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IIIIIIIIIIIIIIIIIIIIIIIIIIII1 8- CD1 9 D2- 1 8
Available in French Canadian (FC)
Upflow / Horizontal and Downflow / HorizontalGas-Fired Furnaces, 2 - Stage,"Fan Assisted Combustion System"*UD2A040A9242A*UD2B080A9362A*UD2C100A9482A*UD2C120A9542A*DD2A040A9242A*DD2B080A9362A*DD2C100A9602A
*UD2A060A9362A*UD2B080A9482A*UD2C100A9602A*UD2D120A9602A*DD2A060A9362A*DD2B100A9482A*DD2D120A9602A
*UD2B060A9362A*UD2B100A9362A*UD2D100A9602A*UD2D140A9602A*DD2B060A9362A*DD2C100A9482A*DD22D140A602A
* First letter may be "A" or "T"
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT -- This Document is customer property and is to remain with this unit.Please return to service information pack upon completion of work.
For VENT SIZING INFORMATION see:USA --
National Fuel Gas Code ........ ANSI Z223.1/NFPA 54 latest version)
CANADA --Natural Gas Installation Code ..... CAN/CGA-B149.1 latest version)
Propane Installation Code ............ CAN/CGA-B149.2 latest version)
USA/CANADA ALTERNATE --
Category I Venting Guide ................................. Pub. No. 18-CH23D1-2
Upflow / Horizontal* Downflow / Horizontal*
*Horizontal Conversion for these furnaces may be left or right side rotation.
A341789P02
Installer's Guide SAFETYSECTIONThe following safety practices and precautions must befollowed during the installation, servicing, and operation ofthis furnace.
1. Use only with the type of gas approved for this furnace.Refer to the furnace rating plate.
2. Install this furnace only in a location and position asspecified in "Location and Clearances" (page 3), of theseinstructions.
3. Provide adequate combustion and ventilation air to thefurnace space as specified in "Air for Combustion andVentilation" (pages 7-8), of these instructions.
4. Combustion products must be discharged outdoors.Connect this furnace to an approved vent system only, asspecified in the "Venting" section (pages 13-14), of theseinstructions.
5. Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections, asspecified in "Gas Piping" (page 19), of theseinstructions.
6.
7.
8.
9.
10.
Always install the furnace to operate within the furnace'sintended temperature-rise range with a duct systemwhich has an external static pressure within the allow-able range, as specified on the unit rating plate. Airflowwith temperature rise for cfm versus static is shown inthe Service Facts accompanying this furnace.
When a furnace is installed so that supply ducts carry aircirculated by the furnace to areas outside the spacecontaining the furnace, the return air shall also behandled by a duct(s) sealed to the furnace casing andterminating outside the space containing the furnace.
A gas-fired furnace for installation in a residentialgarage must be installed as specified in "Location andClearances" section (page 3), of these instructions.
The furnace may be used for temporary heating ofbuildings or structures under construction only when thefollowing conditions have been met:
a. The furnace venting system must be complete andinstalled per manufacturers instructions.
b. The furnace is controlled only by a room thermostat(no field jumpers).
c. The furnace return air duct must be complete andsealed to the furnace and clean air filters are in place.
d. The furnace input rate and temperature rise must beverified to be within nameplate marking.
e. 100% of the furnace combustion air requirementmust come from outside the structure.
f. The furnace return air temperature range is between55 and 80 degrees Fahrenheit.
g. Clean the furnace, duct work, and components uponsubstantial completion of the construction process, andverify furnace operating conditions including ignition,input rate, temperature rise and venting, according to themanufacturer's instructions.
This product must be gas piped by a Licensed Plumber or IGas Fitter in the Commonwealth of Massachusetts. I
Safety signal words are used to designate a degree or level ofseriousness associated with a particular hazard. The signalwords for safety markings are WARNING and CAUTION.
a. WARNING indicates a potentially hazardous situationwhich, if not avoided, could result in death or seriousinjury.
b. CAUTION indicates a potentially hazardous situationwhich, if not avoided, may result in minor or moderateinjury. It is also used to alert against unsafe practicesand hazards involving only property damage.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for eachappliance connected to the venting system beingplaced into operation could result in carbon monoxidepoisoning or death.
The following steps shall be followed for each applianceconnected to the venting system being placed intooperation, while all other appliances connected to theventing system are not in operation:
1.
2.
Seal any unused openings in the venting system.
Inspect the venting system for proper size andhorizontal pitch, as required in the National Fuel GasCode, ANSI Z223.1/NFPA 54 or the CAN/CGA B149Installation Codes and these instructions. Determinethat there is no blockage or restriction, leakage,corrosion and other deficiencies which could cause anunsafe condition.
3. As far as practical, close all building doors andwindows and all doors between the space in which theappliance(s) connected to the venting system arelocated and other deficiencies which could cause anunsafe condition.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance notconnected to the venting system. Turn on any exhaustfans, such as range hoods and bathroom exhausts, sothey are operating at maximum speed. Do not operatea summer exhaust fan.
6.
7.
Follow the lighting instructions. Place the appliancebeing inspected into operation. Adjust the thermostatso appliance is operating continuously.
If improper venting is observed during any of the abovetests, the venting system must be corrected inaccordance with the National Fuel Gas Code,ANSI Z221.1/NFPA 54 and/or CAN/CGA B149Installation Codes.
8. After it has been determined that each applianceconnected to the venting system properly vents wheretested as outlined above, return doors, windows,exhaust fans, fireplace dampers and any other gas-firedburning appliance to their previous conditions of use.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result inserious injury, death or property damage.
Improper servicing could result in dangerous operation,serious injury, death, or property damage.
© 2008 Trane All Rights Reserved 1 8-CD1 9D2-1 8
GENERAL INSTALLATION INSTRUCTIONSThe manufacturer assumes no responsibility for equipmentinstalled in violation of any code or regulation.
It is recommended that Manual J of the Air ConditioningContractors Association (ACCA) or A.R.I. 230 be followed inestimating heating requirements. When estimating heatingrequirements for installation at Altitudes above 2000 ft.,remember the gas input must be reduced (See GAS INPUTADJUSTMENT).
Material in this shipment has been inspected at thefactory and released to the transportation agencywithout known damage. Inspect exterior of carton forevidence of rough handling in shipment. Unpackcarefully after moving equipment to approximatelocation. If damage to contents is found, report thedamage immediately to the delivering agency.
Codes and local utility requirements governing the installa-tion of gas fired equipment, wiring, plumbing, and flueconnections must be adhered to. In the absence of local codes,the installation must conform with latest edition of theNational Fuel Gas Code ANSI Z223.1 • National InstallationCode, CAN/CGA B149.1. The latest code may be obtainedfrom the American Gas Association Laboratories, 400 N.Capitol St. NW, Washington D.C. 20001.1-800-699-9277 or www.aga.org
These furnaces have been classified as Fan AssistedCombustion system CATEGORY I furnaces as required byANSI Z21.47 "latest edition" and CAN/CGA 2.3. Therefore
they do not require any special provisions for venting otherthan what is indicated in these instructions. (Category Idefined on page 13).
These furnaces may be twinned. They shall havecommon returns with equal pressure drops or ductswith equivalent lengths and sizes. See Field WiringDiagrams for Twinning on page 16 for proper hookup.
To prevent shortening its service life, the furnace should notbe used as a "Construction Heater" during the finishingphases of construction until the requirements listed in item9, a-g of the safety section of this publication have been met.Condensate in the presence of chlorides and fluorides frompaint, varnish, stains, adhesives, cleaning compounds, andcement create a corrosive condition which may cause rapiddeterioration of the heat exchanger.
These furnaces are not approved or intended for installationin manufactured (mobile) housing, trailers, or recreationalvehicles. Failure to follow this warning could result inproperty damage, personal injury, or death.
Do not install the furnace in a corrosive or contaminatedatmosphere.
LOCATION AND CLEARANCESThe location of the furnace is normally selected by thearchitect, the builder, or the installer. However, before thefurnace is moved into place, be sure to consider the followingrequirements:
1. Is the location selected as near the chimney or vent andas centralized for heat distribution as practical?
Installer's Guide
ContentsINSTALLATION INSTRUCTIONS
General Installation Instructions
Locations And Clearances
Outline Drawings
Upflow InstallationDownflow Installation
Air For Combustion And Ventilation
Duct Connections
Return Air Filters
Typical Upflow Return Air Filter Installations
Alternate Upflow Filter Clip / Bracket Installation
Typical Downflow Furnace return Air Filter Installations
General Venting Instructions
Venting Into A Masonry ChimneyElectrical Connections
Field Wiring Diagrams
Gas Piping
Sequence Of Operation
Start Up And AdjustmentPreliminary Inspections
Combustion And Input Check
High Altitude Derate
Lighting Instructions
Control And Safety Switch Adjustment
Abnormal Conditions
IFC Error Flash Code
2. Do all clearances between the furnace and enclosureequal or exceed the minimums stated in Clearance Tableon the Outline Drawings.
3. Is there sufficient space for servicing the furnace andother equipment? A minimum of 24 inches front accessi-bility to the furnace must be provided. Any access door orpanel must permit removal of the largest component.
4. Are there at least 3 inches of clearance between thefurnace combustion air openings in the front panel andany closed panel or door provided?
5. Are the ventilation and combustion air openings largeenough and will they remain unobstructed? If outside airis used, are the openings set above the highest snowaccumulation level? (See the Air for Combustion andVentilation section)
6. Allow sufficient height in supply plenum above the furnaceto provide for cooling coil installation, if the cooling coil isnot installed at the time of this furnace installation.
7.
8.
A furnace shall be installed so electrical components areprotected from water.
If the furnace is installed in a residential garage, itmust be installed so that the burners, and the ignitionsource are located not less than 18 inches above the floor
and the furnace must be located or protected to avoidphysical damage from vehicles.
