Trane UX1D100A9601A, UX1C100A9481A, UX1D120A9601A, DX1B040A9241A, UX1B060A9361A User Manual

...
Available in French Canadian (FC)
Installer’s Guide
Upflow/ Horizontal and Downflow/ Horizontal Gas-Fired, Direct Vent Condensing Furnaces
*UX1B040A9241A *UX1B060A9241A *UX1B060A9361A *UX1B080A9241A *UX1B080A9421A
*__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.
*UX-1
*UX1C080A9601A *UX1C100A9361A *UX1C100A9481A *UX1D100A9601A *UX1D120A9601A
*DX-1
*DX1B040A9241A *DX1B060A9361A *DX1B080A9421A *DX1C100A9481A *DX1D120A9601A
UPFLOW
UPFLOW/HORIZONTAL
DOWNFLOW
DOWNFLOW/HORIZONTAL
A341624P06
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 (starting on page 15), of these instructions.
5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifi­cally for the detection of leaks to check all connec­tions, as specified in “Gas Piping” (pages 31-33), of these instructions.
6. Always install the furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified on the unit rating plate. Airflow with temperature rise for cfm versus static is shown in the Service Facts accompa­nying this furnace.
7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the fur­nace casing and terminating outside the space con­taining the furnace.
8. A gas-fired furnace for installation in a residential garage must be installed as specified in “Location and Clearances” section (page 4), of these instruc­tions.
9. The furnace may be used for temporary heating of buildings or structures under construction only when the following conditions have been met: a. The furnace venting system must be complete
and installed per manufacturers instructions.
b. The furnace is controlled only by a room ther-
mostat (no field jumpers).
c. The furnace return air duct must be complete
and sealed to the furnace and clean air filters are in place.
d. The furnace input rate and temperature rise
must be verified to be within nameplate mark­ing.
e. 100% of the furnace combustion air require-
ment must come from outside the structure.
f. The furnace return air temperature range is
between 55 and 80 degrees Fahrenheit.
g. Clean the furnace, duct work, and components
upon substantial completion of the construction process, and verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer's instructions.
10. This product must be gas piped by a Licensed Plumber or Gas Fitter in the Commonwealth of Massachusetts.
!
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 B149.1 In­stallation Codes.
8. After it has been determined that each appliance connected to the venting system properly vents where tested as outlined above, return doors, win­dows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.
© 2008 Trane All Rights Reserved 18-CD19D6-32
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.
GENERAL INSTALLATION INSTRUCTIONS
The manufacturer assumes no responsibility for equip­ment installed in violation of any code or regulation. It is recommended that Manual J of the Air Condition­ing Contractors Association (ACCA) or A.R.I. 230 be fol­lowed in estimating heating requirements. When esti­mating heating requirements for installation at alti­tudes above 2000 ft., remember the gas input may need to be reduced (See High Altitude Installation).
Material in this shipment has been inspected at the factory and released to the transportation agency without known damage. Inspect exterior of carton for evidence of rough handling in ship­ment. Unpack carefully after moving equipment to approximate location. If damage to contents is found, report the damage immediately to the de­livering agency.
Codes and local utility requirements governing the installation of gas fired equipment, wiring, plumbing, and flue connections must be adhered to. In the ab­sence of local codes, the installation must conform with latest edition of the National Fuel Gas Code ANSI Z223.1 • National Installation Code, CAN/CGA B149.1. The latest code may be obtained from the American Gas Association Laboratories, 400 N. Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or www.aga.org These furnaces have been classified as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21.47 • CAN/ CGA 2.3 standards.
Contents
INSTALLATION INSTRUCTIONS
General Installation Instructions 3 Location and Clearances 4 Outline Drawings 5 Upflow Installation 7 Downflow Installation 7 Horizontal Installation 7 Air For Combustion and Ventilation 8 Duct Connections 10 Return Air Filters 11 General Venting Instructions 15 Venting Material 16 Venting Tables 17-19 Horizontal Venting 20 Venting Through The Wall 20 Venting Through The Roof 23 Downward Venting 23 Venting Through a Masonry Chimney 23 Condensate Drain Instructions 26 Electrical Connections 29 Field Wiring Diagrams 28-30 Gas Piping 31 Combustion Input Checks 32
Start Up and Adjustment 35
Preliminary Inspections 35 Lighting Instructions 35 Sequence Of Operation 36 Control And Safety Switch Adjustments 36 Airflow Adjustment 36
Abnormal Conditions 37
IFC Error Flash Code 39
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.
18-CD19D6-32 3
Installer’s Guide
!
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.
!
CAUTION
Do NOT install the furnace in a corrosive or contami­nated atmosphere.
!
WARNING
EXPLOSION HAZARD! PROPANE GAS IS HEAVIER THAN AIR AND MAY COLLECT IN ANY LOW AREAS OR CONFINED SPACES. IN ADDITION, ODORANT FADE MAY MAKE THE GAS UNDETECTABLE EXCEPT WITH A WARN­ING DEVICE. IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR A CONFINED SPACE, IT IS STRONGLY RECOM­MENDED TO CONTACT A GAS SUPPLIER TO IN­STALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.
NOTE: The manufacturer of your furnace does NOT test
any detectors and makes no representations regarding any brand or type of detector.
LOCATION AND CLEARANCES
The location of the furnace is normally selected by the architect, the builder, or the installer. However, before the furnace is moved into place, be sure to consider the following requirements:
1. Is the location selected as near the vent and as cen­tralized for heat distribution as practical?
2. Do all clearances between the furnace and enclo­sure equal or exceed the minimums shown in the Table 1.
3. Is there sufficient space for servicing the furnace and other equipment? A minimum of 24 inches front accessibility to the furnace must be provided. Any access door or panel must permit removal of the largest component.
4. Are there at least 3 inches of clearance between the furnace front panel and any closed panel or door provided?
5. Are the 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.
IMPORTANT:
The furnace must be installed level. The only allowable variation would be slightly to the left and/or forward in upflow installations or slightly toward the front in horizontal installations. This is necessary for proper condensate drain­age.
4 18-CD19D6-32
Installer’s Guide
From Dwg. 21C341884 Rev. 6
(ALL DIMENSIONS ARE IN INCHES)
*UX-C OUTLINE DRAWING
18-CD19D6-32 5
Installer’s Guide
From Dwg. 21C341885 Rev. 6
(ALL DIMENSIONS ARE IN INCHES)
*DX-C DOWNFLOW / HORIZONTAL OUTLINE DRAWING
6 18-CD19D6-32
UPFLOW INSTALLATION
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
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.
1
CASED
UPFLOW
FURNACE
STANDOFFS (4)
COIL
STANDOFFS
(BOTH SIDES)
DRILL SCREWS (4)
FOR VERTICAL
INSTALLATIONS:
SCREWS
(BOTH SIDES)
DOWNFLOW INSTALLATIONS
!
WARNING
Do NOT install the furnace directly on carpeting, tile or other combustible material other than wood flooring. For vertical downflow application, subbase (BAYBASE-
205) must be used between the furnace and combus­tible flooring. When the downflow furnace is installed vertically with a cased coil, a subbase is not required.
Required floor opening:
Installer’s Guide
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FURNACE
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FRONT
HORIZONTAL INSTALLATION
The coil and furnace must be fully supported when used in the horizontal position. It is always recommended that an auxiliary drain pan be installed under a horizon­tally installed evaporator coil or 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 posi- tion. See Figure 4.
