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Trane 4TWX6 Heat Pump User Manual

1. 18 02201 8 High Efficiency Single Stage Upflow Horizontal and Downflow Horizontal Gas Fired Direct Vent Condensing Furnaces UX1B040A9H21B DX1B040A9H21B UX1B060A9H31B DX1B060A9H31B UX1B080A9H31B DX1B080A9H31B UX1C100A9H41B DX1C100A9H31B UX1D120A9H51B DX1D120A9H51B First letter may be A 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 CERTIFIED UX1 H DX1 H 5 DOWNFLOW AIF FLOW UPFLOW AB UPFLOW HORIZONTAL DOWNFLOW HORIZONTAL Es FLOW FLOW 9 A341624P08 Installer s Guide SAFETY SECTION The following safety practices and precautions must be followed during the installation servicing and operation of this furnace 1 2008 Trane Use only with the type of gas approved for this fur nace Refer to the furnace rating plate Install this furnace only in a location and position as specified in Location and Clearances page 4 of these instructions Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combus tion and Ventilation pages 8 9 of these instruc tions Combustion products must be discharged outdoors Connect this furnace to an approved vent sy
2. li AS O i f rt MAIN MANUAL SHUTOFF VALVE dle UNION JOINT AUTOMATIC GAS VALVE WITH MANUAL SHUTOFF HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE UPFLOW SHOWN 30 18 CD22D1 8 A CAUTION Use a backup wrench on the gas valve when installing gas piping to prevent damage to the gas valve and manifold assembly TABLE 10 NATURAL GAS ONLY TABLE OF CUBIC FEET PER HOUR OF GAS FOR VARIOUS PIPE SIZES AND LENGTHS LENGTH OF PIPE tE a 2 1 34 28 _1 520 a o ofo efr 1 0 aso 90 This table is based on pressure drop of 0 3 inch and 0 6 SP GR gas TABLE 11 ORIFICE SIZES INPUT NUMBER MAIN BURNER ORIFICE RATING DRILL SIZE BTUH NAT GAS LP GAS 40 000 60 000 80 000 100 000 120 000 COMBUSTION AND INPUT CHECK 1 Make sure all gas appliances are off except the fur nace 2 Clock the gas meter with the furnace operating de termine the dial rating of the meter for one revolu tion 3 Match the Sec column in the gas flow cfh Table 13 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 2 For 1 2 Cu Ft
3. 5 CONCENTRIC VENT ROOF TOP APPLICATION MAINTAIN 12 IN 18 IN FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE ROOF VENT REMOVE RIBS FROM COMBUSTION AIR ROOF BOOT FIELD SUPPLIED gt _ gt CONCENTRIC VENT ROOF INSTALLATION 18 CD22D1 8 IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installation of through the wall vented gas appliances as follows For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional
4. CAUTION Replace manifold pressure tap threaded plug and leak check after checking adjusting manifold gas pressure Table 11 lists the main burner orifices used with the fur nace If a change of orifices is required to correct the furnace input rating refer to Table 14 TABLE 12 FINAL MANIFOLD PRESSURE SETTINGS FUEL Pressure _ NATURAL GAS 3 5 W C 11 0 W C LP GAS HIGH ALTITUDE DERATE Input ratings BTUH of these furnaces are based on sea 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 input rate BTUH shall be reduced 4 for each 1 000 ft above sea level The furnace input rate shall be checked by clocking the gas flow rate CFH and multiplying by the heating value obtained from the local utility sup plier for the gas being delivered at the installed altitude 32 Separate the tube at the unit Tee and reconnect with a short piece of field supplied tube and another Tee with the U Manometer attached Be sure to reconnect unit tubing to original position after testing the manifold pressure Field supplied barb fitting with manometer tube is attached to the OUTLET PRESSURE TAP on the outlet side of the gas valve Input rate changes can be made by adjusting the mani fold pressure min 3 0 max 3 7 in W C Natural Gas or changing orifices orifice change may not always be required
5. FURNACE SURE POWER AGREES WITH EQUIPMENT 51 LOW VOLTAGE 24 V WIRING TO BE NO 18 A W G MIN GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM THESE LEADS PROVIDE V POWER FOR CONNECTION OF ELECTRONIC AIR CLEANER AND HUMIDIFIER MAX LOAD 1 0 AMPS EACH THE TERMINAL FROM THE THERMOSTAT MUST BE WIRED TO THE TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWER OPERATION DURING COOLING IGNITION CONTROL IS POLARITY SENSITIVE HOT LEG OF 120 VOLT POWER SUPPLY MUST BE CONNECTED TO THE BLACK LINE POWER LEAD AS INDICATED ON THE WIRING DIAGRAM OR IGNITION LOCKOUT WILL OCCUR THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING CONNECTION TO THE 24 V POWER SUPPLY COMMON OUTDOOR UNIT NO TRANSFORMER GROUND e FURNACE JUNCTION T BOX 6 EE TO 115V 1 PH 60 HZ POWER SUPPLY PER LOCAL CODES EAC SEE 5 From drawing B340388 Rv 2 TWINNING CONNECTION DIAGRAM FOR TWINNING 1 STAGE FURNACES WITH SINGLE WIRE TWINNING FEATURE 1 d 1 STAGE HEATING ONLY THERMOSTAT THERMOSTAT WITH FAN SWITCH FURNACE NO 1 FURNACE NO 2 BLOWER OPERATION OF UNIT NO 2 IS SYNCRONIZED WITE UNIT NO TVIR SIGNALS BOTH FURNACES MUST BE POWERED FROM ees THE SAME 115V LEG OF CIRCUIT PANEL NOTES
6. Three brackets with screws are included with down flow furnaces for installation to stabilize and secure the furnace and TXC cased coil in the horizontal posi tion See Figure 4 IMPORTANT The 2 4TXC cased coil must be placed downstream of the furnace In horizontal installations the apex of the coil may point either toward or away from the furnace See the 2 4TXC coil Installer s Guide for more details The cased coil is secured to the furnace and both the furnace and the cased coil must be properly supported The brackets mount using the rear screws on the coil case and use the screws provided to secure the bracket to the furnace The remaining bracket is placed as close to center as possible horizontally between the coil case front and the furnace bottom channel for downflow horizontal furnace Use four of the screws provided to secure the bracket The upflow furnace converted to horizontal aligns and attaches the TXC coil as in Fig ure 1 However the coil requires additional support CASED COIL CONNECTION BRACKET FOR DOWNFLOW FURNACE IN HORIZONTAL DOWNFLOW ONLY The furnace may be installed in an attic or crawl space in the horizontal position by placing the furnace on the left side as viewed from the front in the vertical posi tion The horizontal furnace installation in an attic should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of
7. 18 CD22D1 8 ALTERNATE UPFLOW FILTER CLIP TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER BRACKET INSTALLATION 09224 INSTALLATIONS 1 Determine the location to be used The furnace These furnaces require high velocity type air filters cabinet has dimples for location of the alternate fur Downflow furnace filters must be located outside the nace clips Side return only Pre drill clearance furnace cabinet Typical installations are shown in Fig holes with a 3 16 drill Bottom return holes are Ure 19 Tables 4 5 and 6 provide information for instal pre drilled See Figure 18 lation of the filter retaining brackets shipped with 2 Install the clips in front and rear of the desired loca downflow furnaces tion using the screws provided The filter clip with TABLE 4 the leaf spring mounts in the rear of the cabinet MODELS CABINET FILTER NUMBERS WIDTH QTY amp SIZE DX1B040A9H21B DX1B060A9H31B 17 1 2 2 14 X20 X 1 DX1B080A9H31B DX1C100A9H41B 2 16 X 20 X 1 DX1D120A9H51B 24 1 2 2 16 X 20 X 1 First letter may be TABLE 5 LOCATING FILTER RETAINER BRACKETS IN DUCTWORK x FILTER DIMENSION DIMENSION BRACKET ALTERNATE FILTER LOCATION 15 CLIPS LOCATION 17 1 2 16 1 4 4 Tote 24 1 2 DOWNFLOW DOWNFLOW HORIZONTAL TABLE 6 MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR UPFLOW HORIZONTAL AND DOWNFLOW HORIZONTAL FURNACES FRONT VENT NOTE
8. CAUTION Do NOT run vent through chimney for wood burning or oil furnaces or incinerators If remaining free area between single wall flue pipe and masonry chimney is to be used for another gas appliance venting area must be sufficient to vent that appliance and that appliance must be con nected to chimney with separate entry openings IMPORTANT The single wall flue pipe joints must be sealed The 90 elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of ma sonry chimney 24 SEAL BETWEEN FLANGE PIPE COUPLING AND METAL PANEL WITH HI TEMP RTV SILICONE SEALANT FLUE PIPE COUPLING SUPPORT CEILING GALVANIZED FIRESTOP SHOULD BE FABRICATED WITH 3 7 8 DIA HOLE FOR SUPPORT FLANGE 12 x 12 PANEL OR 12 DIA MIN CLEARANCE ACCEPTABLE FOR PVC VENT SENT 1 ACCEPTABLE FOR TYPE 29 4C STAINLESS STEEL VENT PIPE VENTING THROUGH CEILING PVC PLASTIC VENTING ONLY THROUGH UNUSED CHIMNEY STAINLESS STEEL VENT CAP OPTIONAL SEE CAUTION FLUE PIPE SUPPORT THE SINGLE WALL FLUE PIPE AND CENTER IT IN THE CHIMNEY OPENING WI ANGLES AS SHOWN O ANOTHER EQUIVALEN MANNER JUPLING TO SUPPORT PE FROM ANGLES R OTHER SUITABLE JPPORT METHOD COUPLING AS REQUIRED FLUE PIPE HORIZONTAL VENTING TO VERTICAL VENTING CAUTION Do run vent through chimney for wood burn ing or oil furnaces or incinerators or any other gas appliance IMPORTANT The singl
9. 30 kw 36 inches 91 cm for appliances gt opening 100 000 Btuh 30 kw Clearance to a mechanical air supply inlet 6 feet 1 83m feet 91 cm above if within 10 feet 3m horizontally Clearance above a paved sidewalk or paved driveway 7 feet 2 13 m 7 feet 2 13 m located on public property M Clearance under veranda porch deck or balcony under veranda Clearance under veranda porch deck or balcony deck or balcony 712 Clearance to window or door that be opened Notes 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code t 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 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 ELBOW AND TEE MUST AS CLOSE TOGETHER AS POSSIBLE POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS 18 CD22D1 8 19 Installer s Guide CAUTION When the vent pipe is exposed to temperatures below freezing when it passes through unheated spaces etc the pipe must be insulated with 1 2 inch 2
10. CLEARANCE REQUIRED AT TOP OF PLENUM IS 1 18 CD22D1 8 13 Installer s Guide GENERAL VENTING THIS FURNACE MUST BE VENTED TO THE OUT DOORS THESE FURNACES ARE INDUCED DRAFT VENTED AND MUST NOT BE CONNECTED TO ANY VENT SERVING ANOTHER APPLIANCE PLEASE NOTE THAT THESE FURNACES USE POSITIVE PRES SURE VENT SYSTEMS Proper venting is essential to obtain maximum effi ciency from a condensing furnace Proper installation of the vent system is necessary to assure drainage of the condensate and prevent deterioration of the vent system American Gas Association has certified the design of condensing furnaces for a minimum of 0 clearance from combustible materials with a single wall plastic vent pipe The recommended system is assembled from 2 2 1 2 3 plastic pipe and fittings See Table 7 page 12 Where the system is routed to the outdoors through an existing masonry chimney containing flue products from another gas appliance or where required by local codes then 8 venting of Type 29 4C stainless steel must be used in place of PVC material These furnaces have been classified as CATEGORY IV furnaces in accordance with the latest edition of ANSI 721 47 CAN CGA 2 3 Standards Category IV furnaces operate with positive vent pressure and with a vent gas temperature less than 140 F above the dewpoint These conditions require special venting sys tems which must be gas tight and water tight NOTE When an existi
