Trane AUX1B040A9H21B, AUX1B060A9H31B, AUX1B080A9H31B, AUX1C100A9H41B, AUX1D120A9H51B Installer's Manual

...

Download

Page 1

18- CD22D1- 5

Installer’s Guide

High Efficiency Single Stage Upflow / Horizontal and Downflow / Horizontal Gas-Fired, Direct Vent Condensing Furnaces

*UX1B040A9H21B *UX1B060A9H31B *UX1B080A9H31B *UX1C100A9H41B *UX1D120A9H51B

*__First letter may be “A” or “T”

ALL phases of this installation must comply with NA TIONAL, STA TE AND LOCAL CODES

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

Please return to service information pack upon completion of work.

*UX1-H

*DX1B040A9H21B *DX1B060A9H31B *DX1B080A9H31B *DX1C100A9H31B *DX1D120A9H51B

*DX1-H

DOWNFLOW

UPFLOW

UPFLOW/HORIZONTAL

DOWNFLOW/HORIZONTAL

A341624P08

Page 2

Installer’s Guide

SAFETY SECTION

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

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

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

3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” (pages 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 (pages 11-18), of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in “Gas Piping” (pages 22-23), of these instructions.

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

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

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

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

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

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

c. The furnace return air duct must be complete and sealed to the furnace and clean air filters are in place.

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

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

f. The furnace return air temperature range is between 55 and 80 degrees Farenhiet.

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.

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

a. DANGER indicates an imminently hazardous situation

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

WARNING

▲

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

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

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

1. Seal any unused openings in the venting system.

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

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

4. Close fireplace dampers.

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

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

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

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

b. WARNING indicates a potentially hazardous situation

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

c. CAUTION indicates a potentially hazardous situation

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

WARNING

▲

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.

Page 3

Installer’s Guide

GENERAL INSTALLATION INSTRUCTIONS

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

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

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

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

These furnaces have been classified as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21.47 • CAN/CGA 2.3 standards.

Category IV furnaces operate with positive vent static pressure and with a flue loss less than 17 percent. These conditions require special venting systems, which must be gas tight and water tight. These Category IV Direct Vent furnaces are approved for installation in Manufactured/Mobile housing when used with BAYMFGH100A.

CAUTION

▲

To prevent shortening its service life, the furnace should not be used as a “Construction Heater” during the finishing phases of construction until the requirements listed in item 9, a-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.

Contents

INST ALLA TION INSTRUCTIONS

General Installation Instructions 3 Location and Clearances 3 Outline Drawings 4-5 Upflow Installation 6 Downflow Installation 6 Horizontal Installation 6 Air For Combustion and Ventilation 7- 8 Duct Connections 8 Return Air Filters 9-12 General Venting Instructions 13 Venting Material 13 Venting Tables 14-17 Horizontal Venting 18 Venting Through The Wall 18 Venting Throught The Roof 20 Downward Venting 20 Venting Through a Masonry Chimney 20 Condensate Drain Instructions 22 Electrical Connections 23 Field Wiring Diagrams 24-25 Gas Piping 26 Combustion Input Checks 27

Start Up and Adjustment 29

Preliminary Inspections 29 Lighting Instructions 29 Sequence Of Operation 30 Control And Safety Switch Adjustments 30 Airflow Adjustment 3 0

Abnormal Conditions 3 1

IFC Error Flash Code 32

CAUTION

▲

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?

18-CD22D1-5 3

5. Are the vent pipe and combustion air inlet pipe within vent table lengths? Will the pipes remain unobstructed?

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.

IMPORT ANT:

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.

Page 4

4 18-CD22D1-5

Installer’s Guide

*UX1-H OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

From Dwg. 21C341884 Rev. 1

Page 5

18-CD22D1-5 5

*DX1-H DOWNFLOW / HORIZONTAL OUTLINE DRA WING

(ALL DIMENSIONS ARE IN INCHES)

From Dwg. 21C341885 Rev. 0

Installer’s Guide

Page 6

Installer’s Guide

UPFLOW INST ALLATION

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.

CASED

UPFLOW

FURNACE

STANDOFFS (4)

COIL

STANDOFFS

(BOTH SIDES)

DRILL SCREWS (4)

FOR VERTICAL

INST ALLATIONS:

SCREWS

(BOTH SIDES)

DOWNFLOW INST ALLATIONS

WARNING

▲

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

Required floor opening:

T ABLE 1

CABINET

WIDTH

RETURN

DUCT 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"

FLOOR OPENING PLENUM OPENING

"A" "B" "A" "B"

HORIZONTAL INSTALLATION

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

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

The furnace may be installed in an attic or crawl space in the horizontal position by placing the furnace

CASED COIL CONNECTION

on the left side

(as

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

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

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

The furnace must be

SUBBASE CROSS SECTION

2345678901234567890123456789012123456789012345

FURNACE

2345678901234567890123456789012123456789012345

FRONT

2345678901234567890123456789012123456789012345

6 18-CD22D1-5

A (width)

B (depth)

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.

UPFLOW/ HORIZONT AL

Page 7

Installer’s Guide

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.

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

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

UNCONFINED

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.

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 “uncon- fined space”.