IMPORTANT: The 2/4TXC cased coil must be placed downstream of the furnace. In horizontal installations, the apex of the coil may point either toward or away from the furnace. See the 2/4TXC coil Installer's Guide for more details.
The cased coil is secured to the furnace and both the furnace and the cased coil must be properly supported. The brackets mount using the rear screws on the coil case and use the screws provided to secure the bracket to the furnace. The remaining bracket is placed as close to center as possible (horizontally) between the coil case front and the furnace bottom channel (for 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.
4
CASED COIL CONNECTION
BRACKET FOR DOWNFLOW
FURNACE IN HORIZONTAL
A (width)
B (depth)
D
C
DOWNFLOW ONLY
The furnace may be installed in an attic or crawl space in the horizontal position by placing the furnace on the left side (as viewed from the front in the vertical posi-
2
CABINET
WIDTH
17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"
21" 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8"
24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8"
18-CD19D6-32 7
SUBBASE CROSS SECTION
TABLE 1
RETURN
DUCT WIDTH
FLOOR OPENING PLENUM OPENING
"A" "B" "C" "D"
tion). 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 5 & 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.
Installer’s Guide
5
UPFLOW/ HORIZONTAL SHOWN
The furnace may be placed horizontally in a crawl space on a pad or other noncombustible material which will raise the unit for sufficient protection from moisture.
The furnace must be supported at both ends and the middle when installed horizontally. The furnace must also be elevated a minimum of 6 inches to allow clearance for the condensate drain to exit the cabinet in the horizontal position.
The horizontal furnace may also be suspended from the joists using 3/8" all-thread rods with pieces of angle iron underneath the furnace to form a hanging rack at both ends and the midpoint. The rods need to be of sufficient length to allow for proper clearances from combustible materials. The angle iron needs to be at least 32" in length to allow for access to service panels.
6
50 CU. FT. OR MORE PER 1000 BTU/HR. INPUT ALL EQUIP. INSTALLED
UNCONFINED
AIR FOR COMBUSTION AND VENTILATION
If these furnaces are installed in a nondirect vent capac­ity then the adequate flow of combustion and ventilat­ing air must not be obstructed from reaching the fur­nace. Air openings provided for combustion air must be kept free of obstructions which restrict the flow of air. Airflow restrictions affect the efficiency and safe opera­tion of the furnace. Keep this in mind should you choose to remodel or change the area which contains your furnace. Furnaces must have a free flow of air for proper performance.
Provisions for combustion and ventilation air shall be made in accordance with latest edition of Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1 — CAN/CGA B149.1 or ap­plicable provisions of the local building codes. Special conditions created by mechanical exhausting of air and fireplaces must be considered to avoid unsatisfactory furnace operation.
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 “unconfined space”. Unconfined space is defined in Figure 6. These spaces may 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 are installations with less than 50 cu. ft. of space per 1000 BTU/hr input from all equipment installed. Air for combustion and ventilation require­ments can be supplied from inside the building as in Figure 8 or from the outdoors, as in Figure 9.
8 18-CD19D6-32
Installer’s Guide
MINIMUM AREA IN SQUARE FEET
FOR UNCONFINED SPACE INSTALLATIONS
FURNACE
MAXIMUM BTUH
INPUT RATING
60,000
80,000 100,000 120,000
MINIMUM AREA IN SQUARE FEET
WITH 8 FT. CEILING
OF UNCONFINED SPACE
375 500 625 875
7
CONFINED
SPACE
1. All air from inside the building as in Figure 8: The confined space shall be provided with two perma­nent openings communicating directly with an addi­tional room(s) of sufficient volume so that the com­bined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utiliza­tion equipment installed in the combined space shall be considered in making this determination. Refer to Table 2 for minimum open areas require­ments.
2.
All air from outdoors as in Figure 9: The confined space shall be provided with two permanent open­ings, one commencing within 12 inches of the top and one commencing within 12 inches of the bot­tom of the enclosure. The openings shall communi­cate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 2, for minimum open areas requirements.
MINIMUM FREE AREA IN SQUARE INCHES
EACH OPENING (FURNACE ONLY)
TABLE 2
8
9
Furnace
Maximum
BTUH/INPUT
Rating
60,000
80,000 100,000 120,000
18-CD19D6-32 9
Air
From
Inside
100 100 100 120
Air From Outside
Vertical
Duct
15 20 25 30
Horizontal
Duct
30 40 50 60
Installer’s Guide
DUCT CONNECTIONS
Air duct systems should be installed in accordance with standards for air conditioning systems, National Fire Protection Association Pamphlet No. 90. They should be sized in accordance with ACCA Manual D or which­ever is applicable. Central furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling 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 CONNECTION
NOTE: On upflow 5 or 6 ton airflow models where the airflow requirement exceeds 1800 CFM - Models will require return air openings and filters on: (1) both sides; or (2) one side and the bottom; or (3) just the
bottom.
All return air duct systems should provide for installa­tion of return air filters.
1. Determine the appropriate position to set the furnace in order to connect to the existing supply and return ductwork.
2. For side return installations on upflow models, remove the insulation around the opening in the blower compartment.
10 18-CD19D6-32
NOTE: Minimum return air temperature is 55° F.
3. The side panels on upflow furnaces include locating notches which may be used as guides for cutting an opening for return air. Refer to Figure 12 and the outline drawing on page 5 for duct connection dimensions for various furnaces.
4. If a 3/4" flange is to be used for attaching the air inlet duct, add to cut where indicated by dashed lines in Figure 12. Cut corners diagonally and bend outward to form flange.
5. If flanges are not required, and a filter frame is installed, cut along knockout guidelines.
6. Upflow Furnaces: Use the optional filter rack on either side or on the bottom if the filter is to be used within the furnace cabinet.
When the upflow furnace is installed in the horizon­tal right or left application and a return duct is attached to the top side as shown in Figure 11, install the filter in a remote location.
Do not install the filter in the return duct directly above the furnace in horizontal applications.
!
WARNING
Do not install the filter in the return duct directly above the furnace in horizontal applications. Install the filter remotely. Installing the filter directly above the furnace in horizontal applications may cause property damage, serious injury or death.
!
WARNING
TO PREVENT INJURY OR DEATH DUE TO CONTACT WITH MOVING PARTS, TURN THE POWER TO THE FURNACE OFF BEFORE SERVICING FILTERS.
When the upflow furnace is installed in the horizon­tal right or left application and a close coupled (less than 36") return duct is attached to the bottom side of the furnace as shown in Figure 11, securely attach a 1/2" mesh metal hardware cloth protective screen to the inside bottom of the filter grill to
prevent personal injury from contacting moving parts when reaching into the return opening to replace the filter.
Close coupled (less than 36") return (filter directly beneath bottom side return) is not recommended due to noise considerations.
Downflow Furnaces: Brackets are factory supplied to mount filters in the return air duct work.
Installer’s Guide
REMOVE FILTER FROM UPFLOW FURNACE WHEN RETURN DUCT IS ATTACHED TO FURNACE TOP SIDE (HORIZONTAL LEFT OR RIGHT APPLICATIONS) AS SHOWN.
Close coupled (less than 36") return (filter directly beneath bottom side return) not recommended due to noise considerations. If used, securely attach 1/2" mesh metal hardware cloth protective screen to the inside bottom of filter grill.
FILTER
q
7. Connect the duct work to the furnace. See Outline Drawing (pages 4&5) for supply and return duct size and location. Flexible duct connectors are recom­mended to connect both supply and return air ducts to the furnace. If only the front of the furnace is accessible, it is recommended that both supply and return air plenums are removable.
