Trane Furnace DX1B040A9241A User Manual

1 8 - CD1 9 D6 - 3 2

Available in French Canadian (FC)

Installer’s Guide

Upflow/ Horizontal and Downflow/ Horizontal

Gas-Fired, Direct Vent Condensing Furnaces

*UX1B040A9241A *UX1C080A9601A *DX1B040A9241A

*UX1B060A9241A *UX1C100A9361A *DX1B060A9361A

*UX1B060A9361A *UX1C100A9481A *DX1B080A9421A

*UX1B080A9241A *UX1D100A9601A *DX1C100A9481A

*UX1B080A9421A *UX1D120A9601A *DX1D120A9601A

*__First letter may be “A” or “T”

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT — This Document is customer property and is to remain with this unit.

Please return to service information pack upon completion of work.

*UX-1

*DX-1

DOWNFLOW

UPFLOW

UPFLOW/HORIZONTAL

DOWNFLOW/HORIZONTAL

A341624P06

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Installer’s Guide

Contents

Safety signal words are used to designate a degree or

level of seriousness associated with a particular hazard.

The signal words for safety markings are WARNING and

CAUTION.

a. WARNING indicates a potentially hazardous situa-

tion which, if not avoided, could result in death or

serious injury.

b. CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or mod-

erate injury. It is also used to alert against unsafe

practices and hazards involving only property dam-

age.

INSTALLATION INSTRUCTIONS

General Installation Instructions

Location and Clearances

Outline Drawings

Upflow Installation

Downflow Installation

Horizontal Installation

Air For Combustion and Ventilation

Duct Connections

17-19

28-30

Return Air Filters

General Venting Instructions

Venting Material

▲

WARNING

FIRE OR EXPLOSION HAZARD

Venting Tables

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.

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

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.

Combustion Input Checks

Start Up and Adjustment

Preliminary Inspections

Lighting Instructions

Sequence Of Operation

Control And Safety Switch Adjustments

Airflow Adjustment

Abnormal Conditions

IFC Error Flash Code

Category IV furnaces operate with positive vent static

pressure and with a flue loss less than 17 percent.

These conditions require special venting systems, which

must be gas tight and water tight. These Category IV

Direct Vent furnaces are approved for installation in

Manufactured/ Mobile housing when used with

BAYMFGH100A.

Codes and local utility requirements governing the

installation of gas fired equipment, 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

Z223.1 • National Installation Code, CAN/CGA B149.1.

The latest code may be obtained from the American Gas

Association Laboratories, 400 N. Capitol St. NW,

Washington D.C. 20001.

1-800-699-9277 or www.aga.org

These furnaces have been classified as CATEGORY IV

furnaces in accordance with latest edition of ANSI

Z21.47 • CAN/ CGA 2.3 standards.

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Installer’s Guide

LOCATION AND CLEARANCES

▲

CAUTION

The location of the furnace is normally selected by the

architect, the builder, or the installer. However, before

the furnace is moved into place, be sure to consider the

following requirements:

1. Is the location selected as near the vent and as cen-

tralized for heat distribution as practical?

2. Do all clearances between the furnace and enclo-

sure equal or exceed the minimums shown in the

Table 1.

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.

3. Is there sufficient space for servicing the furnace

and other equipment? A minimum of 24 inches

front accessibility to the furnace must be provided.

Any access door or panel must permit removal of

the largest component.

▲

CAUTION

Do NOT install the furnace in a corrosive or contami-

nated atmosphere.

4. Are there at least 3 inches of clearance between the

furnace front panel and any closed panel or door

provided?

5. Are the vent pipe and combustion air inlet pipe

within vent table lengths? Will the pipes remain un-

obstructed?

6. Allow sufficient height in supply plenum above or

below the furnace to provide for cooling coil installa-

tion 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.

▲ 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

IN A BASEMENT, AN EXCAVATED AREA OR A

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.

8. If the furnace is installed in a residential garage,

it must be installed so that the burners and the ig-

nition source are located not less than 18 inches (46

cm) above the floor and the furnace must be located

or protected to avoid physical damage from ve-

hicles.

NOTE: The manufacturer of your furnace does NOT test

any detectors and makes no representations regarding

any brand or type of detector.

IMPORTANT:

The furnace must be installed level. The only allowable

variation would be slightly to the left and/or forward in

upflow installations or slightly toward the front in horizontal

installations. This is necessary for proper condensate drain-

age.

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Installer’s Guide

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

the standoffs then screwed into the furnace flange.

A (width)

B (depth)

FURNACE

FRONT

The coil is always placed downstream of the furnace air-

flow.

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).

DRILL SCREWS (4)

STANDOFFS (4)

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.

CASED

FOR VERTICAL

INSTALLATIONS:

COIL

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.

SCREWS

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.

(BOTH SIDES)

UPFLO

FURNA

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

▲

WARNING

Do NOT install the furnace directly on carpeting, tile or

other combustible material other than wood flooring.

For vertical downflow application, subbase (BAYBASE-

205) must be used between the furnace and combus-

tible flooring. When the downflow furnace is installed

vertically with a cased coil, a subbase is not required.

4_{CASED COIL CONNECTION}

Required floor opening:

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 the furnace (See Figure 5 & Clearance

Table). Line contact is only permissible between lines

formed by intersections of the top and two sides of the

furnace casing and building joists, studs, or framing.

SUBBASE CROSS SECTION

TABLE 1

FLOOR OPENING PLENUM OPENING

CABINET

WIDTH DUCT WIDTH

RETURN

"A"

"B"

"C"

"D"

17-1/2"

21"

16-1/4"

19-3/4"

23-1/4"

16-5/8" 20-1/8"

20-1/8" 20-1/8"

23-5/8" 20-1/8"

15-5/8"

19-1/8"

22-5/8"

19-3/8"

24-1/2"

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Installer’s Guide

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:

UPFLOW/

HORIZONTAL

SHOWN

The furnace may be placed horizontally in a crawl space

on a pad or other noncombustible material which will

raise the unit for sufficient protection from moisture.

The furnace must be supported at both ends and

the middle when installed horizontally.

* Commercial buildings

* Buildings with indoor pools

* Furnaces installed in “confined” laundry rooms

* Furnaces installed in “confined” hobby or craft rooms

* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion

air supply will also require OUTDOOR AIR for combus-

tion:

* Permanent wave solutions

* Chlorinated waxes and cleaners

* Chlorine based swimming pool chemicals

* Water softening chemicals

* Deicing salts or chemicals

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.

* Carbon Tetrachloride

* Halogen type refrigerants

* Cleaning solvents (such as perchloroethylene)

* Printing inks, paint removers, varnish, etc.

* Hydrochloric acid

50 CU. FT. OR MORE

PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

* Cements and glues

* Antistatic fabric softeners for clothes dryers

* Masonry acid washing materials

Furnace locations may be in a “confined space” or an

“unconfined space”.

UNCONFINED

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.

Unconfined space is defined in Figure 6. These spaces

may have adequate air by infiltration to provide air for

combustion and ventilation. Buildings with tight

construction (for example, weather stripping, heavily

insulated, caulked, vapor barrier, etc.), may need 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.

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Installer’s Guide

MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE 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

375

500

625

875

CONFINED

SPACE

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.

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)

Furnace

Air From Outside

Air

From

Inside

Maximum

BTUH/INPUT

Rating

Vertical

Horizontal

Duct

60,000

80,000

100,000

120,000

100

120

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Installer’s Guide

NOTE:

DUCT CONNECTIONS

Minimum return air temperature is 55° F.