Unconfined space

have adequate air by infiltration to provide air for combustion and ventilation. Buildings with tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), may need additional air to be provided as described for

confined space Confined spaces

space per 1000 BTU/hr input from all equipment installed. Air for combustion and ventilation requirements can be supplied from inside the building as in Figure 8 or from the outdoors, as in Figure 9.

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE

MAXIMUM BTUH

INPUT RATING

60,000

80,000 100,000 120,000

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

is defined in Figure 5. These spaces may

are installations with less than 50 cu. ft. of

MINIMUM AREA IN SQUARE FEET

WITH 8 FT. CEILING

MINIMUM AREA IN SQUARE FEET

OF UNCONFINE D SPACE

375 500 625 875

CONFINED

SPACE

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.

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

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

Air

From

Inside

100 100 100 120

TABLE 2

Air From Outside

Vertical

Duct

15 20 25 30

Horizontal

Duct

30 40 50 60

MINIMUM FREE ARE A IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000

80,000 100,000 120,000

DUCT CONNECTIONS

Air duct systems should be installed in accordance with standards for air conditioning systems, National Fire Protection

18-CD22D1-5 7

Page 8

Installer’s Guide

Association Pamphlet No. 90. They should be sized in accordance with ACCA Manual D or whichever is applicable.

Central furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling coil to avoid condensation in the heat exchanger. With a parallel flow arrangement, the dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering the furnace, and if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in full heat or cool position.

On any job, flexible connections of nonflammable material may be used for return air and discharge connections to prevent transmission of vibration. Though these units have been specifically designed for quiet, vibration free operation, air ducts can act as sounding boards and could, if poorly installed, amplify the slightest vibration to the annoyance level.

When the furnace is located in a utility room adjacent to the living area, the system should be carefully designed with returns to minimize noise transmission through the return air grille. Although these furnaces are designed with large blowers operating at moderate speeds, any blower moving a high volume of air will produce audible noise which could be objectionable when the unit is located very close to a living area. It is often advisable to route the return air ducts under the floor or through the attic. Such design permits the installation of air return remote from the living area (i.e. central hall).

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

RETURN AIR DUCT SYSTEMS Where there is no complete return duct system, the return connection must be run full size from the furnace to a location outside the utility room, basement, attic, or crawl space.

Do Not install return air through the back of the furnace cabinet Do Not install return air through the side of the furnace cabinet

on horizontal applications.

NOTE: Minimum return air temperature is 50° F.

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

1. Set the furnace in place.

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

3. The side panels of the upflow furnace include locating notches that are used as guides for cutting an opening for return air, refer to Figure 10 and the outline drawing on page 4 for duct connection dimensions for various furnaces.

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

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

5. If flanges are not required, and a filter frame is installed, cut between locating notches (See Figure 10).

8 18-CD22D1-5

Page 9

Installer’s Guide

6. The bottom panel of the upflow furnace must be removed for bottom return air. Remove the filter and lay the furnace on its back. Remove the two 1/4" hex screws securing the bottom front channel to the cabinet. Lower the front edge of the bottom front channel and pull forward to remove the channel. The bottom return air panel will now easily slide out of the cabinet. Reinstall the bottom front channel and filter for upflow bottom return installations.

7. The filter retainer is factory supplied for upflow bottom return. Use the filter retainer on side or bottom if filter is to be used within the furnace cabinet on upflow only installations.

The horizontal installation of the upflow furnace requires

an external filter section. Do NOT use the bottom return filter within the furnace. Filter kits are available for horizontal applications.

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

RETURN AIR FILTERS

TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS

These furnaces require high velocity type air filters. The filters may be located within the furnace blower compartment for UPFLOW furnaces in either a BOTTOM or SIDE (left side or right side) return air inlet. Some filters may need to be trimmed for side or bottom filter use.

T ABLE 3

LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT

SEE OUTLINE DRAWING

UPFLOW FURNACE ONLY

CUT OUT FOR SIDE FILTER

FRONT of Furnace

Airflow

MODELS

NUMBERS

*UX1B040A9H21B *UX1B060A9H31B *UX1B080A9H31B

*UX1C100A9H41B 21" 1 - 20" X 25" X 1" *UX1D120A9H51B 24-1/2" 1 - 24" X 25" X 1"

*First letter may be "A" or "T" *** NOTE - On 5 ton airflow models, if the airflow requirement exceeds 1800 CFM, these models will require filters on both sides; OR 1 side and the bottom; OR just the bottom.

CABINET

WIDTH

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

FILTER

QTY & SIZE

The upflow furnace blower door has a hinge at the bottom which allows the door to tilt forward for filter replacement without the door being removed (See Figure 11). The furnace filter in the bottom or side configuration can be removed by simply turning the two latches on the blower door and tilting the door forward.

Blower Door Hinge and Bottom Filter Rack Installation

RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in the horizontal configuration, the return air filters must be installed exterior to the cabinet. Remote filter grilles may be used for homeowner convenience or the filters may be installed in the duct work upstream of the furnace. See Figure 12.

