Trane AUH1D100A9601A, AUH1C080A9601A, AUH1D120A9601A, AUH1C100A9481A, ADH1B065A9421A Installer's Manual

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Page 1

18-CD29D1-11

Installer’s Guide

Upﬂow/ Horizontal, Downﬂow/ Horizontal, Gas-Fired, Direct Vent Condensing Furnaces

*UH1B040A9241A *UH1B060A9361A *UH1B080A9421B *UH1C080A9601A

*__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.

*UH1

UPFLOW

*UH1C100A9481A *UH1D100A9601A *UH1D120A9601A

*DH1B040A9241A *DH1B065A9421A *DH1C085A9481A *DH1D110A9601A

*DH1

DOWNFLOW

*UH1

UPFLOW/HORIZONTAL

*DH1

DOWNFLOW/HORIZONTAL

A341624P13

Page 2

Installer’s Guide

▲

WARNING

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 WARN- ING and CAUTION. a. WARNING indicates a potentially hazardous situa-

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

b. CAUTION indicates a potentially hazardous situa-

tion 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.

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

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

2. Install this furnace only in a location and position as speciﬁed in “Location and Clearances” (page 4), of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as speciﬁed in “Air for Combustion and Ventilation” (pages 8-9), of these instructions.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as speciﬁed in the “Venting” section (starting on page 15), 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” (pages 31-32), 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 4), of these instructions.

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

a. The furnace venting system must be complete

and installed per manufacturers instructions.

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

mostat (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 require-

ment must come from outside the structure.

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 B149.1 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.

Page 3

Installer’s Guide

▲

WARNING

▲

CAUTION

f. The furnace return air temperature range is

between 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.

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.

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, 400 N. Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or www.aga.org These furnaces have been classiﬁed as CATEGORY IV furnaces in accordance with latest edition of ANSI

Z21.47 • CAN/ CGA 2.3 standards.

Category IV furnaces operate with positive vent static pressure and with a ﬂue loss less than 17 percent. These conditions require special venting systems, which must be gas tight and water tight. These Category IV Direct Vent furnaces are approved for installa-

tion in Manufactured/ Mobile housing when used with BAYMFGH100A.

Contents

INSTALLATION INSTRUCTIONS

General Installation Instructions 3 Location and Clearances 4 Outline Drawings 5 Upﬂow Installation 7 Downﬂow Installation 7 Horizontal Installation 7 Air For Combustion and Ventilation 8 Duct Connections 10 Return Air Filters 11 General Venting Instructions 15 Venting Material 17 Venting Tables 18 Horizontal Venting 21 Venting Through The Wall 21 Venting Through The Roof 22 Downward Venting 24 Venting Through a Masonry Chimney 24 Condensate Drain Instructions 27 Electrical Connections 30 Field Wiring Diagrams 29 Gas Piping 32 Combustion Input Checks 33

Start Up and Adjustment 36

Preliminary Inspections 36 Lighting Instructions 36 Sequence Of Operation 37 Control And Safety Switch Adjustments 37 Airﬂow Adjustment 37

Abnormal Conditions 38

IFC Error Flash Code 40

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.

18-CD29D1-11 3

Page 4

Installer’s Guide

▲

CAUTION

▲

WARNING

UPFLOW

FURNACE

CASED

COIL

SCREWS

(BOTH SIDES)

STANDOFFS

(BOTH SIDES)

STANDOFFS (4)

DRILL SCREWS (4)

▲

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.

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

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 vent and as centralized for heat distribution as practical?

2. Do all clearances between the furnace and enclosure equal or exceed the minimums shown in the Table 1.

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 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 12" minimum above the highest snow accumulation level?

6. Allow sufﬁcient height in supply plenum above or below 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 (46 cm) 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) are included with the cased coils for attachment to the furnace. There are clearance alignment holes near the bottom of the coil wrapper. Drill screws are used to engage the furnace top ﬂanges. The standoff is inserted into the cabinet alignment hole. The drill screws are inserted through the standoffs then screwed into the furnace ﬂange.

The coil is always placed downstream of the furnace airﬂow.

FOR VERTICAL

INSTALLATIONS:

DOWNFLOW INSTALLATIONS

FIRE HAZARD Do NOT install the furnace directly on carpeting, tile or other combustible material other than wood ﬂooring. For vertical downﬂow application, subbase (BAYBASE-205) 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:

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.

NOTE: On upﬂow 5 or 6 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.

4 18-CD29D1-11

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"

SUBBASE CROSS SECTION

TABLE 1

RETURN

DUCT WIDTH

FLOOR OPENING PLENUM OPENING

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

Page 5

1. *UH1D120A9601, *UH1C080A9601, *UH1C100A9481, AND

UH1D100A9601 REQUIRE 3” DIAMETER VENT PIPE.

2. DIAMETER OF VENT PIPE MAY BE LIMITED TO 2-1/2” OR 3”

ON SOME MODELS AT DIFFERENT ALTITUDES. REFER TO THE

VENT LENGTH TABLE FOR PROPER APPLICATION.

Installer’s Guide

From Dwg. C341884 Rev. 9

(ALL DIMENSIONS ARE IN INCHES)

*UH1 OUTLINE DRAWING, UPFLOW / HORIZONTAL

18-CD29D1-11 5

Page 6

Installer’s Guide

From Dwg. C341885 Rev. 7

(ALL DIMENSIONS ARE IN INCHES)

*DH1 OUTLINE DRAWING, DOWNFLOW / HORIZONTAL

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

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

*DH1B040A9241

*DH1B065A9421

*DH1C085A9481 21" 2-1/2" 19-3/4" 19-1/2"

*DH1D110A9601 24-1/2" 2-15/16" 23-1/4" 23"

* May be "A" or "T"

Part numbers can end in A-Z

6 18-CD29D1-11

Page 7

Installer’s Guide

A (width)

FURNACE

FRONT

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 95% 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.

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 downow/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.

B (depth)

UPFLOW/ HORIZONTAL SHOWN

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 a minimum of 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.

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

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 Figure 3 & Clearance Table 1). Line contact is only permissible between lines formed by intersections of the top and two sides of the furnace casing and building joists, studs, or framing.

UNCONFINED

AIR FOR COMBUSTION AND VENTILATION

If these furnaces are installed in a nondirect vent capacity then the adequate ﬂow of combustion and ventilating air must not be obstructed from reaching the furnace. Air openings provided for combustion air must be kept free of obstructions which restrict the ﬂow of air. Airﬂow restrictions affect the efﬁciency and safe operation of the furnace.

Keep this in mind should you choose to remodel or change

the area which contains your furnace. Furnaces must have a free ﬂow of air for proper performance. Provisions for combustion and ventilation air shall be made in accordance with latest edition of Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code,

ANSI Z223.1 — CAN/CGA B149.1 or applicable provisions

of the local building codes. Special conditions created by mechanical exhausting of air and ﬁreplaces must be considered to avoid unsatisfactory furnace operation.