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Installer's GuideUPFLOW INSTALLATION
Standoffs and screws (See Figure 1 on page 6) are includedwith the cased coils for attachment to the furnace. There are
clearance alignment holes near the bottom of the coil wrapperand drill screws are used to engage the furnace top flange.The standoff is inserted into the cabinet alignment hole. Thedrill screws are inserted through the standoffs then screwedinto the furnace flange. The coil is always placed downstreamof the furnace airflow. These instructions apply only if the coilis on top of an upflow furnace.
(_ STANDOFFS (4) DRILL SCREWS (4)
J
FOR VERTICALINSTALLATIONS:
SCREWS(BOTH SIDES)
STANDOFFS(BOTH SIDES)
DOWNFLOW INSTALLATION
Do not install the furnace directly on carpeting, tile or othercombustible material other than wood flooring. For verticaldownflow application, subbase (BAYBASE205) must beused between the furnace and combustible flooring. Whenthe downflow furnace is installed vertically with a cased coil,a subbase is not required.
@ CABINET BIDE _ CABINET SIDE
SUB-BASE _ SUB-BASEFLANGE_ilD_E__ _ FLANGE
{BENT UP) -- (BENT UP)
SUB=BASE _ _ INSULATION --_ SUB*BABE
Required floor opening: (DOWNFLOW)See Figure 3 and Table I
TABLE 1
CABINET RETURN FLOOR OPENING PLENUM OPENINGWIDTH DUCT WIDTH "A .... B .... C .... D"
14-1/2" 13-1/4" 13-5/8" 20-1/8" 12-5/8" 19-3/8"
17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"
21" 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8"
24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8"
HORIZONTAL INSTALLATIONThe coil and furnace must be fully supported when used in thehorizontal position.
Three brackets (with screws) are included with downflowfurnaces for installation to stabilize and secure the furnace andTXC cased coil in the horizontal position. See Figure 4.
©CASED COIL CONNECTIONBRACKET FOR DOWNFLOWFURNACE IN HORIZONTAL
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 the furnaceand the cased coil must be properly supported. The bracketsmount using the rear screws on the coil case and use the screwsprovided to secure the bracket to the furnace. The remainingbracket is placed as close to center as possible (horizontally)between the coil case front and the furnace bottom channel (fordownflow/horizontal furnace). Use four of the screws providedto secure the bracket.
This furnace may be installed in an attic or crawl space in thehorizontal position by placing the furnace on the left or rightside (as viewed from the front in the upright position). Thehorizontal furnace installation in an attic should be on aservice platform large enough to allow for proper clearanceson all sides and service access to the front of the furnace (SeeClearance Table on Outline Drawings and Figure 5).
If the furnace is suspended using perforated steel strap(plumber's strap), it must be supported at all four cornersand in the middle at the front of the furnace.
TYPICAL ATTIC PLATFORM INSTALLATION
(UPFLOW/HORIZONTAL FURNACE SHOWN)
6 18-CD19D2-18
The forward most screw on the side of the furnace may beused to connect the strapping (See Figure 6). Line contact isonly permissible between lines formed by the intersection ofthe top and two sides of the furnace casing and the buildingjoists, studs, or framing.
A cutout is provided on both sides of the downflow furnacecabinet to allow a 90 ° elbow to be attached inside the cabinetand the vent piping to connect there. In horizontal, thedownflow furnace may be vented through the top of thecabinet if needed. In vertical configuration, the downflowfurnace may be vented using the side cabinet cutouts. Thisventing configuration could be used if an electronic air cleaneris installed.
Typical Suspended Installation(Upflow/Horizontal Furnace Shown)
When the downflow furnace is vented through the leftside of the furnace cabinet in horizontal or vertical
configuration, Type B vent pipe must be used within thecabinet.
AIR FOR COMBUSTION AND VENTILATION
Adequate flow of combustion and ventilating air must not beobstructed from reaching the furnace. Air openings providedin the furnace casing must be kept free of obstructions whichrestrict the flow of air. Airfow restrictions affect the efficiencyand safe operation of the furnace. Keep this in mind shouldyou choose to remodel or change the area which contains yourfurnace. Furnaces must have a free flow of air for properperformance.
Provisions for combustion and ventilation air shall be made
in accordance with "latest edition" of Section 5.3, Air forCombustion and Ventilation, of the National Fuel Gas Code,ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149Installation Codes, and applicable provisions of the localbuilding codes. Special conditions created by mechanicalexhausting of air and fireplaces must be considered to avoidunsatisfactory furnace operation.
Furnace locations may be in "confined space" or "unconfinedspace". Unconfined space is defined in Table 2 and Figure 7.These spaces may have adequate air by infiltration to provide
©UNCONFINED
50 CU. FT. OR MOREPER 1000 BTU/HR. INPUTALL EQUIP. INSTALLED
WATER I CLOTHESF_ACE HE;R "DRYER
Installer's Guideair for combustion, ventilation, and dilution of flue gases.Buildings with tight construction (for example, weatherstripping, heavily insulated, caulked, vapor barrier, etc.), mayneed additional air provided as described for confined space.
CONFINED
LESS THAN 50 CU. FT.PER 1000 BTU/HR. INPUTALL EQUIP. INSTALLED
Confined spaces are installations with less than 50 cu. ft. ofspace per 1000 BUT/hr input from all equipment installed.Air for combustion and ventilation requirements can besupplied from inside the building as in Figure 9 or from theoutdoors, as in Figure 10.
1. All air from inside the building as in Figure 9: Theconfined space shall be provided with two permanentopenings communicating directly with an additionalroom(s) of sufficient volume so that the combined volumeof all spaces meets the criteria for an unconfined space.The total input of all gas utilization equipment installedin the combined space shall be considered in malting thisdetermination. Refer to Table 3, for minimum openareas required.
2. All air from outdoors as in Figure 10: The confined spaceshall be provided with two permanent openings, onecommencing within 12 inches of the top and one com-mencing within 12 inches of the bottom of the enclosure.The openings shall communicate directly, or by ducts,with the outdoors or spaces (cram or attic) that freelycommunicate with the outdoors. Refer to Table 3, forminimum open areas required.
3. The following types of installations will require use ofOUTDOOR AIR for combustion, due to chemical exposures:* 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 combustion airsupply will also require OUTDOOR AIR for combustion:* Permanent wave solutions* Chlorinated waxes and cleaners
* Chlorine based swimming pool chemicals* Water softening chemicals* Deicing salts or chemicals* Carbon Tetrachloride
* Halogen type refrigerants* Cleaning solvents (such as perchloroethylene)* Printing inks, paint removers, varnish, etc.* Hydrochloric acid* Cements and glues* Antistatic fabric softeners for clothes dryers* Masonry acid washing materials
18-CD19D2-18 7
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Installer's GuideTABLE 2
MINIMUM AREA IN SQUARE FEET FORUNCONFINED SPACE INSTALLATIONS
FURNACE WITH 8 FOOT CEILINGMAXIMUM BTUH/ MINIMUM AREA IN SQUARE FEET
INPUT RATING OF UNCONFINED SPACE
40,00060,00080,000100,000120,000140,000
250375500625750875
®
CONFINED SPACE
AIR FROM INSIDE BU
®
ICONFINED SPACE
AIR FROM OUTDOORS
./_.///lll////.,-////////.,y/..._
OUTLET l
OUTDOOR
AIR DUCTS
INLET 1
CONFINED SPACE
AIR FROM VENTILATED ATTIC/CRAWL SPACE
ATTIC LOUVERS
TO OUTDOORS
CONFINED- AIR
SPACE
ALTERNATE INLET
INLET AiR _ AIR DUCT
CONFINED SPACE
AIR
TABLE 3
MINIMUM FREE AREA IN SQUARE INCHESEACH OPENING (FURNACE ONLY)
Air From OutsideFurnaceMaximum
BTUH/INPUTRating
40,00060,00080,000100,000120,000140,000
Air FromInside
lOOlOOlOOlOO12o14o
VerticalDuct
lO1520253035
HorizontalDuct
203040506070
DUCT CONNECTIONS
Air duct systems should be installed in accordance withstandards for air conditioning systems, National FireProtection Association Pamphlet No. 90. They should besized in accordance with ACCA Manual D or whichever is
applicable. Check on controls to make certain they are correctfor the electrical supply.
Central furnaces, when used in connection with cooling units,shall be installed in parallel or on the upstream side of thecooling units to avoid condensation in the heating element,unless the furnace has been specifically approved for down-stream installation. With a parallel flow arrangement, thedampers or other means used to control flow of air shall beadequate to prevent chilled air from entering the furnace, andif manually operated, must be equipped with means toprevent operation of either unit unless the damper is in fullheat 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 units havebeen specifically designed for quiet, vibration free operation,air ducts can act as sounding boards and could, if poorlyinstalled, amplify the slightest vibration to the annoyancelevel.
When the furnace is located in a utility room adjacent to theliving area, the system should be carefully designed withreturns which minimize noise transmission through thereturn air grille. Although these winter air conditioners aredesigned with large blowers operating at moderate speeds,any blower moving a high volume of air will produce audiblenoise which could be objectionable when the unit is locatedvery close to a living area. It is often advisable to route thereturn air ducts under the floor or through the attic. Suchdesign permits the installation of air return remote from theliving area (i.e. central hall).
When the furnace is installed so that the supply ducts carryair circulated by the furnace to areas outside the spacecontaining the furnace, the return air shall also be handled bya duct(s) sealed to the furnace and terminating outside thespace containing the furnace.
Minimum return air "entering temperature" for thefurnace is 55 ° F.
Where there is no complete return duct system, the returnconnection must be run full size from the furnace to a location
outside the utility room, basement, attic, or crawl space.
DO NOT install return air through the back of thefurnace cabinet.
8 18-CD1 9D2-1 8
Installer's GuideRETURN AIR DUCT CONNECTION
NOTE:On upflow 5 or 6 ton airflow models, if the airflow require-ment exceeds 1800 CFM, these models will require returnair openings and filters on both sides; OR 1 side and thebottom; OR just the bottom.
All return air duct systems should provide for installation ofreturn air filters.
