1009818_Manufacturer_Specifications_and_Installation_Instructions_08-24-2021_09_32_53_TOM MAYER SPECS18-CD19D2-28-EN
IIIIII IIIII IIII IIIIIII IIIII IIII IIIII IIIIII IIII IIII IIIIII IIIII IIII IIIIIII IIIIII II IIII
Installer's Guide
Upflow/ Horizontal and Downflow/ Horizon-
tal Gas -Fired Furnaces, 2 - Stage,
"Fan Assisted Combustion System"
*U D2A040A9242A
*U MB080A9362A
*U D2C100A9482A
*U D2C120A9542A
*DD2A040A9242A
*DD2B080A9362A
*DD2C100A9602A
*UD2A060A9362A
*UD2B080A9482A
*UD2C100A9602A
*UD2D120A9602A
*DD2A060A9362A
*DD2B100A9482A
*DD2D120A9602A
* First letter may be "A" or "T"
*UD2B060A9362A
*U D2 B100A9362A
*U D2 D100A9602A
*U D2 D140A9602A
*DD2B060A9362A
*DD2C100A9482A
*DD22D140A602A
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
is Document is customer property and is to remain with this unit.
Please return to service information pack upon completion of work.
For VENT SIZING INFORMATION see:
USA —
National Fuel Gas Code ........... ANSI Z223.1/NFPA 54 (latest version)
CANADA—
Natural Gas Installation Code .....
Propane Installation Code ............
USA/CANADAALTERNATE —
Category I Venting Guide ..............
CAN/CGA-B149.1 (latest version)
CAN/CGA-B149.2 (latest version)
................. Pub. No. 18-CH23D1-2
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
O 0
o 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
000000 '
p o 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
Upflow/ Horizontal* Downflow/ Horizontal*
*Horizontal Conversion for these furnaces may be left or right side rotation.
A341789P02
Installer's Guide
SAFETY SECTION
The following safety practices and precautions must be
followed during the installation, servicing, and operation of
this furnace.
1. Use only with the type of gas approved for this furnace.
Refer to the furnace rating plate.
2. Install this furnace only in a location and position as
specified in "Location and Clearances" (page 3), of these
instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified in "Air for Combustion and
Ventilation" (pages 7-8), of these instructions.
4. Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system only,
as specified in the "Venting" section (pages 13-14), of
these instructions.
5. Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically
for the detection of leaks to check all connections, as
specified in "Gas Piping" (page 19), of these
instructions.
6. Always install the furnace to operate within the fur-
nace's intended temperature -rise range with a duct sys-
tem which has an external static pressure within the
allowable range, as specified on the unit rating plate.
Airflow with temperature rise for cfm versus static is
shown in the Service Facts accompanying this furnace.
7. When a furnace is installed so that supply ducts carry
air circulated by the furnace to areas outside the space
containing the furnace, the return air shall also be
handled by a duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
8. A gas -fired furnace for installation in a residential
garage must be installed as specified in "Location and
Clearances" section (page 3), of these instructions.
9. The furnace may be used for temporary heating of
buildings or structures under construction only when
the following conditions have been met:
a. The furnace venting system must be complete and
installed per manufacturers instructions.
b. The furnace is controlled only by a room thermo-
stat (no field jumpers).
c. The furnace return air duct must be complete and
sealed to the furnace and clean air filters are in place.
d. The furnace input rate and temperature rise must
be verified to be within nameplate marking.
e. 100% of the furnace combustion air requirement
must come from outside the structure.
f. The furnace return air temperature range is be-
tween 55 and 80 degrees Fahrenheit.
g. Clean the furnace, duct work, and components
upon substantial completion of the construction pro-
cess, and verify furnace operating conditions including
ignition, input rate, temperature rise and venting, ac-
cording to the manufacturer's instructions.
10. This product must be gas piped by a Licensed Plumber
or Gas Fitter in the Commonwealth of Massachusetts.
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 CAU-
TION.
a. WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
b. CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. It is also used to alert against unsafe practices
and hazards involving only property damage.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide
poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 or the CAN/CGA B149
Installation Codes and these instructions. Determine
that there is no blockage or restriction, leakage,
corrosion and other deficiencies which could cause an
unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which the
appliance(s) connected to the venting system are
located and other deficiencies which could cause an
unsafe condition.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they are operating at maximum speed. Do not operate
a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. If improper venting is observed during any of the above
tests, the venting system must be corrected in
accordance with the National Fuel Gas Code,
ANSI Z221.1/NFPA 54 and/or CAN/CGA B149
Installation Codes.
8. After it has been determined that each appliance
connected to the venting system properly vents where
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas -fired
burning appliance to their previous conditions of use.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result
in serious injury, death or property damage.
Improper servicing could result in dangerous operation,
serious injury, death, or property damage.
0 2015 Trane All Rights Reserved
18-CD19D2-28-EN
GENERAL INSTALLATION INSTRUCTIONS
The manufacturer assumes no responsibility for equipment
installed in violation of any code or regulation.
It is recommended that Manual J of the Air Conditioning
Contractors Association (ACCA) or A.R.I. 230 be followed
in estimating heating requirements. When estimating
heating requirements for installation at Altitudes above
2000 ft., remember the gas input must be reduced (See GAS
INPUT ADJUSTMENT).
Material in this shipment has been inspected at the
factory and released to the transportation agency
without known damage. Inspect exterior of carton
for evidence of rough handling in shipment. Unpack
carefully after moving equipment to approximate
location. If damage to contents is found, report the
damage immediately to the delivering agency.
Codes and local utility requirements governing the instal-
lation of gas fired equipment, wiring, plumbing, and flue
connections must be adhered to. In the absence of local
codes, the installation must conform with latest edition of
the National Fuel Gas Code ANSI Z223.1 • National Instal-
lation 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 Fan Assisted
Combustion system CATEGORY I furnaces as required by
ANSI Z21.47 "latest edition" and CAN/CGA 2.3. Therefore
they do not require any special provisions for venting other
than what is indicated in these instructions. (Category I
defined on page 13).
These furnaces may be twinned. They shall have
common returns with equal pressure drops or ducts
with equivalent lengths and sizes. See Field Wir-
ing Diagrams for Twinning on page 17 for proper
hookup.
To prevent shortening its service life, the furnace should
not be used as a "Construction Heater" during the finish-
ing phases of construction until the requirements listed
in item 9, a-g of the safety section of this publication have
been met. Condensate in the presence of chlorides and
fluorides from paint, varnish, stains, adhesives, cleaning
compounds, and cement create a corrosive condition
which may cause rapid deterioration of the heat exchang-
er.
These furnaces are not approved or intended for installa-
tion in manufactured (mobile) housing, trailers, or rec-
reational vehicles. Failure to follow this warning could
result in property damage, personal injury, or death.
Do not install the furnace in a corrosive or contaminated
atmosphere.
LOCATION AND CLEARANCES
The location of the furnace is normally selected by the
architect, the builder, or the installer. However, before the
furnace is moved into place, be sure to consider the follow-
ing requirements:
1. Is the location selected as near the chimney or vent and
as centralized for heat distribution as practical?
Installer's Guide
Contents
INSTALLATION INSTRUCTIONS
General Installation Instructions
Locations And Clearances
Outline Drawings
Upflow Installation
Downflow Installation
Air For Combustion And Ventilation
Duct Connections
Return Air Filters
Typical Upflow Return Air Filter Installations
Alternate Upflow Filter Clip / Bracket Installation
Typical Downflow Furnace return Air Filter Installations
General Venting Instructions
Venting Into A Masonry Chimney
Electrical Connections
Field Wiring Diagrams
Gas Piping
Sequence Of Operation
Start Up And Adjustment
Preliminary Inspections
Combustion And Input Check
High Altitude Derate
Lighting Instructions
Control And Safety Switch Adjustment
Abnormal Conditions
IFC Error Flash Code
2. Do all clearances between the furnace and enclosure
equal or exceed the minimums stated in Clearance
Table on the Outline Drawings.
3. Is there sufficient space for servicing the furnace and
other equipment? A minimum of 24 inches front acces-
sibility to the furnace must be provided. Any access
door or panel must permit removal of the largest com-
ponent.
4. Are there at least 3 inches of clearance between the
furnace combustion air openings in the front panel and
any closed panel or door provided?
5. Are the ventilation and combustion air openings large
enough and will they remain unobstructed? If outside
air is used, are the openings set above the highest snow
accumulation level? (See the Air for Combustion and
Ventilation section)
6. Allow sufficient height in supply plenum above the
furnace to provide for cooling coil installation, if the
cooling coil is not installed at the time of this furnace
installation.
7. A furnace shall be installed so electrical components
are protected from water.
8. If the furnace is installed in a residential garage, it
must be installed so that the burners, and the ignition
source are located not less than 18 inches above the
floor and the furnace must be located or protected to
avoid physical damage from vehicles.
3
3
3
4-5
6
6
7
8
9-13
9
12
12
13
13
14-15
15-18
19
19
W
20
20
22
22
23
23
24
18-CD19D2-28-EN 3
aM C'
5/8
0 7/8 HOLE
ELECTRICAL
CONNECTION
*UD2 OUTLINE DRAWING
(ALL DIMENSIONS ARE IN INCHES)
04 DIAMETER
° FLUE CONNECT
LET ___�
R aM "B"
5/8 3-15/I6
3-15/16 �
I
T 0 1-112 HOLE
IT GAS CONNECTION A A A A A A
2-1/I6
2- 1 /8 ---�
1-5/16 ':0 30-5/8 q0
® 0
P---------------------- ----- 28- 1 /4
14-7/8 S I DE 22- 112 °
RETURN
°
6 _A I -R
1-9/I6
0 7/8" HOLE WITH PLUG
ELECTRICAL CONNECTION
(ALTERNATE)
O 1-5/8" HOLE WITH PLUG
I/2 � 5-5/16
2-1/16 I FLOOR WHEN TYPE 0-1 VENT IS USED.
- -- O 1-5/8" HOLE WITH PLUG
0
32
28-1/4
S I DE 14 7/s
o RETURN
AIR
- ----------------------------------------------
I - 91/16
MINIMUM CLEARANCE TO COMBUSTIBLE MATERIALS
UPFLOW CLOSET
LEFT SIDE 0 IN. FRONT 3 IN,
RIGHT SIDE 0 IN. BACK 0 IN.
