Trane DD1D120A9H51B, DD1B060A9H31B, UD1B060A9H31B, UD1A040A9H21B, UD1B080A9H31B User Manual

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18- CD21D1- 5

Installer’s Guide

High Efficiency Single Stage Upflow/ Horizontal and Downflow/ Horizontal Gas-Fired Furnaces, “Fan Assisted Combustion System”

*UD1A040A9H21B *UD1B060A9H31B *UD1B080A9H31B *UD1C080A9H41B

*__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.

For VENT SIZING INFORMATION see:

USA —

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

CANADA —

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

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

USA/CANADA ALTERNATE —

Category I Venting Guide .................................. Pub. No. 18-CH23D1-2

*UD1-H

*UD1B100A9H31B *UD1C100A9H51B *UD1D120A9H51B *UD1D140A9H51B

*DD1-H

*DD1B060A9H31B *DD1B080A9H31B *DD1C100A9H51B *DD1D120A9H51B

Upflow/ Horizontal* Downflow/ Horizontal*

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

A341789P07

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 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 (pages 13-

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” (page 618), 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 manufacturer’s instructions.

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

stat (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.

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.

Follow the lighting instructions. Place the appliance be-

6. ing 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.

After it has been determined that each appliance

8. 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.

f. The furnace return air temperature range is be-

tween 55 and 80 degrees Fahrenheit.

g. Clean the furnace, duct work, and components

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

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

Installer’s Guide

▲

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

a. WARNING indicates a potentially hazardous situa-

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

b. CAUTION indicates a potentially hazardous situation

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

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.

Contents

Installation Instructions 3

General Installation Instructions 4 Location and Clearances 4

Outline Drawing 5

Upflow Installation 7 Downflow Installation 7 Air For Combustion and Ventilation 8 Duct Connections 10 Return Air Filters 11 Typical Upflow Return Air Filter Installations 11 Alternate Upflow Filter Clip / Bracket Installation 13 Typical Downflow Furnace Return Air Filter Installations 13 General Venting Instructions 14 Venting Into a Masonry Chimney 15 Electrical Connections 16

Field Wiring Diagrams 17

Gas Piping 19 Sequence of Operation 19

Start Up and Adjustment 20

Preliminary Inspections 20 Combustion and Input Check 20 High Altitude Derate 21 Lighting Instructions 22 Control and Safety Switch Adjustment 23

IFC Error Flash Codes 24

Abnormal Conditions 24

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.

WARNING

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

CAUTION

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

18-CD21D1-5 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 must be reduced (See GAS INPUT ADJUSTMENT).

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

Codes and local utility requirements governing the installation of gas fired equipment, wiring, plumbing, and flue connections must be adhered to. In the absence of local codes, the installation must conform with latest edition of the National Fuel Gas Code ANSI Z223.1 • National Installation Code, CAN/CGA B149.1. The latest code may be obtained from the American Gas Association Laboratories, 400 N. Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or www.aga.org These furnaces have been classified as Fan Assisted Combustion system CATEGORY I furnaces as required by ANSI Z21.47 “latest edition” and CAN/CGA 2.3. Therefore they do not require any special provisions for venting other than what is indicated in these instructions. (Category I defined on page 14).

These furnaces may be twinned. They shall have common returns with equal pressure drops or ducts with equivalent lengths and sizes. See Field Wiring Diagrams for Twinning on page 17 for proper hookup.

LOCATION AND CLEARANCES

The location of the furnace is normally selected by the architect, the builder, or the installer. However, before the furnace is moved into place, be sure to consider the following requirements:

1. Is the location selected as near the chimney or vent and as centralized for heat distribution as practical?

2. Do all clearances between the furnace and enclosure equal or exceed the minimums stated in Clearance Table on the Outline Drawings.

3. Is there sufficient space for servicing the furnace and other equipment? A minimum of 24 inches front accessibility to the furnace must be provided. Any access door or panel must permit removal of the largest component.

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

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

6. Allow sufficient height in supply plenum above the furnace to provide for cooling coil installation, if the cooling coil is not installed at the time of this furnace installation.