1. Set the furnace in place.
2. For side return installations on upflow models, removethe insulation around the opening in the blowercompartment.
Do not install the filter in the return duct directly above the
furnace in horizontal applications. Install the filter remotely.Installing the filter directly above the furnace in horizontalapplications may cause property damage, serious injury or
death.
TO PREVENT INJURY OR DEATH DUE TO CONTACT
WITH MOVING PARTS, TURN THE POWER TO THEFURNACE OFF BEFORE SERVICING FILTERS.
3. The side panels on upflow furnaces include locatingnotches which may be used as guides for cutting anopening for return air. Refer to Figure 12 and the outlinedrawing on page 3 for duct connection dimensions forvarious furnaces.
4. Ifa 3/4" flange is to be used for attaching the air inletduct, add to cut where indicated by solid lines inFigure 12. Cut corners diagonally and bend outward toform flange.
5. If flanges are not required, and a filter frame is installed,cut along knockout guidelines.
6. Upflow furnaces: a filter rack is factory supplied forbottom or side return. Use the filter rack on either sideor on the bottom if the filter is to be used within thefurnace cabinet.
7.
When the upflow furnace is installed in the horizontalright or left application and a return duct is attached tothe top side as shown in figure 11, remove the filter fromthe furnace and install in a remote location.Do not install the filter in the return duct directly abovethe furnace in horizontal applications.
When the upflow furnace is installed in the horizontalright or left application and a close coupled (less than36") return duct is attached to the bottom side of thefurnace as shown in figure 11, securely attach a 1/2" meshmetal hardware cloth protective screen to the insidebottom of the filter grill to prevent personal injuryfrom contacting moving parts when reaching intothe return opening to replace the filter.
Close coupled (less than 36") return (filter directlybeneath bottom side return) is not recommended due tonoise considerations.
Downflow Furnaces: Brackets are factory supplied tomount filters in the return air duct work.
Connect the duct work to the furnace. See OutlineDrawing for supply and return duct size and location.Flexible duct connectors are recommended to connectboth supply and return air ducts to the furnace.If only the front of the furnace is accessible, it is recom-mended that both supply and return air plenums areremovable.
8. When replacing a furnace, old duct work should becleaned out. Thin cloths should be placed over theregisters and the furnace fan should be run for 10 min-utes. Don't forget to remove the cloths before you startthe furnace.
I CUT OUT/ FOR
I/LOCATING _NOTCHESPROVIDED I
FOR SIDE /RETURNCUTOUT
*SEE OUTLINE DRAWING
SIDEFILTER
FRONTof Furnace
REMOVE FILTER FROM UPFLOW (_FURNACE WHEN RETURN DUCT IS . _[_ATTACHED TO FURNACE TOP SIDE ]_-5_-_(HORIZONTAL LEFT OR RIGHT ] / ....... / IAPPLICATIONS) AS SHOWN. ]__
IooooooooooooooII° Y J-i [/iooooooooooooooMI] .... I
_A IooooooooooooooItll_-_ illllllllll III I UII o I_ IIIIIIIIIIII II U
I1 1' [Close coupled (less than 36 ) /return (filter directly beneath bottomside return) not recommended due to f]4noise considerations. If used, securely _attach 1/2 mesh metal hardware clothprotective screen to the inside bottom offilter grill.
18-CD19D2-18
RETURN AIR FILTERS
(FILTERS NOT SUPPLIED WITH UNIT)TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONSFilters are not factory supplied for these furnaces. Thesefurnaces require high velocity type air filters. The filters maybe located within the furnace blower compartment forUPFLOW furnaces in either a BOTTOM or SIDE (left side orright side) return air inlet. Some filters may need to betrimmed for side or bottom filter use.
NOTE:On upflow 5 or 6 ton airflow models, if the airflow require-ment exceeds 1800 CFM, these models will require filters onboth sides; OR 1 side and the bottom; OR just the bottom.
The upflow furnace blower door has a hinge at the bottomwhich allows the door to tilt forward for filter replacementwithout the door being removed. The furnace filter in thebottom or side configuration can be removed by simplyturning the two latches on the blower door and tilting the doorforward.
iiiiiiiiiiii
Installer's GuideThe filter rails are spring loaded for automatic adjustment toallow standard size, locally obtainable replacement filters.The filter rack itself slides to adjust to the required widthneeded for bottom or side return.
TABLE 4
UPFLOW FURNACE RETURN AIR FILTERS
CABINET CABINETWIDTH QTY* BOTTOM FILTER
14-1/2" 1 14" X 25" X 1"
17-1/2" 1 17" X 25" X 1"
21" 1 20" X 25" X 1"
24-1/2" 1 24" X 25" X 1"
CABINETSIDE FILTER
17-1/2" X 25" X 1"
17-1/2" X 25" X 1"
17-1/2" X 25" X 1"
17-1/2" X 25" X 1"
*NOTE - On 5 ton airflow models, if the airflowrequirement exceeds 1800 CFM, these models willrequire return air openings and filters on both sides;OF{ 1 side and the bottom; OR just the bottom.
NOTE:The narrow 14.5" width furnace cabinet prevents use of thefilter rack for right side return. The 14.5" width furnacemodels will ship with both an adjustable filter rack for bottomor left and filter clips for right side return air applications.The filter clips are the same as previously used on all upflowfurnaces and will be shipped in a plastic bag attached to thecontrol platform. The furnace cabinet has dimples forlocation of the alternate furnace clips. Pre-drill clearanceholes and then attach filter clips with the screws provided.The filter clip with the leaf spring mounts in the rear of thecabinet
BOTTOM FILTER RACK INSTALLATION
With the filter removed, the filter rack is compressed andthen inserted into the bottom of the furnace. The retainingscrew/pin on each side inserts into engagement holes at thebottom of the furnace cabinet side.
NOTE:Remove the bottom front channel to install the filter rack inthe 14-1/2" width cabinet furnaces.
Blower Door Hinge and Bottom Filter Rack Installation
FILTER
@ RACKRAILS
RETAINING
PIN
(Both Sides)
Optional Filter Rack Accessory Kit - BAYRACK960A
®.,-.% ,"
Blower DeckEngagement
Hole
%..=,
ENGAGEMENTHOLE DETAIL
(Typicalboth sidesand blower deck)
®FurnaceCabinet
Side
Engagement HoleFor Filter Rack
Installation WithBottom Return
Filter
Rack
Filter RackRetainingScrew/Pin
10 18-CD19D2-18
Cabinet Width Left Side Bottom Right Side
17,5 X X X
21 X X X
24,5 X X X
1, UD060C/R936K0 has 10x7 blower which requires use of alternatefilter clips for left side filter, "K1" and later use the filter rack,2, Remove bottom front channel to install or reposition filter rack,X - All Models
OPTIONAL FILTER RACK INSTALLATION FOR SIDE RE-
TURN AIR ON UPFLOW FURNACES (Left or Right)If side air return is desired, it is necessary to move the filterrack from the bottom of the furnace and reinstall it on the
side. The following instructions should be used:
a.
b.
C.
Open or remove the blower door.
Remove the filter.
Compress the filter rack to disengage the retainingpins/screws from the furnace sides and slide the filterrack out.
d. Leave the bottom panel in place.
e. After the side cutout is made following the directionsin the "Return Air Duct Connections" section onpages 8 and 9; compress the filter rack and reinstall inthe side of the furnace. Confirm that the upperretaining pin/screw locks into the engagement hole inthe blower deck and the lower pin/screw rests againstthe side of the bottom panel. See Figures 14 - 19.
f. Reinstall the furnace filter on the side.
® BOTTOM ENGAGEMENTFilter Rack
RetainingFurnace _ T Screw/Pin FilterCabinet '-']_1
/ Rack
Side !_ tEngagement HoleFor Filter RackInstallation With
Bottom Return
Bottom Panel
®BLOWERDECK
Furnace
CabinetSide
Engagement Hole FurnaceFor Filter Rack BlowerInstallation WithSide Return Deck
Retaining RackScrew/Pin Assembly
Installer's Guide
(_ SIDECUTOUT
\RETAINING
PIN _
(Both S_I
SPRINGp_
/// FILTER BOTTOMJJ RACK PANEL
_/// Typical Upflow Left Side Return" Filter Rack Installation
Optional Filter Rack Accessory Kit - BAYRACK960A
Typical Upflow Right Side Return Filter Rack Installation
Typical Filters of Upflow in Horizontal
18-CD19D2-18 11
Installer's GuideRETURN AIR FILTERS FOR UPFLOW FURNACEIN HORIZONTAL CONFIGURATIONWhen the Upflow Furnace is installed in the horizontalconfiguration, the return air filters must be installed exteriorto the cabinet. Remote filter grilles may be used for home-owner convenience or the filters may be installed in the ductwork upstream of the furnace. See Figure 21.
BLOWER DOOR/HINGE REMOVAL
If clearance or other problems create a problem in using thetilting door, the blower door hinge may be removed withoutcreating any problems with the seal of the furnace. To removethe blower door, tilt the door forward 2 to 3 inches and pull up.To remove the tilt feature, simply remove the lower hinge asshown in Figure 22. The bottom of the blower door will catchin the bottom of the furnace front channel for door replace-
iiJiiiiliiiiWiiiiiiiiiiii!ii! iiiiiiilHiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii
ment.
Door Hinge Removed
ALTERNATE UPFLOW FILTER CLIP / BRACKET INSTALLA-TION (KIT09224)
1. Determine the location to be used. The furnace cabinethas dimples for location of the alternate furnace clips(Side return only). Pre-drill clearance holes with a3/16" drill. Bottom return holes are pre-drilled.
2. Install the clips in front and rear of the desired locationusing the screws provided. The filter clip with the leafspring mounts in the rear of the cabinet.
/
ALTERNATE FILTERCLIPS LOCATION
FILTER CLIP - KIT09224
INSTALLING THE FILTERThe filter may need to be cut to fit the unit depending on thelocation of the return air filter.
A score line and the words "CUT HERE" are located on theend of the filter. If your application requires cutting the filter,do so as indicted by the score mark.
UNIT
SIZE BOTTOM
14-1/2" CUT ON LINE
17-1/2" DO NOT CUT
21" DO NOT CUT
24-1/2" DO NOT CUT
TYPICAL DOWNFLOW FURNACERETURN AIR FILTER INSTALLATIONS
@
RETURN AIR
SIDE
DO NOT CUT
DO NOT CUT
CUT ON LINE
CUT ON LINE
Two filters are factory supplied for each downflow furnace.These furnaces require high velocity type air filters. Down-flow furnace filters must be located outside the furnace
cabinet. Typical installations are shown in Figure 24. Tables5 and 6 provide information for installation of the filterretaining brackets shipped with downflow furnaces.
12 18-CD1 9D2-1 8
Installer's GuideTABLE 5
CABINET FILTER FILTER BRACKETWIDTH SIZE LOCATION *
14-1/2" 2 - 14X20X1 12-7/8"
17-1/2" 2 - 16X20X1 14-3/8"
21" 2- 16X20X1 13-1/8"
24-1/2" 2 - 16X20X1 11-5/8"
• Location dimension is from end of duct to the screw holes for the bracket.
TABLE 6
CABINET RETURN FILTER ACCESS FILTER ACCESSDUCT OPENING - OPENING -
WIDTH WIDTH DIMENSION "A" DIMENSION "B"
14-1/2" 13-1/4" 12" 14"
17-1/2" 16-1/4" 15" 14"
21" 19-3/4" 19-1/2" 14"
24-1/2" 23-1/4" 22" 14"
GENERAL VENTING INSTRUCTIONS
VENT PIPINGThese furnaces have been classified as Fan-Assisted Com-bustion System, Category I furnaces under the "latestedition" provisions of ANSI Z21.47 and CAN/CGA 2.3standards. Category I furnaces operate with a non-positivevent static pressure and with a flue loss of not less than 17percent.
NOTE:If desired, a side wall termination can be accomplishedthrough the use of an "add-on" draft inducer. The inducermust be installed according to the inducer manufacturer'sinstructions. Set the barometric pressure relief to achieve-0.02 inch water column.
NOTE:When the downflow furnace is vented through the left side ofthe furnace cabinet using the provided cutout, Type B ventpiping must be used.
The furnace shall be connected to a factory built chimney orvent complying with a recognized standard, or a masonry orconcrete chimney lined with a lining material acceptable tothe authority having jurisdiction.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for eachappliance connected to the venting system beingplaced into operation could result in carbon monoxidepoisoning or death.
The following steps shall be followed for each applianceconnected to the venting system being placed intooperation, 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 andhorizontal pitch, as required in the National Fuel GasCode, ANSI Z223.1/NFPA 54 or the CAN/CGA B149Installation Codes and these instructions. Determinethat there is no blockage or restriction, leakage,corrosion and other deficiencies which could cause anunsafe condition.
3. As far as practical, close all building doors andwindows and all doors between the space in which theappliance(s) connected to the venting system arelocated and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance notconnected to the venting system. Turn on any exhaustfans, such as range hoods and bathroom exhausts, sothey are operating at maximum speed. Do not operatea summer exhaust fan.
6. Follow the lighting instructions. Place the appliancebeing inspected into operation. Adjust the thermostatso appliance is operating continuously.
7. If improper venting is observed during any of the abovetests, the venting system must be corrected inaccordance with the National Fuel Gas Code,ANSI Z221.1/NFPA 54 and/or CAN/CGA B149Installation Codes.
8. After it has been determined that each applianceconnected to the venting system properly vents wheretested as outlined above, return doors, windows,exhaust fans, fireplace dampers and any other gas-firedburning appliance to their previous conditions of use.
Furnace venting into an unlined masonry chimney orconcrete chimney is prohibited. Failure to follow thiswarning could result in property damage, personal injury, ordeath.
VENTING INTO A MASONRY CHIMNEY
If the chimney is oversized, the liner is inadequate, or flue-gascondensation is a problem in your area, consider using thechimney as a pathway or chase for type "B" vent or flexiblevent liner. If flexible liner material is used, size the vent us-ing the "B" vent tables, then reduce the maximum capacity by20% (multiply 0.80 times the maximum capacity). MasonryChimney Kit BAYVENT800B may be used with these fur-naces (Upflow model furnaces only) to allow venting into amasonry chimney. Refer to the BAYVENTS00B Installer'sGuide for application requirements.
Internal Masonry ChimneysVenting of fan assisted appliances into a lined, internalmasonry chimney is allowed only if it is common vented withat least one natural draft appliance; OR, if the chimney islined with type "B", double wall vent or suitable flexible linermaterial (See Table 7).
The chimney liner must be thoroughly inspected to insureno cracks or other potential areas for flue gas leaks arepresent in the liner. Liner leaks will result in early deteriora-tion of the chimney.
Failure to follow this warning could result in carbon monox-ide poisoning or death.
NOTE:
The following section does not apply if BAYVENTSOOB(Masonry Chimney Vent Kit) is used. All instructions withthe kit must be followed.
18-CD19D2-18 13
Installer's GuideTABLE 7
MASONRY CHIMNEY VENTING
Type Furnace
Single FanAssist
Fan Assist+
Fan Assist
Fan Assist+
Natural
Tile Lined Chimney
Internal External
No No
No No
Yes No
Chimney Lining
Flexible"B" Vent Metal Liner
Yes Yes*
Yes*
Yes*
Yes
Yes
Flexible chimney liner size is determined by using the type "B" vent size forthe available BTUH input, then reducing the maximum capacity by 20%(multiply maximum capacity times 0.80). The minimum capacity is the sameas shown in the "B" vent tables.
External Masonry ChimneyVenting of fan assisted appliances into external chimneys(one or more walls exposed to outdoor temperatures), requiresthe chimney be lined with type "B', double wall vent orsuitable flexible chimney liner material. This applies in allcombinations of common venting as well as for fan assistedappliances vented alone.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the installation instructions for the ventingsystem being placed into operation could result in carbonmonoxide poisoning or death.
The following installation practices are recommended tominimize corrosion caused by condensation of flue products inthe furnace and flue gas system.
1. Avoid an excessive number of bends.
2. Horizontal runs should pitch upward at least 1/4" per foot.
3. Horizontal runs should be as short as possible.
4. All vent pipe or connectors should be securely supportedand must be inserted into, but not beyond the inside wallat the chimney vent.
5. When vent connections must pass through walls orpartitions of combustible material, a thimble must beused and installed according to local codes.
6. Vent pipe through the roof should be extended to a heightdetermined by National Fuel Gas Code or local codes. Itshould be capped properly to prevent rain water fromentering the vent. Roof exit should be waterproofed.
7. Use type "B" double wall vent when vent pipe is routedthrough cool spaces (below 60 ° F.).
TABLE 8
GAS VENT TERMINATION
ROOF PITCH MINIMUM HEIGHT
FLAT TO 7/12OVER 7/12 TO 8/12OVER 8/12 TO 9/12OVER 9/12 TO 10/12OVER 10/12 TO 11/12OVER 11/12 TO 12/12OVER 12/12 TO 14/12OVER 14/12 TO 16/12OVER 16/12 TO 18/12OVER 18/12 TO 20/12OVER 20/12 TO 22/12
1.0 FEET *1.5 FEET2.0 FEET2.5 FEET
3.25 FEET4.0 FEET5.0 FEET6.0 FEET7.0 FEET7.5 FEET8.0 FEET
* THIS REQUIREMENT COVERS MOST INSTALLATIONS
® VERTICAL WALL
8' MIN.
LISTEDCAP
LOWEST DISCHARGEOPENING
×
\\,
ROOF PITCH IS X//12
THE VENT TERMINATION SHOULD NOT BELESS THAN 8 FT FROM A VERTICAL WALL
8. Where long periods of airflow are desired for comfort, uselong fan cycles instead of continuous airflow.
9. Apply other good venting practices as stated in theventing section of the National Fuel Gas CodeANSI Z223.1 "latest edition".
10. Vent connectors serving appliance vented bynatural draft or non-positive pressure shall not becomlected into any portion of a mechanized draftsystem operating under positive pressure.
11. Horizontal pipe runs must be supported by hangers,straps or other suitable material in intervals at aminimum of every 3 feet of pipe.
12.
13.
A furnace shall not be connected to a chimney or flueserving a separate appliance designed to burn solid fuel.
The flow area of the largest section of vertical vent orchimney shall not exceed 7 times the smallest listedappliance categorized vent area, flue collar area, or drafthood outlet area unless designed in accordance withapproved engineering methods.
Maximum Vent or Tile - _:(D*)-_2X 7Lined Chimney Flow Area - 4
*DrafLhood outlet diameter, flue collar diameter, or listed appliance categorized ventdiameter.
ELECTRICAL CONNECTIONS
The cabinet must have an uninterrupted or unbroken groundaccording to National Electrical Code, ANSI/NFPA 70 -"latest edition" and Canadian Electrical Code, CSA C22.1 orlocal codes to minimize personal injury if an electrical faultshould occur. A failure to follow this warning could result inan electrical shock, fire, injury, or death.
The integrated furnace control is polarity sensitive. The hotleg of the 115 VAC power must be connected to the BLACKfield lead.
To prevent injury or death due to electrical shock or contactwith moving parts, lock unit disconnect switch in the openposition before servicing the unit. Failure to follow thiswarning could result in electrical shock, personal injury, ordeath.
14 18-CD19D2-18
Installer's GuideMake wiring connections to the unit as indicated on enclosedwiring diagram. As with all gas appliances using electricalpower, this furnace shall be connected into a permanently liveelectric circuit. It is recommended that it be provided with aseparate "circuit protection device" electric circuit. Thefurnace must be electrically grounded in accordance with localcodes or in the absence of local codes with the NationalElectrical Code, ANSI/NFPA 70 "latest edition" or CanadianElectrical Code, CSA C22.1, if an external electrical source isutilized.
All field supplied wiring must conform with the temperaturelimitation for Type T wire [63 ° F. (35 ° C)], when installed inaccordance with these instructions and wiring diagramssupplied with the furnace. A disconnecting means must belocated within sight from, and readily accessible to, thefurnace.
Refer to the SERVICE FACTS literature for unit wiringdiagrams in addition to the diagram inside the blower door.
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE2 STAGE HEATING
USING A 1 STAGE HEATING THERMOSTATNO COOLING
2 STAGE
T 'STAT FURNACE NOTES:SEE
NOTE7 _ I. BE SURE POWER AGREES WITH EQUIPMENT NANPLATE(S)L..--_IT"_'_NI 2. LOWVOLTAGE(24V. WIRING) TO BE NO. 18 A WG. MIN..
3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.4. SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.
] _ 5, THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIRi"1 CLEANER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.6. THIS CONNECTION IS ONLY USED FOR THERMOSTATS REOUIRING
] CONNECTION TO THE 24 V. POWER SUPPLY. (COMMON)7. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONSSEE WHEN USING THIS FEATURE
] NOTE8 _ 8, WHEN A HEATING THERMOSTAT (WITHOUT FAN SWITCH) IS USED,........... lb I NO WIRINGON "G" TERMINALOF IFC IS USED.9. Wl AND W2 MUST BE JUMPERED TOGETHER FOR PROPER OPERATION,
SECOND STAGE HEATING WILL BEGIN I0 MINUTES AFTER FIRST STAGE
[] ...........D,,_' ' JUMPEnW_TOW2 _----_,,,'---- FUR NACE
" ............. ,I I _ BK [ JUNCTIONSEE 1_%_#_%_'15 I', _1 I BOX
[_.__ .N_O_T_E_6_--t'_ TO115V1PH. r_. ....IINTER-COMPONENT WIRING LOCAL CODES LN _ I
--_-- L F_=F -u T_I24 V. LFIELD rw. I I i _ ILIkE v.f WIRING HUMSEE t'--_'-x '_1 J _ I
24 V. _ FACTORY NOTE5 L____ i '1 - '_VILINE V.j WIRING F w. J ', r_l ',
EACSEE L B=-- "_--_J FrornDwg, B341486Rev, 1
T'STAT
__
__
[_--
[_--
SEENOTE7
/
SEE.N__O_T_E_6_
2STAGEFURNACE
--.Fq
Fq
"--E_
--t-_
--r_
- - t"_
INTER-COMPONENT WIRING
24 v. h FIELD
----LINE V.# WIRING
24 V. "_ FACTORY
--LINE V.ffW[RING
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE2 STAGE HEATING
USING A 2 STAGE HEATING THERMOSTATNO COOLING
NOTES:I. BE SUREPOWERAGREESWITH EOUIPMENTNAMPLATE(S).2. LOWVOLTAGE(24V, WIRING) TOBE NO. 18 A.W.G. MIN.,3. GROUNDINGOF EOUIPMENTMUSTCOMPLYWITHLOCALCODES.4. SET THERMOSTATHEATANTICIPATORPERUNIT WIRINGDIAGRAM.5. THESELEADSPROVIDE115 V, POWERFORCONNECTIONOF ELECTRONICAIR
CLEANERANDHUMIDIFIERMAX. LOAD 1.0 AMPSEACH.6, THIS CONNECTIONIS ONLYUSEDFORTHERMOSTATSREOUIRING
CONNECTIONTOTHE24 V. POWERSUPPLY.(COMMON)7, SEETWINNINGCONNECTIONDIAGRAMSFORPROPERCONNECTIONS
WHENUSINGTHIS FEATURE.
GROUNDSCREW
_:--_- FUR NACE',I I _ BIK[ JUNCTION
,,_ ,, BOXFLH BKI_
TO115V1PH. / .... _ WH/,I
60 HZ,, POWER J II _ Ii
SUPPLYPER "I I r-- i
LOCAL CODES / L N ,_._l..4,J_- ] I
r WI.I / / I _ I
HUM SEE J "" _ I I I_ lNOTES]BK __,--I. _ I
WH I IEAC SEE r---- j i I
NOTE 5 I BK _|' "
L" ____ From Dwg. B342024 Rev. O
18-CD19D2-18 15
Installer's Guide
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE2 STAGE HEATING, 1 STAGE COOLING
USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT(OUTDOOR SECTION WITHOUT TRANSFORMER)
OUTDOOR UNIT
(NO TRANSFORMER)
......
T"STAT
__
E_--
SEENOTE 7
L
SEE
.N_O_T_E_8_
SEE
.N_O_T_E_6_
2 STAGEFURNACE
-.F-q
"--E_
'--{_
-- [_3",
',.,,.
@,
,--@
,,J
INTER-COMPONENT WIRING
24 V. "__FIELD----LINE V.jWIRING
24 V. "_.FACTORY--LINE Y._! WIRING
NOTES:I. BE SURE POWERAGREES WITH EQUIPMENT NAMPLATE(S).2. LOW VOLTAGE (24V. WIRING) TO BE NO. 18 A,W.G. MIN.,3, GROUNDINGOF EQUIPMENT MUST COMPLY WITH LOCAL CODES,4. SET THERMOSTATHEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.5. THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIR
CLEANER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.6, THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING
CONNECTION TO THE 24 V. POWERSUPPLY. (COMMON)7. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS
WHEN USING THIS FEATURE,8, THE "Y" TERMININAL FROM THE THERMOSTATMUST BE WIRED
TO THE "Y" TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWEROPERATION DURING COOLING.
9. Wl AND W2 MUST BE JUMPERED TOGETHERFOR PROPEROPERATION.SECOND STAGE HEATING WILL BEGIN I0 MINUTES AFTER FIRST STAGE.
w--_:--_z-- FUR NACE"_, FIELD ADDED , I _ BK r JUNCTION
JUMPER (NOTE W) '1 ! I-_'_ i BOX
r- ,. _KITO115V1PH., / ..... _ WH/I
60 HZ.,POWER/ IISUPPLYPER "_ I I'_LOCAL CODES I L N WK_I__I.F]
L T3r..l I
HUMSEE J '_ ,_1 I ', FNOTE5 I BK----I" '1---_13
I- T _EACSEEI---- , /NOTE5 L BK ._____ From Dwg. B342019 nev. 0
OUTDOOR UNIT
(NOTRANSFORMER)
y! ..........
%
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE
2 STAGE HEATING, 1 STAGE COOLINGUSING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT
(OUTDOOR SECTION WITHOUT TRANSFORMER)
T'STAT
__
--D---
E_---
E_--
@--
SEENOTE7
L
SEE
_NOTE_8
SEE_N_O_T_E_6_
INTER-COMPONEN
24 V, >----LINE V.
24 V. _>--LINE V.
2 STAGEFURNACE
-B
"--D
'--D
• - - _-i-]
"--[_
--@
ii
T WIRING
FIELDWIRING
FACTORYW]RING
NOTES:I. BE SURE POWERAGREESWITH EOUIPMENTNAMPLATE(S).2. LOWVOLTAGE (24V. WIRING) TO BE NO. 18 A.W.G. MIN..3. GROUNDINGOF EQUIPMENTMUST COMPLYWITH LOCAL CODES.4. SET THERMOSTATHEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.5. THESE LEADS PROVIDE 115 V. POWERFOR CONNECTIONOF ELECTRONICAIR
CLEANERAND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.6, THIS CONNECTIONIS ONLY USED FOR THERMOSTATSREOUIRING
CONNECTIONTO THE 24 V, POWERSUPPLY, (COMMON)7. SEE TWINNING CONNECTIONDIAGRAMSFOR PROPERCONNECTIONS
WHENUSING THIS FEATURE.B. THE "Y" TERMININAL FROMTHE THERMOSTATMUST BE WIRED
TO THE "Y" TERMINAL OF THE FURNACECONTROLFOR PROPERBLOWEROPERATIONDURINGCOOLING.
f_:---_ FURNACE
', I _ BIK r JUNCTION
I_ I Boxr-.. _,I1._
TO115V1PH, / .... _ WH/_I60HZ, POWER I I ISUPPLYPER "_ I I'_1 I
LOCALCODES/ L____"---_4--1-_ IL °YI
rWa/ / I J IRUMSEEJ"'_ I ll_ lNOTE5 I BK ___ ,U=n I
WH I I
EACSEEI-----_ I INOTE5 I BX ' '
L '____ FromDwg.B342021Rev.O
16 18-CD1 9D2-1 8
Installer's GuideTWINNINGThese furnaces may be twinned. Twinning requires that twofurnaces with the same configuration, capacity, and airflowmust be used. They shall have common returns with equalpressure drops or ducts with equivalent lengths and sizes.See Field Wiring Diagrams below and on the following pagefor proper hookup.
TWINNING CONNECTION DIAGRAM
FOR TWINNING UD/DD-R FURNACES1 STAGE HEAT / 1 STAGE COOLING THERMOSTAT
OUTDOOR UNIT NO. 1 1 STAGE
(WITH TRANSFORMER} HEATING / COOLING
SEE NOTE 3 THERMOSTAT FURNACE NO. 1
I---" ..... i -1
: :u:140-V/_O© L.... -__.... J
ISOLATION RELAy D(FIELD SUPPUED}
ALTERNATECONNECTION
OUTDOOR UNIT NO. 1
(NO TRANSFORMER)
8J
Fq
D
ON BOTH UNITS.2NDSTAGEWILL FIRE
10MINUTESAFTER1ST i1
D D
D D
@ ........D:1
• i
]
I
• A ,i v I
RI; ",> ;
_SOLAT_ONRECAY(FIELDSUPPLIED)
SEENOTE4
FURNACE NO. 2
SLOWER OPERATION OF
UNiT NO 2 IS SYNCRONIZED
W4TH UMT NO 1 VIA SIGNALS
FROM TWIN CONNECTION
B
[-qSEE NOTE 4
-_.!
Fq
D
B
.......i
I
I
RIIT ;
NOTES:
I, BOTH FURNACESMUST BE POWEREDFROMTHE SAME IISV. LEG OF CIRCUIT PANEL.