Airflow

TYPICAL RETURN AIR FILTER INSTALLA TION IN

UPFLOW MODEL IN HORIZONTAL POSITION

18-CD22D1-5 9

Page 10

Installer’s Guide

BLOWER DOOR/HINGE REMOVAL

If clearance or other problems create a problem in using the tilting door, the blower door hinge may be removed without creating any problems with the seal of the furnace. To remove the blower door, tilt the door forward 2 to 3 inches and pull up. To remove the tilt feature, simply remove the lower hinge as shown in Figure 13. The bottom of the blower door will catch in the bottom of the furnace front channel for door replacement.

Airflow

Door Hinge Removed

ALTERNATE UPFLOW FILTER CLIP / BRACKET INSTALLATION

1. Determine the location to be used. The furnace cabinet has dimples for location of the alternate furnace clips (

return only

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.

). Pre-drill clearance holes with a 3/16" drill.

Side

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS

These furnaces require high velocity type air filters. Downflow furnace filters must be located outside the furnace cabinet. Typical installations are shown in Figure 15. Tables 4, 5 and 6 provide information for installation of the filter retaining brackets shipped with downflow furnaces.

T ABLE 4

MODELS

NUMBERS

CABINET

WIDTH

FILTER

QTY & SIZE

*DX1B040A9H 21B *DX1B060A9H 31B

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

*DX1B080A9H 31B *DX1C100A9H41B 21" 2 - 16" X 20" X 1" *DX1D120A9H51B 24-1/2" 2 - 16" X 20" X 1"

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

T ABLE 5

LOCATING FILTER RETAINER BRACKETS IN DUCTWORK

CABINET

WIDTH

17-1/2" 16-1/4" 15" 14" 14-3/8"

21" 19-3/4" 19-1/2" 14" 13-1/8"

24-1/2" 23-1/4" 22" 14" 13-5/8"

* LOCATION DIMENSION IS FROM END OF DU CT AGAINST THE FURNACE TO THE SCREW HOLES FOR THE BRACKET.

RETURN

DUCT

WIDTH

DIMENSION

"A"

DIMENSION

"B"

FILTER

BRACKET

LOCATION*

SIDE

CUT-OUT

10 18-CD22D1-5

REAR

ALTERNATE FILTER CLIPS LOCATION

Page 11

Installer’s Guide

Airflow

DOWNFLOW

TABLE 6

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/ HORIZONTAL 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"

VERTICAL

CLOSET

GENERAL VENTING

THIS FURNACE MUST BE VENTED TO THE OUTDOORS. THESE FURNACES ARE INDUCED DRAFT VENTED AND

MUST NOT BE CONNECTED TO ANY VENT SERVING ANOTHER A PPLIANCE. 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 7, page 12). Where the system is routed to the outdoors through an existing masonry chimney containing flue products from another gas appliance, or where required by local codes, then 3" venting of Type 29-4C stainless steel must be used in place of PVC material.

These furnaces have been classified as CATEGORY IV furnaces in accordance with 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.

Airflow

DOWNFLOW/ HORIZONT AL

HORIZONTAL

CLOSET

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 attached appliances.

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

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

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

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

the remaining

HORIZONTAL

ALCOVE / ATTIC

18-CD22D1-5 11

Page 12

Installer’s Guide

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

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

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

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 existing

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.

If improper venting is observed during any of the above tests, the remaining common venting system must be corrected. Correction of the remaining common vent system should be done by referring to 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. 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:

IMPORT ANT:

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)

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 7.

VENT FITTING MA TERIAL – PLASTIC

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

Listed in Table 8 & 9 are 2", 2½", 3", and 4" size fittings that meet these requirements. The materials listed are various grades of PVC and ABS plastic.

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

T ABLE 7

PLASTIC PI PE D ES IG NATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

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

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41 **212 ASTM D2846

F441 SCH 40, 80 **212 ASTM F441

F442 SDR SERIES **212 ASTM F442

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV ***180 ASTM D2661

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

* - Allowable temperatures based on c lassi ficat ions covered in ASTM D4 396 [D efle cti on Temps Under Load (264 PSI)] ** - Allowable temperatures based on cla ssific ations c overed in ASTM D1 784 [ Deflec tion Temps Under Load (264 PSI)] *** - Allowable temperatures based on cla ssifica tion s covered in AS TM D39 65 [ Deflec tion Temps Under Load (264 PSI)]

12 18-CD22D1-5

Page 13

Installer’s Guide

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

Be sure to properly support these joints.

BONDING OF PVC

Commercially available solvent cement 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 APPLYING CEMENT.

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

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

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

NOTE: 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.

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.

HORIZONTAL INSTALLATION (Upflow / Horizontal or Downflow / Horizontal)

NOTE: In horizonal venting when the factory supplied “off-set” (2X3 reducing coupling) is used for 3” vent pipe installation, make sure the marking “Top” is located on the top side of the pipe. The straight side must be on bottom for proper condensate drainage. This coupling is factory supplied only with the following models: *UC120 & *DC120, *UX120 & *UY120

*UX100 & *UY100, *UX808C960, and all *DX & *DY models.

NOTE: Follow venting instructions carefully when using PVC cement.

IMPORT ANT:

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

VENT AND INLET AIR CONNECTIONS

Front of Furnace

Seal INLET AIR PIPE

with RTV sealant

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.

Seal VENT PIPE with RTV sealant

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.

LABEL SAYS "TOP"

STRAIGHT SIDE MUST BE ON BOTTOM FOR PROPER CONDENSATE DRAINAGE.

