installer’s guide info/furnace installers guides/t… · rides from paint, varnish, stains,...

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

IMPORTANT — This Document is customer property and is to remain with this unit.Please return to service information pack upon completion of work.

Installer’s Guide

*__First letter may be “A” or “T”

Upflow / Horizontal & Downflow / Horizontal,Gas-Fired, Direct Vent, 2-Stage CondensingFurnaces with Variable Speed Inducer

A341624P03

*UX060R936W*UX080R942W

*UX100R948W*UX120R960W

*DX060R936W*DX080R942W

*DX100R948W*DX120R960W

UPFLOW/HORIZONTAL DOWNFLOW/HORIZONTAL

*UX-R *DX-R

UPFLOW

DOWNFLOW

18-CD19D8-10

© 2004 American Standard Inc. All Rights Reserved 18-CD19D8-10

Installer’s GuideSAFETY SECTION

The following safety practices and precautions must befollowed during the installation, servicing, and operation ofthis furnace.

1. Use only with the type of gas approved for this furnace.Refer to the furnace rating plate.

2. Install this furnace only in a location and position asspecified in “Location and Clearances” (page 3), of theseinstructions.

3. Provide adequate combustion and ventilation air to thefurnace space as specified in “Air for Combustion andVentilation” (pages 7-8), of these instructions.

4. Combustion products must be discharged outdoors.Connect this furnace to an approved vent system only, asspecified in the “Venting” section (pages 13-22), of theseinstructions.

5. Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections, asspecified in “Gas Piping” (page 28), of these instructions.

6. Always install the furnace to operate within thefurnace’s intended temperature-rise range with a ductsystem which has an external static pressure within theallowable range, as specified on the unit rating plate.Airflow with temperature rise for cfm versus static isshown in the Service Facts accompanying this furnace.

7. When a furnace is installed so that supply ducts carryair circulated by the furnace to areas outside the spacecontaining the furnace, the return air shall also behandled by a duct(s) sealed to the furnace casing andterminating outside the space containing the furnace.

8. A gas-fired furnace for installation in a residentialgarage must be installed as specified in “Location andClearances” section (page 3), of these instructions.

9. The furnace may be used for temporary heating ofbuildings or structures under construction only when thefollowing conditions have been met:a. The furnace venting system must be complete and

installed per manufacturer’s instructions.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 requirement 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

substantial completion of the construction process,and verify furnace operating conditions includingignition, input rate, temperature rise and venting,according to the manufacturer’s instructions.

Safety signal words are used to designate a degree or levelof seriousness associated with a particular hazard. Thesignal words for safety markings are DANGER, WARNING,and CAUTION.

a. DANGER indicates an imminently hazardous situationwhich, if not avoided, will result in death or serious injury.This signal word is limited to the most extreme situations.

b. WARNING indicates a potentially hazardous situationwhich, if not avoided, could result in death or serious injury.

c. CAUTION indicates a potentially hazardous situationwhich, if not avoided, may result in minor or moderateinjury. It is also used to alert against unsafe practicesand hazards involving only property damage.

▲ WARNING!FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result inserious injury, death or property damage.

Improper servicing could result in dangerous operation,serious injury, death, or property damage.

▲ CAUTION!To prevent shortening its service life, the furnace shouldnot be used as a “Construction Heater” during the finishingphases of construction until the requirements listed in item9, a-g of the safety section of this publication have beenmet. Condensate in the presence of chlorides and fluo-rides from paint, varnish, stains, adhesives, cleaningcompounds, and cement create a corrosive conditionwhich may cause rapid deterioration of the heat exchanger.

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.

▲ WARNING!

18-CD19D8-10 3

Installer’s Guide

Installation Instructions 3General 3Location and Clearances 3Outline Drawings 4-5Upflow Installation 6Downflow Installations 6Air For Combustion and Ventilation 7Duct Connections 8Return Air Filters 9General Venting 13Venting Materials 14Vent Tables 16Horizontal Venting Through Wall 17Venting Through the Roof 19Venting Routed Through a Masonry Chimney 20Downward Venting 22Condensate Drain Instructions 23Field Wiring Diagrams 25-28Electrical Connections 28Gas Piping 28Combustion and Input Check 30High Altitude Derate 31

Start-up and Adjustment 32Preliminary Inspections 32Lighting Instructions 32Sequence of Operation 33Control and Safety Switch Adjustments 33

Abnormal Conditions 34

IFC Error Flash Codes 35Fault Code Recovery 35

ContentsGENERALThe manufacturer assumes no responsibility for equipmentinstalled in violation of any code or regulation.

It is recommended that Manual J of the Air ConditioningContractors Association (ACCA) or A.R.I. 230 be followed inestimating heating requirements. When estimating heatingrequirements for installation at Altitudes above 2000 ft.,remember the gas input must be reduced (See GAS INPUTADJUSTMENT).

Material in this shipment has been inspected at thefactory and released to the transportation agencywithout known damage. Inspect exterior of carton forevidence of rough handling in shipment. Unpackcarefully after moving equipment to approximatelocation. If damage to contents is found, report thedamage immediately to the delivering agency.

Codes and local utility requirements governing the installa-tion of gas fired equipment, wiring, plumbing, and flueconnections must be adhered to. In the absence of localcodes, the installation must conform with latest edition of theNational Fuel Gas Code ANSI Z223.1 • National InstallationCode, CAN/CGA B149.1. The latest code may be obtainedfrom the American Gas Association Laboratories,8501 E. Pleasant Valley Rd., Cleveland, Ohio 44131.

These furnaces have been classified as CATEGORY IVfurnaces in accordance with latest edition of ANSI Z21.47standards • CAN/CGA 2.3. Category IV furnaces operatewith positive vent static pressure and with a flue loss lessthan 17 percent. These conditions require special ventingsystems, which must be gas tight and water tight. TheseCategory IV Direct Vent furnaces are approved for installa-tion in Manufactured/Mobile housing when used withBAYMFGH001A.

LOCATION AND CLEARANCESThe location of the furnace is normally selected by thearchitect, the builder, or the installer. However, before thefurnace is moved into place, be sure to consider the followingrequirements:

1. Is the location selected as near the chimney or vent andas centralized for heat distribution as practical?

2. Do all clearances between the furnace and enclosureequal or exceed the minimums stated in Clearance Tableon the Outline Drawings.

3. Is there sufficient space for servicing the furnace andother equipment? A minimum of 24 inches front accessi-bility to the furnace must be provided. Any access dooror panel must permit removal of the largest component.

4. Are there at least 3 inches of clearance between thefurnace combustion air openings in the front panel andany closed panel or door provided?

5. Are the ventilation and combustion air openings largeenough and will they remain unobstructed? If outsideair is used, are the openings set above the highest snowaccumulation level? (See the Air for Combustion andVentilation section.)

6. Allow sufficient height in supply plenum above thefurnace to provide for cooling coil installation, if thecooling coil is not installed at the time of this furnaceinstallation.

7. A furnace shall be installed so electrical components areprotected from water.

8. If the furnace is installed in a residential garage, itmust be installed so that the burners, and the ignition

source are located not less than 18 inches above the floorand the furnace must be located or protected to avoidphysical damage from vehicles.

IMPORTANT:The furnace must be installed level. The only allowable variationwould be slightly to the left and/or forward in upflow installationsor slightly toward the front in horizontal installations. This isnecessary for proper condensate drainage.

▲ CAUTION!Do not install the furnace in a corrosive or contaminatedatmosphere. Failure to follow this warning could result inearly equipment failure.

▲ WARNING!Do not install the furnace directly on carpeting, tile or othercombustible material other than wood flooring. For verticaldownflow application, subbase (BAYBASE205) must beused between the furnace and combustible flooring. Whenthe downflow furnace is installed vertically with a casedcoil, a subbase is not required.

418-C

D19D

8-10

Insta

ller’s G

uid

e

From Dwg. 21C341884 Rev. 1

*UX-R-W UPFLOW / HORIZONTAL OUTLINE DRAWING(ALL DIMENSIONS ARE IN INCHES)

18-CD

19D8-10

5

Insta

ller’s G

uid

e

From Dwg. 21C341885 Rev. 0

*DX-R-W DOWNFLOW / HORIZONTAL OUTLINE DRAWING(ALL DIMENSIONS ARE IN INCHES)

6 18-CD19D8-10

Installer’s Guide

DOWNFLOW INSTALLATIONS

UPFLOWFURNACE

CASEDCOIL

SCREWS(BOTH SIDES)

STANDOFFS(BOTH SIDES)

STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

▲ WARNING!Do not install the furnace directly on carpeting, tile or othercombustible material other than wood flooring. Forvertical downflow application, subbase (BAYBASE205)must be used between the furnace and combustibleflooring. When the downflow furnace is installed verticallywith a cased coil, a subbase is not required.

UPFLOW INSTALLATIONStandoffs and screws (See Figure 1) are included with thecased coils for attachment to the furnace. There are clear-ance alignment holes near the bottom of the coil wrapper.Drill screws are used to engage the furnace top flanges. Thestandoff is inserted into the cabinet alignment hole. The drillscrews are inserted through the standoffs then screwed intothe furnace flange. The coil is always placed downstream ofthe furnace airflow.

5

TABLE 1

CABINETWIDTH

RETURNDUCT WIDTH

FLOOR OPENING PLENUM OPENING

"A" "B" "C" "D"14-1/2" 13-1/4" 13-5/8" 20-1/8" 12-5/8" 19-3/8"

17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"

21" 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8"

24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8"

HORIZONTAL INSTALLATIONThe coil and furnace must be fully supported when used inthe horizontal position. It is always recommended that anauxiliary drain pan be installed under a horizontally in-stalled evaporator coil or 90% gas furnace. Connect theauxiliary drain line to a separate drain line (no trap isneeded in this line).

Three brackets (with screws) are included with downflowfurnaces for installation to stabilize and secure the furnaceand TXC cased coil in the horizontal position. See Fig-ure 4. The coil is placed downstream of the furnace, with theapex of the coil pointing in the direction of the airflow forhorizontal installation. The cased coil is secured to thefurnace and both the furnace and the cased coil must beproperly supported. The brackets mount using the rearscrews on the coil case and use the screws provided to securethe bracket to the furnace. The remaining bracket is placedas close to center as possible (horizontally) between the coilcase front and the furnace bottom channel (for downflow/horizontal furnace). Use four of the screws provided tosecure the bracket. The upflow furnace, converted to horizon-

2

Required floor opening: (DOWNFLOW)See Figure 3 and Table 1

1

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FURNACEFRONT

A (width)B (depth)

CD

3

UPFLOW/HORIZONTALSHOWN WITHDIRECT VENT

tal, aligns and attaches the TXC coil as in Figure 1. However,the coil requires additional support.

The furnace may be installed in an attic or crawl space in thehorizontal position by placing the furnace on the left side (asviewed from the front in the vertical position). The horizon-tal furnace installation in an attic should be on a serviceplatform large enough to allow for proper clearances on allsides and service access to the front of the furnace (SeeFigure 5 & Clearance Tables, pages 4-5). Line contact is onlypermissible between lines formed by intersections of the topand two sides of the furnace casing and building joists, studs,or framing.

The furnace may be placed horizontally in a crawl space on apad or other noncombustible material which will raise theunit for sufficient protection from moisture. The furnace

DOWNFLOW ONLY

4 CASED COIL CONNECTIONBRACKET FOR DOWNFLOWFURNACE IN HORIZONTAL

18-CD19D8-10 7

Installer’s Guide

must be supported at both ends and the middle wheninstalled horizontally. The furnace must also beelevated approximately 4-6 inches to allow clearancefor the condensate drain to exit the cabinet in thehorizontal position.

The horizontal furnace may also be suspended from the joistsusing 3/8" all-thread rods with pieces of angle iron under-neath the furnace to form a hanging rack at both ends andthe midpoint. The rods need to be of sufficient length toallow for proper clearances from combustible materials. Theangle iron needs to be at least 32" in length to allow foraccess to service panels.

AIR FOR COMBUSTION AND VENTILATIONIf these furnaces are installed in a nondirect vent capacitythen the adequate flow of combustion and ventilating airmust not be obstructed from reaching the furnace. Airopenings provided for combustion air must be kept free ofobstructions which restrict the flow of air. Airflow restric-tions affect the efficiency and safe operation of the furnace.Keep this in mind should you choose to remodel or changethe area which contains your furnace. Furnaces must have afree flow of air for proper performance.

Provisions for combustion and ventilation air shall be madein accordance with latest edition of Section 5.3, Air forCombustion and Ventilation, of the National Fuel Gas Code,ANSI Z223.1 — CAN/CGA B149.1 or applicable provisions ofthe local building codes. Special conditions created bymechanical exhausting of air and fireplaces must be con-sidered to avoid unsatisfactory furnace operation.

OUTSIDE AIR IS RECOMMENDEDThe use of indoor air for most applications is acceptable,unless there is the presence of corrosive chemicals orcontamination. Certain types of installation will requirethe use of outside air for combustion.

The following types of installations will require use ofOUTDOOR AIR for combustion, due to chemical exposures:

* Commercial buildings* Buildings with indoor pools* Furnaces installed in “confined” laundry rooms* Furnaces installed in “confined” hobby or craft rooms* Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion airsupply will also require OUTDOOR AIR for combustion:

* Permanent wave solutions* Chlorinated waxes and cleaners* Chlorine based swimming pool chemicals* Water softening chemicals* Deicing salts or chemicals* Carbon Tetrachloride* Halogen type refrigerants* Cleaning solvents (such as perchloroethylene)* Printing inks, paint removers, varnish, etc.* Hydrochloric acid* Cements and glues* Antistatic fabric softeners for clothes dryers* Masonry acid washing materials

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

Unconfined space is defined in Figure 6. These spaces mayhave adequate air by infiltration to provide air for combus-tion and ventilation. Buildings with tight construction (forexample, weather stripping, heavily insulated, caulked, vaporbarrier, etc.), may need additional air to be provided asdescribed for confined space.

Confined spaces are installations with less than 50 cu. ft. ofspace per 1000 BTU/hr input from all equipment installed.Air for combustion and ventilation requirements can besupplied from inside the building as in Figure 9 or from theoutdoors, as in Figure 10.

MINIMUM AREA IN SQUARE FEET FOR UNCONFINED SPACE INSTALLATIONS

FURNACEMAXIMUM BTUHINPUT RATING

WITH 8 FT. CEILINGMINIMUM AREA IN SQUARE FEET

OF UNCONFINED SPACE

60,00080,000100,000120,000

375500625875

50 CU. FT. OR MORE

UNCONFINED

1. All air from inside the building as in Figure 9: Theconfined space shall be provided with two permanentopenings communicating directly with an additionalroom(s) of sufficient volume so that the combined volumeof all spaces meets the criteria for an unconfined space.The total input of all gas utilization equipment installedin the combined space shall be considered in making thisdetermination. Refer to Table 2 for minimum open areasrequirements.

2. All air from outdoors as in Figure 10: The confined spaceshall be provided with two permanent openings, onecommencing within 12 inches of the top and one com-mencing within 12 inches of the bottom of the enclosure.The openings shall communicate directly, or by ducts,with the outdoors or spaces (crawl or attic) that freelycommunicate with the outdoors. Refer to Table 2, forminimum open areas requirements.

TABLE 2MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING (FURNACE ONLY)

FurnaceMaximum

BTUH/INPUTRating

AirFromInside

Air From Outside

Vertical Duct

Horizontal Duct

60,00080,000100,000120,000

100100100120

15202530

30405060

6

7

CONFINEDSPACE

8

8 18-CD19D8-10

Installer’s Guide

0

9DUCT CONNECTIONSAir duct systems should be installed in accordance withstandards for air conditioning systems, National Fire Protec-tion Association Pamphlet No. 90. They should be sized inaccordance with ACCA Manual D or whichever is applicable.

Central furnaces, when used in connection with cooling units,shall be installed in parallel or on the upstream side of thecooling coil to avoid condensation in the heat exchanger. Witha parallel flow arrangement, the dampers or other means usedto control flow of air shall be adequate to prevent chilled airfrom entering the furnace, and if manually operated, must beequipped with means to prevent operation of either unitunless the damper is in full heat or cool position.

On any job, flexible connections of nonflammable material maybe used for return air and discharge connections to preventtransmission of vibration. Though these units have beenspecifically designed for quiet, vibration free operation, air ductscan act as sounding boards and could, if poorly installed,amplify the slightest vibration to the annoyance level.

When the furnace is located in a utility room adjacent to theliving area, the system should be carefully designed withreturns to minimize noise transmission through the returnair grille. Although these furnaces are designed with largeblowers operating at moderate speeds, any blower moving ahigh volume of air will produce audible noise which could beobjectionable when the unit is located very close to a livingarea. It is often advisable to route the return air ducts underthe floor or through the attic. Such design permits theinstallation of air return remote from the living area (i.e.central hall).

When the furnace is installed so that the supply ducts carryair circulated by the furnace to areas outside the spacecontaining the furnace, the return air shall also be handledby a duct(s) sealed to the furnace and terminating outsidethe space containing the furnace.

RETURN AIR DUCT SYSTEMSWhere there is no complete return duct system, thereturn connection must be run full size from thefurnace to a location outside the utility room, base-ment, attic, or crawl space.Do Not install return air through the back of the furnacecabinet.

Do Not install return air through the side of the furnacecabinet on horizontal applications.

NOTE:Minimum return air temperature is 50° F.

All return air duct systems should provide for installation ofreturn air filters.

1. Set the furnace in place.2. For upflow side return installations, remove the insula-

tion around the opening in the blower compartment.

3. The side panels of the upflow furnace include locatingnotches that are used as guides for cutting an openingfor return air, refer to Figure 11 and the outlinedrawing on page 4 for duct connection dimensions forvarious furnaces.

NOTE:On upflow 5 ton airflow models, if the airflow requirementexceeds 1800 CFM, these models will require return airopenings and filters on both sides; OR 1 side and thebottom; OR just the bottom.

18-CD19D8-10 9

Installer’s Guide

Blower Door Hinge and Bottom Filter Rack Installation

Airflow

w

4. 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 11.Cut corners diagonally and bend outward to form flange.

5. If flanges are not required, and a filter frame is installed,cut between locating notches (Figure 11).

6. The bottom panel of the upflow furnace must be re-moved for bottom return air. Remove the filter and laythe furnace on its back. Remove the two 1/4" hex screwssecuring the bottom front channel to the cabinet. Lowerthe front edge of the bottom front channel and pullforward to remove the channel. The bottom return airpanel will now easily slide out of the cabinet. Reinstallthe bottom front channel and filter for upflow bottomreturn installations.

7. The filter retainer is factory supplied for upflow bottomreturn. Use the filter retainer on side or bottom if filteris to be used within the furnace cabinet on upflow onlyinstallations.

8. The horizontal installation of the upflow furnacerequires an external filter section. Do NOT use thebottom return filter within the furnace. Filter kitsare available for horizontal applications.

9. Connect duct work to furnace. See Outline Drawing forsupply and return duct size and location. Flexible ductconnectors are recommended to connect both supply andreturn air ducts to the furnace. If only the front of thefurnace is accessible, it is recommended that both supplyand return air plenums are removable.

RETURN AIR FILTERSTYPICAL UPFLOW RETURN AIR FILTERINSTALLATIONSFilters are factory supplied for these furnaces. These fur-naces require high velocity type air filters. The filters may belocated within the furnace blower compartment for UPFLOWfurnaces in either a BOTTOM or SIDE (left side or right side)return air inlet. Some filters may need to be trimmed forside or bottom filter use.

TABLE 3

MODELSNUMBERS

CABINET WIDTH

FILTERQTY & SIZE

*UX060R936*UX080R942

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

*UX100R948 21" 1 - 20" X 25" X 1"*UX120R960 24-1/2" 1 - 24" X 25" X 1"

* First letter may be "A" or "T"** NOTE - On 5 ton airflow models, if the airflow requirementexceeds 1800 CFM, these models will require return air openingsand filters on both sides; OR 1 side and the bottom; OR just thebottom.

Filter Rack Assembly

e

UPFLOW FURNACE ONLY

*SEE OUTLINE DRAWING

FRONTof Furnace

LOCATINGNOTCHES PRO-VIDED FOR SIDERETURN CUTOUT

q

CUT OUT FORSIDE FILTER

NOTE:On upflow 5 ton airflow models, if the airflow requirementexceeds 1800 CFM, these models will require return airopenings and filters on both sides; OR 1 side and thebottom; OR just the bottom.

The upflow furnace blower door has a hinge at the bottomwhich allows the door to tilt forward for filter replacementwithout the door being removed (See Figure 12). The furnacefilter in the bottom or side configuration can be removed bysimply turning the two latches on the blower door and tiltingthe door forward.

The filter rails are spring loaded for automatic adjustment toallow standard size, locally obtainable replacement filters.The filter rack itself slides to adjust to the required widthneeded for bottom or side return (See Figure 13).

BOTTOM FILTER RACK INSTALLATIONWith the filter removed, the filter rack is compressed andthen inserted into the bottom of the furnace. The retainingscrew/pin on each side inserts into engagement holes at thebottom of the furnace cabinet side.

10 18-CD19D8-10

Installer’s Guide

VIEWENGAGEMENTHOLE DETAIL

(Typical both sidesand blower deck)

Blower DeckEngagement

Hole

FilterRackFurnace

CabinetSide

Filter RackRetainingScrew/Pin

Engagement Hole For

Bottom Return

Filter RackInstallation With

r

t

FilterRackAssembly

FurnaceBlowerDeck


Engagement Hole For

Return

Filter RackInstallation WithSide

FurnaceCabinet

Side

BLOWERu

BOTTOM ENGAGEMENT

Bottom Panel

FilterRack

FurnaceCabinet

Side


Engagement Hole For

Bottom Return

Filter RackInstallation With

y

Typical Upflow Left Side Return Filter Rack Installation

RETAININGPIN

(Both Sides)

SPRINGS

SIDECUTOUT

FILTERRACKRAILS

BOTTOMPANEL

INSTALLED

AirfloAirflow

i

FILTER RACK INSTALLATION FOR SIDE RETURN AIR ONUPFLOW FURNACES (Left or Right)If side air return is desired, it is necessary to move the filterrack from the bottom of the furnace and reinstall it on theside. The following instructions should be used:

a. Open or remove the blower door.

b. Remove the filter.

c. Compress the filter rack to disengage the retainingpins/screws from the furnace sides and slide the filterrack out.

d. Leave the bottom panel in place.

e. After the side cutout is made following the directionsin the “Return Air Duct Connections” section onpages 8 and 9, compress the filter rack and reinstallin the side of the furnace. Confirm that the upperretaining pin/screw locks into the engagement hole inthe blower deck and the lower pin/screw rests againstthe side of the bottom panel. See Figures 15-19.

f. Reinstall the furnace filter on the side inserting thechamfer end first.

18-CD19D8-10 11

Installer’s Guide

TYPICAL RETURN AIR FILTER INSTALLATION INUPFLOW MODEL IN HORIZONTAL POSITION

REAR

SIDE

CUT-O

UT

ALTERNATE FILTERCLIPS LOCATION

Airflow

a

Typical Upflow Right Side Return Filter Rack Installation

Air

flo

w

o

dRETURN AIR FILTERS FOR UPFLOW FURNACE INHORIZONTAL CONFIGURATIONWhen the Upflow Furnace is installed in the horizontalconfiguration, the return air filters must be installed exteriorto the cabinet. Remote filter grilles may be used for home-owner convenience or the filters may be installed in the ductwork upstream of the furnace. See Figure 21.

BLOWER DOOR/HINGE REMOVALIf clearance or other problems create a problem in using thetilting door, the blower door hinge may be removed withoutcreating any problems with the seal of the furnace. To removethe blower door, tilt the door forward 2 to 3 inches and pull up.To remove the tilt feature, simply remove the lower hinge asshown in Figure 22. The bottom of the blower door will catchin the bottom of the furnace front channel for door replacement.

ALTERNATE UPFLOW FILTER CLIP / BRACKETINSTALLATION

1. Determine the location to be used. The furnace cabinethas dimples for location of the alternate furnace clips(Side return only). Pre-drill clearance holes with a 3/16"drill. Bottom return holes are pre-drilled.

2. Install the clips in front and rear of the desired locationusing the screws provided. The filter clip with the leafspring mounts in the rear of the cabinet.

CHAMFEREND OF

FILTER GOESINTO FILTER RACK FIRST

p

Airflow

Airf low

Door Hinge Removed

s

12 18-CD19D8-10

Installer’s GuideINSTALLING THE FILTERThe filter may need to be cut to fit the unit depending on thelocation of the return air filter.

A score line and the words “CUT HERE” are located on theend of the filter. If your application requires cutting thefilter, do so as indicted by the score mark.

UNITSIZE

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 FILTERINSTALLATIONSTwo filters are factory supplied for each downflow furnace.These furnaces require high velocity type air filters. Down-flow furnace filters must be located outside the furnacecabinet. Typical installations are shown in Figure 24.Tables 5 and 6 provide information for installation of thefilter retaining brackets shipped with downflow furnaces.

Airflow

DOWNFLOW/HORIZONTAL

DOWNFLOW

Airflow

f

TABLE 4

MODELSNUMBERS

CABINET WIDTH

FILTERQTY & SIZE

*DX060R936*DX080R942

17-1/2" 2 - 14" X 20" X 1"

*DX100R948 21" 2 - 16" X 20" X 1"*DX120R960 24-1/2" 2 - 16" X 20" X 1"

*First letter may be "A" or "T"

TABLE 5LOCATING FILTER RETAINER BRACKETS IN DUCTWORK

CABINETWIDTH

RETURNDUCTWIDTH

DIMENSION"A"

DIMENSION"B"

FILTERBRACKET

LOCATION*17-1/2" 16-1/4" 15" 14" 14-3/8"

21" 19-3/4" 19-1/2" 14" 13-1/8"

24-1/2" 23-1/4" 22" 14" 13-5/8" * LOCATION DIMENSION IS FROM END OF DUCT AGAINST THE FURNACE TO THE SCREW HOLES FOR THE BRACKET.

TABLE 6

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FORUPFLOW/HORIZONTAL AND DOWNFLOW/ HORIZONTAL FURNACES

UNIT LOCATION

FURNACE SURFACE VERTICALCLOSETHORIZONTAL

CLOSETHORIZONTAL

ALCOVE / ATTICSIDES 0" 1" 0"BACK 0" 3" 6"TOP 1" 1" 1"

FRONT 3" 3" 18"VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

OptionalBAYFLTR206

Door Kit

OptionalBAYFLTR206

Door Kit

18-CD19D8-10 13

Installer’s Guide

Carbon monoxide, fire or smoke can cause serious bodilyinjury, death, and/or property damage.

A variety of potential sources of carbon monoxide can befound in a building or dwelling such as gas-fired clothesdryers, gas cooking stoves, water heaters, furnaces andfireplaces. The U.S. Consumer Product Safety Commissionrecommends that users of gas-burning appliances installcarbon monoxide detectors as well as fire and smoke detec-tors per the manufacturer’s installation instructions to helpalert dwelling occupants of the presence of fire, smoke orunsafe levels of carbon monoxide. These devices should belisted by Underwriters Laboratories, Inc. Standards forSingle and Multiple Station Carbon Monoxide Alarms,UL 2034 or CSA International Standard, ResidentialCarbon 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 ortype of detector.

GENERAL VENTINGTHIS FURNACE MUST BE VENTED TO THE OUTDOORS.

THESE FURNACES ARE INDUCED DRAFT VENTEDAND MUST NOT BE CONNECTED TO ANY VENT SERV-ING ANOTHER APPLIANCE. PLEASE NOTE THATTHESE FURNACES USE POSITIVE-PRESSURE VENTSYSTEMS.

Proper venting is essential to obtain maximum efficiencyfrom a condensing furnace. Proper installation of the ventsystem is necessary to assure drainage of the condensateand prevent deterioration of the vent system.

American Gas Association has certified the design of con-densing furnaces for a minimum of 0" clearance from com-bustible materials with a single wall plastic vent pipe.

The recommended system is assembled from 2", 2-1/2", or 3"plastic pipe and fittings (See Table 7, page 15). Where thesystem is routed to the outdoors through an existing masonrychimney containing flue products from another gas appliance,or where required by local codes, then 3" venting of Type 29-4Cstainless steel must be used in place of PVC material.

These furnaces have been classified as CATEGORY IVfurnaces in accordance with ANSI Z21.47 “latest edition”standards. Category IV furnaces operate with positive ventpressure and with a vent gas temperature less than 140° F.above the dewpoint. These conditions require special ventingsystems, which must be gas tight and water tight.

NOTE:When an existing furnace is removed from a ventingsystem serving other gas appliances, the venting system islikely to be too large to properly vent the remainingattached appliances.

The following steps shall be followed with each applianceremaining connected to the common venting system placedin operation, while the other appliances remaining connectedto the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size andhorizontal pitch and determine there is no blockage orrestriction, leakage, corrosion or other deficiencies whichcould cause an unsafe condition.

3. Insofar as is practical, close all building doors andwindows and all doors between the space in which theappliances remaining connected to the common ventingsystem are located and other spaces of the building. Turnon clothes dryers and any appliances not connected tothe common venting system. Turn on any exhaust fans,such as range hoods and bathroom exhausts, so they willoperate at maximum speed. Do not operate a summerexhaust fan, close fireplace dampers.

4. Follow the lighting instructions. Place the appliancebeing inspected in operation. Adjust thermostat soappliance will operate continuously.

5. After it has been determined that each appliance remain-ing connected to the common venting system properlyvents when tested as outlined above, return door, win-dows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.

If improper venting is observed during any of the above tests,the remaining common venting system must be corrected.Correction could require rerouting or resizing the remainingvent system.

IMPORTANT:These furnaces may be installed as Direct Vent (sealed com-bustion) or as Nondirect vent (single pipe). The furnaces areshipped DIRECT VENT with sealed combustion.

For DIRECT VENT APPLICATION: The furnaces must bevented to the exterior of the house and combustion air MUSTcome through the inlet air pipe FROM OUTSIDE AIR. The pipesDO NOT have to exit the exterior of the house together or on thesame side of the house.

For NONDIRECT VENT APPLICATION: The furnace shall bevented to the exterior of the house, but combustion air mayenter from the surrounding area as long as combustion airrequirements are met. (See AIR FOR COMBUSTION ANDVENTILATION)

FURNACE VENT/INLET PIPE INSTALLATIONThere are many different variations of the vent/inlet air pipecombination. The vent/inlet air combination used for instal-lation of these furnaces depends on the needs of the location.However, these guidelines must be followed:

1. The furnace must vent outside the structure.

2. Furnace combustion air requirements must be met fornondirect, single pipe applications (See example onnext page).

3. For direct vent application of these furnaces, the ventpipe and air inlet pipe do not have to exit in the same airspace or even on the same surface of the structure.However, the longest individual pipe will decide the valuefor the longest allowable equivalent vent/inlet air lengthas shown in the vent length table.

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.

▲ WARNING!

14 18-CD19D8-10

Installer’s Guide

Furnace

AirInlet

Vent

Furnace

Vent

AirInlet

(See Note)

NOTE:BAYVENT200* accessories can be used for inlet and outletterminals when the pipes do not exit the structure together.

The following are EXAMPLES ONLY:

EX. 2 —

Example 2 shows the vent pipe exhausting through the roofand the inlet air coming from the interior of the house (SeeNote). The inlet air coming from the interior of the housemust meet combustion requirements for area, etc., as shownin the section AIR FOR COMBUSTION AND VENTILA-TION in this Installer’s Guide.

EX. 3 —

Example 3 shows the vent exiting one side of the house whilethe inlet air is on the opposite side of the structure. Here thevent pipe length must be within the allowable length for thesize of furnace and size of the vent pipe. This exampledemonstrates that the pipes do not have to exit on the sameside of the structure.

EX. 4 —

The inlet air does not have to come from outside the struc-ture. Example 4 shows the inlet air (See Note), may comefrom the attic if the requirements for combustion air are metas shown in the section AIR FOR COMBUSTION ANDVENTILATION.

NOTE:If only the flue gas pipe is to the outside of the structure, astraight section of pipe (long enough to exit the furnacecabinet) must be attached to the inlet air side with an elbow(which is 5 to 10 equiv. ft.) installed on the end to preventdust and debris from falling directly into the furnace.

VENT FITTING MATERIAL – PLASTICGas and liquid tight single wall vent fittings, designed forresistance to corrosive flue condensate, MUST be usedthroughout.

Listed in Table 7 are 2", 2-1/2", and 3" size fittings that meetthese requirements. The materials listed are various gradesof PVC and ABS plastic.

PIPE JOINTS: All joints must be fastened and sealed toprevent escape of combustion products into the building.

NOTE:It is recommended that the first joints from the furnace beconnected and sealed with high temperature RTV. This willenable the pipes to be removed later without cutting.

Be sure to properly support these joints.

BONDING OF PVCCommercially available solvent cement for PVC must beused to join PVC pipe fittings. Follow instructions on con-tainer carefully.

Pipe and Fitting – ASTM D1785, D2466, D2661, & D2665

PVC Primer and Solvent Cement – ASTM D2564

Procedure for Cementing Joints – Ref ASTM D28551. Cut pipe square, remove ragged edges and burrs.

Chamfer end of pipe, then clean fitting socket and pipejoint area of all dirt, grease, moisture or chips.

2. After checking pipe and socket for proper fit, wipe socketand pipe with cleaner-primer. Apply a liberal coat ofprimer to inside surface of socket and outside of pipe.DO NOT ALLOW PRIMER TO DRY BEFORE APPLY-ING CEMENT.

3. Apply a thin coat of cement evenly in the socket. Quicklyapply a heavy coat of cement to the pipe end and insertpipe into fitting with a slight twisting movement until itbottoms out.

Furnace

AirInlet

VentAtticVent

(See Note)

Furnace

AirInlet

Vent

EX. 1 —

Example 1 shows that the vent may go vertical while theinlet air may be on any side of the structure. The vent pipewould decide the maximum equivalent length for the pipedepending on the furnace and pipe size.

18-CD19D8-10 15

Installer’s Guide4. Hold the pipe in the fitting for 30 seconds to prevent

tapered socket from pushing the pipe out of the fitting.5. Wipe all excess cement from the joint with a rag. Allow

15 minutes before handling. Cure time varies accordingto fit, temperature and humidity.

PVC VENT FITTING MATERIAL These fittings are available from your Gas Furnace Distributors.

TABLE 7

PLASTIC PIPE DESIGNATIONSPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

F891 CELLULAR CORE *158 ASTM F891

D2665 DWV PIPE **158 ASTM D2665

D1785 SCH 40, 80, 120 **158 ASTM D1785

D2241 SDR SERIES **158 ASTM D2241

CPVCASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41 **212 ASTM D2846

F441 SCH 40, 80 **212 ASTM F441

F442 SDR SERIES **212 ASTM F442

ABSASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV ***180 ASTM D2661

F628 SCH 40 DWV CELLULAR CORE ***180 ASTM F628

* - Allowable temperatures based on classifications covered in ASTM D4396 [Deflection Temps Under Load (264 PSI)] ** - Allowable temperatures based on classifications covered in ASTM D1784 [Deflection Temps Under Load (264 PSI)] *** - Allowable temperatures based on classifications covered in ASTM D3965 [Deflection Temps Under Load (264 PSI)]

NOTE:Follow venting instructions carefully when using PVCcement.

IMPORTANT:All joints must be water tight. Flue condensate is somewhatacidic, and leaks can cause equipment damage.

Connection of the pipe and collar of the combustion air inletshould just be a friction fit. It is recommended that the inletair joint be sealed with RTV type sealant to allow the joint tobe separated for possible future service. The inlet and ventpipes must be properly supported throughout the entirelength.

Connection of the vent pipe to the vent collar should also beaccomplished using RTV type sealant. This type sealantprovides a connection which remains flexible and can beseparated in the future if service needs require the removalof the vent pipe for service or clearance.

NOTE:Vent termination kit BAYVENT100A or BAYVENT200A/Bmay be used in addition to the horizontal and verticaltermination options shown in the following figures.

Seal VENT PIPEwith RTV sealant

Seal INLET AIR PIPEwith RTV sealant

Front of Furnace

VENT AND INLET AIR CONNECTIONSg

16 18-CD19D8-10

Installer’s GuideVENT LENGTH TABLE

ALTITUDEMAXIMUM TOTAL EQUIVALENT LENGTH IN FEET

FOR VENT AND INLET AIR (SEE NOTES)

0-7,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 INCH PIPE

UX/DX060R936 200 200 200

UX/DX080R942 50 120 200

UX/DX100R948 Not Allowed 60 200

UX/DX120R960 Not Allowed Not Allowed 200

7,000-9,500 Feet 2 INCH PIPE 2.5 INCH PIPE 3 INCH PIPE

UX/DX060R936 100 100 100

UX/DX080R942 25 60 100



9,500-12,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 INCH PIPE

UX/DX060R936 50 50 50




NOTES: * - First letter may be "A" or "T"1. Minimum vent length for all models: 3' horizontal or 3' vertical.2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adaptersat the top of the furnace). If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limitshown in the table above (See note 6 below for exception). The inlet pipe can be of a larger diameter, but never smaller thanthe vent pipe.3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS THEMAXIMUM LENGTH OF EACH (Vent or Inlet air pipes).4. One SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is equivalent to 6' of 3" pipe. One90° elbow is equivalent to 7½' of 2½" pipe or 5' of 2" pipe. Two 45° elbows equal one 90°elbow.5. The termination tee or bend must be included in the total number of elbows. If the BAYVENT100A termination kit is used, theequivalent length of pipe is 5 feet. BAYVENT200A/B equivalent length is 0 feet.6. Pipe adapters are field supplied (except 120).

VENT TABLES

HORIZONTAL INSTALLATION(Upflow / Horizontal or Downflow / Horizontal)

NOTE:When the factory supplied 2X3" offset reducing coupling isused for 3" vent pipe installation, make sure the marking“TOP” is located on the top side of the pipe.

The straight side of the coupling must be on bottom forproper drainage of condensate. See Figure 26.

h

18-CD19D8-10 17

Installer’s Guide

VENT

1" MAX.

ELBOW(FIELDSUPPLIED)

STRAP(FIELD SUPPLIED)

VENT

COMBUSTION AIR

RAINCAP

COMBUSTIONAIR

3" PIPING3" PIPING

2", 2-1/2"2", 2-1/2"or 3" PIPINGor 3" PIPING

REDUCING REDUCING COUPLING,COUPLING,FIELD SUPPLIEDFIELD SUPPLIEDIF NEEDEDIF NEEDED

SEAL ALLSEAL ALLWALL CAVITIESWALL CAVITIES

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

j

ELBOW AND TEE MUST BEAS CLOSE TOGETHERAS POSSIBLE

NOTE: VENT AND INLET MUST BE SUPPORTEDAT A MAXIMUM OF 3' INTERVALS

BAYVENT100A

TEE

BAYVENT200A/B

k

40" UPFLOW ORDOWNFLOW MODELS

SEE VENTING TABLE

OUTSIDEWALL

NOTE: ANY FITTINGS PASSINGTHROUGH AN UNHEATED SPACEMUST BE INSULATED.

FIRST SUPPORT SHOULD BE ASCLOSE TO FURNACE CONNECTIONAS POSSIBLE.

UPWARD PITCH -- 1/4" PER FOOT

STRAPS OR OTHER SUITABLE SUPPORTSAT MAXIMUM OF 3'-0" INTERVALS

COMBUSTIONAIR INLET

USE ONLYAPPROVED

TERMINATION

HORIZONTAL VENTING THROUGH WALL

18 18-CD19D8-10

Installer’s Guide

VENT

1" MAX.

ELBOW(FIELDSUPPLIED)

STRAP(FIELD SUPPLIED)

VENT

COMBUSTION AIR

RAINCAP

COMBUSTIONAIR

BAYVENT100A(Sidewall)

;

VENT

COMBUSTIONAIR

VENT

VENTPLATE

VENTCAP

12" MINIMUMTO OVERHANG

MAINTAIN 12" (18" FOR CANADA) MINIMUMCLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

SCREWS(4 req.)

ANCHORS(4 req.)

7.2"

3.2"

BAYVENT200A/B

l

▲ CAUTION!When the vent pipe is exposed to temperatures belowfreezing, i.e., when it passes through unheated spaces, etc.,the pipe must be insulated with 1/2 inch (22.7 mm) thickArmaflex-type insulation or equal.

If the space is heated sufficiently to prevent freezing, thenthe insulation would not be required. If domestic waterpipes are not protected from freezing then it is assumed thespace meets the condition of a heated space.

HORIZONTAL VENTING THROUGH WALLThese furnaces may be installed as direct vent (asshipped) or as nondirect vent. Installation mustconform to national, state, and local codes.

The vent & inlet terminals must be located at least 12"minimum above normally expected snow accumulation level.

Avoid areas where staining or condensate drippage may bea problem.

Location of the vent/wind terminal should be chosen to meetthe requirements of Figure 39 for either direct or nondirectvent applications.

PITCH — Venting through the wall must maintain 1/4" perfoot pitched upward to insure that condensate drains back tothe furnace.

FLUE GAS DEGRADATION — The moisture content ofthe flue gas may have a detrimental effect on some building

materials. This can be avoided by using the roof or chimneyventing option. When wall venting is used on any surfacethat can be affected by this moisture, it is recommended thata corrosion resistant shield (24 inches square) be used behindthe vent terminal. This shield can be wood, plastic, sheetmetal, etc. Also, silicone caulk all cracks, seams and jointswithin 3 feet of the vent terminal.

COMBUSTIBLE MATERIAL WALLA minimum clearance of 1" to combustible materials must bemaintained when using single wall stainless steel venting.See Figure 31.

Shield material to be a minimum of 24 gauge stainless oraluminized sheet metal. Minimum dimensions are 12"x12".Shield must be fastened to both inside and outside of wall.Use screws or anchor type fasteners suited to the outside orinside wall surfaces.

NONCOMBUSTIBLE MATERIAL WALLThe hole through the wall must be large enough to maintainpitch of vent and properly seal.

Use cement mortar seal on inside and outside of wall. SeeFigure 32.

x

z

12" MIN. ABOVENORMALLY EXPECTEDSNOW ACCUMULATION1" CLEARANCE

( AIR SPACE )

90˚ 12" MIN.

PVC WALL MOUNTFLANGE

STUD

COUPLING( PLASTICVENTING )

6 IN. MIN.(TO JOINT)

VENTING THROUGH COMBUSTIBLE WALLSPitch -- 1/4 Inch Per Ft.

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )1" ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE )

VENTING THROUGH NON-COMBUSTIBLE WALLSPitch – 1/4 Inch Per Ft.

12" MIN. ABOVENORMALLY EXPECTEDSNOW ACCUMULATION

CEMENTMORTAR SEAL

INSIDE &OUTSIDE

90˚ ELBOW

12" MIN.

COUPLING( PLASTICVENTING )

PVC WALL MOUNTFLANGE

6 IN. MIN.( TO JOINT )

18-CD19D8-10 19

Installer’s Guide

COMBUSTIONAIR

MAINTAIN 12 IN.(18 IN. FOR CANADA)MINIMUM CLEARANCEABOVE HIGHESTANTICIPATED SNOW LEVEL. MAXIMUM OF24 IN. ABOVE ROOF.

VENTVENT

VENT COMBUSTIONAIR

SUPPORT(FIELD SUPPLIED)

VENT MAINTAIN 12 IN.(18 IN. FOR CANADA)MINIMUM CLEARANCEABOVE HIGHESTANTICIPATED SNOW LEVEL. MAXIMUM OF24 IN. ABOVE ROOF

ROOF BOOT(FIELD SUPPLIED)

COMBUSTIONAIR

ELBOW

BAYVENT100A (VERTICAL)

v

b n

GALVANIZED FIRESTOP SHOULDBE FABRICATED WITH 3-7/8" DIA.HOLE FOR SUPPORT FLANGE(12" x 12" PANEL OR 12" DIA MIN.)

VENTING THROUGH CEILING

CEILING

SUPPORTFLANGE

FLUE PIPE

COUPLING

SEAL BETWEEN FLANGE, PIPE,COUPLING AND METAL PANELWITH HI TEMP RTV SILICONE SEALANT

CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )( 1" ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE )

SUPPORT HORIZONTAL PIPE EVERY 3' 0"WITH THE FIRST SUPPORT AS CLOSE TOTHE FURNACE AS POSSIBLE. INDUCEDDRAFT BLOWER, HOUSING, ANDFURNACE MUST NOT SUPPORT THEWEIGHT OF THE FLUE PIPE.

c

VENTING THROUGH THE ROOF

20 18-CD19D8-10

Installer’s Guide

m

TYPE 29-4C STAINLESS STEEL VENTING –USED THROUGH CHIMNEY THAT VENTS

ANOTHER GAS APPLIANCE

PVC PLASTIC VENTING – ONLYTHROUGH UNUSED CHIMNEY

SUPPORT THE SINGLEWALL FLUE PIPE AND CENTER IT IN THE CHIMNEY OPENING WITH ANGLES AS SHOWN OR ANOTHER EQUIVALENT MANNER.

NOTE:HORIZONTAL VENTING TO VERTICAL VENTING

6 IN. MIN.

STAINLESSSTEELVENT CAP

SEE CAUTION

FLUE PIPE

COUPLINGAS REQUIRED

FLUE PIPE

COUPLING TO SUPPORT PIPE FROM ANGLES OR OTHER SUITABLESUPPORT METHOD

SUPPORT THE SINGLE WALL STAINLESS STEEL GASVENTING AND CENTER IT IN THE CHIMNEY OPENING WITH ANGLES AS SHOWN OR ANOTHER EQUIVALENTMANNER.

NOTE:HORIZONTAL VENTINGTO VERTICAL VENTING

6 IN. MIN.SEE CAUTION

STAINLESSSTEELVENT CAP

STAINLESS STEELVENT CAP

(OPTIONAL)

STAINLESS STEELVENT CAP

(OPTIONAL)

,

▲ CAUTION!Do not run vent through chimney for wood burning oroil furnaces or incinerators or any other gas appliance.

IMPORTANT –The single wall flue pipe joints must be sealed.

The 90° elbow connection to vertical pipe must be sealed toprevent condensate leakage to base of masonry chimney.

▲ CAUTION!Do not run vent through chimney for wood burning or oilfurnaces or incinerators.

If remaining free area between single wall flue pipe andmasonry chimney is to be used for another gas applianceventing area must be sufficient to vent that appliance andthat appliance must be connected to chimney withseparate entry openings.

IMPORTANT –The single wall flue pipe joints must be sealed.

The 90° elbow connection to vertical pipe must be sealed toprevent condensate leakage to base of masonry chimney.

VENTING ROUTED THROUGH A MASONRY CHIMNEY

VENTING THROUGH THE ROOFWhen penetrating roof with a 2" PVC vent pipe, a 2" electri-cal conduit flashing may be used for a weather tight seal.Lubricate flexible seal on flashing before PVC pipe is pushedthrough the seal. (Field Supplied)

NOTE:No vent cap as shown in Figure 34 is the preferred methodfor vertical vent termination in extremely cold climates.

In extreme climate conditions, insulate the exposed pipeabove the roof line with Armaflex type insulation.

VENT FITTING MATERIAL – STAINLESS STEELGas and liquid tight single wall metal vent fitting, designedfor resistance to corrosive flue condensate such as Type29-4C MUST be used throughout.

These fittings and fitting accessories are to be suppliedlocally.

DIRECTION OF STAINLESS STEEL FITTINGAll stainless steel fitting must be installed with male endtowards the furnace.

All horizontal stainless steel sections must be positionedwith the seam on top.

All long horizontal sections must be supported to preventsagging.

All pipe joints must be fastened and sealed to prevent escapeof combustion products into the building.

m

18-CD19D8-10 21

Installer’s Guide

V

D

EE

V

G

INSIDECORNER DETAIL

BL V

V

FIXED CLOSED

OPERABLE

F

B

C

VFIXED

CLOSEDV

V

VB

B

B

A

X

J

B

H

I

V X

K

M

V VENT TERMINAL X AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED

OPERABLE

HORIZONTAL VENT CLEARANCES.

Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

A=Clearance above grade, veranda, porch, deck, orbalcony

12 inches (30 cm) 12 inches (30 cm)

B= Clearance to window or door that may be opened

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),12 inches (30 cm) for appliances > 10,000 Btuh (3 kw)and =/< 100,000 Btuh (30 kw),36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

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

C= Clearance to permanently closed window * *

D=Vertical clearance to ventilated soffit located abovethe terminal within a horizontal distance of 2 feet(61 cm) from the center line of the terminal

* *

E= Clearance to unventilated soffit * *

F= Clearance to outside corner * *

G= Clearance to inside corner * *

H= Clearance to each side of center line extendedabove meter/regulator assembly

3 feet (91 cm) with a height 15 feet (4.5 m) above themeter/regulator assembly

*

I= Clearance to service regulator vent outlet 3 feet (91 cm) *

J=Clearance to nonmechanical air supply inlet tobuilding or the combustion air inlet to any otherappliance


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

K= Clearance to a mechanical air supply inlet 6 feet (1.83m)3 feet (91 cm) above if within

10 feet (3m) horizontally

L=Clearance above a paved sidewalk or paveddriveway located on public property

7 feet (2.13 m) † 7 feet (2.13 m)

M= Clearance under veranda, porch, deck, or balcony 12 inches (30 cm) ‡ *

Notes: 1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code. 2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code. †. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. ‡. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

22 18-CD19D8-10

Installer’s Guide

6" Min.

40 Inch Upflow or Downflow Furnace

Slope 1/4" per ft.

Slope 1/4" per ft.

All horizontal pipes must besupported at maximum of 3

foot intervals

DOWNWARD VENTINGFurnace may be in vertical or horizontal configuration.

/

NOTES:A) Condensate trap for vent pipe must be a minimum of 6 inches in height.B) Condensate trap for vent and inlet pipe must be connected into a condensate drain pump; an open or

vented drain; or it can be connected to the outlet hose of the furnace's condensate trap. Outdoor drain-ing of the furnace and coil condensate is permissible if allowed by local codes. Caution should be takento prevent drains from freezing or causing slippery conditions that could lead to personal injury. Exces-sive draining of condensate may cause saturated ground conditions that may result in damage to plants.

C) The condensate trap should be primed at initial start up prior to heating season operation.

DOWNWARD VENT LENGTH ISLIMITED TO A MAXIMUM OF 15

EQUIVALENT FEET.

Direct Vent Terminal Clearances

Canadian Installations US Installations

A=Clearance above grade, veranda, porch,deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

B=Clearance to window or door that may beopened



C= Clearance to permanently closed window * *

D=

Vertical clearance to ventilated soffitlocated above the terminal within ahorizontal distance of 2 feet (61 cm)from the center line of the terminal

* *

E= Clearance to unventilated soffit * *

F= Clearance to outside corner * *

G= Clearance to inside corner * *

H=Clearance to each side of center lineextended above meter/regulator assembly

3 feet (91 cm) with a height 15 feet (4.5 m) above themeter/regulator assembly *

I= Clearance to service regulator vent outlet 3 feet (91 cm) *

J=Clearance to nonmechanical air supplyinlet to building or the combustion airinlet to any other appliance



K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally

L=Clearance above a paved sidewalk orpaved driveway located on public property

7 feet (2.13 m) † *

M=Clearance under veranda, porch, deck,or balcony 12 inches (30 cm) ‡ *

Notes: 1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code. 2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.†. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings.‡. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

18-CD19D8-10 23

Installer’s GuideCONDENSATE DRAIN INSTRUCTIONS FOR HORIZONTAL FURNACES

Knock outs are provided on the left and right hand side ofboth furnace cabinets for drain connections IN VERTICALAPPLICATIONS. The standard arrangement is for the drainconnection on the left side. The tubing may have to betrimmed in this application to avoid kinking.

The upflow (vertical application) has provisions for rightside drain connections by turning the trap and extending thetubing to the lower right front corner of the furnace. Trim allexcess tubing to avoid kinking. The connecting tubing for leftor right side condensate drain shown in Figure 41A isshipped in the blower compartment.

The downflow (vertical application) may be right sidedrain by removing the drain lines and rotating the trap fromleft to right, reconnecting the lines, and running 1/2" CPVCpipe from the trap to the right side knock out just over andabove the burner section (Use RTV high temperature siliconesealant to connect the CPVC pipe to the trap for ease ofremoving and cleaning the trap). See Figure 41B.

▲ CAUTION!It is recommended that a drain pan be installed under thefurnace to prevent property damage, personal injury ordeath from leaking condensate.

It is always recommended that an auxiliary drain pan beinstalled under a horizontally installed evaporator or 90%gas furnace. Connect the auxiliary drain line to a separatedrain line (no trap is needed in this line).

All horizontal applications are left side only andrequire repositioning the condensate canister trap tothe exterior of the cabinet. Additionally the draintubing connected to the inducer housing must berepositioned for removing the plug and reconnectingthe tubing to the lower connection on the inducerhousing. See Figure 42.For horizontal installation, remove the condensate trap andposition the trap outside the cabinet through the slottedopening next to the secondary cell. On upflow/horizontalmodels, remove lines from the blower section and pullthrough the blower deck. Cut and reattach the line from thesecondary cell (use the spring to prevent kinking).

The inducer housing has a secondary drain opening at its9 o’clock position. Remove the plug and use the plug to coverthe hole at the 6 o’clock position. Reposition the inducerdrain tube from 6 o’clock to the 9 o’clock location. Cut andreattach the tube to the canister trap. Plug openings inblower deck, inducer and blower section. See Figure 42.

Connections must be made to an OPEN/VENTED DRAIN.Refer to illustrations of typical connections.

NOTE:Use 1/2" size PVC pipe and fittings throughout for drainconnections (fittings, pipe and PVC solvent cement notprovided).

THE UPFLOW AND DOWNFLOW (VERTICAL) MAY BE INSTALLEDLEFT OR RIGHT SIDE CONDENSATE DRAIN

UPFLOW FURNACE(Vertical)

DOWNFLOW FURNACE(Vertical)

CPVC PIPE REQUIRED

TO DRAINRIGHT SIDE

HEADER

TO DRAINLEFT SIDE

HEADER

TO DRAINLEFT SIDE

HEADER

TO DRAINRIGHT SIDE

HEADER

41A 41B

24 18-CD19D8-10

Installer’s Guide

NOTE:A corrosion resistant condensate pump must be used if apump is required for a specific drain system.

IMPORTANT:The condensate drain should be installed with provisions toprevent winter freeze-up of the condensate drain line. Frozencondensate will block drains, resulting in furnace shutdown. Ifthe drain line cannot be installed in a conditioned space and/orits surrounding ambient temperature is expected to fall belowfreezing, then heat tape should be applied as required to preventfreezing (per manufacturer’s instructions). The heat tape shouldbe rated at 5 or 6 watts per foot at 120 volts. Self-regulating(preferred) or thermostatically controlled heat tape is required.

Typical sources of UL listed heat tapes are W.W. Granger, Inc.(Wintergard Plus™ Series), McMaster Carr Supply Co.(3554 Series), or your equipment supplier.

The condensate drain may be cleaned or inspected byremoval of the drain tube at the header as shown in theillustrations.

▲ WARNING!CARBON MONOXIDE POISONING HAZARD

Failure to follow the installation instructions for the ventingsystem being placed into operation could result in carbonmonoxide poisoning or death.

ALL HORIZONTAL APPLICATIONSARE LEFT SIDE DRAIN ONLY

TOOPEN/

VENTEDDRAIN

UPFLOW FURNACE ON LEFT SIDEWITH LEFT DRAIN SHOWN

HEADER

@

Primary drain vent stackmust terminate belowsecondary heat exchangercondensate drain outlet.

To drain opening

If upflow furnace is installedover a finished ceiling, overflowfrom the primary drain ventstack must flow into an auxillarydrain pan to prevent damage tothe finished ceiling below.

Evaporator and furnace condensate drain piping may bemanifolded together as shown in Figure 43. A primary drainvent stack must be installed and terminated below the outletof the secondary heat exchanger drain connection to preventwater from damaging furnace controls if the primary drainoutlet plugs up. See Figure 43. Where the furnace is installedabove a finished ceiling, the primary drain vent stack mustbe installed such that overflow from the vent stack openingwill flow into an auxiliary drain pan in order to preventwater damage to the finished ceiling below.

#

18-CD19D8-10 25

Installer’s Guide

SEE NOTE 6

From Dwg. 21B342024 Rev. 0

2 STAGE FURNACE

TWIN

SEE NOTE 7

B/CB/C TO 115 V 1 PH.,60 HZ., POWERSUPPLY PERLOCAL CODES

HUM SEENOTE 5

EAC SEENOTE 5

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTATNO COOLING

SEE NOTE 6


2 STAGE FURNACE

TWIN

SEE NOTE 7

FIELD ADDED JUMPER W1 TO W2.

2ND STAGE WILL FIRE10 MINUTES AFTER 1ST.

SEE NOTE 8

B/C B/C

TO 115 V 1 PH.,60 HZ., POWERSUPPLY PERLOCAL CODES

HUM SEENOTE 5

EAC SEENOTE 5

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE1 STAGE HEATING

USING A 1 STAGE HEATING THERMOSTATNO COOLING

Field Wiring

26 18-CD19D8-10

Installer’s Guide

SEE NOTE 6

From Dwg. B342021 Rev. 0

2 STAGE FURNACE

TWIN

SEE NOTE 7

OUTDOOR UNIT (NO TRANSFORMER)

SEE NOTE 8


HUM SEENOTE 5

EAC SEENOTE 5

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE2 STAGE HEATING, 1 STAGE COOLING

USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT(OUTDOOR SECTION WITHOUT TRANSFORMER)

OUTDOOR UNIT (NO TRANSFORMER)

SEE NOTE 6

From Dwg. B342019 Rev. 0

SEE NOTE 8

FIELD ADDED JUMPER (NOTE 9)

2 STAGE FURNACE

TWIN

SEE NOTE 7


HUM SEENOTE 5

EAC SEENOTE 5

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE2 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT(OUTDOOR SECTION WITHOUT TRANSFORMER)

18-CD19D8-10 27

Installer’s Guide

TWIN TWIN

TWINNING CONNECTION DIAGRAMFOR TWINNING UX/DX-R FURNACES

1 STAGE HEAT / 1 STAGE COOLING THERMOSTAT

1 STAGEHEATING / COOLING

THERMOSTAT FURNACE NO. 1 FURNACE NO. 2

BLOWER OPERATION OF UNIT NO. 2 IS SYNCRONIZEDWITH UNIT NO. 1 VIA SIGNALS

FROM TWIN CONNECTION.

SEE NOTE 4

OUTDOOR UNIT NO. 1(NO TRANSFORMER)

OUTDOOR UNIT NO. 1(WITH TRANSFORMER)

SEE NOTE 3

RC

ISOLATION RELAY(FIELD SUPPLIED)

ALTERNATE CONNECTION

R1

R1

SEE NOTE 5


SEE NOTE 4

ISOLATION RELAYSEE NOTE 4

JUMPER W1 TO W2ON BOTH UNITS.

2ND STAGE WILL FIRE10 MINUTES AFTER 1ST.

B/CB/CB/CFrom Dwg. 21B341336 Rev. 2

TWIN TWIN



2 STAGE HEATING1 STAGE COOLING




SEE NOTE 4


OUTDOOR UNIT NO. 1(WITH TRANSFORMER)

SEE NOTE 3

RC



R2

R2

SEE NOTE 5


SEE NOTE 4


R1R1

B/C B/C B/CFrom Dwg. 21B341337 Rev. 2

28 18-CD19D8-10

Installer’s Guide

TWIN TWIN



2 STAGE HEATING1 STAGE COOLING




SEE NOTE 4



SEE NOTE 3

R2

R2

SEE NOTE 5


SEE NOTE 4


R1R1

OUTDOOR UNIT (WITH TRANSFORMER)

SEE NOTE 3

RC



B/CB/CB/C


ELECTRICAL CONNECTIONSMake wiring connections to the unit as indicated on enclosedwiring diagram. As with all gas appliances using electricalpower, this furnace shall be connected into a permanentlylive electric circuit. It is recommended that furnace beprovided with a separate “circuit protection device” electriccircuit. The furnace must be electrically grounded in accor-dance with local codes or in the absence of local codes withthe National Electrical Code, ANSI/NFPA 70 or CSA C22.1Electrical Code, if an external electrical source is utilized.The integrated furnace control is polarity sensitive.The hot leg of the 120V power supply must be connected tothe black power lead as indicated on the wiring diagram.Provision for hooking up an electronic air cleaner and orhumidifier is provided on the integrated control.

Refer to the SERVICE FACTS literature and unit wiringdiagram attached to furnace.

GAS PIPINGThe upflow/horizontal furnace is shipped standard for leftside installation of gas piping. A knockout is provided on theright side for an alternate gas piping arrangement. SeeFigure 45.

The installation of piping shall be in accordance with pipingcodes and the regulations of the local gas company. Pipe jointcompound must be resistant to the chemical reaction withliquefied petroleum gases.

Refer to piping Table 8, for delivery sizes. Connect gassupply to the unit, using a ground joint union and a manualshut-off valve as shown in Figures 44 & 45. National codesrequire a condensation drip leg to be installed ahead of thecontrols as shown in Figures 45 & 46.

▲ CAUTION!Use a backup wrench on the gas valve when installing gaspiping to prevent damage to the gas valve and manifoldassembly.

The furnace and its individual shut-off valve must be discon-nected from the gas supply piping system during any pres-sure testing of that system at test pressures in excess of1/2 psig (3.5 kPa).

The furnace must be isolated from the gas supply piping byclosing its individual manual shut-off valve during anypressure testing of the gas supply piping system at testpressures equal to or less than 1/2 psig (3.5 kPa).

NOTE:Maximum pressure to the gas valve for natural gas is 13.8"W.C. Minimum pressure is 5.0" W.C. Maximum pressure tothe gas valve for propane is 13.8" W.C. Minimum pressureis 11.0" W.C.

All gas fittings must be checked for leaks using a soapysolution before lighting the furnace. DO NOT CHECKWITH AN OPEN FLAME!

TABLE 8NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GASFOR VARIOUS PIPE SIZES AND LENGTHS

PIPESIZE

LENGTH OF PIPE

10 20 30 40 50 60 70

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

1-1/4 1050 730 590 520 440 400 370

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

18-CD19D8-10 29

Installer’s Guide

MAIN MANUALSHUT-OFF

VALVE

GROUND UNION JOINTAUTOMATIC GAS VALVEWITH MANUAL SHUT-OFF

MAIN MANUALSHUT-OFF VALVE

GROUNDUNION JOINT

DRIPLEG

DRIPLEG

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE(Typical UPFLOW Furnace in horizontal configuration shown)

AUTOMATIC GAS VALVEWITH MANUAL SHUT-OFF

^

UPFLOW MAY BE LEFT ORRIGHT HAND GAS PIPING



GROUNDUNIONJOINT

DRIPLEG



GROUNDUNIONJOINT

DRIPLEG

$

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

%

30 18-CD19D8-10

Installer’s GuideTABLE 9

ORIFICE SIZES

INPUTRATINGBTUH

NUMBEROF

BURNERS

MAIN BURNER ORIFICEDRILL SIZE

NAT. GAS LP GAS

60,00080,000100,000120,000

3456

45454545

56565656

COMBUSTION AND INPUT CHECK(See also High Altitude Derate)

1. Make sure all gas appliances are off except the furnace.2. Clock the gas meter with the furnace operating (deter-

mine the dial rating of the meter) for one revolution.3. Match the “Sec” column in the gas flow (in cfh) Table 10

with the time clocked.4. Read the “Flow” column opposite the number of seconds

clocked.5. Use the following factors if necessary:

For 1 Cu. Ft. Dial Gas Flow CFH =Chart Flow Reading ÷ 2

For 1/2 Cu Ft. Dial Gas Flow CFH =Chart Flow Reading ÷ 4

For 5 Cu. Ft. Dial Gas Flow CFH =10X Chart Flow Reading ÷ 4

6. Multiply the final figure by the heating value of thegas obtained from the utility company and compare tothe nameplate rating. This must not exceed thenameplate rating.

7. Changes can be made by adjusting the manifold pres-sure (See Table 11), or changing orifices (orifice changemay not always be required). To adjust the manifoldpressure:a. Turn off all electrical power to the system.b. Attach a manifold pressure gauge to the outlet

pressure tap marked “OUT PRESS TAP” onWhite-Rodgers gas valve model 36E or boss marked

“OUT P” on White-Rodgers gas valve model 36G. (SeeFigure 48 for White-Rodgers gas valve model 36E andFigure 49 for White-Rodgers gas valve model 36G).For the gas valve model 36E, measurements requireremoval of the plug and installation of a barbedfitting. Attach flexible tubing and a manometer to thebarbed fitting. For the gas valve model 36G, do notremove the pressure tap test screw. Loosen thepressure tap test screw one turn and install flexibletubing and a manometer directly onto the outletpressure boss.

c. The other side of the manifold pressure gauge must bereferenced to the burner box as shown in Figure 46.

d. Turn on system power and energize valve.e. For the White-Rodgers gas valve model 36E:

1. Adjust low fire by removing the low adjustmentseal screw (See Figure 48).

2. To increase outlet pressure, turn the 3/32" socketset screw clockwise. To decrease outlet pressure,turn the set screw counterclockwise. Adjustregulator until pressure shown on manometermatches the pressure specified in Table 11.

3. Replace low adjustment seal screw and tightensecurely.

4. Cycle the valve several times to verify regulatorsetting.

5. Adjust high fire by removing the high adjustmentseal screw (See Figure 48).

6. To increase outlet pressure, turn the 3/32" socketset screw clockwise. To decrease outlet pressure,turn the set screw counterclockwise. The finalmanifold pressure setting shall be as specified inTable 11 with an input of no more than nameplaterating and no less than 93% of the nameplaterating, unless the unit is derated for high altitude.

7. Replace high adjustment seal screw and tightensecurely.


▲ CAUTION: Return all tubing, caps, and/or plugs to original positions when pressure checks are completed.

&

18-CD19D8-10 31

Installer’s Guide

HIGH ALTITUDE DERATEInput ratings (BTUH) of these furnaces are based on sealevel operation and should not be changed at elevations up to2,000 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 gasflow rate (CFH) and multiplying by the heating valueobtained from the local utility supplier for the gas beingdelivered at the installed altitude. Input rate changes can bemade by adjusting the manifold pressure (min 3.0 - max3.7 in. W.C. - Natural Gas) or changing orifices (orifice changemay not always be required).

If the desired input rate cannot be achieved with a change inmanifold pressure, then the orifices must be changed. LPinstallations will require an orifice change.

IMPORTANT:Reinstall the propane orifices to the same depth as the orificessupplied with the equipment.

See Table 13 for help in selecting orifices if orifice change isrequired. Furnace input rate and temperature rise should bechecked again after changing orifices to confirm the properrate for the altitude.

The vent length table on page 16 shows the required ventlengths for installations at various altitudes. An optionalhigh altitude kit is available for installations above 5000 feetInstallations above 12,000 feet are not allowed).

TABLE 12PART NUMBERS FOR REPLACEMENT ORIFICESDRILLSIZE

PARTNUMBER

DRILLSIZE

PARTNUMBER

44454647484950

ORF00501ORF00644ORF00909ORF00910ORF01099ORF00503ORF00493

545556575859

ORF00555ORF00693ORF00907ORF00908ORF01338ORF01339

f. For the White-Rodgers gas valve model 36G:1. Adjust low fire by removing the low adjustment

regulator cover screw (See Figure 49).2. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet pressure,turn the regulator adjust screw counterclockwise.Adjust regulator until pressure shown on mano-meter matches the pressure specified in Table 11.

3. Replace and tighten the regulator cover screwsecurely.


5. Adjust high fire by removing the high adjustmentregulator cover screw (See Figure 49).

6. To increase outlet pressure, turn the regulatoradjust screw clockwise. To decrease outlet pressure,turn the regulator adjust screw counterclockwise.The final manifold pressure setting shall be asspecified in Table 11 with an input of no more thannameplate rating and no less than 93% of thenameplate rating, unless the unit is derated forhigh altitude.

7. Replace high adjustment regulator cover screw andtighten securely.


g. Turn off all electrical power to the system.

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIALSEC. FLOW SEC. FLOW SEC. FLOW SEC. FLOW

8 900 29 248 50 144 82 889 800 30 240 51 141 84 8610 720 31 232 52 138 86 8411 655 32 225 53 136 88 8212 600 33 218 54 133 90 8013 555 34 212 55 131 92 7814 514 35 206 56 129 94 7615 480 36 200 57 126 96 7516 450 37 195 58 124 98 7317 424 38 189 59 122 100 7218 400 39 185 60 120 104 6919 379 40 180 62 116 108 6720 360 41 176 64 112 112 6421 343 42 172 66 109 116 6222 327 43 167 68 106 120 6023 313 44 164 70 103 124 5824 300 45 160 72 100 128 5625 288 46 157 74 97 132 5426 277 47 153 76 95 136 5327 267 48 150 78 92 140 5128 257 49 147 80 90 144 50

TABLE 10

FINAL MANIFOLD PRESSURE SETTINGS (inches w.c.)

FUEL 2nd Stage Max. 1st Stage Max.

NATURAL GAS 3.5" W.C. 1.7" W.C.

LP GAS 10.5" W.C. 6.0" W.C.

TABLE 11

h. Remove the manometer and flexible tubing. Removethe barbed fitting and replace the plug or tighten thepressure test screw.

i. Turn on electrical power to the system and energizevalve.

j. Using a leak detection solution or soap suds, check forleaks at plug or pressure boss screw.

NOTE:The manifold pressure must be referenced to the burnerbox. The burner box pressure tap equalizes the gas valvepressure regulator. Manifold pressure is checked byinstalling a tee (field supplied) in the tubing, between thetee coming from the burner box tube and the gas valve,in addition to the regular gas valve pressure tap on theoutlet side of the gas valve. See Figure 47.

▲ CAUTION!Replace and/or tighten all plugs removed or loosenedwhen adjusting gas pressure. Leak check the fittingsbefore placing the furnace into regular service. Failureto follow this warning could result in fire, explosion, orproperty damage.

32 18-CD19D8-10

Installer’s Guide

White-Rodgers 36G

Table 12 lists the main burner orifices used with the furnace.If a change of orifices is required to correct the furnace inputrating refer to Table 13.

REINSTALLATION OF THE BURNER BOX COVERFigure 49 shows the correct way to reinstall the burner boxcover if adjustment or replacement of the flame sensor, hotsurface igniter, or main burner orifices have required re-moval of the cover.

OrificeTwist Drill

Size IfInstalledAt SeaLevel

ALTITUDE ABOVE SEA LEVEL

and Orifice Required At Other Elevations

2000 3000 4000 5000 6000 7000 8000 9000 10000424344454647

424445464748

434445474748

434445474749

434546474849

444547484849

444647484950

454748494950

464748495051

474850505152

5455565758

5455565859

5555565960

5555575960

5556576061

5556576062

5556586162

5656596263

5656596363

5657606364

From National Fuel Gas Code - Table F-4

ROTATE THE FRONTCOVER INWARD MAKINGSURE THAT ALL SIDEFLANGES ARE OUTSIDEOF THE BOX.

INSERT THE TOP FLANGEOF THE FRONT COVERUNDER THE LIP INSIDETHE BOX

ALL SIDE FLANGES MUSTBE OUTSIDE OF THE BOX

ROTATE THE FRONTCOVER AS SHOWN

)TABLE 13

START-UP AND ADJUSTMENTPRELIMINARY INSPECTIONS

▲ WARNING!Disconnect power to the unit before removing the blowerdoor. Allow a minimum of 10 seconds for IFC power supplyto drain to 0 volts. Failure to follow this warning couldresult in property damage, personal injury or death.

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 the main gas valve toggle switch (See Figures 48 & 49)within the unit to the “OFF” position. Turn the external gasvalve 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. Allow5 minutes for any gas that might have escaped to dissipate.

LP Gas being heavier than air may require forced ventila-tion. Turn the toggle switch on the gas valve in the unit tothe “ON” position.

LIGHTING INSTRUCTIONS

▲ WARNING!DO NOT attempt to manually light the burner. Failure tofollow this warning could result in property damage,personal injury or death.

Lighting instructions appear on each unit. Each installationmust be checked out at the time of initial start up to insureproper operation of all components. Check out should includeputting the unit through one complete cycle as outlined below.

Turn on the main electrical supply and set the thermostatabove the indicated temperature. The ignitor will automati-cally heat, then the gas valve is energized to permit the flow

Gas Valve On / OffToggle Switch

1st Stage (LO)ManifoldPressureAdjustment

2nd Stage (HI)ManifoldPressureAdjustment

(

Gas Valve On / OffToggle Switch

1st Stage (LO)ManifoldPressureAdjustment

2nd Stage (HI)ManifoldPressureAdjustment

* White-Rodgers 36E

18-CD19D8-10 33

Installer’s Guideof gas to the burners. After ignition and flame is established,the flame control module monitors the flame and suppliespower to the gas valve until the thermostat is satisfied.

To shut offFor complete shutdown: Turn the gas cock knob on the maingas valve to the “OFF” position (See Figure 44). Disconnectthe electrical supply to the unit.

▲ CAUTION!If this is done during the cold weather months, provisionsmust be taken to prevent freeze-up of all water pipes andwater receptacles.

Whenever your house is to be vacant, arrange to havesomeone inspect your house for proper temperature.This is very important during freezing weather. If forany reason your furnace should fail to operate dam-age could result, such as frozen water pipes.

SEQUENCE OF OPERATION

Thermostat call for heat (2-stage thermostat)Call for 1st stage only:W1 thermostat contacts close signaling the control module torun its self-check routine. After the control module hasverified that the 1st stage pressure switch contac

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