8. When replacing a furnace, old duct work should be cleaned out. Thin cloths should be placed over the registers and the furnace fan should be run for 10 minutes. Don’t forget to remove the cloths before you start the furnace.
w
LOCATING NOTCHES PROVIDED FOR SIDE RETURN CUTOUT
SEE OUTLINE DRAWING
*
*
*
*
*
CUT OUT
FOR
SIDE
FILTER
FRONT
of Furnace
RETURN AIR FILTERS
(Filter and filter rack are not supplied with unit)
TYPICAL UPFLOW RETURN AIR FILTER INSTALLA­TIONS
These furnaces require high velocity type air filters. The optional filters may be located within the furnace blower compartment for UPFLOW furnaces in either a BOTTOM or SIDE (left side or right side) return air inlet. Some optional filters may need to be trimmed for side or bottom filter use.
NOTE:
On upflow 5 or 6 ton airflow models where the airflow requirement exceeds 1800 CFM - Models will require return air openings and filters on: (1) both sides; or (2) one side and the bottom; or (3) just the bottom.
The furnace and the blower filter rack installation can be seen in Figure 13.
The optional furnace filter in the bottom or side con­figuration can be removed by simply turning the two latches on the blower door and tilting the door forward.
The filter rails are spring loaded for automatic adjust­ment to allow standard size, locally obtainable replace­ment filters. The filter rack itself slides to adjust to the required width needed for bottom or side return.
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
18-CD19D6-32 11
: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"
VERTICAL
CLOSET
HORIZONTAL
CLOSET
HORIZONTAL
ALCOVE / ATTIC
Installer’s Guide
TABLE 4
UPFLOW FURNACE RETURN AIR FILTERS
CABINET
WIDTH
14-1/2" 1 14" X 25" X 1" 17-1/2" X 25" X 1"
17-1/2" 1 17" X 25" X 1" 17-1/2" X 25" X 1"
21" 1 20" X 25" X 1" 17-1/2" X 25" X 1"
24-1/2" 1 24" X 25" X 1" 17-1/2" X 25" X 1"
**NOTE: For upflow 5 ton airflow models where the airflow
requirement exceeds 1800 CFM - Models will require return air openings and filters on: (1) both sides, or (2) one side and the bottom, or (3) just on the bottom
QTY*
CABINET
BOTTOM FILTER
CABINET
SIDE FILTER
Airflow
NOTE: The narrow 14.5" width furnace cabinet prevents use of the filter rack for right side return. Pre-drill clearance holes and then attach filter clips with the screws provided. The filter clip with the leaf spring mounts in the rear of the cabinet
OPTIONAL FILTER RACK INSTALLATION FOR BOTTOM RETURN
With the filter removed, the filter rack is compressed and then inserted into the bottom of the furnace. The retaining screw/pin on each side inserts into engagement holes at the bottom of the furnace cabinet side. See Figures 13, 14 & 16.
NOTE: Remove the bottom front channel to install the filter rack in the 14-1/2" width cabinet furnaces.
t
Blower Deck Engagement
Hole
r
e
Airflow
BOTTOM FILTER RACK INSTALLATION
ENGAGEMENT
HOLE DETAIL
(Typical both sides and blower deck)
y
Furnace
Cabinet
Side
Engagement Hole For
Filter Rack Installation With Bottom Return
VIEW
Filter Rack
Filter Rack Retaining Screw/Pin
Optional Filter Rack Accessory Kit
BAYRACK960A
12 18-CD19D6-32
Installer’s Guide
Airflow
Airflow
TABLE 5
Cabinet Width Left Side Bottom Right Side
14.5 X
17.5 X X X
21 X X X
24.5 X X X
1. UD060C/R936K0 has 10x7 blower which requires use of alternate filter clips for left side filter. "K1" and later use the filter rack.
2. Remove bottom front channel to install or reposition filter rack.
X - All Models
OPTIONAL FILTER RACK INSTALLATION FOR SIDE RETURN AIR ON UPFLOW FURNACES (Left or Right)
If side air return is desired, the following instructions should be used:
a. Open or remove the blower door.
b. Leave the bottom panel in place. (Some models
require field supplied bottom panels.)
c. After the side cutout is made following the directions
in the “Return Air Duct Connections” section on pages 8 and 9; compress the filter rack and reinstall in the side of the furnace. Confirm that the upper retaining pin/screw locks into the engagement hole in the blower deck and the lower pin/screw rests against the side of the bottom panel. See Figures 14, 15, & 17-20.
d. Install the furnace filter on the side. See Figures 14,
15, & 17-20.
u
Furnace
Cabinet
Side
1
BOTTOM ENGAGEMENT
X2Use Alternate Filter Clips Only
Filter Rack Retaining Screw/Pin
Filter Rack
o
Typical Upflow Left Side Return Filter Rack Installation
p
SIDE
CUTOUT
RETAINING
PIN
(Both Sides)
SPRINGS
Airflow
FILTER
RACK RAILS
Airflow
BOTTOM
PANEL
INSTALLED
SIDE
CUTOUT
RETAINING
PIN
(Both Sides)
SPRINGS
Engagement Hole
For
Installation With
Bottom Return
i
BLOWER DECK
Furnace
Cabinet
Side
Filter Rack
Engagement Hole For
Filter Rack Installation With Side
Return
Filter Rack Retaining Screw/Pin
Bottom Panel
Furnace Blower Deck
Filter Rack Assembly
BOTTOM
PAN EL
INSTALLED
Typical Upflow Right Side Return Filter Rack Installation
FILTER
RACK
RAILS
a
Airflow
Optional door kit BAYFLTR206
Typical Horizontal Filter Installation
18-CD19D6-32 13
Installer’s Guide
RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION
When the Upflow Furnace is installed in a horizontal configu­ration, the filter must never be installed inside or outside the cabinet directly above the blower assembly. See Figure 11 (page 9). Remote filter grilles may be used for homeowner convenience or the filters may be installed in the duct work upstream of the furnace. See Figures 11 (page 9) and 21 (page
11).
ALTERNATE UPFLOW FILTER CLIP / BRACKET INSTALLATION - KIT09224
1. Determine the location to be used. The furnace cabinet has dimples for location of the alternate furnace clips (Side return only). Pre-drill clearance holes with a 3/16" drill. Bottom return holes are pre-drilled.
2. Install the clips in front and rear of the desired location using the screws provided. The filter clip with the leaf spring mounts in the rear of the cabinet. See Figure 22.
s
REAR
SIDE
CUT-OUT
TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS
i
d
Airflow
f
ALTERNATE FILTER CLIPS LOCATION
Optional horizontal filter conversion kits are BAYFLTR203 for 17 1/2" width cabinets, BAYFLTR204 for 21" width cabinets, and BAYFLTR205 for 24" width cabinets. These include filters and brackets necessary for horizontal filters. In addition, optional door kit BAYFLTR206 is also available. See Figures 21 and 24.
INSTALLING THE OPTIONAL FILTER
The filter may need to be cut to fit the unit depending on the location of the return air filter.
A score line and the words “CUT HERE” are located on the end of the filter. If your application requires cutting the filter, do so as indicted by the score mark.
TABLE 6
UNIT SIZE
RETURN AIR
BOTTOM SIDE
14-1/2" CUT ON LINE DO NOT CUT
17-1/2" DO NOT CUT DO NOT CUT
21" DO NOT CUT CUT ON LINE
24-1/2" DO NOT CUT CUT ON LINE
Airflow
Optional door kit BAYFLTR206
Two high velocity type air filters are required for each down­flow furnace. Downflow furnace filters must be located outside the furnace cabinet. Typical installations are shown in Figures 23 and 24. Tables 7 and 8 (page 13) provide information for installation of the filter retaining brackets shipped with downflow furnaces.