11. INSURE 24 FURNACE TRANSFORMERS ARE IN PHASE PRIOR TO COMPLETING CONNECTIONS CHECK VOLTAGE BETWEEN R TERMINALS OF EACH FURNACE IF VOLTAGE IS GREATER THAN 10V REVERSE THE BL AN RD SECONDARY LEADS ON ONE OF THE FURNACE TRANSFORMERS CONNECTION MAY BE REQUIRED FOR ELECTRONIC THERMOSTAT IF CURRENT EXCEEDS THERMOSTAT CURRENT RATING USE ISOLATION RELAYS RI AS SHOWN DO NOT CONNECT W TO W ISOLATIONIRELAY ISOLATION RELAY NOT NEEDED IF THE THERMOSTAT CONTACTS ARE RATED 1 0 OR ABOVE 1 ISOLATION RELAY SEE NOTE 4 INTER COMPONENT WIRING ALTERNATE WIRING CONFIGURATION 77 SEE NOTE 4 FIELD LINE WIRING FACTORY esa LINE V J WIRING p SEE NOTE 3 From Dwg 21B341422 Rev 3 28 18 CD22D1 8 Installers Guide TWINNING CONNECTION DIAGRAM FOR TWINNING 1 STAGE FURNACES WITH SINGLE WIRE TWINNING FEATURE 1 STAGE HEAT 1 STAGE COOL THERMOSTAT 1 STAGE HEATING COOLING THERMOSTAT OUTDOOR UNIT WITH TRANSFORMER FURNACE NO 1 ISOLATION RELAY FIELD SUPPLIED SEE NOTE 3 OUTDOOR UNIT NO TRANSFORMER SEE NOTE 5 GAS PIPING The upflow horizontal furnace is shipped standard for left side installation of gas piping A knockout is pro vided on the right side for an alternate gas piping ar rangement See Figure 37 The installation of piping shall be in accordance with piping codes and the regulations of the loc
12. Quickly apply a heavy coat of cement to the pipe end and insert pipe into fitting with a slight twisting movement until it bottoms out 4 Hold the pipe in the fitting for 30 seconds to pre vent tapered socket from pushing the pipe out of the fitting 5 Wipe all excess cement from the joint with a rag Allow 15 minutes before handling Cure time varies according to fit temperature and humidity TABLE 7 PLASTIC PIPE DESIGNATIONS ASTM STANDARD F891 D2665 D1785 D2241 PIPE TYPE ALLOWABLE TEMPERATURE MARKING CPVC ASTM STANDARD D2846 F441 F442 ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING kk Allowable temperatures based on classifications covered in ASTM 04396 Deflection Temps Under Load 264 PSI Allowable temperatures based on classifications covered in ASTM 01784 Deflection Temps Under Load 264 PSI Allowable temperatures based on classifications covered in ASTM 03965 Deflection Temps Under Load 264 51 NOTE It is recommended that the first joints from the furnace be connected and sealed with high temperature RTV This will enable the pipes to be removed later without cutting Be sure to properly support these joints BONDING OF PVC Commercially available solvent cement must be used to join the pipe and fittings Follow instructions on the container carefully Procedure for Cementing Joints 1 Cut pipe square remove ragged edges and burrs Chamfer end of pipe then c
13. WALL MOUNT FLANGE OPTIONAL APPROVED TERMINATION 12 MIN ABOVE NORMALLY EXPECTED 1 CLEARANCE SNOW ACCUMULATION AIR SPACE VENTING THROUGH COMBUSTIBLE WALLS Pitch 1 4 Inch Per Ft CLEARANCE 0 ACCEPTABLE FOR PVC VENT PIPE 1 ACCEPTABLE FOR 29 4C STAINLESS STEEL VENT PIPE 18 CD22D1 8 Installer s Guide SUPPORT HORIZONTAL PIPE EVERY 3 WITH THE FIRST SUPPORT AS CLOSE TO THE FURNACE AS POSSIBLE INDUCED DRAFT BLOWER HOUSING AND FURNACE MUST NOT SUPPORT THE WEIGHT OF THE FLUE PIPE WALL MOUNT FLANGE OPTIONAL COUPLING PLASTIC VENTING 4 6 IN MIN APPROVED TO JOINT TERMINATION RST OVER JE PIPE i i INLET Fa OUTLET 00 els UPWARD PITCH 1 4 PER FOOT CEMENT 12 MIN ABOVE MORTAR SEAL NORMALLY EXPECTED INSIDE amp SNOW ACCUMULATION OUTSIDE ABEN ET 40 UPFLOW OR DOVNFLOW FURNACE ic HORIZONTAL AND VERTICAL VERTICAL VENTING THROUGH NON COMBUSTIBLE WALLS Pitch 1 4 Inch Per Ft NOTE VENT AND INLET MUST BE SUPPORTED A MAXIMUM 3 INTERVALS STRAPS OR OTHER SUITABLE SUPPORTS MAXIMUM OF 3 0 INTERVALS Y APPROVED 1 TERMINATION amp 3 upwaro PITCH 1 4 PER FOOT FIRST SUPPORT SHOULD BE AS CLOSE TO FURNACE CONNECTION OUTSIDE AS POSSIBLE WALL COMBUSTION AIR INLET 40 UPFLOW OR NOTE ANY FITTINGS PASS
14. 08 LNOYJONY 2 1 1 LNOYJONY 101 1131 8 1 X 81 1 14405 17214121313 JIOH 8 1 1 1 53015 31 8311 OTN 1331 355 950 19415 91 1 9 IS A INO 3015 30113 WLNOZIMOH 17214123413 INOMIONY 8 1 1 21144 1 021 401 9 11 7 53015 3 378115 9 09 01 SONVEVS 10 WNIWININ 2 5310 335 123 02 3011 40 3015100 J D 18 5 i 2 uno gt SSHONI NI SNOISNANIA SNIMVdd ANILLNO H EXN 8 6 18 CD22D1 8 Installers Guide 0 ASH 98817018 011 21144 834084 804 118 1 19 11 INJA OL 814348 10 1111 183811310 LV 13000 JWOS NO YO 2 1 2 01 0311011 39 AVW 3414 INJA 10 ae SILON Z V 18 AWW 811111 3305 v 6 0 z 18 AWW 831111 131305 ses nlu YO 39 AVW 14384 LNOWDONY NIVYG 31 5 30802 1 1 7 1 02 62 0 NI I 401 NI LNOY4 Wer dae PIVINT ULV NI I 0 1123 02 NOILOINNOD uf 53015 SY9 2 1 10 155019 NI 0 1013 2 NII 401 INOWIONY M 1 1 01123 802 NI O 1431 191912313 8 10 NI 0 1 9 53015 1 01121 502 0 1337 3HL NO 394VHOSIC 30715 WLNOZIMOH NI 0 3011 NI I 401 NI
15. 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 gas obtained from the utility company and compare to the nameplate rating This must not exceed the nameplate rating 7 Changes can be made by adjusting the manifold pressure or changing orifices orifice change may not always be required To adjust the manifold pressure a Turn off all electrical power to the system 18 CD22D1 8 Installers Guide b Attach a manifold pressure gauge to the outlet pressure tap marked OUT PRESS TAP on White Rodgers gas valve model 36 boss marked OUT P on White Rodgers gas valve model 36G See Figure 53 for White Rodgers gas valve model 36F and Figure 54 for White Rodgers gas valve model 36G For the gas valve model 36F measurement requires removal of the plug and installation of a barbed fitting Attach flexible tubing and a manometer to the barbed fitting For the gas valve model 36G do not remove the pressure tap test screw Using a 3 32 hex wrench loosen the pressure tap test screw one turn and install 5 16 flexible tubing and a ma nometer directly onto the outlet pressure boss c Turn on system power and energize valve d Remove the regulator adjustment screw cap on the gas valve for manifold pressure adjustment e Turn the adjustment nut clockwise to increase the gas flow rate and counterclockwise to de crease t
16. WATER FURNACE Nearer CLOTHES DRYER UNCONFINED AIR FOR COMBUSTION AND VENTILATION If these furnaces are installed in a nondirect vent capac ity then the adequate flow of combustion and ventilat ing air must not be obstructed from reaching the fur nace Air openings provided for combustion air must be kept free of obstructions which restrict the flow of air Airflow restrictions affect the efficiency and safe opera tion of the furnace Keep this in mind should you choose to remodel or change the area which contains your furnace Furnaces must have a free flow of air for proper performance Provisions for combustion and ventilation air shall be made in accordance with latest edition of Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 CAN CGA B149 1 or ap plicable provisions of the local building codes Special conditions created by mechanical exhausting of air and fireplaces must be considered to avoid unsatisfactory furnace operation OUTSIDE AIR IS RECOMMENDED The use of indoor air for most applications is acceptable unless there is the presence of corrosive chemicals or contamination Certain types of installation will require the use of outside air for combustion The following types of installations will require use of OUTDOOR AIR for combustion due to chemical expo sures Commercial buildings Buildings with indoor pools Furnaces installed in confin
17. a potentially hazardous situation which if not avoided could result in death or serious injury b CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It is also used to alert against unsafe practices and hazards involving only property damage A WARNING FIRE OR EXPLOSION HAZARD Failure 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 GENERAL INSTALLATION INSTRUCTIONS The 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 may need to be reduced See High Altitude Installation Material in this shipment has been inspected at the factory and released to the transportation agency without known damage Inspect exterior of carton for evidence of rough handling in ship ment Unpack carefully after moving equipment to approximate location If damage to contents is found report the damage immediately to the de livering agency Codes and local utility requirements governing the installation of gas fired equipment
18. ceiling below 18 CD22D1 8 ELECTRICAL CONNECTIONS Make wiring connections to the unit as indicated on en closed wiring diagram As with all gas appliances using electrical power this furnace shall be connected into a permanently live electric circuit It is recommended that furnace be provided with a separate circuit protec tion device in the electric circuit The furnace must be electrically grounded in accordance with local codes or in the absence of local codes with the National 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 The hot leg of the 120V power supply must be connected to the black power lead as indicated on the wiring diagram Provision for hooking up an electronic air cleaner and or humidifier is provided on the integrated control Refer to the SERVICE FACTS literature and unit wir ing diagram attached to furnace diagram attached to furnace TWINNING FURNACES These furnaces may be twinned Twinning requires that two furnaces with the same configuration capacity and airflow must be used They shall have common re turns with equal pressure drops or ducts with equiva lent lengths and sizes See Field Wiring Diagrams for proper hookup FIELD WIRING DIAGRAM FOR If upflow furnace is installed over a finished ceiling overflow from the primary drain vent stack must flow into an auxillary dr