INSURE 24V. FURNACETRANSFORMERSAREIN PHASE. PRIOR TO COMPLETINGCONNECTIONS,CHECK VOLTAGE BETWEEN "g • TERI_IgALS OFEACH FURNACE. IF VOLTAOEIS GREATER TN_NIOV., REVERSE THE BL AN RU SECONDARYLEADSON ONE OF THE FURNACETRANSFOR_RS,
IF OUTER UNIT HAS A 24V. TRANSFORMER,AN ISOLATION RELAY MUST BE INSTALLED,
(FIELD SUPPLIED " USE PILOT DUTY RELAY
t "RC'), SUCH AS RLYODt5. I SEE ALL CONNECTION.
IF CURRENT EXCEEDS THERMOSTAT CURRENT
RATING, USE ISOLATION RELAYS ("gl "l AS
SHOWN, tOO HOT CONNECT W TO W_ISOLATION RELAY gOT NEEDED IF THE THERMOSTAT
CONTACTS ARE RATED AT I.OA. OR ABOVE,
5. CONNECTIONMAY BE REOUIRED FOR ELECTRONICTHERMOSTATS.
INTER CO_,,PONENT WIRING
ALTERNATEWIRING CONFIGURATION......... SEE NOTE4
V. -_\ FIEL
-- -- L ] NE '_ ..J_ ,/',/;R I N O
4 'v/. ', FA_, •0 ,_Y
--LINE '7._f "',¢,i]RINo
From Dwg. 21B341487 Rev. 1
18-CD19D2-18 17
Installer's Guide
TWINNING CONNECTION DIAGRAM
FOR TWINNING UD/DD-R FURNACES2 STAGE HEAT / 1 STAGE COOLING THERMOSTAT
OUTDOOR UNIT NO. 1 2 STAGE HEATING
WITH TRANSFORMEF 1 STAGE COOLINGSEE NOTE 3 THERMOSTAT
i--_ ..... ' -1
i 301i i14__ /_-t_° I........................................................................
i......... ii_ V _ j
ISOLATIONnE/A¥ D(FIELD SUPPLIED)
ALTERNATE CONNECTION
OUTDOOR UNIT NO. 1
(NO TRANSFORMER) Fq
D
Fq
Fq
D
FURNACE NO. 1
Pq................................................. i
D
Fq
Fq
SEE NOTE5 @ ............
iiL "I
ISOLATION RElAy
(FIELDSUPPUEO)SEENOTE4
r----i
-i-01
RI;'_ i
!Oh
iv i ,
R2I "_ ; :
--_-".iiIiiI
I
Iii
i
FURNACE NO. 2
BLOWEROPERATIONOFUNIT NO 2 IS SYNCROMZED
WITH UNIT NO 1 VIA SIGNALS
FROM TWIN CONNECTION
B
Fq
\DiSEE NOTE 4
EFt
Fq
Fq
@
OUTDOOR UNIT NO. 2 2 STAGE HEATING
(NO TRANSFORMEF 2 STAGE COOLING
SEE NOTE 3 THERMOSTAT
OUTDOOR UNIT NO. 1
(NO TRANSFORMER)
FqF
17t
r-q
Fq
Fq
D
TWINNING CONNECTION DIAGRAMFOR TWINNING UD/DD-R FURNACES
2 STAGE HEAT/2 STAGE COOLING THERMOSTAT
SEE NOTE 5
FURNACE NO. 1
Fq
Fq
Fq
ISOLATIONRElY_mEhOSUPPLIED)
SEENOTE4r----i
RI; _ i
i/__b
R21_; :
I
I
I
I
I
..... I
FURNACE NO. 2
SLOWEROPERATIONOF
WiTH UNIT NO 1 VIA SIGNALS
E3
Fq
\FI SEE NOTE 4
Fq
Fq
iL •
From Dwg. 21B341489 Rev. 1
MOTES:
l, BOTH FURNACES MOST BE POWERED FRO_THE SANE IISV, LEG OF CIRCUIT PANEL,
INSURE EAR. FURHACETRANSFORNERSAREIN PHASE. PRIOR TO CONPLETINGCONNECTIONS,CHECK VOLTAGEBETWEEN"R" TEHN/NALS OFE_CH FURNACE. IF VOLTAGEIS GREATER THANIOV., REVERSETHE BL AN HO SECONDARYLEADSON ONE OF THE FURRACE T#ANSFO_ERS.
IF OUTD_R UNIT HAGA 2RV. TRANSFORMER,AN ISOLATION RELAY RUST BE INSTALLED.IFIELD SUPPLIED " USE PILOT DUTY RELAY! 'RC'), SUCH AS RLYOBIS+I SEE ALT. CONNECTION+
A.
%_['.%"#p_F---I s.
1
'.:#i
IF CURRENT EXCEEDS TNER_STAT CURRENT
RATING, USE ISOLATION RELAYS t "RI ") AS
SHOMH. tDO HOT CONNECT W TO W;
ISOLATION RELAY NOT NEEDED IF THE THERMOSTAT
CONTACTS ARE RATED AT I,OA, OR ABOVE,
COHHECTIOHNAY BE REOUIRED FOR ELECTRONICTHERNOSTATS.
INTE C/)k,'l ( ENT "¢/IRI ;
2/- V. t FIELD
---- L ]NE ,+/ )_" W[R INS
m24 V. L FACTORY
-- LINE ' . _ i,'[RIN("
From Dwg. 21B341488 Rev 1
NOTES:
!, BOTH PGRNACED MUST UE POWERED FROHTHE SANE HSV, LEO OF CIRCUIT PANEL,
E, INSURE24V, FURNACETRANSFORMERSAREIN PHASE. PRIOR TOCOMPLETINGCONRECTIOHS.CHECKVOLTAGEUET_EEN 'N' TENNIN_LSOFEACH FURNACE._E VOLTAGEIS GREATERTHANION.. REVERSETHEUL AN RD SECONDARYLEADSOH ONEOF THEPURRACETRAHSEODN_BS.
_. IF OUTDOORUNIT HAS A E_R. TRANSFORMER.AN ISOLATION RELAYMUST BE INSTALLED.IEIELD SUPPLIED - USE PILOT DUTYRELAYI+NC+I, SUCHAS NLYOBtB.I SEE ALT. CONNECTION.
iE---i Bml _. I
#.:=:_ I
--_-.i
IF CURRENTEXCEEDSTHERMOSTATCURRENTRATING. USE ISOLATION RELAYS I+RI'; ASSHOWN. fDO NOTCONNECTWTO WIISOLATION RELAY NOTNEEDEDIF THE THERMOSTATCONTACTSARE RATEDAT /,OA. ORABOVE¸
CONNECTIONMAYRE HEOUIREO FOR ELECTRONICTHERMOSTATS,
OUTDOOR UNIT
NITH TRANSFORMERSEE NOTE 3
_R_Y,-_ ..... ' -1
14"_ /_--_O I ......I_V _ ,
ISOLATION RELAy
(FIELD SUPPLIED)
ALTERNATE CONNECTION
Fq %INTER COMFONENT '.¢,/IF{]NO
ALTE_ATE +HR_)6 CO_2F_URAT_O_
/- '/. _L FIELD
----LINE '/"2 _'/''']_IN"
'v'. ",, FACTORY
--LIqE ,,'. _W]RING
18 18-CD1 9D2-1 8
FIREOREXPLOSIONHAZARDFailure to follow the safety warnings exactly could result inserious injury, death or property damage.
Never test for gas leaks with an open flame. Use a com-mercially available soap solution made specifically for thedetection of leaks to check all connections. A fire orexplosion may result causing property damage, personalinjury, or loss of life.
(_ LEFT SIDE PIPING (STANDARD)
MANUAL MAINSHUTOFF
GROUNDUNION JOINT
DRIP LEG
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
RIGHT SIDE PIPING (OPTIONAL)
SHUTOFF VALVE
UNION JOINT
LEG
AUTOMATIC GAS VALVEWITH MANUAL SHUTOFF
TOP VIEW OF RIGHT SIDE PIPING
WITH MANUAL SHUTOFF
J
TO PREVENT AN EXPLOSION OR POSSIBLE INJURY,DEATH AND EQUIPMENT DAMAGE, DO NOT STORECOMBUSTIBLE MATERIALS, GASOLINE OR OTHERFLAMMABLE VAPORS OR LIQUIDS NEAR THE UNIT.
Installer's GuideGAS PIPINGThis unit is shipped standard for left side installation of gaspiping. A piping knockout is also provided in the right side foran alternate piping arrangement. The installation of pipingshall be in accordance with piping codes and the regulationsof the local gas company. Pipe joint compound must beresistant to the chemical reaction with liquefied petroleumgases.
Refer to piping Table 8 for delivery sizes. Connect gas supplyto the unit, using a ground joint union and a manual shut-offvalve as shown in Figure 26. National codes require acondensation drip leg to be installed ahead of the controls asshown in Figure 26.
The furnace and its individual shut-off valve must be discon-nected from the gas supply piping system during any pressuretesting of that system at test pressures in excess of 1/2 psig.
The furnace must be isolated from the gas supply piping byclosing its individual manual shut-off valve during anypressure testing of the gas supply piping system at testpressures equal to or less than 1/2 psig.
NOTE:Maximum pressure to the gas valve for natural gas is13.8" W.C. Minimum pressure is 5.0" W.C. Maximumpressure to the gas valve for propane is 13.8" W.C. Mini-mum 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!
The following warning complies with State of California law, Proposition 65. ]
Hazardous Gases!
Exposure to fuel substances or by-products of incompletefuel combustion is believed by the state of California tocause cancer, birth defects, or other reproductive harm.
SEQUENCE OF OPERATION
Thermostat call for heat (2-stage thermostat)Call for 1st stage only:R and Wl thermostat contacts close signaling the controlmodule to run its self-check routine. After the control modulehas verified that the 1st stage pressure switch contacts areopen and the limit switch(es) contacts are closed, the draftblower will be energized.
As the induced draft blower comes up to speed, the pressureswitch contacts will close and the ignitor warm up period willbegin. The ignitor will heat for approx. 20 seconds, then thegas valve is energized in 1st stage to permit gas flow to theburners. The flame sensor confirms that ignition has beenachieved within the 4 second ignition trial period.
As the flame sensor confirms that ignition has been achieved,the delay to fan ON period begins timing and after approx.45 seconds the indoor blower motor will be energized at lowspeed and will continue to run during the heating cycle.
Call for 2nd stage after 1st stage:R and W2 thermostat contacts close signaling a call for 2ndstage heat. After a 30 second delay, the induced draft blowerwill be energized on high speed and the 2nd stage pressureswitch contacts will close allowing the gas valve to be energizedin 2nd stage and the indoor blower motor in high speed.
18-CD19D2-18 19
Installer's Guide2rid stage satisfied, 1st stage still called:R and W2 thermostat contacts open signaling that 2nd stageheating requirements are satisfied. The induced draft bloweris reduced to low speed allowing the 2nd stage pressureswitch contacts to open and the gas valve is reduced to 1ststage. After approx. 30 seconds the indoor blower motor isreduced to low speed.
1st stage satisfied:R and W1 thermostat contacts open signaling that 1st stageheating requirements are satisfied. The gas valve will closeand the induced draft blower will be de-energized. The indoorblower motor will continue to run for the fan off period (Fieldselectable at 60, 100, 140 or 180 seconds - Factory setting is100 seconds), then will be de-energized by the control module.
Thermostat call for heat (1-stage Thermostat)R and W1/W2 (jumpered) thermostat contacts close signalinga call for heat. 1st stage sequence of operation remains thesame as above. 2nd stage heat has a 10 minute delay fromthe time of 1st stage ignition.
Thermostat satisfied:R and W1/W2 (jumpered) contacts open signaling the controlmodule to close the gas valve and de-energize the induceddraft blower. The indoor blower motor will continue tooperate at high heat speed for approx. 30 seconds after theflames are extinguished and then is switched to low heatspeed for the remaining FAN-OFF period.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result inserious injury, death or property damage.
Never test for gas leaks with an open flame. Use a com-mercially available soap solution made specifically for thedetection of leaks to check all connections. A fire orexplosion may result causing property damage, personalinjury, or loss of life.
START UP AND ADJUSTMENT
PRELIMINARY INSPECTIONSWith gas and electrical power "OFF"
1. Duct connections are properly sealed
2. Filters are in place
3. Venting is properly assembled
4. Blower door is in place
Turn knot) on main gas valve within the unit to the "OFF"position. Turn the external gas valve to "ON". Purge the airfrom the gas lines. After purging, check all gas connections forleaks with 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 ventilation. Turn the knot) on the gasvalve in the unit to the "ON" position.
COMBUSTION AND INPUT CHECK1. Make sure all gas appliances are off except the furnace.
2. Clock the gas meter with the furnace operating (deter-mine the dial rating of the meter) for one revolution.
3. Match the "Sec" column in the gas flow (in cfh) Table 13with the time clocked.
4. Read the "Flow" column opposite the number of secondsclocked.
5. Use the following factors if necessary:
For 1 Cu. Ft. Dial Gas Flow CFH =Chart Flow Reading + 2
For 1/2 Cu Ft. Dial Gas Flow CFH =Chart Flow Reading + 4
For 5 Cu. Ft. Dial Gas Flow CFH =10X Chart Flow Reading + 4
6. Multiply the final figure by the heating value of the gasobtained from the utility company and compare to thenameplate rating. This must not exceed the nameplaterating.
7. Changes can be made by adjusting the manifold pressure(See Table 9), or changing orifices (orifice change may notalways be required). To adjust the manifold pressure:
a. Turn off all electrical power to the system.
b. Attach a manifold pressure gauge to the outletpressure tap marked "OUT PRESS TAP" on White-Rogers gas valve model 36E or boss marked "OUT P"on White-Rodgers gas valve model 36G. (See Figure 27for White-Rodgers gas valve model 36E and Figure 28for White-Rodgers gas valve model 36G).For the gas valve model 36E, measurements requireremoval of the plug and installation of a barbedfitting. Attach flexible tubing and a manometer to thebarbed fitting. For the gas valve model 36G, do notremove the pressure tap test screw. Loosen thepressure tap test screw one turn and install flexibletubing and a manometer directly onto the outletpressure boss.
c. Turn on system power and energize valve.
d. For the White-Rodgers gas valve model 36E:
1. Adjust low fire by removing the low adjustmentseal screw (See figure 27).
2. To increase outlet pressure, turn the 3/32" socketset screw clockwise.
To decrease outlet pressure, turn the set screwcounterclockwise.
Adjust regulator until pressure shown onmanometer matches the pressure specified in table9.
3. Replace low adjustment seal screw and tightensecurely.
4. Cycle the valve several times to verify regulatorsetting.
5. Adjust high fire by removing the high adjustmentregulator cover screw (See Figure 27).
6. To increase outlet pressure, turn the regulatoradjust screw clockwise. To decrease outlet pressure,turn the regulator adjust screw counterclockwise.The final manifold pressure setting shall be asspecified in Table 9 with an input of no more thannameplate rating and no less than 93% of thenameplate rating, unless the unit is derated forhigh altitude.
7. Replace high adjustment regulator cover screw andtighten securely.
8. Cycle the valve several times to verify regulatorsetting.
e. For the White-Rodgers gas valve model 36G:
1. Adjust low fire by removing the low adjustmentregulator cover screw (See Figure 28).
20 18-CD19D2-18
Installer's Guide
£
h.
i.
2. To increase outlet pressure, turn the regulatoradjust screw clockwise. To decrease outlet pressure,turn the regulator adjust screw counterclockwise.Adjust regulator until pressure shown on manometer matches the pressure specified in Table 9.
3. Replace and tighten the regulator cover screwsecurely.
4. Cycle the valve several times to verify regulatorsetting.
5. Adjust high fire by removing the high adjustmentregulator cover screw (See Figure 28 ).
6. To increase outlet pressure, turn the regulatoradjust screw clockwise. To decrease outlet pressure,turn the regulator adjust screw counterclockwise.The final manifold pressure setting shall be asspecified in Table 9 with an input of no more thannameplate rating and no less than 93% of thenameplate rating, unless the unit is derated forhigh altitude.
7. Replace high adjustment regulator cover screw andtighten securely.
8. Cycle the valve several times to verify regulatorsetting.
Turn off all electrical power to the system.
Remove the manometer and flexible tubing. Removethe barbed fitting and replace the plug or tighten thepressure test screw.
Turn on electrical power to the system and energizevalve.
Using a leak detection solution or soap suds, check forleaks at plug or pressure boss screw.
Replace and/or tighten all plugs removed or loosened whenadjusting gas pressure. Leak check the fittings beforeplacing the furnace into regular service. Failure to followthis warning could result in fire, explosion, or propertydamage.
For LP gases, the final manifold pressure setting shall be10.5" W.C. with an input of no more than the nameplaterating and no less than 93% of the nameplate rating, unlessthe unit is derated for altitude.
Table 11 lists the main burner orifices shipped with thefurnace. If a change of orifices is required to correct the inputrate, refer to Table 12.
(_ White-Rodgers 36E
©
Gas Valve On / OffToggle Switch
2nd Stage (HI)
Pressure
Adjustment
1st Stage (LO)ManifoldPressure
Adjustment
@ White-Rodgers 36G
d/
Gas Valve On / Off
Toggle Switch
TABLE 9
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.
TABLE 10
NATURAL GAS ONLY
TABLE OF CUBIC FEET PER HOUR OF GASFORVARIOUSPIPE SIZESAND LENGTHS
PIPE LENGTH OF PIPE
SIZE 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 SRGR. gas
TABLE 11
ORIFICE SIZES
MAIN BURNER ORIFICEDRILL SIZE
INPUTRATING
BTUH
40,00060,00080,000100,000120,000140,000
NUMBEROF
BURNERS
234567
NAT. GAS
454545454545
LP GAS
565656565656
TABLE 12
PART NUMBERS FOR REPLACEMENT ORIFICESDRILLSIZE
44454647484950
PARTNUMBER
ORF00501ORF00644ORF00909ORF00910ORF01099ORF00503ORF00493
DRILLSIZE
545556575859
PARTNUMBER
ORF00555ORF00693ORF00907ORF00908ORF01338ORF01339
18-CD19D2-18 21
Installer's GuideTABLE 13
GAS FLOW IN CUBIC FEET PER HOUR
2 CUBIC FOOT DIAL
SEC. FLOW SEC. FLOW SEC. FLOW SEC. FLOW
8 900 29 248 50 144 82 88
9 800 30 240 51 141 84 86
10 720 31 232 52 138 86 84
11 655 32 225 53 136 88 82
12 600 33 218 54 133 90 80
13 555 34 212 55 131 92 78
14 514 35 206 56 129 94 76
15 480 36 200 57 126 96 75
16 450 37 195 58 124 98 73
17 424 38 189 59 122 100 72
18 400 39 185 60 120 104 69
19 379 40 180 62 116 108 67
20 360 41 176 64 112 112 64
21 343 42 172 66 109 116 62
22 327 43 167 68 106 120 60
23 313 44 164 70 103 124 58
24 300 45 160 72 100 128 56
25 288 46 157 74 97 132 54
26 277 47 153 76 95 136 53
27 267 48 150 78 92 140 51
28 257 49 147 80 90 144 50
HIGH ALTITUDE DERATE
Input ratings (BTUH) of these furnaces are based on sea leveloperationandshouldnotbechangedatelevationsupto2,000ft.
If the installation is 2,000 ft. or above, the furnace input rate(BTUH) shall be reduced 4% for each 1,000 ft. above sea level.The furnace input rate shall be checked by clocldng the gasflow rate (CFH) and multiplying by the heating value ob-tained from the local utility supplier for the gas being deliv-ered at the installed altitude. Input rate changes can bemade by adjusting the manifold pressure (min 3.0 - max 3.7in. W.C. - Natural Gas) or changing orifices (orifice changemay not always be required). If the desired input rate can notbe achieved with a change in manifold pressure, then theorifices must be changed. LP installations will require anorifice change.
IMPORTANT:
Re-install the propane orifices to the same depth as theorifices supplied with the equipment.
See Table 14 for help in selecting orifices if orifice change isrequired. Furnace input rate and temperature rise should bechecked again after changing orifices to confirm the properrate for the altitude.
Installations above 4,000 feet may require a pressure switchchange. If required, use the BAYHALT*** Kit (High AltitudeAccessory Kit) listed in PRODUCT DATA.Installation of this furnace at altitudes above 2,000 ft.(610m) shall be in accordance with the local codes, or in theabsence of local codes, the National Fuel Gas Code, ANSIZ223.1 / NFPA 54 or National Standard of' Canada, NaturalGas and Propane Installation Code, CSA 149.1. Installation ofthis furnace at altitudes above 2,000 ft. (610m) shall be madein accordance with the listed high Altitude Conversion Kitavailable with this furnace.
TABLE 14
OrificeTwist Drill
Size IfInstalledAt SeaLevel
424344454647
ALTITUDE ABOVE SEA LEVEL
and Orifice Required At Other Elevations
2006 3000 4000 5006 6000 7000 800G 9000 10000
42 43 43 43 44 44 45 46 4744 44 44 45 45 46 47 47 4845 45 45 46 47 47 48 48 5046 47 47 47 48 48 49 49 5047 47 47 48 48 49 49 50 5148 48 49 49 49 50 50 51 52
54 54 55 55 55 55 55 56 56 5655 55 55 55 56 56 56 56 56 5756 56 56 57 57 57 58 59 59 6057 58 59 59 60 60 61 62 63 6358 59 60 60 61 62 62 63 63 64
From National Fuel Gas Code-Table F-4
LIGHTING INSTRUCTIONS
DO NOT attempt to manually light the burner. Failure tofollow this warning could result in property damage, per-sonal injury or death.
EXPLOSION HAZARD!PROPANE GAS IS HEAVIER THAN AIR AND MAY COL-LECT IN ANY LOW AREAS OR CONFINED SPACES. INADDITION, ODORANT FADE MAY MAKE THE GASUNDETECTABLE EXCEPT WITH A WARNING DEVICE. IFTHE GAS FURNACE IS INSTALLED IN A BASEMENT, ANEXCAVATED AREA OR A CONFINED SPACE, IT ISSTRONGLY RECOMMENDED TO CONTACT A GASSUPPLIER TO INSTALL A GAS DETECTING WARNINGDEVICE IN CASE OF A GAS LEAK.
NOTE: The manufacturer of your furnace does NOT test anydetectors and makes no representations regarding any
brand or type of detector.
Lighting instructions appear on each unit. Each hlstal-lation must be checked out at the time of initial start upto insure proper operation of all components. Checkout should include putting the unit through one com-plete cycle as outlined below.
Turn on the main electrical supply and set the thermostatabove the indicated temperature. The ignitor will automati-cally heat, then the gas valve is energized to permit the flowof gas to the burners. After ignition and flame is established,the flame control module monitors the flame and suppliespower to the gas valve until the thermostat is satisfied.
TO SHUT OFF
For complete shutdown: Move the control switch on the maingas valve to the "OFF" position (See Figure 27 and 28).Disconnect the electrical supply to the unit.
If this is done during the cold weather months, provisionsmust be taken to prevent freeze-up of all water pipes andwater receptacles. Failure to follow this warning could resultin property damage.
22 18-CD19D2-18
Whenever your house is to be vacant, arrange to havesomeone inspect your house for proper temperature.This is very important in below freezing weather. If forany reason your furnace should fail to operate damagecould result, such as frozen water pipes.
CONTROL AND SAFETY SWITCHADJUSTMENT
LIMIT SWITCH CHECK OUTThe limit switch is a safety device designed to close the gasvalve should the furnace become overheated. Since properoperation of this switch is important to the safety of the unit,it must be checked out on initial start up by the in-staller.
To check for proper operation of the limit switches, set thethermostat to a temperature higher than the indicatedtemperature to bring on the gas valve. Restrict the airflow byblocking the return air or by disconnecting the blower. Whenthe furnace reaches the maximum outlet temperature asshown on the rating plate, the burners must shut off. If theydo not shut off after a reasonable time and overheating isevident, a faulty limit switch is probable and the limit switchmust be replaced. After checking the operation of the limitcontrol, be sure to remove the paper or cardboard from thereturn air inlet, or reconnect the blower.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the installation instructions for the ventingsystem being placed into operation could result in carbonmonoxide poisoning or death.
AIRFLOW ADJUSTMENTCheck inlet and outlet air temperatures to make sure theyare within the ranges specified on the furnace rating name-plate. If the airflow needs to be increased or decreased, seethe wiring diagram for information on changing the speed ofthe blower motor.
Disconnect power to the unit before removing the blowerdoor. Failure to follow this warning could result in propertydamage, personal injury or death.
This unit is equipped with a blower door switch which cutspower to the blower and gas valve causing shutdown when thedoor is removed. Operation with the door removed or ajar canpermit the escape of dangerous fumes. All panels must besecurely closed at all times for safe operation of the furnace.
NOTE:
Direct drive motors have bearings which are permanentlylubricated and under normal use, lubrication is not recom-mended.
INDOOR BLOWER TIMINGThe control module controls the indoor blower. The blower
starts approximately 45 seconds after ignition. The FAN-OFF period is approximately 100 seconds from the interrup-tion of gas flow.
ROOM AIR THERMOSTATHEAT ANTICIPATOR ADJUSTMENT
Set the thermostat heat anticipator according to the currentflow measured, or the settings found in the notes on thefurnace wiring diagram (found inside the furnace casing).
Installer's GuideINSTRUCTIONS TO THE OWNERSIn the event that electrical, fuel, or mechanical failuresoccur, the owner should immediately turn the gassupply off at the manual gas valve, located in the burnercompartment (See Figure26). Also turn off electricalpower to the furnace and contact the service agencydesignated by your dealer.
Should overheating occur, or the gas supply fail to shut off,shut off the gas valve to the unit before shutting off theelectrical supply. Failure to follow this warning could resultin property damage, personal injury, or death.
Carbon monoxide, fire or smoke can cause serious bodilyinjury, death, and!or property damage.
A variety of potential sources of carbon monoxide can be foundin a building or dwelling such as gas-fired clothes dryers, gascooking stoves, water heaters, furnaces and fireplaces. TheU.S. Consumer Product Safety Commission recommendsthat users of gas-burning appliances install carbon monoxidedetectors as well as fire and smoke detectors per the manu-facturers installation instructions to help alert dwellingoccupants of the presence of fire, smoke or unsafe levels ofcarbon monoxide. These devises should be listed by Under-writers Laboratories, Inc. Standards [br Single and MultipleStation Carbon 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 any detec-tors and makes no representations regarding any brand ortype of detector.
OPERATING INFORMATIONFLAME ROLL-OUT DEVICE
All models are equipped with a thermal control device on theburner cover. In case of flame roll-out, the device will thecause the circuit to open which shuts off all flow of gas.
ABNORMAL CONDITIONS1. EXCESSIVE COMBUSTION VENT
PRESSURE OR FLUE BLOCKAGE
If pressure against the induced draft blower outletbecomes excessive, the pressure switch will shut offthegas valve until acceptable combustion pressure is againavailable.
2. LOSS OF FLAME OR GAS SUPPLY FAILURE
If loss of flame occurs during a heating cycle (when flameis not present at the sensor), the control module will retrythe ignition sequence up to two times after the sensorcools. If ignition is not achieved, it will lockout thefurnace.
3. POWER FAILURE
If there is a power failure during a heating cycle, thesystem will restart the ignition sequence automaticallywhen power is restored, if the thermostat still calls forheat.
4. INDUCED DRAFT BLOWER FAILURE
If pressure is not sensed by the pressure switch, it willnot allow the gas valve to open, therefore the unit will notstart. If failure occurs during a running cycle, the pres-sure switch will cause the gas valve to close and shut theunit down.
18-CD19D2-18 23
Installer's Guide
Failure to follow safety warnings exactly, could resultin a fire or explosion causing property damage,personal injury or loss of life.
-- Do not store or use gasoline or other flammablevapors and liquids in the vicinity of this or anyother 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 aneighbor's phone. Follow the gas supplier'sinstructions.
• If you cannot reach your gas supplier,call the fire department.
-- Installation and service must be performed bya qualified installer, service agency or the gassupplier.
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 theState of California to cause cancer through inhalation.Glasswool fibers may also cause respiratory, skin, oreye 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: rinsewasher thoroughly.
• Operations such as sawing, blowing, tear-out, andspraying may generate fiber concentrations requiringadditional respiratory protection. Use the appropriateNIOSH approved respirator in these situations.
FIRST AID MEASURES
Eye Contact - Flush eyes with water to remove dust.If symptoms persist, seek medicalattention.
Skin Contact - Wash affected areas gently with soapand warm water after handling.
Flashing Slow ---
Flashing Fast---Continuous ON ---
Continuous OFF ---
2 Flashes ---
3 Flashes ---
4 Flashes ---
5 Flashes ---
6 Flashes ---
7 Flashes ---
8 Flashes ---
9 Flashes ---
INTEGRATED FURNACE CONTROL ERROR FLASH CODES
Normal - No call for Heat
Normal - Call for Heat
Replace IFCCheck Power
System Lockout (Retries or Recycles exceeded)
Draft Pressure Error - Possible problemsa) Venting problem
b) Pressure seitch problem
c) Inducer problemOpen High Limit Device
Flame sensed when no flame should be present
115 Volt AC power reversed or Poor GroundingGas valve circuit error
Low flame sense signal
Check Ignitor circuit and Line "N" to 24VAC
"Common" voltage (< 2volts)(possible grounding problem)
Tr_'_
6200 Troup Highway
Tyler, TX 75707
For more information contact Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right
your local dealer (distributor) to change design and specifications without notice.