TABLE 7
CABINET
WIDTH
14-1/2" 2 - 14X20X1 12-7/8" 17-1/2" 2 - 16X20X1 14-3/8"
21" 2 - 16X20X1 13-1/8"
24-1/2" 2 - 16X20X1 11-5/8"
* Location dimension is from end of duct to the screw holes for the bracket.
CABINET
WIDTH
14-1/2" 13-1/4" 12" 14" 17-1/2" 16-1/4" 15" 14"
21" 19-3/4" 19-1/2" 14"
24-1/2" 23-1/4" 22" 14"
RETURN
DUCT
WIDTH
FILTER
SIZE
TABLE 8
FILTER ACCESS
OPENING -
DIMENSION "A"
FILTER BRACKET
LOCATION *
FILTER ACCESS
OPENING -
DIMENSION "B"
14 18-CD19D6-32
Installer’s Guide
GENERAL VENTING
IMPORTANT:
These furnaces may be installed as Direct Vent (sealed combustion) or as Nondirect vent (single pipe). The fur­naces are shipped DIRECT VENT with sealed combus- tion.
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)
THIS FURNACE MUST BE VENTED TO THE OUT­DOORS. THESE FURNACES ARE INDUCED DRAFT VENTED AND MUST NOT BE CONNECTED TO ANY VENT SERVING ANOTHER APPLIANCE. PLEASE NOTE THAT THESE FURNACES USE POSITIVE- PRESSURE VENT SYSTEMS. Proper venting is essential to obtain maximum effi­ciency from a condensing furnace. Proper installation of the vent system is necessary to assure drainage of the condensate and prevent deterioration of the vent system. American Gas Association has certified the design of condensing furnaces for a minimum of 0" clearance from combustible materials with a single wall plastic vent pipe. The recommended system is assembled from 2", 2-1/2", or 3" plastic pipe and fittings (See Table 9, page 17). Where the system is routed to the outdoors through an existing masonry chimney containing flue products from another gas appliance, or where required by local codes, then 3" venting of Type 29-4C stainless steel must be used in place of PVC material. These furnaces have been classified as CATEGORY IV furnaces in accordance with the latest edition of ANSI Z21.47 • CAN/ CGA-2.3 Standards. Category IV furnaces operate with positive vent pressure and with a vent gas temperature less than 140°F above the dewpoint. These conditions require special venting sys­tems, which must be gas tight and water tight.
NOTE: When an existing furnace is removed from a venting system serving other gas appliances, the venting sys­tem is likely to be too large to properly vent
maining attached appliances.
the re-
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.
4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance will operate continuously.
5. Test for spillage at the draft hood relief opening af­ter 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a ciga­rette, cigar, or pipe.
6. After it has been determined that each appliance re­maining connected to the common venting system properly vents when tested as outlined above, re­turn door, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previ­ous conditions of use.
If improper venting is observed during any of the above tests, the 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:
a. Determine the Btu per hour input of all remain-
ing 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.
18-CD19D6-32 15
Installer’s Guide
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 8.
VENT FITTING MATERIAL – PLASTIC
Gas and liquid tight single wall vent fittings, designed for resistance to corrosive flue condensate, MUST be used throughout. Listed in Table 10 & 11 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.
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: Follow venting instructions carefully when using PVC cement.
IMPORTANT:
All joints must be water tight. Flue condensate is some­what acidic, and leaks can cause equipment damage.
Connection of the pipe and collar of the combustion air inlet should just be a friction fit. It is recommended
that the inlet air joint be sealed with RTV type sealant to allow the joint to be separated for possible future ser­vice. The inlet and vent pipes must be properly sup­ported throughout the entire length.
TABLE 9
PLASTIC PIPE DESIGNATIONS
PVC
ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING
F891 CELLULAR CORE *158 ASTM F891
D2665 DWV PIPE **158 ASTM D2665
D1785 SCH 40, 80, 120 **158 ASTM D1785
D2241 SDR SERIES **158 ASTM D2241
CPVC
ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING
D2846 CPVC 41 **212 ASTM D2846
F441 SCH 40, 80 **212 ASTM F441
F442 SDR SERIES **212 ASTM F442
ABS
ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING
D2661 SCH 40 DWV ***180 ASTM D2661
F628 SCH 40 DWV CELLULAR CORE ***180 ASTM F628
* - Allowable temperatures based on classifications covered in ASTM D4396 [Deflection Temps Under Load (264 PSI)] ** - Allowable temperatures based on classifications covered in ASTM D1784 [Deflection Temps Under Load (264 PSI)] *** - Allowable temperatures based on classifications covered in ASTM D3965 [Deflection Temps Under Load (264 PSI)]
16 18-CD19D6-32
Installer’s Guide
NONDIRECT VENT (1 PIPE SYSTEM) -MAXIMUM TOTAL
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.
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.
g
VENT AND INLET AIR CONNECTIONS
Seal VENT PIPE with RTV sealant
Front of Furnace
Seal INLET AIR PIPE
with RTV sealant
IMPORTANT:
Products installed in Canada must use vent systems that are certified to the Standard for Type BH Gas Vent­ing Systems (ULC S636) for Class II-A venting systems (up to 65°C). Components of the vent system must not be interchanged with other vent systems or unlisted pipe or fittings. Plastic components, specified prim­ers, and glues must be from a single system manufac­turer and not intermixed with other system manufacturer's vent system parts. In addition, the first three feet of the vent pipe must be visible for inspec­tion.
UPFLOW/ HORIZONTAL VENTING TABLE
TABLE 10
MAXIMUM VENT LENGTH:
DIRECT VENT (2 PIPE SYSTEM) -
MAXIMUM TOTAL EQUIVALENT FEET FOR
VENT AND INLET AIR PIPES (See Notes)
2" PIPE
MODEL
*UX1B040A9241A
*UX1B0
60A9241A
*UX1B060A9361A
*UX1B080A9241A
*UX1B080A9421A
*UX1C080A9601A
*UX1C100A9361A
*UX1C100A9481A
*UX1D100A9601A
*UX1D120A9601A
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 SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH 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.