18-CD29D1-11 7

Page 8

Installer’s Guide

OUTSIDE AIR IS RECOMMENDED

The use of indoor air for most applications is acceptable, unless there is the presence of corrosive chemicals or contamination. Certain types of installation will require the use of outside air for combustion. The following types of installations will require use of OUTDOOR AIR for combustion, due to chemical exposures: * Commercial buildings

* Buildings with indoor pools

* Furnaces installed in “conﬁned” laundry rooms * Furnaces installed in “conﬁned” hobby or craft rooms * Furnaces installed near chemical storage areas. Exposure to the following substances in the combustion air supply will also require OUTDOOR AIR for combustion: * Permanent wave solutions * Chlorinated waxes and cleaners * Chlorine based swimming pool chemicals * Water softening chemicals * Deicing salts or chemicals * Carbon Tetrachloride * Halogen type refrigerants * Cleaning solvents (such as perchloroethylene) * Printing inks, paint removers, varnish, etc. * Hydrochloric acid * Cements and glues * Antistatic fabric softeners for clothes dryers * Masonry acid washing materials

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

Unconﬁned space is deﬁned in Figure 6. These spaces may have adequate air by inﬁltration to provide air for combus-

tion and ventilation. Buildings with tight construction (for

example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), may need additional air to be provided as described for conﬁned space.

1. All air from inside the building as in Figure 8: The conﬁned space shall be provided with two permanent openings communicating directly with an additional room(s) of sufﬁcient volume so that the combined volume of all spaces meets the criteria for an unconﬁned space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Refer to Table 2 for minimum open areas requirements.

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

TABLE 3

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

40,000 60,000 80,000 97,000

110,000

Air

From

Inside

100 100 100 100 110

Air From Outside

Vertical

Duct

10 15 20 25 28

Horizontal

Duct

20 30 40 50 55

Conﬁned spaces are installations with less than 50 cu. ft. of

space per 1000 BTU/hr input from all equipment installed,

as in Figure 7. 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.

Table 2

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE MAXI-

MUM BTUH INPUT

RATING

40,000 60,000 80,000 97,000

110,000

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE FEET

OF UNCONFINED SPACE

250 375 500 625 688

CONFINED

SPACE

8 18-CD29D1-11

Page 9

Installer’s Guide

On any job, ﬂexible connections of nonﬂammable material may be used for return air and discharge connections to pre vent transmission of vibration. Though these units have been speciﬁcally designed for quiet, vibration free operation, air ducts can act as sounding boards and could, if poorly installed, amplify the slightest vibration to the annoyance level. When the furnace is located in a utility room adjacent to the living area, the system should be carefully designed with returns to minimize noise transmission through the return air grille. Although these furnaces are designed with large blowers operating at moderate speeds, any blower moving a high volume of air will produce audible noise which could be objectionable when the unit is located very close to a living area. It is often advisable to route the return air ducts under the ﬂoor or through the attic. Such design permits the installation of air return remote from the living area (i.e. central hall). When the furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace and terminating outside the space containing the furnace.

RETURN AIR DUCT CONNECTION

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 the existing supply and return ductwork.

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

DUCT CONNECTIONS

Air duct systems should be installed in accordance with standards for air conditioning systems, National Fire Protection Association Pamphlet No. 90. They should be sized in accordance with ACCA Manual D or whichever is applicable. Central furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling coil to avoid condensation in the heat exchanger. With a parallel ﬂow arrangement, the dampers or other means used to control ﬂow of air shall be adequate to prevent chilled air from entering the furnace, and if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in full heat or cool position.

NOTE: Minimum return air temperature is 55° F.

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 11 and the outline drawing on pages 5-6 for duct connection dimensions for various furnaces.

4. If a 3/4" ange is to be used for attaching the air inlet

duct, add to cut where indicated by dashed lines in Figure 11. 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: Use the optional ﬁlter rack 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

application and a return duct is attached to the top side as shown in Figure 10, install the ﬁlter in a remote location.

Do not install the ﬁlter in the return duct directly

above the furnace in horizontal applications.

18-CD29D1-11 9

Page 10

Installer’s Guide

▲

WARNING

▲

WARNING

When the upﬂow furnace is installed in the horizontal

application and a close coupled (less than 36") return duct is attached to the bottom side of the furnace as

shown in Figure 10, 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.

FIRE OR EXPLOSION HAZARD

Do not install the ﬁlter in the return duct directly above the furnace in horizontal applications. Install the ﬁlter remotely. Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

SAFETY HAZARD

To prevent injury or death due to contact with moving parts, turn the power to the furnace off before servicing ﬁlters

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

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

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.

FILTER

7. Connect the duct work to the furnace. See Outline Drawing (pages 5-6) 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.

LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT

CUT OUT

FOR

SIDE

FILTER

FRONT

of Furnace

*SEE OUTLINE DRAWING

RETURN AIR FILTERS (Filter and ﬁlter rack are not supplied with unit)

TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS

These furnaces require high velocity type air ﬁlters. The optional 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 optional ﬁlters may need to be trimmed for side or bottom ﬁlter use.

The furnace and the blower ﬁlter rack installation can be seen in Figure 12.

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

The ﬁlter rails are spring loaded for automatic adjustment to allow standard size, locally obtainable replacement ﬁlters. The ﬁlter rack itself slides to adjust to the required width needed for bottom or side return.

TABLE 4 - MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL LEFT AND DOWNFLOW/HORIZONTAL RIGHT FURNACES

UNIT LOCATION

FURNACE SURFACE

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

10 18-CD29D1-11

VERTICAL

CLOSET

HORIZONTAL

CLOSET

HORIZONTAL

ALCOVE / ATTIC

Page 11

Installer’s Guide

Filter

TABLE 5

UPFLOW FURNACE RETURN AIR FILTERS

CABINET

WIDTH

14-1/2" 1 14" X 25" X 1" 17-1/2" X 25" X 1"

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"

**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

Airflow

NOTE: The narrow 14.5" width furnace cabinet prevents use of the ﬁlter rack for right side return. Pre-drill clearance holes and then attach ﬁlter clips with the screws provided. The ﬁlter clip with the leaf spring mounts in the rear of the cabinet

OPTIONAL FILTER RACK INSTALLATION FOR BOTTOM RETURN - BAYRACK960

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

a. Remove the ﬁlter.

b. Remove the bottom panel.

c. Pre-drill two engagement holes with 3/16" drill at

dimple locations. See Figure 14.

d. With the ﬁlter removed, the ﬁlter rack is compressed

and then inserted into the bottom of the furnace. The retaining screw/pin on each side inserts into engagement holes at the bottom of the furnace cabinet side. See Figure 15.

e. Reinstall the furnace ﬁlter in the bottom position by

inserting the chamfer end ﬁrst into the ﬁlter rack.

NOTE: Remove the bottom front channel to install the ﬁlter rack in the 14-1/2" width cabinet furnaces.