2" TO 3" COUPLING

FACTORY SUPPLIED ONLY WITH THE FOLLOWING MODELS: UC120 & DC120 UX120 & UY120 UX100 & UY100 UX080C960 ALL DX & DY MODLES

FURNACE VENT OUTLET

18-CD22D1-5 13

Page 14

Installer’s Guide

UPFLOW / HORIZONTAL VENTING TABLE

T ABLE 8

MAXIMUM VENT LENG TH:

DIRECT VENT (2 PIPE SYSTEM) -

MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT AND INLET AIR PIPES (See Notes)

MODEL

*UX1B040A9H21B 60 80 100 130 50 80 80 130 *UX1B060A9H31B *UX1B080A9H31B *UX1C100A9H41B *UX1D120A9H51B

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

1. The INLET AIR of one pipe systems require the installation of a 90° elbow (to prevent dust and debris from falling straight into thefurnace) and a 2 foot horizontal or vertical straight pipe section connected before or after the elbow.

2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace). If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See Note 7 below for exception). The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SH OWN IS NOT A COMBINED TOTAL, IT IS THE M AXIMUM L ENGTH OF EACH (Vent or Inlet air pipes in two pipe systems).

4. One standard radius 90° elbow is equivalent to 12' of 4" pipe; one SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is equivalent to 6' of 3" pipe. One SHORT/LONG radius 90° elbow is equivalent to 7½' of 2½" pipe, & 5' of 2" pipe. Two 45° elbows equal one 90°elbow.

5. The termination tee or bend must be included in the total number of elbows. If the BAYVENT100 termination kit is used, the equivalent length of pipe is 5 feet. There is zero equivalent length for the BAYVENT200.

6. Pipe adapters are field supplied.

7. 4" pipe may be reduced to 3" for termination with BAYAIR30AVENTA or BAYVENT200 without additional length restriction.

2" PIPE

& FITTINGS

60 80 100 130 50 80 80 130

50 80 100 130 40 80 80 130 NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130 NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130

2-1/2" PIPE

& FITTINGS

3" PIPE

& FITTINGS

4" PIPE

& FITTINGS

MAXIMUM VENT LENGTH:

DIRECT VENT (2 PIPE SYSTEM) -

MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT AND INLET AIR PIPES (See Notes)

MODEL *DX1B040A9H21B *DX1B060A9H31B *DX1B080A9H31B *DX1C100A9H41B *DX1D120A9H51B

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

2. DO N OT MIX PIPE DIAMETE R S IN TH E SAME LENGTH OF PIPE OUTSIDE THE F URNACE CA B INE T (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 7 below for exception). The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

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

5. The termination tee or bend must be included in the total number of elbows. If the BA YAIR30VENTA termination kit is used, the equivalent length of pipe is 5 feet. There is zero equivalent length for the BAYVENT200.

6. Pipe adapters are field supplied.

7. 4" pipe may be reduced to 3" for termination with BA YAIR30AV ENT A or BAYVENT 200 w ithout additional length restriction.

2" PIPE

& FITTINGS

60 80 100 130 50 80 80 130 50 80 100 130 50 80 80 130

45 80 100 130 40 80 80 130 NOT ALLOWED 80 100 130 NOT ALLOWED 80 80 130 NOT A LLOWED 15 60 130 NO T A LLOWED 25 70 130

2-1/2" PIPE

& FITTINGS

3" PIPE

& FITTINGS

4" PIPE

& FITTINGS

NONDIRECT VENT (1 PIPE SYSTEM) -

MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT PIPE ONLY (See Notes)

2" PIPE

MAXIMUM TOTAL EQUIVA LENT FEET FOR

2" PIPE

2-1/2" PIPE

& FITTINGS

NONDIRECT VENT (1 PIPE SYSTEM) -

VENT PIPE ONLY (See Notes)

2-1/2" PIPE

& FITTINGS

3" PIPE

& FITTINGS

3" PIPE

& FITTINGS

4" PIPE

& FITTINGS

4" PIPE

& FITTINGS

SINGLE PIPE VENTING

UPFLOW FURNACE

Air Inlet

14 18-CD22D1-5

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

Vent only to outside

DOWNFLOW

FURNACE

Vent only to outside

A = 2' minimum

Page 15

INSIDE

CORNER DETAIL

Installer’s Guide

FIXED

CLOSED

VENT TERMINAL

Clearance above grad e, veran da , p or ch, deck, or

balcony

B= C le aran c e to wi n dow or door that may be op en ed

C= Clearance to permanently closed window * *

Vertical clearance to ven ti la te d so ffit l oc ate d ab ove the

terminal within a horizontal distance of 2 feet (61 cm)

from the center l in e of t he terminal E= Clearance to unventilated soffit * * F= Clearance to outside corner * * G= Clearance to insi de corner * *

Clearance to each side of center line extended above H=

meter/regulator assembly I= Clear an ce to s e rvice regulato r vent ou tl et 3 feet (91 cm) *

Clearance to n on me cha ni c al air s u pply i nl e t to build i ng J=

or the combustion air inlet to any othe r appl iance

K= C le aran c e to a m ec ha ni cal a ir supply inlet 6 feet (1.83m) 3 feet (91 cm) above if wi thin 10 feet (3m) hor iz ont al ly

Clearance above a p aved si dewalk or p aved dr i veway L=

located on public proper ty M= Clearance under veranda , p orc h, de ck, or b al c ony `12 inches (30 cm ) ‡ *

Notes:

1. In accordance with the cur ren t C SA B149.1 Natural Gas a nd P rop ane Installatio n C ode.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code. †. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. ‡. Pemitted only if veranda, po rch , d eck, o r ba lco ny is fu l ly o pe n on a mi ni mu m of two si de s be ne ath th e flo or. * Clearance in ac c ord an ce with local instal lati on c od es a nd th e re qu irem ents of the gas supplier and t he ma nufactur er' s In s tal lati on In s tr u ctio ns .