& FITTINGS
60 80 100 130 50 80 80 130
60 80 100 130 50 80 80 130
60 80 100 130 50 80 80 130
50 80 100 130 40 80 80 130
50 80 100 130 40 80 80 130
NOT ALLOWED 60 100 130 NOT ALLOWED 60 80 130
NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130
NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130
NOT ALLOWED 40 100 130 NOT ALLOWED 40 80 130
NOT ALLOWED 15 60 130 NOT ALLOWED 25 70 130
2-1/2" PIPE
& FITTINGS
3" PIPE
& FITTINGS
4" PIPE
& FITTINGS
EQUIVALENT FEET FOR
VENT PIPE ONLY (See Notes)
2" PIPE
& FITTINGS
2-1/2" PIPE
& FITTINGS
3" PIPE
& FITTINGS
4" PIPE
& FITTINGS
18-CD19D6-32 17
Installer’s Guide
DOWNFLOW/ HORIZONTAL VENTING TABLE
TABLE 11
MAXIMUM VENT LENGTH:
DIRECT VENT (2 PIPE SYSTEM) -
MAXIMUM TOTAL EQUIVALENT FEET FOR
VENT AND INLET AIR PIPES (See Notes)
MODEL
*DX1B040A9241A
*DX1B060A9361A
*DX1B080A9421A
*DX1C100A9481A
*DX1D120A9601A
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 the furnace) 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 SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH 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 50 80 80 130
45 80 100 130 40 80 80 130
NOT ALLOWED 80 100 130 NOT ALLOWED 80 80 130
NOT ALLOWED 15 60 130 NOT ALLOWED 25 70 130
2-1/2" PIPE
& FITTINGS
3" PIPE
& FITTINGS
4" PIPE
& FITTINGS
& FITTINGS
SINGLE PIPE VENTING
UPFLOW FURNACE
B
A (0-2') or greater B (0-2') or greater
NONDIRECT VENT (1 PIPE SYSTEM) -
MAXIMUM TOTAL EQUIVALENT FEET FOR
VENT PIPE ONLY (See Notes)
2" PIPE
Air Inlet
2-1/2" PIPE
& FITTINGS
3" PIPE
& FITTINGS
DOWNFLOW
FURNACE
4" PIPE
& FITTINGS
A+B = 2' minimum
Air Inlet
A
Vent only
A
Vent only to outside
A = 2' minimum
to outside
h
INSIDE
CORNER DETAIL
G
V
H
I
M
X
V
K
j
D
EE
V
V
L
B
V
VENT TERMINAL
C
FIXED
V
CLOSED
OPERABLE
V
F
B
X
AIR SUPPLY INLET
B
B
OPERABLE
V
V
B
A
AREA WHERE TERMINAL IS NOT PERMITTED
FIXED
CLOSED
J
B
V
X
18 18-CD19D6-32
Installer’s Guide
Table 12 - See Figure 27
Direct Vent Ter minal Clearances
Canadian Installations US Installations
Clearance above grade, veranda, porch, deck, or
A=
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 permanently closed window * *
Vertical clearance to ventilated soffit located above the
D=
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 cor ner * *
G-
Clearance to inside corner * *
=
Clearance to each side of center line extended above
H=
meter/regulator assembly
I= Clearance to service regulator vent outlet 3 feet (91 cm) *
Clearance to nonmechanical air supply inlet to building
J=
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 terminate 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)
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/< 50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)
**
meter/regulator assembly
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/< 50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)
7 feet (2.13 m) † *
*
Table 12A - See Figure 27
Non-Direct Vent Terminal Clearances
Canadian Installations US Installations
Clearance above grade, veranda, porch, deck, or
A=
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 permanently closed window * *
Vertical clearance to ventilated soffit located above the
D=
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
H=
meter/regulator assembly
I= Clearance to service regulator vent outlet 3 feet (91 cm) *
Clearance to nonmechanical air supply inlet to building
J=
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= Cle arance under veranda, porch, deck, or balcony `12 inches (30 cm) ‡ *
Notes:
1. In accordance with the current CSA B149.1 Natural Gas and Propane Instal lation Code.
2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code. †. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. ‡. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * Clearance in accordance wi th local installation codes a nd the requirements of the gas supp lier and the manufacturer's Installation Instr uctions.
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)
*
18-CD19D6-32 19
Installer’s Guide
VENT
COMBUSTION AIR
VENT
VENT PLATE
VENT CAP
12" MINIMUM TO OVERHANG
MAINTAIN 12" (18" FOR CANADA) MINIMUM
CLEARANCE ABOVE HIGHEST ANTICIPATED
SNOW LEVEL OR GRADE WHICHEVER IS GREATER
SCREWS (4 req.)
ANCHORS (4 req.)
7.2"
3.2"
k
ELBOW AND TEE MUST BE AS CLOSE TO­GETHER AS POSSIBLE
POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS
HORIZONTAL VENTING
l
NOTE: Vent termination kit BAYAIR30AVENTA or BAYVENT200B may be used instead of the horizontal and vertical termination options shown in the follow­ing figures.
!
CAUTION
When the vent pipe is exposed to temperatures below freezing, i.e., when it passes through unheated spaces, etc., the pipe must be insulated with 1/2 inch (22.7 mm) thick Armaflex-type insulation or equal. If the space is heated sufficiently to prevent freezing, then the insula­tion would not be required. If domestic water pipes are not protected from freezing then it is assumed the space meets the condition of a heated space.
HORIZONTAL VENTING THROUGH WALL
These furnaces may be installed as direct vent (as shipped) or as nondirect vent. Installation must conform to national, state, and local codes.
The vent & inlet terminals must be located at least 12" minimum above normally expected snow accumulation level. 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 27 for either direct or
20 18-CD19D6-32
non-direct vent applications.
BAYVENT200B
Installer’s Guide
PITCH – Venting through the wall must maintain 1/4" per foot pitched upward to insure that condensate drains back to the furnace. FLUE GAS DEGRADATION – The moisture content of the flue gas may have a detrimental effect on some building materials. This can be avoided by using the roof or chimney venting option. When wall venting is used on any surface that can be affected by this mois­ture, it is recommended that a corrosion resistant shield (24 inches square) be used behind the vent termi­nal. This shield can be wood, plastic, sheet metal, etc. Also, silicone caulk all cracks, seams and joints within 3 feet of the vent terminal.
COMBUSTIBLE MATERIAL WALL
A minimum clearance of 1" to combustible materials must be maintained when using single wall stainless steel venting. See Figure 31.
;
12" MIN TO OVERHANG
1
"
2
1"
z
x
COMBUSTION AIR
BAYAIR30AVENTA
(Sidewall)
VENT
MAINTAIN 12 IN (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE
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 32.
VENTING THROUGH THE ROOF
When penetrating roof with a 2" PVC vent pipe, a 2" electrical conduit flashing may be used for a weather tight seal. Lubricate flexible seal on flashing before PVC pipe is pushed through the seal. (Field Supplied)
c
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:
No vent cap as shown in Figure 36 is the preferred method for vertical vent termination in extremely cold climates. In extreme climate conditions, insulate the exposed pipe above the roof line with Armaflex type insulation.
18-CD19D6-32 21
Installer’s Guide
4
N
3" PIPING
2", 2-1/2"
or 3" PIPING
REDUCING COUPLING, FIELD SUPPLIED IF NEEDED
SEAL ALL
WALL CAVITIES
v
COMBUSTION AIR INLET
0" UPFLOW OR
DOWNFLOW MODELS
SEE VENTING TABLE
STRAPS OR OTHER SUITABLE SUPPORTS AT MAXIMUM OF 3'-0" INTERVALS
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.
USE ONLY
APPROVED
TERMINATIO
OUTSIDE
WALL
NOTE: VENT AND INLET MUST BE SUPPORTED
AT A MAXIMUM OF 3' INTERVALS
TEE
BAYAIR30AVENTA
VENT
COMBUSTION AIR
STRAP (FIELD SUPPLIED)
ELBOW (FIELD SUPPLIED)
COMBUSTION AIR
RAIN CAP
VENT
1" + 1/2"
BAYVENT200B
22 18-CD19D6-32
Installer’s Guide
MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.
VENT
COMBUSTION AIR
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.
Slope 1/4" per ft.
All horizontal pipes must be supported
15
Upflow or Downflow
Furnace
6" Min.
at a maximum of 3 foot intervals
b
40 Inch
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.
NOTE: Both venting methods shown in Figure 40 & 42 must also have the combustion air inlet installed - meeting dimension requirements of Figure 36.
n
m
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 STAINLESS STEEL FITTING
All stainless steel fitting must be installed with male end towards the furnace. All horizontal stainless steel sections must be posi­tioned with the seam on top. All long horizontal sections must be supported to pre­vent sagging. All pipe joints must be fastened and sealed to prevent escape of combustion products into the building.