Airflow

BOTTOM FILTER RACK INSTALLATION

Blower Deck Engagement

PRE-DRILL

Two clearance holes with a 3/16” drill at dimple locations (one per side)

Furnace

Cabinet

Side

Hole

VIEW

Rack

Filter Rack Retaining

Optional Filter Rack Accessory Kit

Engagement Hole For

Filter Rack Installation With Bottom Return (Pre-drill 3/16” diameter clearance holes)

Screw/Pin

BAYRACK960A

18-CD29D1-11 11

Page 12

Installer’s Guide

Filter Rack Assembly

Furnace Blower Deck

Filter Rack Retaining Screw/Pin

Engagement Hole For

Return

Filter Rack Installation With Side

Furnace

Cabinet

Side

Filter Rack

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

TABLE 6

Cabinet Width Left Side Bottom Right Side

14.5 X

17.5 X X X

21 X X X

24.5 X X X

1. UC1B060C 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

OPTIONAL FILTER RACK INSTALLATION FOR SIDE RETURN AIR ON UPFLOW FURNACES (Left or Right) BAYRACK960

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

a. Remove the ﬁlter.

b. Leave the bottom panel in place.

c. Make side cutout by following the directions in the

“Return Air Duct Connections” section on page 9.

d. Compress the ﬁlter rack and reinstall in the side

position on the furnace. Conﬁrm that the upper retaining pin/screw locks into the engagement hole in the blower deck and the lower pin/screw rests against the side of the bottom panel. See Figures 14, 18-20.

e. Reinstall the furnace ﬁlter in the side position by

inserting the chamfer end ﬁrst into the ﬁlter rack.

X2Use Alternate Filter Clips Only

Typical Upﬂow Left Side Return Filter Rack Installation

BLOWER DECK

12 18-CD29D1-11

BOTTOM ENGAGEMENT

Furnace

Cabinet

Side

Retaining Screw/Pin

Filter Rack

Bottom Panel

Typical Upﬂow Right Side Return Filter Rack Installation

Airﬂow

Accessory ﬁlter kit

BAYFLTR203, 204, or

205 used for Upﬂow Horizontal furnaces

Typical Horizontal Filter Installation

Page 13

Installer’s Guide

REAR

SIDE

CUT-OUT

ALTERNATE FILTER CLIPS LOCATION

RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION

When the Upﬂow Furnace is installed in a horizontal conﬁguration, the ﬁlter must never be installed inside or outside the cabinet directly above the blower assembly. See Figure 10 (page 11). Remote ﬁlter grilles may be used for homeowner convenience or the ﬁlters may be installed in the duct work upstream of the furnace. See Figures 20 (page 13).

Optional horizontal lter conversion kits are BAYFLTR203 for 17 1/2" width cabinets, BAYFLTR204 for 21" width cabinets, and BAYFLTR205 for 24" width cabinets. These

include ﬁlters and brackets necessary for horizontal ﬁlters. See Figure 20.

ALTERNATE UPFLOW FILTER CLIP / BRACKET INSTALLATION - KIT09224

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.

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 Figure21.

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS

Two high velocity type air ﬁlters are required for each downﬂow furnace. Downﬂow furnace ﬁlters must be located outside the furnace cabinet. Typical installations are shown in Figures 22 and 23. Tables 8 and 9 provide information for installation of the ﬁlter retaining brackets shipped with downﬂow furnaces.

Airﬂow

INSTALLING THE OPTIONAL FILTER

The ﬁlter may need to be cut to ﬁt the unit depending on the location of the return air ﬁlter.

A score line and the words “CUT HERE” are located on the end of the ﬁlter. If your application requires cutting the ﬁlter, do so as indicted by the score mark.

TABLE 7

UNIT SIZE

RETURN AIR

BOTTOM SIDE

14-1/2" CUT ON LINE DO NOT CUT

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

18-CD29D1-11 13

CABINET

WIDTH

14-1/2" 2 - 14X20X1 12-7/8" 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

14-1/2" 13-1/4" 12" 14" 17-1/2" 16-1/4" 15" 14"

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

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

Optional accessory door kit BAYFLTR206 is also available

with narrow door to avoid ﬂue piping in downﬂow furnaces.

RETURN

DUCT

WIDTH

TABLE 8

FILTER

SIZE

TABLE 9

FILTER ACCESS

OPENING - DI-

MENSION "A"

FILTER BRACKET

LOCATION *

FILTER ACCESS

OPENING -

DIMENSION "B"

Page 14

Installer’s Guide

▲

WARNING

GENERAL VENTING

CARBON MONOXIDE POISONING HAZARD FURNACE MUST BE VENTED PROPERLY. FAILURE TO FOLLOW THE INSTALLATION INSTRUCTIONS FOR THE VENTING SYSTEM COULD RESULT IN CARBON MONOXIDE POISONING, FIRE OR SMOKE THAT CAN CAUSE SERIOUS BODILY INJURY, DEATH OR PROPERTY DAMAGE.

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

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", or

3" plastic pipe and ﬁttings (See Table 10, page 16). Where the system is routed to the outdoors through an existing masonry chimney containing ﬂue products from another gas appliance, or where required by local codes, then 3" venting of Type 29-4C stainless steel must be used in place of PVC material. These furnaces have been classiﬁed as CATEGORY IV furnaces in accordance with 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.

IMPORTANT These Furnaces may be installed as Direct Vent (sealed combustion) or as Nondirect Vent (single pipe). The Furnaces are shipped DIRECT VENT with sealed combustion.

WARNING

▲

CARBON MONOXIDE POISONING HAZARD

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

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

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1 Natural Gas and Propane Installation Code 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.

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

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

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

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

The following are general steps to be used to correct or resize a remaining vent system when a furnace which may not be common vented is removed from the system:

a. Determine the Btu per hour input of all remaining

appliances attached to the venting system.

b. Determine the diameter, rise, and lateral of the ex-

isting venting system, as well as quantity and type of bends.

c. Use the appropriate tables in the latest edition of

the National Fuel Gas Code (ANSI Z223.1 • CAN/ CGA B149.1 Installation Codes or “Exhibit J” of ANSI Z21.47 • CAN/ CGA-2.3 Standards. “Exhibit J”

includes examples and drawings of typical venting systems.

IMPORTANT:

These furnaces may be installed as Direct Vent (sealed combustion) or as Nondirect vent (single pipe). The furnaces are shipped DIRECT VENT with sealed combustion.

For DIRECT VENT APPLICATION: The furnaces must be vented to the exterior of the house and combustion air MUST come through the inlet air pipe FROM OUTSIDE AIR.

For NONDIRECT VENT APPLICATION: The furnace shall be vented to the exterior of the house, but combustion air may enter from the surrounding area as long as combustion air requirements are met. (See AIR FOR COMBUSTION AND VENTILATION)

14 18-CD29D1-11

Page 15

Installer’s Guide

Furnace

Vent

Air

Inlet

(See Note)

Furnace

Air

Inlet

Vent

Attic Vent

(See Note)

For DIRECT VENT APPLICATION: The Furnaces must be vented to the exterior of the house and combustion air MUST come through the inlet air pipe FROM OUTSIDE AIR.

NOTE: BAYVENT200* accessories can be used for inlet and outlet terminals when the pipes do not exit the structure together. For Canadian applications, venting systems must meet ULC-S636 requirements.

For NONDIRECT VENT APPLICATION: The Furnace shall be vented to the exterior of the house, but combustion air may enter from the surrounding area as long as combustion air requirements are met. (See AIR FOR

COMBUSTION AND VENTILATION)

FURNACE VENT / INLET PIPE INSTALLATION

There are many different variations of the vent / inlet air pipe combination. The vent / inlet air combination used for

installation of these Furnaces depends on the needs of the location. However, these guidelines must be followed:

1. The Furnace must vent outside the structure.

2. Furnace combustion air requirements must be met for non-direct, single pipe applications.

3. For direct vent application of these Furnaces, the vent pipe and air inlet pipe do not have to exit in the same air space. However, the longest individual pipe will

decide the value for the longest allowable equivalent vent/ inlet air length as shown in the vent length tables on page 17 and 18.