FIXED

CLOSED

OPERABLE

AIR SUPPLY INLET

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 (3 0 k w ), 36 i nc he s (91 c m) for ap pl i an ce s > 100,000 Btuh (3 0 k w )

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

OPERABLE

AREA WHERE TERMINAL IS NOT PERMITTED

Direct Vent Terminal Clearances

Canadian Instal l ation s US Installations

12 inches (30 c m ) 12 inches (3 0 c m )

meter/ reg ul at or a ss em bly

7 feet (2.13 m) † *

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9 inches (23 cm ) for app li a nces > 1 0,0 00 B tu h ( 3 kw ) an d =/< 50,000 Btuh (15 kw ), 12 i nch es ( 30 cm ) for appl i an c es > 5 0,0 00 Btuh (15 kw)

18-CD22D1-5 15

Page 16

Installer’s Guide

Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch, deck, or

balcony

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

B= Clearance to window or door that may be opened

C= Clearance to perm anently closed window * *

Vertical clearance to ventilated soffit located above the

terminal within a horizontal distance of 2 feet (61 cm)

from the center line of the terminal E= Clearance to unventilated soffit * * F= Clearance to outside corner * * G= Clearance to inside corner * *

Clearance to each side of center line extended above

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

Clearance to nonmechanical air supply inlet to building

or the combustion air inlet to any other appliance

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

Clearance above a paved sidewalk or paved driveway L=

located on public property M= Clearance under veranda, porch, deck, or balcony `12 inches (30 cm) ‡ *

Notes:

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

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

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

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

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

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

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

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)

ELBOW AND TEE MUST BE AS CLOSE TOGETHER AS POSSIBLE

POSSIBLE CONFIGURA TIONS FOR TWO PIPE VENTING SYSTEMS

16 18-CD22D1-5

Page 17

Installer’s Guide

▲

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.

HORIZONT AL VENTING THROUGH W ALL 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. Avoid areas where staining or condensate drippage may be a problem.

Location of the vent/wind terminal should be chosen to meet the requirements of Figure 20 or 21 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 DEGRADA TION – 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

CAUTION

ANCHORS

3.2"

COMBUSTION AIR

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 MA TERIAL WALL

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

Shield material to be a minimum of 24 gauge stainless or aluminized sheet metal. Minimum dimensions are 12"x12". Shield must be fastened to both inside and outside of wall. Use screws or anchor type fasteners suited to the outside or inside wall surfaces.

NONCOMBUSTIBLE MATERIAL WALL

The hole through the wall must be large enough to maintain pitch of vent and properly seal.

Use cement mortar seal on inside and outside of wall. See Figure 23.

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

(4 req.)

VENT

VENT CAP

PLATE

VENT

MAINTAIN 12" (18" FOR CANADA) MINIMUM

CLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

BA YVENT200B

12" MINIMUM TO OVERHANG

SCREWS (4 req.)

BA YAIR30A VENTA

(Sidewall)

flexible seal on flashing before PVC pipe is pushed through the seal. (Field Supplied)

NOTE:

No vent cap as shown in Figure 27 is the preferred method for vertical vent termination in extremely cold climates.

In extreme climate conditions, insulate the exposed pipe

18-CD22D1-5 17

Page 18

Installer’s Guide

SEE VENTING TABLE

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

USE ONLY

APPROVED

TERMINATIO

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.

NOTE: VENT AND INLET MUST BE SUPPORTED

A T A MAXIMUM OF 3' INTERVALS

COMBUSTION AIR INLET

0" UPFLOW OR

DOWNFLOW MODELS

VENT

COMBUSTION AIR

STRAP (FIELD SUPPLIED)

ELBOW (FIELD SUPPLIED)

UPWARD PITCH -- 1/4" PER FOOT

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

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

COMBUSTION AIR

RAIN CAP

VENT

1" + 1/2"

OUTSIDE

WALL

TEE

REDUCING COUPLING, FIELD SUPPLIED IF NEEDED

2", 2-1/2"

or 3" PIPING

3" PIPING

BAYAIR30AVENTA

BA YVENT200B

SEAL ALL

WALL CAVITIES

18 18-CD22D1-5

Page 19

Installer’s Guide

REMOVE RIBS FROM CAP

COMBUSTION AIR

ROOF 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

DOWNWARD VENTING

Furnace may be in vertical or horizontal configuration.

DOWNWARD VENT

LENGTH IS LIMITED

TO A MAXIMUM OF

EQUIVALENT FEET.

Slope 1/4" per ft.

All horizontal pipes must be supported at a maximum of 3 foot

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.

Upflow or Downflow

6" Min.

intervals

40 Inch

Furnace

above the roof line with Armaflex type insulation.

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

BAYAIR30AVENTA

VENT

COMBUSTION AIR

CONCENTRIC VENT

ROOF TOP APPLICATION

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 29-4C MUST be used throughout.

These fittings and fitting accessories are to be supplied locally.

DIRECTION OF ST AINLESS STEEL FITTING

All stainless steel fitting must be installed with male end towards the furnace.

All horizontal stainless steel sections must be positioned with the seam on top.

All long horizontal sections must be supported to prevent sagging.

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

NOTE: Both venting methods shown in Figure 27 & 28 must also have the combustion air inlet installed - meeting dimension requirements of Figure 22.

18-CD22D1-5 19

CONCENTRIC VENT

ROOF INSTALLATION

GAS PIPING

The upflow /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 34.

Page 20

Installer’s Guide

L N

STAINLESS

;

TYPE 29-4C ST AINLESS STEEL VENTING -

USED THROUGH CHIMNEY THA T VENTS

ANOTHER GAS APPLIANCE

STAINLESS STEEL

STEEL

VENT CAP

(OPTIONAL)

E CAUTION

6 IN. MIN.

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

FLUE PIPE

COUPLING

SUPPORT

FLANGE

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

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

VENTING THROUGH CEILING

PVC PLASTIC VENTING - ONLY

FLUE PIPE

THROUGH UNUSED CHIMNEY

STAINLESS STEEL

TAINLE

VENT CAP

STEEL

(OPTIONAL)

VENT CAP

SEE CAUTION

6 IN. MIN.

CEILING

SUPPORT THE SINGLE WA STAINLESS STEEL GAS VENTING AND CENTER IT I THE CHIMNEY OPENING WI ANGLES AS SHOWN OR ANOTHER EQUIVALENT MANNER.

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

CAUTION

▲

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

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

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.

UPLING TO SUPPORT

PE FROM ANGLES

OTHER SUITABLE PPORT METHOD

FLUE PIPE

CAUTION

▲

NOTE: HORIZONTAL VENTING TO VERTICAL VENTING

SUPPORT THE SINGL WALL FLUE PIPE AND CENTER IT IN THE CHIMNEY OPENING WI ANGLES AS SHOWN O ANOTHER EQUIVALEN MANNER.

COUPLING AS REQUIRED

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

IMPORTANT –

The single wall flue pipe joints must be sealed. The 90° elbow connection to vertical pipe must be sealed to

prevent condensate leakage to base of masonry chimney.

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.

20 18-CD22D1-5

Page 21

CONDENSATE DRAIN INSTRUCTIONS

▲

CAUTION

▲

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

Installer’s Guide

Downflow furnace - The furnace is shipped with the left side drainage setup. To change the right side drain, remove the drain lines from the trap, rotate the trap 180° so it exits to the right, reconnect the lines, and run a 1/2" CPVC pipe from the trap out through the right side knock-out. Use RTV silicone sealant to connect the CPVC pipe to the trap for ease of removing to clean the trap.

VERTICAL APPLICATIONS 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.

HORIZONTALAPPLICATIONS 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 90% gas furnace. Connect the auxillary drain pan to a separate drain line (no trap is needed in this line).

Left side

Right side

UPFLOW (VERTICAL)

Use Inducer Drain

hose without

extension

UPFLOW HORIZONTAL 17" UNITS

(Left side only)

UPFLOW (VERTICAL)

Use extension hose here

UPFLOW HORIZONT AL 21" & 24" UNITS

(Left side only)

18-CD22D1-5 21

Page 22

Installer’s Guide

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, next to the secondary recouperative 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. This tube on downflow units will need to be cut to fit between the inducer

Left

side

Cut off curved end of

Inducer drain hose

DOWNFLOW (HORIZONT AL)

and the trap. On upflow units, this tube may need to be extended, using the tubing shipped with the furnace.

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

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

DOWNFLOW (VERTICAL)

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

DOWNFLOW (VERTICAL)

Right

side

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

IMPORT ANT:

The condensate drain should be installed with provisions to prevent winter freeze-up of the condensate drain line. Frozen condensate will block drains, resulting in furnace shutdown. If the drain line cannot be installed in a conditioned space, then 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. 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 auxillary drain pan in order to prevent water damage to the finished ceiling below.

22 18-CD22D1-5

Page 23

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.

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.

Installer’s Guide

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

18-CD22D1-5 23

Page 24

Installer’s Guide

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

USING A 1 STAGE HEATING THERMOSTAT

FURNACE

SEE

B/C

NOTE 7

SEE

NOTE 6

TWIN

B/C

1 STAGE HEATING

NO COOLING

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

HUM SEE NOTE 5

OUTDOOR UNIT

(NO TRANSFORMER)

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)

FURNACE

SEE

NOTE 6

SEE

B/C

NOTE 8

B/C

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

From drawing B341437 Rv 1

HUM SEE NOTE 5

EAC SEE NOTE 5

From drawing B340388 Rv 2

24 18-CD22D1-5

Page 25

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

1 STAGE HEAT

ONLY

THERMOSTAT

(WITH FAN SWITCH) FURNACE NO. 1

SINGLE WIRE TWINNING FEA TURE

1 STAGE HEATING ONLY THERMOSTAT

TWIN

ISOLATION RELAY (FIELD SUPPLIED)

SEE NOTE 4

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO. 2 IS SYNCRONIZED

WITH UNIT NO. 1 VIA SIGNALS

FROM TWIN CONNECTION.

