHECK WITH AN OPEN FLAME!

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 13 with the time clocked.

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

5. Use the following factors if necessary:

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 =

10X Chart Flow Reading ÷ 4

6. Multiply the ﬁnal ﬁgure by the heating value of the gas

▲

WARNING

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

Gas Valve Adjustment

Changes can be made by adjusting the manifold pressure

(See Table 9), or changing oriﬁces (oriﬁce change may not always be required). To adjust the manifold pressure:

1. Turn off all electrical power to the system.

2. Attach a manifold pressure gauge with ﬂexible tubing to the outlet pressure boss marked “OUT P” on WhiteRodgers gas valve model 36J. See Figure 27 for WhiteRodgers gas valve model 36J.

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

a. The pressure tap adjustment kit (KIT07611) con-

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

4. Turn on system power and energize valve.

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

a. To increase outlet pressure, turn the regulator ad-

just screw clockwise.

b. To decrease outlet pressure, turn the regulator ad-

just screw counterclockwise.

c. Adjust regulator until pressure shown on mano-

meter matches the pressure speciﬁed in Table 9.

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

d. Replace and tighten the regulator cover screw se-

curely.

6. Adjust 2nd stage gas heat by removing the high (HI) adjustment regulator cover screw.

a. To increase outlet pressure, turn the regulator ad-

just screw clockwise.

b. To decrease outlet pressure, turn the regulator ad-

just screw counterclockwise.

c. Adjust regulator until pressure shown on mano-

meter matches the pressure speciﬁed in Table 9.

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

d. Replace and tighten the regulator cover screw se-

curely.

7. Cycle the valve several times to verify regulator set-

ting.

a. Repeat steps 5-7 if needed.

8. Turn off all electrical power to the system.

9. Remove the manometer and ﬂexible tubing and tighten

the pressure tap screw.

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

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

11. Turn on system power and check operation of the

unit.

Installer’s Guide

Explosion Hazard 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.

For LP gases, the ﬁnal manifold pressure setting shall be

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

Table 11 lists the main burner oriﬁces shipped with the furnace. If a change of oriﬁces is required to correct the input rate, refer to Table 12.

Outlet Pressure Boss

Inlet Pressure Boss

2nd Stage (HI) Manifold Pressure Adjustment

Gas Valve On / Off Toggle Switch

White-Rodgers 36J

1st Stage (LO) Manifold Pressure Adjustment

18-CD31D1-5 19

Installer’s Guide

TABLE 9

FINAL MANIFOLD PRESSURE SETTINGS (inches w.c.)

FUEL 2nd Stage Max. 1st Stage Max.

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

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

TABLE 10

ORIFICE SIZES

INPUT

RATING

BTUH

40,000 60,000

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

PIPE

SIZE

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

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

NUMBER

BURNERS

2 3 4 5 6 7

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

10 20 30 40 50 60 70

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 45 45 45 45 45

TABLE 11

LENGTH OF PIPE

TABLE 12

56 56 56 56 56 56

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). 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.

PART

NUMBER

ORF00501 ORF00644 ORF00909 ORF00910 ORF01099 ORF00503 ORF00493

DRILL

SIZE

54 55 56 57 58 59

PART

NUMBER

ORF00555 ORF00693 ORF00907 ORF00908 ORF01338 ORF01339

Important:

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

See Table 14 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. Installation of this furnace at altitudes above 2,000 ft. (610m) shall be in accordance with the 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 149.1. Installation

of this furnace at altitudes above 2,000 ft. (610m) shall be made in accordance with the listed high Altitude Conversion Kit available with this furnace.