NOTE: For single pressure zone applications, see Figure

27.

The following are EXAMPLES ONLY:

EX. 1 —

Example 1 shows the vent pipe exhausting through the roof and the inlet air coming from the interior of the house. The inlet air coming from the interior of the house must meet combustion requirements for area, etc., as shown in the sec-

tion AIR FOR COMBUSTION AND VENTILATION in this

Installer’s Guide.

Example 1

EX. 2 —

The inlet air does not have to come from outside the structure. Example 2 shows the inlet air, may come from the attic if the requirements for combustion air are met as shown in the section AIR FOR COMBUSTION AND VENTILATION.

NOTE: If only the ﬂue gas pipe is to the outside of the structure, a straight section of pipe (long enough to exit the Furnace cabinet) must be attached to the inlet air side with an elbow (which is 5 to 10 equiv. ft.) installed on the end to prevent dust and debris from falling directly into the Furnace.

Example 2

18-CD29D1-11 15

Page 16

Installer’s Guide

▲

WARNING

▲

WARNING

PVC 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", 2½", 3", or 4" diameter. The allowable materials are shown in Table 10.

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 10 are designations for different types of 2" and 3" size pipe and ﬁttings that meet these requirements. The materials listed are various grades of PVC, CPVC, ABS, and DuraVent PolyPro®.

ATTACHING VENT PIPING

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

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

MANUFACTURED MODULAR VENTING SYSTEMS

CARBON MONOXIDE POISONING HAZARD See Table 10 for manufactured modular venting systems that are approved for use with this product. Follow the manufacturer's installation instructions when installing the venting system. Failure to follow this warning may result in property damage, severe personal injury, or death.

APPROVED VENT PIPE MATERIALS

CARBON MONOXIDE POISONING HAZARD Do not use cement on polypropelene venting systems. Follow the manufacturer's installation instructions when installing the venting system. Failure to follow this warning may result in property damage, severe personal injury, or death.

For manufactured modular venting systems that are approved with this product see Table 10. Do not drill into polypropelene venting pipes

BONDING OF PVC 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.

Commercially available solvent cement must be used to join the pipe and ﬁttings. Follow instructions on the container carefully. Procedure for Cementing Joints:

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 APPLY-

ING 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

TABLE 10

PLASTIC VENT PIPE DESIGNATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE °F MARKING

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

1 158 2 158 2 158 2 158

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41

F441 SCH 40, 80

F442 SDR SERIES

2 212 2 212 2 212

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV

F628 SCH 40 DWV CELLULAR CORE

3 180 3 180

DuraVent PolyPro® 45

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

NA NA 230 ULC-S636

1 Allowable temperatures based on classiﬁcations covered in ASTM D4396 [Deﬂection Temps Under Load (264 PSI)] 2 Allowable temperatures based on classiﬁcations covered in ASTM D1784 [Deﬂection Temps Under Load (264 PSI)] 3 Allowable temperatures based on classiﬁcations covered in ASTM D3965 [Deﬂection Temps Under Load (264 PSI)] 4 This furnace family is approved for venting with DuraVent PolyPro® venting systems. 5 Canadian venting systems must be composed of materials that meet ULC-S636.

ASTM F891 ASTM D2665 ASTM D1785 ASTM D2241

ASTM D2846

ASTM F441

ASTM F442

ASTM D2661

ASTM F628

16 18-CD29D1-11

Page 17

Seal VENT PIPE with RTV sealant

Seal INLET AIR PIPE

with RTV sealant

Front of Furnace

▲

WARNING

15 minutes before handling. Cure time varies according to ﬁt, temperature and humidity.

NOTE: Follow venting instructions carefully when using PVC cement.

IMPORTANT:

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

Connection of the pipe and collar of the combustion air inlet should just be a friction ﬁt. It is recommended that

the inlet air joint be sealed with RTV type sealant to allow the joint to be separated for possible future service. The inlet and vent pipes must be properly supported throughout the entire length. Connection of the vent pipe to the vent collar should also be accomplished using RTV type sealant. This type sealant provides a connection which remains ﬂexible and can be separated in the future if service needs require the removal of the vent pipe for service or clearance. See Figure 24.

NOTE: To ensure proper operation at the vent lengths indicated, the combustion air inlet and vent terminals should be in the same pressure zone. Terminating the vent and inlet in different pressure zones will change the maximum vent lengths and may cause nuisance tripping of the pressure switch(es). The amount of change can not be predicted. The selection of the inlet and outlet terminal locations are the responsibility of the designer/installer. If the installer chooses separate pressure zones for the terminals, the combustion air inlet termination must be in the higher (more positive) pressure zone.

Installer’s Guide

CARBON MONOXIDE POISONING HAZARD FAILURE TO FOLLOW THE DURAVENT INSTALLATION INSTRUCTIONS IF THE POLYPROPELENE VENTING SYSTEM IS BEING PLACED INTO OPERATION COULD RESULT IN CARBON MONOXIDE POISONING OR DEATH.

VENT AND INLET AIR CONNECTIONS

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

MAXIMUM VENT LENGHT TABLE

MAXIMUM VENT LENGTH:

*UH1B040A9241A 60 80 100 130 50 80 80 130

*UH1B060A9361A 60 80 100 130 50 80 80 130

*UH1B080A9421B 40 80 100 130 30 80 80 130

*UH1C080A9601A NOT ALLOWED NOT ALLOWED 70 130 NOT ALLOWED NOT ALLOWED 50 130

*UH1C100A9481A NOT ALLOWED NOT ALLOWED 90 130 NOT ALLOWED NOT ALLOWED 70 130

*UH1D100A9601A NOT ALLOWED NOT ALLOWED 90 130 NOT ALLOWED NOT ALLOWED 70 130

*UH1D120A9601A NOT ALLOWED NOT ALLOWED 50 130 NOT ALLOWED NOT ALLOWED 30 130

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

1. FOR DURAVENT MANUFACTURED MODULAR VENTING SYSTEMS THAT ARE APPROVED IN TABLE 10, EQUIVALENT VENT LENGTHS MAY BE DIF-

FERENT FROM WHAT IS SHOWN ABOVE. REFER TO THE VENTING SYSTEM MANUFACTURER'S INSTALLATION INSTRUCTIONS FOR APPROPRIATE VENTING DIAMETERS AND EQUIVALENT LENGTHS.

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

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

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

5. One SHORT radius 90° elbow is equivalent to 10' of 4" pipe, 10' of 3" pipe, or 8’ of 2” pipe. One LONG radius elbow is equivalent to 6' of 4" pipe, 7’ of 3” pipe, 6’ of 2.5” pipe, or 5' of 2" pipe. Two 45° elbows equal one 90° LONG elbow.