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 can act as sounding boards and could,

if poorly installed, amplify the slightest vibration to the

annoyance level.

3. The side panels on upflow furnaces include locating

notches which may be used as guides for cutting an

opening for return air. Refer to Figure 12 and the

outline drawing on page 5 for duct connection

dimensions for various furnaces.

4. If a 3/4" flange is to be used for attaching the air

inlet duct, add to cut where indicated by dashed

lines in Figure 12. Cut corners diagonally and bend

outward to form flange.

5. If flanges are not required, and a filter frame is

installed, cut along knockout guidelines.

6. Upflow Furnaces: Use the optional filter rack on

either side or on the bottom if the filter is to be

used within the furnace cabinet.

When the upflow furnace is installed in the horizon-

tal right or left application and a return duct is

attached to the top side as shown in Figure 11,

install the filter in a remote location.

Do not install the filter in the return duct directly

above the furnace in horizontal applications.

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.

▲

WARNING

Do not install the filter in the return duct directly above the

furnace in horizontal applications. Install the filter remotely.

Installing the filter directly above the furnace in horizontal

applications may cause property damage, serious injury or

death.

▲

WARNING

TO PREVENT INJURY OR DEATH DUE TO CONTACT

WITH MOVING PARTS, TURN THE POWER TO THE

FURNACE OFF BEFORE SERVICING FILTERS.

When the upflow furnace is installed in the horizon-

tal right or left application and a close coupled (less

than 36") return duct is attached to the bottom side

of the furnace as shown in Figure 11, securely

attach a 1/2" mesh metal hardware cloth protective

screen to the inside bottom of the filter grill to

prevent personal injury from contacting

moving parts when reaching into the return

opening to replace the filter.

RETURN AIR DUCT CONNECTION

NOTE:

On upflow 5 or 6 ton airflow models where the

airflow requirement exceeds 1800 CFM - Models will

require return air openings and filters on: (1) both

sides; or (2) one side and the bottom; or (3) just the

bottom.

All return air duct systems should provide for installa-

tion of return air filters.

Close coupled (less than 36") return (filter directly

beneath bottom side return) is not recommended

due to noise considerations.

1. Determine the appropriate position to set the

furnace in order to connect to the existing supply

and return ductwork.

Downflow Furnaces: Brackets are factory

supplied to mount filters in the return air duct

work.

2. For side return installations on upflow models,

remove the insulation around the opening in the

blower compartment.

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Installer’s Guide

REMOVE FILTER FROM UPFLOW

FURNACE WHEN RETURN DUCT IS

ATTACHED TO FURNACE TOP SIDE

(HORIZONTAL LEFT OR RIGHT

APPLICATIONS) AS SHOWN.

q w

CUT OUT

FOR

SIDE

LOCATING

FILTER

NOTCHES

PROVIDED

FOR SIDE

RETURN

CUTOUT

FRONT

of Furnace

SEE OUTLINE DRAWING

Close coupled (less than 36")

return (filter directly beneath bottom

side return) not recommended due to

noise considerations. If used, securely

attach 1/2" mesh metal hardware cloth

protective screen to the inside bottom of

filter grill.

RETURN AIR FILTERS

(Filter and filter rack are not supplied with unit)

TYPICAL UPFLOW RETURN AIR FILTER INSTALLA-

TIONS

These furnaces require high velocity type air filters.

The optional filters may be located within the furnace

blower compartment for UPFLOW furnaces in either a

BOTTOM or SIDE (left side or right side) return air

inlet. Some optional filters may need to be trimmed for

side or bottom filter use.

7. Connect the duct work to the furnace. See Outline

Drawing (pages 4&5) for supply and return duct size

and location. Flexible duct connectors are recom-

mended 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.

NOTE:

On upflow 5 or 6 ton airflow models where the

airflow requirement exceeds 1800 CFM - Models will

require return air openings and filters on: (1) both

sides; or (2) one side and the bottom; or (3) just the

bottom.

8. When replacing a furnace, old duct work should be

cleaned out. Thin cloths should be placed over the

registers and the furnace fan should be run for

10 minutes. Don’t forget to remove the cloths

before you start the furnace.

The furnace and the blower filter rack installation can

be seen in Figure 13.

The optional furnace filter in the bottom or side con-

figuration can be removed by simply turning the two

latches on the blower door and tilting the door forward.

The filter rails are spring loaded for automatic adjust-

ment to allow standard size, locally obtainable replace-

ment filters. The filter rack itself slides to adjust to the

required width needed for bottom or side return.

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/ HORIZONTAL FURNACES

UNIT LOCATION

VERTICAL

CLOSET

HORIZONTAL

CLOSET

HORIZONTAL

ALCOVE / ATTIC

FURNACE SURFACE

SIDES

BACK

TOP

FRONT

VENT

18"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

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Installer’s Guide

TABLE 4

NOTE: The narrow 14.5" width furnace cabinet prevents use

of the filter rack for right side return. Pre-drill clearance

holes and then attach filter clips with the screws provided.

The filter clip with the leaf spring mounts in the rear of the

cabinet

UPFLOW FURNACE RETURN AIR FILTERS

CABINET

WIDTH

CABINET

BOTTOM FILTER

CABINET

SIDE FILTER

QTY*

14-1/2"

17-1/2"

21"

14" X 25" X 1"

17" X 25" X 1"

20" X 25" X 1"

24" X 25" X 1"

17-1/2" X 25" X 1"

OPTIONAL FILTER RACK INSTALLATION FOR BOTTOM

RETURN

With the filter removed, the filter rack is compressed and

then inserted into the bottom of the furnace. The retaining

screw/pin on each side inserts into engagement holes at the

bottom of the furnace cabinet side. See Figures 13, 14 & 16.

24-1/2"

**NOTE: For upflow 5 ton airflow models where the airflow

requirement exceeds 1800 CFM - Models will require return air

openings and filters on: (1) both sides, or (2) one side and the

bottom, or (3) just on the bottom

NOTE: Remove the bottom front channel to install the filter

rack in the 14-1/2" width cabinet furnaces.

Airflow

Blower Deck

Engagement

Hole

VIEW

ENGAGEMENT

HOLE DETAIL

(Typical both sides

and blower deck)

Filter

Rack

Airflow

Furnace

Cabinet

Side

BOTTOM FILTER RACK INSTALLATION

Filter Rack

Retaining

Screw/Pin

Engagement Hole

For Filter Rack

Installation With

Bottom Return

Optional Filter Rack Accessory Kit

BAYRACK960A

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Installer’s Guide

TABLE 5

Cabinet Width Left Side Bottom

SIDE

CUTOUT

Right Side

14.5

17.5

X¹

X²

Use Alternate Filter Clips Only

RETAINING

(Both Sides)

24.5

1. UD060C/R936K0 has 10x7 blower which requires use of alternate

filter clips for left side filter. "K1" and later use the filter rack.

2. Remove bottom front channel to install or reposition filter rack.

X - All Models

OPTIONAL FILTER RACK INSTALLATION FOR SIDE

RETURN AIR ON UPFLOW FURNACES (Left or Right)

If side air return is desired, the following instructions should

be used:

SPRINGS

BOTTOM

PANEL

INSTALLED

FILTER

RACK

RAILS

a. Open or remove the blower door.

b. Leave the bottom panel in place. (Some models

require field supplied bottom panels.)

c. After the side cutout is made following the directions

in the “Return Air Duct Connections” section on

pages 8 and 9; compress the filter rack and reinstall in

the side of the furnace. Confirm that the upper

retaining pin/screw locks into the engagement hole in

the blower deck and the lower pin/screw rests against

the side of the bottom panel. See Figures 14, 15, &

17-20.