TWIN

SEE NOTE 4

Installer’s Guide

B/C

OUTDOOR UNIT

(WITH TRANSFORMER)

ISOLATION RELAY (FIELD SUPPLIED)

SEE NOTE 3

OUTDOOR UNIT

(NO TRANSFORMER)

SEE NOTE 3

B/C

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE

HEATING / COOLING

THERMOSTAT FURNACE NO. 1

1 STAGE HEAT / 1 STAGE COOL THERMOSTAT

TWIN

B/C

ISOLATION RELAY

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO. 2 IS SYNCRONIZED

WITH UNIT NO. 1 VIA SIGNALS

FROM TWIN CONNECTION.

TWIN

SEE NOTE 4

From Dwg. 21B341422 Rev. 3

ISOLATION RELAY

SEE NOTE 4

ISOLATION RELAY (FIELD SUPPLIED)

SEE NOTE 4

B/C

From Dwg. 21B341423 Rev. 2

B/C

SEE NOTE 5

B/C

18-CD22D1-5 25

Page 26

Installer’s Guide

Refer to piping Table 10, for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve as shown in Figures 34-36.

National codes require a condensation drip leg to be installed ahead of the controls as shown in Figures 34-36.

The furnace and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).

The furnace must be isolated from the gas supply piping by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).

NOTE: Maximum pressure to the gas valve for natural gas is

13.8" W.C. Minimum pressure is 5.0" W.C. Maximum pressure to the gas valve for propane is 13.8" W.C. Minimum pressure is 1 1.0" W.C.

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION JOINT

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

All gas fittings must be checked for leaks using a soapy solution before lighting the furnace.

DO NOT CHECK WITH

AN OPEN FLAME!

CAUTION

▲

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

TABLE 10

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE SIZE

1/2 132 92 73 63 56 50 46 3/4 278 190 152 130 115 105 96

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

This table is based on pressure drop of 0.3 inch W.C. and 0.6 SP.GR. gas

10 20 30 40 50 60 70

1 520 350 285 245 215 195 180

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

LENGTH OF PIPE

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 INST ALLED LEFT OR RIGHT SIDE GAS PIPING

26 18-CD22D1-5

Page 27

Installer’s Guide

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION JOINT

DRIP LEG

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

TABLE 11

ORIFICE SIZES

INPUT

RATING

BTUH

40,000 60,000

80,000 100,000 120,000

COMBUSTION AND INPUT CHECK

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

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

3. Match the “Sec” column in the gas flow (in cfh) Table 13 with the time clocked.

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

5. Use the following factors For 1 Cu. Ft. Dial Gas Flow CFH =

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

For 5 Cu. Ft. Dial Gas Flow CFH =

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

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

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

tap marked "OUT PRESS TAP" on White-Rodgers gas valve model 36F or boss marked "OUT P" on WhiteRodgers gas valve model 36G. (See Figure 39 for White-Rodgers gas valve model 36F and Figure 40 for White-Rodgers gas valve model 36G.). For the gas valve model 36F, measurement requires removal of the

NUMBER

BURNERS

2 3 4 5 6

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 45 45 45 45

if necessary:

Chart Flow Reading ÷2

Chart Flow Reading ÷4

10X Chart Flow Reading ÷4

56 56 56 56 56

MAIN MANUAL

SHUTOFF VALVE

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

plug and installation of a barbed fitting. Attach flexible tubing and a manometer to the barbed fitting. For the gas valve model 36G, do not remove the pressure tap test screw. Using a 3/32" hex wrench, loosen the pressure tap test screw one turn and install 5/16" flexible tubing and a manometer directly onto the outlet pressure boss.

c. Turn on system power and energize valve.

d. Remove the regulator adjustment screw cap on the gas valve for manifold pressure adjustment.

e. Turn the adjustment nut clockwise to increase the gas

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

f. The final manifold pressure setting shall be as specified

in Table 12 with an input of no more than nameplate rating and no less than 93% of the nameplate rating, unless the unit is derated for high altitude.

g. Replace the regulator adjustment screw cap and

tighten securely.

h. Turn off all electrical power to the system.

i. Remove the manometer and flexible tubing. Remove

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

j. Turn on electrical power to the system and energize

valve.

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

leaks at plug or pressure boss screw.

▲

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

GROUND UNION JOINT

DRIP LEG

CAUTION

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 37.

18-CD22D1-5 27

Page 28

Installer’s Guide

CAUTION

▲

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

Table 11 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 14.

TABLE 12

FINAL MANIFOLD PRESSURE SETTINGS

FUEL PRESSURE

NATURAL GAS 3.5" W.C.

LP GAS 11.0" W.C.

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

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

IMPORT ANT: Re-install the propane orifices to the same depth as the

orifices supplied with th equipment.

See Table 15 for help in selecting orifices if orifice change is required. Furnace input rate and temperature rise should be checked again after changing orifices to confirm the proper rate for the altitude.