TABLE 13

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

TABLE 14

Oriﬁce

Twist Drill

ALTITUDE ABOVE SEA LEVEL

and Oriﬁce Required At Other Elevations

Size If

Installed

At Sea

2000 3000 4000 5000 6000 7000 8000 9000 10000

Level

42 43 44 45 46 47

54 55 56 57 58

42 44 45 46 47 48

54 55 56 58 59

43 44 45 47 47 48

55 55 56 59 60

43 44 45 47 47 49

55 55 57 59 60

43 45 46 47 48 49

55 56 57 60 61

44 45 47 48 48 49

55 56 57 60 62

44 46 47 48 49 50

55 56 58 61 62

45 47 48 49 49 50

56 56 59 62 63

46 47 48 49 50 51

56 56 59 63 63

47 48 50 50 51 52

56 57 60 63 64

From National Fuel Gas Code - Table F-4

20 18-CD31D1-5

▲

WARNING

DO NOT attempt to manually light the burner. Failure to

▲

CAUTION

▲

WARNING

follow this warning could result in property damage, personal injury or death.

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

Turn knob on 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. Turn the knob on the gas valve in the unit to the “ON” position.

LIGHTING INSTRUCTIONS

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.

TO SHUT OFF

For complete shutdown: Move the control switch on the main gas valve to the “OFF” position (See Figures 28 and

29). Disconnect the electrical supply to the unit.

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 in below freezing weather. If for any reason your furnace should fail to operate damage could result, such as frozen water pipes.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Installer’s Guide

SEQUENCE OF OPERATION

Thermostat call for heat (2-stage thermostat)

Call for 1st stage only:

R and W1 thermostat contacts close signaling the control module to run its self-check routine. After the control module has veriﬁed that the 1st stage pressure switch contacts are open and the limit switch(es) contacts are closed, the draft blower will be energized.

As the induced draft blower comes up to speed, the pressure switch contacts will close and the ignitor warm up period will begin. The ignitor will heat for approx. 20 seconds, then the gas valve is energized in 1st stage to permit gas ﬂow to the burners. The ﬂame sensor conﬁrms that ignition has been achieved within the 4 second ignition trial period.

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

Call for 2nd stage after 1st stage:

R and W2 thermostat contacts close signaling a call for 2nd stage heat. After a 30 second delay, the induced draft blower will be energized on high speed and the 2nd stage pressure switch contacts will close allowing the gas valve to be energized in 2nd stage and the indoor blower motor in high speed.

2nd stage satisﬁed, 1st stage still called:

R and W2 thermostat contacts open signaling that 2nd stage heating requirements are satisﬁed. The induced draft blower is reduced to low speed allowing the 2nd stage pressure switch contacts to open and the gas valve is reduced to 1st stage. After approx. 30 seconds the indoor blower motor is reduced to low speed.

1st stage satisﬁed:

R and W1 thermostat contacts open signaling that 1st stage heating requirements are satisﬁed. The gas valve will close 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 90, 120, 150 or 180 seconds - Factory setting is 90 seconds), then will be de-energized by the control module.

Thermostat call for heat (1-stage Thermostat)

R and W thermostats close signaling a call for heat. 1st stage sequence of operation remains the same as above. 2nd stage delay will be reﬂective dip switch S7-1 and S7-2. Reference the back of service facts for delay options.

Thermostat satisﬁed:

R and W contacts open signaling the control module to close the gas valve and de-energize the induced draft blower. The indoor blower motor will continue to operate at high heat speed for approx. 30 seconds after the ﬂames are extinguished and then is switched to low heat speed for the remaining FAN-OFF period.

INDOOR BLOWER OPERATION WITH THERMOSTAT FAN SWITCH “ON”:

Fan is R-G.

R-W energized, fan continues to run without interruption.

Heat Low speed if it is a two stage furnace.

Heat speed if it is a single stage furnace.

18-CD31D1-5 21

Installer’s Guide

▲

WARNING

▲

WARNING

▲

WARNING

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

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

CONTROL AND SAFETY SWITCH ADJUSTMENT

LIMIT SWITCH CHECK OUT

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

To check for proper operation of the limit switches, set the thermostat to a temperature higher than the indicated temperature to bring on the gas valve. Restrict the airﬂow by blocking the return air or by disconnecting the blower. When the furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and overheating is evident, a faulty limit switch is probable and the limit switch must be replaced. After checking the operation of the limit control, be sure to remove the paper or cardboard from the return air inlet, or reconnect the blower.