FLUE N6 IN. TOP I IN.
-----------------
-
--------------------------------
HORIZONTAL CLOSET (SEE NOTE 1)
TOP 2 IN. BACK 3 IN.
FLUE N6 IN. SIDES I IN.
FRONT 18 IN.
--------------------------------------------------
ALCOVE (SEE NOTF I )
TOP I IN. BACK 0 IN,
FLUE 8
6 IN. SIDES 0 IN,
FRONT 18 IN.
----------------------------------------------
N - MAY BE I" WHEN TYPE B-I VENT IS USED
NOTES:
I) MAY BE INSTALLED ON COMBUSTIBLE
23 3/4I/2 �DIM "A"--� �23-3/4� 1-5/16
— 28-I/2
BOTTOM
aM -o RETURN
AIR
3/4
3/4 JL 23-112 3-13/I6
MODEL
DIM "A"
"B
,
"D11
*UD2A04OA9242A, UD2AO6OA9362A
14-1/2"
9-5/8"
13-1/4"
13"
*UD2BO6OA9362A, *UD21308OA9362A
17-1/2"
9-5/8"
16-1/4"
16"
*UD2BO8OA9482A,*UD2B100A9482A
*UD2C100A9482A, *UD2C100A9602A
21"
13-1/16"
19-3/4"
19-1/2"
UD2C12OA9542A
*UD2D100A9602A,*UD2D12OA9602A
24-1/2"
15 5/16"
23 1/4"
23"
*UD2D14OA9602A
* -The First Letter May Be "A" or "T"
c
CL
IS
*DD2 OUTLINE DRAWING
(ALL DIMENSIONS ARE IN INCHES)
5/8
04 FLUE
o INLET OPENING
Elm -C- A I R
DM -B-
19-5/8 4-1/8
5/8
SIDE PANEL CUTOUT 3-3/g 3-I/2 4 FLUE
HORIZONTAL VENTING CONNECTION
THROUGH CABINET I/2
2 5-
/ 7
5
0 7/8 HOLE 2 I/8 ° I/2
ELECTRICAL 2-1/8
CONNECTION
3 15/16 R A A A A R 40 29-1/2
rr 31 20-114
0 1-5/8" HOLE T
WITH PLUG (3)
12-3/8 O -------- 10
0 1-112 HOLE
GAS CONNECTION
2 1/16 �— DIM 'A' -� 5-5/16
I/2
28-I/2
am'DI OUTLET
AIR
3/4 J
3/4 19-9/16 7-3/4
Gr,
SIDE PANEL CUTOUT
HORIZONTAL VENTING
THROUGH CABINET
� 24- 112 �
MINIMUM CLEARANCE TO COMBUSTIBLE MATERIALS
SIDES I ILN. W/SINGLE WALL VENT - 0 IN. W/TYPE B-I VENT
FLUE 6 IX. W/SINGLE WALL VENT - I IN. W/TYPE B-I VENT
FRONT 6 IN. BACK I IN.
----------------------------------------------------
FiORQONTAL fYDSET na u: D6GIANOE Lffn
TOP 2 IN. W/SINGLE WALL VENT 2 IN. W/TYPE B-1 VENT
FLUE 6 IX. W/SINGLE WALL VENT - I IN. W/TYPE B-I VENT
FRONT 6 IN. BACK 3 IN. SIDES I IN.
HDFfZONrAL CLDfiET Ip IF D6aUWE f11IWT1 O
i0P 2 IX. W/SINGLE WALL VENT
FLUE 6 IN. W/SINGLE WALL VENT - I IN. W/TYPE B-I VENT
FRONT 6 IN. BACK 3 IN. SIDES I IN.
FOR INSTALLATION ON COMBUSTIBLE FLOORING ONLY
WHEN 0 - I
VENT CONNECTOR IS USED.
--'--------------------------------------------------
HOFIIONTAL ALODYE fLIE OISCFWW)E LEFTI
TOP I IN. WISINGLE WALL VENT - I IN. W/TYPE B-1 VENT
F LUf 6 IN. W/SINGLE WALL VENT - I IN. W/TYPE B-I Vf NY
FRONT 18 IN, BACK 0 IN. SIDES 0 IN.
TOP I IN. W/SINGLE WALL VENT
FL UC 6 N. W/SINGLE WALL VENT - I IN. W/TYPE 0-1 VENT
FRONT 18 IN. BACK 0 IN. SIDES 0 IN.
0 7/8" HOLE WITH PLUG
ELECTRICAL CONNECTION
(ALTERNATE)
0 1-5/8' HOLE WITH PLUG
1-1/2" X 2-1/2" OVAL
GAS CONNECTION
MODEL
DIM "A..
DIM
DIM
DIM
B"
..C..
"D11
`DD2AO4OA9242A, 'DD2AO6OA9362A
14-1/2"
9-5/8"
13-1/4"
13"
`DD2BO6OA9362A, `DD21308OA9362A
17-1/2"
9-5/8"
16-1/4"
16"
`DD2BO8OA9482A,`DD2B100A9482A
`DD2C100A9482A, "DD2C100A9602A
21"
13-1/16"
19-3/4"
19-1/2"
'DD2D12OA9602A, 'DD2D140A9602A
24-1/2"
15-5/16"
23-1/4"
23"
. - The First Letter May Be "A" or "T"
y
V
y
rOL
c
CL
Installer's Guide
UPPLOW INSTALLATION
Standoffs and screws (See Figure I on page 6) are included
with the cased coils for attachment to the furnace.
NOTE: The top flanges on the furnace must be bent 90
degrees upward to allow the coil attachment.
There are clearance alignment holes near the bottom of the
coil wrapper and drill screws are used to engage the furnace
top flange. The standoff is inserted into the cabinet align-
ment hole. The drill screws are inserted through the stand-
ofrs then screwed into the furnace flange. The coil is always
placed downstream of the furnace airflow. These instruc-
tions apply only if the coil is on top of an upflow furnace.
1 STANDOFFS (4) ti DRtLL SCREWS (4)
4c,..I
11
j ~ FOR VERTICAL
1 Cr,B I INSTALLATIONS:
i COjt � l
] (l
� ll
4;9
SCREWS
IboTNSlncs:
t
STANDOFFS
(UOTN SIDES)
EDOWNFLOW INSTALLATION
Do not install the furnace directly on carpeting, the or
other combustible material other than wood flooring. For
vertical downflow application, subbase (BAY13ASE205)
must be used between the furnace and combustible floor-
ing. When the downflow furnace is installed vertically
with a cased coil, a subbase is not required.
C118INE1SIUE - � CA8iNE7 SIDE
O EUB•BASE j SUB•BASC
fLANGE "-' FLANGE
MENT UP) -••_
•- I (BENT UPI
SI/&BASC
INSULATION 5UB-0ASC
_ I
PLENUM Kj
Duct .::.:.....
; .....::
vltul"
Required floor opening: (DOWNFLOW)
See Figure 3 and Table 1
TABLE 1
CABINET
WIDTH
RETURN
DUCTWIDTH
FLOOR OPENING
PLENUM OPENING
CIA-
"B'
.,C•.
"D"
14-1/2'
13.1/4'
13-5/8"
20-1/8"
12-5/B'
19.318"
17-1/2'
164/4'
16-518"
20-118"
15-5.1W
19-318"
21"
19.3/4'
20.1/8'
20-118'
19.1/8'
19.3/8"
24-112"
23.1/4"
23.518*
20-1/8'
1 22.5/9'
19-3/8"
HORIZONTAL INSTALLATION
The coil and furnace must be fully supported when used in
the horizontal position.
Three Brackets (with screws) are included with downflow
Furnaces for installation to stabilize and secure the furnace
and cased coil in the horizontal position. See Figure 4.
CASED COIL CONNECTION
BRACKET FOR DOWNF LOW c
FURNACE IN HORIZONTAL rJ lT
IMPORTANT:
The cased coil must be placed downstream of the fur-
nace. In horizontal installations, the apex of the coil may
point either toward or away from the furnace. See the coil
Installer's Guide for more details.
The cased coil is secured to the furnace and both the furnace
and the cased coil must- be properly supported. The brack-
ets 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.
This furnace may be installed in an attic or crawl space in
the horizontal position by placing the furnace on the left or
right side (as viewed from the front in the upright 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 Clearance Table on Outline Drawings and
Figure 5).
If the furnace is suspended using perforated steel strap
(plumber's strap), it must be supported at all four corners
and in the middle at the front of the furnace.
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SCRVICE AREA
TYPICAL ATTIC PLATFORM INSTALLATION
(UPFLOW/HORIZONTAL FURNACE SHOWN)
18-CD19D2-28-EN
The forward most screw on the side of the furnace may be
used to connect the strapping ( See Figure 6). Line contact
is only permissible between lines formed by the intersection
of the top and two sides of the furnace casing and the build-
ing joists, studs, or framing.
A cutout is provided on both sides of the downflow fur-
nace cabinet to allow a 90' elbow to be attached inside the
cabinet and the vent piping to connect there. In horizontal,
the downflow furnace may be vented through the top of the
cabinet. if needed. In vertical configuration, the downflow
furnace may be vented using the side cabinet cutouts. This
venting configuration could be used if an electronic air
cleaner is installed.
0
Typical Suspended Installation
(Upflow/Horizontai Furnace Shown)
left side of the furnace cabinet in horizontal or verti-
cal configuration, Type B vent pipe must be used
within the cabinet.
AIR FOR COMBUSTION AND VENTILATION
Adequate flow of combustion and ventilating air must not
be obstructed from reaching the furnace. Air openings
provided in the furnace casing must be kept free of obstrue-
tions which restrict the flow of air. Airflow restrictions
affect the efficiency and safe operation of the furnace. Keep
this in mind should you choose to remodel or change the
area which contains your furnace. Furnaces must have a
free flow of air for proper performance.
Provisions for combustion and ventilation air shall be
made in accordance with "latest, edition" of Section 5.3, Air
for Combustion and Ventilation, of the National Fuel Gas
Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of CA1V/CGA
B149 Installation Code.%, and applicable provisions of the
local building codes. Special conditions created by mechani-
cal exhausting of air and fireplaces must be considered to
avoid unsatisfactory furnace operation.