Typical Upflow Left Side Return Filter Rack Installation

SIDE

CUTOUT

d. Install the furnace filter on the side. See Figures 14,

15, & 17-20.

RETAINING

(Both Sides)

BOTTOM ENGAGEMENT

Filter Rack

Retaining

Screw/Pin

Furnace

Cabinet

Side

Filter

Rack

SPRINGS

BOTTOM

PANEL

INSTALLED

FILTER

RACK

RAILS

Engagement Hole

For Filter Rack

Installation With

Bottom Return

Bottom Panel

Furnace

Typical Upflow Right Side Return Filter Rack Installation

BLOWER

DECK

Engagement Hole

For Filter Rack

Installation With

Side Return

Blower

Deck

Furnace

Cabinet

Side

Filter

Rack

Assembly

Filter Rack

Retaining

Screw/Pin

Optional door kit

BAYFLTR206

Typical Horizontal Filter Installation

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Installer’s Guide

RETURN AIR FILTERS FOR UPFLOW FURNACE

IN HORIZONTAL CONFIGURATION

TYPICAL DOWNFLOW FURNACE

RETURN AIR FILTER INSTALLATIONS

When the Upflow Furnace is installed in a horizontal configu-

ration, the filter must never be installed inside or outside the

cabinet directly above the blower assembly. See Figure 11

(page 9). Remote filter grilles may be used for homeowner

convenience or the filters may be installed in the duct work

upstream of the furnace. See Figures 11 (page 9) and 21 (page

11).

ALTERNATE UPFLOW

FILTER CLIP / BRACKET INSTALLATION - KIT09224

1. Determine the location to be used. The furnace cabinet

has dimples for location of the alternate furnace clips

(Side return only). Pre-drill clearance holes with a

3/16" drill. Bottom return holes are pre-drilled.

2. Install the clips in front and rear of the desired location

using the screws provided. The filter clip with the leaf

spring mounts in the rear of the cabinet. See Figure 22.

REAR

SIDE

-OUT

CUT

ALTERNATE FILTER

CLIPS LOCATION

Optional door kit

BAYFLTR206

Optional horizontal filter conversion kits are BAYFLTR203

for 17 1/2" width cabinets, BAYFLTR204 for 21" width

cabinets, and BAYFLTR205 for 24" width cabinets. These

include filters and brackets necessary for horizontal filters.

In addition, optional door kit BAYFLTR206 is also available.

See Figures 21 and 24.

Two high velocity type air filters are required for each down-

flow furnace. Downflow furnace filters must be located

outside the furnace cabinet. Typical installations are shown

in Figures 23 and 24. Tables 7 and 8 (page 13) provide

information for installation of the filter retaining brackets

shipped with downflow furnaces.

INSTALLING THE OPTIONAL FILTER

The filter may need to be cut to fit the unit depending on the

location of the return air filter.

TABLE 7

CABINET

WIDTH

FILTER

SIZE

FILTER BRACKET

LOCATION *

A score line and the words “CUT HERE” are located on the

end of the filter. If your application requires cutting the filter,

do so as indicted by the score mark.

14-1/2"

17-1/2"

21"

2 - 14X20X1

2 - 16X20X1

12-7/8"

14-3/8"

13-1/8"

11-5/8"

TABLE 6

RETURN AIR

UNIT

24-1/2"

* Location dimension is from end of duct to the screw holes for the bracket.

SIZE

BOTTOM

SIDE

TABLE 8

14-1/2"

17-1/2"

21"

CUT ON LINE DO NOT CUT

DO NOT CUT DO NOT CUT

DO NOT CUT CUT ON LINE

RETURN FILTER ACCESS FILTER ACCESS

CABINET

DUCT

OPENING -

WIDTH

DIMENSION "A" DIMENSION "B"

14-1/2"

17-1/2"

21"

13-1/4"

16-1/4"

19-3/4"

23-1/4"

12"

15"

14"

24-1/2"

19-1/2"

22"

24-1/2"

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Installer’s Guide

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.

GENERAL VENTING

IMPORTANT:

These furnaces may be installed as Direct Vent (sealed

combustion) or as Nondirect vent (single pipe). The fur-

naces are shipped DIRECT VENT with sealed combus-

tion.

1. Seal any unused openings in the common venting

system.

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.

2. Visually inspect the venting system for proper size

and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion or other

deficiencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the common

venting system are located and other spaces of the

building. Turn on clothes dryers and any appliances

not connected to the common venting system. Turn

on any exhaust fans, such as range hoods and 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 ciga-

rette, cigar, or pipe.

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 combus-

tion air requirements are met. (See AIR FOR COMBUS-

TION AND VENTILATION)

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-

PRESSURE 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",

or 3" plastic pipe and fittings (See Table 9, page 17).

Where the system is routed to the outdoors through an

existing masonry chimney containing flue products

from another gas appliance, or where required by local

codes, then 3" venting of Type 29-4C stainless steel

must be used in place of PVC material.

These furnaces have been classified as CATEGORY IV

furnaces in accordance with the latest edition of

ANSI Z21.47 • CAN/ CGA-2.3 Standards. Category IV

furnaces operate with positive vent pressure and with a

vent gas temperature less than 140°F above the

dewpoint. These conditions require special venting sys-

tems, which must be gas tight and water tight.

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) • CAN/

CGA B149.1 Installation Codes or “Exhibit J” of

ANSI Z21.47 • CAN/ CGA-2.3 Standards. The following

are general steps to be used to correct or resize a 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.

NOTE:

When an existing 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.

c. Use the appropriate tables in the latest edition of

the National Fuel Gas Code (ANSI Z223.1 •

CAN/ CGA B149.1 Installation Codes or “Exhibit

J” of ANSI Z21.47 • CAN/ CGA-2.3 Standards.

“Exhibit J” includes examples and drawings of

typical venting systems.

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Installer’s Guide

PVC VENT FITTING MATERIAL

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.

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.

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", 2½", 3", or 4" diameter. The al-

lowable materials are shown in Table 8.

VENT FITTING MATERIAL – PLASTIC

Gas and liquid tight single wall vent fittings, designed

for resistance to corrosive flue condensate, MUST be

used throughout.

Listed in Table 10 & 11 are 2", 2½", 3", and 4" size fittings

that meet these requirements. The materials listed are

various grades of PVC and ABS plastic.

PIPE JOINTS: All joints must be fastened and sealed to

prevent escape of combustion products into the build-

ing.

NOTE:

Follow venting instructions carefully when using PVC

cement.

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.

IMPORTANT:

All joints must be water tight. Flue condensate is some-

what acidic, and leaks can cause equipment damage.

Be sure to properly support these joints.

BONDING OF PVC

Connection of the pipe and collar of the combustion

air inlet should just be a friction fit. It is recommended

that the inlet air joint be sealed with RTV type sealant

to allow the joint to be separated for possible future ser-

vice. The inlet and vent pipes must be properly sup-

ported throughout the entire length.

Commercially available solvent cement must be used to

join the pipe and fittings. Follow instructions on the

container carefully.

Procedure for Cementing Joints:

1. Cut pipe square, remove ragged edges and burrs.

Chamfer end of pipe, then clean fitting socket and

pipe joint area of all dirt, grease, moisture or chips.

TABLE 9

PLASTIC PIPE DESIGNATIONS

PVC

ASTM STANDARD

PIPE TYPE

CELLULAR CORE

DWV PIPE

ALLOWABLE TEMPERATURE

MARKING

ASTM F891

ASTM D2665

ASTM D1785

ASTM D2241

F891

D2665

D1785

D2241

*158

**158

SCH 40, 80, 120

SDR SERIES

CPVC

ABS

ASTM STANDARD

PIPE TYPE

CPVC 41

ALLOWABLE TEMPERATURE

MARKING

ASTM D2846

ASTM F441

ASTM F442

D2846

F441

F442

**212

SCH 40, 80

SDR SERIES

ASTM STANDARD

PIPE TYPE

SCH 40 DWV

ALLOWABLE TEMPERATURE

MARKING

ASTM D2661

ASTM F628

D2661

F628

***180

SCH 40 DWV CELLULAR CORE

- Allowable temperatures based on classifications covered in ASTM D4396 [Deflection Temps Under Load (264 PSI)]

** - Allowable temperatures based on classifications covered in ASTM D1784 [Deflection Temps Under Load (264 PSI)]

*** - Allowable temperatures based on classifications covered in ASTM D3965 [Deflection Temps Under Load (264 PSI)]

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Installer’s Guide

VENT AND INLET AIR CONNECTIONS

Connection of the vent pipe to the vent collar should

also be accomplished using RTV type sealant. This type

sealant provides a connection which remains flexible

and can be separated in the future if service needs re-

quire the removal of the vent pipe for service or clear-

ance.

Seal VENT PIPE

with RTV sealant

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.

Front of Furnace

Seal INLET AIR PIPE

with RTV sealant

IMPORTANT:

Products installed in Canada must use vent systems

that are certified to the Standard for Type BH Gas Vent-

ing Systems (ULC S636) for Class II-A venting systems

(up to 65°C). Components of the vent system must not

be interchanged with other vent systems or unlisted

pipe or fittings. Plastic components, specified 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.

UPFLOW/ HORIZONTAL VENTING TABLE

TABLE 10

MAXIMUM VENT LENGTH:

DIRECT VENT (2 PIPE SYSTEM) -

MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT AND INLET AIR PIPES (See Notes)

NONDIRECT VENT (1 PIPE SYSTEM) -MAXIMUM TOTAL

EQUIVALENT FEET FOR

VENT PIPE ONLY (See Notes)

2" PIPE

& FITTINGS

2-1/2" PIPE

3" PIPE

4" PIPE

2" PIPE

& FITTINGS

2-1/2" PIPE

3" PIPE

4" PIPE

& FITTINGS

MODEL

& FITTINGS & FITTINGS & FITTINGS

& FITTINGS & FITTINGS

*UX1B040A9241A

*UX1B060A9241A

*UX1B060A9361A

*UX1B080A9241A

*UX1B080A9421A

100

130

*UX1C080A9601A NOT ALLOWED

*UX1C100A9361A NOT ALLOWED

*UX1C100A9481A NOT ALLOWED

*UX1D100A9601A NOT ALLOWED

*UX1D120A9601A NOT ALLOWED

NOTES: * - First letter may be "A" or "T"

NOT ALLOWED

1. The INLET AIR of one pipe systems require the installation of a 90° elbow (to prevent dust and debris from falling straight into thefurnace) and a 2 foot

horizontal or vertical straight pipe section connected before or after the elbow.

2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace).

If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See Note 7 below for exception).

The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH OF EACH

(Vent or Inlet air pipes in two pipe systems).

4. One standard radius 90° elbow is equivalent to 12' of 4" pipe; one SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is

equivalent to 6' of 3" pipe. One SHORT/LONG radius 90° elbow is equivalent to 7½' of 2½" pipe, & 5' of 2" pipe. Two 45° elbows equal one 90°elbow.

5. The termination tee or bend must be included in the total number of elbows. If the BAYVENT100 termination kit is used, the equivalent length of pipe is 5 feet.

There is zero equivalent length for the BAYVENT200.

6. Pipe adapters are field supplied.

7. 4" pipe may be reduced to 3" for termination with BAYAIR30AVENTA or BAYVENT200 without additional length restriction.

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Installer’s Guide

DOWNFLOW/ HORIZONTAL VENTING TABLE

TABLE 11

MAXIMUM VENT LENGTH:

DIRECT VENT (2 PIPE SYSTEM) -

MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT AND INLET AIR PIPES (See Notes)

NONDIRECT VENT (1 PIPE SYSTEM) -

MAXIMUM TOTAL EQUIVALENT FEET FOR

VENT PIPE ONLY (See Notes)

2" PIPE

& FITTINGS

2-1/2" PIPE

3" PIPE

4" PIPE

2" PIPE

& FITTINGS

2-1/2" PIPE

3" PIPE

4" PIPE

MODEL

& FITTINGS & FITTINGS & FITTINGS

*DX1B040A9241A

*DX1B060A9361A

*DX1B080A9421A

100

130

*DX1C100A9481A NOT ALLOWED

*DX1D120A9601A NOT ALLOWED

NOTES: * - First letter may be "A" or "T"

1. The INLET AIR of one pipe systems require the installation of a 90° elbow (to prevent dust and debris from falling straight into the furnace) and a 2 foot

horizontal or vertical straight pipe section connected before or after the elbow.

2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace).

NOT ALLOWED

If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See Note 7 below for exception).

The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH OF EACH

(Vent or Inlet air pipes in two pipe systems).

4. One standard radius 90° elbow is equivalent to 12' of 4" pipe; one SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is

equivalent to 6' of 3" pipe. One SHORT/LONG radius 90° elbow is equivalent to 7½' of 2½" pipe, & 5' of 2" pipe. Two 45° elbows equal one 90°elbow.

5. The termination tee or bend must be included in the total number of elbows. If the BAYVENT100 termination kit is used, the equivalent length of pipe is 5 feet.

There is zero equivalent length for the BAYVENT200.

6. Pipe adapters are field supplied.

7. 4" pipe may be reduced to 3" for termination with BAYAIR30AVENTA or BAYVENT200 without additional length restriction.

SINGLE PIPE VENTING

DOWNFLOW

FURNACE

UPFLOW FURNACE

Air Inlet

A (0-2') or greater

B (0-2') or greater

A+B = 2' minimum

Vent only

to outside

Air Inlet

Vent only

to outside

A = 2' minimum

INSIDE

CORNER DETAIL

AREA WHERE TERMINAL IS NOT PERMITTED

VENT TERMINAL

AIR SUPPLY INLET

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Installer’s Guide

Table 12 - See Figure 27

Direct Vent Terminal Clearances

Canadian Installations

US Installations

Clearance above grade, veranda, porch, deck, or

balcony

12 inches (30 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

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

100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >

100,000 Btuh (30 kw)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9

inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/<

50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000

Btuh (15 kw)

B= Clearance to window or door that may be opened

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the

D= terminal within a horizontal distance of 2 feet (61 cm)

from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G-

Clearance to inside corner

Clearance to each side of center line extended above

meter/regulator assembly

3 feet (91 cm) with a height 15 feet (4.5 m) above the

meter/regulator assembly

Clearance to service regulator vent outlet

3 feet (91 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

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

100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >

100,000 Btuh (30 kw)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9

inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/<

50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000

Btuh (15 kw)

Clearance to nonmechanical air supply inlet to building

or the combustion air inlet to any other appliance

K= Clearance to a mechanical air supply inlet

6 feet (1.83m)

3 feet (91 cm) above if within 10 feet (3m) horizontally

Clearance above a paved sidewalk or paved driveway

7 feet (2.13 m) †

located on public property

M-

Clearance under veranda, porch, deck, or balcony

`12 inches (30 cm) ‡

Notes:

1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

†. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings.

‡. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

Table 12A - See Figure 27

Non-Direct Vent Terminal Clearances

Canadian Installations

US Installations

Clearance above grade, veranda, porch, deck, or

balcony

12 inches (30 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

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

100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >

100,000 Btuh (30 kw)

4 feet (1.2m) below or to the side of opening; 1 foot (0.3m)

above opening.

B= Clearance to window or door that may be opened

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the

D= terminal within a horizontal distance of 2 feet (61 cm)

from the center line of the terminal

E= Clearance to unventilated soffit

Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line extended above

meter/regulator assembly

3 feet (91 cm) with a height 15 feet (4.5 m) above the

meter/regulator assembly

Clearance to service regulator vent outlet

3 feet (91 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12

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

100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >

100,000 Btuh (30 kw)

Clearance to nonmechanical air supply inlet to building

or the combustion air inlet to any other appliance

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

opening

K= Clearance to a mechanical air supply inlet

6 feet (1.83m)

7 feet (2.13 m) †

`12 inches (30 cm) ‡

3 feet (91 cm) above if within 10 feet (3m) horizontally

Clearance above a paved sidewalk or paved driveway

located on public property

7 feet (2.13 m)

M= Clearance under veranda, porch, deck, or balcony

Notes:

1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

†. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings.

‡. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

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Installer’s Guide

ELBOW AND TEE MUST

BE AS CLOSE TO-

GETHER

AS POSSIBLE

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

HORIZONTAL VENTING

NOTE:

Vent

ANCHORS

(4 req.)

termination

kit

BAYAIR30AVENTA

7.2"

BAYVENT200B may be used instead of the horizontal

and vertical termination options shown in the follow-

ing figures.

VENT

PLATE

VENT

3.2"

12" MINIMUM

TO OVERHANG

COMBUSTION

AIR

▲

CAUTION

SCREWS

(4 req.)

When the vent pipe is exposed to temperatures below

freezing, i.e., when it passes through unheated spaces,

etc., the pipe must be insulated with 1/2 inch (22.7 mm)

thick Armaflex-type insulation or equal. If the space is

heated sufficiently to prevent freezing, then the 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.

VENT

CAP

MAINTAIN 12" (18" FOR CANADA) MINIMUM

CLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

BAYVENT200B

HORIZONTAL VENTING THROUGH WALL

The vent & inlet terminals must be located at least 12"

minimum above normally expected snow accumulation

level.

Avoid areas where staining or condensate drippage may

be a problem.

These furnaces may be installed as direct vent (as

shipped) or as nondirect vent. Installation must

conform to national, state, and local codes.

Location of the vent/ wind terminal should be chosen to

meet the requirements of Figure 27 for either direct or

non-direct vent applications.

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Installer’s Guide

PITCH – Venting through the wall must maintain 1/4"

per foot pitched upward to insure that condensate

drains back to the furnace.

FLUE GAS DEGRADATION – The moisture content

of the flue gas may have a detrimental effect on some

building materials. This can be avoided by using the

roof or chimney venting option. When wall venting is

used on any surface that can be affected by this 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.

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials

must be maintained when using single wall stainless

steel venting. See Figure 31.

;

12" MIN TO

OVERHANG

COMBUSTION

AIR

VENT

MAINTAIN 12 IN

(18 IN. FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE

WHICHEVER IS GREATER

BAYAIR30AVENTA

(Sidewall)

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.

SUPPORT HORIZONTAL PIPE EVERY 3'

0" WITH THE FIRST SUPPORT AS

CLOSE TO THE FURNACE AS POSSIBLE.

INDUCED DRAFT BLOWER, HOUSING,

AND FURNACE MUST NOT SUPPORT

THE WEIGHT OF THE FLUE PIPE.

Use cement mortar seal on inside and outside of wall.

See Figure 32.

VENTING THROUGH THE ROOF

When penetrating roof with a 2" PVC vent pipe, a 2"

electrical conduit flashing may be used for a weather

tight seal. Lubricate flexible seal on flashing before PVC

pipe is pushed through the seal. (Field Supplied)

NOTE:

No vent cap as shown in Figure 36 is the preferred

method for vertical vent termination in extremely cold

climates.

In extreme climate conditions, insulate the exposed

pipe above the roof line with Armaflex type insulation.

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Installer’s Guide

NOTE: VENT AND INLET MUST BE SUPPORTED

AT A MAXIMUM OF 3' INTERVALS

SEE VENTING TABLE

STRAPS OR OTHER SUITABLE SUPPORTS

AT MAXIMUM OF 3'-0" INTERVALS

USE ONLY

APPROVED

TERMINATION

COMBUSTION

AIR INLET

UPWARD PITCH -- 1/4" PER FOOT

FIRST SUPPORT SHOULD BE AS

CLOSE TO FURNACE CONNECTION

AS POSSIBLE.

OUTSIDE

WALL

40" UPFLOW OR

DOWNFLOW MODELS

NOTE: ANY FITTINGS PASSING

THROUGH AN UNHEATED SPACE

MUST BE INSULATED.

TEE

COMBUSTION

AIR

REDUCING

COUPLING,

STRAP

(FIELD SUPPLIED)

FIELD SUPPLIED

IF NEEDED

RAIN CAP

VENT

2", 2-1/2"

or 3" PIPING

1" + 1/2"

ELBOW

(FIELD

COMBUSTION AIR

SUPPLIED)

3" PIPING

BAYAIR30AVENTA

SEAL ALL

WALL CAVITIES

BAYVENT200B

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Installer’s Guide

NOTE:

DOWNWARD VENTING

Both venting methods shown in Figure 40 & 42 must

also have the combustion air inlet installed - meeting

dimension requirements of Figure 36.

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.

6" Min.

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 to personal in-

jury. Excessive draining of condensate may cause

saturated ground conditions that may result in

damage to plants.

VENT

MAINTAIN 12 IN.

COMBUSTION

AIR

C) The condensate trap should be primed at initial

start up prior to heating season operation.

(18 IN. FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF.

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.

BAYAIR30AVENTA

MAINTAIN 12 IN.

VENT

(18 IN. FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF

REMOVE RIBS

FROM CAP

COMBUSTION

AIR

All horizontal stainless steel sections must be posi-

tioned with the seam on top.

ROOF FLASHING BOOT

(FIELD SUPPLIED)

All long horizontal sections must be supported to pre-

vent sagging.

SUPPORT

(FIELD SUPPLIED)

All pipe joints must be fastened and sealed to prevent

escape of combustion products into the building.

ELBOW

(FIELD SUPPLIED)

COMBUSTION

AIR

VENT

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Installer’s Guide

SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT

FLUE PIPE

COUPLING

SUPPORT

FLANGE

CEILING

GALVANIZED FIRESTOP SHOULD

BE FABRICATED WITH 3-7/8" DIA.

HOLE FOR SUPPORT FLANGE

(12" x 12" PANEL OR 12" DIA MIN.)

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )

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

TYPE 29-4C STAINLESS STEEL VENTING -

USED THROUGH CHIMNEY THAT VENTS

VENTING THROUGH CEILING

ANOTHER GAS APPLIANCE

STAINLESSSTEEL

STAINLESS

PVC PLASTIC VENTING - ONLY

THROUGH UNUSED CHIMNEY

STAINLESSSTEEL

STEEL

VENTCAP

VENT CAP

(OPTIONAL)

SEE CAUTION

6 IN. MIN.

STAINLESS

VENTCAP

STEEL

(OPTIONAL)

VENT CAP

SEE CAUTION

FLUE PIPE

6 IN. MIN.

SUPPORT THE SINGLE WAL

STAINLESS STEEL GAS

VENTING AND CENTER IT IN

THE CHIMNEY OPENING WIT

ANGLES AS SHOWN OR

ANOTHER EQUIVALENT

MANNER.

SUPPORT THE SINGLE

OUPLING TO SUPPORT

PE FROM ANGLES

R OTHER SUITABLE

UPPORT METHOD

WALL FLUE PIPE AND

CENTER IT IN THE

CHIMNEY OPENING WI

ANGLES AS SHOWN O

ANOTHER EQUIVALEN

MANNER.

COUPLING

AS REQUIRED

FLUE PIPE

NOTE:

HORIZONTAL VENTING

TO VERTICAL VENTING

NOTE:

HORIZONTAL VENTING

TO VERTICAL VENTING

▲

CAUTION

Do NOT run vent through chimney for wood burn-

ing 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.

▲

CAUTION

Do NOT run vent through chimney for wood burning or

oil furnaces or incinerators or any other gas appliance.

IMPORTANT –

The single wall flue pipe joints must be sealed.

The 90° elbow connection to vertical pipe must be sealed to

prevent condensate leakage to base of masonry chimney.

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.

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Installer’s Guide

INSPECTION. The state or local gas inspector of

IMPORTANT:

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.

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:

This appliance requires a special venting system. If

BAYAIR30AVENTA or BAYVENT200B are used, a copy of

the installation instructions for the kit shall remain with

the appliance or equipment at the completion of

installation. The venting system installation instructions

can be obtained from the manufacturer by writing to the

following address:

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:

American Standard, Inc.

INSTALLATION OF CARBON MONOXIDE

6200 Troup Highway

Tyler, TX 75707

Attention: Manager of Field Operations Excellence

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 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

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.

In the event that the requirements of this

subdivision can not be met at the time of completion of

installation, the owner shall have a period of thirty (30)

days to comply with the above requirements; provided,

however, that during said thirty (30) day period, a battery

operated carbon monoxide detector with an alarm shall be

installed.

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.

SIGNAGE. A metal or plastic identification plate

shall be permanently mounted to the exterior of the

building at a minimum height of eight (8) feet above grade

directly in line with the exhaust vent terminal for the

horizontally vented gas fueled heating appliance or

equipment. The sign shall read, in print size no less than

one-half (1/2) inch in size, “GAS VENT DIRECTLY

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

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Installer’s Guide

HORIZONTAL INSTALLATION

VERTICAL APPLICATIONS

(Upflow/ Horizontal or Downflow/ Horizontal)

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

NOTE:

In horizontal venting when the factory supplied “off-

set” (2X3 reducing coupling) is used for 3” vent pipe side of the unit and trim all excess tubing to avoid

installation, make sure the marking “Top” is located on

the top side of the pipe. The straight side must be on

bottom for proper condensate drainage. This coupling

is factory supplied only with the following models:

*UC120 & *DC120, *UX120 & *UY120 *UX100 & *UY100,

*UX808C960, and all *DX & *DY models.

kinks.

WHEN THE FACTORY SUPPLIED "OFF-SET" (2X3

REDUCING COUPLING) IS USED FOR 3" VENT PIPE

INSTALLATION, MAKE SURE THE MARKING "TOP" IS

LOCATED ON THE TOP SIDE OF THE PIPE.

LABEL

SAYS

"TOP"

Right side

STRAIGHT SIDE MUST BE

ON BOTTOM FOR PROPER

CONDENSATE DRAINAGE.

UPFLOW (VERTICAL)

2" TO 3" COUPLING

FACTORY SUPPLIED ONLY WITH

THE FOLLOWING MODELS:

UC120 & DC120

UX120 & UY120

UX100 & UY100

UX080C960

ALL DX & DY MODLES

Use Inducer Drain

hose without

extension

UPFLOW HORIZONTAL 17" UNITS

(Left side only)

FURNACE

VENT

OUTLET

Downflow furnace - The furnace is shipped with the

left side drainage setup. To change the right side drain,

remove the drain lines from the trap, rotate the trap

180° so it exits to the right, reconnect the lines, and run

a 1/2" CPVC pipe from the trap out through the right

side knock-out. Use RTV silicone sealant to connect the

CPVC pipe to the trap for ease of removing to clean the

trap.

CONDENSATE DRAIN INSTRUCTIONS

▲

CAUTION

IT IS RECOMMENDED THAT A DRAIN PAN BE INSTALLED

UNDERTHE FURNACETO PREVENT PROPERTY DAMAGE,

PERSONAL INJURY OR DEATH FROM LEAKING CONDEN-

SATE.

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Installer’s Guide

HORIZONTALAPPLICATIONS

Upflow and Downflow furnaces - All horizontal ap-

plications are left side only. It is always recommended

that the auxiliary drain pan be installed under a hori-

zontally installed evaporator and/or 90% gas furnace.

Connect the auxiliary drain pan to a separate drain line

(no trap is needed in this line).

(

Left

side

DOWNFLOW (VERTICAL)

)

Left side

UPFLOW (VERTICAL)

Right

side

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

DOWNFLOW (VERTICAL)

Use

extension

hose here

UPFLOW HORIZONTAL 21" & 24" UNITS

(Left side only)

The trap must be repositioned to the exterior of the

cabinet. Remove the trap from its present location and

reposition the trap outside of the unit, through the long

circular hole, next to the secondary recuperated cell.

Remove the larger drain line (from the secondary cell)

and trim to fit between the secondary cell and the new

trap location. On upflow units, plug the hole in the

blower deck where the tube went through.

Cut off curved end of

Inducer drain hose

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

upflow units, this tube may need to be extended, using

the tubing shipped with the furnace.

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 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.

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Installer’s Guide

NOTE:

Evaporator and furnace condensate drain piping may

be manifolded together as shown in Figure 52. A pri-

mary drain vent stack must be installed and termi-

nated below the outlet of the secondary heat exchanger

drain connection to prevent water from damaging fur-

nace controls if the primary drain outlet plugs up.

Where the furnace is installed above a finished ceiling,

the primary drain vent stack must be installed such

that overflow from the vent stack opening will flow into

an axillary drain pan in order to prevent water damage

to the finished ceiling below.

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 provi-

sions to prevent winter freeze-up of the condensate

drain line. Frozen condensate will block drains, result-

ing in furnace shutdown. If the drain line cannot be in-

stalled in a conditioned space, then UL listed heat tape

should be applied as required to prevent freezing (per

manufacturer’s instructions). The heat tape should be

rated at 5 or 6 watts per foot at 120 volts. Self-regulat-

ing (preferred) or thermostatically controlled heat tape

is required.

TWINNING FURNACES

These furnaces may be twinned. Twinning requires that

two furnaces with the same configuration, capacity, and

airflow must be used. They shall have common returns

with equal pressure drops or ducts with equivalent

lengths and sizes. See Field Wiring Diagrams for proper

hookup.

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTAT

NO COOLING

FURNACE

SEE

NOTE 7

TWIN

If upflow furnace is installed

over a finished ceiling, overflow

from the primary drain vent

stack must flow into an auxillary

drain pan to prevent damage to

the finished ceiling below.

SEE

NOTE 6

TO 115 V 1 PH.,

60 HZ., POWER

SUPPLY PER

B/C

Primary drain vent stack

must terminate below

secondary heat exchanger

condensate drain outlet.

LOCAL CODES

HUM SEE

NOTE 5

EAC SEE

NOTE 5

To drain opening

From drawing B341437 Rv 1

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Installer’s Guide

FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE

1 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

FURNACE

OUTDOOR UNIT

(NO TRANSFORMER)

SEE

NOTE 6

SEE

NOTE 8

B/C

TO 115 V 1 PH.,

60 HZ., POWER

SUPPLY PER

LOCAL CODES

HUM SEE

NOTE 5

EAC SEE

NOTE 5

From drawing B340388 Rv 2

ELECTRICAL CONNECTIONS

The integrated furnace control is polarity sensi-

Make wiring connections to the unit as indicated on en- tive. The hot leg of the 120V power supply must be con-

closed wiring diagram. As with all gas appliances using nected to the black power lead as indicated on the wir-

electrical power, this furnace shall be connected into a ing diagram. Provision for hooking up an electronic air

permanently live electric circuit. It is recommended cleaner and or humidifier is provided on the integrated

that furnace be provided with a separate “circuit protec- control.

tion device” in the electric circuit. The furnace must be Refer to the SERVICE FACTS literature and unit wiring

electrically grounded in accordance with local codes or diagram attached to furnace diagram attached to fur-

in the absence of local codes with the National Electri- nace.

cal Code, ANSI/NFPA 70 or CSA C22.1 Electrical Code,

if an external electrical source is utilized.

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TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEAT

ONLY

1 STAGE HEATING ONLY THERMOSTAT

THERMOSTAT

(WITH FAN SWITCH)

FURNACE NO. 1

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO. 2 IS SYNCRONIZED

WITH UNIT NO. 1 VIA SIGNALS

FROM TWIN CONNECTION.

TWIN

SEE NOTE 4

ISOLATION RELAY

(FIELD SUPPLIED)

SEE NOTE 4

ISOLATION RELAY

SEE NOTE 4

SEE NOTE 3

B/C

From Dwg. 21B341422 Rev. 3

TWINNING CONNECTION DIAGRAM

FOR TWINNING 1 STAGE FURNACES WITH

SINGLE WIRE TWINNING FEATURE

1 STAGE HEAT / 1 STAGE COOL THERMOSTAT

1 STAGE

OUTDOOR UNIT

(WITH TRANSFORMER)

HEATING / COOLING

THERMOSTAT

FURNACE NO. 1

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO. 2 IS SYNCRONIZED

WITH UNIT NO. 1 VIA SIGNALS

FROM TWIN CONNECTION.

TWIN

ISOLATION RELAY

(FIELD SUPPLIED)

SEE NOTE 3

SEE NOTE 4

OUTDOOR UNIT

(NO TRANSFORMER)

ISOLATION RELAY

SEE NOTE 4

SEE NOTE 5

B/C

ISOLATION RELAY

(FIELD SUPPLIED)

SEE NOTE 4

From Dwg. 21B341423 Rev. 2

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Installer’s Guide

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).

GAS PIPING

The upflow/ horizontal furnace is shipped standard for

left side installation of gas piping. A knock-out is pro-

vided on the right side for an alternate gas piping ar-

rangement. See Figure 53.

NOTE:

The installation of piping shall be in accordance with

piping codes and the regulations of the local gas com-

pany. Pipe joint compound must be resistant to the

chemical reaction with liquefied petroleum gases.

Refer to piping Table 13, for delivery sizes. Connect gas

supply to the unit, using a ground joint union and a

manual shut-off valve as shown in Figures 53-55.

National codes require a condensation drip leg to be in-

stalled ahead of the controls as shown in Figures 53-55.

The furnace and its individual shut-off valve must be

disconnected from the gas supply piping system during

any pressure testing of that system at test pressures in

excess of 1/2 psig (3.5 kPa).

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!

▲

CAUTION

Use a backup wrench on the gas valve when installing

gas piping to prevent damage to the gas valve and

manifold assembly.

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

MAIN MANUAL

SHUTOFF VALVE

MAIN MANUAL

SHUTOFF VALVE

GROUND

UNION

JOINT

GROUND

UNION

JOINT

DRIP

LEG

DRIP

LEG

UPFLOW – LEFT HAND GAS PIPING

UPFLOW – RIGHT HAND GAS PIPING

THE DOWNFLOW (VERTICAL) MAY BE INSTALLED LEFT OR RIGHT SIDE GAS PIPING

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MAIN MANUAL

SHUTOFF VALVE

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

GROUND UNION JOINT

DRIP

LEG

MAIN MANUAL

SHUTOFF VALVE

DRIP

LEG

GROUND

UNION JOINT

AUTOMATIC GAS VALVE

WITH MANUAL SHUTOFF

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE (UPFLOW SHOWN)

TABLE 13

6. Multiply the final figure by the heating value of the

NATURAL GAS ONLY

gas obtained from the utility company and compare

to the nameplate rating. This must not exceed the

nameplate rating.

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

LENGTH OF PIPE

PIPE

SIZE

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:

132

278

520

1050

1/2

3/4

190

350

730

152

285

590

130

245

520

115

215

440

105

195

400

180

370

a. Turn off all electrical power to the system.

b.Attach a manifold pressure gauge to the outlet

pressure tap marked "OUT PRESS TAP" on

White-Rodgers gas valve model 36F or boss

marked "OUT P" on White-Rodgers gas valve

model 36G. (See Figure 58 for White-Rodgers gas

valve model 36F and Figure 59 for White-Rodgers

gas valve model 36G). For the gas valve model

36F, measurement requires removal of the plug

and installation of a barbed fitting. Attach flexible

tubing and a manometer to the barbed fitting.

For the gas valve model 36G, do not remove the

pressure tap test screw. Using a 3/32" hex

wrench, loosen the pressure tap test screw one

turn and install 5/16" flexible tubing and a ma-

nometer directly onto the outlet pressure boss.

c. Turn on system power and energize valve.

d.Remove the regulator adjustment screw cap on

the gas valve for manifold pressure adjustment.

e.Turn the adjustment nut clockwise to increase

the gas flow rate, and counterclockwise to de-

crease the gas flow rate using a 3/32" hex wench.

f. The final manifold pressure setting shall be as

specified in Table 15 with an input of no more

than nameplate rating and no less than 93% of

the nameplate rating, unless the unit is derated

for high altitude.

1-1/4

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

TABLE 14

ORIFICE SIZES

MAIN BURNER ORIFICE

DRILL SIZE

INPUT

RATING

BTUH

NUMBER

BURNERS

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 (in cfh)

Table 16 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. Dial Gas Flow CFH =

Chart Flow Reading ÷4

For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading ÷4

g. Replace the regulator adjustment screw cap and

tighten securely.

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Installer’s Guide

h. Turn off all electrical power to the system.

i. Remove the manometer and flexible tubing. Re-

move the barbed fitting and replace the plug or

tighten the pressure test screw.

j. Turn on electrical power to the system and ener-

gize valve.

Table 14 lists the main burner orifices used with the

furnace. If a change of orifices is required to correct the

furnace input rating. Refer to Table 17.

TABLE 15

FINAL MANIFOLD PRESSURE SETTINGS

k. Using a leak detection solution or soap suds,

check for leaks at plug or pressure boss screw.

FUEL

NATURAL GAS

LP GAS

PRESSURE

3.5" W.C.

▲

WARNING

11.0" W.C.

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 53.

▲

CAUTION

Replace manifold pressure tap threaded plug and leak

check after checking/ adjusting manifold gas pressure.

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Installer’s Guide

HIGH ALTITUDE DERATE

ROTATE THE FRONT

COVER AS SHOWN

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.

INSERT THE TOP

FLANGE OF THE FRONT

COVER UNDER THE LIP

INSIDE THE BOX

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.

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). 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.

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.

Installation of this furnace at altitudes above 2,000 ft.

(610m) shall be in accordance with the local codes, or in

the absence of local codes, the National Fuel Gas Code,

ANSI Z223.1/ NFPA 54 or National Standard of

Canada, Natural Gas and Propane Installation Code,

CSA 149.1. Installation of this furnace at altitudes

above 2,000 ft. (610m) shall be made in accordance with

the listed high Altitude Conversion Kit available with

this furnace.

TABLE 16

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

SEC. FLOW SEC. FLOW SEC. FLOW SEC. FLOW

IMPORTANT:

Re-install the propane orifices to the same depth as the

orifices supplied with the equipment.

900

800

720

655

600

555

514

480

450

424

400

379

360

343

327

313

300

288

277

267

257

248

240

232

225

218

212

206

200

195

189

185

180

176

172

167

164

160

157

153

150

147

144

141

138

136

133

131

129

126

124

122

120

116

112

109

106

103

100

104

108

112

116

120

124

128

132

136

140

144

18-CD19D6-32

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Installer’s Guide

DO NOT CHECK WITH AN OPEN FLAME. Allow 5

minutes for any gas that might have escaped to dissi-

pate. LP Gas being heavier than air may require forced

ventilation. Flip the switch on the gas valve in the unit

to the “ON” position.

See Table 17 & 18 for help 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.

Regulator

Adjustment

Outlet Pressure Boss

TABLE 17

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

PART

NUMBER

DRILL

SIZE

PART

NUMBER

ORF00501

ORF00644

ORF00909

ORF00910

ORF01099

ORF00503

ORF00493

ORF00555

ORF00693

ORF00907

ORF00908

ORF01338

ORF01339

Inlet Pressure

REINSTALLATION OF THE BURNER BOX COVER

Figure 57 shows the correct way to reinstall the burner

box cover if adjustment or replacement of the flame

sensor, hot surface igniter, or main burner orifices have

required removal of the cover.

Boss (opt.)

On/Off Switch

White-Rodgers 36G gas valve

On/Off Switch

TABLE 18

Orifice

ALTITUDE ABOVE SEA LEVEL

Twist Drill

Size If

and Orifice Required At Other Elevations

Installed

At Sea

Level

2000 3000 4000 5000 6000 7000 8000 9000 10000

42 43 43 43 44 44 45 46

44 44 44 45 45 46 47 47

45 45 45 46 47 47 48 48

46 47 47 47 48 48 49 49

47 47 47 48 48 49 49 50

48 48 49 49 49 50 50

54 55 55 55 55 55 56 56

55 55 55 56 56 56 56 56

56 56 57 57 57 58 59 59

58 59 59 60 60

61 62 63

White-Rodgers 36F gas valve

59 60 60 61 62 62 63 63

From National Fuel Gas Code - Table F-4

LIGHTING INSTRUCTIONS

▲

WARNING

▲

WARNING

CARBON MONOXIDE POISONING HAZARD

DO NOT attempt to manually light the burner.

Failure to follow this warning could result in property

damage, personal injury or death.

Failure to follow the installation instructions for the

venting system being placed into operation could re-

sult in carbon monoxide poisoning 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 gas valve until the

thermostat is satisfied.

START UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

With gas and electrical power “OFF”

1. Duct connections are properly sealed

2. Filters are in place

3. Venting is properly assembled

4. Blower door is in place

Flip the switch on main gas valve within the unit to the

“OFF” position. Turn the external gas valve to “ON”.

Purge the air from the gas lines. After purging, Check

all gas connections for leaks with a soapy solution —

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Installer’s Guide

To shut off.

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 instructions.

For complete shut-down: Flip the switch on the main

gas valve to the “OFF” position, (See Figure 58 & 59).

Disconnect the electrical supply to the unit.

▲

CAUTION

If this is done during the cold weather months, provi-

sions must be taken to prevent freeze-up of all water

pipes and water receptacles.

NOTE TO INSTALLER

Failure to follow this warning could result in property

damage.

Review the following warnings with the owner. Review

contents of USER’S INFORMATION MANUAL with the

owner.

Whenever your house is to be vacant, arrange to

have someone inspect your house for proper tem-

perature. This is very important during freezing

weather. If for any reason your furnace should

fail to operate damage could result, such as fro-

zen water pipes.

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.

SEQUENCE OF OPERATION

Thermostat call for heat

▲

WARNING

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.

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.

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. After 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.

INDOOR BLOWER TIMING

Heating: The integrated furnace control module con-

trols the indoor blower. The blower start is fixed at 45

seconds after ignition. The FAN-OFF period is field se-

lectable by dip switches at 60, 100, 140, or 180 seconds.

The factory setting is 100 seconds (See wiring diagram).

Cooling: The fan delay off period is factory set at 0 sec-

onds. The option for 80 second delay off is field select-

able (See wiring diagram).

ROOM AIR THERMOSTAT

HEAT ANTICIPATOR ADJUSTMENT

Set the thermostat heat anticipator according to the

current flow measured, or the settings found in the

notes on the furnace wiring diagram (found in the SER-

VICE FACTS or inside the furnace casing).

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

INSTRUCTIONS TO THE OWNERS

In the event that electrical, fuel, or mechanical

failures occur, the owner should immediately

turn the gas supply off at the manual gas valve,

located in the burner compartment. Also turn off

electrical power to the furnace and contact the

service agency designated by your dealer.

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Installer’s Guide

8. RESET AFTER BURNER BOX LIMIT SHUT-

DOWN

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.

ABNORMAL CONDITIONS

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN

EXCESS OF 40 M.P.H.) VENT OR FLUE BLOCK-

AGE

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 termina-

tions, the limit switch must be reset by a

qualified servicer.

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.

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 Labo-

ratories, 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

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 auto-

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.

NOTE:

The manufacturer of your furnace does not test any de-

tectors and makes no representations regarding any

brand or type of detector.

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 completed within 30 seconds.

18-CD19D6-32

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Installer’s Guide

18-CD19D6-32

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Installer’s Guide

INTEGRATED FURNACE CONTROL ERROR FLASH CODES

Flashing Slow ---

Flashing Fast ---

Continuous ON ---

Normal - No call for Heat

Normal - Call for Heat

Replace IFC

Continuous OFF --- Check Power

2 Flashes ---

System Lockout (Retries or Recycles exceeded)

Draft Pressure Error - Possible problems:

a) Venting problem

b) Pressure switch problem

3 Flashes ---

c) Inducer problem

4 Flashes ---

5 Flashes ---

6 Flashes ---

7 Flashes ---

8 Flashes ---

Open Temperature Limit Circuit

Flame sensed when no flame should be present

115 volt AC power reversed, poor grounding or system voltage too low

Gas valve circuit error

Low flame sense signal

Check Ignitor Circuit and Line "N" to 24VAC "Common" voltage (≤ 2 volts)

[possible grounding problem]

9 Flashes ---

18-CD19D6-32

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Literature Order Number 18-CD19D6-32

File Number

Supersedes

Date

18-CD19D6-32

18-CD19D6-31

05/08

Trane

6200 Troup Highway

Tyler, TX 75707

Since the manufacturer has a policy of continuous product and product data improvement, it reserves the

right to change design and specifications without notice.

For more information contact

your local dealer (distributor)

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