7. A furnace shall be installed so electrical components are protected from water.

8. If the furnace is installed in a residential garage, it must be installed so that the burners, and the ignition source are located not less than 18 inches above the floor and the furnace must be located or protected to avoid physical damage from vehicles.

4 18-CD21D1-5

Installer’s Guide

From Dwg. 21C341699 Sh. 1 Rev. 4

(ALL DIMENSIONS ARE IN INCHES)

*UD1-H OUTLINE DRAWING

18-CD21D1-5 5

Installer’s Guide

From Dwg. 21C341700 Sh. 1 Rev. 0

(ALL DIMENSIONS ARE IN INCHES)

*DD1-HF OUTLINE DRAWING

6 18-CD21D1-5

Installer’s Guide

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UPFLOW INSTALLATION

Standoffs and screws (See Figure 1 on page 6) are included with the cased coils for attachment to the furnace. There are clearance alignment holes near the bottom of the coil wrapper and drill screws are used to engage the furnace top flange. 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. These instructions apply only if the coil is on top of an upflow furnace.

CASED

UPFLOW

FURNACE

STANDOFFS (4)

COIL

STANDOFFS

(BOTH SIDES)

DRILL SCREWS (4)

FOR VERTICAL

INSTALLATIONS:

SCREWS

(BOTH SIDES)

required.

REQUIRED FLOOR OPENING: (DOWNFLOW)

2345678901234567890123456789012123456789012345

FURNACE

2345678901234567890123456789012123456789012345

FRONT

A (width)

B (depth)

SEE FIGURE 3 AND TABLE 1

TABLE 1

CABINET

WIDTH

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

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

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

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

RETURN

DUCT WIDTH

FLOOR OPENING PLENUM OPENING

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

HORIZONTAL INSTALLATION

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

DOWNFLOW INSTALLATION

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

18-CD21D1-5 7

CASED COIL CONNECTION BRACKET FOR DOWNFLOW FURNACE IN HORIZONTAL

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. This furnace may be installed in an attic or crawl space in the horizontal position by placing the furnace on the left or right side (as viewed from the front in the upright position). The horizontal furnace installation in an attic should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of the furnace (See Clearance Table on Outline Drawings and Figure 5).

Installer’s Guide

If the furnace is suspended using perforated steel strap (plumber’s strap), it must be supported at all four corners and in the middle at the front of the furnace. The forward most screw on the side of the furnace may be used to connect the strapping (See Figure 6). Line contact is only permissible between lines formed by the intersection of the top and two sides of the furnace casing and the building joists, studs, or framing.

UNCONFINED

50 CU. FT. OR MORE

PER 1000 BTU/ HR.

INPUT ALL EQUIP-

MENT INSTALLED

TYPICAL ATTIC PLATFORM INSTALLATION

(UPFLOW/HORIZONTAL FURNACE SHOWN)

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

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

AIR FOR COMBUSTION AND VENTILATION

Adequate flow of combustion and ventilating air must not be obstructed from reaching the furnace. Air openings provided in the furnace casing must be kept free of obstructions which restrict the flow of air. Airflow restrictions affect the efficiency and safe operation of the furnace. Keep this in mind should you choose to remodel or change the area which contains your furnace. Furnaces must have a free flow of air for proper performance. Provisions for combustion and ventilation air shall be made in accordance with “latest edition” of Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CAN/ CGA B149 Installation Codes, and applicable provisions of the local building codes. Special conditions created by mechanical exhausting of air and fireplaces must be considered to avoid unsatisfactory furnace operation. Furnace locations may be in “confined space” or “unconfined space”. Unconfined space is defined in Table 2 and Figure 7. These spaces may have adequate air by infiltration to provide air for combustion, ventilation, and dilution of flue gases. Buildings with tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), may need additional air provided as described for confined space.

Typical Suspended Installation

(Upflow/Horizontal Furnace Shown)

8 18-CD21D1-5

Confined spaces are installations with less than 50 cu. ft. of space per 1000 BTU/ hr input from all equipment installed. Air for combustion and ventilation requirements can be supplied from inside the building as in Figure 9 or from the outdoors, as in Figure 10.

CONFINED

LESS THAN 50 CU. FT.

PER 1000 BTU/ HR.

INPUT ALL EQUIP-

MENT INSTALLED

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