19. conditions that could lead to personal in jury Excessive draining of condensate may cause satu rated ground conditions that may result in damage to plants NOTE Use 1 2 or larger PVC or CPVC pipe and fittings as re quired for drain connections fittings pipe and solvent cement not provided NOTE A corrosion resistant condensate pump must be used if a pump is required for a specific drain system IMPORTANT The condensate drain should be installed with provisions to prevent winter freeze up of the condensate drain line Fro zen condensate will block drains resulting in furnace shut down If the drain line cannot be installed in a conditioned space then UL listed heat tape should be applied as re quired to prevent freezing per manufacturer s instructions The heat tape should be rated at 5or 6 watts per foot at 120 volts Self regulating preferred or thermostatically controlled heat tape is required Evaporator and furnace condensate drain piping may be manifolded together A primary drain vent stack must be installed and terminated below the outlet of the secondary heat exchanger drain connection to pre vent water from damaging furnace controls if the pri mary drain outlet plugs up Where the furnace is in stalled above a finished ceiling the primary drain vent stack must be installed such that overflow from the vent stack opening will flow into an axillary drain pan in order to prevent water damage to the finished
20. 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 18 18 CD22D1 8 Installers Guide Non Direct Vent Terminal Clearances petit above grade veranda porch deck or 12 inches 30 cm 12 inches 30 cm 6 inches 15 cm for appliances lt 10 000 Btuh 3 kw inches 2 cm for appliances gt 10 000 Btuh 3 5 and 4 feet 1 2m below to the side of opening 1 foot 0 3m 100 000 Btuh 30 kw 36 inches 91 cm for appliances gt above opening 100 000 Btuh 30 kw Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm 5 from the center line of the terminal G Clearance to inside comer 00000 to inside corner Clearance to each side of center line extended above 3 feet 91 cm with a height 15 feet 4 5 m above the meter regulator assembly meter regulator assembly 6 inches 15 cm for appliances lt 10 000 Btuh 3 kw 12 Clearance to nonmechanical air supply inlet to building inches 30 cm for appliances gt 10 000 Btuh 3 kw and lt 4 feet 1 2 below or to side of opening 1 foot 300 above or the combustion air inlet to any other appliance 100 000 Btuh
21. no trap is needed in this line Left side extension hose here UPFLOW HORIZONTAL 21 amp 24 UNITS Left side only 25 Installer s Guide The trap must be repositioned to the exterior of the cabinet Remove the trap from its present location and reposition the trap outside of the unit through the long circular hole next to the secondary recuperative cell Remove the larger drain line from the secondary cell and trim to fit between the secondary cell and the new trap location On upflow units plug the hole in the blower deck where the tube went through Remove the hose from the induced blower and reposi tion into the other drain tap of the inducer which is lo cated 90 clockwise around the inducer Move the cap from that drain tap to the unused drain tap On upflow units plug the hole in the blower deck where the tube went through This tube on downflow units will need to be cut to fit between the inducer and the trap On up flow units this tube may need to be extended using the tubing shipped with the furnace DOWNFLOW VERTICAL Use CPVC tubing from Trap outlet over burner box to cabinet exit 26 Cut off curved end of Inducer drain hose ees DOWNFLOW HORIZONTAL Connections must be made to an OPEN VENTED DRAIN Outdoor draining of the furnace and coil con densate is permissible if allowed by local codes Caution should be taken to prevent drains from freezing or caus ing slippery
22. req MAINTAIN 12 18 FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER BAYVENT200B COMBUSTIBLE MATERIAL WALL A minimum clearance of 1 to combustible materials must be maintained when using single wall stainless steel venting See Figure 28 20 Shield material to be a minimum of 24 gauge stainless or aluminized sheet metal Minimum dimensions are 12 x12 Shield must be fastened to both inside and out side of wall Use screws or anchor type fasteners suited to the outside or inside wall surfaces NONCOMBUSTIBLE MATERIAL WALL The hole through the wall must be large enough to maintain pitch of vent and properly seal Use cement mortar seal on inside and outside of wall See Figure 29 VENTING THROUGH THE ROOF When penetrating roof with a 2 PVC vent pipe a 2 electrical conduit flashing may be used for a weather tight seal Lubricate flexible seal on flashing before PVC pipe is pushed through the seal Field Supplied _12 MINTO _ _ oo OWERHANG MAINTAIN 12 IN 18 IN FOR CANADA INIMUM CLEARANCE ABOVE HIGHEST LEVEL OR GRADE BAYAIRSOAVENTA WHICH EVER IS GREATER Sidewall NOTE No vent cap as shown in Figure 33 is the preferred method for vertical vent termination in extremely cold climates In extreme climate conditions insulate the exposed pipe above the roof line with Armaflex type insulation COUPLING PLASTIC VENTING
23. the furnace See Figure 4 amp Clearance Table Line contact is only permissible between lines formed by intersections of the top and two sides of the furnace casing and building joists studs or framing Installer s Guide The furnace may be placed horizontally in a crawl space on a pad or other noncombustible material which will raise the unit for sufficient protection from moisture The furnace must be supported at both ends and the middle when installed horizontally a ae PIE Oa ee oe MO eg ett a a D 2 f NA io lt OSS or N 22 N 7 i S 40 SSN HORIZONTAL ar lt Sy Se AD BIKAR ACK SHOWN NS ARN S 4 SON ae The furnace must also be elevated a minimum of 6 inches to allow clearance for the condensate drain to exit the cabinet in the horizontal position The horizontal furnace may also be suspended from the joists using 3 8 all thread rods with pieces of angle iron underneath the furnace to form a hanging rack at both ends and the midpoint The rods need to be of sufficient length to allow for proper clearances from combustible materials The angle iron needs to be at least 32 in length to allow for access to service panels 50 CU FT OR MORE PER 1000 BTU HR INPUT ALL EQUIP INSTALLED
24. to 712 of 27 pipe amp 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 BAYAIRSOVENTA termination kit is used the equivalent length of pipe is 5 feet There is zero equivalent length for the BAYVENT200 6 Pipe adapters are field supplied 7 4 pipe be reduced to 3 for termination with BAYAIRS0OAVENTA BAYVENT200 without additional length restriction 23 SINGLE PIPE VENTING DOWNFLOW FURNACE UPFLOW FURNACE 0 27 or greater gt 0 27 A B 2 minimum Vent only to outside Air Inlet A A 2 minimum Vent only to outside 18 CD22D1 8 17 Installer s Guide INSIDE CORNER DETAIL N VENT TERMINAL 9 AIR SUPPLY INLET 55 AREA WHERE TERMINAL IS PERMITTED Direct Vent Terminal Clearances Canadian Installations US Installations A a above grade veranda porch deck or 12 inches 30 cm 12 inches 30 cm 6 inches 15 cm for appliances lt 10 000 Btuh 3 kw 12 6 inches 15 cm for appliances lt 10 000 Btuh 3 kw 9 inches 30 cm for appliances gt 10 000 Btuh 3 kw and lt inches 23 cm for appliances gt 10 000 Btuh 3 kw and lt 100 000 Btuh 30 kw 36 inches 91 cm for appliances gt 50 000 Btuh 15 kw 12 inches 30 cm for appliances gt 50 000 100 000 Btuh 30 kw Btuh 15 kw Vertical clearance to ventilated soffit located abov
25. wiring plumbing and flue connections must be adhered to In the ab sence of local codes the installation must conform with latest edition of the National Fuel Gas Code ANSI 2228 1 National Installation Code CAN CGA B149 1 The latest code may be obtained from the American Gas Association Laboratories 400 N Capitol St NW Washington D C 20001 1 800 699 9277 www aga org These furnaces have been classified as CATEGORY IV furnaces in accordance with latest edition of ANSI Z21 47 CGA 2 3 standards 18 CD22D1 8 Installers Guide Contents INSTALLATION INSTRUCTIONS General Installation Instructions Location and Clearances Outline Drawings Upflow Installation Downflow Installation Horizontal Installation Air For Combustion and Ventilation Duct Connections Return Air Filters General Venting Instructions Venting Material Venting Tables Horizontal Venting Venting Through The Wall Venting Through The Roof Downward Venting Venting Through a Masonry Chimney Condensate Drain Instructions Electrical Connections Field Wiring Diagrams Gas Piping Combustion Input Checks Start Up and Adjustment Preliminary Inspections Lighting Instructions Sequence Of Operation Control And Safety Switch Adjustments Airflow Adjustment Conditions Affecting Furnace Operation IFC Error Flash Code Category IV furnaces operate with positive vent static pressure and with a flue loss less than 17 percent These condi
26. 2 7 mm thick Armaflex type insulation or equal If the space is heated sufficiently to prevent freezing then the insula tion would not be required If domestic water pipes are not protected from freezing then it is assumed the space meets the condition of a heated space HORIZONTAL VENTING THROUGH WALL These furnaces may be installed as direct vent as shipped or as nondirect vent Installation must con form to national state and local codes The vent amp inlet terminals must be located at least 12 minimum above normally expected snow accumulation level Avoid areas where staining or condensate drippage may be a problem Location of the vent wind terminal should be chosen to meet the requirements of Figure 24 for either direct or non direct vent applications PITCH Venting through the wall must maintain 1 4 per foot pitched upward to insure that condensate drains back to the furnace FLUE GAS DEGRADATION The moisture content of the flue gas may have a detrimental effect on some building materials This can be avoided by using the roof or chimney venting option When wall venting is used on any surface that can be affected by this mois ture it is recommended that a corrosion resistant shield 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 3 feet of the vent terminal 12 MINIMUM TO OVERHANG SCREWS 4
27. CE AIR FROM OUTDOORS 54 225 2 2 22 40 52252 OUTLET SPACE OUTDOOR AIR DUCTS CONFINED SPACE kK AIR FROM VENTILATED ATTIC CRAWL SPACE ATTIC LOUVERS TO OUTDOORS CONFINED SPACE INLET AIR DUCT ALTERNATE INLET AIR 2 gt CONFINED SPACE AIR FROM VENTILATED ATTIC ATTIC LOUVERS TO OUTDOORS CONFINED 7 2 4 4 gt vA 4 2 7 2 Installer s Guide DUCT CONNECTIONS Air duct systems should be installed in accordance with standards for air conditioning systems National Fire Protection Association Pamphlet No 90 They should be sized in accordance with ACCA Manual D or which ever is applicable Central furnaces when used in connection with cooling units shall be installed in parallel or on the upstream side of the cooling coil to avoid condensation in the heat exchanger With a parallel flow arrangement the damp ers or other means used to control flow of air shall be adequate to prevent chilled air from entering the fur nace and if manually operated must be equipped with means to prevent operation of either unit unless the damper is in full heat or cool position On any job flexible connections of nonflammable mate rial may be used for return air and discharge connections to prevent transmission of vibration Though these units have been specifically designed for quiet vibration free operation air ducts