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

7. Pipe adapters are ﬁeld supplied (except for the *UH/DH2D120 models).

8. For Canadian applications, venting systems must meet ULC-S636 requirements.

18-CD29D1-11 17

MODEL

UPFLOW/ HORIZONTAL VENTING TABLE

DIRECT VENT (2 PIPE SYSTEM) -

MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT AND INLET AIR PIPES (See Notes)

2" PIPE

& FITTINGS

2-1/2" PIPE

& FITTINGS

3" PIPE

& FITTINGS

TABLE 11

4" PIPE

& FITTINGS

NONDIRECT VENT (1 PIPE SYSTEM) -MAXIMUM TOTAL

2" PIPE

& FITTINGS

EQUIVALENT FEET FOR

VENT PIPE ONLY (See Notes)

2-1/2" PIPE

& FITTINGS

3" PIPE

& FITTINGS

4" PIPE

& FITTINGS

Page 18

Installer’s Guide

Vent only to outside

Air Inlet

A (0-2') or greater B (0-2') or greater A+B = 2' minimum

UPFLOW FURNACE

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

FIXED

CLOSED

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

OPERABLE

Vent only to outside

Air Inlet

A = 2' minimum

DOWNFLOW

FURNACE

DOWNFLOW/ HORIZONTAL VENTING TABLE

TABLE 12

MAXIMUM VENT LENGTH:

DIRECT VENT (2 PIPE SYSTEM) - MAXIMUM TOTAL EQUIV-

ALENT FEET FOR VENT AND INLET AIR PIPES (SEE NOTES)

MODEL

2" PIPE

& FITTINGS

2-1/2" PIPE

& FITTINGS

3" PIPE

& FITTINGS

4" PIPE

& FITTINGS

*DH1B040A9241A 60 80 100 130 50 80 80 130

*DH1B065A9421A 45 80 100 130 40 80 80 130

*DH1C085A9481A NOT ALLOWED 80 100 130 NOT ALLOWED 80 80 130

*DH1D110A9601A NOT ALLOWED 15 60 130 NOT ALLOWED 25 70 130

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

1. FOR DURAVENT MANUFACTURED MODULAR VENTING SYSTEMS THAT ARE APPROVED IN TABLE 10, EQUIVALENT VENT LENGTHS MAY BE DIFFER-

ENT FROM WHAT IS SHOWN ABOVE. REFER TO THE VENTING SYSTEM MANUFACTURER'S INSTALLATION INSTRUCTIONS FOR APPROPRIATE VENTING DIAMETERS AND EQUIVALENT LENGTHS.

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

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

5. One SHORT radius 90° elbow is equivalent to 10' of 4" pipe, 10' of 3" pipe, or 8’ of 2” pipe. One LONG radius elbow is equivalent to 6' of 4" pipe, 7’ of 3” pipe, 6’ of

2.5” pipe, or 5' of 2" pipe. Two 45° elbows equal one 90° LONG elbow.

7. Pipe adapters are ﬁeld supplied (except for the *UH/DH2D120 models).

8. For Canadian applications, venting systems must meet ULC-S636 requirements.

NONDIRECT VENT (1 PIPE SYSTEM) - MAXIMUM TOTAL

EQUIVALENT FEET FOR VENT PIPE ONLY (SEE NOTES)

2" PIPE

& FITTINGS

2-1/2" PIPE

& FITTINGS

3" PIPE

& FITTINGS

4" PIPE

& FITTINGS

VENT CLEARANCES

See Tables 13 & 14

SINGLE PIPE VENTING

18 18-CD29D1-11

Page 19

Installer’s Guide

Table 13 - See Figure 22

Direct Vent Terminal Clearances

A= Clearance above grade, veranda, porch, deck,

B= Clearance to window or door that may be

C= Clearance to permanently closed window * * D= Vertical clearance to ventilated sofﬁt located

E= Clearance to unventilated sofﬁt * * F= Clearance to outside corner * * G= Clearance to inside corner * * H= Clearance to each side of center line extended

I= Clearance to service regulator vent outlet 3 feet (91 cm) * J= Clearance to nonmechanical air supply inlet

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally L= Clearance above a paved sidewalk or paved

M= Clearance under veranda, porch, deck, or

Table 14 - See Figure 22

A= Clearance above grade, veranda, porch, deck, or

B= Clearance to window or door that may be opened 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

C= Clearance to permanently closed window * * D= Vertical clearance to ventilated sofﬁt located above

E= Clearance to unventilated sofﬁt * * F= Clearance to outside corner * * G= Clearance to inside corner * * H= Clearance to each side of center line extended

I= Clearance to service regulator vent outlet 3 feet (91 cm) * J= Clearance to nonmechanical air supply inlet to

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m)

L= Clearance above a paved sidewalk or paved drive-

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

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

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

or balcony

opened

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

above meter/regulator assembly

to building or the combustion air inlet to any other appliance

driveway located on public property

balcony

Notes:

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

balcony

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

above meter/regulator assembly

building or the combustion air inlet to any other appliance

way located on public property

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

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

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

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

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

18-CD29D1-11 19

Canadian Installations US Installations

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

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

* *

above the meter/regulator assembly

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

7 feet (2.13 m) † *

`12 inches (30 cm) ‡ *

Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

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

4 feet (1.2m) below or to the side of opening; 1 foot (0.3m) above opening.

* *

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

meter/regulator assembly

4 feet (1.2 m) below or to side of opening; 1 foot (300 m) above opening

7 feet (2.13 m) † 7 feet (2.13 m)

horizontally

Page 20

Installer’s Guide

▲

CAUTION

6” Min. 24” Max.

12” Min. 15” Max

9” Minimum minimum from end of exhaust pipe to end of inlet pipe

6” Min. 24” Max.

VENT

COMBUSTION AIR

VENT

VENT PLATE

VENT CAP

12" MINIMUM TO OVERHANG

MAINTAIN 12" MINIMUM CLEARANCE

ABOVE HIGHEST ANTICIPATED SNOW LEVEL

OR GRADE WHICHEVER IS GREATER

SCREWS (4 req.)

ANCHORS (4 req.)

7.2"

3.2"

▲

WARNING

6” Min. 24” Max.

12” Min. 15” Max

6” Min. 24” Max.

12” Min.

15” Max

9” Minimum minimum from end of exhaust pipe to end of inlet pipe

ELBOW AND TEE MUST BE AS CLOSE TOGETHER AS POSSIBLE

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS WHEN

BOTH TERMINATIONS ARE LOCATED IN THE SAME PRESSURE ZONE

CARBON MONOXIDE POISONING HAZARD Do not replace any of the factory supplied venting components with ﬁeld fabricated parts. Failure to follow this safety warning exactly could result in damaged vents, damaged components, carbon monoxide poisoning, or death.

9” Minimum minimum from end of exhaust pipe to end of inlet pipe

HORIZONTAL VENTING

NOTE: Vent termination kit BAYAIR30AVENTA or BAYVENT200B may be used instead of the horizontal and vertical termination options shown in the following ﬁgures. For Canadian applications, venting systems must meet ULC-S636 requirements..

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.

20 18-CD29D1-11

For Canadian applications, horizontal vent termination kits must meet ULCS636.

DO NOT Install return air through the side of furnace cabinet on horizontal applications.

HORIZONTAL VENTING THROUGH WALL

These furnaces may be installed as direct vent (as shipped) or as nondirect vent. Installation must conform to national, state, and local codes.