18-CD19D6-32 23
BAYAIR30AVENTA
,
ROOF FLASHING BOOT (FIELD SUPPLIED)
REMOVE RIBS FROM CAP
COMBUSTION AIR
VENT
VENT
MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF
SUPPORT (FIELD SUPPLIED)
ELBOW (FIELD SUPPLIED)
COMBUSTION AIR
Installer’s Guide
L
N
T
E
S
SS
.
SEAL BETWEEN FLANGE, PIPE, COUPLING AND METAL PANEL
!
WITH HI TEMP RTV SILICONE SEALANT
SUPPORT
FLANGE
FLUE PIPE
COUPLING
TYPE 29-4C STAINLESS STEEL VENTING -
/
USED THROUGH CHIMNEY THAT VENTS
ANOTHER GAS APPLIANCE
STAINLESS STEEL
STAINLESS STEEL
VENT CAP
VENT CAP
(OPTIONAL)
SEE CAUTION
!
6 IN. MIN.
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.
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 )
CEILING
VENTING THROUGH CEILING
PVC PLASTIC VENTING - ONLY
@
FLUE PIPE
UPLING TO SUPPORT
PE FROM ANGLES
OTHER SUITABLE PPORT METHOD
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.
THROUGH UNUSED CHIMNEY
STAINLESS STEEL
TAINLE
VENT CAP
STEEL
(OPTIONAL)
VENT CAP
SEE CAUTION
FLUE PIPE
NOTE: HORIZONTAL VENTING TO VERTICAL VENTING
!
CAUTION
6 IN. MIN.
SUPPORT THE SINGL WALL FLUE PIPE AND CENTER IT IN THE CHIMNEY OPENING WI ANGLES AS SHOWN O ANOTHER EQUIVALEN MANNER.
COUPLING AS REQUIRED
24 18-CD19D6-32
Installer’s Guide
IMPORTANT:
The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows:
For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back­up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. This appliance requires a special venting system. If BAYAIR30AVENTA or BAYVENT200B are used, a copy of the installation instructions for the kit shall remain with the appliance or equipment at the completion of installation. The venting system installation instructions can be obtained from the manufacturer by writing to the following address:
American Standard, Inc. 6200 Troup Highway Tyler, TX 75707 Attention: Manager of Field Operations Excellence
18-CD19D6-32 25
Installer’s Guide
HORIZONTAL INSTALLATION (Upflow/ Horizontal or Downflow/ Horizontal)
NOTE: In horizontal venting when the factory supplied “off­set” (2X3 reducing coupling) is used for 3” vent pipe installation, make sure the marking “Top” is located on the top side of the pipe. The straight side must be on bottom for proper condensate drainage. This coupling is factory supplied only with the following models: *UC120 & *DC120, *UX120 & *UY120 *UX100 & *UY100, *UX808C960, and all *DX & *DY models.
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.
#
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.
%
Right side
UPFLOW (VERTICAL)
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
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.
^
Use Inducer Drain
hose without
extension
UPFLOW HORIZONTAL 17" UNITS
(Left side only)
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.
26 18-CD19D6-32
HORIZONTAL APPLICATIONS
Upflow and Downflow furnaces - All horizontal ap­plications are left side only. It is always recommended that the auxiliary drain pan be installed under a hori­zontally installed evaporator and/or 90% gas furnace. Connect the auxiliary drain pan to a separate drain line (no trap is needed in this line).
&
Left side
UPFLOW (VERTICAL)
Installer’s Guide
(
Left
side
DOWNFLOW (VERTICAL)
)
*
Use extension hose here
UPFLOW HORIZONTAL 21" & 24" UNITS
(Left side only)
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 recuperated cell. Remove the larger drain line (from the secondary cell) and trim to fit between the secondary cell and the new trap location. On upflow units, plug the hole in the blower deck where the tube went through. Remove the hose from the induced blower and reposi­tion into the other drain tap of the inducer, which is lo­cated 90° clockwise around the inducer. Move the cap from that drain tap to the unused drain tap. On upflow units, plug the hole in the blower deck where the tube went through. This tube on downflow units will need to be cut to fit between the inducer and the trap. On upflow units, this tube may need to be extended, using the tubing shipped with the furnace.
Right
side
Use CPVC tubing from Trap outlet,
over burner box to cabinet exit
DOWNFLOW (VERTICAL)
Q
Cut off curved end of
Inducer drain hose
DOWNFLOW (HORIZONTAL)
Connections must be made to an OPEN/ VENTED DRAIN. Outdoor draining of the furnace and coil con-
densate is permissible if allowed by local codes. Caution should be taken to prevent drains from freezing or caus­ing slippery conditions that could lead to personal in­jury. Excessive draining of condensate may cause satu­rated ground conditions that may result in damage to plants.
18-CD19D6-32 27
Installer’s Guide
NOTE: Use 1/2" or larger PVC or CPVC pipe and fittings as re­quired for drain connections (fittings, pipe and solvent cement not provided).
NOTE: A corrosion resistant condensate pump must be used if a pump is required for a specific drain system.
IMPORTANT: The condensate drain should be installed with provi­sions to prevent winter freeze-up of the condensate drain line. Frozen condensate will block drains, result­ing in 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.
FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE
W
SEE
NOTE 7
Evaporator and furnace condensate drain piping may be manifolded together as shown in Figure 52. 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 axillary drain pan in order to prevent water damage to the finished ceiling below.
TWINNING FURNACES
These furnaces may be twinned. Twinning requires that two furnaces with the same configuration, capacity, and airflow must be used. They shall have common returns with equal pressure drops or ducts with equivalent lengths and sizes. See Field Wiring Diagrams for proper hookup.
1 STAGE HEATING
USING A 1 STAGE HEATING THERMOSTAT
NO COOLING
FURNACE
TWIN
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
B/C
SEE
NOTE 6
B/C
TO 115 V 1 PH., 60 HZ., POWER SUPPLY PER LOCAL CODES
HUM SEE NOTE 5
EAC SEE NOTE 5
From drawing B341437 Rv 1
28 18-CD19D6-32
OUTDOOR UNIT
(NO TRANSFORMER)
Installer’s Guide
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
HUM SEE NOTE 5
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.
EAC SEE NOTE 5
From drawing B340388 Rv 2
The integrated furnace control is polarity sensi­tive. The hot leg of the 120V power supply must be con-
nected to the black power lead as indicated on the wir­ing diagram. Provision for hooking up an electronic air cleaner and or humidifier is provided on the integrated control. Refer to the SERVICE FACTS literature and unit wiring diagram attached to furnace diagram attached to fur­nace.
18-CD19D6-32 29
TWINNING CONNECTION DIAGRAM
FOR TWINNING 1 STAGE FURNACES WITH
1 STAGE HEAT
ONLY
THERMOSTAT
(WITH FAN SWITCH) FURNACE NO. 1
SINGLE WIRE TWINNING FEATURE
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
B/C
OUTDOOR UNIT
(WITH TRANSFORMER)
RC
ISOLATION RELAY (FIELD SUPPLIED)
SEE NOTE 3
OUTDOOR UNIT
(NO TRANSFORMER)
SEE NOTE 3
HEATING / COOLING
THERMOSTAT FURNACE NO. 1
1 STAGE
B/C
1 STAGE HEAT / 1 STAGE COOL THERMOSTAT
R1
R1
B/C
TWINNING CONNECTION DIAGRAM
FOR TWINNING 1 STAGE FURNACES WITH
SINGLE WIRE TWINNING FEATURE
FURNACE NO. 2
BLOWER OPERATION OF
UNIT NO. 2 IS SYNCRONIZED
WITH UNIT NO. 1 VIA SIGNALS
FROM TWIN CONNECTION.
TWIN
SEE NOTE 4
TWIN
ISOLATION RELAY
SEE NOTE 4
From Dwg. 21B341422 Rev. 3
B/C
SEE NOTE 5
B/C
R1
ISOLATION RELAY (FIELD SUPPLIED)
SEE NOTE 4
B/C
R1
ISOLATION RELAY
SEE NOTE 4
From Dwg. 21B341423 Rev. 2
Installer’s Guide
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 53. The installation of piping shall be in accordance with piping codes and the regulations of the local gas com­pany. Pipe joint compound must be resistant to the chemical reaction with liquefied petroleum gases. Refer to piping Table 13, for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve as shown in Figures 53-55. National codes require a condensation drip leg to be in­stalled ahead of the controls as shown in Figures 53-55. 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).
E
MAIN MANUAL
SHUTOFF VALVE
GROUND
UNION
JOINT
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
The furnace must be isolated from the gas supply piping by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).
NOTE: Maximum pressure to the gas valve for natural gas is
13.8" W.C. Minimum pressure is 5.0" W.C. Maximum pressure to the gas valve for propane is 13.8" W.C. Minimum pressure is 11.0" W.C. All gas fittings must be checked for leaks using a soapy solution before lighting the furnace. 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.
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
MAIN MANUAL
SHUTOFF VALVE
GROUND
UNION
JOINT
DO NOT
DRIP
LEG
R
DRIP
LEG
UPFLOW – LEFT HAND GAS PIPING
UPFLOW – RIGHT HAND GAS PIPING
THE DOWNFLOW (VERTICAL) MAY BE INSTALLED LEFT OR RIGHT SIDE GAS PIPING
18-CD19D6-32 31
Installer’s Guide
T
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
MAIN MANUAL
SHUTOFF VALVE
GROUND
UNION JOINT
DRIP LEG
HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE (UPFLOW SHOWN)
TABLE 13
NATURAL GAS ONLY
TABLE OF CUBIC FEET PER HOUR OF GAS
FOR VARIOUS PIPE SIZES AND LENGTHS
PIPE SIZE
1/2 132 92 73 63 56 50 46
3/4 278 190 152 130 115 105 96
1-1/4 1050 730 590 520 440 400 370
This table is based on pressure drop of 0.3 inch W.C. and 0.6 SP.GR. gas
10 20 30 40 50 60 70
1 520 350 285 245 215 195 180
LENGTH OF PIPE
TABLE 14
ORIFICE SIZES
INPUT
RATING
BTUH
40,000 60,000
80,000 100,000 120,000
NUMBER
OF
BURNERS
2 3 4 5 6
MAIN BURNER ORIFICE
DRILL SIZE
NAT. GAS LP GAS
45 45 45 45 45
56 56 56 56 56
COMBUSTION AND INPUT CHECK
1. Make sure all gas appliances are off except the fur­nace.
2. Clock the gas meter with the furnace operating (de­termine the dial rating of the meter) for one revolu­tion.
3. Match the “Sec” column in the gas flow (in cfh) Table 16 with the time clocked.
4. Read the “Flow” column opposite the number of sec­onds clocked.
5. Use the following factors
if necessary:
For 1 Cu. Ft. Dial Gas Flow CFH =
Chart Flow Reading ÷2
For 1/2 Cu Ft. Dial Gas Flow CFH =
Chart Flow Reading ÷4
For 5 Cu. Ft. Dial Gas Flow CFH =
10X Chart Flow Reading ÷4
MAIN MANUAL
SHUTOFF VALVE
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
GROUND UNION JOINT
DRIP LEG
6. Multiply the final figure by the heating value of the gas obtained from the utility company and compare to the nameplate rating. This must not exceed the nameplate rating.
7. Changes can be made by adjusting the manifold pressure or changing orifices (orifice change may not always be required). To adjust the manifold pressure: a. Turn off all electrical power to the system. b.Attach a manifold pressure gauge to the outlet
pressure tap marked "OUT PRESS TAP" on White-Rodgers gas valve model 36F or boss marked "OUT P" on White-Rodgers gas valve model 36G. (See Figure 58 for White-Rodgers gas valve model 36F and Figure 59 for White-Rodgers gas valve model 36G). For the gas valve model 36F, measurement requires removal of the plug and installation of a barbed fitting. Attach flexible tubing and a manometer to the barbed fitting. For the gas valve model 36G, do not remove the pressure tap test screw. Using a 3/32" hex wrench, loosen the pressure tap test screw one turn and install 5/16" flexible tubing and a ma-
nometer directly onto the outlet pressure boss. c. Turn on system power and energize valve. d.Remove the regulator adjustment screw cap on
the gas valve for manifold pressure adjustment. e.Turn the adjustment nut clockwise to increase
the gas flow rate, and counterclockwise to de-
crease the gas flow rate using a 3/32" hex wench.
f. The final manifold pressure setting shall be as
specified in Table 15 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.
32 18-CD19D6-32
Installer’s Guide
h. Turn off all electrical power to the system.
i. Remove the manometer and flexible tubing. Re-
move the barbed fitting and replace the plug or tighten the pressure test screw.
j. Turn on electrical power to the system and ener-
gize valve.
k. Using a leak detection solution or soap suds,
check for leaks at plug or pressure boss screw.
!
WARNING
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.
Y
Table 14 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 17.
TABLE 15
FINAL MANIFOLD PRESSURE SETTINGS
FUEL PRESSURE
NATURAL GAS 3.5" W.C.
LP GAS 11.0" W.C.
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, pressure tap on the outlet side of the gas valve. See Figure 53.
Replace manifold pressure tap threaded plug and leak check after checking/ adjusting manifold gas pressure.
in addition to the regular gas valve
!
CAUTION
18-CD19D6-32 33
Installer’s Guide
HIGH ALTITUDE DERATE
Input ratings (BTUH) of these furnaces are based on sea level operation and should not be changed at eleva­tions up to 2,000 ft. If the installation is 2,000 ft. or above, the furnace input rate (BTUH) shall be reduced 4% for each 1,000 ft. above sea level. The furnace input rate shall be checked by clocking the gas flow rate (CFH) and multiplying by the heating value obtained from the local utility sup­plier for the gas being delivered at the installed altitude. Input rate changes can be made by adjusting the mani­fold pressure (min 3.0 - max 3.7 in. W.C. - Natural Gas) or changing orifices (orifice change may not always be required). If the desired input rate can not be achieved with a change in manifold pressure, then the orifices must be changed. LP installations will require an orifice change. Installation of this furnace at altitudes above 2,000 ft. (610m) shall be in accordance with the local codes, or in the absence of local codes, the National Fuel Gas Code,
ANSI Z223.1/ NFPA 54 or National Standard of Canada, Natural Gas and Propane Installation Code, CSA 149.1. Installation of this furnace at altitudes
above 2,000 ft. (610m) shall be made in accordance with the listed high Altitude Conversion Kit available with this furnace.
IMPORTANT: Re-install the propane orifices to the same depth as the orifices supplied with the equipment.
U
TABLE 16
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
ROTATE THE FRONT COVER AS SHOWN
INSERT THE TOP FLANGE OF THE FRONT COVER UNDER THE LIP INSIDE THE BOX
ALL SIDE FLANGES MUST BE OUTSIDE OF THE BOX
ROTATE THE FRONT COVER INWARD MAKING SURE THAT ALL SIDE FLANGES ARE OUTSIDE OF THE BOX.
34 18-CD19D6-32
Installer’s Guide
On/Offff
Switchch
See Table 17 & 18 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 17
PART NUMBERS FOR REPLACEMENT ORIFICES
DRILL
SIZE
44 45 46 47 48 49 50
PA RT
NUMBER
ORF00501 ORF00644 ORF00909 ORF00910 ORF01099 ORF00503 ORF00493
DRILL
SIZE
54 55 56 57 58 59
PA RT
NUMBER
ORF00555 ORF00693 ORF00907 ORF00908 ORF01338 ORF01339
REINSTALLATION OF THE BURNER BOX COVER
Figure 57 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 18
Orifice
Twist Drill
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 Required At Other Elevations
43
43
43
44
44
45
44
44
45
45
47
47
47
47
48
49
55
55
55
55
56
57
59
59
60
60
!
WARNING
45 46 47 48 49
55 56 57 60
61
45 47 48 48
49
55 56 57 60 62
46 47 48 49 50
55 56 58
61
62
47 48 49 49 50
56 56 59 62 63
46 47 48 49 50 51
56 56 59 63 63
47 48 50 50 51 52
56 57 60 63 64
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.
I
Inlet Pressure Boss (opt.)
O
Outlet Pressure Boss
On/Off Switch
White-Rodgers 36G gas valve
Swi
White-Rodgers 36F gas valve
Regulator Adjustment
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.
18-CD19D6-32 35
Installer’s Guide
To shut off.
For complete shut-down: Flip the switch on the main gas valve to the “OFF” position, (See Figure 58 & 59). Disconnect the electrical supply to the unit.
!
CAUTION
If this is done during the cold weather months, provi­sions must be taken to prevent freeze-up of all water pipes and water receptacles. Failure to follow this warning could result in property damage.
Whenever your house is to be vacant, arrange to have someone inspect your house for proper tem­perature. This is very important during freezing weather. If for any reason your furnace should fail to operate damage could result, such as fro­zen water pipes.
SEQUENCE OF OPERATION Thermostat call for heat
R and W thermostat contacts close signaling the control module to run its self-check routine. After the control module has verified that the pressure switch contacts are open and the limit switch(es) contacts are closed, the draft blower will be energized. As the induced draft blower comes up to speed, the pressure switch contacts will close and the ignitor warm up period will begin. The ignitor will heat for approxi­mately 20 seconds, then the gas valve is energized to permit gas flow to the burners. The flame sensor con­firms that ignition has been achieved. After the flame sensor confirms within a 4 second trial period that ignition has been achieved, the delay to fan ON period begins timing. After approximately 45 sec­onds the indoor blower motor will be energized and con­tinue to run during the heating cycle. When the thermostat is satisfied, R and W thermostat contacts open, the gas valve will close, the flames will extinguish, and the induced draft blower will be de-en­ergized. The indoor blower motor will continue to run for the fan off period (Field selectable at 60, 100, 140 or 180 seconds), then be de-energized by the control mod­ule.
CONTROL AND SAFETY SWITCH ADJUSTMENTS LIMIT SWITCH CHECK OUT
The limit switch is a safety device designed to close the gas valve should the furnace become overheated. Since proper operation of this switch is important to the safety of the unit, it must be checked out on initial start up by the installer. To check for proper operation of the limit switches, set the thermostat to a temperature higher than the indi­cated temperature to bring on the gas valve. Restrict the airflow by blocking the return air (disconnecting the indoor blower may trip the inducer limit). When the
furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and over­heating is evident, a faulty limit switch is probable and the limit switch must be replaced. After checking the operation of the limit control, be sure to remove the pa­per or cardboard from the return air inlet. Refer to Ser­vice Facts for additional instructions.
NOTE TO INSTALLER
Review the following warnings with the owner. Review contents of USER’S INFORMATION MANUAL with the owner.
AIRFLOW ADJUSTMENT
Check inlet and outlet air temperatures to make sure they are within the ranges specified on the furnace rat­ing nameplate. If the airflow needs to be increased or decreased, see the wiring diagram for information on changing the speed of the blower motor.
!
WARNING
Disconnect power to the unit before removing the blower door. Failure to follow this warning could result in property damage, personal injury or death.
This unit is equipped with a blower door switch which cuts power to the blower and gas valve causing shut­down when the door is removed. Operation with the door removed or ajar can permit the escape of danger­ous fumes. All panels must be securely closed at all times for safe operation of the furnace.
INDOOR BLOWER TIMING
Heating: The integrated furnace control 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 THERMOSTAT HEAT ANTICIPATOR ADJUSTMENT
Set the thermostat heat anticipator according to the current flow measured, or the settings found in the notes on the furnace wiring diagram (found in the SER­VICE FACTS or inside the furnace casing).
INSTRUCTIONS TO THE OWNERS
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.
36 18-CD19D6-32
Installer’s Guide
BURNER BOX TEMPERATURE LIMIT DEVICE
All models are equipped with a manual reset tempera­ture limit located on the burner box. In case of exces­sive temperature, the limit will open and cause the cir­cuit to open which shuts off all flow of gas.
ABNORMAL CONDITIONS
1. EXCESSIVE COMBUSTION PRESSURE (WIND IN EXCESS OF 40 M.P.H.) VENT OR FLUE BLOCK­AGE If pressure against induced draft blower outlet be­comes excessive, the pressure switch will open and shut off the gas valve until acceptable combustion pressure is again available.
2. LOSS OF FLAME If loss of flame occurs during a heating cycle, or flame is not present at the sensor, the flame control module will close the gas valve. The flame control module will then recycle the ignition sequence, then if ignition is not achieved, it will shut off the gas valve and lock out the system.
3. POWER FAILURE If there is a power failure during a heating cycle, the system will restart the ignition sequence auto­matically when power is restored if the thermostat still calls for heat.
4. GAS SUPPLY FAILURE If loss of flame occurs during a heating cycle, the system integrated control module will recycle the ignition sequence, 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 proce-
dure 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 termina-
tions, 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. Standards for Single and Multiple Station Carbon Monoxide Alarms, UL 2034 or CSA Interna­tional Standard, Residential Carbon Monoxide Alarming Devices, CSA 6.19
NOTE: The manufacturer of your furnace does not test any de­tectors and makes no representations regarding any brand or type of detector.
18-CD19D6-32 37
Installer’s Guide
38 18-CD19D6-32
Installer’s Guide
INTEGRATED FURNACE CONTROL ERROR FLASH CODES
Flashing Slow --- Normal - No call for Heat Flashing Fast --- Normal - Call for Heat
Continuous ON --- Replace IFC Continuous OFF --- Check Power 2 Flashes --- System Lockout (Retries or Recycles exceeded)
Draft Pressure Error - Possible problems:
3 Flashes ---
4 Flashes --- Open 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 ---
a) Venting problem b) Pressure switch problem c) Inducer problem
Check Ignitor Circuit and Line "N" to 24VAC "Common" voltage ( 2 volts) [possible grounding problem]
18-CD19D6-32 39
Trane 6200 Troup Highway Tyler, TX 75707
Literature Order Number 18-CD19D6-32
File Number 18-CD19D6-32
Supersedes 18-CD19D6-31
Date 05/08
For more information contact your local dealer (distributor)
Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right to change design and specifications without notice.
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