Furnace locations may be in "confined space" or "unconfined
space.". Unconfined space is defined in Table 2 and Fig-
ure 7. These spaces may have adequate air by infiltration
0
UNCONFINED
50 CU. FT. OR MORE NO
PER 1000 BTU/HR. INPUT °ouws\
ALL EQUIP. INSTALLED
fLFA{nCk WATER CCOT/iE5
HEATER ORYER
i s
Installer's Guide
to provide air for combustion, ventilation, and dilution of
flue gases. Buildings with tight construction (for example,
weather stripping, heavily insulated, caulked, vapor bar-
rier, etc.), may need additional air provided as described for
confined space.
s CONFINED
FURNACE
LESS THAN 50 CU. FT.
PER 1000 BTU/HR. INPUT
ALL EQUIP. INSTALLED
Confined spaces are installations with less than 50 cu. ft. of
space per 1000 BUT/hr input from all equipment installed.
Air for combustion and ventilation requirements can be
supplied from inside the building as in Figure 9 or from the
outdoors, as in Figure 10.
1. All air froin inside the buildii as in Figure 9: The con-
fined space shall be provided with two permanent open-
ings communicating directly with an additional room(s)
of sufficient volume so that the combined volume of all
spaces meets the criteria for an unconfined space. The
total input of all gas utilization equipment installed in
the combined space shall be considered in making this
determination. Refer to Table 3, for minimum open
areas required.
2, All air from outdoors as in Figure 10: The confined
space shall be provided with two permanent open-
ings, one commencing within 12 inches of the top and
one commencing within 12 incises of the bottom of the
enclosure. The openings shall communicate directly,
or by ducts, with the outdoors or spaces (crawl or attic)
that freely communicate with the outdoors. Refer to
Table 3, for minimum open areas required.
3. The following types of installations will require use of
OUTDOOR AIR for combustion, due to chemical expo-
sures:
Commercial buildings
Buildings with indoor pools
Purnaces installed in commercial laundry rooms
Y Furnaces installed in hobbv or craft rooms
r Furnaces installed near chemical storage areas.
Exposure to the following substances in the combustion
air supply will also require OUTDOOR AIR. for combos- • .
tion:
" Permanent wave solutions
Chlorinated waxes and cleaners
* Chlorine based swimming pool chemicals
Water softening chemicals
Deicing salts or chemicals
* Carbon Tetrachloride
s: Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
"Printing inks, paint removers, varnish, etc.
Hydrochloric acid
Cements and glues
"Antistatic fabric softeners for clothes dryers
1VIasonry acid washing materials
18-CD19D2-28-EN
7
Installer's Guide
TABLE 2
MINIMUM AREA
UNCONFINED
IN SQUARE FEET FOR
SPACE INSTALLATIONS
FURNACE
WITH 8 FOOT CEILING
MAXIMUM BTUH/
MINIMUM AREA IN SQUARE FEET
INPUT RATING
OF UNCONFINED SPACE
40,000
250
60,000
375
80,000
500
100,000
625
120,000
750
140,000
1 875
OCONFINEDSPACE
AIR FROM INSIDE BUILDING
CONifNEO
SAACE
PERMANENT
OdEN1NC5
i
1
CONFINED SPACE
AIR FROM OUTDOORS
CONFINED SPACE t\\
AIR FROM VENTILATED ATTICJCRAWL SPACE
-.� ATTM EOUY[AS
YO OU�OOOAS
nAIN
CONiffiEDAt,TEkNAT4 1NlETAfA���
CONFINED SPACE L�\
AIR FROM VENTILATED ATTIC
_ ._ A1Tk; lOUVLAS
f�ff'r����jj� TO OUTDOUA�
s
TABLE 3
MINIMUM
FREE AREA IN SQUARE INCHES
DUCT
EACH OPENING FURNACE ONLY
Furnace
Air From Outside
Maximum
Air From
Vertical
Horizontal
BT'UFllitdPUT
Inside
Rating
Duct
Duct
40,000
100
10
20
60,000
100
15
sa
80,000
100
20
40
100,000
100
25
50
120,000
120
30
60
140,000
140
35
70
CONNECTIONS
NOTE: The tap flanges an the furnace must 6e bent 90
degrees upward to allow connection to the ducting.
Air duct systems should be installed in accordance with
standards for air conditioning systems, National Fire Pro-
tection Association Pamphlet No. 90. They should be sized
in accordance with A(.;CA Manual D or whichever is appli-
cable. Check on controls to make certain they are correct
for the electrical supply.
Central furnaces, when used in connection with cooling
units, shall be installed in parallel or on the upstream side
oi'the cooling units to avoid condensation in the heating
element, unless the furnace has been specifically approved
for downstream installation. With a parallel flow arrange-
ment, the dampers or other means used to control {low of
air shall be adequate to prevent chilled air From entering
the furnace, and if manually operated; must be equipped
with means to prevent operation of either unit unless the
damper is in full heat or cool position.
On any jab, flexible connections of nonflammable mate-
rial may be used far return air and discharge connections
to prevent transmission of Nribration. Though these units
have been specifically designed for quiet, Nibration free
operation, air ducts can act as sounding boards and could,
ifpoorly installed, amplify the slightest vibration to the
annoyance level.
When the furnace is located in a utility room adjacent to
the living area, the system should he carefully designed
with returns which minimize noise transmission through
the return air grille. Although these winter air condition-
ers are designed with large blowers operating at moderate
speeds, any blower moving a high volume of air will pro-
duce audible noise which could be objectionable when the.
unit is located very close to a living area. It is often advis-
able to route the return air ducts under• l.he floor or through
the attic. Such design permits the installation of air return
remote from the living area (i.e. central hall*).
When the furnace is installed so that the supply ducts carry
air circulated by the furnace to areas outside the space
containing the furnace, the return air shall also be handled
by a duct(s) sealed to the furnace and terminating outside
the space containing the furnace.
Minimum return air "entering temperature" for the
furnace is 55° F.
Where there is no complete return duct system, the return
connection must be run full size fi•arn the furnace to a
location outside the utility zoom, basement; attic, or crawl
space.
RO NOT install return air through the back of the
furnace cabinet.
8 18-CQ9 9132-28-EN
RETURN AIR DUCT CONNECTION
NOTE:
On upflow 5 or 6 ton airflow models where the airflow re-
quirement exceeds 1800 CFM - Models will require return
air openings and filters on: (1) both sides; or (2) one side
and the bottom; or (3) just the bottom.
All return air duct systems should provide for installation
of return air filters.
1. Determine the appropriate position to set the furnace
in order to connect to the existing supply and return
ductwork.
2. For side return installations on upflow models, remove
the insulation around the opening in the blower com-
partment.
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 out-
line drawing on page 4 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 in-
stalled, cut along knockout guidelines.
6. Upflow Furnaces: Use the optional filter rack on
either side or on the bottom if the filter is to be used
within the furnace cabinet.
When the upflow furnace is installed in the horizontal
right or left application and a return duct is attached to
the top side as shown in Figure 11, install the filter in
a remote location.
Do not install the filter in the return duct directly above the
furnace in horizontal applications. Install the filter remotely.
Installing the filter directly above the furnace in horizontal
applications may cause property damage, serious injury or
death.
1 �
TO PREVENT INJURY OR DEATH DUE TO CONTACT
WITH MOVING PARTS, TURN THE POWER TO THE
FURNACE OFF BEFORE SERVICING FILTERS.
Do not install the filter in the return duct directly
above the furnace in horizontal applications.
When the upflow furnace is installed in the horizontal
right or left application and a close coupled (less than
36") return duct is attached to the bottom side of the
furnace as shown in Figure 11, securely attach a 1/2"
mesh metal hardware cloth protective screen to the
inside bottom of the filter grill to prevent personal
injury from contacting moving parts when reach-
ing into the return opening to replace the filter.
Close coupled (less than 36") return (filter directly
beneath bottom side return) is not recommended due to
noise considerations.
Downflow Furnaces: Brackets are factory supplied
to mount filters in the return air duct work.
Installer's Guide
REMOVE FILTER FROM UPFLOW 11
FURNACE WHEN RETURN DUCT IS
ATTACHED TO FURNACE TOP SIDE
(HORIZONTAL LEFT OR RIGHT AP-
PLICATIONS) AS SHOWN.
00000000000000
ME 000000000
00000000 0 0 0 0 0 0
000000000000 00
00 OM00000 00
00000000000000
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.
7. Connect the duct work to the furnace. See Outline
Drawing for supply and return duct size and location.
Flexible duct connectors are recommended to connect
both supply and return air ducts to the furnace.
If only the front of the furnace is accessible, it is recom-
mended that both supply and return air plenums are
removable.
8. When replacing a furnace, old duct work should be
cleaned out. Thin cloths should be placed over the
registers and the furnace fan should be run for 10 min-
utes. Don't forget to remove the cloths before you start
the furnace.
Return Air Filters
(Filter and filter rack are not supplied with
unit)
TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS
These furnaces require high velocity type air filters. The
optional filters may be located within the furnace blower
compartment for UPFLOW furnaces in either a BOTTOM
or SIDE (left side or right side) return air inlet. Some
optional filters may need to be trimmed for side or bottom
filter use.
NOTE.
On upflow 5 or 6 ton airflow models where the airflow re-
quirement exceeds 1800 CFM - Models will require return
air openings and filters on: (1) both sides; or (2) one side
and the bottom; or (3) just the bottom.
The furnace and the blower filter rack installation can be
seen in Figure 13.
12
CUT OUT
FOR
SIDE
LOCATING
�\
FILTER
NOTCHES
PROVIDED
FOR SIDE
RETURN
CUTOUT
J
FRONT
'`SEE OUTLINE
�\
DRAWING �/
of Furnace
18-CD19D2-28-EN
Installer's Guide
The optional furnace filter in the bottom or side configura-
tion can be removed by simply turning the two latches on
the blower door and tilting the door forward.
The filter rails are spring loaded for automatic adjustment
to allow standard size, locally obtainable replacement
filters. The filter rack itself slides to adjust to the required
width needed for bottom or side return.
TABLE 4
UPFLOW
FURNACE RETURN AIR FILTERS
CABINET
QTY*
CABINET
CABINET
WIDTH
BOTTOM FIL-
SIDE FILTER
14-1 /2"
1
14" X 25" X 1 "
17-1 /2" X 25" X 1 "
17-1 /2"
1
17" X 25" X 1 "
17-1 /2" X 25" X 1 "
21 "
1
20" X 25" X 1 "
17-1 /2" X 25" X 1 "
24-1 /2"
1
24" X 25" X 1 "
17-1 /2" X 25" X 1 "
**NOTE: For upflow 5 ton airflow models where the airflow
requirement exceeds 1800 CFM - Models will require return air
openings and filters on: (1) both sides, or (2) one side and the
bottom, or (3) just on the bottom
FILTER
14 RACK
RAILS
0— SPRINGS
AUTOMATIC
ADJUSTMENT RETAINING
PIN
(Both Sides)
Optional Filter Rack Accessory Kit
BAYRACK960A
NOTE: The narrow 14.5" width furnace cabinet prevents
use of the filter rack for right side return. Pre -drill clear-
ance holes and then attach filter clips with the screws
provided. The filter clip with the leaf spring mounts in the
rear of the cabinet
ALTERNATE FILTER RACK INSTALLATION FOR BOTTOM
RETURN - BAYRACK960
The following checklist should be used when installing as a
bottom return filter on an upflow furnace:
a. Remove the filter.
b. Remove the bottom panel.
c. Pre -drill two engagement holes with 3/16" drill at
dimple locations. See Figure 15.
d. 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 en-
gagement holes at the bottom of the furnace cabinet
side. See Figure 16.
e. Reinstall the furnace filter in the bottom position by
inserting the chamfer end first into the filter rack. .
NOTE: Remove the bottom front channel to install the
filter rack in the 14-112" width cabinet furnaces.
15
F
Deck
ment
Hole
PRE-DRILLTwo
\locations
clearance h3/16"
drill at dim
(one per side)
Filter
Furnace Rack
Cabinet
Side )1o.
Filter Rack
t� Retaining
Engagement Hole %�� Screw/Pin
For Filter Rack /
Installation With
Bottom Return
(Pre -drill 3/16" diameter
clearance holes)
10 18-CD19D2-28-EN
TABLE 5
Cabinet Width
Left Slide
Bottom
Right Side
14.5
X'
X-
Use Mic-nale Fiter Clps On>j
17.5
x
x
x
21
x
x
x
24.5
x
X
x
1. UC1B060C has 1b,r7 blower %ftich raryures traa of attarnwrip hoar
dips kA Iafl srda filler. 'K1' and later use Bne filler rack.
2. 1`10010%* bonom hcnl CtornW to install or rpfvi4ncn tfrar r,-irh
X • At fllodeys
OPTIONAL FILTER RACK INSTALLATION FOR SIDE
RETURN AIR ON UPFLOW FURNACES (Left or Right)
If side air return is desired. the following itibtructiuns
%hould he umA:
a. Open or remove the blower door and remove the
filter.
b. Leave the bottom panel in place. (Some models
require field stipplied Ixit tom pntx?ls.i
c. After the side cutout is made following the directions
in the -Return Air I)uct Connections —section (in
pages 8 and 9: eompn•.. the filter rack and r6nmall
in the side of the furnace. Confirm that the upper
retaining pur•ncrew• locks into the engagement hole
in the blower deck and thi• lower pin -screw rests
against the tide of the Iiottoin panel. bee Figures I.I.
15. & 1 7-20.
d. Reinstall the furnace, filter in the side position by
inserting the chamfer end first into the filter rack
17
BOTTOM ENGAGEMENT
Filter Rack
Retaining
Furnace Screw)Pin Filter
Cabinet —11110� Rack
Side
JL-J
t ,
Bottom Panel
OCre~mr,t 1 ou Furnace
BLOWER htu" N O Bluer
i.wwuio. win Deck
DECK nai„m
Furnace
Cabinet -40-
Side
Filler Rack Filter ..
Retaining Rack
Screw/Pin Assembly
Installer's Guide
19 SIDE
CUTOUT
RETAINING
-
PIN
IBoth Sides)
SPRINGS
J
FILTER
BOTTOM
RACK
PANEL
RAILS
INSTALLED
Typical Upflow Left Side Return Filter Rack Installation
21
r-
ti J
Accessory filter kit _
FY R203, 204, 205 used
for Upflow Horizontal
furnaces.
Typical Horizontal Filter Installation
18-CD19D2-28-EN
Installer's Guide
RETURN AIR FILTERS FOR UPFLOW FURNACE
TYPICAL DOWNFLOW FURNACE
IN HORIZONTAL CONFIGURATION
RETURN AIR FILTER INSTALLATIONS
When the Upflow Furnace is installed in a horizontal
configuration, the filter must never be installed inside or
Two high velocity type air filters are required for each
outside the cabinet directly above the blower assembly, See
downilow furnace. Dowriflow furnace filters must be
Figure 11, Remote filter grilles may be used for homeowner
located outside the furnace cabinet. Typical installations
convenience or the filters may be installed in the duct work
are shown in Figures 23 and 24. Tables 7 and 8 provide
upstream of the furnace. See Figures 1..1 and 21.
information for installation of the filter retaining brackets
shipped with downfiow furnaces.
Optional horizontal filter conversion kits are BAYFI TR203
for 17 1/2" width cabinets, BAYFLTR204 for 21" width
cabinets, and BAYrLTR205 for 24" width cabinets. These
include filters and brackets necessary for horizontal filters.
See Figure 21..
NOTE. Upflow models only - Installation of the alternate
bottom filter kit requires the bottom flange to be bent flat.
ALTERNATE UPFLOW
FILTER CLIP / BRACKET INSTALLATION - KIT09224
I. 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
i
ALTERNATE FILTER
CLIPS LOCATION
P
INSTALLING THE OPTIONAL FILTER
T`he filter may need to be cut to fit the unit depending on
the location of the return air filter.
A score line and the words "CUT HERE" are located on the
end of the filter. If your application requires cutting the
filter, do so as indicted by the score mark.
TABLE 6
UNIT
SIZE
RETURN AIR
BOTTOM
SIDE
14-1/2"
CUT ON LINE
DO NOT CUT
17-1/2"
DO NOT CUT
DO NOT CUT
21"
DO NOT CUT
CUT ON LINE
24-1/2"
DO NOT CUT
CUT ON LINE
CABINET
WIDTH
FILTER
SIZE
FILTER BRACKET
LOCATION'
14-1/2"
2- 14X20X1
12-7/8"
17-1/2"
2-16X20X1
14-3/8"
21"
2 - 16X20X1
13-1/8"
24-1/2" 2 - 16X20X1 11-5/8"
Location dimension is from end of duct to the screw hates for the bracket.
TABLE 8
CABINET
CT
ABINE
RETURN
FILTER ACCESS
FILTER ACCESS
WIDTH
DUCT
OPENING - DI-
OPENING -
WIDTH
MENSION "A"
DIMENSION "B"
14-1/2"
13-1/4'
12"
14"
17-1/2"
16-1/4"
15"
14"
21"
19-3/4"
19-1/2"
14"
24-1/2"
23-1/4'
22
14"
12 18-CD19D2-28-EN
Important: When using high velocity filters. the filter
support base must be installed into the furnace duct
flange prior to ductwork installation.
Remove the brackets from the blower compartment. They
are wrapped in foam and taped to the side of the downflow
unit.
Remove the four screws securing the top panel. Save
screws.
Slide the top panel forward approximately 1 ".
With support tabs facing up, install the filter base by inserting
one end tab into the duct flange at the rear of the furnace.
Slide the top panel back to its original position, engaging the
other end tab in the slot. Replace screws.
Remc
b racks
Screw
locations /
0
Flanges
upward
Installer's Guide
GENERAL VENTING INSTRUCTIONS
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide
poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 or the CAN/CGA B149
Installation Codes and these instructions. Determine
that there is no blockage or restriction, leakage,
corrosion and other deficiencies which could cause an
unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which the
appliance(s) connected to the venting system are
located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they are operating at maximum speed. Do not operate
a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. If improper venting is observed during any of the above
tests, the venting system must be corrected in
accordance with the National Fuel Gas Code,
ANSI Z221.1/NFPA 54 and/or CAN/CGA 13149
Installation Codes.
8. After it has been determined that each appliance
connected to the venting system properly vents where
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas -fired
burning appliance to their previous conditions of use.
VENT PIPING
These furnaces have been classified as Fan -Assisted
Combustion System, Category I furnaces under the "lat-
est edition" provisions of ANSI Z21.47 and CAN/CGA 2.3
standards. Category I furnaces operate with a non -positive
vent static pressure and with a flue loss of not less than 17
percent.
NOTE.
If desired, a side wall termination can be accomplished
through the use of an "add -on "draft inducer. The inducer
must be installed according to the inducer manufacturer's
instructions. Set the barometric pressure relief to achieve
-0.02 inch water column.
18-CD19D2-28-EN 13
Installer's Guide
NOTE:
When the downflow furnace is vented through the left side
of the furnace cabinet using the provided cutout, Type B
vent piping must be used.
The furnace shall be connected to a factory built chim-
ney or vent complying with a recognized standard, or a
masonry or concrete chimney lined with a lining material
acceptable to the authority having jurisdiction.
Furnace venting into an unlined masonry chimney or con-
crete chimney is prohibited. Failure to follow this warning
could result in property damage, personal injury, or death.
VENTING INTO A MASONRY CHIMNEY
If the chimney is oversized, the liner is inadequate, or
flue -gas condensation is a problem in your area, consider
using the chimney as a pathway or chase for type `B" vent
or flexible vent liner. If flexible liner material is used, size
the vent using the `B" vent tables, then reduce the maxi-
mum capacity by 20% (multiply 0.80 times the maximum
capacity). Masonry Chimney Kit BAYVENT800B may be
used with these furnaces (Upflow model furnaces only)
to allow venting into a masonry chimney. Refer to the BAY-
VENT800B Installer's Guide for application requirements.
Internal Masonry Chimneys
Venting of fan assisted appliances into a lined, internal ma-
sonry chimney is allowed only if it is common vented with
at least one natural draft appliance; OR, if the chimney
is lined with type `B", double wall vent or suitable flexible
liner material (See Table 9).