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

BAYVENT200B

Page 21

Avoid areas where staining or condensate drippage may be

COUPLING (PLASTIC VENTING)

STUD

PVC WALL MOUNT FLANGE (OPTIONAL)

APPROVED TERMINATION

1” CLEARANCE (AIR SPACE)

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

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

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

6 IN. MIN. (TO JOINT)

COUPLING (PLASTIC VENTING)

PVC WALL MOUNT FLANGE (OPTIONAL)

APPROVED TERMINATION

CEMENT MORTAR SEAL INSIDE & OUTSIDE

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

12” MINIMUM ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

6 IN. MIN. (TO JOINT)

a problem.

Location of the vent/ wind terminal should be chosen to

meet the requirements of Figure 26 for either direct or nondirect vent applications.

PITCH – Venting through the wall must maintain 1/4" per

foot pitched upward to insure that condensate drains back to the furnace. FLUE GAS DEGRADATION – The moisture content of the ﬂue gas may have a detrimental effect on some building materials. This can be avoided by using the roof or chimney venting option. When wall venting is used on any surface that can be affected by this moisture, it is recommended that a corrosion resistant shield (24 inches square) be used behind the vent terminal. This shield can be wood, plastic, sheet metal, etc. Also, silicone caulk all cracks, seams and joints within 3 feet of the vent terminal.

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials must be maintained when using single wall stainless steel venting. See Figure 30.

Installer’s Guide

;

12" MIN TO OVERHANG

1" + "

COMBUSTION AIR

BAYAIR30AVENTA

(Sidewall)

For Canadian applications, horizontal vent termination kits must meet ULC-S636.

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.

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 31.

VENT

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

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.

18-CD29D1-11 21

Page 22

Installer’s Guide

40" UPFLOW OR DOWNFLOW MODELS

SEE VENTING TABLE

OUTSIDE

WALL

NOTE: ANY FITTINGS PASSING THROUGH AN UNHEATED SPACE MUST BE INSULATED.

FIRST SUPPORT SHOULD BE AS CLOSE TO FURNACE CONNECTION AS POSSIBLE.

UPWARD PITCH -- 1/4" PER FOOT

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

COMBUSTION AIR INLET

USE ONLY

APPROVED

TERMINATION

RAIN CAP

COMBUSTION AIR

STRAP (FIELD SUPPLIED)

COMBUSTION AIR

VENT

ELBOW (FIELD SUPPLIED)

VENT

1" + 1/2"

3" PIPING

2", 2-1/2"

or 3" PIPING

REDUCING COUPLING, FIELD SUPPLIED IF NEEDED

SEAL ALL

WALL CAVITIES

▲

CAUTION

NOTE: VENT AND INLET MUST BE SUPPORT-

ED AT A MAXIMUM OF 3' INTERVALS

TEE

The vent for this appliance shall not terminate

(1) Over public walkways; or

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

(3) Where condensate vapor could cause damage or

22 18-CD29D1-11

BAYAIR30AVENTA

For Canadian applications, horizontal vent termination kits must meet ULC-S636.

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

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

BAYVENT200B

Page 23

Installer’s Guide

MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

VENT

COMBUSTION AIR

REMOVE RIBS FROM CAP

COMBUSTION AIR

ROOF FLASHING BOOT (FIELD SUPPLIED)

COMBUSTION AIR

VENT

ELBOW (FIELD SUPPLIED)

MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF

SUPPORT (FIELD SUPPLIED)

VENT

6" Min.

40 Inch

Upflow or

Downflow

Furnace

Slope 1/4" per ft.

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

DOWNWARD VENTING

Furnace may be in vertical or horizontal conﬁguration.

DOWNWARD VENT

LENGTH IS LIMITED

TO A MAXIMUM OF 15

EQUIVALENT FEET.

All horizontal pipes must be supported

at a maximum of 3 foot intervals

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.

VENTING THROUGH THE ROOF

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

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

NOTE: Both venting methods shown in Figure 39 & 41 must also have the combustion air inlet installed - meeting dimension requirements of Figure 35.

For Canadian applications, vertical vent termination kits

BAYAIR30AVENTA

must meet ULC-S636.

NOTE:

No vent cap as shown in Figure 35 is the preferred method for vertical vent termination in extremely cold climates. In extreme climate conditions, insulate the exposed pipe above the roof line with Armaﬂex type insulation.

VENTING ROUTED THROUGH A MASONRY CHIMNEY VENT FITTING MATERIAL – STAINLESS STEEL

Gas and liquid tight single wall metal vent ﬁtting, designed for resistance to corrosive ﬂue condensate such as Type 294C 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.

18-CD29D1-11 23

For Canadian applications, vertical vent termination kits must meet ULC-S636.

Page 24

Installer’s Guide

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

VENTING THROUGH CEILING

CEILING

SUPPORT

FLANGE

FLUE PIPE

COUPLING

SEAL BETWEEN FLANGE, PIPE, COUPLING AND METAL PANEL WITH HI TEMP RTV SILICONE SEALANT

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

STAINLESS STEEL

▲

CAUTION

▲

CAUTION

TYPE 29-4C STAINLESS STEEL VENTING -

USED THROUGH CHIMNEY THAT VENTS

ANOTHER GAS APPLIANCE

VENT CAP (OPTIONAL)

SEE CAUTION

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.

PVC PLASTIC VENTING - ONLY

COUPLING TO SUPPORT PIPE FROM ANGLES OR OTHER SUITABLE SUPPORT METHOD

THROUGH UNUSED CHIMNEY

STAINLESS STEEL VENT CAP (OPTIONAL)

SEE CAUTION

FLUE PIPE

6 IN. MIN.

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

COUPLING AS REQUIRED

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

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.

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.

24 18-CD29D1-11

FLUE PIPE

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

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.

Page 25

Installer’s Guide

IMPORTANT:

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

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

1. INSTALLATION OF CARBON MONOXIDE

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

2. APPROVED CARBON MONOXIDE

DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with

NFPA 720 and be ANSI/UL 2034 listed and IAS certied.

3. SIGNAGE. A metal or plastic identiﬁcation plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less

than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. This appliance requires a special venting system. If

BAYAIR30AVENTA or BAYVENT200B are used, a copy

of the installation instructions for the kit shall remain with the appliance or equipment at the completion of installation. The venting system installation instructions can be obtained from the manufacturer by writing to the following address: Trane 6200 Troup Highway Tyler, TX 75707 Attention: Manager of Field Operations Excellence

For Canadian installations, if you used a ULC-S636 approved manufactured modular venting system, a copy of the manufacturer's instructions should remain with the system. The installation instruction can be obtained from the vent termination manufacturer.

18-CD29D1-11 25

Page 26

Installer’s Guide

▲

CAUTION

LABEL SAYS "TOP"

STRAIGHT SIDE MUST BE ON BOTTOM FOR PROPER CONDENSATE DRAINAGE.

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

2" TO 3" COUPLING

FURNACE VENT OUTLET

FACTORY SUPPLIED ONLY WITH THE FOLLOWING MODELS: *UH1C080A9601A, ALL 100,000 BTUH UPFLOW MODELS, ALL 120,000 BTUH UPFLOW MODELS, AND ALL *DH1 DOWNFLOW MODELS

#CPL00938

HORIZONTAL INSTALLATION Upﬂow/ Horizontal

NOTE: In horizontal venting when the factory supplied “offset” (2X3 reducing coupling) is used for 3” vent pipe installation, make sure the marking “Top” is located on the top side of the pipe. The straight side must be on bottom for proper condensate drainage. This coupling is only factory supplied with all 100,000 BTU upﬂow models, *UH1C080A9601A, all 120,000 BTU upﬂow models, and all downﬂow models.