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

TABLE 13

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

ROT ATE THE FRONT

INSERT THE TOP FLANGE OF THE FRONT

ALL SIDE FLANGES MUST BE OUTSIDE

ROT ATE THE FRONT COVER INWARD MAKING SURE THAT ALL SIDE FLANGES ARE OUTSIDE OF THE

28 18-CD22D1-5

Page 29

Installer’s Guide

TABLE 14

PART NUMBERS FOR REPL ACEMENT ORIFIC ES

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 50 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 15

Orifice

Twist Dri ll

Size If

Installed

At Sea

Level

42 43 44 45 46 47

54 55 56 57 58

2000 3000 4000 5000 6000 7000 8000 9000 10000

42 44 45 46 47 48

54 55 56 58 59

From National Fuel Gas Code - Table F-4

ALTITUDE ABOVE SEA LEVEL

and Orifice Require d At Ot her El evations

WARNING

▲

45 46 47 48 49

55 56 57

60 61

45 47 48 48 49

55 56 57 60 62

47 48 49

47 48 49 49 50

56 56 59 62 63

47 48 49 50

56 56 59 63 63

47 48 50 50 51 52

56 57 60 63 64

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

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

LIGHTING INSTRUCTIONS

WARNING

▲

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

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

Turn on the main electrical supply and set the thermostat above the indicated temperature. The ignitor will automatically heat, then the gas valve is energized to permit the flow of gas to the burners. After ignition and flame is established, the flame control module monitors the flame and supplies power to the gas valve until the thermostat is satisfied.

To shut off.

For complete shut-down: Flip the switch on the main gas valve to the “OFF” position, (See Figure 39 & 40). Disconnect the electrical supply to the unit.

CAUTION

▲

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

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

SEQUENCE OF OPERA TION 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

18-CD22D1-5 29

heating cycle.

Page 30

Installer’s Guide

Swi

Outlet Pressure Boss

Swi

let Pressure

Boss

tor

Adj

ust

Inlet Pressure

Boss

(opt.)

Outlet Pressure Boss

On/Offff Swi

White-Rodgers 36G gas valve

On/Offff Swi

tch

Regululator

Adj

ust

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 deenergized by the control module.

CONTROL AND SAFETY SWITCH ADJUSTMENTS LIMIT SWITCH CHECK OUT

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

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

NOTE TO INST ALLER

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.

White-Rodgers 36F gas valve

CAUTION

▲

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

SEQUENCE OF OPERATION Thermostat call for heat

WARNING

▲

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

This unit is equipped with a blower door switch which cuts power to the blower and gas valve causing shutdown when the door is removed. Operation with the door removed or ajar can permit the escape of dangerous fumes. All panels must be securely closed at all times for safe operation of the furnace.

INDOOR BLOWER TIMING Heating: The integrated furnace control module controls the

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

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

ROOM AIR THERMOSTA T 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).

30 18-CD22D1-5

Page 31

Installer’s Guide

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

BURNER BOX TEMPERA TURE LIMIT DEVICE

All models are equipped with a manual reset temperature limit located on the burner box. In case of excessive temperature, the limit will open and cause the circuit to open which shuts off all flow of gas.

ABNORMAL CONDITIONS

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

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

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

4. GAS SUPPLY FAILURE If loss of flame occurs during a heating cycle, the system integrated control module will re-cycle 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, improper draining, or by freezing condensate, the pressure switch will sense the accumulation of condensate in the furnace drain pan. The pressure switch contacts will open and remain open, not allowing unit operation. The unit will not operate until the condensate drain has been cleared, and the condensate flows freely.

7. RESET AFTER LOCKOUT When the integrated control module has shut the system down and gone into lockout, the system must be manually reset before the unit will restart. To reset, turn the system power off, then on, then off and then on again within 30 seconds. This may be done at the unit’s power source or at the thermostat.

The system will not reset unless the

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

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

the limit switch must be reset by a qualified servicer.

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

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

Carbon Monoxide Alarms, UL 2034

Standard, CSA 6.19

Standards for Single and Multiple Station

or CSA International

Residential Carbon Monoxide Alarming Devices,

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

18-CD22D1-5 31

Page 32

INTEGRATED FURNACE CONTROL ERROR FLASH CODES

Flashing Slow --- Normal - No call for Heat Flashing Fast --- N or mal - Cal l for Heat

Continuous ON --- Replace I FC Continuous OFF --- Check Power 2 Flashes --- System Lockout (Retries or Recycles exceeded)

Draft Pressure Error - Possible problems:

3 Flashes ---

a) Venting pr oblem b) Pressure switch problem

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

9 Flashes ---

Check Ignitor Circuit and Line "N" to 24VAC "Common" voltage (≤ 2 volts)

[possible grounding problem]

American Standard Inc. 6200 Troup Highway Tyler, TX 75707

For more information contact your local dealer (distributor)

Literature Order Number * File Number 18-CD22D1-5 Supersedes 18-CD22D1-4 Stocking Location PI Louisville & Webb/Mason-Houston

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

P.I.

Trane AUX1B040A9H21B, AUX1B060A9H31B, AUX1B080A9H31B, AUX1C100A9H41B, AUX1D120A9H51B Installer's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual