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BLD2022-0707_Manufacturer_Specifications_and_Installation_Instructions_5.31.2022_8.36.13_AM_2900781IIIIIIIIIIIIIIII�IIIIIIIIIIIIIIIII Installer's Guide Variable Speed, 2-Stage Communicating or 24V Upflow/ Horizontal and Downflow/ Horizontal, Gas -Fired Furnaces, "Fan Assisted Combustion System" *UD2B060ACV32B *UD2C100ACV52B *DD2B060ACV32B *UD2B080ACV32B *UD2D120ACV52B *DD2B080ACV32B *UD2C080ACV42B *UD2D140ACV52B *DD2C100ACV52B *UD2B100ACV32B *DD2D120ACV52B * First letter may be "A" or "T" ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES Left IMPORTANT —This Document is customer property and is to remain with this unit Please return to service information pack upon completion of work. For VENT SIZING INFORMATION see: USA — National Fuel Gas Code .......................... ANSI Z223.1/NFPA 54 (latest version) CANADA — Natural Gas Installation Code ........................ CAN/CGA-B149.1 (latest version) Propane Installation Code .............................. CAN/CGA-B149.2 (latest version) USA/CANADAALTERNATE — Category I Venting Guide ..........................Pub. No. 18-CH23D1 (latest version) Right *DD2-ACV Downflow/ Horizontal O Horizontal Conversion for these furnaces may be left or right side rotation. ® Horizontal Conversion for these furnaces may be left or right side rotation (Important: See venting applications, page 8). A341789P11 Installer's Guide Safety signal words are used to designate a degree or level of seri- ousness associated with a particular hazard. The signal words for safety markings are WARNING and CAUTION. 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. 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. 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. EXPLOSION HAZARD Propane gas is heavier than air and may collect in any low areas or confined spaces. In addition, odor- ant fade may make the gas undetectable except with a warning device. If the gas furnace is installed in a basement, an excavated area or a confined space, it is strongly recommended to contact a gas supplier to install a gas detection warning device in case of a gas leak. Failure to follow this warning could result in property damage, personal injury or death. NOTE: The manufacturer of your furnace does NOT test any detectors and makes no representations regarding any brand or type of detector. SAFETY HAZARD This information is intended for use by individuals posessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a cen- tral air conditioning product may result in property damage, personal injury, or death. The manufacturer or seller cannot be responsible for the interpretation of this information, not can it assume any liability in connection with its use. Failure to follow this warn- ing could result in property damage, personal injury or death. Sharp Edge Hazard. Be careful of sharp edges on equipment or any cuts made on sheet metal while installing or servicing. Personal injury may result. © 2016 Trane All Rights Reserved 18-CD32D1-9-EN Installer's Guide EXPLOSION HAZARD NEVER USE AN OPEN FLAME TO DETECT GAS LEAKS. EXPLOSIVE CONDITIONS MAY OCCUR. USE A LEAKTEST SOLUTION OR OTHER AP- PROVED METHODS FOR LEAKTESTING. FAIL- URE TO FOLLOW THIS WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. To prevent shortening its service life, the Furnace should NOT be used as a "Construction Heater" during the finishing phases of construction until the requirements listed in item 9, a-i of the safety sec- tion 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 exchanger. SAFETY HAZARD DO NOT USE SEMI -RIGID METALLIC GAS CONNEC- TORS (flexible GAS lines) within the Furnace cabinet. 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. SAFETY HAZARD Do not install the furnace directly on carpeting, tile or other combustible material other than wood flooring. For vertical downflow application, subbase (BAY- BASE205) must be used between the furnace and combustible flooring. When the downflow furnace is installed vertically with a cased coil, a subbase is not required. Failure to follow this warning could result in property damage, personal injury or death. LABELING WIRES! Label all wires prior to disconnection when servicing con- trols. Wiring errors can cause improper and dangerous operation. Verify Proper Operation after servicing. 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 4), of these instructions. 3. Provide adequate combustion and ventilation air to the furnace space as specified in "Air for Combustion and Ventilation" (pages 9), of these instructions. Contents Safety Section Installation Instructions General Installation Instructions Location and Clearances Outline Drawing Upflow Installation Downflow Installation Horizontal Installation Air for Combustion and Ventilation Duct Connections Return Air Filters General Venting Instructions Venting into a Masonry Chimney Electrical Connections Field Wiring Diagrams Gas Piping Combustion and Input Check Gas Valve Adjustment High Altitude Derate Start Up and Adjustment Preliminary Inspections Lighting Instructions User Interface menu - Communicating Mode User Interface menu - 24 VAC Mode Sequence Of Operation Control and Safety Switch Adjustment Conditions Affecting Furnace Operation Furnace Alert Codes 4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the "Venting" section (pages 15-16), of these instructions. 5. Never test for gas leaks with an open flame. Use a commer- cially available soap solution made specifically for the detection of leaks to check all connections, as specified in "Gas Piping" (page 22) of these instructions. 6. Always install the furnace to operate within the furnace's in- tended temperature -rise range with a duct system which has an external static pressure within the allowable range, as specified on the unit rating plate. Airflow with temperature rise for cfm versus static is shown in the Service Facts accompanying this furnace. 7. When a furnace is installed so that supply ducts carry air cir- culated 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 contain- ing the furnace. 8. A gas -fired furnace for installation in a residential garage must be installed as specified in "Location and Clearances" section (page 4) of these instructions. 9. The furnace may be used for temporary heating of buildings or structures under construction only when the following condi- tions have been met: a. The furnace venting system must be complete and installed per manufacturer's instructions. 2 4 4 5-6 7 7 7 9 10 12 15 15 17 17-20 22 22 23 24 25 25 25 27 28 29 32 33 35 18-CD32D1-9-EN Installer's Guide b. The furnace is controlled only by a room thermostat (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 require- ment must come from outside the structure. f. The furnace return air temperature range is between 55 and 80 degrees Fahrenheit. g. Clean the furnace, duct work, and components upon sub- stantial completion of the construction process, and verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufac- turer's instructions. 10. This product must be gas piped by a Licensed Plumber or Gas Fitter in the Commonwealth of Massachusetts. FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Improper ser- vicing could result in dangerous operation, serious injury, death, or property damage. GENERAL INSTALLATION INSTRUCTIONS The manufacturer assumes no responsibility for equipment installed in violation of any code or regulation. This furnace can be configured for Communicating or 24 VAC modes. Using fully Communicating or 24 VAC modes, the furnace can support single or multi stage heat pump, AC, or heating only applications. Combined with a communicating Comfort Control only, the furnace will support a single stage 24 VAC cooling outdoor unit only. 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 installation of gas fired equipment, wiring, plumbing, and flue connections must be ad- hered to. In the absence of local codes, the installation must conform with latest edition of the National Fuel Gas Code ANSI Z223.1 • Na- tional Installation Code, CAN/CGA B 149.1. 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 15). SAFETY HAZARD 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. 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 following requirements: 1. Is the location selected as near the chimney or vent and as cen- tralized for heat distribution as practical? 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 accessibility to the furnace must be provided. Any access door or panel must permit removal of the largest component. 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 pro- tected 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. UPFLOW INSTALLATION Standoffs and screws (See Figure 1) 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. 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. The coil is always placed downstream of the furnace airflow. The above instructions apply only if the coil is on top of an upflow furnace. 18-CD32D1-9-EN T 0 CO N 6 rF Z Cn 5/8 *UD-ACV OUTLINE DRAWING (ALL DIMENSIONS ARE IN INCHES) 04 DIAMETER 0 FLUE CONNECT OUTLET --_ DIM "c" AIR DIM "B" 19-5/8 3-15/16 5/8 0 7/8 HOLE 3-15/16 ELECTRICAL 112 CONNECTION T G I CO HOLE ° TI GAS CONNECTION RRF�R Fa F= 2-1/16 2-1/8 1-5/16 0 30-5/8 40 14-7/8 S I DE 22 I/z ° RETURN AIR A----------------------------------------------d 1-9/16 23-3/4 DIM "A" 112 28-112 BOTTOM [Am "D" RETURN AIR 3/4 3/4 IL 23-112 3-13/I6 0 7/8" HOLE WITH PLUG ELECTRICAL CONNECTION (ALTERNATE) 0 1-5/8" HOLE WITH PLUG 2-1116 — 32 28-114 MINIMUM CLEARANCE TO COMBUSTIBLE MATERIALS UPFLOW CLOSET LEFT SIDE 0 IN. FRONT 3 IN. RIGHT SIDE 0 IN. BACK 0 IN. FLUE #6 N. TOP I IN. ------------------------ ------------------- HORIZONTAL CLOSET (SEE NOTE I) TOP 2 IN. BACK 3 IN. FLUE #6 IN. SIDES I IN. FRONT 18 N. -------------------- HORIZONTAL ALCOVE (SEE NOTE I) TOP I IN. BACK 0 IN. FLUE #6 IN. SIDES 0 IN. FRONT 18 N. # - MAY BE I" WHEN TYPE B-I VENT IS USED NOTES. II MAY 8E INSTALLED ON COMBUSTIBLE FLOOR WHEN TYPE B-I VENT IS USED. 0 1-5/8" HOLE WITH PLUG S I DE 14-7/8 o RETURN A------------------- AIR -------- ----------------d 1-9/16 23-3/4 1-5/16 MODEL A B c D *UD2BO60ACV32B *UD2BO80ACV32B 17-1/2" 9-5/8" 16-1/4" 16" *UD2B100ACV32B *UD2CO80ACV42B 21" 13-1/16" 19-3/4" 19-1/2" *UD2C100ACV52B *UD2D12OACV52B 24-1/2" 15 5/16" 23 1/4" 23" *U =140ACV52B * The First Letter May Be "A" or "T" From Dwg. C341699 Rev. 9 M V y c liJ r.iIIIIIIIIIII *DD2-ACV OUTLINE DRAWING (ALL DIMENSIONS ARE IN INCHES) 5/8 04 FLUE INLET a OPENING _ DIM "C" A I R DM "B" 19-5/8 4-1/8 5/8 SIDE PANEL CUTOUT 3 I/2 \YHORIZONTAL VENTING 3 3/8 4 FLUE THROUGH CABINET [1112 I CONNECTION 5-1/2 5 ---- 0 7/8 HOLE 2-1/8 ° ELECTRICAL CONNECTION 0 _ AFaRAAA —R{ 3- 15/ 16 31 01-5/8"HOLE WITH PLUG (3) I'O 12-3/8 0 1-112 HOLE - - - - - GAS CONNECTION DIM "A"� L2-I/16 28-I/2 DIM' "D" O U T L E T AIR 3/ 3 � 19-9/ 16� 7-3/4 5- 7 112 T—: 2-1/8� 40 29-112 20-114 0 5-5/I6 SIDE PANEL CUTOUT HORIZONTAL VENTING THROUGH CABINET � 24-I/2 MINIMUM CLEARANCE TO COMBUSTIBLE MATERIALS D WEn F OW CLOSET SIDES 0 IN. W/SINGLE WALL VENT - 0 IN. W/TYPE B-I VENT FLUE 6 IN. W/SINGLE WALL VENT - IN. W/TYPE B-I VENT FRONT 6 IN. BACK I IN. r1a1¢ar►ru riosEr FLUE Lffn ----------------------- TOP 1 IN. W/SINGLE WALL VENT - 2 IN. W/TYPE B-I VENT FLUE 6 IN. W/SINGLE WALL VENT - I IN. W/TYPE B-I VENT FRONT 6 IN. BACK 3 IN. SIDES I IN. g5lifl�- Kl5iff aosEr p IF olscwwaE NDNiI TOP 1 IN. W/SINGLE WALL VENT FLUE 6 IN. W/SINGLE WALL VENT - I IN. W/TYPE B-1 VENT FRONT 6 IN. BACK 3 IN. SIDES I IN. FOR INSTALLATION ON COMBUSTIBLE FLOORING ONLY WHEN B-1 VENT CONNECTOR IS USED. TOP I IN. W/SINGLE WALL VENT - IN. W/TYPE B-I VENT FLUE 6 IN. W/SINGLE WALL VENT - IN. W/TYPE B-I VENT FRONT 18 IN. BACK 0 IN. SIDES 0 IN. TOP I IN. W/SINGLE WALL VENT FLUE 6 IN. W/SINGLE WALL VENT - I IN. W/TYPE B-I VENT FRONT 18 IN. BACK 0 IN. SIDES 0 IN. 0 7/8" HOLE WITH PLUG ELECTRICAL CONNECTION (ALTERNATE) N-- 0 1-5/8" HOLE WITH PLUG 1-1/2" X 2-1/2" OVAL GAS CONNECTION MODEL A B C D 'DD2BO60ACV32B 'DD2BO80ACV32B 17-1/2" 9-5/8" 16-1/4" 16" 'DD2C100ACV52B 21" 13-1/16" 1 19-3/4" 1 19-1/2" 'DD2D12OACV52B 24-1/2" 15-5/16" 23-1/4" 23" - The First Letter May Be "A" or "T" From Dwg. C341700 Rev. 5 y v y c ME CL ltJ Installer's Guide DOWNFLOW INSTALLATION FIRE HAZARD Do not install the furnace directly on carpeting, tile or other combustible material other than wood flooring. For vertical downflow application, subbase (BAY- BASE205) must be used between the furnace and combustible flooring. When the downflow furnace is installed vertically with a cased coil, a subbase is not required. Failure to follow this warning could result in property damage, personal injury or death. OSTANDOFFS (4) SCREWS (4) O��DRILL i FOR VERTICAL INSTALLATIONS: SCREWS (BOTH SIDES) �Atiq F STANDOFFS (BOTH SIDES) OFLANGE -� FLANGE 2(BENT UP) (BENT UP) SUB -BASE SUB -BASE -- �I INSULATION _ ---PLENUM DUCT COMBUSTIBLE FLOOR REQUIRED FLOOR OPENING: (DOWNFLOW) See Figure 3 and Table 1 TABLE 1 CABINET WIDTH RETURN DUCT WIDTH FLOOR OPENING PLENUM OPENING "A" "B" "C" I'D" 17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8" 2111 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8" 24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8" HORIZONTAL INSTALLATION The coil and furnace must be fully supported when used in the horizontal. 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. IMPORTANT: The cased coil must be placed downstream in the supply air of the furnace. 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 brackets mount us- ing 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 4 CASED COIL CONNECTION 0 BRACKET FOR DOWNFLOW FUR- O Q o 3 NACE IN HORIZONTAL lr' (as viewed from the front in the upright position). 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. The forward most screw on the side of the OLINES CONTACT SIB E BETWEEN LINES FORMED BY THE INTERSEC- TIONS OF THE TOP AND TWO SIDES OFTHE / FURNACE CASING AND BUILDING JOISTS, STUDS, OR FAMING. 40 GAS ENTRY �flnnnnp� °ppp�p,ul� T-NLE tl Y i . SERVICEAREA/� Typical Upflow/Horizontal Attic Installation furnace may be used to connect the strapping (See Figure 7). Line contact is only permissible between lines formed by the intersection of the top and two sides of the furnace casing and the building joists, studs, or framing. 18-CD32D1-9-EN 7 Installer's Guide O Downflow-Horizontal Furnace Vent Applications Horizontal NOT APPROVED F Airflow APPROVED F Airflow APPROVED I I APPROVED MwA Airflow --0- NOT APPROVED �.:........:� Airflow Vertical APPROVED Airflow Airflow-0- APPROVED Airflow 8 18-CD32D1-9-EN Installer's Guide IMPORTANT.• Limited Warranty is conditional upon proper furnace and vent system application and installation. Downflow fur- naces installed in the vertical or horizontal position may be vented through top or right side of the furnace cabinet only (see figure 6 for defined top, left and right). A 90 de- gree elbow may be installed inside the cabinet and rotated so the vent pipe entering through the right side furnace cabinet cutout can be connected to the elbow. Right side venting may be used to provide access if an electronic air cleaner is installed. Left side venting must use a 90 degree elbow outside the cabinet (Figure 6). 4P GAS qFT ENTRY �11 �pfl0�nn n n n � ph�pUUU� ��.oaAE U u CENTER OF FURNACE MUST BE SUPPORTED AT THE FRONT OF THE FURNACE. ATTACH USING \\ THE FRONT SCREW Typical Suspended Upflow/Horizontal Furnace 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 free of obstructions 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 ac- cordance 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 CAN/CGA B 149 Installation Codes, and applicable provisions of the local building codes. Special condi- tions created by mechanical 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 Figure 8. These spaces may have adequate air by infiltration to provide air for combustion, ventilation, and dilution of flue gases. Buildings with tight construc- tion (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), may need additional air 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 requirements can be supplied from inside the build- ing as in Figure 9 or from the outdoors, as in Figure 10. 1. All air from inside the buildin¢ as in Figure 9: The confined space shall be provided with two permanent openings con- nected directly to 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 equip- ment 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 11: The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. ® UNCONFINED 50 CU. FT. OR MORE rFjUNjAC PER 1000 BTU/HR. INPUT ALL EQUIP. INSTALLED ATERJ.�IFR CLOTHES EATER O9 CONFINED LESS THAN 50 CU. FT. FURNACE PER 1000 BTU/HR. INPUT - ALL EQUIP INSTALLED The openings shall be connected directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely connect to the outdoors. Refer to Table 3, for minimum open areas required. 3. The following types of installations will require use of OUT- DOOR AIR for combustion, due to chemical exposures: * Commercial buildings * Buildings with indoor pools * Furnaces installed in commercial laundry rooms * Furnaces installed in hobby or craft rooms * Furnaces installed near chemical storage areas. Exposure to the following substances in the combustion air sup- ply will also require OUTDOOR AIR for combustion: * Permanent wave solutions * Chlorinated waxes and cleaners * Chlorine based swimming pool chemicals * Water softening chemicals * Deicing salts or chemicals * Carbon Tetrachloride * Halogen type refrigerants * Cleaning solvents (such as perchloroethylene) * Printing inks, paint removers, varnish, etc. * Hydrochloric acid * Cements and glues * Antistatic fabric softeners for clothes dryers * Masonry acid washing materials TABLE 2 MINIMUM AREA IN SQUARE FEET FOR UNCONFINED SPACE INSTALLATIONS FURNACE WITH 8 FT CEILING MAXIMUM BTUH MINIMUM AREA IN SQUARE INPUT RATING FEET OF UNCONFINED SPACE 60,000 375 80,000 500 100,000 625 120,000 750 140,000 875 18-CD32D1-9-EN Installer's Guide TABLE 3 MINIMUM FREE AREA IN SQUARE INCHES EACH OPENING (FURNACE ONLY) Furnace Maximum BTLIH/INPUT Air From Air From Outside Vertical Horizontal Rating Inside Duct Duct 60,000 100 15 30 80,000 100 20 40 100,000 100 25 50 120,000 120 30 60 140,000 140 35 70 10 CONFINED SPACE AIR FROM INSIDE BUILDING CONFINED SPACE PERMANENT OPENINGS CONFINED SPACE AIR FROM OUTDOORS SPACE AIR DUCTS INLET J_ CONFINED SPACE AIR FROM VENTILATED ATTIC/CRAWL SPACE ® ATTIC LOUVERS TO OUTDOORS CONFINED SPACE OUTLET AIR ALTERNATE INLET INLETAIR AIR DUCT CONFINED SPACE ■�j�\ AIR FROM VENTILATED ATTIC CONFINED SPACE -ATTIC LOUVERS ® TO OUTDOORS LI�I_X�1[a1�? NOTE: The top flanges on the furnace must be 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 Protection Associa- tion Pamphlet No. 90. They should be sized in accordance with ACCA Manual D or whichever is applicable. 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 of the cool- ing units to avoid condensation in the heating element, unless the furnace has been specifically approved for downstream instal- lation. With a parallel flow arrangement, the dampers or other means used to control flow 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 job, flexible connections of nonflammable material may be used for return air and discharge connections to prevent trans- mission 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 slight- est vibration to the annoyance level. When the furnace is located in a utility room adjacent to the living area, the system should be carefully designed with returns which minimize noise transmission through the return air grille. Although these winter air conditioners 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 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/"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 from the furnace to a location outside the utility room, basement, attic, or crawl space. DO NOT install return air through the back of the furnace cabinet. 10 18-CD32D1-9-EN Installer's Guide RETURN AIR DUCT CONNECTION NOTE: On upflow 5 ton airflow models, if the airflow requirement exceeds 1800 CFM, these models will require return air openings and filters on both sides; OR 1 side and the bot- tom; OR just the bottom. All return air duct systems should provide for installation of return air filters. PREPARATION FOR UPFLOW BOTTOM AND SIDE RE- TURN AIR FILTER INSTALLATION 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 existing supply and return ductwork. 2. The return air filter is shipped in either the bottom or side loca- tion. Remove the filter by first turning the two latches on the blower door and tilting the door forward to remove. Remove the filter by sliding it out. 3. For upflow side return installations, remove the insulation around the opening in the blower compartment. 4. The side panels of the upflow furnace include locating notches that are used as guides for cutting an opening for return air, refer to Figure 13 and the outline drawing on page 4 for duct connection dimensions for various furnaces. 5. The bottom panel of the upflow furnace must be removed for bottom return air. After removing the filter, lay the furnace on its back. Remove the two 5/16" hex screws securing the front of the bottom channel to the cabinet. Rotate the channel downward (or remove by lowering the front edge of the channel and pulling forward). Slide the bottom return air panel out of the cabinet. Rotate the front channel to its original position and reinstall the two 5/16" screws. 6. If a 3/4" flange is to be used for attaching the air inlet duct, add to cut where indicated by dotted lines in Figure 13. Cut corners diagonally and bend outward to form flange. 7. If flanges are not required, and a filter frame is installed, cut between locating notches (See Figure 13). 8. Upflow Furnaces: filter clips are factory supplied for bot- tom or side return. Use the filter clips on either side or on the bottom if the filter is to be used within the furnace cabinet. REMOVE FILTER FROM UPFLOW 12 FURNACE WHEN RETURN DUCT IS ATTACHED TO FURNACE TOP SIDE (HORIZONTAL LEFT OR RIGHT AP- [FILTER PLICATIONS) AS SHOWN. 00090000000000 . /"/ 10000000000 0 0 09000090000000 m000uuooDUDuu o 000000000000 00 Om00000000000 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. 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 12, remove the filter from the furnace and install in a remote location. 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 12, securely attach a 1/2" mesh metal hardware cloth protective screen to the inside bottom of the filter grill to prevent per- sonal injury from contacting moving parts when reaching into the return opening to replace the filter. 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. TO PREVENT INJURY OR DEATH DUE TO CONTACT WITH MOVING PARTS, TURN THE POWER TO THE FURNACE OFF BEFORE SERVICING FILTERS. Close coupled (less than 36") return (filter directly beneath bottom side return) is not recommended due to noise consider- ations. Downflow Furnaces: Brackets are factory supplied to mount filters in the return air duct work. 9. Connect the duct work to the furnace. See Outline Drawing for supply and return duct size and location. Flexible duct con- nectors are recommended to connect both supply and return air ducts to the furnace. If only the front of the furnace is accessible, it is recommended that both supply and return air plenums are removable. 13 CUT OUT FOR SIDE LOCATING FILTER NOTCHES PROVIDED y< FOR SIDE RETURN CUTOUT J FRONT "SEE OUTLINE \ DRAWING of Furnace 10. 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. 11. The horizontal installation of the upflow furnace requires an external filter section. Do NOT use the bottom return filter within the furnace. Filter kits are available for horizontal ap- plications. 18-CD32D1-9-EN 11 Installer's Guide RETURN AIR FILTERS TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS Filters are factory supplied for these furnaces. These furnaces re- quire high velocity type air filters. The 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 filters may need to be trimmed for side or bottom filter use. NOTE. For upflow 5 ton airflow models where the airflow requirement exceeds 1800 CFM - Models will require re- turn air openings and filters on: (1) both sides, or (2) one side and the bottom, or (3) just the bottom. The furnace and the bottom filter rack, BAYRACK960, installation can be seen in Figures 14 and 15. TABLE 4 UPFLOW FURNACE RETURN AIR FILTERS CABINET OTY* CABINET CABINET WIDTH BOTTOM FILTER SIDE FILTER 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 1 1 24" X 25" X 1 " 17-1/2" X 25" X 1 " *First letter may be "A" or "T" **NOTE: For upflow 5 ton airflow models where the airflow requirement exceeds 1800 CFM - 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 14 Aid low i471V i 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 16. 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 engagement holes at the bottom of the furnace cabinet side. See Figure 17. e. Reinstall the furnace filter in the bottom position by inserting the chamfer end first into the filter rack. BOTTOM FILTER RACK INSTALLATION 15 FILTER RACK RAILS / C SPRINGS y AUTOMATIC ADJUSTMENT RETAINING PIN (Both Sides) Filter Rack Assembly 16 o Blower Deck Engagement Hole 0 L PRE -DRILL ft�� Two clearance holes with a 3/16" drill at dimple locations (one per side) 12 18-CD32D1-9-EN Installer's Guide 17 Filter Furnace Cabinet Rack Side -•)o- Filter Rack Retaining EngagementHole � For Filterr Rack Rack Installation With Bottom Return (Pre -drill 3/16" diameter clearance holes) � Screw/Pin Cabinet Width Left Side Bottom Right Side 17.5 X X X 21 X X X 24.5 X X X 1. Remove bottom front channel to install or reposition filter rack. X All Models ALTERNATE FILTER RACK INSTALLATION FOR SIDE RETURN AIR ON UPFLOW FURNACES (LEFT OR RIGHT) - BAYRACK960 The following checklist should be used when installing a right or left side return filter in an upflow furnace: a. Remove the filter. b Leave the bottom panel in place. c. Make side cutout by following the directions in the "Return Air Duct Connections" section on page 11. d. Compress the filter rack and reinstall in the side position on 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 16, 18-21. e. Reinstall the furnace filter in the side position by inserting the chamfer end first into the filter rack. 18 BOTTOM ENGAGEMENT Furnace Cabinet Side Filter Rack Retaining Screw/Pin Filter Rack f ` Bottom Panel 19 Engagement Hole Furnace BLOWER For Filter Rack Blower Installation With DECK SideReturnDeck i Furnace Cabinet mm)o- Side Filter Rack Filter Retaining Rack Screw/Pin Assembly 21 SIDE CUTOUT RETAINING N ides) BOTTOM PANEL FILTER INSTALLED RACK RAILS Typical Upflow Right Side Return Filter Rack Instal ation 18-CD32D1-9-EN 13 Installer's Guide RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION When the Upflow Furnace is installed in the horizontal configuration, the return air filters must be installed exterior to the furnace cabinet. Remote filter grilles may be used for homeowner convenience or the filters may be installed in the duct work upstream of the furnace. See Figure 22. Conversion kits for horizontal filters are BAYFLTR203 for 17 1/2" width cabinets, BAYFLTR204 for 2 1 " width cabinets, and BAY- FLTR205 for 24" width cabinets. These include filters and brackets necessary for horizontal filters. See Figure 22. 22 u ll i Airflow ' Y I �J Accessory filter kit BAYFLTR203, 204, 205 used for Upflow Hori- zontalfurnaces. Typical Horizontal Filter Installation UPFLOW FILTER CLIP / BRACKET INSTALLATION NOTE. Upflow models only - Installation of the alternate bottom filter kit requires the bottom flange to be bent flat. 1. Determine the location to be used. The furnace cabinet has dimples for location of the furnace clips (Side return only). Pre- drill clearance holes with a 3/16" drill. Bottom return holes are pre -drilled. Attach clip to bottom channel and rear of unit with screws provided for bottom return. 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 23. INSTALLING THE FILTER The 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. UNIT SIZE RETURN AIR BOTTOM SIDE 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 TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS Two filters are factory supplied for each downflow furnace. These furnaces require high velocity type air filters. Downflow furnace filters must be located outside the furnace cabinet. Typical installa- tions are shown in Figure 24. Tables 5 and 6 provide information for installation of the filter retaining brackets shipped with downflow furnaces. 24 A DOWNFLOW r B u. v DOWNFLOW/ HORIZONTAL p p d nn tl —I r� 5 �U�pJ I U� yyy e 14 18-CD32D1-9-EN Installer's Guide Important. When using the supplied 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. Remove brackets Screw locations A / r c� Flanges upward TABLE 5 CABINET WIDTH FILTER SIZE FILTER BRACKET LOCATION 17-1/2" 2 - 16X20X1 14-3/8" 21" 2 - 16X20X1 13-1/8" 24-1/2" 2 - 16X20X1 11-5/8" * Location dimension is from end of duct to the screw holes for the bracket. TABLE 6 CABINET RETURN FILTER ACCESS FILTER ACCESS WIDTH DUCT OPENING - DI- OPENING - WIDTH MENSION "A" DIMENSION "B" 17-1/2" 16-1/4" 15" 14" 21 " 1 19-3/4" 19-1 /2" 14" 24-1/2" 1 23-1/4" 22" 14" 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 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. VENT PIPING These furnaces have been classified as Fan -Assisted Combustion Sys- tem, Category I furnaces under the "latest 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-CD32 D 1-9-E N 15 Installer's Guide NOTE. When the downflow furnace is installed in the hori- zontal right position with the right side of the furnace cabi- net facing down, the vent pipe must be routed through the top panel of the furnace (See illustration 7 on page 8). Do not install the vent pipe through the left side of the cabinet. The furnace shall be connected to a factory built chimney or vent complying with a recognized standard, or a mason- ry or concrete chimney lined with a lining material accept- able to the authority having jurisdiction. CARBON MONOXIDE HAZARD 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 con- densation is a problem in your area, consider using the chimney as a pathway or chase for type `B" vent or flexible vent liner. If flex- ible liner material is used, size the vent using the `B" vent tables, then reduce the maximum 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 BAYVENT800B Installer's Guide for application requirements. Internal Masonry Chimneys Venting of fan assisted appliances into a lined, internal masonry chim- ney 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 7). CARBON MONOXIDE HAZARD 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 7 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), requires the chimney be lined with type `B", double wall vent or suitable flexible chimney liner mate - TABLE 8 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 OVER 10/12 2.5 FEET TO 11112 OVER 11/12 TO 12/12 3.25 FEET OVER 12/12 TO 14/12 OVER 4.0 FEET 14/12 TO 16/12 5.0 FEET OVER 16/12 TO 18/12 6.0 FEET OVER 18/12 TO 20/12 OVER 7.0 FEET 20/12 TO 22/12 7.5 FEET 8.0 FEET *THIS REQUIREMENT COVERS MOST INSTALLATIONS 25 VERTICAL WALL �- S' MIN. -----� LISTED LOWEST DISCHARGE CAP OPENING MINIMUM x HEIGHT ROOF PITCH lS X/12 rial. This applies in all combinations of common venting as well as for fan assisted appliances vented alone. The following installation practices are recommended to minimize cor- rosion caused by condensation of flue products in the furnace and flue gas system. CARBON MONOXIDE POISONING HAZARD Failure to follow the installation instructions for the venting system being placed into operation could result in carbon monoxide poisoning or death. 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 supported 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 accord- ing to local codes. 6. Vent pipe through the roof should be extended to a height deter- mined 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 waterproofed. 7. Use type `B" double wall vent when vent pipe is routed through cool spaces (below 60' F.). 8. Apply other good venting practices as stated in the venting section of the National Fuel Gas Code ANSI Z223.1 "latest edition". 9. 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. 10. Horizontal pipe runs must be supported by hangers, straps or other suitable material in intervals at a minimum of every 3 feet of pipe. 16 18-CD32D1-9-EN Installer's Guide 11. A furnace shall not be connected to a chimney or flue serving a separate appliance designed to burn solid fuel. 12. The flow area of the largest section of vertical vent or chimney shall not exceed 7 times the smallest listed appliance categorized vent area, flue collar area, or draft hood outlet area unless designed in accordance with approved engineering methods. Maximum Vent or Tile _ Tc(D *12 X 7 Lined Chimney Flow Area 4 *Drafthood outlet diameter, flue collar diameter, or listed appliance categorized vent diameter. SAFETY HAZARD 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 warning could result in an elec- trical shock, fire, injury, or death. The integrated furnace control is polarity sensitive. The hot leg of the 115 VAC power must be connected to the BLACK field lead. SHOCK HAZARD To prevent injury or death due to electrical shock or contact with moving parts, lock unit disconnect switch in the open position before servicing the unit. Failure to follow this warn- ing could result in electrical shock, personal injury, or death. ELECTRICAL CONNECTIONS Protect from Property Damage Do NOT connect the furnace line voltage to a GFCI pro- tected circuit. Failure to follow this warning could result in property damage NOTE: The maximum total cable length for the entire Comfort Control communicating system is 500 ft. 18 AWG. The maximum distance of any single cable from a transformer is 250 ft. 18 AWG. WHOLE HOUSE AIR CLEANER CONNECTION NOTE: The BIC terminal will require three wires to be con- nected to the low voltage terminal strip. To make this easier, create a pigtail using a short length of thermostat wire to connect the three wires to the BIC terminal. NOTE: *FD whole house air cleaners with "D" or later in the 14th digit of the model number must use the BAYACCE- COMM101 kit when connected for 24 volt mode. *FD whole house air cleaners with "A", "B", or "C" in the 14th digit of the model number must use the BAYACCECOMM101 kit when connected for 24 volt or communicating modes. See the BAYACCECOMM101 Installer's Guide for field wiring. Make wiring connections to the unit as indicated on following field wiring diagrams. As with all gas appliances using electrical power, this furnace shall be connected into a permanently live 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. The hot leg of the 120V power supply must be connected to the black power lead as indicated on the wiring diagram. Provision for hooking up an Elec- tronic Air Cleaner and/ or Humidifier is provided on the Integrated Control. The furnace control is polarity sensitive. All field supplied wiring must conform with the temperature limitation for Type T wire [63' F (35' Q], when installed in accordance with these instruc- tions and wiring diagrams supplied with the furnace. A disconnecting means must be located within sight from, and readily accessible to, the furnace. Refer to the SERVICE FACTS literature for unit wiring diagrams in addition to the diagram inside the blower door. COMMUNICATING COMMUNICATING MODE COMMUNICATING Communicating COMFORT CONTROL INDOOR UNIT OUTDOOR UNIT BN Indoor Unit with Communicating Comfort Control W3 NOTE 4 NOTE T and Communicat- ing Outdoor Unit W2 WI I FGFND -----FACTORY WIRING FIELD WIRING G TERMINAL MAY Q OR MAY NOT BE PRESENT ON D D D UNIT NOTES: NOTE 5 I. SEE WIRING DIAGRAMS IN SERVICE FACTS FOR COMPLETE WIRING INFORMATION. R R 2. LOW VOLTAGE WIRING TO BE NO. 18 AWG MINIMUM CONDUCTOR. NOTE 6 3. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT NAMEPLATE. B B B POWER WIRING AND GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES. YI 4. IN COMMUNICATING MODE, UNUSED TERMINALS ARE NOT FUNCTIONAL, DO NOT USE. 5. "D" IS THE DATA LINE. INSTALLER TO SELECT A WIRE COLOR. 6. TO CONNECT OPTIONAL DEVICES (SUCH A$ A FLOAT $WITCH) Y2 WIRE IN SERIES FROM INDOOR ..R" TO COMFORT CONTROL "R". 1. WHEN CONVERTING OUTDOOR UNIT TO 24 VAC 0 MODE. USE 24 VAC HARNESS ACCESSORY (BAYACHP024-). PRINTED FROM D802614POI REV01 18-CD32 D 1-9-E N 17 Installer's Guide Communicating Indoor Unit with Communicating Comfort Control and 24VAC Single Stage Cooling COMMUNICATING COMMUNICATING MODE 24 VAC OUTDOOR UNIT COMFORT CONTROL INDOOR UNIT I -STAGE AC ONLY ------ FACTORY WIRING FIELD WIRING T TERMINAL MAY OR MAY NOT BE PRESENT ON UNIT NOTES: I. SEE WIRING DIAGRAMS IN SERVICE FACTS FOR COMPLETE WIRING INFORMATION. 2. LOW VOLTAGE WIRING TO BE NO, 18 AWG MINIMUM CONDUCTOR. 3. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT NAMEPLATE. POWER WIRING AND GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES. 4. IN COMMUNICATING MODE, UNUSED TERMINALS ARE NOT FUNCTIONAL. DO NOT USE. 5. "D' IS THE DATA LINE. INSTALLER TO SELECT A WIRE COLOR. 6. TO CONNECT OPTIONAL DEVICES (SUCH AS A FLOAT SWITCH) WIRE IN SERIES FROM INDOOR 'R" TO COMFORT CONTROL "R'. PRINTED FROM D80261002 REV01 24VAC Mode Indoor Unit with 24VAC Comfort Control and 24VAC Single Stage Cooling TYPICAL 24 VAC COMFORT CONTROL 24 VAC MODE 24 VAC OUTDOOR UNIT (SEE CONTROL INSTALLER'S GUIDE) INDOOR UNIT I -STAGE AC ONLY I FCFND ------ FACTORY WIRING FIELD WIRING TERMINAL MAY T OR MAY NOT BE PRESENT ON UNIT NOTES: I. SEE WIRING DIAGRAMS IN SERVICE FACTS FOR COMPLETE WIRING INFORMATION. 2. LOW VOLTAGE WIRING TO BE NO. 18 AWG MINIMUM CONDUCTOR. 3. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT NAMEPLATE. POWER WIRING AND GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES. 4. OPTIONAL FIELD WIRING. CONNECT ONLY IF THESE HEATING STAGES ARE USED. 5. CONNECTIONS TO 'R" , "BK", AND "0" MUST BE MADE AS SHOWN FOR PROPER OPERATION WITH OPTIONAL HUMIDISTAT IN COOLING. FACTORY "R' TO 'BK' JUMPER ON TERMINAL BLOCK MUST BE REMOVED ON AIR HANDLING UNITS. FACTORY "R' TO 'BK' JUMPER ON FURNACE CONTROL MUST BE CUT ON FURNACES. PRINTED FROM D802614P03 REV01 NOTE: To locate the BK to R jumper on the IFC board, see page 21. 18 18-CD32D1-9-EN Installer's Guide 24VAC Mode Indoor Unit with 24VAC Comfort Control and 24VAC 2-Stage or 2-Step Cooling TYPICAL 24 VAC COMFORT CONTROL 24 VAC MODE 24 VAC OUTDOOR UNIT (SEE CONTROL INSTALLER'S GUIDE) INDOOR UNIT 2-STAGE OR 2-STEP AC I FGFNQ ------ FACTORY WIRING FIELD WIRING TERMINAL MAY T OR MAY NOT BE PRESENT ON UNIT NOTES: I. SEE WIRING DIAGRAMS IN SERVICE FACTS FOR COMPLETE WIRING INFORMATION. 2. LOW VOLTAGE WIRING TO BE NO. 18 AWG MINIMUM CONDUCTOR. 3. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT NAMEPLATE. POWER WIRING AND GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES, 4. OPTIONAL FIELD WIRING, CONNECT ONLY IF THESE HEATING STAGES ARE USED. 5. CONNECTIONS TO "R' , 'BK', AND "0' MUST BE MADE AS SHOWN FOR PROPER OPERATION WITH OPTIONAL HUMIDISTAT IN COOLING. FACTORY "R' TO "BK' JUMPER ON TERMINAL BLOCK MUST BE REMOVED ON AIR HANDLING UNITS. FACTORY "R' TO IK' JUMPER ON FURNACE CONTROL MUST BE CUT ON FURNACES. 6. SEE USER INTERFACE 24 VAC MODE SETUP MENU FOR IST STAGE CFM OPTIONS. 2-STAGE = 39-64% 2-STEP = 65-80% PRINTED FROM D802614PO4 REV01 NOTE: To locate the BK to R jumper on the IFC board, see page 21. 24VAC Mode Indoor Unit with 24VAC Comfort Control and 24VAC Single Stage Heat Pump TYPICAL 24 VAC COMFORT CONTROL 24 VAC MODE 24 VAC OUTDOOR UNIT (SEE CONTROL INSTALLER'S GUIDE) INDOOR UNIT I -STAGE HEATPUMP I FGFNO ------ FACTORY WIRING FIELD WIRING TERMINAL MAY T OR MAY NOT BE PRESENT ON UNIT NOTES: I. SEE WIRING DIAGRAMS IN SERVICE FACTS FOR COMPLETE WIRING INFORMATION. 2. LOW VOLTAGE WIRING TO BE N0, 18 AWG MINIMUM CONDUCTOR. 3. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT NAMEPLATE. POWER WIRING AND GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES. 4. OPTIONAL FIELD WIRING. CONNECT ONLY IF THESE HEATING STAGES ARE USED. 5. CONNECTIONS TO "R' , 'BK", AND "0' MUST BE MADE AS SHOWN FOR PROPER OPERATION WITH OPTIONAL HUMIDISTAT IN COOLING. FACTORY "R' TO "BK' JUMPER ON TERMINAL BLOCK MUST BE REMOVED ON AIR HANDLING UNITS. FACTORY "R' TO "BK' JUMPER ON FURNACE CONTROL MUST BE CUT ON FURNACES. 6. ON FURNACE APPLICATIONS, COMFORT CONTROL MUST BE DUAL FUEL COMPATIBLE (SEE CONTROL INSTALLERS GUIDE) OR MUST USE TAYPLUS103. PRINTED FROM D802614P05 REV01 NOTE: To locate the BK to R jumper on the IFC board, see page 21. 18-CD32D1-9-EN 19 Installer's Guide 24VAC Mode Indoor Unit with 24VAC Comfort Control and 24VAC 2-Stage or 2-Step Heat Pump TYPICAL 24 VAC COMFORT CONTROL 24 VAC MODE 24 VAC OUTDOOR UNIT (SEE CONTROL INSTALLER'S GUIDE) INDOOR UNIT 2-STAGE OR 2-STEP HP I FGFND ------ FACTORY WIRING FIELD WIRING E] TERMINAL MAY OR MAY NOT BE PRESENT ON UNIT NOTES: I. SEE WIRING DIAGRAMS IN SERVICE FACTS FOR COMPLETE WIRING INFORMATION, 2. LOW VOLTAGE WIRING TO BE NO. 18 AWG MINIMUM CONDUCTOR. 3. BE SURE POWER SUPPLY AGREES WITH EQUIPMENT NAMEPLATE. POWER WIRING AND GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES. 4. OPTIONAL FIELD WIRING. CONNECT ONLY IF THESE HEATING STAGES ARE USED. 5. CONNECTIONS TO 'R" , 'BK", AND '0' MUST BE MADE AS SHOWN FOR PROPER OPERATION WITH OPTIONAL HUMIDISTAT IN COOLING. FACTORY 'R" TO 'BK" JUMPER ON TERMINAL BLOCK MUST BE REMOVED ON AIR HANDLING UNITS. FACTORY 'R" TO 'BK" JUMPER ON FURNACE CONTROL MUST BE CUT ON FURNACES, 6. ON FURNACE APPLICATIONS, COMFORT CONTROL MUST BE DUAL FUEL COMPATIBLE (SEE CONTROL INSTALLERS GUIDE) OR MUST USE TAYPLUS103. 1. SEE USER INTERFACE 24 VAC MODE SETUP MENU FOR IST STAGE CFM OPTIONS. 2-STAGE = 39-64% 2-STEP = 65-80% NOTE: To locate the BK to R jumper on the IFC board, see page 21. Wiring Notes: 20 18-CD32D1-9-EN Installer's Guide O 000 no(7) O -� 0 o O D (0) L� O O J� O i0 L 00 L � - BK Jumper I'll 2 W K 0 DD R /C Y� u 2 O The factory installed jumper be- tween "R" and "BK" on the circuit board must be cut if an optional Humidistat is installed. HUMIDISTAT HOOKUP - 24 V Mode ONLY If an optional humidistat for humidity control in cooling is used, the factory installed `BK Jumper" must be cut. The BK Jumper must also be cut if a multi -zone controller is con- nected or *CONT402 is installed and using the BK enabled feature. See the 24VAC field hookup wiring diagrams for more information. 18-CD32D1-9-EN 21 Installer's Guide 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. EXPLOSION HAZARD DO NOT STORE COMBUSTIBLE MATERIALS, GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS NEAR THE UNIT. FAILURE TO FOLLOW WARNING MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH. 27 LEFT SIDE PIPING (STANDARD) a a a DRIP LEGS a a a� a a a a RIGHT SIDE PIPING (OPTIONAL) a ° F� DRIP LEG a e a e TOP VIEW OF RIGHT SIDE PIPING II 10 �w9 a4 � ® a AUTOMATIC GAS VALVE WITH MANUAL SHUTOFF TOP VIEW 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. This unit is shipped standard for left side installation of 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 regulations of the local gas company. Pipe joint compound must be resistant to the chemical reaction with liquefied - petroleum gases. Refer to piping Table 9 for delivery sizes. NOTE: Refer to local codes and the National Fuel Gas Code, cur- rent edition, for gas pipe requirements. 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. Use a backup wrench on the gas valve when installing gas piping to prevent damage to the gas valve and manifold assembly. 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. COMBUSTION AND INPUT CHECK 1. Make sure all gas appliances are off except the furnace. 2. Clock the gas meter with the furnace operating (determine the dial rating of the meter) for one revolution. 3. Match the "See' column in the gas flow (in cfh) Table 13 with the time clocked. 4. Read the "Flow" column opposite the number of seconds clocked. 5. Use the following factors if necessarv: 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= 1 OX Chart Flow Reading - 4 22 18-CD32D1-9-EN Installer's Guide 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 To adjust the manifold outlet pressure: 1. Turn off all electrical power to the system 2. Attach a manifold pressure gauge with flexible tubing to the boss marked "OUT P" on White -Rodgers gas valve model 36J or 36G. See Figure 28 for White -Rodgers gas valve model 36J. See Figure 29 for model 36G. 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) contains a 3/32" hex wrench, a 5/16" hose and a connector and can be ordered through Global Parts. 4. Turn on system power and energize valve. 5. Adjust 1 st stage gas heat by removing the low (LO) adjustment regulator cover screw. a. To increase outlet pressure, turn the regulator adjustment screw clockwise. b. To decrease outlet pressure, turn the regulator adjust- ment screw counterclockwise. c. Adjust regulator until pressure shown on manometer matches the pressure specified in Table 9. 1. The input should be more than the nameplate rating and no less than 93% of the nameplate rating, unless the unit is being de -rated for high altitude. d. Replace and tighten the HI adjustment cover screw. 6. Adjust 2nd stage gas heat by removing the high (HI) adjustment regulator cover screw. a. To increase outlet pressure, turn the regulator adjustment screw clockwise. b. To decrease outlet pressure, turn the regulator adjust- ment screw counterclockwise. c. Adjust regulator until pressure shown on manometer matches the pressure specified in Table 9. 1. The input should be more than the nameplate rating and no less than 93% of the nameplate rating, unless the unit is being de -rated for high altitude. d. Replace and tighten the HI adjustment cover screw. 7. Cycle the valve several times to verify regulator setting. a. Repeat the steps 5-7 if needed. 8. Turn off all electrical power to the system. 9. Remove the manometer and tubing and tighten the pressure tap screws. 10. Using a leak detection solution of 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. Tighten all pressure test screws loosened when adjusting gas pressure. Replace both regulator cover screws. 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, unless the unit is derated for altitude. Table 11 lists the main burner orifices shipped with the furnace. If a change of orifices is required to correct the input rate, refer to Table 12. TABLE 9 FINAL MANIFOLD PRESSURE SETTINGS inches w.c. FUEL 2nd Stage Max. 1st Stage Max. NATURAL GAS 3.5" W.C. 1.7" W.C. LP GAS 10.5" W.C. 6.0" W.C. .�MUL p O o 0 0 ■_■ 29 White -Rodgers 36G Outlet 2nd Stage (HI) Pressure Manifold Pressure Boss Adjustment mu�') Ell V 000) 00 1st Stage (LO) Inlet Gas Valve On/ Manifold Pressure Pressure Boss Toggle Switch Adjustment 18-CD32D1-9-EN 23 Installer's Guide TABLE 10 NATURAL GAS ONLY TABLE OF CUBIC FEET PER HOUR OF GAS FOR VARIOUS PIPE SIZES AND LENGTHS PIPE SIZE LENGTH OF PIPE 10 1 20 30 40 50 60 70 1/2 132 92 73 63 56 50 46 3/4 278 190 152 130 115 105 96 1 520 350 285 245 215 195 180 1-1/4 1050 730 590 520 440 400 370 This table is based on pressure drop of 0.3 inch W.C. and 0.6 SRGR. gas TABLE 11 ORIFICE SIZES INPUT RATING BTUH NUMBER OF BURNERS MAIN BURNER ORIFICE DRILL SIZE NAT. GAS LP GAS 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 TABLE 12 PART NUMBERS FOR REPLACEMENT ORIFICES DRILL SIZE PART NUMBER DRILL SIZE PART NUMBER 44 ORF00501 45 ORF00644 54 ORF00555 46 ORF00909 55 ORF00693 47 OR F0091 0 56 ORF00907 48 O RF01099 57 O RF00908 49 O RF00503 58 O RF01338 50 ORF00493 59 O RF01339 HIGH ALTITUDE DERATE Input ratings (BTUH) of these furnaces are based on sea level opera- tion 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 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 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 cannot be achieved with a change in manifold pressure, then the orifices must be changed. LP installations will require an orifice change. Important. Reinstall the propane orifices to the same depth as the orifices supplied with the equipment. See Table 14 for help in selecting orifices if orifice change is re- quired. 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 Na- tional 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 13 GAS FLOW IN CUBIC FEET PER HOUR 2 CUBIC FOOT DIAL SEC. FLOW SEC. FLOW SEC. FLOW SEC. FLOW 8 900 29 248 50 144 82 88 9 800 30 240 51 141 84 86 10 720 31 232 52 138 86 84 11 655 32 225 53 136 88 82 12 600 33 218 54 133 90 80 13 555 34 212 55 131 92 78 14 514 35 206 56 129 94 76 15 480 36 200 57 126 96 75 16 450 37 195 58 124 98 73 17 424 38 189 59 122 100 72 18 400 39 185 60 120 104 69 19 379 40 180 62 116 108 67 20 360 41 176 64 112 112 64 21 343 42 172 66 109 116 62 22 327 43 167 68 106 120 60 23 313 44 164 70 103 124 58 24 300 45 160 72 100 128 56 25 288 46 157 74 97 132 54 26 277 47 153 76 95 136 53 27 267 48 150 78 92 140 51 28 257 49 147 1 80 90 144 50 TABLE 14 Orifice ALTITUDE ABOVE SEA LEVEL Twist Drill and Orifice Required At Other Elevations Size If 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 48 48 49 49 49 50 50 51 52 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 24 18-CD32D1-9-EN Installer's Guide START UP AND ADJUSTMENT SAFETY WARNING DO NOT attempt to manually light the burner. Failure to follow this warning could result in property damage, per- sonal injury or death. 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 connections 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. LIGHTING INSTRUCTIONS 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. Whenever your house is to be vacant, arrange to have someone inspect your house for proper temperature. This is very important during freezing weather. If for any reason your furnace should fail to operate damage could result, such as frozen water pipes. 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 components. 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 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. TO SHUT OFF For complete shutdown: Move the control switch on the main gas valve to the "OFF" position (See Figures 28 and 29). Disconnect the electrical supply to the unit. If complete shutdown is done during the cold weather months, provisions must be taken to prevent freeze-up of all water pipes and water receptacles. 18-CD32D1-9-EN 25 Installer's Guide SERVICE PROCEDURE TO ACCESS USER INTERFACE FOR 2-STAGE FURNACE This procedure should only be performed by trained service personnel. ELECTRICAL SHOCK HAZARD DO NOT BYPASS THE DOOR SWITCH BY ANY PERMANENT MEANS. FAILURE TO FOLLOW WARNING COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH. ELECTRICAL SHOCK HAZARD DO NOT TOUCH ANY COMPONENTS OTHER THAN THE DISPLAY ASSEMBLY AND THE DOOR SWITCH DURING THIS PROCEDURE. FAILURE TO FOLLOW WARNING COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH. 1. Remove Blower Door panel by a) turning the two door latches on the upflow furnace or b) removing the 5/16" screws on the downflow furnace. 2. Lower door panel and remove from service access area. 3. Depress the door switch (there must be power to the control system for the display assembly to function) and keep the door switch depressed during programming. 4. Move through the Display Assembly menu using the arrow buttons. 5. The User Interface menu starting on page 27 is a guide to the menu options. 6. When programming is complete release Door Switch and replace the Blower Door. NOTE: If power is lost during programming, all changes made will be saved. 57 USER INTERFACE Push left & right to scroll through Viewing Window menu options Push up & down J to scroll through ENTER / setup menu Push ENTER to make selection User Interface pictured above adjusts Variable Speed Airflow options and is used for custom setup of Furnace operations- See menu options in User Interface on pages 27 & 28. 26 18-CD32D1-9-EN Installer's Guide USER INTERFACE MENU - COMMUNICATING SYSTEM AITCONT900 Variable Speed Standy Screen System Status Information Menu I Information Options Setup Options [ ] = Current Setting 0 CFM LAST 4 FAULTS LAST 4 FAULTS NO ALERTS INDOOR ALERTS INDOORALERTS NO ALERTS UNIT TEST UNIT TEST NO [NO] YES TEMP SENSOR TEMP SENSOR SNSR1 SNSR1 SNSR2 DLT2-1 MOTOR RPM MOTOR RPM 0 RPM INDUCER RPM INDUCER RPM OFF [OFF] LO HI OFF RESET LST FAULT RESET LST FAULT NO NO YES PART LIST PART LIST CNT* PM SERIAL NUM PM SERIAL NUM >tMUW CNTNGNCY MODE CNTNGNCY MODE NOT AVAILABLE with data line connected and active EXIT EXIT NO NO YES NOTES: D This menu will only display at comfort control mode when AITCONT900 is NOT connected See next page for 24VAC setup options * Unit specific A/TUD2B060 3T [3TJ 1.ST 2T 2.ST A/TUD2B080 3T [3T] 3.5T 2.5T A/TUD2C080 4T 4 2.5T 3T 3.ST AfTUD2B100 3T 3 1.5T 2T 2.5T AfTUD2C700 51 5 3T 3.ST 4T .UD2D720 5T 5 3.5T 4T AiTUD213140 5T 5 3T 3.5T 4T A1TDD2B060 3T 3 1.5T 2T 2.5T A/TDD2B080 3.5T [3.STJ 2.ST 3T A/TDD2C100 5T [ST] 3T 3.5T 4T .DD21M. 5T 5 3.5T 4T "*Units .cif. AtTUD2B66D 1000 1000 1060 820 A/TUD2B080 1380 [1380] 1470 1200 A/TUD2C080 1260 [1260] 1380 1110 AfTUD2B100 1390 1390 1490 1290 A/TUD2C1 U0 1540 1540 1650 1300 AfTUD2D120 1650 1650 1900 1300 AfTUD2D140 1920 1920 2030 1610 .DD2B060 960 960 1060 860 A1TDD2B080 1120 [11201 1260 1000 A/TDD22100 1460 [1460] 1600 1300 A/TDD2D120 1820 [1820] 2000 1600 CNTNGNCY MODE <STAGE> STAGE OF OFF 1 2 DUTY CYCLE [101 10 20 30 40 50 START NO NO YES EXIT [NO] NO YES ARE YOU SURE NO NO YES 18-CD32D1-9-EN 27 Installer's Guide USER INTERFACE MENU - 24V SYSTEM 24V Variable Speed System Status Setup Options [ ] = Current Setting CMFRT CNT MODE COMM [24VAC] 24VAC * Unit specific A/TUD2B060 13T [3T] 1.5T 2T 2.5T A/TUD2B080 3T 3T 3.5T 2.5T A/TUD2C080 4T 4T 2.5T 3T 3.5T A/TUD21B100 3T [3T] 1.5T 2T 2.5T A/TUD2C100 5T 5 3T 3.5T 4T A/TUD2D120 5T [5 3.5T 4T A/TUD2D140 5T [5T] 3T 3.5T 4T A1TDD2B060 3T [3T1 1.5T 2T 2.5T A/TDD2B080 3.5T 3.5 2.5T 3T A/TDDR500 ST 5 3T 3.5T 4T A/TDD2D120 15T 5T 3.5T 4T ** Unit snerifir. A/TUD21B060 1000 [10001 1060 820 A/TUD2B080 1380 [13801 1470 1200 A/TUD2C080 1260 [12601 1380 1110 A/TUD2B100 1390 [13901 1490 1290 A/TUD2C100 1540 1540 1650 1300 A1TUD2D120 1650 [16501 1900 1300 A/TUD2D140 1920 [19201 2030 1610 A/TDD2B060 1 960 960 1060 860 A/TDD2B080 1120 [1120] 1260 1000 A/TD D KI 00 1460 [14601 1600 1300 A/TDD2D120 11820 [18201 2000 1600 NOTES: ® This menu will only display at the comfort control mode when 2 STGS is chosen in previous menu. 28 18-CD32D1-9-EN Installer's Guide SEQUENCE OF OPERATION (Communicating Mode) Comfort control call for 1st stage heat (A/TCONT900): The comfort control signals the control board (IFC) to run its self - check routine. After the control has verified that all safeties are closed and the 1 st stage pressure switch contacts are open, the draft inducer will be energized on high speed. After the draft inducer comes up to speed, the 1st stage pressure switch contacts will close, the draft inducer switches to low speed, and the igniter warm-up pe- riod will begin. The igniter will heat for approximately 20 seconds; the 1 st stage gas valve will be energized to permit gas flow to the burners. The flame sensor confirms that ignition has been achieved within the 4 second ignition trial period. As the flame sensor confirms that ignition has been achieved, the delay to fan ON period begins timing and after approximately 45 seconds the indoor blower motor will be energized at the 1 st stage speed and will continue to run during the heating cycle. Comfort control call for 2nd stage after 1st stage: The comfort control signals a call for 2nd stage heat. After a 30 sec- ond delay, the draft inducer will be energized on high speed. The 2nd stage pressure contacts will close allowing the 2nd stage gas valve to be energized. The indoor blower motor will ramp up to 2nd stage heating airflow. 2nd stage satisfied, 1st stage still called for: The comfort control signals that 2nd stage heating requirements have been satisfied. The draft inducer motor is reduced to low speed allowing the 2nd stage pressure switch to open. The 2nd stage gas valve is de -energized allowing 1st stage heating operation. After approximately 30 seconds, the indoor blower motor is reduced to 1 st stage heating airflow. 1st stage satisfied: The comfort control signals that the 1st stage heating requirements have been satisfied. The 1st stage gas valve will be de -energized and gas flow will cease. The draft inducer motor will be de -energized after a 5 second post purge. The indoor blower motor will be de - energized after the fan off delay period has ended. (The indoor blower heat fan off delay is field selectable and can be adjusted using the User Interface menu. It is factory set at 100 seconds but can be set to 60, 140, or 180 seconds) Indoor Blower motor operation thermostat fan switch "ON" (Communicating Mode) The communicating comfort control signals a continuous fan call. The factory setting is 50% of the cooling cfim selected but can be adjusted from 25% - 100% through the Installer Setup menu on the communicating comfort control. If the outdoor unit is a 2 stage system, the factory setting is 50% of the 2nd stage cooling cfm. If the outdoor unit is a 24 volt single stage cooling system, the factory setting is 50% of the cooling cfin. NOTE: If the actual relative humidity (RH) is at or below the set - point, the fan will run until the continuous fan call is removed or the actual RH exceeds the set -point. If the actual RH is above the set -point, the fan will not turn on. See the communicating comfort control Installer's Guide for ad- ditional information. Indoor Blower Timing: The furnace control module (IFC) controls the variable speed motor in the heating mode. The fan "ON" time is set at 45 seconds and is not field selectable. The blower "OFF" delay is factory set at 100 seconds and can be adjusted to 60, 140, or 180 seconds. (24v Mode) Thermostat call for 1st stage heat (2 stage heating thermostat): R and W 1 thermostats contacts close signaling the control board (IFC) to run its self -check routine. After the control has verified that all safeties are closed and the 1st stage pressure switch contacts are open, the draft inducer will be energized on high speed. After the draft inducer comes up to speed, the 1st stage pressure switch contacts will close, the draft inducer switches to low speed, and the igniter warm-up period will begin. The igniter will heat for approximately 20 seconds; the 1 st stage gas valve will be energized to permit gas flow to the burners. The flame sensor confirms that ignition has been achieved within the 4 second ignition trial period. As the flame sensor confirms that ignition has been achieved, the delay to fan ON period begins timing and after approximately 45 seconds the indoor blower motor will be energized at the 1 st stage speed and will continue to run during the heating cycle. Thermostat call for 2nd stage after 1st stage: R and W2 thermostat contacts close signaling a call for 2nd stage heat. After a 30 second delay, the draft inducer will be energized on high speed. The 2nd stage pressure contacts will close allowing the 2nd stage gas valve to be energized. The indoor blower motor will ramp up to 2nd stage heating airflow. 2nd stage satisfied, 1st stage still called for: R and W2 thermostat contacts open signaling that 2nd stage heating requirements have been satisfied. The draft inducer motor is reduced to low speed allowing the 2nd stage pressure switch to open. The 2nd stage gas valve is de -energized allowing 1st stage heating operation. After approximately 30 seconds, the indoor blower motor is reduced to 1 st stage heating airflow. 1st stage satisfied: R and W 1 thermostat contacts open signaling that the 1 st stage heat- ing requirements have been satisfied. The 1 st stage gas valve will be de -energized and gas flow will cease. The draft inducer motor will be de -energized after approximately a 5 second post purge. The indoor blower motor will be de -energized after the fan off delay period has ended. (The indoor blower heat fan off delay is field selectable and can be adjusted using the User Interface menu. It is factory set at 100 seconds but can be set to 60, 140, or 180 seconds) Thermostat call for heat (1 stage heating thermostat) W 1 and W2 must be jumpered at the control board. R and W thermostat contacts close signaling a call for heat. The control board (IFC) runs it self check routine. After the control has verified that all safeties are closed and the 1 st stage pressure switch contacts are open, the draft inducer will be energized on high speed. After the draft inducer comes up to speed, the 1st stage pressure switch contacts will close, the draft inducer switches to low speed, and the igniter warm-up period will begin. The igniter will heat for approximately 20 seconds; the 1 st stage gas valve will be energized to permit gas flow to the burners. The flame sensor confirms that ignition has been achieved within the 4 second ignition trial period. As the flame sensor confirms that ignition has been achieved, the delay to fan ON period begins timing and after approximately 45 seconds the indoor blower motor will be energized at the 2nd stage speed heating airflow. At the same time, the 2nd stage draft inducer is energized and the 2nd stage pressure switch then closes. The 2nd stage gas valve is then energized. (The inter -stage delay is field selectable and can be adjusted through the User Interface menu. It is factory set at 0 minutes but can be adjusted to 5, 10, or 15 minutes.) This option can help optimize the furnace to try to satisfy the heating requirement during low heating load conditions. Thermostat satisfied: R and W thermostat contacts open signaling the heating require- ments have been satisfied. The gas valve is de -energized and after a 5 second draft inducer post purge, the draft inducer is de -energized. If the inter -stage delay was met and the furnace was operating on 2nd stage heat, the indoor motor will operate at 2nd stage heating airflow for the duration of the 2nd stage heating fan off delay. 18-CD32 D 1-9-E N 29 Installer's Guide If the furnace was operating on 1 st stage heat, the indoor motor will operate at 1 st stage heating airflow for the duration of the 1 st stage heating fan off delay. Indoor Blower motor operation thermostat fan switch "ON" (24V Mode) R and G comfort control contacts close signaling a continuous fan call. The continuous fan cfm is field selectable and can be adjusted through the User Interface menu. The factory setting is 50% of the cooling cfm selected but can be set at 25%, 50%, 75%, or 100%. If the system has a 2 stage outdoor unit, the setting is 50% of the 2nd stage cooling cfin. Indoor Blower Timing: The furnace control module (IFC) controls the variable speed motor in the heating mode. The fan "ON" time is set at 45 seconds and is not field selectable. The blower "OFF" delay is factory set at 100 seconds and can be adjusted. PERSONALITY MODULE The Personality Module is a removable memory device, on which is stored model specific data required for proper furnace operation. The Personality Module is tethered to the unit and must remain with the furnace at all times. The Personality module must remain plugged into the furnace IFC. UNIT TEST MODE This furnace is equipped with a Unit Test mode that can be accessed through the User Interface. See the User Interface menu on how to enter this option. The test mode can be performed in communicating or 24vac modes. In communicating or 24vac modes, the unit test can only be en- tered when there is not a heat, cool, continuous fan, or circulation demands. If a heat demand occurs when the unit test is running, the test mode will be aborted and the normal heating sequence will be started. If a cooling, circulator, or continuous fan demand occurs when the unit test is running, the test mode will be completed before the other demand is started. All safety functions will be operable during the Unit Test function. Any safety device that is triggered during the test mode will termi- nate the test and the fault will be reported in the Indoor Alerts and the Last Four Faults sections of the user interface. When the Unit Test option is activated, the unit will start the indoor blower and energize the Y1 output. After approximately 10 seconds, the indoor blower and Y 1 will turn off. Next, the furnace will begin the ignition sequence. After the flame has been sensed, the 45 second fan on delay will be initiated. After the 45 second period, the indoor blower is energized for 10 seconds in 1st stage heating airflow. The furnace will then transition to 2nd stage gas valve and blower opera- tion for 10 seconds. The furnace will then transition to off, running the normal post -purge and the normal heat off delays. If a button on the User Interface is pressed during the Unit Test mode, the test will be terminated. The furnace will exit the Unit Test mode and return to normal operation, automatically, after 180 seconds of operation in Unit Test mode. 115 VOLT 60 HZ. I PH POWER SUPPLY PER LOCAL CODE :H 1'N �GRt�GND DOOR SWITCH IFC� TINE-H ,BK/IJ %FMR-H B1/4 BK/4 13 ICIRC-H BK/7� 120V 2dV' IVS IM-H I rWH/4 RD— �1 ©UR I I 1nsl-2 3 Sns2-1 IS L N" W K 5 IC Ili I I L__��n _J I I I Communicating Comfort Control UD2 30 18-CD32D1-9-EN Installer's Guide The information to be displayed on the user interface during Unit Test mode is: • On start of the Unit Test sequence, the words "UNIT TEST" will appear on the first line. • "Y1 ON FAN ON" will appear on the second line during the first test. • When the unit lights in first stage heating, "STAGE 1" will ap- pear on the second line. • When the unit transitions to second stage, "STAGE 2" will ap- pear on the second line. • When the unit transitions to the heat off delay, the user interface will return to the standby screen. If Unit Test mode operation is terminated for any reason, the user interface will return to the standby screen. STAND ALONE OPERATION (CONTINGENCY MODE) The Contingency Mode allows the installer to set the equipment to operate in an ON/ OFF Duty Cycle mode. This mode will be activated using the User Interface. The user will select the desired level of capacity required, Stage 1 or 2. The user will select the desired ON/ OFF Duty Cycle, 10% minimum to 50% maximum, (10% increments, 10% = 2 minutes On, 18 minutes Off, 50% = 10 minutes on, 10 minutes off). CONTINGENCY MODE • Stand alone operation can only be entered at the user interface. • Stand alone operation can be set up to operate the furnace in Heating Only. • The contingency mode is used when the communi- cating comfort Control is not communicating with the furnace or when setting gas pressures. • Before attempting to enter contingency mode, disconnect the Data wire D from the Furnace IFC terminal block. • The contingency mode will function only when the Furnace IFC is not flashing a fault code at its Fault LED. • To enter the contingency mode of operation, cycle the 120 VAC power supply off and then back on. • Scroll down using the down arrow - at the User Interface until you see CNTNGNCY Mode, then press the Enter button. • CNTNGNCY MODE and 1 STAGE ► will now be displayed. Press the Enter button. • STAGE and 1 OFF [OFF] will now be displayed. A First or Second Stage of heat must be selected. Use the 4 or ► arrows to select the stage of heat wanted and then push the Enter button and then the � button. • DUTY CYCLE and 10% [10%] will now be displayed. A duty cycle must now be selected from 10 to 50%. A 10% duty cycle will run the furnace for 2 minutes and then off for 18 minutes. A 50% duty cycle will run the furnace for 10 minutes and then be off for 10 minutes. These duty cycles will be repeated 3 times per hour. Use the 1 or ► arrows to select a duty cycle and then push the Enter button and then the - button. • Start and NO [NO] will now be displayed. With a NO/NO question being asked, use the 1 or ► arrows to select the YES and then press the ENTER button. • Are you Sure and NO [NO] will now be displayed. With a NO/ NO question being asked, use the 4 or ► arrows to select the YES and then press the ENTER button. • Turn 120 VAC power off. When the Green LED on the variable speed inducer drive goes out, turn 120 VAC power back on. • When the furnace is operating in the contingency mode (stand alone operating cycle), the user interface will display the following information. The top line will say CNTNGNCY MODE. The bottom line will show the operating stage number STG (1 or 2) selected, and the percent number 10-50 % selected. • All furnace operating controls, pressure switches and communications between the IFC and the variable speed indoor blower will be functional during continuous mode operation of the furnace. • The 1 ► - � and ENTER buttons do not function in the contingency mode of operation. • To exit the contingency mode of operation turn off the 120 VAC power to the furnace. • The contingency mode (stand alone operation) will stop for any of the following reasons: (1) If the furnace IFC receives a signal from the communicating comfort control. This will only happen if the data wire D from the comfort control has been reconnected to the furnace IFC terminal board terminal D. (2) Power is removed from the furnace and then turned back on. Note: If a communicating comfort control is detected to be present and the contingency mode menu is selected, "NOT AVAILABLE" will be displayed on the user interface. (3) The Furnace IFC enters a RESET mode of operation. (4) A fault is detected by the furnace IFC. Fault LED will be flashing an Alert Code. 24V CONTINGENCY MODE An alternative method for the contingency mode can be used by changing the mode of operation in the user interface to 24v mode and installing a conventional 24v comfort control. To set this mode of operation: Remove all wiring from the *CONT900 comfort control and install a 24v comfort control. If the comfort control requires a 24v common; connect R and B to respective terminals. Connect 3rd wire to "W". At the control board, connect the same 3 wires to the corresponding terminals. Jumper WI to W2 at the control board. The stage delay between W 1 & W2 can be set by scrolling thru the user interface. It is factory set at zero minutes but can be adjusted to 5, 10, or 15 minutes. 18-CD32D1-9-EN 31 Installer's Guide 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 warning device. If the gas furnace is installed in a basement, an excavated area or a confined space, it is strongly recommended to contact a gas supplier to install a gas detection warning device in case of a gas leak. Failure to follow this warning could result in property damage, personal injury or death. NOTE. The manufacturer of your furnace does NOT test any detectors and makes no representations regarding any brand or type of detector. 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 safe operation 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 Comfort Control to a temperature higher than the indicated room temperature to start the furnace. Restrict the airflow by blocking the return air (disconnecting the Indoor Blower may trip the Inducer Limit). When the Furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and overheating 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 restriction from the return air inlet. AIRFLOW ADJUSTMENT Check inlet and outlet air temperatures to make sure they are within the range specified on the Furnace rating nameplate. If the airflow needs to be increased or decreased, see the Airflow Label on the Furnace or the unit's Service Facts for information on changing the speed of the Blower Motor for your specific model. Blower speed changes are made on the User Interface. Where long periods of air- flow are desired for comfort, use long fan cycles instead of continu- ous airflow. ELECTRICAL SHOCK HAZARD Do not touch any components other than the display assembly and the door switch during this procedure. Failure to follow this warning could result in property damage, personal injury or death. ELECTRICAL HAZARD Disconnect power to the unit before removing the Blower door. Allow a minimum of 10 seconds for IFC Power Supply to discharge to 0 volts. Failure to follow this warning could result in property damage, personal injury or death. SAFETY HAZARD MAKE SURETHATTHE BLOWER DOOR IS IN PLACE AND NOT AJAR. DANGEROUS FUMES COULD ESCAPE. FAILURE TO FOLLOW WARNING COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH. This unit is equipped with a Blower Door Switch which cuts power to the Furnace causing shutdown when the door is removed. Opera- tion 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. NOTE TO INSTALLER Review the following instructions with the homeowner. Review con- tents of USER'S INFORMATION MANUAL with the homeowner. INSTRUCTIONS TO THE HOMEOWNER 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 your dealer or a qualified service agent. NOTE: Direct drive motors have bearings which are permanently lubricated and under normal use, lubrication is not recom- mended. 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 inside the furnace casing). Also turn off electrical power to the furnace and con- tact the service agency designated by your dealer. SAFETY HAZARD 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. 32 18-CD32D1-9-EN Installer's Guide CONDITIONS AFFECTING FURNACE OPERATION 1. EXCESSIVE COMBUSTION PRESSURE (WIND IN EX- CESS OF 40 M.P.H.) VENT OR FLUE BLOCKAGE If pressure against induced draft blower outlet becomes exces- sive, the pressure switch will open and shut off the gas valve until acceptable combustion pressure is again available. 2. LOSS OF FLAME If loss of flame occurs during a heating cycle, or flame is not present at the sensor, the flame control module will close the gas valve. The flame control module will then recycle the igni- tion 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 automatically 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 inte- grated control module will recycle the ignition sequence, then if ignition is not achieved, the integrated control module will shut off the gas valve and lock out the system. 5. INDUCED DRAFT BLOWER FAILURE If pressure is not sensed by the pressure switch, the contacts will remain open and not allow the gas valve to open, therefore the unit will not start. If failure occurs during a running cycle, the pressure switch contacts will open and the gas valve will close to shut the unit down. 6. 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 thermostat. The system will not reset unless the procedure off -on -off -on is completed within 30 seconds. 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 detectors per the manufacturers installation instructions to help alert dwelling occupants of the presence of fire, smoke or unsafe levels of carbon monoxide. These devices 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. 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. 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. 18-CD32D1-9-EN 33 Installer's Guide ALERT CODE RECOVERY On power up, last 4 Alerts, if any, will be flashed on the Red Alert LED. The newest Alert detected will flash first and the oldest last. There will be a 2 second delay between Alert Code flashes. Solid Red LED error codes will not be displayed. The Green BM LED will be on solid when the control is pow- ered. The Green status LED indicator light will operate as shown in the table. The Red LED will only flash when a fault is present. NOTE: Use the flash code menu for detail of the alerts. Alert codes also are displayed on the User Interface menu using a descriptive text message and on the comfort control display using an alert code number. A com- plete list of the alert codes is included with the comfort control. Table 21 LED DESCRIPTION FUNCTION FAST FLASH - CALL GREEN STATUS LED FOR HEAT SLOW FLASH - NO CALL FOR HEAT NO. OF FLASHES RED ALERT LED - SEE DIAGNOSTIC CODES GREEN BITMASTER ON SOLID WHEN UNIT (BM) POWERED AMBER COM FLASHES DEVICE COUNT Line voltage o Neutral connections �� � n connections "Com" LED U } �J Motor bus (Amber) F70 connections o m EA fir-oEQ-- 0 r_�r_,r_, L Bitmaster (BM) --000r-, o r User interface 0 000 �- LED (Green) �J o �or, connection 0o Opr o m o o d c ua o b Status LED ,� oo 0 p (m Green) o moon o 24V furnace F-1© o 0 0 0 -� ° 00 0 0 0 0 00 Lp= component ` m�Q o0`'4 = Personality module connections OHO m o 0 o E o 00_ o = _ connection Ij 000 �OOO 0 o0 00 Low Voltage o 01) o Terminal board Fault LED m (Red) 5 Amp control 0 fuse BK Jumper 59 IFC BOARD 34 18-CD32D1-9-EN Installer's Guide TABLE 22- FURNACE ALERT CODES Alert Notification Alert Alert Group Alert Description Fault LED COM LED User Interface Display Control Display Code Flame is off when flame should be RECYCLE Flame lost or Ignition detected. Furnace tries to relight N/A 20 failure itself. RETRY Furnace tries to light, but no flame is 2 Flash Device count detected. RECYCLE LO 10 recycles within a single call for Soft lockout due to heat will cause 1 hr lockout. ERR 22 22 flame lost or ignition 3 ignition attempts in a row within a RETRY LO retries single call for heat results in 1 hr lockout. PS2 OPEN Open Pressure Switch, second stage PS2 CLOSED Shorted Pressure Switch, second Pressure Switch PS1 OPEN Open Pressure Switch, first stage 3 Flash Device count N/A 1 Failure PS1 CLOSED Shorted Pressure Switch, first stage Open Reverse Flow - Heat exchanger temperature too high. AUX LIMIT Could be caused by low airflow or fan High Temp Limit failure. ERR 26 46 Fault 4 Flash Device count Open High Limit - Heat exchanger HIGH LIMIT temperature too high. Could be caused by low airflow or fan failure. ROLLOUT OPEN ERR 87 87 Roll Out Fault Open flame rollout 5 Flash Device count FLAME ERROR ERR 34 34 Flame Detect Fault Flame detected, should not be resent POLARITY ERR N/A 33 Line Polarity Fault Voltage reverse polarity Occurs when proper earth ground is 6 Flash Device count GND FAULT N/A 88 Ground Fault not detected. IGNITER ERR ERR 10 10 Ignition Means Fault Igniter fault TRIAC ERR Triac fault Control senses 24V present at the 7 Flash EXT GV ERR as valve when it should not be Control tried to turn on gas valve, but Device count ERR 93 93 Gas Valve Fault 24V not sensed. Solid ON INT GV ERR Control senses 24V present at the gas valve when it should not be resent. Flame current is low, but still strong 8 Flash Device count LO FLAME SNS N/A 4 Low Flame Signal enough to allow operation. COMM system unrecognized SYS COMM CRC response IND COMM CRC Inducer Motor unrecognized Device count N/A 90 Communication Busy Fault response BLW COMM CRC Blower motor unrecognized response 10 Flash Device count BLW COMM ERR Blower motor no COMM response I IND COMM ERR ERR 91 91 Communication Fault Inducer motor no COMM response Fast Flash SYS COMM ERR Loss of heat/cool demand #REF! #REF! Communication Message has been Device count 24V COMM MSMTCH ERR 139 139 Communication detected while configured for 24V Failure Mode Solid ON Device count CNTRL FAULT ERR 18 18 Control Failure Internal control failure None Device count TWIN ERROR N/A 19 Twinning Fault Twinning Not Allowed with Variable Speed Data Section is Corrupt but PM is PM DATA ERR useable N/A Compressor size does not match CAP MISMATCH capacity in PM Blower HP/OEM does not match PM None Device count ID MTR ERR ERR 114 114 Bad or Missing PM Data PM MISSING No PM Primary Copy of Unit Data File is PM UNIT ERR N/A Corrupt. Primary and Secondary copies of Uni PM MEM ERROR ERR 114 Data File are Corrupt None Device count AC VOLTS LOW N/A 59 AC Line Fault Voltage too low AC VOLTS HI Voltage too high None Device count CHECK FUSE N/A 92 Fuse 24V Fuse Open Y1 OFF ERR Y1 Output OFF when it should be ON None Device count ERR 101 101 Y1 Relay Failure Y1 ON ERR Y1 Output ON when it should be OFF TS 1 SHORT Temperature sensor 1 shorted. None Device count TS 1 OPEN N/A 119 Temperature Sensor Temperature sensor 1 open. TS 2 SHORT Tem erature sensor 2 shorted. Failure TS 2 OPEN Tem erature sensor 2 open. Notes: Comfort Control will switch system to "OFF' until this fault condition clears D342960P02 PRINTED FROM: D802247P01 Rev10 18-CD32D1-9-EN 35 Installer's Guide Trane 6200Troup Highway Tyler, TX 75707 For more information contact your local dealer (distributor) This product may be covered by one or more of the following patents and their foreign equivalents: 5621888, 5901156, 6208263, 6353376, and 6448901. Other patents are pending. Made under license. Literature Order Number 18-CD32D1-9-EN File Number 18-CD32D1-9-EN Supersedes 18-CD32D1-8-EN Date 12/16 C us OTSTf Intertek The manufacturer has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.