CONDENSATE DRAIN INSTRUCTIONS VERTICAL APPLICATIONS

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

Upﬂow furnace - The connection tubing for left and right side drainage is shipped in the blower compartment. Install the connection tubing from the trap to the side of the unit and trim all excess tubing to avoid kinks.

UPFLOW

(VERTICAL)

Right side

UPFLOW HORIZONTAL 17"

UNITS (Left side only)

Downﬂow furnace - Use RTV silicon sealant to connect the ﬁtting to the trap for ease of removal when cleaning the trap.

For left side drain a 1/2" slip PVC tting is needed.

See Figure 48. To change to a right side drain, remove the drain lines from the trap, rotate the trap 180° so it exits to the

right, then reconnect the lines. Start with a 1/2" 90°

CPVC street elbow connected to the trap using RTV

silicon sealant. Run 1/2" CPVC pipe to a CPVC elbow. Run 1/2" CPVC pipe from the elbow out through the

right side knock-out. See Figure 49.

Use Inducer Drain

hose without

extension

26 18-CD29D1-11

Page 27

HORIZONTAL APPLICATIONS

Upﬂow and Downﬂow furnaces - All horizontal applications are left side only. It is always recommended that the auxiliary drain pan be installed under a horizontally

installed evaporator and/or 95% gas furnace. Connect the

auxiliary drain pan to a separate drain line (no trap is needed in this line). The trap must be repositioned to the exterior of the cabinet. Remove the trap from its present location and reposition the trap outside of the unit, through the long circular hole,

Installer’s Guide

UPFLOW

(VERTICAL)

Left side

UPFLOW HORIZONTAL 21" & 24" UNITS

(Left side only)

Use exten-

sion hose

here

Left

side

DOWNFLOW (VERTICAL)

(

Right

side

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

DOWNFLOW (VERTICAL)

)

next to the secondary recuperated cell. Remove the larger drain line (from the secondary cell) and trim to ﬁt between the secondary cell and the new trap location. On upﬂow units, plug the hole in the blower deck where the tube went through. Remove the hose from the induced blower and reposition into the other drain tap of the inducer, which is located 90° clockwise around the inducer. Move the cap from that drain tap to the unused drain tap. On upﬂow units, plug the hole in the blower deck where the tube went through. On upﬂow units, this tube may need to be extended, using the tubing shipped with the furnace.

Connections must be made to an OPEN or VENTED DRAIN. Outdoor draining of the furnace and coil condensate is permissible if allowed by local codes. Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants.

18-CD29D1-11 27

DOWNFLOW (HORIZONTAL)

Cut off curved end of

Inducer drain hose

Page 28

Installer’s Guide

SEE

NOTE 6

From drawing B341437 Rv 1

FURNACE

TWIN

SEE

NOTE 7

B/C

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

HUM SEE NOTE 5

EAC SEE NOTE 5

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

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

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

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

Evaporator and furnace condensate drain piping may be manifolded together as shown in Figure 51. A primary drain vent stack must be installed and terminated below the outlet of the secondary heat exchanger drain connection

to prevent water from damaging furnace controls if the primary drain outlet plugs up. Where the furnace is installed above a ﬁnished ceiling, the primary drain vent stack must be installed such that overﬂow from the vent stack opening will ﬂow into an auxiliary drain pan in order to prevent water damage to the ﬁnished ceiling below.

TWINNING FURNACES

These furnaces may be twinned. Twinning requires that two furnaces with the same conﬁguration, capacity, and airﬂow must be used. They shall have common returns with equal pressure drops or ducts with equivalent lengths and sizes. See Field Wiring Diagrams for proper hookup.

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

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

To drain opening

28 18-CD29D1-11

Page 29

Installer’s Guide

OUTDOOR UNIT

(NO TRANSFORMER)

SEE

NOTE 6

From drawing B340388 Rv 2

SEE

NOTE 8

FURNACE

B/C

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

HUM SEE NOTE 5

EAC SEE NOTE 5

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

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” in the 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 diagram attached to furnace.

18-CD29D1-11 29

Page 30

Installer’s Guide

TWIN

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEATING ONLY THERMOSTAT

1 STAGE HEAT

ONLY

THERMOSTAT

(WITH FAN SWITCH) FURNACE NO. 1

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO. 2 IS SYNCRONIZED

WITH UNIT NO. 1 VIA SIGNALS

FROM TWIN CONNECTION.

SEE NOTE 4

SEE NOTE 3

ISOLATION RELAY (FIELD SUPPLIED)

SEE NOTE 4

ISOLATION RELAY

SEE NOTE 4

B/C

From Dwg. 21B341422 Rev. 3

TWIN

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNAC ES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEAT / 1 STAGE COOL THERMOSTAT

1 STAGE

HEATING / COOLING

THERMOSTAT FURNACE NO. 1

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO. 2 IS SYNCRONIZED

WITH UNIT NO. 1 VIA SIGNALS

FROM TWIN CONNECTION.

SEE NOTE 4

SEE NOTE 5

ISOLATION RELAY

(FIELD SUPPLIED)

SEE NOTE 4

ISOLATION RELAY

SEE NOTE 4

OUTDOOR UNIT

(NO TRANSFORMER)

OUTDOOR UNIT

(WITH TRANSFORMER)

ISOLATION RELAY (FIELD SUPPLIED)

SEE NOTE 3

B/C

From Dwg. 21B341423 Rev. 2

30 18-CD29D1-11

Page 31

Installer’s Guide

▲

CAUTION

GAS PIPING

The upow/ horizontal furnace is shipped standard for left

side installation of gas piping. A knock-out is provided on the right side for an alternate gas piping arrangement. See Figure 52. 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 15, for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve as shown in Figures 52-53. National codes require a condensation drip leg to be installed ahead of the controls as shown in Figures 52-53. 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).

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION

JOINT

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

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!

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

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION

JOINT

DRIP

LEG

DRIP

LEG

UPFLOW – LEFT HAND GAS PIPING

UPFLOW – RIGHT HAND GAS PIPING

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

18-CD29D1-11 31

Page 32

Installer’s Guide

AUTOMATIC GAS VALVE WITH

MANUAL SHUTOFF

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION JOINT

DRIP LEG

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE (UPFLOW SHOWN)

TABLE 15

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

1 520 350 285 245 215 195 180

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

10 20 30 40 50 60 70

MODEL

*UH1B040A9241A 40,000 2 45 56 *UH1B060A9361A 60,000 3 45 56

*UH1B080A9421B 77,000 4 45 56 *UH1C080A9601A 80,000 4 45 56 *UH1C100A9481A

*UH1D100A9601A *UH1D120A9601A 110,000 6 45 56

*DH1B040A9241A 40,000 2 45 56

*DH1B065A9421A 60,000 4 48 56 *DH1C085A9481A 80,000 5 48 56 *DH1D110A9601A 110,000 6 48 56

LENGTH OF PIPE

TABLE 16

ORIFICE SIZES

INPUT

RATING

BTUH

NUMBER

BURNERS

MAIN BURNER

ORIFICE

DRILL SIZE

NAT. GAS LP GAS

100,000 5 45 56

MAIN MANUAL

SHUTOFF VALVE

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

GROUND UNION JOINT

DRIP LEG

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 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 17, 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 tub-

ing to the outlet pressure boss marked “OUT P” on White-Rodgers gas valve model 36G or 36J. See Figure 58 for White-Rodgers gas valve model 36J. See Figure 57 for White-Rodgers gas valve model 36G.