28. ING DOWNFLOW MODELS THROUGH AN UNHEATED SPACE MUST INSULATED 2 45 ELBOW 2 ALA E 6 5 45 N OUTSIDE WALL STUB CUT AT COMBUSTION SS REDUCING 45 ANGLE AIR FIELD ED IF NEEDED I nae 2 2 1 2 T LJ or 3 PIPING COMBUSTION AIR 3 PIPING 7 SUPPLIED SEAL ALL BAYAIR30AVENTA BAYVENT200B WAIL CAVITIES 18 CD22D1 8 21 Installer s Guide DOWNWARD VENTING Furnace may be in vertical or horizontal configuration DOWNWARD VENT LENGTH IS LIMITED TO A MAXIMUM OF 15 EQUIVALENT FEET 40 Inch Upflow or Downflow Furnace Slope 1 4 per ft 4 y Slope 1 4 per ft 6 a All horizontal pipes must be supported at a maximum of 3 foot intervals NOTES A Condensate trap for vent pipe must be a minimum of 6 inches in height B Condensate trap for vent and inlet pipe must be connected into a condensate drain pump an open or vented drain or it can be connected to the outlet hose of the furnace s condensate trap Outdoor draining of the furnace and coil condensate is per missible if allowed by local codes Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead t
29. INOU4 NI O NI O 3015 MOTJNMOG SIWWIHSLVW 32181150805 01 J NVYVJTO WNINININ ONIMVYA ANIILNO TVLNOZIHOH MOTANMOGC n91 G 1 2 uc 1 61 uV E 61 1 91 1 2 2 1 1 21812313 8 10 SSHONI SNOISNAINIG vv IGH6VOZIGIXG sCAGYOZIAC 0964021 60 1096 02101 0 16 6 02101 0 eVAGYOOIAC 29 68001 60 18 76 00121 0 1 6 08081 0 1 6 09081 0 vv CHOVOVOGI 6 080 0 68090 0 2 68080 0 9 695090 0 1076 08081 0 19 6 09081 0 7206 07081 0 0 SLON 335 TAON AINO 3015 1 21144 IVINOZIYOH INOWIONY 91 5 10 0 JLVSNIGNOD 18 CD22D1 8 lt 1 91 6 61 1371110 INOWIONM 31 31 IV 01123 02 5 9 211 18 8 lt 1 ub I LI 91 61 19915 1 21412313 8 10 INOMDIONY 1015 Zi 8 1 x 8 1 1 NIVUd JLVSNIGNOD IWLNOZIYOH 8 6 9818340 D 1 4 2 1 9 5 310 33S L3NNOD 1111 2D UPFLOW INSTALLATION Standoffs and screws See Figure 1 are included with the cased coils for attachment to the furnace There are clearance alignment holes near the bottom of the coil wrapper Drill screws are used to engage the furnace top flanges The standoff is inserted into the cabinet alignment hole The drill screws are inserted through th
30. INSTALLATIONS FURNACE WITH 8 FT CEILING MAXIMUM BTUH MINIMUM AREA IN SQUARE FEET INPUT RATING OF UNCONFINED SPACE 60 000 80 000 100 000 120 000 1 All air from inside the building as in Figure 8 The confined space shall be provided with two 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 an unconfined space The total input of all gas utiliza tion equipment installed in the combined space shall be considered in making this determination Refer to Table 2 for minimum open areas require ments 7 FURNACE CONFINED SPACE LESS THAN 50 CU FT PER 1000 BTU HR INPUT ALL EQUIP INSTALLED 2 All air from outdoors as in Figure 9 The confined space shall be provided with two permanent open ings one commencing within 12 inches of the top and one commencing within 12 inches of the bot tom of the enclosure The openings shall communi cate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors Refer to Table 2 for minimum open areas requirements TABLE 2 MINIMUM FREE AREA IN SQUARE INCHES EACH OPENING FURNACE ONLY From Duct Duct Furnace Maximum BTUH INPUT Rating 60 000 80 000 100 000 120 000 18 CD22D1 8 Installer s Guide CONFINED SPACE AIR FROM INSIDE BUILDING CONFINED SPACE PERMANENT OPENINGS CONFINED SPA
31. If the desired input rate can not be achieved with a change in manifold pressure then the orifices must be changed LP installations will require an orifice change Installation of this furnace at altitudes above 2 000 ft 610m shall be in accordance with local codes or in the absence of local codes the National Fuel Gas Code TABLE 13 _ 8 900 29 248 50 144 82 88 9 800 30 240 51 141 84 86 10 720 31 232 52 138 86 84 _12 600 33 218 54 133 90 80 15 480 36 200 57 126 96 75 16 450 37 195 58 124 98 73 18 400 39 185 60 120 104 69 21 343 42 172 66 109 116 62 _ 22 327 43 167 68 106 120 60 28 257 49 147 80 90 144 50 18 CD22D1 8 COVER AS SHOWN INSERT THE TOP FLANGE OF THE FRONT COVER UNDER THE LIP INSIDE THE BOX ALL SIDE FLANGES MUST BE OUTSIDE OF THE BOX ROTATE THE FRONT COVER INWARD MAKING SURE THAT ALL SIDE FLANGES ARE OUTSIDE OF THE BOX ANSI 2Z223 1 NFPA 54 or National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 Installation of this furnace at altitudes above 2 000 ft 610m shall be made in accordance with the listed high Altitude Conversion Kit available with this furnace IMPORTANT Re install the propane orifices to the same depth as the orifices supplied with the equipment See Table 15 for h
32. NT EXCEEDS THERMOSTAT CURRENT RATING USE ISOLATION RELAYS RI AS SHOWN DO NOT CONNECT W TO W ISOLATION RELAY NOT NEEDED IF THE THERMOSTAT CONTACTS ARE RATED AT 1 04 OR ABOVE CONNECTION MAY BE REQUIRED FOR ELECTRONIC THERMOSTATS ISOLATION RELAY SEE NOTE 4 WIRING ALTERNATE WIRING CONFIGURATION 77 SEE NOTE 4 t V N 2 RING CT OY RING W ISOLATION RELAY FIELD SUPPLIED SEE NOTE 4 From Dwg 21B341423 Rev 2 NOTE Maximum pressure to the gas valve for natural gas is 13 8 W C Minimum pressure is 5 0 W C Maximum pressure to the gas valve for propane is 13 8 W C Minimum pressure is 11 0 W C All gas fittings must be checked for leaks using a soapy solution before lighting the furnace DO NOT CHECK WITH AN OPEN FLAME 29 Installer s Guide AUTOMATIC GAS VALVE AUTOMATIC GAS VALVE WITH MANUAL SHUTOFF WITH MANUAL SHUTOFF MAIN MANUAL SHUTOFF VALVE ty MAIN MANUAL 7 SHUTOFF VALVE GROUND UNION JOINT SZ THE DOWNFLOW VERTICAL MAY INSTALLED LEFT OR RIGHT SIDE GAS PIPING 50 MAIN MANUAL AUTOMATIC GAS VALVE SHUTOFF VALVE WITH MANUAL SHUTOFF Sia 1 DRIP GROUND UNION JOINT
33. See Notes MODEL amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS o wo 1 so so 1o 100 s o 5 130 45 so 1o no o 5 130 DXICIO0ASHA1B NOT ALLOWED so 1o 130 so s 100 NOTES First letter may be T 1 The INLET AIR of one pipe systems require the installation of a 90 elbow to prevent dust and debris from falling straight into thefurnace and a 2 foot horizontal or vertical straight pipe section connected before or after the elbow 2 DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET Except adapters at the top of the furnace If different inlet and vent pipe sizes are used the vent pipe must adhere to the maximum length limit shown in the table above See Note 7 below for exception The inlet pipe can be of a larger diameter but never smaller than the vent pipe 3 MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED THE LENGTH SHOWN IS NOT A COMBINED TOTAL IT IS THE MAXIMUM LENGTH OF EACH Vent or Inlet air pipes in two pipe systems 4 One standard radius 90 elbow is equivalent to 12 of 4 pipe one SHORT radius 90 elbow is equivalent to 10 of 3 pipe and one LONG radius elbow is equivalent to 6 of pipe SHORT LONG radius 90 elbow is equivalent
34. TRUCTIONS 18 CD22D1 8 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 This appliance requires a special venting system If BAYATR30AVENTA or BAYVENT200B are used copy of the installation instructions for the kit shall remain with the appliance or equipment at the completion of installation The venting system installation instructions can be obtained from the manufacturer by writing to the following address American Standard Inc 6200 Troup Highway Tyler TX 75707 Attention Manager of Field Operations Excellence 23 Installer s Guide SEAL BETWEEN FLANGE PIPE COUPLING AND METAL PANEL WITH TEMP SILICONE SEALANT COUPLING SUPPORT FLANGE GALVANIZED PANEL FIRESTOP FLOOR FLUE PIPE CLEARANCE 0 ACCEPTABLE FOR PVC VENT PIPE 1 ACCEPTABLE FOR TYPE 29 4C STAINLESS STEEL VENT PIPE VENTING THROUGH FLOOR TYPE 29 4C STAINLESS STEEL VENTING USED THROUGH CHIMNEY THAT VENTS ANOTHER GAS APPLIANCE STAINLESS STEEL VENTCAP OPTIONAL ZE CAUTION SUPPORT THE SINGLE WAI STAINLESS STEEL GAS VENTING AND CENTER IT IN THE CHIMNEY OPENING WI ANGLES AS SHOWN OR ANOTHER EQUIVALENT MANNER HORIZONTAL VENTING TO VERTICAL VENTING
35. a rette cigar or pipe 6 After it has been determined that each appliance re maining connected to the common venting system properly vents when tested as outlined above re turn door windows exhaust fans fireplace dampers and any other gas burning appliance to their previ ous conditions of use If improper venting is observed during any of the above tests the remaining common venting system must be corrected Correction of the remaining common vent system should be done by referring to the latest edition of the National Fuel Gas Code ANSI Z223 1 CGA B149 1 Installation Codes or Exhibit J of ANSI Z21 47 CAN CGA 2 3 Standards The following are general steps to be used to correct or resize a re maining vent system when a furnace which may not be common vented is removed from the system a Determine the Btu per hour input of all remain ing appliances attached to the venting system b Determine the diameter rise and lateral of the existing venting system as well as quantity and type of bends c Use the appropriate tables in the latest edition of the National Fuel Gas Code ANSI Z223 1 CAN CGA B149 1 Installation Codes or Exhibit J of ANSI 2721 47 CAN CGA 2 3 Standards hibit J includes examples and drawings of typical venting systems These furnaces may be installed as Direct Vent sealed combustion or as Nondirect vent single pipe The furnaces are shipped DIRECT VENT with se
36. a bottom return filter on an upflow furnace a Remove the filter b Remove the filter rack c Remove the bottom panel e With the filter removed the filter rack is com pressed and then inserted into the bottom of the furnace The retaining screw pin on each side inserts into engagement holes at the bottom of the furnace cabinet side See Figure 12 f Reinstall the furnace filter in the bottom posi tion by inserting the chamfer end first into the filter rack 2 Filter Rack Retaining Screw Pin 4 Cabinet gt Side Filter Rack Engagement Hole For Filter Rack Installation With A Bottom Return Bottom Panel Installer s Guide FILTER RACK INSTALLATION FOR SIDE RETURN AIR ON UPFLOW FURNACES Left or Right The following checklist should be used when installing a right or left side return filter on an upflow furnace a Remove the filter b Remove the filter rack c Leave the bottom panel in place e Make side cutout by following the directions in the Return Air Duct Connections section on page 10 e Compress the filter rack and reinstall in the side position on the furnace Confirm that the upper retaining pin screw locks into the engage ment hole in the blower deck and the lower pin screw rests against the side of the bottom panel See Figures 13 16 f Reinstall the furnace filter in the side position by inserting the chamfer end first into the filter
37. ain pan to prevent damage to the finished ceiling below Primary drain vent stack must terminate below secondary heat exchanger condensate drain outlet To drain opening N 1 STAGE FURNACE 1 STAGE HEATING USING A 1 STAGE HEATING THERMOSTAT NO COOLING FURNACE NOTES OW VOLTAGE DING OF gt ADM D 4 2 115 V 1PH 60 HZ POWER SUPPLY PER LOCAL CODES HUM SEE NOTE 5 EAC SEE NOTE 5 18 CD22D1 8 SURE POWER AGREES WITH EQUIPMENT NAMP HERMOSTAT HEAT ANTICIPATOR PER UNIT LEADS PROVIDE 115 V POWER FOR CONNECTION OF ELECTRONIC AIR LEANER AND HUMIDIFIER MAX HIS CONNECTION KAFEES I 24V WIRING TO BE NO 18 A W G MIN EQUIPMENT MUST COMPLY WITH LOCAL CODES WIRING DIAGRAM LOAD 1 0 AMPS EACH S ONLY USED FOR THERMOSTATS REQUIRING ONNECTION TO THE 24 V POWER SUPPLY COMMON EE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS HEN USING THIS FEATURE JUNC TION BOX From drawing B341437 Rv 1 Installers Guide 27 Installers Guide FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE 1 STAGE HEATING 1 STAGE COOLING USING A 1 STAGE HEATING 1 STAGE COOLING THERMOSTAT OUTDOOR SECTION WITHOUT TRANSFORMER
38. al gas com pany Pipe joint compound must be resistant to the chemical reaction with liquefied petroleum gases Refer to piping Table 10 for delivery sizes Connect gas supply to the unit using a ground joint union and a manual shut off valve as shown in Figures 37 39 National codes require a condensation drip leg to be in stalled ahead of the controls as shown in Figures 37 39 The furnace and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5 kPa The furnace must be isolated from the gas supply piping by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 5 kPa 18 CD22D1 8 NOTES 1 BOTH FURNACES MUST BE POWERED FROM FURNACE NO 2 THE SAME 1150 LEG OF CIRCUIT PANEL BLOWER OPERATION OF UNIT NO 2 IS SYNCRONIZED 2 WITH UNIT NO 1 VIA SIGNALS FROM TWIN CONNECTION INSURE 24 FURNACE TRANSFORMERS ARE IN PHASE PRIOR TO COMPLETING CONNECTIONS CHECK VOLTAGE BETWEEN R TERMINALS OF EACH FURNACE IF VOLTAGE 15 GREATER THAN 10V REVERSE THE BL AN RD SECONDARY LEADS ON ONE OF THE FURNACE TRANSFORMERS OUTDOOR UNIT HAS 24V TRANSFORMER AN ISOLATION RELAY MUST BE INSTALLED FIELD SUPPLIED USE PILOT DUTY RELAY SUCH AS RLYO975 SEE ALT CONNECTION LF CURRE
39. aled combustion For DIRECT VENT APPLICATION The furnaces must be vented to the exterior of the house and combustion air MUST come through the inlet air pipe FROM OUTSIDE AIR For NONDIRECT VENT APPLICATION The furnace shall be vented to the exterior of the house but combustion air may enter from the surrounding area as long as combustion air requirements are met See AIR FOR COMBUSTION AND VENTILATION 14 18 CD22D1 8 VENT FITTING MATERIAL These fittings are available from your Gas Furnace Distributors Straight Pipe Sections Couplings 45 Elbows 60 El bows 90 Elbows Vent or Sanitary Tee or other neces sary fittings may be 2 2 3 or 4 diameter The al lowable materials are shown in Table 7 VENT FITTING MATERIAL PLASTIC Gas and liquid tight single wall vent fittings designed for resistance to corrosive flue condensate MUST be used throughout Listed in Table 8 amp 9 are 2 2 3 and 4 size fittings that meet these requirements The materials listed are various grades of PVC and ABS plastic PIPE JOINTS All joints must be fastened and sealed to prevent escape of combustion products into the build ing 2 After checking pipe and socket for proper fit wipe socket and pipe with cleaner primer Apply a liberal coat of primer to inside surface of socket and 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
40. can act as sounding boards and could if poorly installed amplify the slightest vibration to the annoyance level When the furnace is located in a utility room adjacent to the living area the system should be carefully de signed with returns to minimize noise transmission through the return air grille Although these furnaces are designed with large blowers operating at moderate speeds any blower moving a high volume of air will produce audible noise which could be objectionable when the unit is located very close to a living area It is often advisable to route the return air ducts under the floor or through the attic Such design permits the in stallation of air return remote from the living area i e central hall When the furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace and termi nating outside the space containing the furnace RETURN AIR DUCT SYSTEMS Where there is no complete return duct system the re turn connection must be run full size from the furnace to a location outside the utility room basement attic or crawl space Do Not install return air through the back of the furnace cabinet Do Not install return air through the side of the furnace cabinet on horizontal applications NOTE Minimum return air temperature is 55 F All return air duct systems should
41. e furnace must be installed level The only allowable variation would be slightly to the left and or forward in up flow installations or slightly toward the front in horizontal in Stallations This is necessary for proper condensate drain age 18 CD22D1 8 788176012 BMA vv IGH6YOZIQIXN eeGAGOUOCIANS 011 21144 834084 801 11871 19 31 INGA ita JHL 01 43434 53001111 1 3933410 1Y 5130084 INOS NO 491 61 2 01 6 YO 2 1 2 OL 31 1 38 AVW 1414 INJA 30 72 1414 INIA YILIWVIG 1096 00101 0 YO 2 1 2 53810038 0962001 1 976 001 0 71414 INJA 538100384 096 021 0 I vv 17 6 00121 SALON DAGYOOI ANS 9764001 1096 08021 0 1876 00121 08081 1 6 09081 10 6 07081 6 080 6 090 1 91 asl 2p G6H0Q0XN8 9 68090 1076 08081 0 1926 09081 726 07081 Installer s Guide Z SLON 339 TS00W C 1 82 8 6 1 91 6 1 1 11 61 1 8 2 3015 iV 1 82 1113 401 91 6 1 INOYS 1431 JLVNYSL IV LHOLY NIVYd 11758340802 53015 91 8 NIYYO 31 5 30802 INOWIONY 8 1 1 8 6 JLYNYILTY IVLNOZIYOH 30113 401 114405 SY9 ve 1 NIVYd 21 5 30 02 1
42. e standoffs then screwed into the furnace flange The coil is always placed downstream of the furnace air flow Q STANDOFFS 4 DRILL SCREWS 4 lt FOR VERTICAL INSTALLATIONS SCREWS BOTH SIDES STANDOFFS BOTH SIDES DOWNFLOW INSTALLATIONS A WARNING Do NOT install the furnace directly on carpeting tile or other combustible material other than wood flooring For vertical downflow application subbase BAYBASE205 must be used between the furnace and combustible flooring When the downflow furnace is in stalled vertically with a cased coil a subbase is not re quired Required floor opening CABINET SIDE SU8 BASE FLANGE BENT UP SUB BASE INSULATION SUB BASE d nN Lt tittttitithhith ZA 22222222227 PLENUM 4 DUCT CABINET SIDE SUB BASE FLANGE BENT UP COMBUSTIBLE FLOOR SUBBASE CROSS SECTION TABLE 1 CABINET RETURN FLOOR OPENING PLENUM OPENING ee a ee Be see 18 CD22D1 8 Installers Guide FURNACE FRONT HORIZONTAL INSTALLATION The coil and furnace must be fully supported when used in the horizontal position It is always recommended that an auxiliary drain pan be installed under a horizon tally installed evaporator coil or 90 gas furnace Con nect the auxiliary drain line to a separate drain line no trap is needed in this line
43. e the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit Clearance to window or door that may be opened _ Clearance to each side of center line extended above 3 feet 91 cm with a height 15 feet 4 5 m above the F meter regulator assembly meter regulator assembly Clearance to service regulator vent outlet 3 feet 91 cm 6 inches 15 cm for appliances lt 10 000 Btuh 3 kw 12 6 inches 15 cm for appliances lt 10 000 Btuh 3 kw 9 Clearance to nonmechanical air supply inlet to building inches 30 cm for appliances gt 10 000 Btuh 3 kw and lt inches 23 cm for appliances gt 10 000 Btuh 3 kw and lt or the combustion air inlet to any other appliance 100 000 Btuh 30 kw 36 inches 91 cm for appliances gt 50 000 Btuh 15 kw 12 inches 30 cm for appliances gt 50 000 100 000 Btuh 30 kw Btuh 15 kw K Clearance to a mechanical air supply inlet 6 feet 1 83m 3 feet 91 cm above if within 10 feet 3m horizontally i L Clearance above a paved sidewalk or paved driveway 7 feet 2 13 7 located on public property Clearance under veranda porch deck or balcony 712 inches 30 cm Notes In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code In accordance with the current ANSI 2223 1 54 National Fuel Gas Code A vent shall not terminate directly above a sidewalk or paved driveway that
44. e wall flue pipe joints must be sealed The 90 elbow connection to vertical pipe must be sealed to prevent condensate leakage to base of ma sonry chimney 18 CD22D1 8 eens 6 Guide CONDENSATE DRAIN INSTRUCTIONS A CAUTION IT IS RECOMMENDED THAT A DRAIN PAN BE INSTALLED UNDER THE FURNACE TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH FROM LEAKING CONDEN SATE VERTICAL APPLICATIONS Upflow furnace The connection tubing for left and right side drainage is shipped in the blower compart ment Install the connection tubing from the trap to the side of the unit and trim all excess tubing to avoid kinks Right side UPFLOW HORIZONTAL 17 UNITS Left side only Use Inducer Drain hose without extension 18 CD22D1 8 Downflow furnace The furnace is shipped with the left side drainage setup To change the right side drain remove the drain lines from the trap rotate the trap 180 so it exits to the right reconnect the lines and run 1 2 CPVC pipe from the trap out through the right side knockout Use RTV silicone sealant to connect the CPVC pipe to the trap for ease of removing to clean the trap HORIZONTAL APPLICATIONS Upflow and Downflow furnaces All horizontal appli cations are left side only It is always recommended that the auxiliary drain pan be installed under a horizontally installed evaporator and or 90 gas furnace Connect the auxiliary drain pan to a separate drain line
45. ed laundry rooms Furnaces installed in confined hobby or craft rooms Furnaces installed near chemical storage areas Exposure to the following substances in the combustion air supply will also require OUTDOOR AIR for combus tion Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals Deicing salts or chemicals Carbon Tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnish etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials Furnace locations may be in a confined space or an unconfined space Uncontined space is defined in Figure 5 These spaces may have adequate air by infiltration to provide air for combustion and ventilation Buildings with tight construction for example weather stripping heavily insulated caulked vapor barrier etc may need addi tional air to be provided as described for confined space Confined spaces are installations with less than 50 cu ft of space per 1000 BTU hr input from all equipment installed Air for combustion and ventilation require ments can be supplied from inside the building as in Figure 8 or from the outdoors as in Figure 9 18 CD22D1 8 6 MINIMUM AREA SQUARE FEET FOR UNCONFINED SPACE
46. elp in selecting orifices if orifice change is required Furnace input rate and tempera ture rise should be checked again after changing ori fices to confirm the proper rate for the altitude Installations above 4 000 feet may require a pressure switch change If required use the BAYHALT Kit High Altitude Accessory Kit listed in PRODUCT DATA TABLE 14 PART NUMBERS FOR REPLACEMENT ORIFICES SIZE NUMBER SIZE NUMBER 44 ORFO00501 54 ORF00555 45 ORF00644 55 ORF00693 ORFO0909 56 ORF00907 ORF00910 57 ORF00908 1099 58 01338 ORF00503 59 ORF01339 ORF00493 REINSTALLATION OF THE BURNER BOX COVER Figure 52 shows the correct way to reinstall the burner box cover if adjustment or replacement of the flame sensor hot surface igniter or main burner orifices have required removal of the cover 18 CD22D1 8 Installers Guide TABLE 15 Orifice Twist Drill Size If Installed At Sea ALTITUDE ABOVE SEA LEVEL and Orifice Required At Other Elevations 42 44 45 46 47 48 54 55 56 58 59 From National Fuel Gas Code Table F 4 A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the installation instructions for the venting system being placed into operation could re sult in carbon monoxide poisoning or death START UP AND ADJUSTMENT PRELIMINARY INSPECTIONS With gas and electrical power OFF 1 Duct connections are properly sealed 2 Filters are in place 3 Venting is properly a
47. flange 6 If flanges are not required and a filter frame is installed cut between locating notches See Figure 10 7 The bottom panel of the upflow furnace must be removed for bottom return air After removing the filter and filter rack lay the furnace on its back Remove the two 5 16 hex screws securing the front of the bottom channel to the cabinet Rotate the channel downward or remove by lowering the front edge of the channel and pulling forward Slide the bottom return air panel out of the cabinet Rotate the front channel to its original position and rein stall the two 5 16 screws 8 The filter retainer is factory supplied for upflow bot tom return Use the filter retainer on side or bot tom if filter is to be used within the furnace cabinet on upflow only installations 18 CD22D1 8 9 horizontal installation of the upflow furnace requires an external filter section Do NOT use the bottom return filter within the furnace Filter kits are available for horizon tal applications 10 Connect duct work to furnace See Outline Drawing for supply and return duct size and location Flex ible duct connectors are recommended to connect both supply and return air ducts to the furnace If only the front of the furnace is accessible it is recommended that both supply and return air plenums are removable RETURN AIR FILTERS TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS furnaces require high velocity type ai
48. he gas flow rate using a 3 32 hex wench f The final manifold pressure setting shall be as specified in Table 12 with an input of no more than nameplate rating and no less than 93 of the nameplate rating unless the unit is derated for high altitude g Replace the regulator adjustment screw cap tighten securely h Turn off all electrical power to the system i Remove the manometer and flexible tubing Re move the barbed fitting and replace the plug or tighten the pressure test screw j Turn on electrical power to the system and ener gize valve k Using a leak detection solution or soap suds check for leaks at plug or pressure boss screw 31 Installer s Guide CORRECT METHOD OF CHECKING DIRECT VENT MANIFOLD PRESSURE WITH BURNER BOX REFERENCED CAUTION Replace and or tighten all plugs removed or loosened when adjusting gas pressure Leak check the fittings before placing the furnace into regular service Failure to follow this warning could result in fire ex plosion or property damage NOTE The manifold pressure must be referenced to the burner box The burner box pressure tap equalizes the gas valve pressure regulator Manifold pressure is checked by installing a tee field supplied in the tub ing between the tee coming from the burner box tube and the gas valve in addition to the regular gas valve pressure tap on the outlet side of the gas valve See Figure 51
49. ir duct must be complete and sealed to the furnace and clean air filters are in place d The furnace input rate and temperature rise must be verified to be within nameplate mark ing All Rights Reserved e 100 of the furnace combustion air require ment must come from outside the structure f furnace return air temperature range is between 55 and 80 degrees Fahrenheit g Clean the furnace duct work and components upon substantial completion of the construction pro cess and verify furnace operating conditions includ ing ignition input rate temperature rise and vent ing according to the manufacturer s instructions This product must be gas piped by a Licensed Plumber or Gas Fitter in the Commonwealth of Massachusetts A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each ap pliance connected to the venting system being placed into operation could result in carbon monoxide poi soning or death The following steps shall be followed for each appli ance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 2 Follow the lighting instructions Seal any unused openings in the venting system Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI 2223 1 54 or the CAN CGA B149 Installation Codes a
50. izontal venting when the factory supplied off set 2X3 reducing coupling is used for 3 vent pipe installation make sure the marking Top is located on the top side of the pipe The straight side must be on bottom for proper condensate drainage This coupling is factory supplied only with the following models UC120 amp DC120 UX120 amp UY120 UX100 amp UY100 UX808C960 and all amp DY models 18 CD22D1 8 Installers Guide UPFLOW HORIZONTAL VENTING TABLE TABLE 8 MAXIMUM VENT LENGTH DIRECT VENT 2 PIPE SYSTEM NONDIRECT VENT 1 PIPE SYSTEM MAXIMUM TOTAL EQUIVALENT FEET FOR MAXIMUM TOTAL EQUIVALENT FEET FOR VENT AND INLET AIR PIPES See Notes VENT PIPE ONLY See Notes MODEL amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS amp FITTINGS 60 s o 60 so 1o ns s s s to 50 so 1o 100 o o 71 uxiciooasHaiB NOTALLOWED 40 100 190 NOTALLOWED s s to uxipi20asH51B NOT ALLOWED 40 1o00 190 noranoweo s s to NOTES First letter be A T 1 The INLET AIR of one pipe systems require the installation of a 90 elbow to prevent dust and debris from falling straight into thefurnace and a 2 foot horizontal or vertical straight pipe section connected before or afte
51. lean fitting socket and pipe joint area of all dirt grease moisture or chips 18 CD22D1 8 IMPORTANT Products installed in Canada must use vent systems that are certified to the Standard for Type BH Gas Vent ing Systems ULC S636 for Class venting systems up to 65 C Components of the vent system must not be interchanged with other vent systems or unlisted pipe or fittings Plastic components specified prim ers and glues must be from a single system manufac turer and not intermixed with other system manufacturer s vent system parts In addition the first three feet of the vent pipe must be visible for inspec tion Installer s Guide VENT AND INLET AIR CONNECTIONS Seal VENT PIPE with RTV sealant Front of Furnace Seal INLET AIR PIPE with RTV sealant NOTE Follow venting instructions carefully when using PVC cement IMPORTANT All joints must be water tight Flue condensate is some what acidic and leaks can cause equipment damage Connection of the pipe and collar of the combustion air inlet should just be a friction fit It is recommended that the inlet air joint be sealed with type sealant to allow the joint to be separated for possible future ser vice The inlet and vent pipes must be properly sup ported throughout the entire length Connection of the vent pipe to the vent collar should also be accomplished using RTV type sealant This type sealant provides a connection which remains f
52. leted within 30 seconds 35 Installers Guide 8 RESET AFTER BURNER BOX LIMIT SHUTDOWN If the furnace shuts down one thing that can be checked is the burner box temperature limit switch It is located on the bottom of the burner box The vent and combustion air inlet terminations should be checked for blockage If blockage exists clear the problem and then the reset button may be de pressed If there is no blockage of the terminations the limit switch must be reset by a qualified servicer Carbon monoxide fire or smoke can cause serious bodily injury death and or property damage A variety of potential sources of carbon monoxide can be found in a building or dwelling such as gas fired clothes dryers gas cooking stoves water heaters furnaces and fireplaces The U S Consumer Product Safety Commis sion recommends that users of gas burning appliances install carbon monoxide detectors as well as fire and smoke 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 Station Carbon Monoxide Alarms UL 2034 or CSA Interna tional Standard Residential Carbon Monoxide Alarming Devices CSA 6 19 NOTE The manufacturer of your furnace does not test any de tectors and makes no representations regarding any brand or type of detec
53. level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 80 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBS
54. lexible and can be separated in the future if service needs re quire the removal of the vent pipe for service or clear ance NOTE To ensure proper operation at the vent lengths indi cated the combustion air inlet and vent terminals should be in the same pressure zone Terminating the vent and inlet in different pressure zones will change the maximum vent lengths and may cause nuisance tripping of the pressure switch es The amount of change can not be predicted The selection of the inlet and outlet terminal locations are the responsibility of the designer installer If the installer chooses separate pressure zones for the terminals the combustion air inlet termination must be in the higher more positive pressure zone HORIZONTAL VENTING NOTE Vent termination kit BAYAIR30AVENTA or BAYVENT200B may be used instead of the horizontal and vertical termination options shown in the follow ing figures 16 WHEN THE FACTORY SUPPLIED OFF SET 2X3 REDUCING COUPLING IS USED FOR 3 VENT PIPE INSTALLATION MAKE SURE THE MARKING TOP IS LOCATED ON THE TOP SIDE OF THE PIPE STRAIGHT SIDE MUST BE ON BOTTOM FOR PROPER CONDENSATE DRAINAGE FACTORY SUPPLIED ONLY WITH THE FOLLOWING MODELS UC120 amp DC120 UX120 amp UY120 UX100 amp UY100 UX080C960 ALL DX amp DY MODLES UX3 amp DX3 UH3 amp DH3 FURNACE VENT OUTLET HORIZONTAL INSTALLATION Upflow Horizontal or Downflow Horizontal NOTE In hor
55. measured or the settings found in the notes on the furnace wiring diagram found in the SERVICE FACTS or inside the furnace casing INSTRUCTIONS TO THE OWNERS In the event that electrical fuel or mechanical failures occur the owner should immediately turn the gas sup ply off at the manual gas valve located in the burner compartment Also turn off electrical power to the fur nace and contact the service agency designated by your dealer 18 CD22D1 8 Installers Guide BURNER BOX TEMPERATURE LIMIT DEVICE All 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 CONDITIONS AFFECTING FURNACE OPERATION 1 EXCESSIVE COMBUSTION PRESSURE WIND IN EXCESS OF 40 MP H VENT OR FLUE BLOCKAGE If pressure against induced draft blower outlet be comes excessive the pressure switch will open and shut off the gas valve until acceptable combustion pressure is again available 2 LOSS OF FLAME If loss of flame occurs during a heating cycle or flame is not present at the sensor the flame control module will close the gas valve The flame control module will then recycle the ignition sequence then if ignition is not achieved it will shut off the gas valve and lock out the system 3 POWER FAILURE If there is a power failure during a heating cycle the system will restart the ignition sequence aut
56. nd these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other deficiencies which could cause an unsafe condition Close fireplace dampers Turn on clothes dryers and any appliance not con nected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan Place the appli ance being inspected into operation Adjust the thermostat so appliance is operating continuously If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI 2221 1 54 and or CAN CGA 149 1 In stallation Codes After it has been determined that each appliance connected to the venting system properly vents where tested as outlined above return doors win dows exhaust fans fireplace dampers and any other gas fired burning appliance to their previous conditions of use 18 CD22D1 8 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
57. ng furnace is removed from a venting system serving other gas appliances the venting sys tem is likely to be too large to properly vent the re maining 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 are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition IMPORTANT 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bath room exhausts so they will operate at maximum speed Do not operate a summer exhaust fan close fireplace dampers 4 Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening af ter 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cig
58. o matically when power is restored if the thermostat still calls for heat 4 GAS SUPPLY FAILURE If loss of flame occurs during a heating cycle the system integrated control module will recycle the ignition sequence then if ignition is not achieved the integrated control module will shut off the gas valve and lock out the system 5 INDUCED DRAFT BLOWER FAILURE If pressure is not sensed by the pressure switch the contacts will remain open and not allow the gas valve to open therefore the unit will not start If failure occurs during a running cycle the pressure switch contacts will open and the gas valve will close to shut the unit down 6 CONDENSATE DRAIN BLOCKAGE If the condensate drain is blocked either by debris improper draining or by freezing condensate the pressure switch will sense the accumulation of con densate in the furnace drain pan The pressure switch contacts will open and remain open not al lowing unit operation The unit will not operate un til the condensate drain has been cleared and the condensate flows freely 7 RESET AFTER LOCKOUT When the integrated control module has shut the system down and gone into lockout the system must be manually reset before the unit will restart To reset turn the system power off then on then off and then on again within 30 seconds This may be done at the unit s power source or at the ther mostat The system will not reset unless the proce dure off on off on is comp
59. o 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 VENTING ROUTED THROUGH A MASONRY CHIMNEY VENT FITTING MATERIAL STAINLESS STEEL Gas and liquid tight single wall metal vent fitting de signed for resistance to corrosive flue condensate such as Type 29 4C MUST be used throughout These fittings and fitting accessories are to be supplied locally DIRECTION OF STAINLESS STEEL FITTING All stainless steel fitting must be installed with male end towards the furnace All horizontal stainless steel sections must be 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 prevent escape of combustion products into the building 22 NOTE Both venting methods shown in Figure 30 amp 31 must also have the combustion air inlet installed meeting dimension requirements of Figure 21 12 INCH CLEARANCE MUST BE MAINTAINED ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM NOT TO EXCEED 24 INCHES ABOVE ROOF 12 ti DISEANCE FROM AIR INLET MUST 12 T COMBUSTION AIR INLET MAINTAIN 12 IN 18 IN FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE ROOF gt E oe
60. ons NOTE TO INSTALLER Review the following warnings with the owner Review contents of USER S INFORMATION MANUAL with the owner 18 CD22D1 8 AIRFLOW ADJUSTMENT Check inlet and outlet air temperatures to make sure they are within the ranges specified on the furnace rat ing nameplate If the airflow needs to be increased or decreased see the wiring diagram for information on changing the speed of the blower motor A WARNING Disconnect power to the unit before removing the blower door Failure to follow this warning could result in property damage personal injury or death This unit is equipped with a blower door switch which cuts power to the blower and gas valve causing shut down when the door is removed Operation with the door removed or ajar can permit the escape of danger ous fumes All panels must be securely closed at all times for safe operation of the furnace INDOOR BLOWER TIMING Heating The integrated furnace control module controls the indoor blower The blower start is fixed at 45 seconds after ignition The FAN OFF period is field selectable by dip switches at 60 100 140 or 180 sec onds The factory setting is 100 seconds See wiring diagram Cooling The fan delay off period is factory set at 0 seconds The option for 80 second delay off is field selectable See wiring diagram ROOM AIR THERMOSTAT HEAT ANTICIPATOR ADJUSTMENT Set the thermostat heat anticipator according to the current flow
61. poor grounding or system voltage too low 7 Flashes Gas valve circuit error Check Ignitor Circuit and Line N to 24VAC Common voltage lt 2 volts 9 Flashes possible grounding problem 18 CD22D1 8 37 CERTIFIED Trane Literature Order Number 18 CD22D1 8 6200 Troup Highway File Number 18 CD22D1 8 Tyler TX 75707 Supersedes 18 CD22D1 7 Date 05 08 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
62. provide for installa tion of return air filters 10 PREPARATION FOR UPFLOW BOTTOM AND SIDE RETURN AIR FILTER INSTALLATION All return air duct systems should provide for installa tion of return air filters 1 Determine the appropriate position to set the furnace in order to existing supply and return ductwork 2 The return air filter and rack are shipped in either the bottom or side location Remove the filter and filter rack by first turning the two latches on the blower door and tilting the door forward to remove Remove the filter by sliding it out of the rack Compress the spring loaded filter rack to disengage the retaining pins screws from the furnace sides and slide the filter rack out The filter rails are spring loaded for automatic adjustment to allow standard size locally obtainable replacement filters The filter rack itself slides to adjust to the required width needed for bottom or side return 3 For upflow side return installations remove the insulation around the opening in the blower compart ment 4 The side panels of the upflow furnace include locating notches that are used as guides for cutting an opening for return air refer to Figure 10 and the outline drawing on page 5 for duct connection dimensions for various furnaces 5 If a 3 4 flange is to be used for attaching the air inlet duct add to cut where indicated by dotted lines in Figure 10 Cut corners diagonally and bend outward to form
63. r LOCATION AND CLEARANCES The location of the furnace is normally selected by the ar chitect the builder or the installer However before the fur nace is moved into place be sure to consider the following requirements 1 Is the location selected as near the vent and as cen tralized for heat distribution as practical 2 Do all clearances between the furnace and enclosure equal or exceed the minimums shown in the Table 1 3 Is there sufficient space for servicing the furnace and other equipment A minimum of 24 inches front acces sibility to the furnace must be provided Any access door or panel must permit removal of the largest com ponent 4 Are there at least 3 inches of clearance between the fur nace front panel and any closed panel or door provided 5 Are the vent pipe and combustion air inlet pipe within vent table lengths Will the pipes remain unobstructed 6 Allow sufficient height in supply plenum above or below the furnace to provide for cooling coil installation if the cooling coil is not installed at the time of this furnace installation 7 A furnace shall be installed so electrical components are protected from water 8 If the furnace is installed a residential garage it must be installed so that the burners and the ignition source are located not less than 18 inches 46 cm above the floor and the furnace must be located or pro tected to avoid physical damage from vehicles IMPORTANT Th
64. r filters The filters may be installed within the furnace blower compartment for UPFLOW furnaces in either a BOT TOM or SIDE eft side or right side return air inlet Some filters may need to be trimmed for side or bottom filter use UPFLOW FURNACE ONLY LOCATING NOTCHES PRO VIDED FOR SIDE RETURN CUTOUT U CUT OUT FOR SIDE of Furnace SEE OUTLINE DRAWING BOTTOM FILTER RACK INSTALLATION 18 CD22D1 8 TABLE 3 MODELS CABINET FILTER NUMBERS WIDTH QTY amp SIZE UX1B040A9H21B UX1B060A9H31B 17 1 2 1 17 X25 X 1 UX1C100A9H41B 1 20 X 25 X 1 UX1B080A9H31B UX1D120A9H51B 24 1 2 1 24 X 25 X 1 First letter may be A or T NOTE For upflow 5 ton airflow models where the airflow requirement exceeds 1800 CFM Modles will require return air openings and filters on 1 both sides or 2 one side and the bottom or 3 just on the bottom NOTE For upflow 5 ton airflow models where the airflow requirement exceeds 1800 Models will require return air openings and filters on 1 both sides or 2 1 side and the bottom or 3 just the bottom The furnace and the bottom filter rack installation can be seen in Figure 11 The furnace filter in the bottom or side configuration can be removed by simply turning the two latches on the blower door and tilting the door forward OPTIONAL FILTER RACK INSTALLATION FOR BOT TOM RETURN The following checklist should be used when installing
65. r the elbow 2 DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET Except adapters at the top of the furnace If different inlet and vent pipe sizes are used the vent pipe must adhere to the maximum length limit shown in the table above See Note 7 below for exception The inlet pipe can be of a larger diameter but never smaller than the vent pipe 3 MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED THE LENGTH SHOWN IS NOT A COMBINED TOTAL IT IS THE MAXIMUM LENGTH OF EACH Vent or Inlet air pipes in two pipe systems 4 One standard radius 90 elbow is equivalent to 12 of 4 pipe one SHORT radius 90 elbow is equivalent to 10 of 3 pipe and one LONG radius elbow is equivalent to 6 of 3 pipe One SHORT LONG radius 90 elbow is equivalent to 712 of 2 pipe amp 5 of 2 pipe Two 45 elbows equal one 90 elbow 5 The termination tee or bend must be included in the total number of elbows If the BAYVENT100 termination kit is used the equivalent length of pipe is 5 feet There is zero equivalent length for the 200 6 Pipe adapters are field supplied 7 4 pipe be reduced to 3 for termination with BAYVENT200 without additional length restriction MAXIMUM VENT LENGTH DIRECT VENT 2 PIPE SYSTEM NONDIRECT VENT 1 PIPE SYSTEM MAXIMUM TOTAL EQUIVALENT FEET FOR MAXIMUM TOTAL EQUIVALENT FEET FOR VENT AND INLET AIR PIPES See Notes VENT PIPE ONLY
66. rack SIDE CUTOUT RETAINING BOTTOM PANEL INSTALLED FILTER RACK RAILS Typical Upflow Left Side Return Filter Rack Installation SIDE CUTOUT RETAINING PIN Both Sides BOTTOM PANEL INSTALLED FILTER RACK NN RAILS NN Typical Upflow Right Side Return Filter Rack Installation 12 Furnace Blower Deck BLOWER DECK Engagement Hole For Filter Rack Installation With Side Return Furnace Cabinet gt Side Filter Rack Assembly Filter Rack Retaining Screw Pin Filter Furnace Cabinet Rack Side gt Filter Rack Qa Retaining 7 Screw Pin Engagement Hole For Filter Rack Installation With Bottom Return Conversion kits for horizontal filters are BAYFLTR203 for 17 1 2 width cabinets BAYFLTR204 for 21 width cabinets and BAYFLTR205 for 24 width cabinets These include filters and brackets necessary for hori zontal filters In addition optional door kit BAYFLTR206 is also available See Figures 17 and 19 RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION When the Upflow Furnace is installed in the horizontal configuration the return air filters must be installed exterior to the furnace cabinet Remote filter grilles may be used for homeowner convenience or the filters may be installed in the duct work upstream of the fur nace See Figure 17 Optional door kit BAYFLTR206 Typical Horizontal Filter Installation
67. s valve until the thermostat is satisfied To shut off For complete shut down Flip the switch on the main gas valve to the OFF position See Figure 53 amp 54 Disconnect the electrical supply to the unit CAUTION If this is done during the cold weather months provi sions must be taken to prevent freeze up of all water pipes and water receptacles Failure to follow this warning could result in property damage Whenever your house is to be vacant arrange to have someone inspect your house for proper temperature This is very important during freezing weather If for any reason your furnace should fail to operate damage could result such as frozen water pipes 34 SEQUENCE OF OPERATION Thermostat call for heat R and W thermostat contacts close signaling the control module to run its self check routine After the control module has verified that the pressure switch contacts are open and the limit switch es contacts are closed the draft blower will be energized As the induced draft blower comes up to speed the pressure switch contacts will close and the ignitor warm up period will begin The ignitor will heat for approxi mately 20 seconds then the gas valve is energized to permit gas flow to the burners The flame sensor con firms that ignition has been achieved After the flame sensor confirms within a 4 second trial period that ignition has been achieved the delay to fan ON period begins timing Af
68. ssembled 4 Blower door is in place Flip the switch on main gas valve within the unit to the OFF position Turn the external gas valve to ON Purge the air from the gas lines After purging Check all gas connections for leaks with a soapy solution DO NOT CHECK WITH AN OPEN FLAME Allow 5 min utes for any gas that might have escaped to dissipate LP Gas being heavier than air may require forced venti lation Flip the switch on the gas valve in the unit to the ON position Regulator Adjustment Outlet Pressure Boss Inlet Pressure Boss opt On Off Switch White Rodgers 36G gas valve 33 Installer s Guide On Off Switch White Rodgers 36F gas valve LIGHTING INSTRUCTIONS A WARNING DO NOT attempt to manually light the burner Failure to follow this warning could result in property damage personal injury or death Lighting instructions appear on each unit Each instal lation must be checked out at the time of initial start up to insure proper operation of all components Check out should include putting the unit through one complete cycle as outlined below Turn on the main electrical supply and set the thermo stat above the indicated temperature The ignitor will automatically heat then the gas valve is energized to permit the flow of gas to the burners After ignition and flame is established the flame control module monitors the flame and supplies power to the ga
69. stem only as specified in the Venting section pages 13 22 of these instructions Never test for gas leaks with an open flame Use a commercially available soap solution made specifi cally for the detection of leaks to check all connec tions as specified in Gas Piping pages 29 30 of these instructions Always install the furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified on the unit rating plate Airflow with temperature rise for cfm versus static is shown in the Service Facts accompa nying this furnace When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the fur nace casing and terminating outside the space con taining the furnace A gas fired furnace for installation in a residential garage must be installed as specified in Location and Clearances section page 4 of these instruc tions The furnace may be used for temporary heating of buildings or structures under construction only when the following conditions have been met a The furnace venting system must be complete and installed per manufacturers instructions b The furnace is controlled only by a room ther mostat no field jumpers c The furnace return a
70. ter approximately 45 sec onds the indoor blower motor will be energized and con tinue to run during the heating cycle When the thermostat is satisfied R and W thermostat contacts open the gas valve will close the flames will extinguish and the induced draft blower will be de en ergized The indoor blower motor will continue to run for the fan off period Field selectable at 60 100 140 or 180 seconds then be de energized by the control mod ule CONTROL AND SAFETY SWITCH ADJUSTMENTS LIMIT SWITCH CHECK OUT The limit switch is a safety device designed to close the gas valve should the furnace become overheated Since proper operation of this switch is important to the safety of the unit it must be checked out on initial start up by the installer To check for proper operation of the limit switches set the thermostat to a temperature higher than the indi cated temperature to bring on the gas valve Restrict the airflow by blocking the return air disconnecting the indoor blower may trip the inducer limit When the furnace reaches the maximum outlet temperature as shown on the rating plate the burners must shut off If they do not shut off after a reasonable time and over heating is evident a faulty limit switch is probable and the limit switch must be replaced After checking the operation of the limit control be sure to remove the pa per or cardboard from the return air inlet Refer to Ser vice Facts for additional instructi
71. tions require special venting systems which must be gas tight and water tight These Category IV Direct Vent furnaces are approved for installation in Manufactured Mobile housing when used with BAYMFGH100A NNN OF 11 14 15 15 16 20 20 22 22 25 27 27 29 31 33 34 34 34 35 35 37 Installer s Guide CAUTION To prevent shortening its service life the furnace should not be used as a Construction Heater during the finishing phases of construction until the require ments listed in item 9 a g of the safety section of this publication have been met Condensate in the pres ence of chlorides and fluorides from paint varnish stains adhesives cleaning compounds and cement create a corrosive condition which may cause rapid de terioration of the heat exchanger CAUTION Do install the furnace corrosive contami nated atmosphere A WARNING EXPLOSION HAZARD PROPANE GAS IS HEAVIER THAN AIR AND MAY COLLECT IN ANY LOW AREAS OR CONFINED SPACES IN ADDITION ODORANT FADE MAY MAKE THE GAS UNDETECTABLE EXCEPT WITH A WARN ING DEVICE IF THE GAS FURNACE IS INSTALLED INA BASEMENT AN EXCAVATED AREA ORA CONFINED SPACE IT IS STRONGLY RECOM MENDED TO CONTACT A GAS SUPPLIER TO IN STALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK NOTE The manufacturer of your furnace does NOT test any detectors and makes no representations regarding any brand or type of detecto
72. tor 36 The following warning complies with State of California law Proposition 65 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 geni and warm water after han Og lina 18 CD22D1 8 INTEGRATED FURNACE CONTROL ERROR FLASH CODES Flashing Slow Normal No call for Heat Flashing Fast Normal Call for Heat 2 Flashes System Lockout Retries or Recycles exceeded Draft Pressure Error Possible problems a Venting problem b Pressure switch problem c Inducer problem 3 Flashes 5 Flashes Flame sensed when no flame should be present 6 Flashes 115 volt AC power reversed

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