The chimney liner must be thoroughly inspected to insure
no cracks or other potential areas for flue gas leaks are
present in the liner. Liner leaks will result in early deterio-
ration of the chimney.
Failure to follow this warning could result in carbon mon-
oxide poisoning or death.
NOTE:
The following section does not apply if BAYVENT800B
(Masonry Chimney Vent Kit) is used. All instructions with
the kit must be followed.
TABLE 9
MASONRY CHIMNEY VENTING
Tile Lined Chimney
Chimney Lining
Flexible
Type Furnace
Internal
External
"B" Vent
Metal Liner
Single Fan
Assist
No
No
Yes
Yes*
Fan Assist
+
No
No
Yes
Yes*
Fan Assist
Fan Assist
+
Yes
No
Yes
Yes*
Natural
* Flexible chimney liner size is determined by using the type "B" vent size
for the available BTUH input, then reducing the maximum capacity by 20
(multiply maximum capacity times 0.80). The minimum capacity is the same
as shown in the "B" vent tables.
External Masonry Chimney
Venting of fan assisted appliances into external chimneys
(one or more walls exposed to outdoor temperatures), re-
quires the chimney be lined with type "B", double wall vent
or suitable flexible chimney liner material. This applies in
all combinations of common venting as well as for fan as-
sisted appliances vented alone.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the installation instructions for the vent-
ing system being placed into operation could result in
carbon monoxide poisoning or death.
The following installation practices are recommended to
minimize corrosion caused by condensation of flue products
in the furnace and flue gas system.
1. Avoid an excessive number of bends.
2. Horizontal runs should pitch upward at least 1/4" per
foot.
3. Horizontal runs should be as short as possible.
4. All vent pipe or connectors should be securely support-
ed and must be inserted into, but not beyond the inside
wall at the chimney vent.
5. When vent connections must pass through walls or
partitions of combustible material, a thimble must be
used and installed according to local codes.
6. Vent pipe through the roof should be extended to a
height determined by National Fuel Gas Code or local
codes. It should be capped properly to prevent rain
water from entering the vent. Roof exit should be wa-
terproofed.
7. Use type `B" double wall vent when vent pipe is routed
through cool spaces (below 60' F.).
TABLE 10
GAS VENT TERMINATION
ROOF PITCH
MINIMUM HEIGHT
FLAT TO 7/12
1.0 FEET'
OVER 7/12 TO 8/12
1.5 FEET
OVER 8/12 TO 9/12
2.0 FEET
OVER 9/12 TO 10/12
2.5 FEET
OVER 10/12 TO 11/12
3.25 FEET
OVER 11/12 TO 12/12
4.0 FEET
OVER 12/12 TO 14/12
5.0 FEET
OVER 14/12 TO 16/12
6.0 FEET
OVER 16/12 TO 18/12
7.0 FEET
OVER 18/12 TO 20/12
7.5 FEET
OVER 20/12 TO 22/12
8.0 FEET
`THIS REQUIREMENT COVERS MOST INSTALLATIONS
8. Where long periods of airflow are desired for comfort,
use long fan cycles instead of continuous airflow.
9. Apply other good venting practices as stated in
the venting section of the National Fuel Gas Code
ANSI Z223.1 "latest edition".
10. Vent connectors serving appliance vented by
natural draft or non -positive pressure shall not
be connected into any portion of a mechanized
draft system operating under positive pressure.
11. Horizontal pipe runs must be supported by hangers,
straps or other suitable material in intervals at a mini-
mum of every 3 feet of pipe.
12. A furnace shall not be connected to a chimney or flue
serving a separate appliance designed to burn solid
fuel.
14 18-CD19D2-28-EN
13. The flow area of the largest section of vertical rent or
chimney shall not exceed 7 times the smallest listed ap-
pliance categorized vent area, flue collar area, or draft
hood outlet area unless designed in accordance with
approved engineering methods.
25 V'Eft1 iCAL Vint-t
E S MIN. --�
LISTE D LOWEST D151-KARGE
CAP OPENING
HEGHT
ROOF PITCH IS X 42
THE VENT TTRMINA.!i&i SHOULC /a.''iT Ee
LESS T}iAli $ F T FROM A vFRTICAL'iVALL
Nlaximum Vent or Tile _ X 7
Lined Chimney Flow Area ~
'tT)rafi}x,rx3 I,mlet dit—dul-, fluct cr,IL•v dixn•.ewr,'rr. 1i%tud oppliatxr r•.lecnli+nl .c»t
ala r„(t(r.
ELECTRICAL CONNECTIONS
t a
The cabinet must have an uninterrupted or unbroken
ground according to National Electrical Code, ANSI/
NFPA 70 — "latest edition" and Canadian Electrical Code,
CSA C22.1 or local codes to minimize personal injury if an
electrical fault should occur. A failure to follow this warn-
ing could result in an electrical shock, fire, injury, or death.
T'STA?
SEE.
TOTE E
Installer's Guide
The integrated furnace control is polarity sensitive. The
hot leg of the 115 VAC power must be connected to the
BLACK field lead.
To prevent Injury or death due to electrical shock or con-
tact with moving parts, lock unit disconnect switch in the
open position before servicing the unit. Failure to follow
this warning could result in electrical Shock, personal
injury, or death.
Make wiriIig connections to the unit as indicated on en-
closed wiring diagram. As with all gas appliances using
electrical power, this furnace shall be connected into a
permanently lire electric circuit. It is recommended that
it be provided with a separate "circuit protection device"
electric circuit. The furnace must be electrically grounded
in accordance with local codes or in the absence of local
codes with the National Electrical Code, ANSI/NFPA 70
"latest edition" or Canadian Electrical Code, CSA C22.1, if
an external electrical source is utilized.
All field supplied wiring must conform with the tem-
perature limiudion for Type T wire 1.63" F (36" CA, when
installed in accordance with these instructions and wir-
ing diagrams supplied with the furnace. A disconnecting
means must be located 'within sight from, and readily acces-
sible to, the €ulnace.
Refer to the SERVICE FACTS literature for unit wiring
diagrams in addition to the diagram inside the blower door.
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE
2 STAGE HEATING,
USING A 1 STAGE HEATING THERMOSTAT
NO COOLING
2 STAGE
H' 1 L
I. 3vS" c•rM1TR AGREES 9 'OUI•^Mr9T NA WN A IL'i
LLn VMAPUE t2a';. 91P.M2 t5 R.'B.
3 i •J�3 I Il CA fGii l l'S:N 1 k1i;>' C!i!E L 5 v IN :?i ! i.GDL:
4. .ESc ;(AbS PRAVi(:E :I; ' hC'Ri? n t^Nk((1:^vN OF E(f£.110RIC Rib
ERAEi AA;• ;;NiD:FicR WAX
S "N" C011NEC1;04 IS GNL, 'H C1R%,F•N.0—h- nE.'ulRkrtS
CONvo:6' %, slit ?� '':ipiF.. $c!'F:I ?%CiRkONS
c. SEE TWINNI11G QkktC DIAGRAMS £'ri ?RC-FL-7 Cr:NNE;ISCNS
WHFIJ dk!%C IRIS FL.A'Jli-
.A 0 MIIG 114RMOS'Ai iW1`;6UI •k E011;1;) 1S L'Sf.
Ilv CRING Gx "v 1r-II91%A: Ur .FC IS lSL'V.
t_ UND
-yam Ful
Cl f 10 fi
1
TU 115 Y' 7 7'H.. 1
i
'•••�':I
i0 efL., YLRYtR l
I I
SUPPLr PER
LOCAL CWiS
�i. _N .
II
tiV6t$.^;G !`_...I
Mil—.
[E__J i
LAC SEE 1 �
•4J7E4 T_'�.
.............. --J from Mlg. ll3{1•H, Hq,t
18-CD19D2-28-EN 15
Installer's Guide
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE
2 STAGE HEATING
USING A 2 STAGE HEATING THERMOSTAT
2STAGE NO COOLING
T'STAT FURNACE
SEE
NOTE 6
n
El--
-----
--E-G]
I f--------
-- WI
W2 --
-----
-- W2
SEE
NOTE 5
INTER -COMPONENT
WIRING
------ 24 V. FIELD
--LINE V. WIRING
24 V. FACTORY
LINE V. WIRING
0
Ur000R UNIT
(NOTRANSFORMER)
YJ'----
J I
I
I
I
I
I
I
I
I
I
I
i
I
I
I
NOTES:
I. BE SURE POWER AGREES WITH EQUIPMENT NAMPLATE(S).
2. LOW VOLTAGE (24V. WIRING) TO BE NO. 18 A.W.G. MIN..
3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.
4. THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIR
CLEANER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.
5. THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING
CONNECTION TO THE 24 V. POWER SUPPLY. (COMMON)
6. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS
WHEN USING THIS FEATURE.
GROUND
sCREW
eK
FURNACE
JUNCTION
BOX
TO 115 V 1 PH.,
LH BK WH/1
60 HZ., POWER
SUPPLY PER
I
LOCALCODES
LN _ H
�� BK/3
r
WH
J
HUM SEE I
NOTE4
L
BK
WH
BK/2
I
I
EAC SEE
NOTE 4 tIK::
-�
From Dwg. B342024 Rev. 0
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE
2 STAGE HEATING, 1 STAGE COOLING
USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT
(OUTDOOR SECTION WITHOUT TRANSFORMER)
2 STAGE
T'STAT FURNACE
SEE
VOTE 6
SEE
NOTE Fy I
----- --I
----- -- WI
W2
SEE
NOTE 5
I
i
L------------------------------j
INTER -COMPONENT WIRING
------ 24 V.
FIELD
--LINE
V.
WIRING
24 V.
FACTORY
LINE
V._f
WIRING
NOTES:
I. BE SURE POWER AGREES WITH EQUIPMENT NAMPLATE(S).
2. LOW VOLTAGE (24V. WIRING) TO BE NO. 18 A.W.G. MIN..
3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.
4. THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIR
CLEANER AND HUMIDIFIER MAX. LOAD 1.0
AMPS EACH.
5. THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING
CONNECTION TO THE 24 V. POWER SUPPLY, (COMMON)
6. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS
WHEN USING THIS FEATURE.
7. THE "Y" TERMININAL FROM THE THERMOSTAT MUST BE WIRED
TO THE "Y.. TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWER
OPERATION DURING COOLING.
GROUND
SCREW
FURNACE
I BK JUNCTION
I� I BOX
TO 115 V 1 PH.,
LH BK
WH/I
60 HZ., POWER
SUPPLY PER
LOCAL CODES
L N _ WH
BK/3
r
HUM SEE
WH
J_
NOTE 1L
OK
WH
BK/2
I I
EAC SEE
_� I I
NOTE
BK _—_11From Dwg. B342019 Rev. 0
16 18-CD19D2-28-EN
OUTDOOR UNIT
INOTRANFORMER)
Y—F---
LLB
Installer's Guide
FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE
2 STAGE HEATING, 1 STAGE COOLING
USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT
(OUTDOOR SECTION WITHOUT TRANSFORMER)
2 STAGE
T'STAT FURNACE
SEE
VOTE 6
---- --F—R]
SEE
NOTE 7
---- - WI
----- -- W2
SEE
NOTES
INTER -COMPONENT WIRING
------- 24 V.
FIELD
--LINE
V. WIRING
24 V.
FACTORY
LINE
V. WIRING
NOTES:
I. BE SURE POWER AGREES WITH EQUIPMENT NAMPLATE(S).
2. LOW VOLTAGE (24V. WIRING) TO BE NO. I8 A.W.G. MIN..
3. GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.
4. THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIR
CLEANER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.
5. THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING
CONNECTION TO THE 24 V. POWER SUPPLY. (COMMON)
6. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS
WHEN USING THIS FEATURE.
7. THE "Y" TER MININAL FROM THE THERMOSTAT MUST BE WIRED
TO THE "Y" TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWER
OPERATION DURING COOLING.
GROUND
sCREW FURNACE
I B" JUNCTION
BOX
TO 1,E V 1 PH.. LH BK W /II
60 H .., POWER I
SUPPLY PER I
LOCAL CODES yfJ_ _ JyLi
r
r WH
J
HUM SEE 1 — 8K
NOTE L BK
y!I{ I I
EAC SEE r a—�--�
NOTE jL BK s
From Dwg. B342021 Rev. 0
TWINNING
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 below and on the following page for proper hookup.
TWINNING CONNECTION DIAGRAM
FOR TWINNING UD/DD-R FURNACES
1 STAGE HEAT/ 1 STAGE COOLING THERMOSTAT
OUTDOOR UNIT NO.1 1 STAGE NOTES'
(WITH TRANSFORMER) HEATING/COOLING
I. ROT" FURNACE S MUST RI CIRCUIT FROM
SEE NOTE THERMOSTAT FURNACE N0.1 FURNACE N0.2 THE SANE IISV. LEG OF CIRCUIT PANEL.
xazls svrvcR 1. IF OUTDOOR UNIT HAS A 24V. TRANSFORMER.
4 UNIT ox¢Eo
L wnR UNIT NO,11=rvAs AN ISOLATION RELAY MUST RE INSTALLED.
Y PPanrvulx corvNDTnx. !FIELD SUPPLIED - USF PILOT DUTY RELAY
pp !'UC'1, SUCH AS RLY0975.1 SEE ALT. CONNECTION.
,..:..--n -;---1 TWIN ______ ____________ _ _TWIN
3. IF CURRENT EXCEEDS THERMOSTAT CURRFNT
O� RAr)NG. USE ISOLATION RELAYS !'RI'1 AS
D; SHOWN, LDO NOT CONNECT N TO WI
(); ISOLATION RELAY MOT NEEDED IF THE THERMOSTAT
- ---------------------------------------------- - CONTACTS ARE RAICD AT I, III, OR AROYE.
...............:
IDwrron REuv _____ ____________ ______
)FIELD EDPMID)D Y Y Y 1. THIS CO'I- TIUNISONLY USED FOSTHEN(Co. SNEWIFNNG
TERNAiE cauNEDTN ❑ CONNECTIONTOTHEXV. POWER SUPPLY. (COMMON)
, SEE NOTE 3
OUTDOOR UNIT NO.1
(NO TRANSFORMER)
W -"-"--------"-"--- ""-"-- RR I ------------------ ----- W ; ----------.
YJ///------"���-------------' WZ WZ INTER -COMPONENT WIRING
E fl. ALTERNATE WIRING CONFIGURATION
B i '•--------- SEE NOTE S.
- LINE
V. FIELD
R1 T ? --LINE V. WIRING
L'------------------ -- - ❑R R = _I
24 V. FACTORY
LINE V. WIRING
I I
I I
R71 From Dwg. 21 B341487 Rev. 1
SEE -----
B/C � • B/C
(RELDSUPPLIED)
------------------------------------------------------------------------
18-CD19D2-28-EN 17
Installer's Guide
OUTDOOR UNIT NO.1
(WITH TRANSFORMER)
SEE NOTE22
QllI LR !r Y
—I g
SOIATION RELAY
RiELo NE �) ALTER_
CON
-011
I
OUTDOOR UNIT NO.1
(NOTRANSFORMER)
I
JQ
i Y Q
I '
I
2 STAGE HEATING
1 STAGE COOLING
THERMOSTAT
OUTDOOR UNIT NO.2
(NO TRANSFORMER)
SEE NOTE 2
2 STAGE HEATING
2STAGE COOLING
THERMOSTAT
____________
Y------
____
Y 2
!LB
OUTDOOR UNIT NO.1
(NOTRANSFORMER)
F1_____ -
4
YJ------- -
9----
B
I
TWINNING CONNECTION DIAGRAM
FOR TWINNING UD/DD-R FURNACES
2 STAGE HEAT / 1 STAGE COOLING THERMOSTAT
FURNACE NO. 1
SEE NOTE 4
FURNACE NO.2
rR M TWINNEcnoN.
IT I
-wi
TEE NOTE 3
w2
B/C
TWINNING CONNECTION DIAGRAM
FOR TWINNING UD/DD-R FURNACES
2 STAGE HEAT/2 STAGE COOLING THERMOSTAT
FURNACE NO. 1 FURNACE NO.2
mD._IN DNNE ON.
TWIN ____ ___________ _ TWIN
------ -----El
IT I
ISOLATICN REIAY
UIELO SU"..'
-- w I ___ E'ENDE; -IM, w 1 - +
Jlj=I= =1111 i
�I
p I,
--------- ----- R
i
i
--------- -----❑
SEE NOTE 4
_____ B�Ci BBC
From Dwg. 21 B341489 Rev. 1
NOTES:
1. BOTH FURNACES MUST BE POWERED FROM
THE SAME 115V. LED OF CIRCUIT PANEL,
2. IF OUTDOOR UNIT HAS A 24V. TRANSFORMER,
AN ISOLATION RELAY MUST BE INSTALLED.
(FIELD SUPPLIED - USE PILOT DUTr RELAY
('RC'F, SUCH AS RLY0975.) SEE ALI. CONNECTION.
3. IF CURRENT EXCEEDS THERMOSTAT CURRENT
RA LING, USE ISOLATION RELAYS ('RI') AS
SHOIYN. (DO NOT CONNECT W TO WI
I SOLAiION RELAY NOT NEEDED IF THE THERMOSTAT
CONTACTS ARE RATED AT I.OA. OR ABOVE.
4. CONNECTION MAY BE REOVIRED FOR ELECTRONIC
THERMOSTATS.
ISOLATION RELAY
SEE-NpNOOTE'
R1,. r
1 INTER -COMPONENT WIRING
jALTERNATE WIRING CONFIGURATION
1 _________SEE NOTE 4
--------24 V.FIELD
—' --LINE V._f
WIRING
24 V.
FACTORY
LINE V.
WIRING
From Dwg. 21 B341488 Rev. 1
NOTES:
1. 8 IN FURNACES MUST BE POWERED FROM
THE SAME 115V. LEG OF CIRCUIT PANEL,
2. IF OUTDOOR UNIT HAS A ZAV. TRANSFORMER.
AN ISOLATION RELAY MUST BE INSTALLED.
f FICID SUPPLIED - USE PILOT DUTY RELAY
!'RC'1, SUCH AS RL Y0975.1 SEE AL T. CONNECTION.
3. IF CURRENT EXCEEDS THERMOSTAT CURRENT
RATING, USE ISOLATION RELAYS ('RI'1 AS
SHOWN. 100 N01 CONNECT W TO W)
ISOLATION RELAY NO! NEEDED IF !NE THERMOSTAT
CONTACTS ARE RATED AT I.OA. OR ABOVE.
4. CONNECTION MAY BE REOUIRED FOR ELECTRONIC
THERMOSTATS,
ISO
9 SE INOTE13 RELAY
RI1 T i
1V
OUTDOOR UNIT
(WITH TRANSFORMER)
SEE NOTE 2
I
=j
8211a
!LR!LY
i
FEL o
A — CONNECTION
CONNECTION
I �
a o
INTER -COMPONENT WIRING
AL 4BAIL WINING CON IGUNAI ION
SEE NOTE 4
24 V. FIELD
LINE V. WIRING
24 V. FACTORY
LINE Vj WIRING
18-CD19D2-28-EN
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a com-
mercially available soap solution made specifically for
the detection of leaks to check all connections. A fire or
explosion may result causing property damage, personal
injury, or loss of life.
IMPORTANT.•
A sediment trap must be installed in the gas line
before the furnace gas valve. The sediment trap
must be located as close to the furnace cabinet
as practical.
LEFT SIDE PIPING (STANDARD)
DRIP
RIGHT SIDE PIPING (OPTIONAL)
DRIP LEG
TOP VIEW OF RIGHT SIDE PIPING
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
TOP VIEW
TO PREVENT AN EXPLOSION OR POSSIBLE INJURY,
DEATH AND EQUIPMENT DAMAGE, DO NOT STORE COM-
BUSTIBLE MATERIALS, GASOLINE OR OTHER FLAM-
MABLE VAPORS OR LIQUIDS NEAR THE UNIT.
Installer's Guide
GAS PIPING
FIRE - EXPLOSION HAZARD
DO NOT RUN FLEXIBLE GAS LINE THROUGH THE FUR-
NACE CABINET WALL. FAILURE TO FOLLOW THIS WARN-
ING COULD RESULT IN PROPERTY DAMAGE, SERIOUS
PERSONAL INJURY, OR DEATH.
is unit is shipped standard tor lett side installation ot gas
piping. A piping cutout is also provided in the right side for
an alternate piping arrangement. The installation of piping
shall be in accordance with piping codes and the regula-
tions of the local gas company. Pipe joint compound must be
resistant to the chemical reaction with liquefied petroleum
gases. Refer to piping Table 12 for delivery sizes.
NOTE: Refer to local codes and the National Fuel
Gas Code, current edition, for gas pipe requirements.
The furnace and its individual shut-off valve must be discon-
nected from the gas supply piping system during any pres-
sure testing of that system at test pressures in excess of 1/2
psig.
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.
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.
NOTE:
Maximum pressure to the gas valve for natural gas is
13.8" W.C. Minimum pressure is 5.0" W.C. Maximum pres-
sure 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!
The following warning complies with State of California law, Proposition 65.
Hazardous Gases!
Exposure to fuel substances or by-products of incomplete
fuel combustion is believed by the state of California to
cause cancer, birth defects, or other reproductive harm.
SEQUENCE OF OPERATION
Thermostat call for heat (2-stage thermostat)
Call for 1st stage only:
R and W1 thermostat contacts close signaling the control
module to run its self -check routine. After the control mod-
ule has verified that the 1st stage pressure switch contacts
are open and the limit switch(es) contacts are closed, the
draft blower will be energized.
As the induced draft blower comes up to speed, the pressure
switch contacts will close and the ignitor warm up period
will begin. The ignitor will heat for approx. 20 seconds,
then the gas valve is energized in 1st stage to permit gas
flow to the burners. The flame sensor confirms that ignition
has been achieved within the 5 second ignition trial period.
As the flame sensor confirms that ignition has been
achieved, the delay to fan ON period begins timing and
after approx. 45 seconds the indoor blower motor will be
energized at low speed and will continue to run during the
heating cycle.
18-CD19D2-28-EN 19
Installer's Guide
Call for 2nd stage after 1st stage:
R and W2 thermostat contacts close signaling a call for 2nd
stage heat. The induced draft blower will be energized on
high speed and the 2nd stage pressure switch contacts will
close allowing the gas valve to be energized in 2nd stage and
the indoor blower motor in high speed.
2nd stage satisfied, 1st stage still called:
R and W2 thermostat contacts open signaling that 2nd
stage heating requirements are satisfied. The induced draft
blower is reduced to low speed allowing the 2nd stage pres-
sure switch contacts to open and the gas valve is reduced to
1st stage. After approx. 30 seconds the indoor blower motor
is reduced to low speed.
1st stage satisfied:
R and W1 thermostat contacts open signaling that 1st stage
heating requirements are satisfied. The gas valve will close
and the induced draft blower will be de -energized. The in-
door blower motor will continue to run for the fan off period
(Field selectable at 90, 120, 150 or 180 seconds, then will be
de -energized by the control module.
Thermostat call for heat (1-stage Thermostat)
R and W thermostat contacts close signaling a call for heat.
1st stage sequence of operation remains the same as above.
2nd stage delay will be reflective by dip switch S1-1 and S1-
2. Reference the wiring diagrams for delay options.
Thermostat satisfied: R and W contacts open signaling
the control module to close the gas valve and de -energize
the induced draft blower. The indoor blower motor will
continue to operate at high heat speed (if running on second
stage) for approximately 30 seconds after the flames are
extinguished. It will then switch to low heat speed for the
remaining FAN -OFF period selected on dip switch S1-3 and
S1-4.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a com-
mercially available soap solution made specifically for
the detection of leaks to check all connections. A fire or
explosion may result causing property damage, personal
injury, or loss of life.
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
Turn knob 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 connec-
tions for leaks with a soapy solution — DO NOT CHECK
WITH AN OPEN FLAME. Allow 5 minutes for any
gas that might have escaped to dissipate. LP Gas, being
heavier than air, may require forced ventilation. Turn the
knob on the gas valve in the unit to the "ON" position.
COMBUSTION AND INPUT CHECK
1. Make sure all gas appliances are off except the furnace.
2. Clock the gas meter with the furnace operating (deter-
mine the dial rating of the meter) for one revolution.
3. Match the "Sec" column in the gas flow (in cfh) Table 15
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 =
1OX Chart Flow Reading _ 4
6. Multiply the final figure by the heating value of the gas
obtained from the utility company and compare to the
nameplate rating. This must not exceed the nameplate
rating.
Gas Valve Adjustment
Changes can be made by adjusting the manifold pressure
(See Table 11), or changing orifices (orifice change may
not always be required). To adjust the manifold pres-
sure:
1. Turn off all electrical power to the system.
2. Attach a manifold pressure gauge with flexible tubing
to the outlet pressure boss marked "OUT P" on the gas
valve. See Figure 27.
3. Loosen (Do Not remove) the pressure tap test set
screw one turn with 3/32" hex wrench.
a. The pressure tap adjustment kit (KIT07611) con-
tains a 3/32" hex wrence, a 5/16" hose and a connec-
tor and can be ordered through Global Parts.
4. Turn on system power and energize valve.
5. Adjust 1st stage gas heat by removing the low (LO)
adjustment regulator cover screw.
a. To increase outlet pressure, turn the regulator ad-
just screw clockwise.
b. To decrease outlet pressure, turn the regulator ad-
just screw counterclockwise.
c. Adjust regulator until pressure shown on mano-
meter matches the pressure specified in Table 11.
1. The input of no more than nameplate rating and
no less than 93% of the nameplate rating, unless the
unit is derated for high altitude.
d. Replace and tighten the regulator cover screw se-
curely.
6. Adjust 2nd stage gas heat by removing the high (HI)
adjustment regulator cover screw.
a. To increase outlet pressure, turn the regulator ad-
just screw clockwise.
b. To decrease outlet pressure, turn the regulator ad-
just screw counterclockwise.
c. Adjust regulator until pressure shown on mano-
meter matches the pressure specified in Table 11.
1. The input of no more than nameplate rating and
no less than 93% of the nameplate rating, unless the
unit is derated for high altitude.
d. Replace and tighten the regulator cover screw securely.
20 18-CD19D2-28-EN
7. Cycle the valve several times to verify regulator set-
ting.
a. Repeat steps 5-7 if needed.
8. Turn off all electrical power to the system.
9. Remove the manometer and flexible tubing and
tighten the pressure tap screw.
10. Using a leak detection solution or soap suds, check
for leaks at the pressure outlet boss and pressure tap
test screw.
11. Turn on system power and check operation of the
unit.
Replace and/or tighten all plugs removed or loosened
when adjusting gas pressure. Leak check the fittings
before placing the furnace into regular service. Failure
to follow this warning could result in fire, explosion, or
property damage.
For LP gases, the final manifold pressure setting shall be
10.5" W.C. with an input of no more than the nameplate
rating and no less than 93% of the nameplate rating, un-
less the unit is derated for altitude.
Table 13 lists the main burner orifices shipped with the
furnace. If a change of orifices is required to correct the
input rate, refer to Table 14.
TABLE 11
FINAL MANIFOLD PRESSURE SETTINGS inches w.c.
FUEL
2nd Stage Max.
1st Stage Max.
NATURAL GAS
3.5" W.C.
1.7" W.C.
LP GAS
10.51, W.C.
6.0" W.C.
TABLE 12
NATURAL GAS ONLY
TABLE OF CUBIC FEET PER HOUR OF GAS
FOR VARIOUS PIPE SIZES AND LENGTHS
PIPE
SIZE
LENGTH OF PIPE
10
20
30
40
50
60
70
1/2
132
92
73
63
56
50
46
3/4
278
190
152
130
115
105
96
1
520
350
285
245
215
195
180
1-1/4
1050
1 730
1 590
1 520
1 440
1 400
1 370
This table is based on pressure drop of 0.3 inch W.C. and 0.6 SP.GR. gas
TABLE 13
ORIFICE SIZES
INPUT
RATING
BTUH
NUMBER
OF
BURNERS
MAIN BURNER ORIFICE
DRILL SIZE
NAT. GAS
LP GAS
40,000
2
45
56
60,000
3
45
56
80,000
4
45
56
100,000
5
45
56
120,000
6
45
56
140,000
7
45
56
Installer's Guide
TABLE 14
PART NUMBERS FOR REPLACEMENT ORIFICES
DRILL
SIZE
PART
NUMBER
DRILL
SIZE
PART
NUMBER
44
ORF00501
54
ORF00555
45
ORF00644
55
ORF00693
46
ORF00909
56
ORF00907
47
ORF00910
57
ORF00908
48
ORF01099
58
ORF01338
49
ORF00503
59
ORF01339
50
1 ORF00493
27 2nd Stage (HI) Manifold 1st Stage (LO)
Pressure Adjustment Manifold Pressure
Outlet Adjustment
Pressure
Boss
y ® I
(� eo
O o U000�
Inlet Pressure Gas Valve On/
Boss Toggle Switch
36J Gas Valve
18-CD19D2-28-EN 21
Installer's Guide
TABLE 15
GAS FLOW IN CUBIC FEET PER HOUR
2 CUBIC FOOT DIAL
SEC.
FLOW
SEC.
FLOW
SEC.
FLOW
SEC.
FLOW
8
900
29
248
50
144
82
88
9
800
30
240
51
141
84
86
10
720
31
232
52
138
86
84
11
655
32
225
53
136
88
82
12
600
33
218
54
133
90
80
13
555
34
212
55
131
92
78
14
514
35
206
56
129
94
76
15
480
36
200
57
126
96
75
16
450
37
195
58
124
98
73
17
424
38
189
59
122
100
72
18
400
39
185
60
120
104
69
19
379
40
180
62
116
108
67
20
360
41
176
64
112
112
64
21
343
42
172
66
109
116
62
22
327
43
167
68
106
120
60
23
313
44
164
70
103
124
58
24
300
45
160
72
100
128
56
25
288
46
157
74
97
132
54
26
277
47
153
76
95
136
53
27
267
48
150
78
92
140
51
28
257
49
147
80
90
144
50
HIGH ALTITUDE DERATE
Input ratings (BTUH) of these furnaces are based on sea
level operation and should not be changed at elevations up
to 2,000 ft.
If the installation is 2,000 ft. or above, the furnace input
rate (BTUH) shall be reduced 4% for each 1,000 ft. above
sea level. The furnace input rate shall be checked by clock-
ing the gas flow rate (CFH) and multiplying by the heating
value obtained from the local utility supplier for the gas be-
ing delivered at the installed altitude. Input rate changes
can be made by adjusting the manifold pressure (min 3.0 -
max 3.7 in. W.C. - Natural Gas) or changing orifices (orifice
change may not always be required). If the desired input
rate can not be achieved with a change in manifold pres-
sure, then the orifices must be changed. LP installations
will require an orifice change.
IMPORTANT. -
Re -install the propane orifices to the same depth as the
orifices supplied with the equipment.
See Table 16 for help in selecting orifices if orifice change is
required. Furnace input rate and temperature rise should
be checked again after changing orifices to confirm the
proper rate for the altitude.
Installations above 4,000 feet may require a pressure
switch change. If required, use the BAYHALT*** Kit (High
Altitude Accessory Kit) listed in PRODUCT DATA.
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, Natu-
ral Gas and Propane Installation Code, CSA 149.1. Instal-
lation 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
Orifice
ALTITUDE ABOVE SEA LEVEL
Twist Drill
Size If
and Orifice Re uired At Other Elevations
Installed
At Sea
2000
3000
4000
5000
6000
7000
8000
9000
10000
Level
42
42
43
43
43
44
44
45
46
47
43
44
44
44
45
45
46
47
47
48
44
45
45
45
46
47
47
48
48
50
45
46
47
47
47
48
48
49
49
50
46
47
47
47
48
48
49
49
50
51
47
148
48
149
149
49
150
150
51
152
54
54
55
55
55
55
55
56
56
56
55
55
55
55
56
56
56
56
56
57
56
56
56
57
57
57
58
59
59
60
57
58
59
59
60
60
61
62
63
63
58
59
60
60
61
62
62
63
63
64
From National Fuel Gas Code - Table F-4
LIGHTING INSTRUCTIONS
DO NOT attempt to manually light the burner. Failure to
follow this warning could result in property damage, per-
sonal injury or death.
EXPLOSION HAZARD!
PROPANE GAS IS HEAVIER THAN AIR AND MAY COL-
LECT IN ANY LOW AREAS OR CONFINED SPACES. IN
ADDITION, ODORANT FADE MAY MAKE THE GAS UNDE-
TECTABLE EXCEPT WITH A WARNING DEVICE. IFTHE
GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCA-
VATED AREA OR A CONFINED SPACE, IT IS STRONGLY
RECOMMENDEDTO CONTACT A GAS SUPPLIER TO
INSTALL A GAS DETECTING WARNING DEVICE IN CASE
OF A GAS LEAK.
NOTE: The manufacturer of your furnace does NOT test any
detectors and makes no representations regarding any brand
or type of detector.
Lighting instructions appear on each unit. Each
installation must be checked out at the time of initial
start up to insure proper operation of all compo-
nents. Check out should include putting the unit
through one complete cycle as outlined below.
Turn on the main electrical supply and set the thermostat
above the indicated temperature. The ignitor will auto-
matically 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.
TO SHUT OFF
For complete shutdown: Move the control switch on the
main gas valve to the "OFF" position (See Figure 27 and
28). Disconnect the electrical supply to the unit.
If this is done during the cold weather months, provisions
must be taken to prevent freeze-up of all water pipes and
water receptacles. Failure to follow this warning could
result in property damage.
22 18-CD19D2-28-EN
Whenever your house is to be vacant, arrange to
have someone inspect your house for proper tem-
perature. This is very important in below freezing
weather. If for any reason your furnace should fail
to operate damage could result, such as frozen water
pipes.
CONTROL AND SAFETY SWITCH
ADJUSTMENT
LIMIT SWITCH CHECK OUT
The limit switch is a safety device designed to close the gas
valve should the furnace become overheated. Since proper
operation of this switch is important to the safety of the
unit, it must be checked out on initial start up by the
installer.
To check for proper operation of the limit switches, set the
thermostat to a temperature higher than the indicated
temperature to bring on the gas valve. Restrict the airflow
by blocking the return air or by disconnecting the blower.
When the furnace reaches the maximum outlet tempera-
ture 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 paper or card-
board from the return air inlet, or reconnect the blower.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the installation instructions for the vent-
ing system being placed into operation could result in
carbon monoxide poisoning or death.
AIRFLOW ADJUSTMENT
Check inlet and outlet air temperatures to make sure they
are within the ranges specified on the furnace rating name-
plate. If the airflow needs to be increased or decreased, see
the wiring diagram for information on changing the speed
of the blower motor.
Disconnect power to the unit before removing the blower
door. Failure to follow this warning could result in prop-
erty damage, personal injury or death.
This unit is equipped with a blower door switch which cuts
power to the blower and gas valve causing shutdown when
the door is removed. Operation with the door removed or
ajar can permit the escape of dangerous fumes. All panels
must be securely closed at all times for safe operation of the
furnace.
NOTE:
Direct drive motors have bearings which are permanently
lubricated and under normal use, lubrication is not recom-
mended.
INDOOR BLOWER TIMING
The control module controls the indoor blower. The blower
starts approximately 45 seconds after ignition. The FAN -
OFF period is approximately 150 seconds from the inter-
ruption of gas flow.
Installer's Guide
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 (See Figure 26). Also turn
off electrical power to the furnace and contact the
service agency designated by your dealer.
Should overheating occur, or the gas supply fail to shut
off, shut off the gas valve to the unit before shutting off
the electrical supply. Failure to follow this warning could
result in property damage, personal injury, or death.
Carbon monoxide, fire or smoke can cause serious bodily
injury, death, and/or property damage.
A variety of potential sources of carbon monoxide can be
found in a building or dwelling such as gas -fired clothes
dryers, gas cooking stoves, water heaters, furnaces and
fireplaces. The U.S. Consumer Product Safety Commission
recommends that users of gas -burning appliances install
carbon monoxide detectors as well as fire and smoke detec-
tors per the manufacturers installation instructions to help
alert dwelling occupants of the presence of fire, smoke or
unsafe levels of carbon monoxide. These devises should be
listed by Underwriters Laboratories, Inc. Standards for
Single and Multiple Station Carbon Monoxide Alarms, UL
2034 or CSA International Standard, Residential Carbon
Monoxide Alarming Devices, CSA 6.19
NOTE.
The manufacturer of your furnace does not test any detec-
tors and makes no representations regarding any brand
or type of detector.
OPERATING INFORMATION
FLAME ROLL -OUT DEVICE
All models are equipped with a thermal control device on
the burner cover. In case of flame roll -out, the device will
the cause the circuit to open which shuts off all flow of gas.
ABNORMAL CONDITIONS
1. EXCESSIVE COMBUSTION VENT
PRESSURE OR FLUE BLOCKAGE
If pressure against the induced draft blower outlet
becomes excessive, the pressure switch will shut off the
gas valve until acceptable combustion pressure is again
available.
2. LOSS OF FLAME OR GAS SUPPLY FAILURE
If loss of flame occurs during a heating cycle (when
flame is not present at the sensor), the control module
will retry the ignition sequence up to two times after
the sensor cools. If ignition is not achieved, it will
lockout the furnace.
3. POWER FAILURE
If there is a power failure during a heating cycle, the
system will restart the ignition sequence automatically
when power is restored, if the thermostat still calls for
heat.
4. INDUCED DRAFT BLOWER FAILURE
If pressure is not sensed by the pressure switch, it will
not allow the gas valve to open, therefore the unit will
not start. If failure occurs during a running cycle, the
pressure switch will cause the gas valve to close and
shut the unit down.
18-CD19D2-28-EN 23
Installer's Guide
Failure to follow safety warnings exactly, could result
in a fire or explosion causing property damage,
personal injury or loss of life.
— Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier,
call the fire department.
— Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
The following warning complies with State of California law, Proposition 65.
This product contains fiberglass wool insulation!
Fiberglass dust and ceramic fibers are believed by the
State of California to cause cancer through inhalation.
Glasswool fibers may also cause respiratory, skin, or
eye irritation.
PRECAUTIONARY MEASURES
• Avoid breathing fiberglass dust.
• Use a NIOSH approved dust/mist respirator.
• Avoid contact with the skin or eyes. Wear long-sleeved,
loose -fitting clothing, gloves, and eye protection.
• Wash clothes separately from other clothing: rinse
washer thoroughly.
• Operations such as sawing, blowing, tear -out, and
spraying may generate fiber concentrations requiring
additional respiratory protection. Use the appropriate
NIOSH approved respirator in these situations.
FIRST AID MEASURES
Eye Contact — Flush eyes with water to remove dust.
If symptoms persist, seek medical
attention.
Skin Contact — Wash affected areas gently with soap
and warm water after handling.
GREEN LED
FLASH
AMBER LED
FLASH
RED LED
FLASH
ERROR
1
Flame sensed when no flame should be present
2
Pressure switch is stuck closed
3
1st stage pressure switch is stuck open (not closing)
4
Open primary limit, flame roll out or reverse flow switch
5
Open roll out / Open low voltage fuse
6
1st stage pressure switch has opened 5 times within one cycle--1 hour lockout
7
System lockout Retry
8
System lockout Recycle
9
Reverse polarity or poor grounding
10
Gas valve energized without call for heat
11
Primary limit has been open for more than 5 minutes, check blower
12
Ignitor relay failure internal in board. Replace IFC
Solid On
Gas valve relay failure internal in board. Replace IFC
Rapid
Twinning Error, incorrect 24V Phasing
3 Double
2nd stage pressure switch open. Furnace reverts back to 1st stage heating
1
1 st stage call for heat
2
2nd stage call for heat
3
W2 call present without W1
4
Y call present without G
Rapid
Low flame sense
1
Standby mode or call for cooling
ifaraTi ira (briar Niimhar 1A-r n1Qn9-9R-FN
LFile Number 18-C'D19D2-28-EN
c i �I us Supersedes 18--D19D2-27-EN
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6200Troup Highway
Tyler, TX 75707 Intertek
For more information contact The manufacturer has a policy of continuous product and product data improvement and reserves the right to
your local dealer (distributor) change design and specifications without notice.