INDOOR BLOWER TIMING

Heating: The Integrated Furnace Control (IFC) controls the variable speed indoor blower. The blower “on” time is ﬁxed at 45 seconds after ignition. The FAN-OFF period is ﬁeld selectable by dip switches S7-3 and S7-4 on the Integrated Furnace Control at 90, 120, 150, or 180 seconds. The factory setting is 90 seconds (See unit wiring diagram).

Cooling: The fan delay-off period is set by dip switches on the Integrated Furnace Control. The options for cooling delay off is ﬁeld selectable by dip switches S4-1 and S4-2.

The following table and graph explain the delay-off settings:

TABLE 12 COOLING OFF - DELAY OPTIONS

SWITCH SETTINGS SELECTION

S4-1 - OFF S4-2 - OFF NONE SAME

S4-1 - ON S4-2 - OFF 1.5 MINUTES 100% *

S4-1 - OFF S4-2 - ON 3 MINUTES 50%

S4-1 - ON S4-2 - ON ** 50 - 100%

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.

NOMINAL AIRFLOW

* - This setting is equivalent to BAY24X045 relay ben-

eﬁt.

** - This selection provides ENHANCED MODE, which

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

100% if necessary

80%

Dehumidify

50%

Fast Cooling

OFF

minute

See Wiring Diagram on the unit or in the Service Facts

for complete wiring setup for Enhanced Mode.

7.5

minutes

Efﬁciency

50%

OFF

minutes

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

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 inside the furnace casing).

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 (See Figure 27).

Also turn off electrical power to the furnace and contact the service agency designated by your dealer.

Should overheating occur, or the gas supply fail to shut off, shut off the gas valve to the unit before shutting off the electrical supply. Failure to follow this warning could result in property damage, personal injury, or death.

22 18-CD31D1-5

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

ABNORMAL CONDITIONS

▲

WARNING

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

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.

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, then if ignition is not achieved, the integrated control module will shut off the gas valve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE 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. 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.

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

A variety of potential sources of carbon monoxide can be found in a building or dwelling such as gas-ﬁred clothes dryers, gas cooking stoves, water heaters, furnaces and ﬁreplaces. The U.S. Consumer Product Safety Commission recommends that users of gas-burning appliances install carbon monoxide detectors as well as ﬁre and smoke detectors per the manufacturers installation instructions to help alert dwelling occupants of the presence of ﬁre, smoke or unsafe levels of carbon monoxide. These devices should be listed by Underwriters Laboratories, Inc. Standards

for Single and Multiple Station Carbon Monoxide Alarms, UL 2034 or CSA International Standard, Residential Carbon Monoxide Alarming Devices, CSA 6.19

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

18-CD31D1-5 23

Installer’s Guide

IFC ERROR FLASH CODES

Installer’s Guide

* The diagnostics will indicate the speciﬁc fault through the following code:

GREEN LED AMBER LED RED LED ERROR

FLASH FLASH FLASH

1 1st stage call for heat 2 2nd stage call for heat 3 W2 call present without W1 4 Y call present without G

Rapid Low flame sense current

1 Standby mode or call for cooling

1 Flame Sensed when no flame should be present 2 Pressure switch stuck closed 3 1st stage pressure switch is open / not closing 4 Open thermal limit or open rollout 5 Open low voltage fuse 6 1st stage pressure switch opened 5 times within one cycle--1 hour lockout 7 System lockout Retry 8 System lockout Recycle

9 Reverse polarity or poor grounding 10 Gas valve energized without call for heat 12 Ignitor relay failure internal in board. Replace IFC

Solid Gas valve relay failure internal in board. Replace IFC

3 Double 2nd stage pressure switch open; system reverts back to 1st stage heat

See Service Facts for additional troubleshooting information.

Literature Order Number 18-CD31D1-5

File Number 18-CD31D1-5

Supersedes 18-DC31D1-4

Trane 6200 Troup Highway Tyler, TX 75707

For more information contact your local dealer (distributor)

Date 06/11

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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