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 wrench, a 5/16" hose and a con-

nector and can be ordered through Global Parts.

4. Turn on system power and energize valve.

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 18 with the time clocked.

32 18-CD29D1-11

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Installer’s Guide

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CAUTION

▲

WARNING

5. Adjust gas heat by removing the 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 17.

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. Cycle the valve several times to verify regulator set-

ting.

a. Repeat steps 5-6 if needed.

7. Turn off all electrical power to the system.

8. Remove the manometer and ﬂexible tubing and tighten

the pressure tap screw.

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

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

10. Turn on system power and check operation of the

unit.

SAFETY 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.

NOTE: The manifold pressure must be referenced to the burner box. The burner box pressure tap equalizes the gas valve pressure regulator. Manifold pressure is checked by installing a tee (ﬁeld supplied) in the tubing, between the tee coming from the burner box tube and the gas valve, in addition to the regular gas valve pressure tap on the outlet side of the gas valve. See Figure 55.

Replace manifold pressure tap threaded plug and leak check after checking/ adjusting manifold gas pressure.

Table 19 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 20.

TABLE 17

FINAL MANIFOLD PRESSURE SETTINGS

MODEL FUEL PRESSURE

NATURAL GAS LP GAS

*UH1B040A9241A 3.5" W.C. 11.0" W.C.

*UH1B060A9361A 3.5" W.C. 11.0" W.C.

*UH1B080A9421B

*UH1C080A9601A *UH1C100A9481A

*UH1D100A9601A

*UH1D120A9601A 3.3" W.C. 11.0" W.C.

*DH1B040A9241A 3.5" W.C. 11.0" W.C.

*DH1B065A9421A 3.0" W.C. 9.5" W.C.

*DH1C085A9481A 3.5" W.C. 11.0" W.C.

*DH1D110A9601A 4.5" W.C. 11.0" W.C.

3.5" W.C. 11.0" W.C.

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Installer’s Guide

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 for upﬂow models and min

3.0 - max 4.5 in. W.C. - Natural Gas for downﬂow models) or changing oriﬁces (oriﬁce change may not always be required). If the desired input rate can not be achieved with a change in manifold pressure, then the oriﬁces must be changed. LP installations will require an oriﬁce change. 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. Instal-

lation 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.

IMPORTANT: Re-install the propane oriﬁces to the same depth as the oriﬁces supplied with the equipment.

ROTATE THE FRONT COVER AS SHOWN

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

ALL SIDE FLANGES MUST BE OUTSIDE OF THE BOX

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

TABLE 18

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

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

8 900 29 248 50 144 82 88

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

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WARNING

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WARNING

Outlet Pressure Boss

On/Off Switch

Inlet Pressure

Boss (opt.)

Regulator

Adjust

See Table 19 & 20 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 19

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

44 45 46 47 48 49 50

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

REINSTALLATION OF THE BURNER BOX COVER

Figure 56 shows the correct way to reinstall the burner box cover if adjustment or replacement of the ﬂame sensor, hot surface igniter, or main burner oriﬁces have required removal of the cover.

TABLE 20

Oriﬁce

Twist

Drill

Size If

Installed

At Sea

Level

42 43 44 45 46 47 48

54 55 56 57 58

From National Fuel Gas Code - Table F-4

ALTITUDE ABOVE SEA LEVEL and Oriﬁce Required

2000 3000 4000 5000 6000 7000 8000 9000 10000

At Other Elevations

44 45 47 48 48 49 50

55 56 57 60 62

44 46 47 48 49 50 50

55 56 58 61 62

45 47 48 49 49 50 51

56 56 59 62 63

46 47 48 49 50 51 51

56 56 59 63 63

47 48 50 50 51 52 52

56 57 60 63 64

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.

White-Rodgers 36G gas valve

Inlet Pressure Boss (opt.)

Outlet Pressure Boss

White-Rodgers 36J gas valve

On/Off Switch

LIGHTING INSTRUCTIONS

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

Regulator Adjustment

Lighting instructions appear on each unit. Each instal-

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.

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

lation 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.

4. Blower door is in place

Flip the switch 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,

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Installer’s Guide

▲

WARNING

▲

WARNING

▲

CAUTION

To shut off.

For complete shut-down: Flip the switch on the main gas valve to the “OFF” position, (See Figure 57 & 58). 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 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. After the ﬂame sensor conﬁrms within a 4 second trial period that ignition has been achieved, the delay to fan ON period begins timing. After approximately 45 seconds the indoor blower motor will be energized and continue to run during the heating cycle (downﬂow models have a 10 second blower ON delay). 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 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 reason able 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.

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.

ELECTRICAL SHOCK HAZARD 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 module controls the indoor blower. The blower start is ﬁxed at 45 seconds after ignition (10 seconds for downﬂow models). The FANOFF 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).

INSTRUCTIONS TO THE OWNERS

EXPLOSION HAZARD

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

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.

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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 sys-

tem 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. CONDENSATE DRAIN BLOCKAGE

If the condensate drain is blocked, either by debris, im-

proper draining, or by freezing condensate, the pressure switch will receive a signal warning of the accumulation of condensate in the heat exchanger assembly. The pressure switch contacts will open and remain open, not allowing unit operation. The unit will not operate until the condensate drain has been cleared, and the condensate ﬂows freely.

7. RESET AFTER LOCKOUT

When the integrated control module has shut the sys-

tem 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.

Carbon monoxide, ﬁre or smoke can cause serious bodily in-

jury, death, and/or property damage.

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

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

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

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Installer’s Guide

38 18-CD29D1-11

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TABLE 21

INTEGRATED FURNACE CONTROL ERROR FLASH CODES

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)

Draft Pressure Error - Possible problems

3 Flashes ---

4 Flashes --- Open High Limit Device

5 Flashes --- Flame sensed when no ﬂame should be present

6 Flashes --- 115 Volt AC power reversed or Poor Grounding

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

Installer’s Guide

7 Flashes --- Gas valve circuit error

8 Flashes --- Low ﬂame sense signal

Check Ignitor circuit and Line "N" to 24VAC "Com-

9 Flashes ---

mon" voltage (< 2volts) (possible grounding problem)

18-CD29D1-11 39

Page 40

Trane 6200 Troup Highway Tyler, TX 75707

Literature Order Number 18-CD29D1-11

File Number 18-CD29D1-11

Supersedes 18-CD29D1-10

Date 03/14

For more information contact your local dealer (distributor)

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

Trane AUH1D100A9601A, AUH1C080A9601A, AUH1D120A9601A, AUH1C100A9481A, ADH1B065A9421A Installer's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual