18- cd25d1- 2 installer’s guide

44
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. Installer’s Guide *__First letter may be “A” or “T” Upflow/ Horizontal, Gas-Fired, Direct Vent, 2-Stage Condensing Furnaces with Variable Speed Inducer and Whole House Air Cleaner A341624P10 *UX2B060AFV3VA *UX2C100AFV4VA *UX2B080AFV3VA *UX2D120AFV5VA 18- CD25D1- 2 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 mod- erate injury. It is also used to alert against unsafe practices and hazards involving only property dam- age. This unit is equipped with an integrated high efficiency Whole House Air Cleaner. Careful consideration must be taken in the installation process to avoid personal in- jury, property damage or equipment damage. These in- structions do not cover all variations in systems or pro- vide for every possible contingency. Should further in- formation be desired or particular problems arise which are not covered sufficiently by this manual, contact your local distributor or the manufacturer as listed on the Furnace nameplate. In addition, these Furnaces are suitable for installation in an attic, garage or crawl space with ducted supply and return air. Bottom Return ONLY UPFLOW/ HORIZONTAL UPFLOW Available in French Canadian (FC)

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Page 1: 18- CD25D1- 2 Installer’s Guide

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.

Installer’s Guide

*__First letter may be “A” or “T”

Upflow/ Horizontal, Gas-Fired, Direct Vent,2-Stage Condensing Furnaces with VariableSpeed Inducer and Whole House Air Cleaner

A341624P10

*UX2B060AFV3VA *UX2C100AFV4VA*UX2B080AFV3VA *UX2D120AFV5VA

1 8 - CD2 5 D1 - 2

Safety signal words are used to designate a degree orlevel 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 orserious injury.

b. CAUTION indicates a potentially hazardous situationwhich, if not avoided, may result in minor or mod-erate injury. It is also used to alert against unsafepractices and hazards involving only property dam-age.

This unit is equipped with an integrated high efficiencyWhole House Air Cleaner. Careful consideration mustbe taken in the installation process to avoid personal in-jury, property damage or equipment damage. These in-structions do not cover all variations in systems or pro-vide for every possible contingency. Should further in-formation be desired or particular problems arise whichare not covered sufficiently by this manual, contactyour local distributor or the manufacturer as listed onthe Furnace nameplate.In addition, these Furnaces are suitable for installationin an attic, garage or crawl space with ducted supplyand return air.

Bottom Return ONLY

UPFLOW/ HORIZONTAL

UPFLOW

Available in French Canadian (FC)

Page 2: 18- CD25D1- 2 Installer’s Guide

© 2008 Trane All Rights Reserved 18-CD25D1-2

Installer’s GuideSAFETY SECTION

▲ WARNING!FIRE OR EXPLOSION HAZARDFailure to follow the safety warnings exactly could re-sult in serious injury, death or property damage.Improper servicing could result in dangerous opera-tion, serious injury, death, or property damage.

The following safety practices and precautions must befollowed during the installation, servicing, and operationof this Furnace.

1. Use only with the type of gas approved for this Fur-nace. Refer to the Furnace rating plate.

2. Install this Furnace only in a location and positionas specified in “Location and Clearances” (page 4) ofthese instructions.

3. Provide adequate combustion and ventilation air tothe Furnace space as specified in “Air for Combus-tion and Ventilation” (page 9), of these instructions.

4. Combustion products must be discharged outdoors.Connect this Furnace to an approved vent systemonly, as specified in the “Venting” section (pages 11-23), of these instructions.

5. Never test for gas leaks with an open flame. Use acommercially available soap solution made specifi-cally for the detection of leaks to check all connec-tions, as specified in the “Gas Piping” section ofthese instructions on page 31.

6. Always install the Furnace to operate within theFurnace’s intended temperature-rise range with aduct system which has an external static pressurewithin the allowable range, as specified on the unitrating plate. Airflow with temperature rise for cfmversus static is shown in the Service Facts accompa-nying this Furnace.

▲ WARNING!CARBON MONOXIDE POISONING HAZARDFailure to follow the steps outlined below for each ap-pliance connected to the venting system being placedinto operation could result in serious carbon monox-ide poisoning or death.The following steps shall be followed for each applianceconnected to the venting system being placed into op-eration while all other appliances connected to theventing system are not in operation.

1. Seal any unused openings in the venting system.2. Inspect the venting system for proper size and hori-

zontal pitch, as required in the National Fuel GasCode, ANSI Z223.1/NFPA 54 or the CSA B149.1Natural Gas and Propane Installation Code andthese instruction. Determine that there is noblockage or restriction, leakage, corrosion andother deficiencies which could cause an unsafe con-dition.

3. As far as practical, close all building doors and win-dows and all doors between the space in which theappliance(s) connected to the venting system are lo-cated and other deficiencies which could cause anunsafe condition.

4. Close fireplace dampers.5. Turn on clothes dryer and any appliance not con-

nected to the venting system. Turn on any exhaustfans, such as range hoods and bathroom exhausts,so they are operating at maximum speed. Do notoperate a summer exhaust fan.

6. Follow the lighting instructions. Place the appli-ance being inspected into operation. Adjust thethermostat so appliance is running continuously.

7. Test for spillage from draft hood equipped appli-ances at the draft hood relieve opening after 5 min-utes of main burner operation. Use the flame of amatch or candle.

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

9. After it has been determined that each applianceconnected to the venting system properly ventswhere tested as outlined above, return doors, win-dows, exhaust fans, fireplace dampers and anyother gas-fired appliances to their previous condi-tion of use.

▲ WARNING!Failure to follow the safety warnings exactly could re-sult in a fire or explosion causing property damage,personal injury or loss of life.-- Do not store or use gasoline or flammable vapors andliquids in the vicinity of this or any other appliance.

-- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance

• Do not touch any electrical switch;

do not use any phone in your building

• Immediately call your gas supplier from a neighbor'sphone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier.

call the fire department.

-- Installation and service must be performed by a qualifiedinstaller, service agency or the gas supplier.

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18-CD25D1-2 3

Installer’s Guide

Safety Section 2

Installation Instructions 4General 4Location and Clearances 4Outline Drawings 6Upflow Installation 7Horizontal Installation 7Air For Combustion and Ventilation 9Duct Connections 10General Venting 11Venting Materials 12Vent Tables 15Horizontal Venting Through Wall 17Venting Through The Roof 19Venting Routed Through a Masonry Chimney 20Downward Venting 22Condensate Drain Instructions 24Field Wiring Diagrams 26Electrical Connections 31Gas Piping 31Combustion and Input Check 33High Altitude Derate 34

Start-up and Adjustment 35Preliminary Inspections 35Lighting Instructions 35Sequence of Operation 36Control and Safety Switch Adjustments 36

Conditions Affecting System Operation 38

Whole House Air Cleaner Maintenance 39

IFC Error Flash Codes 41

Checkout Procedure 43

Contents

▲ CAUTION!To prevent shortening its service life, the Furnaceshould not be used as a “Construction Heater” duringthe finishing phases of construction until the require-ments listed in item 9, a-i of the safety section of thispublication have been met. Condensate in the pres-ence of chlorides and fluorides from paint, varnish,stains, adhesives, cleaning compounds, and cementcreate a corrosive condition which may cause rapiddeterioration of the heat exchanger.

▲ CAUTION!Chemicals used to during construction may causedamage to the COLLECTION CELL.

7. When a Furnace is installed so that supply ductscarry air circulated by the Furnace to areas outsidethe space containing the Furnace, the return airshall also be handled by a duct(s) sealed to the Fur-nace casing and terminating outside the space con-taining the Furnace.

8. A gas-fired Furnace for installation in a residentialgarage must be installed as specified in “Locationand Clearances” section (page 4) , of these instruc-tions.

9. The Furnace may be used for temporary heating ofbuildings or structures under construction onlywhen the following conditions have been met:a. The Furnace venting system must be completeand installed per manufacturers instructions.b. The Furnace is controlled only by a room Com-fort Control (no field jumpers).c. The Furnace return air duct must be completeand sealed to the Furnace.d. The Furnace input rate and temperature risemust 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 isbetween 550 and 800 Fahrenheit.g. Clean the Furnace, duct work, and componentsupon substantial completion of the construction pro-cess, and verify Furnace and whole house aircleaner operating conditions including ignition, in-put rate, temperature rise and venting, according tothe manufacturer's instructions.h. Remove the Whole House Air Cleaner andstore in clean dry location during the constructionprocess. To be reinstalled when construction is com-plete. See page 39 for proper air cleaner removal.i. An external field supplied air filter must beused during construction.

10. This product must be gas piped by a LicensedPlumber or Gas Fitter in the Commonwealth ofMassachusetts.

▲ WARNING!DO NOT USE SEMI-RIGID METALLIC GAS CONNEC-TORS (FLEXIBLE GAS LINES) WITHIN THE FURNACECABINET.FAILURE TO FOLLOW THIS WARNING COULD RESULTIN PROPERTY DAMAGE, PERSONAL INJURY ORDEATH.

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4 18-CD25D1-2

Installer’s GuideGENERAL INSTALLATION INSTRUCTIONSThe manufacturer assumes no responsibility for equip-ment installed in violation of any code or regulation.It is recommended that Manual J of the Air Condition-ing Contractors Association (ACCA) or A.R.I. 230 be fol-lowed in estimating heating requirements. When esti-mating heating requirements for installation at Alti-tudes above 2000 ft., remember the gas input must bereduced (See combustion and input check page 31).Material in this shipment has been inspected atthe factory and released to the transportationagency without known damage. Inspect exteriorof carton for evidence of rough handling in ship-ment. Unpack carefully after moving equipmentto approximate location. If damage to contents isfound, report the damage immediately to the de-livering agency.

Codes and local utility requirements governing theinstallation of gas fired equipment, wiring, plumbing,and flue connections must be adhered to. In the ab-sence of local codes, the installation must conform withlatest edition of the National Fuel Gas Code ANSIZ223.1 • National Installation Code, CAN/CGA B149.1.The latest code may be obtained from the American GasAssociation Laboratories, 400 N. Capitol St. NW,Washington D.C. 20001.1-800-699-9277 or www.aga.orgThese Furnaces have been classified as CATEGORY IVfurnaces in accordance with latest edition of ANSIZ21.47 standards • CSA 2.3. Category IV furnaces oper-ate with positive vent static pressure and with a flueloss less than 17 percent. These conditions require spe-cial venting systems, which must be gas tight and watertight. These Category IV Direct Vent Furnaces are ap-proved for installation in Manufactured/ Mobile housingwhen used with BAYMFGH001A.

LOCATION AND CLEARANCES

▲ WARNING!Do NOT install the Furnace directly on carpeting, tile orother combustible material other than wood flooring.

▲ CAUTION!Do NOT install the Furnace in a corrosive or contami-nated atmosphere.Failure to follow this warning could result in earlyequipment failure.

The location of the Furnace is normally selected by thearchitect, the builder, or the installer. However, beforethe Furnace is moved into place, be sure to consider thefollowing requirements:1. Is the location selected as near the chimney or vent

and as centralized for heat distribution as practical?

2. Do all clearances between the Furnace and enclo-sure equal or exceed the minimums stated inClearance Table on the Outline Drawings?

3. Is there sufficient space for servicing the Furnaceand other equipment? A minimum of 24 inchesfront accessibility to the Furnace must be provided.Any access door or panel must permit removal ofthe largest component.

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

5. Are the ventilation and combustion air openingslarge enough and will they remain unobstructed? Ifoutside air is used, are the openings set above thehighest snow accumulation level? (See the Air forCombustion and Ventilation section, page 8)

6. A heavy gauge steel plate is attached to thebottom of the unit for protection during ship-ping and handling prior to the unit installa-tion. Leave this plate in place until the unit isready to be connected to the ductwork.

7. A Pre-filter is not required to be installed withthe furnace containing a Whole House Air Clean-er. If the use of a Pre-Filter is desired, it must beinstalled at least 6" away from the Whole HouseAir Cleaner. The additional pressure drop of thePre-Filter must be considered during duct designor evaluation to ensure proper airflow.

8. Allow sufficient height in supply plenum above theFurnace to provide for cooling coil installation, ifthe cooling coil is not installed at the time of thisFurnace installation.

IMPORTANT:The Furnace must be installed level. The only allow-able variation would be slightly to the left and/ or for-ward in upflow installations or slightly toward the frontin horizontal installations. This is necessary for propercondensate drainage.

9. A Furnace shall be installed so electrical compo-nents are protected from water.

10. DO NOT use silicon based sealant in the airstream.This causes a coating on the FIELD CHARGER pinsthat will decrease the efficiency of the air cleaner.

11. Allow a minimum of 24 inches clearance in front ofthe air cleaner to permit removal of COLLECTIONCELL and FIELD CHARGER.

12. Do Not install furnace where the air cleaner can beexposed to UV light.

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18-CD25D1-2 5

Installer’s GuideNOTE: Do NOT install an atomizing style humidifier inthe return plenum of this unit.

13. Flow-through Bypass HumidifiersExcessive bypass air may cause water blow-off,which will adversely affect system operation and aircleaner performance. To verify bypass airflow, fol-low the Bypass Humidifier Pre-Installation Check-out and Set-Up Procedures available through yourlocal distributor. Ask for publication number 18-CH37D1-1.Steam and Flow-through Fan Power Duct-mounted HumidifiersFollow the humidifier installation instructions.These should only be installed on the supply airside of the system.Other Duct Mounted Humidifiers are not rec-ommended for installation with the aircleaner.

Components of the integrated Whole House Air Cleaner:

1) FIELD CHARGER - Charges the contaminants2) COLLECTION CELL - removes and collects very smallimpurities from the air.3) Power Supply - the solid state power supply convertsthe 24 Volt AC to the high-voltage, direct current requiredto power the FIELD CHARGER and COLLECTION CELL.Check carefully for any shipping damage. This mustbe reported to and claims made against the transpor-tation company immediately. Check to be sure allmajor components are in the unit. Any missing partsshould be reported to your supplier at once, andreplaced with authorized parts only.

Figure 1. COMPONENTS OF THE INTEGRATED WHOLE HOUSE AIR CLEANER

2

1

3

14. If the Furnace is installed in a residential garage,it must be installed so that the burners, and the ig-nition source are located not less than 18 inchesabove the floor and the Furnace must be located orprotected to avoid physical damage from vehicles.

15. The whole house air cleaner is designed to run at amaximum indoor relative humidity of 65%.

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6 18-CD25D1-2

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18-CD25D1-2 7

Installer’s Guide

HORIZONTAL INSTALLATIONThe coil and Furnace must be fully supported whenused in the horizontal position. It is always recom-mended that an auxiliary drain pan be installed under ahorizontally installed evaporator coil or 90% Gas Fur-nace. Connect the auxiliary drain line to a separatedrain line (no trap is needed in this line).IMPORTANT:The 2/4TXC cased coil must be placed downstream of thefurnace. In horizontal installations, the apex of the coilmay point either toward or away from the furnace. Seethe 2/4TXC coil Installer's Guide for more details.

The cased coil is secured to the Furnace and both theFurnace and the cased coil must be properly supported.The brackets mount using the rear screws on the coilcase and use the screws provided to secure the bracketto the Furnace. The remaining bracket is placed asclose to center as possible (horizontally) between thecoil case front and the upflow Furnace, converted tohorizontal, aligns and attaches to the TXC coil. How-ever, the coil requires additional support.The Furnace may be installed in an attic or crawl spacein the horizontal position by placing the Furnace on theleft side (as viewed from the front in the vertical posi-tion). The horizontal Furnace installation in an atticshould be on a service platform large enough to allowfor proper clearances on all sides and service access tothe front of the Furnace (See Figure 3 & ClearanceTable 1). Line contact is only permissible between linesformed by intersections of the top and two sides of thefurnace casing and building joists, studs, or framing.

INSTALLATION INSTRUCTIONS

▲ CAUTION!Bottom panel for furnace to remain in place untilunit reaches final installation location. If bottompanel is removed before installation the COLLEC-TION CELL and FIELD CHARGER must also be re-moved to protect installation personnel.

▲ CAUTION!Remove the COLLECTION CELL and remove and dis-card the cardboard over the cell.

NOTE: No sheetmetal screws may be used from 0-4"from the bottom of the unit. Screws will interfere withthe Air Cleaner. See Figure 4.

REMOVING THE BOTTOM PLATEa. Once the furnace is in place, remove the two screws

located at the front bottom corners of the furnace.b. Lean the furnace back slightly and remove the bot-

tom panel.c. Replace the two screws removed in step a.REMOVING THE COLLECTION CELLAND FIELD CHARGERWhen COLLECTION CELLS and FIELD CHARGERmust be removed, follow the steps below.a. Remove the lower furnace door.b. Remove the four screws holding the inner blower

panel and remove panel. Set aside in a safe placeuntil the unit is set in place and ready to start up.

d. Remove the COLLECTION CELL by sliding for-ward. Remove the cardboard from the COLLEC-TION CELL and discard. Set aside in a safe placeuntil the unit is set in place and ready to start up.

e. Disconnect the Green return wire and the Red highvoltage wire. Twist and pull the connector on theRed wire to release.

f. Remove the two hold down screws on the bottom ofthe FIELD CHARGER and retain.

g. Remove the Field Charger. Set aside in a safe placeuntil the unit is set in place and ready to start up.

h. Set furnace in place. Repeat step a-g in reverse or-der. Do Not put cardboard back in furnace. Innerblower door MUST be put back into place.

UPFLOW INSTALLATIONStandoffs and screws (See Figure 2) are included withthe cased coils for attachment to the Furnace. Thereare clearance alignment holes near the bottom of thecoil wrapper.Drill screws are used to engage the Furnace topflanges. The standoff is inserted into the cabinet align-ment hole. The drill screws are inserted through thestandoffs then screwed into the Furnace flange. Thecoil is always placed downstream of the Furnace airflow.The above instructions apply only if the coil is on top ofan upflow Furnace.

UPFLOWFURNACE

CASEDCOIL

SCREWS(BOTH SIDES)

STANDOFFS(BOTH SIDES)

STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

Figure 2

UPFLOW/HORIZONTALSHOWN WITHDIRECT VENT

Figure 3

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Installer’s Guide

GUIDE FOR THE INSTALLATION OF DUCT FLANGES

▲ CAUTION!Failure to use pre-drilled holes and the factoryprovided screws can potentially damage air cleanercomponents.

Materials

• Duct FlangesTwo 23.5" FlangesTwo Additional Flanges 15.92" (for 17.5" cabinet) 19.42" (for 21" cabinet) 21.92" (for 24.5" cabinet)

• ScrewsEight 5/16" Blunt Tip Screws with 5/16" HexHead

Steps

1. See Figures 5, 6, and 7 for flange orientation.

NOTE: Do NOT install screws to the bottom of theunit except with Duct Flanges and Screws provided.

NOTE: No sheet-metal screws may beused from 0-4" fromthe bottom of theunit. Screws will in-terfere with the aircleaner.

"

Figure 4

The Furnace may be placed horizontally in a crawlspace on a pad or other noncombustible material whichwill raise the unit for sufficient protection from mois-ture.The Furnace must be supported at both ends andthe middle when installed horizontally. TheFurnace must also be elevated approximately 4-6inches to allow clearance for the condensate drainto exit the cabinet in the horizontal position.The horizontal Furnace may also be suspended fromthe joists using all-thread rods with a substantial metalsupport frame that supports the entire length of thefurnace. The rods need to be of sufficient length toallow for proper clearances from combustible materials.The frame needs to be at least 32" in length to allow foraccess to service panels.If the Furnace is suspended using steel strap, it must besupported at all four corners and in the middle at thefront of the Furnace.

2. Attach flanges 1, 2, and 3 (Fig 7) to the unit usingthe factory provided screws and the pre-drilledholes in the wrapper. Flanges 1 and 2 are the23.5" flanges that are generic to all units. Flange3 will be one of two short flanges and the lengthof which is dependent on the cabinet size.

3. Attach flange 4 (Fig 7) to the duct work (Flangesshould be inside duct work). Flange 4 is theremaining short flange.

4. Place duct work with single flange over theflanges that are currently attached to the unit

5. Attach duct work to remaining 3 flanges.6. Attach the front flange from step 3 to the unit by

drilling 1/8" holes into the bottom channel. Usethe factory provided 5/16" blunt tip screws toattach.

7. Use field supplied material to make an adequateseal.

DO NOT use silicon based sealant in theairstream.

Figure 6: Bottom View - Pre-drilled holes

Use pre-drilledholes

Use pre-drilledholes

1

2

3

4

Use pre-drilledholes

Figure 5: Horizontal Left

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Installer’s Guide

Table 1

Minimum Clearance to Cumbustible Materials

Upflow Closet

Left Side 0 inches Front 3 inches (note 1)

Right Side 0 inches Back 0 inches

Flue 6 inches * Top 1 inch

Horizontal Closet(see note 2)

Top 2 inches Back 3 inches

Flue 6 inches * Sides 1 inch

Front 18 inches (note 1)

Horizontal Alcove(see note 2)

Top 1 inch Back 0 inches

Flue 6 inches Sides 0 inches

Front 18 inches

* May be 1" when type B-1 vent is usedNOTES:1) Minumum clearance to front on *UD2D120 is 6 inches2) May be installed on combustible floor when type B-1 vent is used.

AIR FOR COMBUSTION AND VENTILATIONAdequate flow of combustion and ventilating air mustnot be obstructed from reaching the Furnace. Air open-ings provided in the Furnace casing must be kept freeof obstructions which restrict the flow of air. Airflow re-strictions affect the efficiency and safe operation of theFurnace. Keep this in mind should you choose to re-model or change the area which contains your Furnace.Furnaces must have a free flow of air for proper perfor-mance.

1. All air from inside the building as in Figure 10: Theconfined space shall be provided with two perma-nent openings communicating directly with an addi-tional room(s) of sufficient volume so that the com-bined volume of all spaces meets the criteria for anunconfined space. The total input of all gas utiliza-tion equipment installed in the combined spaceshall be considered in making this determination.Refer to Table 3, for minimum open areas required.

2. All air from outdoors as in Figure 11: The confinedspace shall be provided with two permanent open-ings, one commencing within 12 inches of the topand one commencing within 12 inches of the bot-tom of the enclosure.The openings shall communicate directly, or byducts, with the outdoors or spaces (crawl or attic)that freely communicate with the outdoors. Refer toTable 3, for minimum open areas required.

1

2

3

4

Figure 7: Bottom View -Flange Attachment

TABLE 2

MINIMUM AREA IN SQUARE FEETFOR UNCONFINED SPACE INSTALLATIONS

FURNACEMAXIMUM BTUHINPUT RATING

WITH 8 FT. CEILINGMINIMUM AREA IN SQUARE

FEET OF UNCONFINED SPACE

60,00080,000100,000120,000140,000

375500625750875

Provisions for combustion and ventilation air shall bemade in accordance with “latest edition” of Section 5.3,Air for Combustion and Ventilation, of the NationalFuel Gas Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4of CSA B149.1 Installation Codes, and applicable provi-sions of the local building codes. Special conditions cre-ated by mechanical exhausting of air and fireplacesmust be considered to avoid unsatisfactory Furnace op-eration.Furnace locations may be in “confined space” or “uncon-fined space”. Unconfined space is defined in Table 2 andFigure 8. These spaces may have adequate air by infil-tration to provide air for combustion, ventilation, anddilution of flue gases. Buildings with tight construction(for example, weather stripping, heavily insulated,caulked, vapor barrier, etc.), may need additional airprovided as described for confined space.

50 CU. FT. OR MOREPER 1000 BTU/ HR. INPUTALL EQUIP. INSTALLED

UNCONFINED

Figure 8

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Installer’s GuideDUCT CONNECTIONSAir duct systems should be installed in accordance withstandards for air conditioning systems, National FireProtection Association Pamphlet No. 90. They shouldbe sized in accordance with ACCA Manual D or which-ever is applicable.Central Furnaces, when used in connection with coolingunits, shall be installed in parallel or on the upstreamside of the cooling coil to avoid condensation in the heatexchanger. With a parallel flow arrangement, the damp-ers or other means used to control flow of air shall be ad-equate to prevent chilled air from entering the Furnace,and if manually operated, must be equipped with meansto prevent operation of either unit unless the damper isin full heat or cool position.On any job, flexible connections of nonflammable materialmay be used for return air and discharge connections toprevent transmission of vibration. Though these unitshave been specifically designed for quiet, vibration free op-eration, air ducts can act as sounding boards and could, ifpoorly installed, result in vibration to the annoyancelevel.When the Furnace is located in a utility room adjacentto the living area, the system should be carefully de-signed with returns to minimize noise transmissionthrough the return air grille. Although these Furnacesare designed with large blowers operating at moderatespeeds, any blower moving a high volume of air willproduce audible noise which could be objectionablewhen the unit is located very close to a living area. It isoften advisable to route the return air ducts under thefloor or through the attic. Such design permits the in-stallation of air return remote from the living area (i.e.central hall).When the Furnace is installed so that the supply ductscarry air circulated by the Furnace to areas outside thespace containing the Furnace, the return air shall alsobe handled by a duct(s) sealed to the Furnace and termi-nating outside the space containing the Furnace.Where there is no complete return duct system,the return connection must be run full size fromthe Furnace to a location outside the utilityroom, basement, attic, or crawl space.Do NOT install return air through the back of the Fur-nace cabinet.Bottom Return Only

NOTE: Minimum return air temperature is 55° F.

NOTE: No sheetmetal screws may be used from 0-4"from the bottom of the unit. Screws will interfere withthe air cleaner. See Figure 4.

Confined spaces are installations with less than 50 cu.ft. of space per 1000 BTU/ hr input from all equipmentinstalled. Confined space is defined in Figure 9. Air forcombustion and ventilation requirements can be sup-plied from inside the building as in Figure 10 or fromthe outdoors, as in Figure 11.

3. The following types of installations will require useof OUTDOOR AIR for combustion, due to chemicalexposures:* Commercial buildings* Buildings with indoor pools* Furnaces installed in commercial laundry rooms* Furnaces installed in hobby or craft rooms* Furnaces installed near chemical storage areas.Exposure to the following substances in the com-bustion air supply will also require OUTDOORAIR 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

NOTE: Extended warranties are not available in someinstances. Extended warranty does not cover repairs toequipment installed in establishments with corrosiveatmospheres, including but limited to, dry cleaners,beauty shops, and printing facilities.

TABLE 3MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

FurnaceMaximum

BTUH/INPUTRating

AirFromInside

Air From Outside

Vertical Duct

Horizontal Duct

60,00080,000100,000120,000140,000

100100100120140

1520253035

3040506070

CONFINED

LESS THAN 50 CU. FT.PER 1000 BTU/ HR. INPUTALL EQUIP INSTALLEDFigure 9

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Installer’s Guide

Connect duct work to Furnace. See Outline Drawing forsupply and return duct size and location. Flexible ductconnectors are recommended to connect both supplyand return air ducts to the Furnace. If only the front ofthe Furnace is accessible, it is recommended that bothsupply and return air plenums are removable.

GENERAL VENTINGTHIS FURNACE EXHAUST MUST BE VENTED TOTHE OUTDOORS. THESE FURNACES ARE INDUCEDDRAFT VENTED AND MUST NOT BE CONNECTEDTO ANY VENT SERVING ANOTHER APPLIANCE.PLEASE NOTE THAT THESE FURNACES USEPOSITIVE-PRESSURE VENT SYSTEMS.Proper venting is essential to obtain maximum effi-ciency from a condensing Furnace. Proper installationof the vent system is necessary to assure drainage ofthe condensate and prevent deterioration of the ventsystem.American Gas Association has certified the design ofcondensing Furnaces for a minimum of 0" clearancefrom combustible materials with a single wall plasticvent pipe.

Carbon monoxide, fire or smoke can cause seriousbodily injury, death, and/ or property damage.A variety of potential sources of carbon monoxide can befound in a building or dwelling such as gas-fired clothesdryers, gas cooking stoves, water heaters, Furnaces andfireplaces. The U.S. Consumer Product Safety Commis-sion recommends that users of gas-burning appliancesinstall carbon monoxide detectors as well as fire andsmoke detectors per the manufacturers installation in-structions to help alert dwelling occupants of the pres-ence of fire, smoke or unsafe levels of carbon monoxide.These devises should be listed by Underwriters Labora-tories, Inc. Standards for Single and Multiple StationCarbon Monoxide Alarms, UL 2034 or CSA Interna-tional Standard, Residential Carbon Monoxide AlarmingDevices, CSA 6.19

NOTE: The manufacturer of your Furnace does NOT test anydetectors and makes no representations regarding anybrand or type of detector.

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

Hazardous Gases!

Exposure to fuel substances or by-products of incomplete fuel combustion is believed by the state of California to cause cancer, birth defects, or other reproductive harm.

▲ WARNING!Figure 10

Figure 11

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12 18-CD25D1-2

Installer’s GuideIMPORTANT:These Furnaces may be installed as Direct Vent (sealedcombustion) or as Nondirect Vent (single pipe). The Fur-naces are shipped DIRECT VENT with sealed combus-tion.

For DIRECT VENT APPLICATION: The Furnacesmust be vented to the exterior of the house and com-bustion air MUST come through the inlet air pipeFROM OUTSIDE AIR.

NOTE: BAYVENT200* accessories can be used for inletand outlet terminals when the pipes do not exit thestructure together.

For NON-DIRECT VENT APPLICATION: The Fur-nace shall be vented to the exterior of the house, butcombustion air may enter from the surrounding areaas long as combustion air requirements are met.(See AIR FOR COMBUSTION AND VENTILATION)

FURNACE VENT/ INLET PIPE INSTALLATIONThere are many different variations of the vent/ inletair pipe combination. The vent/ inlet air combinationused for installation of these Furnaces depends on theneeds of the location. However, these guidelines mustbe followed:

1. The Furnace must vent outside the structure.2. Furnace combustion air requirements must be met

for non-direct, single pipe applications.3. For direct vent application of these Furnaces, the

vent pipe and air inlet pipe do not have to exit inthe same air space or even on the same surface ofthe structure. However, the longest individual pipewill decide the value for the longest allowableequivalent vent/ inlet air length as shown in thevent length table on page 14.

The following are EXAMPLES ONLY:EX. 1 —Example 1 shows that the vent may go vertical whilethe inlet air may be on any side of the structure. Thevent pipe would decide the maximum equivalent lengthfor the pipe depending on the furnace and pipe size.VENT FITTING MATERIAL – PLASTICGas and liquid tight single wall vent fittings, designedfor resistance to corrosive flue condensate, MUST beused throughout.Listed in Table 4 are 2" and 3" size fittings that meetthese requirements. The materials listed are variousgrades of PVC and ABS plastic.PIPE JOINTS: All joints must be fastened and sealedto prevent escape of combustion products into the build-ing.

The recommended system is assembled from 2", 2-1/2",or 3" plastic pipe and fittings (See Table 4, page 12).Where the system is routed to the outdoors through anexisting masonry chimney containing flue products fromanother gas appliance, or where required by local codes,then 3" venting of Type 29-4C stainless steel must beused in place of PVC material.These Furnaces have been classified as CATEGORY IVFurnaces in accordance with ANSI Z21.47 “latest edi-tion” standards. Category IV Furnaces operate withpositive vent pressure and with a vent gas temperatureless than 140°F above the dewpoint. These conditionsrequire special venting systems, which must be gastight and water tight.

NOTE: When an existing Furnace is removed from aventing system serving other gas appliances, the vent-ing system is likely to be too large to properly vent theremaining attached appliances.

The following steps shall be followed with each appli-ance remaining connected to the common venting sys-tem placed in operation, while the other appliances re-maining connected to the common venting system arenot in operation.

1. Seal any unused openings in the common ventingsystem.

2. Visually inspect the venting system for proper sizeand horizontal pitch and determine there is noblockage or restriction, leakage, corrosion or otherdeficiencies which could cause an unsafe condition.

3. In so far as is practical, close all building doors andwindows and all doors between the space in whichthe appliances remaining connected to the commonventing system are located and other spaces of thebuilding. Turn on clothes dryers and any appliancesnot connected to the common venting system.Turn on any exhaust fans, such as range hoods andbathroom exhausts, so they will operate at maxi-mum speed. Do not operate a summer exhaust fan,close fireplace dampers.

4. Follow the lighting instructions. Place the appliancebeing inspected in operation. Adjust Comfort Con-trol so appliance will operate continuously.

5. After it has been determined that each appliance re-maining connected to the common venting systemproperly vents when tested as outlined above, returndoor, windows, exhaust fans, fireplace dampers andany other gas-burning appliance to their previousconditions of use.

If improper venting is observed during any of the abovetests, the remaining common venting system must becorrected. Correction could require rerouting orresizing the remaining vent system.

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Installer’s Guide

s

Furnace

AirInlet

Vent

Furnace

Vent

AirInlet

(See Note)

Furnace

AirInlet

VentAtticVent

(See Note)

Furnace

AirInlet

Vent

EX. 2 —Example 2 shows the vent pipe exhausting through theroof and the inlet air coming from the interior of thehouse (See Note 1). The inlet air coming from the inte-rior of the house must meet combustion requirementsfor area, etc., as shown in the section AIR FOR COM-BUSTION AND VENTILATION in this Installer’sGuide.

EX. 3 —Example 3 shows the vent exiting one side of the housewhile the inlet air is on the opposite side of the struc-ture. Here the vent pipe length must be within the al-lowable length for the size of Furnace and size of thevent pipe. This example demonstrates that the pipes donot have to exit on the same side of the structure.

EX. 4 —The inlet air does not have to come from outside thestructure. Example 4 shows the inlet air (See Note 1),may come from the attic if the requirements for com-bustion air are met as shown in the section AIR FORCOMBUSTION AND VENTILATION.

NOTE: If only the flue gas pipe is to the outside of thestructure, a straight section of pipe (long enough toexit the Furnace cabinet) must be attached to the inletair side with an elbow (which is 5 to 10 equiv. ft.) in-stalled on the end to prevent dust and debris from fall-ing directly into the Furnace.

NOTE: It is recommended that the first joints from theFurnace be connected and sealed with high tempera-ture RTV. This will enable the pipes to be removed laterwithout cutting.

Be sure to properly support these joints.BONDING OF PVCCommercially available solvent cement for PVC mustbe used to join PVC pipe fittings. Follow instructions oncontainer carefully.Pipe and Fitting – ASTM D1785, D2466, D2661, &D2665PVC Primer and Solvent Cement – ASTM D2564Procedure for Cementing Joints – Ref ASTM D2855

1. Cut pipe square, remove ragged edges and burrs.Chamfer end of pipe, then clean fitting socket andpipe joint area of all dirt, grease, moisture or chips.

2. After checking pipe and socket for proper fit, wipesocket and pipe with cleaner-primer. Apply a liberalcoat of primer to inside surface of socket and out-side of pipe.DO NOT ALLOW PRIMER TO DRY BEFORE AP-PLYING CEMENT.

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

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Installer’s Guide

A variety of potential sources of carbon monoxide can befound in a building or dwelling such as gas-fired clothesdryers, gas cooking stoves, water heaters, furnaces andfireplaces. The U.S. Consumer Product Safety Commis-sion recommends that users of gas-burning appliancesinstall carbon monoxide detectors as well as fire andsmoke detectors, listed by a nationally recognizedagency (e.g. Underwriters Laboratories or InternationalApproval Services), to help alert dwelling occupants ofthe presence of fire, smoke or unsafe levels of carbonmonoxide.

NOTE: The manufacturer of your furnace does not testany detectors and makes no representations regardingany brand or type of detector.

4. Hold the pipe in the fitting for 30 seconds to pre-vent tapered socket from pushing the pipe out ofthe fitting.

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

NOTE: Follow venting instructions carefully when us-ing PVC cement.

IMPORTANT:All joints must be water tight. Flue condensate issomewhat acidic, and leaks can cause equipment dam-age.

Connection of the pipe and collar of the combustion airinlet should just be a friction fit. It is recommended thatthe inlet air joint be sealed with RTV type sealant to al-low the joint to be separated for possible future service.The inlet and vent pipes must be properly supportedthroughout the entire length. See Figure 12.

TABLE 4

PLASTIC PIPE DESIGNATIONS

PVCASTM 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

CPVCASTM 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

ABSASTM 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)]

NOTE: Vent termination kit BAYAIR30AVENTA orBAYVENT200B may be used in addition to the horizon-tal and vertical termination options shown in the fol-lowing figures.

PVC VENT FITTING MATERIAL These fittings are available from your Gas Furnace Distributors.

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Installer’s Guide

TABLE 5

VENT LENGTH TABLE

ALTITUDEMAXIMUM TOTAL EQUIVALENT LENGTH IN FEET

FOR VENT AND INLET AIR (SEE NOTES)

0-7,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 INCH PIPE

UX2B060AFV3VA 200 200 200

UX2B080AFV3VA 50 120 200

UX2C100AFV4VA Not Allowed 60 200

UX2D120AFV5VA Not Allowed Not Allowed 200

7,000-9,500 Feet 2 INCH PIPE 2.5 INCH PIPE 3 INCH PIPE

UX2B060AFV3VA 100 100 100

UX2B080AFV3VA 25 60 100

UX2C100AFV4VA Not Allowed 30 100

UX2D120AFV5VA Not Allowed Not Allowed 100

9,500-12,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 INCH PIPE

UX2B060AFV3VA 50 50 50

UX2B080AFV3VA Not Allowed 30 50

UX2C100AFV4VA Not Allowed Not Allowed 50

UX2D120AFV5VA Not Allowed Not Allowed 50

NOTES: * - First letter may be "A" or "T"1. Minimum vent length for all models: 3' horizontal or 3' vertical.2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Exceptadapters at the top of the furnace). If different inlet and vent pipe sizes are used, the vent pipe must adhere to themaximum length limit shown in the table above (See note 6 below for exception). The inlet pipe can be of a larger diameter,but never smaller than the vent pipe.3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT ISTHE MAXIMUM LENGTH OF EACH (Vent or Inlet air pipes).4. 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 90° elbow is equivalent to 7½' of 2½" pipe or 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 BAYAIR30AVENTA termination kit isused, the equivalent length of pipe is 5 feet. BAYVENT200B equivalent length is 0 feet.6. Pipe adapters are field supplied (except 120).

Seal VENT PIPEwith RTV sealant

Seal INLET AIR PIPEwith RTV sealant

Front of Furnace

VENT AND INLET AIR CONNECTIONS

Figure 12

IMPORTANT:

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

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Installer’s Guide

9" MINIMUM

9" MINIMUM

9" MINIMUM

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

9" MINIMUM

9" MINIMUM

ELBOW AND TEE MUST BEAS CLOSE TOGETHERAS POSSIBLE

Figure 14

Figure 13

▲ CAUTION!When the vent pipe is exposed to temperatures belowfreezing, 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 domesticwater pipes are not protected from freezing then it isassumed the space meets the condition of a heatedspace.

HORIZONTAL INSTALLATION(Upflow/ Horizontal)

NOTE: When the factory supplied 2X3" offset reducingcoupling is used for 3" vent pipe installation, makesure the marking “TOP” is located on the top side ofthe pipe.The straight side of the coupling must be on bottomfor proper drainage of condensate. See Figure 13.

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Installer’s Guide

HORIZONTAL VENTING THROUGH WALLThese Furnaces may be installed as direct vent(as shipped) or as nondirect vent. Installationmust conform to national, state, and local codes.The vent & inlet terminals must be located at least 12"minimum above normally expected snow accumulationlevel.Avoid areas where staining or condensate drippage maybe a problem.Location of the vent/ wind terminal should be chosen tomeet the requirements of Figure 16 for either direct ornon-direct vent applications.PITCH — Venting through the wall must maintain 1/4"per foot pitched upward to insure that condensatedrains back to the Furnace.FLUE GAS DEGRADATION — The moisture contentof the flue gas may have a detrimental effect on somebuilding materials. This can be avoided by using theroof or chimney venting option. When wall venting isused on any surface that can be affected by this mois-ture, it is recommended that a corrosion resistantshield (24 inches square) be used behind the vent termi-nal. This shield can be wood, plastic, sheet metal, etc.Also, silicone caulk all cracks, seams and joints within 3feet of the vent terminal.

VENT

COMBUSTIONAIR

VENT

VENTPLATE

VENTCAP

12" MINIMUMTO OVERHANG

MAINTAIN 12" (18" FOR CANADA) MINIMUMCLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

SCREWS(4 req.)

ANCHORS(4 req.)

7.2"

3.2"

BAYVENT200BFigure 16

RAIN CAP

COMBUSTION AIR

STRAP(FIELD SUPPLIED)

COMBUSTIONAIR

VENT

ELBOW(FIELD SUPPLIED)

VENT

1" + 1/2"

3" PIPING

2", 2-1/2"or 3" PIPING

REDUCING COUPLING,FIELD SUPPLIEDIF NEEDED

SEAL ALLWALL CAVITIES

NOTE: VENT AND INLET MUST BE SUP-PORTED AT A MAXIMUM OF 3' INTERVALS

BAYAIR30AVENTA

TEE

BAYVENT200B

40" UPFLOW ORDOWNFLOW MODELS

SEE VENTING TABLE

OUTSIDEWALL

NOTE: ANY FITTINGS PASSINGTHROUGH AN UNHEATED SPACEMUST BE INSULATED.

FIRST SUPPORT SHOULD BE ASCLOSE TO FURNACE CONNECTIONAS POSSIBLE.

UPWARD PITCH -- 1/4" PER FOOT

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

COMBUSTIONAIR INLET

USE ONLYAPPROVED

TERMINATION

Figure 15

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Installer’s Guide

COMBUSTIBLE MATERIAL WALLA minimum clearance of 1" to combustible materialsmust be maintained when using single wall stainlesssteel venting. See Figure 18.

Shield material to be a minimum of 24 gauge stainlessor aluminized sheet metal. Minimum dimensions are12"x12". Shield must be fastened to both inside and out-side of wall. Use screws or anchor type fasteners suitedto the outside or inside wall surfaces.

NONCOMBUSTIBLE MATERIAL WALLThe hole through the wall must be large enough tomaintain pitch of vent and properly seal.Use cement mortar seal on inside and outside of wall.See Figure 19.

SUPPORT HORIZONTAL PIPE EVERY 3' 0"WITH THE FIRST SUPPORT AS CLOSE TOTHE FURNACE AS POSSIBLE. INDUCEDDRAFT BLOWER, HOUSING, ANDFURNACE MUST NOT SUPPORT THEWEIGHT OF THE FLUE PIPE.

Figure 20

RAIN CAP

COMBUSTION AIR

STRAP(FIELD SUPPLIED)

COMBUSTIONAIR

VENT

ELBOW(FIELD SUPPLIED)

VENT

1" + 1/2"

BAYAIR30AVENTA(Sidewall)

Figure 17

Figure 18

Figure 19

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Installer’s Guide

MAINTAIN 12 IN.(18 IN. FOR CANADA)MINIMUM CLEARANCEABOVE HIGHESTANTICIPATED SNOW LEVEL. MAXIMUM OF24 IN. ABOVE ROOF.

VENT

COMBUSTIONAIR

Figure 21

REMOVE RIBSFROM CAP

COMBUSTION AIR

ROOF BOOT(FIELD SUPPLIED)

COMBUSTIONAIR

VENT

ELBOW(FIELD SUPPLIED)

MAINTAIN 12 IN.(18 IN. FOR CANADA)MINIMUM CLEARANCEABOVE HIGHEST ANTICIPATED SNOWLEVEL. MAXIMUM OF24 IN. ABOVE ROOF

SUPPORT(FIELD SUPPLIED)

VENT

BAYAIR30AVENTA (VERTICAL)

Figure 22

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

VENTING THROUGH CEILING

CEILING

SUPPORTFLANGE

FLUE PIPE

COUPLING

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

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

Figure 23

VENTING THROUGH THE ROOFWhen penetrating roof with a 2" PVC vent pipe, a 2"electrical conduit flashing may be used for a weathertight seal. Lubricate flexible seal on flashing before PVCpipe is pushed through the seal. (Field Supplied)

NOTE: No vent cap as shown in Figure 21 is the pre-ferred method for vertical vent termination in extremelycold climates.In extreme climate conditions, insulate the exposedpipe above the roof line with Armaflex type insulation.

VENT FITTING MATERIAL – STAINLESS STEELGas and liquid tight single wall metal vent fitting, de-signed for resistance to corrosive flue condensate suchas Type 29-4C MUST be used throughout.These fittings and fitting accessories are to be field sup-plied.DIRECTION OF STAINLESS STEEL FITTINGAll stainless steel fitting must be installed with maleend towards the Furnace.All horizontal stainless steel sections must be posi-tioned with the seam on top.All long horizontal sections must be supported to pre-vent sagging.All pipe joints must be fastened and sealed to preventescape of combustion products into the building.

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Installer’s GuideFigure 24

TYPE 29-4C STAINLESS STEEL VENTING - USEDTHROUGH CHIMNEY THAT VENTS ANOTHER GAS

APPLIANCE

VENTING ROUTED THROUGH A MASONRY CHIMNEY

PVC PLASTIC VENTING - ONLYTHROUGH UNUSED CHIMNEY

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

NOTE:HORIZONTAL VENTING TO VERTICAL VENTING

6 IN. MIN.

STAINLESSSTEELVENT CAP

SEE CAUTION

FLUE PIPE

COUPLINGAS REQUIRED

FLUE PIPE

COUPLING TO SUPPORT PIPE FROM ANGLES OR OTHER SUITABLESUPPORT METHOD

SUPPORT THE SINGLE WALL STAINLESS STEEL GASVENTING AND CENTER IT IN THE CHIMNEY OPENING WITH ANGLES AS SHOWN OR ANOTHER EQUIVALENTMANNER.

NOTE:HORIZONTAL VENTINGTO VERTICAL VENTING

6 IN. MIN.SEE CAUTION

STAINLESSSTEELVENT CAP

STAINLESS STEELVENT CAP (OP-

TIONAL)

STAINLESS STEELVENT CAP (OP-

TIONAL)

▲ CAUTION!Do NOT run vent through chimney for wood burn-ing or oil Furnaces or incinerators or any other gasappliance.

IMPORTANT –The single wall flue pipe joints must be sealed.The 90° elbow connection to vertical pipe must besealed to prevent condensate leakage to base of ma-sonry chimney.

▲ CAUTION!Do NOT run vent through chimney for wood burningor oil Furnaces or incinerators.If remaining free area between single wall flue pipeand masonry chimney is to be used for another gasappliance venting area must be sufficient to vent thatappliance and that appliance must be connected tochimney with separate entry openings.

IMPORTANT –The single wall flue pipe joints must be sealed.The 90° elbow connection to vertical pipe must besealed to prevent condensate leakage to base of ma-sonry chimney.

Figure 23

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Installer’s Guide

Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

A= Clearance above grade, veranda, porch, deck, orbalcony 12 inches (30 cm) 12 inches (30 cm)

B= Clearance to window or door that may beopened

6 inches (15 cm) for appliances =/< 10,000 Btuh (3kw),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 (30kw)

4 feet (1.2m) below or to the side ofopening;

1 foot (0.3m) above opening.

C= Clearance to permanently closed window * *

D=

Vertical clearance to ventilated soffit locatedabove the terminal within a horizontal distance of2 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 * *

H= Clearance to each side of center line extendedabove meter/regulator assembly

3 feet (91 cm) with a height 15 feet (4.5 m) above themeter/regulator assembly *

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

J=Clearance to nonmechanical air supply inlet tobuilding or the combustion air inlet to any otherappliance

6 inches (15 cm) for appliances =/< 10,000 Btuh (3kw),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 (30kw)

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

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within10 feet (3m) horizontally

L= Clearance above a paved sidewalk or paveddriveway located on public property 7 feet (2.13 m) † 7 feet (2.13 m)

M-=

Clearance under veranda, porch, deck, orbalcony 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.

V

D

EE

V

G

INSIDECORNER DETAIL

BL V

V

FIXED CLOSED

OPERABLE

F

B

C

VFIXED

CLOSEDV

V

VB

B

B

A

X

J

B

H

I

V X

K

M

V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED

OPERABLE

HORIZONTAL VENT CLEARANCESFigure 25

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Installer’s GuideDirect Vent Terminal Clearances

Canadian Installations US Installations

A= Clearance above grade, veranda,porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

B= Clearance to window or door that maybe opened

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

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

C= Clearance to permanently closedwindow * *

D=

Vertical clearance to ventilated soffitlocated above the terminal within ahorizontal 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 * *

H=Clearance to each side of center lineextended above meter/regulatorassembly

3 feet (91 cm) with a height 15 feet (4.5 m) above themeter/regulator assembly *

I= Clearance to service regulator ventoutlet 3 feet (91 cm) *

J=Clearance to nonmechanical air supplyinlet to building or the combustion airinlet to any other appliance

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

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

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

horizontally

L=Clearance above a paved sidewalk orpaved driveway located on publicproperty

7 feet (2.13 m) † *

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.

All horizontal pipes must besupported at maximum of 3

foot intervals

DOWNWARD VENTINGFurnace may be in vertical or horizontal configuration.

Figure 26

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 condensate trap. Outdoor draining of the Furnace and coilcondensate is permissible if allowed by local codes.

▲ CAUTION!Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to personal in-jury. 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.

6" Min.

40 Inch Upflow or Downflow Furnace

Slope 1/4" per ft.

Slope 1/4" per ft.

DOWNWARD VENT LENGTH ISLIMITED TO A MAXIMUM OF 15

EQUIVALENT FEET.

▲ CAUTION!

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18-CD25D1-2 23

Installer’s GuideIMPORTANT:

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

For all side wall horizontally vented gas fueled equipmentinstalled in every dwelling, building or structure used inwhole or in part for residential purposes, including thoseowned or operated by the Commonwealth and where theside 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, thefollowing requirements shall be satisfied:1. INSTALLATION OF CARBON MONOXIDEDETECTORS. At the time of installation of the side wallhorizontal vented gas fueled equipment, the installingplumber or gasfitter shall observe that a hard wiredcarbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipmentis to be installed. In addition, the installing plumber orgasfitter shall observe that a battery operated or hardwired carbon monoxide detector with an alarm is installedon each additional level of the dwelling, building orstructure served by the side wall horizontal vented gasfueled equipment. It shall be the responsibility of theproperty owner to secure the services of qualified licensedprofessionals for the installation of hard wired carbonmonoxide detectorsa. In the event that the side wall horizontally ventedgas fueled equipment is installed in a crawl space or anattic, the hard wired carbon monoxide detector with alarmand battery back-up may be installed on the next adjacentfloor level.b. In the event that the requirements of thissubdivision can not be met at the time of completion ofinstallation, 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 batteryoperated carbon monoxide detector with an alarm shall beinstalled.2. APPROVED CARBON MONOXIDEDETECTORS. Each carbon monoxide detector as requiredin accordance with the above provisions shall comply withNFPA 720 and be ANSI/UL 2034 listed and IAS certified.3. SIGNAGE. A metal or plastic identification plateshall be permanently mounted to the exterior of thebuilding at a minimum height of eight (8) feet above gradedirectly in line with the exhaust vent terminal for thehorizontally vented gas fueled heating appliance orequipment. The sign shall read, in print size no less thanone-half (1/2) inch in size, “GAS VENT DIRECTLYBELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector ofthe side wall horizontally vented gas fueled equipmentshall not approve the installation unless, upon inspection,the inspector observes carbon monoxide detectors andsignage installed in accordance with the provisions of 248CMR 5.08(2)(a)1 through 4.This appliance requires a special venting system. IfBAYAIR30AVENTA or BAYVENT200B are used, a copy ofthe installation instructions for the kit shall remain withthe appliance or equipment at the completion ofinstallation. The venting system installation instructionscan be obtained from the manufacturer by writing to thefollowing address:

American Standard, Inc.6200 Troup HighwayTyler, TX 75707Attention: Manager of Field Operations Excellence

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24 18-CD25D1-2

Installer’s GuideCONDENSATE DRAIN INSTRUCTIONS

▲ WARNING!CARBON MONOXIDE POISONING HAZARDFailure to follow the installation instructions for theventing system being placed into operation could re-sult in carbon monoxide poisoning or death.

▲ CAUTION!It is recommended that a drain pan be installed underthe furnace to prevent property damage, or personalinjury.

Knock outs are provided on the left and right hand sideof both furnace cabinets for drain connections IN VER-TICAL APPLICATIONS. The standard arrangement isfor the drain connection on the left side. The tubingmay have to be trimmed in this application to avoidkinking.The upflow (vertical application) has provisions forright side drain connections by turning the trap and ex-tending the tubing to the lower right front corner ofthe Furnace. Trim all excess tubing to avoid kinking.The connecting tubing for left or right side condensatedrain shown in Figure 27 is shipped in the blower com-partment.It is always recommended that an auxiliary drain panbe installed under a horizontally installed evaporatoror 90% Gas Furnace. Connect the auxiliary drain lineto a separate drain line (no trap is needed in this line).

All horizontal applications are left side only andrequire repositioning the condensate canister trapto the exterior of the cabinet. Additionally thedrain tubing connected to the inducer housingmust be repositioned for removing the plug and re-connecting the tubing to the lower connection onthe inducer housing. See Figure 28.For horizontal installation, remove the condensate trapand position the trap outside the cabinet through theslotted opening next to the secondary cell. On upflow/horizontal models, remove lines from the blower sec-tion and pull through the blower deck. Cut and reattachthe line from the secondary cell (use the spring to pre-vent kinking).The inducer housing has a secondary drain opening atits 9 o’clock position. Remove the plug and use the plugto cover the hole at the 6 o’clock position. Repositionthe Inducer drain tube from 6 o’clock to the 9 o’clock lo-cation. Cut and reattach the tube to the canister trap.Plug openings in Blower deck, Inducer and Blower sec-tion. See Figure 28.Connections must be made to an OPEN/ VENTEDDRAIN.

NOTE: Use 1/2" size PVC pipe and fittings through-out for drain connections (fittings, pipe and PVC sol-vent cement not provided).

THE UPFLOW (VERTICAL) MAY BE INSTALLEDLEFT OR RIGHT SIDE CONDENSATE DRAIN

TO DRAINRIGHT SIDE

HEADERUPFLOW FURNACE

(Vertical)

TO DRAINLEFT SIDE

HEADER

Figure 27

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18-CD25D1-2 25

Installer’s Guide

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

IMPORTANT:The condensate drain should be installed with provisionsto prevent winter freeze-up of the condensate drain line.Frozen condensate will block drains, resulting in furnaceshutdown. If the drain line cannot be installed in a condi-tioned space and/ or its surrounding ambient tempera-ture is expected to fall below freezing, then heat tapeshould be applied as required to prevent freezing (permanufacturer’s instructions). The heat tape should berated at 5 or 6 watts per foot at 120 volts. Self-regulating(preferred) or thermostatically controlled heat tape is re-quired.

Typical sources of UL listed heat tapes are W.W.Granger, Inc. (Wintergard PlusTM Series), McMasterCarr Supply Co. (3554 Series), or your equipment sup-plier.The condensate drain may be cleaned or inspected byremoval of the drain tube at the header.

Evaporator and Furnace condensate drain piping maybe manifolded together as shown in Figure 29. A pri-mary drain vent stack must be installed and terminatedbelow the outlet of the secondary heat exchanger drainconnection to prevent water from damaging Furnacecontrols if the primary drain outlet plugs up.Where the Furnace is installed above a finishedceiling, the primary drain vent stack must be in-stalled such that overflow from the vent stackopening will flow into an auxiliary drain pan inorder to prevent water damage to the finishedceiling below.

ALL HORIZONTAL APPLICATIONSARE LEFT SIDE DRAIN ONLY

TOOPEN/

VENTEDDRAIN

UPFLOW FURNACE ON LEFT SIDEWITH LEFT DRAIN SHOWN

HEADER

Figure 28

Primary drain vent stackmust terminate belowsecondary heat exchangercondensate drain outlet.

To drain opening

If upflow furnace is installedover a finished ceiling, overflowfrom the primary drain ventstack must flow into an auxillarydrain pan to prevent damage tothe finished ceiling below.

Figure 29

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Installer’s Guide

1. Be sure power agrees with equipment nameplates. 2. Low voltage (24 volt wiring) to be No. 18 A.W.G. min. 3. Grounding of equipment must comply with local codes. 4. Set thermostat heat anticipator per unit wiring diagram. 5. These leads provide 115V. power for connection of humidifier MAX. load 1.0 amp. 6. When a single stage heating thermostat without fan switch

is used, no wiring on "G" terminal is used. 7. W1 and W2 must be jumpered together for proper operation.

Second stage heat will begin 10 minutes after first stage. 8. Set dip switches with power off per installation instructions

to set airflow and indoor fan off delays. 9. Continuous fan airflow can be increased by adding this jumper. 10. This wire is only for thermostats requiring connection to

transformer common terminal. 11. Optional humidistat is to be connected between R and BK. Factory installed jumper R

to BK on the circuit board must be cut if optional humidistat is used. The jumper must also be cut when applying an airflow command signal to the BK input such as with the variable speed single-zone and multi-zone system controllers. On single speed cooling only/non-heat pump systems, jumper Y to O for proper operation of the delay profiles and the humidistat. For two compressor or two speed systems, jumper YLo to O.

W14

SEE NOTE 10

SEE NOTE 9

Y1/Ylo

W14 JUMPERSEE NOTE 11

FIELD ADDED JUMPER W1 TO W2.

2ND STAGE WILL FIRE10 MINUTES AFTER 1ST.

From Dwg. B342027 Rev. 0

SEE NOTE 6

B/C B/C

TO 115 V 1 PH.,60 HZ., POWERSUPPLY PERLOCAL CODES

HUM SEENOTE 5

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTATNO COOLING

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18-CD25D1-2 27

Installer’s Guide

1. Be sure power agrees with equipment nameplates.2. Low voltage (24 volt wiring) to be No. 18 A.W.G. min.3. Grounding of equipment must comply with local codes.4. Set thermostat heat anticipator per unit wiring diagram.5. These leads provide 115V. power for connection of humidifier MAX. load 1.0 amp.6. This wire is only for thermostats requiring connection to

transformer common terminal.7. Continuous fan airflow can be increased by adding this jumper.8. Set dip switches with power off per installation instructions

to set airflow and indoor fan off delays.9. Optional humidistat is to be connected between R and BK. Factory

installed jumper R to BK on the circuit board must be cut if optional humidistat is used. The jumper must also be cut when applying an airflow command signal to the BK input such as with the variable speed single-zone and multi-zone system controllers. On single speed cooling only/non-heat pump systems, jumper Y to O for proper operation of the delay profiles and the humidistat. For two compressor or two speed systems, jumper YLo to O.

W14

SEE NOTE 6

From Dwg. B342025 Rev. 0

Y1/Ylo

W14 JUMPERSEE NOTE 9

SEE NOTE 7

B/C B/C

TO 115 V 1 PH.,60 HZ., POWERSUPPLY PERLOCAL CODES

HUM SEENOTE 5

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTATNO COOLING

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28 18-CD25D1-2

Installer’s Guide

W14

OUTDOOR UNIT (NO TRANSFORMER)

SEE NOTE 6

SEE NOTE 7

From drawing B342022 Rv 0

Y1/Ylo

W14 JUMPERSEE NOTE 9

FIELD ADDED JUMPER W1 TO W2.

2ND STAGE WILL FIRE10 MINUTES AFTER 1ST.

B/CB/C

TO 115 V 1 PH.,60 HZ., POWERSUPPLY PERLOCAL CODES

HUM SEENOTE 5

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE1 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT(OUTDOOR SECTION WITHOUT TRANSFORMER)

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18-CD25D1-2 29

Installer’s Guide

W14

OUTDOOR UNIT (NO TRANSFORMER)

SEE NOTE 6

SEE NOTE 7

Y1/Ylo

SEE NOTE 9

W14 JUMPERSEE NOTE 9

From Dwg. B342020 Rev. 0

B/CB/C

TO 115 V 1 PH.,60 HZ., POWERSUPPLY PERLOCAL CODES

HUM SEENOTE 5

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE2 STAGE HEATING, 1 STAGE COOLING

USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT(OUTDOOR SECTION WITHOUT TRANSFORMER)

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Installer’s Guide

HUMIDISTAT HOOKUPIf an optional Humidistat is to be connected between“R” and “BK”, the factory installed jumper between “R”and “BK” on the circuit board must be cut. If an optionalHumidistat is used, the jumper must also be cut whenapplying an airflow command signal to the “BK” inputsuch as with the variable speed single-zone and multi-zone system controller. On single speed cooling only/non-heat pump systems, jumper “Y” to “O” for properoperation of the delay profiles and the Humidistat. Fortwo compressor or two speed systems, jumper “Ylo” to“O”.

W14

OUTDOOR UNIT NO. 2(NO TRANSFORMER)

OUTDOOR UNIT NO. 1(NO TRANSFORMER)

SEE NOTE 3

SEE NOTE 6

SEE NOTE 7

From Dwg. B342018 Rev. 0

B/CB/C

TO 115 V 1 PH.,60 HZ., POWERSUPPLY PERLOCAL CODES

HUM SEENOTE 5

FIELD WIRING DIAGRAM FOR VARIABLE SPEED 2 STAGE FURNACE2 STAGE HEATING, 2 STAGE COOLING

(OUTDOOR SECTION WITHOUT TRANSFORMER)

The factory installed jumper be-tween “R” and “BK” on the circuitboard must be cut if an optionalHumidistat is installed.

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18-CD25D1-2 31

Installer’s GuideELECTRICAL CONNECTIONSMake wiring connections to the unit as indicated on en-closed wiring diagram. As with all gas appliances usingelectrical power, this Furnace shall be connected into apermanently live electric circuit. It is recommendedthat Furnace be provided with a separate “circuit pro-tection device” electric circuit. The Furnace must beelectrically grounded in accordance with local codes orin the absence of local codes with the National Electri-cal Code, ANSI/ NFPA 70 or CSA C22.1 Electrical Code,if an external electrical source is utilized. The inte-grated Furnace control is polarity sensitive. Thehot leg of the 120V power supply must be connected tothe black power lead as indicated on the wiring dia-gram. Provision for hooking up a humidifier is providedon the integrated control.Refer to the SERVICE FACTS literature and unit wiringdiagram attached to furnace.GAS PIPING

▲ WARNING!DO NOT USE SEMI-RIGID METALLIC GAS CONNEC-TORS (FLEXIBLE GAS LINES) WITHIN THE FURNACECABINET.FAILURE TO FOLLOW THIS WARNING COULD RESULTIN PROPERTY DAMAGE, PERSONAL INJURY ORDEATH.

TABLE 6

TABLE 7

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

Hazardous Gases!

Exposure to fuel substances or by-products of incomplete fuel combustion is believed by the state of California to cause cancer, birth defects, or other reproductive harm.

▲ WARNING!

▲ CAUTION!Use a backup wrench on the Gas Valve when installinggas piping to prevent damage to the Gas Valve andManifold Assembly.

The installation of piping shall be in accordance withpiping codes and the regulations of the local gas com-pany. Pipe joint compound must be resistant to thechemical reaction with liquefied petroleum gases.Refer to piping Table 6, for delivery sizes. Connect gassupply to the unit, using a ground joint union and amanual shut-off Valve as shown in Figure 31. Nationalcodes require a condensation drip leg to be installedahead of the controls as shown in Figures 31 & 32.The Furnace and its individual shut-off valve must bedisconnected from the gas supply piping system duringany pressure testing of that system at test pressures inexcess of 1/2 psig (3.5 kPa).The Furnace must be isolated from the gas supply pip-ing by closing its individual manual shut-off Valve dur-ing any pressure testing of the gas supply piping systemat test pressures equal to or less than 1/2 psig (3.5 kPa).

NOTE: Maximum pressure to the Gas Valve for naturalgas is 13.8" W.C. Minimum pressure is 5.0" W.C. Maxi-mum 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 soapysolution before lighting the Furnace. DO NOT CHECKWITH AN OPEN FLAME!

▲ WARNING!EXPLOSION HAZARD!PROPANE GAS IS HEAVIER THAN AIR AND MAYCOLLECT IN ANY LOW AREAS OR CONFINEDSPACES. IF THE GAS FURNACE IS INSTALLED IN ABASEMENT, AN EXCAVATED AREA OR A CONFINEDSPACE, IT IS STRONGLY RECOMMENDED TO CON-TACT A GAS SUPPLIER TO INSTALL A GAS DETECT-ING WARNING DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOT testany detectors and makes no representations regardingany brand or type of detector.

▲ WARNING!EXPLOSION HAZARD!ODORANT FADE MAY MAKE THE GAS UNDETECT-ABLE EXCEPT WITH A WARNING DEVICE. IF THEGAS FURNACE IS INSTALLED IN A BASEMENT, ANEXCAVATED AREA OR A CONFINED SPACE, IT ISSTRONGLY RECOMMENDED TO CONTACT A GASSUPPLIER TO INSTALL A GAS DETECTING WARN-ING DEVICE IN CASE OF A GAS LEAK.

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GASFOR VARIOUS PIPE SIZES AND LENGTHS

PIPESIZE

LENGTH OF PIPE

10 20 30 40 50 60 70

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

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

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

ORIFICE SIZES

INPUTRATINGBTUH

NUMBEROF

BURNERS

MAIN BURNER ORIFICEDRILL SIZE

NAT. GAS LP GAS

60,00080,000100,000120,000

3456

45454545

56565656

NOTE: The manufacturer of your furnace does not testany detectors and makes no representations regardingany brand or type of detector.

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Installer’s Guide

UPFLOW MAY BE LEFT ORRIGHT HAND GAS PIPING

AUTOMATIC GAS VALVEWITH MANUAL SHUTOFF

MAIN MANUALSHUTOFF VALVE

GROUNDUNIONJOINT

DRIPLEG

AUTOMATIC GAS VALVEWITH MANUAL SHUTOFF

MAIN MANUALSHUTOFF VALVE

GROUNDUNIONJOINT

DRIPLEG

Figure 30

MAIN MANUALSHUTOFF VALVE

GROUND UNION JOINTAUTOMATIC GAS VALVEWITH MANUAL SHUTOFF

MAIN MANUALSHUTOFF VALVE

GROUNDUNION JOINT

DRIPLEG

DRIPLEG

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE(Typical UPFLOW Furnace in horizontal configuration shown)

AUTOMATIC GAS VALVE WITHMANUAL SHUTOFF

Figure 31

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18-CD25D1-2 33

Installer’s GuideCOMBUSTION AND INPUT CHECK(See also High Altitude Derate)

▲ WARNING!Replace and/ or tighten all plugs removed or loosenedwhen adjusting gas pressure. Leak check the fittingsbefore placing the Furnace into regular service.Failure to follow this warning could result in fire, ex-plosion, property damage, or death.

1. Make sure all gas appliances are off except the Fur-nace.

2. Clock the gas meter with the Furnace operating(determine the dial rating of the meter) for onerevolution.

3. Match the “Sec” column in the gas flow (in cfh)Table 8 with the time clocked.

4. Read the “Flow” column opposite the number of sec-onds clocked.

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

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

Chart Flow Reading ÷4For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading ÷46. Multiply the final figure by the heating value of the

gas obtained from the utility company and compareto the nameplate rating. This must not exceed thenameplate rating.

7. Changes can be made by adjusting the ManifoldPressure (See Table 9), or changing orifices (orificechange may not always be required). To adjust theManifold 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” onWhite-Rodgers gas valve model 36G. (see Fig-ure 33 for White-Rodgers gas valve model 36G).Attach flexible tubing and a Manometer to thebarbed fitting. For the Gas Valve model 36G, donot remove the pressure tap test screw.Loosen the pressure tap test screw one turnand install flexible tubing and a Manometer di-rectly onto the outlet pressure boss.

c. The other side of the Manifold Pressure Gaugemust be referenced to the Burner Box as shownin Figure 32.

d. Turn on system power and energize Valve.e. For the White-Rodgers Gas Valve model 36G:

1. Adjust low fire by removing the low adjust-ment regulator cover screw (See Figure33).

2. To increase outlet pressure, turn the regu-lator adjust screw clockwise. To decreaseoutlet pressure, turn the regulator adjustscrew counter-clockwise. Adjust regulatoruntil pressure shown on Manometermatches the pressure specified in Table 9.

3. Replace and tighten the regulator coverscrew securely.

4. Cycle the Valve several times to verifyregulator setting.

5. Adjust high fire by removing the high ad-justment regulator cover screw (See Figure33).

▲ CAUTION: Return all tubing, caps, and/or plugs to original positions when pressure checks are completed.

Figure 32

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34 18-CD25D1-2

Installer’s Guide6. To increase outlet pressure, turn the regu

lator adjust screw clockwise. To decreaseoutlet pressure, turn the regulator adjustscrew counter-clockwise. The final ManifoldPressure setting shall be as specified inTable 9 with an input of no more thannameplate rating and no less than 93% ofthe nameplate rating, unless the unit is de-rated for high altitude.

7. Replace high adjustment regulator coverscrew and tighten securely.

8. Cycle the Valve several times to verifyregulator setting.

g. Turn off all electrical power to the system.h. Remove the Manometer and flexible tubing.

Remove the barbed fitting and replace the plugor tighten the pressure test screw.

i. Turn on electrical power to the system and en-ergize valve.

j. Using a leak detection solution or soap suds,check for leaks at plug or pressure boss screw.

NOTE: The Manifold Pressure must be referenced tothe Burner Box. The Burner Box pressure tap equalizesthe Gas Valve pressure regulator. Manifold Pressure ischecked by installing a tee (field supplied) in the tub-ing, between the tee coming from the Burner Box tubeand the Gas Valve, in addition to the regular Gas Valvepressure tap on the outlet side of the Gas Valve. SeeFigure 32.

Table 7 lists the main burner orifices used with the Fur-nace. If a change of orifices is required to correct theFurnace input rating refer to Table 10.REINSTALLATION OF THE BURNER BOX COVERFigure 34 shows the correct way to reinstall the BurnerBox cover if adjustment or replacement of the flamesensor, hot surface igniter, or main burner orifices haverequired removal of the cover.HIGH ALTITUDE DERATEInput ratings (BTUH) of these Furnaces are based onsea level operation and should not be changed at eleva-tions up to 2,000 ft.If the installation is 2,000 ft. or above, the Furnace inputrate (BTUH) shall be reduced 4% for each 1,000 ft. abovesea level.Installation of this furnace at altitudes above 2,000 ft.(610m) shall be in accordance with local codes, or in theabsence of local codes, the National Fuel Gas Code,ANSI Z223.1/ NFPA 54 or National Standard ofCanada, Natural Gas and Propane Installation Code,CSA B149.1. Installation of this furnace at altitudesabove 2,000 ft. (610m) shall be made in accordance withthe listed high Altitude Conversion Kit available withthis furnace.

The Furnace input rate shall be checked by clocking thegas flow rate (CFH) and multiplying by the heatingvalue obtained from the local utility supplier for the gasbeing delivered at the installed altitude. Input ratechanges can be made by adjusting the Manifold Pres-sure (min 3.0 - max 3.7 in. W.C. - Natural Gas) orchanging orifices (orifice change may not always be re-quired).If the desired input rate can not be achieved with achange in Manifold Pressure, then the orifices must bechanged. LP installations will require an orifice change.

IMPORTANT:Reinstall the propane orifices to the same depth as the ori-fices supplied with the equipment.

TABLE 8

TABLE 9

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIALSEC. FLOW SEC. FLOW SEC. FLOW SEC. FLOW

8 900 29 248 50 144 82 889 800 30 240 51 141 84 8610 720 31 232 52 138 86 8411 655 32 225 53 136 88 8212 600 33 218 54 133 90 8013 555 34 212 55 131 92 7814 514 35 206 56 129 94 7615 480 36 200 57 126 96 7516 450 37 195 58 124 98 7317 424 38 189 59 122 100 7218 400 39 185 60 120 104 6919 379 40 180 62 116 108 6720 360 41 176 64 112 112 6421 343 42 172 66 109 116 6222 327 43 167 68 106 120 6023 313 44 164 70 103 124 5824 300 45 160 72 100 128 5625 288 46 157 74 97 132 5426 277 47 153 76 95 136 5327 267 48 150 78 92 140 5128 257 49 147 80 90 144 50

FINAL MANIFOLD PRESSURE SETTINGS (inches w.c.)

FUEL 2nd Stage Max. 1st Stage Max.

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

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

See Table 10 for help in selecting orifices if orifice changeis required. Furnace input rate and temperature riseshould be checked again after changing orifices to con-firm the proper rate for the altitude.The vent length table on page 14 shows the requiredvent lengths for installations at various altitudes. An op-tional high altitude kit is available for installationsabove 5000 feet. Installations above 12,000 feet are notallowed.

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Installer’s Guide

LIGHTING INSTRUCTIONS

▲ WARNING!DO NOT ATTEMPT TO MANUALLY LIGHT THE BURNER.FAILURE TO FOLLOW THIS WARNING COULD RESULTIN PROPERTY DAMAGE, PERSONAL INJURY ORDEATH.

▲ CAUTION!If this is done during the cold weather months, provi-sions must be taken to prevent freeze-up of all waterpipes and water receptacles.

Lighting instructions appear on each unit. Each installa-tion must be checked out at the time of initial start up toinsure proper operation of all components. Check outshould include putting the unit through one completecycle as outlined below.

TABLE 11

ROTATE THE FRONTCOVER INWARD MAKINGSURE THAT ALL SIDEFLANGES ARE OUTSIDEOF THE BOX.

INSERT THE TOP FLANGEOF THE FRONT COVERUNDER THE LIP INSIDETHE BOX

ALL SIDE FLANGES MUSTBE OUTSIDE OF THE BOX

ROTATE THE FRONTCOVER AS SHOWN

Figure 34

Figure 33

OrificeTwist Drill

Size IfInstalledAt SeaLevel

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

2000 3000 4000 5000 6000 7000 8000 9000 10000424344454647

424445464748

434445474748

434445474749

434546474849

444547484849

444647484950

454748494950

464748495051

474850505152

5455565758

5455565859

5555565960

5555575960

5556576061

5556576062

5556586162

5656596263

5656596363

5657606364

From National Fuel Gas Code - Table F-4

TABLE 10

Turn the main Gas Valve toggle switch (See Figures 30& 31) within the unit to the “OFF” position. Turn the ex-ternal gas valve to “ON”. Purge the air from the gaslines. After purging, check all gas connections for leakswith a soapy solution -- DO NOT CHECK WITH ANOPEN FLAME. Allow 5 minutes for any gas that mighthave escaped to dissipate.LP Gas being heavier than air may require forced ventila-tion. Turn the toggle switch on the Gas Valve in the unitto the “ON” position.

START-UP AND ADJUSTMENTPRELIMINARY INSPECTIONS

▲ WARNING!Disconnect power to the unit before removing theblower door. Allow a minimum of 15 seconds for IFCpower supply to discharge to 0 volts.Failure to follow this warning could result in propertydamage, personal injury or death.

With gas and electrical power “OFF”1. Duct connections are properly sealed2. Air cleaner and filters(if applicable) are in place3. Venting is properly assembled4. Blower door is in place

PART NUMBERS FOR REPLACEMENT ORIFICESDRILLSIZE

PARTNUMBER

DRILLSIZE

PARTNUMBER

44454647484950

ORF00501ORF00644ORF00909ORF00910ORF01099ORF00503ORF00493

545556575859

ORF00555ORF00693ORF00907ORF00908ORF01338ORF01339

2nd Stage (HI) ManifoldPressure Adjustment

Gas Valve On / OffToggle Switch

1st Stage (LO)Manifold PressureAdjustment

White-Rodgers 36G

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Installer’s GuideTurn on the main electrical supply and set the ComfortControl above the indicated temperature. The ignitorwill automatically heat, then the Gas Valve is energizedto permit the flow of gas to the burners. After ignitionand flame is established, the flame control modulemonitors the flame and supplies power to the Gas Valveuntil the Comfort Control is satisfied.To shut off.For complete shutdown: Turn the gas cock knob on themain Gas Valve to the “OFF” position (See Figures 30 &31). Disconnect the electrical supply to the unit.

SEQUENCE OF OPERATION

NOTE: Whole House Air Cleaner is energized whenblower is operating and there is a call for heat or cool.This can result in brief periods of blower operationwith the whole house air cleaner off. This can occurduring the heat fan off period or if the enhancedmode of operation is chosen for cooling.

Comfort Control call for heat (2-Stage Comfort Control)Call for 1st Stage only:W1 Comfort Control contacts close signaling the controlmodule to run its self-check routine. After the controlmodule has verified that the 1st Stage Pressure Switchcontacts are open and the Limit Switch(es) contacts areclosed, the draft blower will be energized.As the induced draft blower comes up to speed, thePressure Switch contacts will close and the ignitorwarm up period will begin. The ignitor will heat forapprox. 20 seconds, then the Gas Valve is energized in1st Stage to permit gas flow to the burners.The flame sensor confirms that ignition has beenachieved within the 4 second ignition trial period.As the flame sensor confirms that ignition has beenachieved, the delay to fan ON period begins timing andafter approx. 45 seconds the indoor blower motor will beenergized at low speed and will continue to run duringthe heating cycle. The whole house air cleaner will en-ergize.Call for 2nd Stage after 1st Stage:W2 Comfort Control contacts close signaling a call for2nd Stage Heat. After a 30 second delay, the induceddraft blower will be energized on high speed and the2nd Stage Pressure Switch contacts will close. The GasValve is energized in 2nd Stage and the indoor blowermotor in high speed.2nd Stage satisfied, 1st Stage still called:W2 Comfort Control contacts open signaling that 2ndStage Heating requirements are satisfied.The induced draft blower is reduced to low speed allow-ing the 2nd Stage Pressure Switch contacts to open andthe Gas Valve is reduced to 1st Stage. The indoorblower motor is reduced to low speed.

1st stage satisfied:W1 Comfort Control contacts open signaling that 1stStage heating requirements are satisfied. The GasValve will close and the induced draft blower and thewhole house air cleaner will be de-energized. The in-door blower motor will continue to run for the fan offperiod (Field selectable at 60, 100, 140 or 180 seconds),then will be de-energized by the control module.Comfort Control call for heat (1-Stage ComfortControl)W1/ W2 (jumpered) Comfort Control contacts close sig-naling a call for heat. 1st Stage sequence of operationremains the same as above. 2nd Stage Heat will ener-gize after the Stage delay timer (10 minutes) has ex-pired.Comfort Control satisfied:W1/ W2 (jumpered) contacts close signaling the controlmodule to close the Gas Valve. The induced draft bloweris switched to low speed and de-energized after the postpurge timer has expired. The indoor blower motor willcontinue to operate after the flames are extinguishedand then is switched to low heat speed for the FAN-OFF period. The whole house air cleaner will be de-en-ergized.

NOTE TO INSTALLER:Review warnings and the contents of USER’S INFOR-MATION MANUAL with the homeowner when installa-tion is complete and equipment is ready to be turnedover to the homeowner for normal operation.

CONTROL AND SAFETY SWITCHADJUSTMENTLIMIT SWITCH CHECK OUTThe limit switch is a safety device designed to close theGas Valve should the Furnace become overheated.Since proper operation of this switch is important to thesafety of the unit, it must be checked out on initialstart up by the installer.To check for proper operation of the Limit Switches, setthe Comfort Control to a temperature higher than theindicated temperature to bring on the Gas Valve. Re-strict the airflow by blocking the return air or by dis-connecting the blower. When the Furnace reaches themaximum outlet temperature as shown on the ratingplate, the burners must shut off. If they do not shut offafter a reasonable time and overheating is evident, afaulty Limit Switch is probable and the Limit Switchmust be replaced. After checking the operation of theLimit Control, be sure to remove the paper or card-board from the return air inlet, or reconnect theblower. Refer to the Service Facts for additional instruc-tions.

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Installer’s Guide

This unit is equipped with a blower door switch whichcuts power to the blower and Gas Valve causing shut-down when the door is removed.ROOM AIR COMFORT CONTROLHEAT ANTICIPATOR ADJUSTMENTSet the Comfort Control heat anticipator according tothe current flow measured, or the settings found in thenotes on the Furnace wiring diagram (found in the SER-VICE FACTS or inside the furnace casing).INSTRUCTIONS TO THE OWNERSIn the event that electrical, fuel, or mechanicalfailures occur, the owner should immediatelyturn the gas supply off at the manual Gas Valve,located in the burner compartment. Also turn offelectrical power to the Furnace and contact aqualified service technician.BURNER BOX TEMPERATURE LIMIT DEVICEAll models are equipped with a manual reset tempera-ture limit located on the Burner Box. In case of exces-sive temperature, the limit will open and cause the cir-cuit to open which shuts off all flow of gas.

INDOOR BLOWER TIMING

▲ WARNING!DISCONNECT POWER TO THE UNIT BEFORE REMOV-ING THE BLOWER DOOR.FAILURE TO FOLLOW THIS WARNING COULD RESULTIN PROPERTY DAMAGE, PERSONAL INJURY ORDEATH.

Heating: The Integrated Furnace Control (IFC) con-trols the Variable Speed Indoor Blower. The blower “on”time is fixed at 45 seconds after ignition. The FAN-OFFperiod is field selectable by dip switches #1 and #2 lo-cated on the Integrated Furnace Control between the 5-pin and 9-pin wire connectors. The delay may be set at60, 100, 140, or 180 seconds. The factory setting is 100seconds (See unit wiring diagram).Cooling: The fan delay-off period is set by dip switcheson the Integrated Furnace Control. The options forcooling delay off is field selectable by dip switches #5and #6.The following table and graph explain the delay-off set-tings:

AIRFLOW ADJUSTMENT

▲ WARNING!Disconnect power to the unit before removing theblower door. Allow a minimum of 15 seconds for IFCpower supply to discharge to 0 volts.Failure to follow this warning could result in propertydamage, personal injury or death.

▲ WARNING!Operation with the door removed or ajar can permit theescape of dangerous fumes. All panels must be se-curely closed at all times for safe operation of the Fur-nace.Failure to follow this warning could result in propertydamage, personal injury or death.

Check inlet and outlet air temperatures to make surethey are within the ranges specified on the Furnace rat-ing nameplate. If the airflow needs to be increased ordecreased, see the Service Facts for information onchanging the speed of the blower motor.

This unit is equipped with a blower door switch whichcuts power to the blower and Gas Valve causing shut-down when the door is removed. Operation with thedoor removed or ajar can permit the escape of danger-ous fumes. All panels must be securely closed at alltimes for safe operation of the Furnace.* - This setting is equivalent to BAY24X045 relay ben-

efit.** - This selection provides ENHANCED MODE, which

is a ramping up and ramping down of the blowerspeed to provide improved comfort, quietness, andpotential energy savings. See Wiring Diagramnotes on the unit or in the Service Facts for com-plete wiring setup for ENHANCED MODE. Thegraph which follows, shows the ramping process.

See Wiring Diagram on the unit or in the Service Factsfor complete wiring setup for Enhanced Mode.

1

minute

3

minutes

7.5

minutes

OFF

50%50%

80%

Dehumidify

EfficiencyFast Cooling

100% if necessary

OFF

TABLE 12 FAN OFF - DELAY OPTIONS

SWITCH SETTINGS SELECTION NOMINALAIRFLOW

5 - OFF 6 - OFF NONE SAME

5 - ON 6 - OFF 1.5 MINUTES 100% *

5 - OFF 6 - ON 3 MINUTES 50%

5 - ON 6 - ON EnhancedMode** 50 - 100%

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38 18-CD25D1-2

Installer’s GuideCONDITIONS THAT AFFECT SYSTEM OPERATION

1. EXCESSIVE COMBUSTION PRESSURE (WIND INEXCESS OF 40 M.P.H.) VENT OR FLUE BLOCKAGEOn a call for heat, the Variable Speed Draft Inducermust first ramp up to speed and close the PressureSwitch before the ignition sequence is allowed to be-gin. If the Pressure Switch does not close, the motorwill ramp up to maximum speed and continue to op-erate there for about 1 minute.After one minute, the Integrated Furnace Controlwill turn the motor off for about 30 seconds andthen back on in an attempt to reestablish proper op-eration. This condition is indicative of a highly re-stricted or blocked inlet or outlet vent pipe or afailed Pressure Switch.If pressure against induced draft blower outlet be-comes excessive, the Pressure Switch will open. Ifthe Pressure Switch is open for more than 3.5 sec-onds, the variable speed draft inducer will speed upand attempt to close the Pressure Switch. If thePressure Switch is not closed within 12 seconds orif the maximum speed of the motor is reached, thedraft inducer sends a Fault signal to the IntegratedFurnace Control. If the unit is operating in SecondStage, an Inducer Fault will cause the FurnaceControl to transition the system to First Stage andit will operate there for 10 minutes before attempt-ing to run again in Second Stage. If the unit is oper-ating in First Stage, an Inducer Fault will cause theFurnace Control to shut the system down and wait30 seconds before attempting to reestablish opera-tion in First Stage.

2. LOSS OF FLAMEIf loss of flame occurs during a heating cycle, orflame is not present at the sensor, the flame controlmodule will close the Gas Valve. The IntegratedFurnace Control will then recycle the ignition se-quence, then if ignition is not achieved, it will shutoff the Gas Valve and lock out the system.

3. POWER FAILUREIf there is a power failure during a heating cycle,the system will restart the ignition sequence auto-matically when power is restored, if the ComfortControl still calls for heat.

4. GAS SUPPLY FAILUREIf loss of flame occurs during a heating cycle, thesystem Integrated Control Module will recycle the ig-nition sequence, then if ignition is not achieved, theIntegrated Control Module will shut off the GasValve and lock out the system.

5. INDUCED DRAFT BLOWER FAILUREPlease refer to the Variable Speed Draft Inducertroubleshooting manual for diagnostic assistance.

6. CONDENSATE DRAIN BLOCKAGEIf the condensate drain is blocked, either by debris,improper draining, or by freezing condensate, thePressure Switch will sense the accumulation of con-densate in the Furnace drain trap. The unit will notoperate properly until the condensate drain hasbeen cleared, and the condensate flows freely.

7. RESET AFTER LOCKOUTWhen the Integrated Furnace Control has shut thesystem down and gone into lockout, the systemmust be manually reset before the unit will restart.The system can be reset by turning the systempower off for more than 1 second, or by removing24VAC from the control for more than 1 second, orby removing the Comfort Control call for heat formore than 1 second but less than 20 seconds.

8. RESET AFTER BURNER BOX LIMIT SHUTDOWNIf the Furnace shuts down, one thing that can bechecked is the Burner Box temperature LimitSwitch. It is located on the bottom of the BurnerBox. The vent and combustion air inlet termina-tions should be checked for blockage. If blockage ex-ists, clear the problem and then the reset buttonmay be depressed. If there is no blockage of the ter-minations, the Limit Switch must be reset by quali-fied service personnel.

WHOLE HOUSE AIR CLEANER CHECKOUT

▲ CAUTION!Before changing the position of the High Voltage se-lector switch on the High Voltage power supply,make sure the power has been removed from the fur-nace and the High Voltage power supply.

Check out the Furnace Whole House Air Cleaner instal-lation in accordance with this instructions page 40. Ad-just ozone setting if needed. See figure 38 on page 40.

NOTE: Whole House Air Cleaner is energized whenblower is operating and there is a call for heat or cool.This can result in brief periods of blower operationwith the whole house air cleaner off. This can occurduring the heat fan off period or if the enhancedmode of operation is chosen for cooling.

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Installer’s GuideCLEANING THE COLLECTION CELL1. Turn the air conditioning system off at the Comfort

Control and turn off service disconnect.2. Remove top furnace door.3. Slide COLLECTION CELL out of Furnace.

CLEANINGThe COLLECTION CELL may be cleaned either byvacuuming (recommended method) or by washing.

VACUUM CLEANINGRemove the COLLECTION CELL from the condi-tioned space before vacuuming. Vacuum both sides ofthe COLLECTION CELL to clean.

WASHINGUse low-pressure water spray, such as a sink sprayeror garden hose to clean the COLLECTION CELL.Some residue may require warm water to be re-moved.

• Do NOT use soap or detergent in cleaningthe COLLECTION CELL.

• Do NOT immerse the COLLECTION CELLcompletely in water.

• Do NOT place the COLLECTION CELL intoa dishwasher to clean.

• ALLOW THE COLLECTION CELL TO DRYTHOROUGHLY BEFORE REINSTALLING.

Slightly tap the COLLECTION CELL to remove wa-ter retained in the filter. Allow the COLLECTIONCELL to dry thoroughly before reinstalling.

CLEANING THE FIELD CHARGER

▲ CAUTION!FIELD CHARGER PINS ARE SHARP. DO NOT BENDFIELD CHARGER PINS. WEAR APPROPRIATE GLOVESWHEN HANDLING THE FIELD CHARGER.

1. Turn off the Comfort Control and the service dis-connect.

2. Turn off power to the Furnace and remove the topfurnace door panel.

3. Remove COLLECTION CELL.4. Remove the inner blower door panel by removing

four screws.5. Disconnect green return wire and red high voltage

wire. To remove high voltage wire, twist and pullconnecter apart.

6. Remove the two 5/16" hold down screws at the frontcenter.

7. Lift up the front of the FIELD CHARGER and slideforward to remove from the case. Lay the FIELDCHARGER on a secured flat surface.

8. Wipe down the face Plate of the FIELD CHARGERwith a dry shop towel or use a vacuum cleaner. Donot disassemble the FIELD CHARGER.

WHOLE HOUSE AIR CLEANERMAINTENANCE1. For maximum efficiency the COLLECTION CELL

should be inspected and cleaned on a regular basis.

NOTE: A 30 to 90 day cleaning interval is normalfor the COLLECTION CELL and should be ad-justed based upon unit run time and the homeenvironment.

2. The FIELD CHARGER must be removed andcleaned only by a qualified service professional.

3. The FIELD CHARGER must be cleaned at least oncea year.

4. The FIELD CHARGER may require more frequentcleaning in homes with high indoor relative humid-ity (greater than 65% RH).

5. Consult your service professional about cleaningintervals.

▲ WARNING!TO PREVENT INJURY OR DEATH DUE TO CONTACTWITH MOVING PARTS, TURN THE POWER TO THEFURNACE OFF BEFORE CLEANING OR SERVICINGTHE WHOLE HOUSE AIR CLEANER.FAILURE TO FOLLOW THIS WARNING COULD RE-SULT IN PROPERTY DAMAGE, PERSONAL INJURYOR DEATH.

▲ WARNING!RISK OF ELECTRIC SHOCK:THESE SERVICING INSTRUCTIONS ARE FOR USEBY QUALIFIED PERSONNEL ONLY. TO REDUCETHE RISK OF ELECTRIC SHOCK, DO NOT PERFORMANY SERVICING OTHER THAN THAT CONTAINED INTHESE OPERATING INSTRUCTIONS UNLESS YOUARE QUALIFIED TO DO SO.FAILURE TO FOLLOW THIS WARNING COULD RE-SULT IN PROPERTY DAMAGE, PERSONAL INJURYOR DEATH.

▲ CAUTION!High Voltage is present within the air cleaner for opera-tion. Turn the power off and wait at least 15 seconds toallow voltage to discharge.

NOTE: System InformationBefore cleaning the coil or ducts in the furnace, re-move the COLLECTION CELL and FIELD CHARGERfrom the air cleaner. Chemicals used during thecleaning of the Furnace, or ductwork can damage theair cleaner components and degrade the perfor-mance of the air cleaner.

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Installer’s Guide

IFC Error Flash Codes

9. To clean pins, push a block of foam down over theFIELD CHARGER Pin.

10. Rotate the foam block on the FIELD CHARGERPin.

11. Use the foam block to clean the faceplate openingedges.

12. Repeat steps 9 and 10 for each FIELD CHARGERPin.

13. Reverse steps to reassemble the air cleaner. Theinner blower door MUST be reinstalled.

NOTE: Do NOT use water, soap, detergent, or chemi-cals to clean the FIELD CHARGER.

Figure 35

Figure 36

INDOOR MOTOR MAINTENANCE

NOTE: Direct drive motors have bearings which arepermanently lubricated and under normal use, lubri-cation is not recommended.

ROOM AIR COMFORT CONTROLHEAT ANTICIPATOR ADJUSTMENTSet the Comfort Control heat anticipator according tothe current flow measured, or the settings found in thenotes on the Furnace wiring diagram (found inside theFurnace casing).Also turn off electrical power to the Furnace andcontact the service agency designated by yourdealer.

▲ WARNING!Should overheating occur, or the gas supply fail toshut off, shut off the Gas Valve to the unit before shut-ting off the electrical supply.Failure to follow this warning could result in propertydamage, personal injury, or death.

Failure to follow safety warnings exactly, could result in a fire or explosion causing property damage, personal injury or loss of life.

— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

— Installation and service must be performed by a qualified installer, service agency or the gas supplier.

▲ WARNING!

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Installer’s Guide

INTEGRATED FURNACE CONTROL RED LED "ERROR" FLASH CODES2 Flashes --- System Lockout (Retries or Recycles exceeded)

3 Flashes ---

Draft Pressure Error - Possible problems: a) Venting problem b) Pressure switch problem c) Inducer problem

4 Flashes --- Open Temperature Limit Switch5 Flashes --- Flame sensed when no flame should be present

6 Flashes --- 115 volt AC power reversed, ignitor (Triac) fault, poor grounding orsystem voltage too low

7 Flashes --- Gas valve circuit error8 Flashes --- Low flame sense9 Flashes --- Open Inducer Limit switch10 Flashes --- Inducer communication errorSolid --- Internal GV error or Low TH voltageSolid Red w/SolidGreen "STATUS" LED Continuous Reset caused by a blown fuse or internal error.

▲ WARNING!

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

This product contains fiberglass wool insulation!

Fiberglass dust and ceramic fibers are believed by the State of California to cause cancer through inhalation. Glasswool fibers may also cause respiratory, skin, or eye irritation.

PRECAUTIONARY MEASURES

● Avoid breathing fiberglass dust.

● Use a NIOSH approved dust/mist respirator.

● Avoid contact with the skin or eyes. Wear long-sleeved, loose-fitting clothing, gloves, and eye protection.

● Wash clothes separately from other clothing: rinse washer thoroughly.

● Operations such as sawing, blowing, tear-out, and spraying may generate fiber concentrations requiring additional respiratory protection. Use the appropriate NIOSH approved respirator in these situations.

FIRST AID MEASURES

Eye Contact – Flush eyes with water to remove dust. If symptoms persist, seek medical attention.

Skin Contact – Wash affected areas gently with soap and warm water after handling.

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Installer’s GuideFAULT CODE RECOVERYOn power up, last 4 Faults, if any, will be flashed on theRed LED. The newest Fault detected will flash first andthe oldest last. There will be a 2 second delay betweenFault Code flashes. Solid Red LED error codes will notbe displayed.The Green LED will be on solid during last Fault Re-covery. At any other time the control is powered, theGreen LED indicator light will operate as shown inTable 13 and the Red LED will flash LitePort data (oneflash) every 20 seconds.

TABLE 13

*UX2/ DX2 Integrated Furnace Control

Figure 37

Red LitePortTM LEDGreen Status LED

NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GASFOR VARIOUS PIPE SIZES AND LENGTHS

PIPESIZE

LENGTH OF PIPE

10 20 30 40 50 60 70

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

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

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

Fault Code ResetThe last 4 Fault Codes can be erased from memory bypowering up the control with "G" energized and then ap-plying "R" to the "W1" terminal 3 times within 6 sec-onds. The control will acknowledge the reset by turningon the Red LED for 2 seconds.

NOTE: In normal operation, the furnace makes a slightsound as the air passes through and is cleaned. Insome applications, you may notice this sound comingfrom the return air vent(s). If desired, this sound levelcan be reduced with minimal impact on air cleaning ef-ficiency by reducing the power setting of the FIELDCHARGER. The unit is shipped with the power set at9.6KV (high). If sound is heard, reduce power level to8.0KV (low) at the switch on the power supply. See Fig-ure 38.

LED

High Voltage switch9.6 to 8.0 KVDC

Return from air cleaner

High voltage power lead

24 VAC Hot

24 VAC Common

Green

Pink

Red

Blue

9.6 KVDC is top down |\8.0 KVDC is bottom down |/

Figure 38

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Installer’s GuideCHECKOUT PROCEDURES

After installation has been completed, it is recommended that the Furnace be checked against the followingchecklist.

1. Make sure power is “OFF” at powerdisconnect switch ............................................... [ ]

2. Check all field wiring for tight connections.See that grounding of unit is in accord with code............................................................................ [ ]

3. Make sure unit suspension (if used) is secureand that there are no tools or loose debris in,around or on top of the unit .............................. [ ]

4. Check all duct outlets; they must be openand unrestricted ................................................ [ ]

5. Check drain lines and be sure all joints are tight ............................................................................. [ ]

6. Make sure secondary drain pan is installed ..... [ ]7. Check power supply for correct requirements

per unit nameplate ............................................ [ ]8. Energize the system and carefully observe

its operation; make any necessary adjustment [ ]9. Adjust ozone setting, if needed ......................... [ ]

10. Instruct owner on proper operating procedure andleave Use and Care Manual with owner .......... [ ]

11. Check the Whole House Air Cleaner power outputby the Green LED illumination. If the LED is on,this indicates High Voltage output to the aircleaner. .............................................................. [ ]a) Turn the Comfort Control to fan only.b) Remove blower door panel.

▲ WARNING!RISK OF ELECTRICAL SHOCK:ELECTRICAL POWER IS PRESENT FOR THENEXT 2 STEPS. THESE STEPS SHOULD BEPERFORMED ONLY BY QUALIFIED PERSON-NEL.FAILURE TO FOLLOW THIS WARNING COULDRESULT IN PERSONAL INJURY, ELECTRICALSHOCK, OR DEATH.

c) Depress blower door switch.d) Verify with Fan running that Green LED is il-

luminated.e) Release Blower Door Switch and put Blower

Door back on.f) Turn Comfort Control to desired position.

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3/08

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

Trane6200 Troup HighwayTyler, TX 75707

For more information contactyour local dealer (distributor)

Literature Order Number 18-CD25D1-2

File Number 18-CD25D1-2

Supersedes 18-CD25D1-1

Date 03/08