1 8 - CD2 2 D1 - 8
Installer’s Guide
High Efficiency Single Stage Upflow/ Horizontal
and Downflow/ Horizontal Gas-Fired, Direct Vent
Condensing Furnaces
*UX1B040A9H21B
*UX1B060A9H31B
*UX1B080A9H31B
*UX1C100A9H41B
*UX1D120A9H51B
*__First letter may be “A” or “T”
*DX1B040A9H21B
*DX1B060A9H31B
*DX1B080A9H31B
*DX1C100A9H31B
*DX1D120A9H51B
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.
*UX1-H
*DX1-H
DOWNFLOW
UPFLOW
UPFLOW/HORIZONTAL
DOWNFLOW/HORIZONTAL
A341624P08
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
Contents
Safety signal words are used to designate a degree or level
of seriousness associated with a particular hazard. The
signal words for safety markings are WARNING and
CAUTION.
INSTALLATION INSTRUCTIONS
General Installation Instructions
Location and Clearances
Outline Drawings
3
4
a. WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
5
Upflow Installation
7
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.
Downflow Installation
Horizontal Installation
Air For Combustion and Ventilation
Duct Connections
7
7
8
10
11
14
15
15
16
20
20
22
22
25
27
27
29
31
Return Air Filters
General Venting Instructions
Venting Material
Venting Tables
!
▲
WARNING
Horizontal Venting
FIRE OR EXPLOSION HAZARD
Venting Through The Wall
Venting Through The Roof
Downward Venting
Failure to follow the safety warnings exactly could re-
sult in serious injury, death or property damage.
Improper servicing could result in dangerous opera-
tion, serious injury, death, or property damage.
Venting Through a Masonry Chimney
Condensate Drain Instructions
Electrical Connections
Field Wiring Diagrams
Gas Piping
GENERAL INSTALLATION INSTRUCTIONS
The manufacturer assumes no responsibility for equip-
ment installed in violation of any code or regulation.
It is recommended that Manual J of the Air Condition-
ing Contractors Association (ACCA) or A.R.I. 230 be fol-
lowed in estimating heating requirements. When esti-
mating heating requirements for installation at alti-
tudes above 2000 ft., remember the gas input may need
to be reduced (See High Altitude Installation).
Material in this shipment has been inspected at
the factory and released to the transportation
agency without known damage. Inspect exterior
of carton for evidence of rough handling in ship-
ment. Unpack carefully after moving equipment
to approximate location. If damage to contents is
found, report the damage immediately to the de-
livering agency.
Combustion Input Checks
Start Up and Adjustment
33
Preliminary Inspections
33
34
34
34
35
Lighting Instructions
Sequence Of Operation
Control And Safety Switch Adjustments
Airflow Adjustment
Conditions Affecting Furnace Operation
35
37
IFC Error Flash Code
Category IV furnaces operate with positive vent static
pressure and with a flue loss less than 17 percent.
These conditions require special venting systems, which
must be gas tight and water tight. These Category IV
Direct Vent furnaces are approved for installation in
Manufactured/Mobile housing when used with
BAYMFGH100A.
Codes and local utility requirements governing the
installation of gas fired equipment, wiring, plumbing,
and flue connections must be adhered to. In the ab-
sence of local codes, the installation must conform with
latest edition of the National Fuel Gas Code ANSI
Z223.1 • National Installation Code, CAN/CGA B149.1.
The latest code may be obtained from the American Gas
Association Laboratories, 400 N. Capitol St. NW,
Washington D.C. 20001.
These furnaces have been classified as CATEGORY IV
furnaces in accordance with latest edition of ANSI
Z21.47 • CAN/ CGA 2.3 standards.
18-CD22D1-8
3
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
LOCATION AND CLEARANCES
!
▲
CAUTION
The location of the furnace is normally selected by the ar-
chitect, the builder, or the installer. However, before the fur-
nace is moved into place, be sure to consider the following
requirements:
1. Is the location selected as near the vent and as cen-
tralized for heat distribution as practical?
2. Do all clearances between the furnace and enclosure
equal or exceed the minimums shown in the Table 1.
3. Is there sufficient space for servicing the furnace and
other equipment? A minimum of 24 inches front acces-
sibility to the furnace must be provided. Any access
door or panel must permit removal of the largest com-
ponent.
To prevent shortening its service life, the furnace
should not be used as a “Construction Heater” during
the finishing phases of construction until the require-
ments listed in item 9, a-g of the safety section of this
publication have been met. Condensate in the pres-
ence of chlorides and fluorides from paint, varnish,
stains, adhesives, cleaning compounds, and cement
create a corrosive condition which may cause rapid de-
terioration of the heat exchanger.
!
▲
CAUTION
Do NOT install the furnace in a corrosive or contami-
nated atmosphere.
4. Are there at least 3 inches of clearance between the fur-
nace front panel and any closed panel or door provided?
5. Are the vent pipe and combustion air inlet pipe within
vent table lengths? Will the pipes remain unobstructed?
6. Allow sufficient height in supply plenum above or below
the furnace to provide for cooling coil installation if the
cooling coil is not installed at the time of this furnace
installation.
!
▲ WARNING
EXPLOSION HAZARD!
PROPANE GAS IS HEAVIER THAN AIR AND MAY
COLLECT IN ANY LOW AREAS OR CONFINED
SPACES. IN ADDITION, ODORANT FADE MAY MAKE
THE GAS UNDETECTABLE EXCEPT WITH A WARN-
ING DEVICE. IF THE GAS FURNACE IS INSTALLED
IN A BASEMENT, AN EXCAVATED AREA OR A
CONFINED SPACE, IT IS STRONGLY RECOM-
MENDED TO CONTACT A GAS SUPPLIER TO IN-
STALL A GAS DETECTING WARNING DEVICE IN
CASE OF A GAS LEAK.
7. A furnace shall be installed so electrical components
are protected from water.
8. If the furnace is installed in a residential garage, it
must be installed so that the burners and the ignition
source are located not less than 18 inches (46 cm)
above the floor and the furnace must be located or pro-
tected to avoid physical damage from vehicles.
NOTE: The manufacturer of your furnace does NOT test
any detectors and makes no representations regarding
any brand or type of detector.
IMPORTANT:
The furnace must be installed level. The only allowable
variation would be slightly to the left and/or forward in up-
flow installations or slightly toward the front in horizontal in-
stallations. This is necessary for proper condensate drain-
age.
4
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
18-CD22D1-8
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
6
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
UPFLOW INSTALLATION
2
Standoffs and screws (See Figure 1) are included with
the cased coils for attachment to the furnace. There are
clearance alignment holes near the bottom of the coil
wrapper. Drill screws are used to engage the furnace
top flanges. The standoff is inserted into the cabinet
alignment hole. The drill screws are inserted through
the standoffs then screwed into the furnace flange.
The coil is always placed downstream of the furnace air-
flow.
A (width)
B (depth)
FURNACE
FRONT
D
C
HORIZONTAL INSTALLATION
The coil and furnace must be fully supported when used
in the horizontal position. It is always recommended
that an auxiliary drain pan be installed under a horizon-
tally installed evaporator coil or 90% gas furnace. Con-
nect the auxiliary drain line to a separate drain line (no
trap is needed in this line).
DRILL SCREWS (4)
STANDOFFS (4)
1
Three brackets (with screws) are included with down-
flow furnaces for installation to stabilize and secure the
furnace and TXC cased coil in the horizontal posi-
tion. See Figure 4.
CASED
COIL
FOR VERTICAL
INSTALLATIONS:
IMPORTANT:
The 2/4TXC cased coil must be placed downstream of the
furnace. In horizontal installations, the apex of the coil
may point either toward or away from the furnace. See
the 2/4TXC coil Installer's Guide for more details.
SCREWS
(BOTH SIDES)
UPFLO
FURNA
The cased coil is secured to the furnace and both the
furnace and the cased coil must be properly supported.
The brackets mount using the rear screws on the coil
case and use the screws provided to secure the bracket
to the furnace. The remaining bracket is placed as close
to center as possible (horizontally) between the coil case
front and the furnace bottom channel (for downflow/
horizontal furnace). Use four of the screws provided to
secure the bracket. The upflow furnace, converted to
horizontal, aligns and attaches the TXC coil as in Fig-
ure 1. However, the coil requires additional support.
W
CE
STANDOFFS
(BOTH SIDES)
DOWNFLOW INSTALLATIONS
!
▲
WARNING
Do NOT install the furnace directly on carpeting, tile or
other combustible material other than wood flooring.
For
vertical
downflow
application,
subbase
(BAYBASE205) must be used between the furnace and
combustible flooring. When the downflow furnace is in-
stalled vertically with a cased coil, a subbase is not re-
quired.
3CASED COIL CONNECTION
BRACKET FOR DOWNFLOW
FURNACE IN HORIZONTAL
Required floor opening:
DOWNFLOW ONLY
The furnace may be installed in an attic or crawl space
in the horizontal position by placing the furnace on the
left side (as viewed from the front in the vertical posi-
tion). The horizontal furnace installation in an attic
should be on a service platform large enough to allow
for proper clearances on all sides and service access to
the front of the furnace (See Figure 4 & Clearance
Table). Line contact is only permissible between lines
formed by intersections of the top and two sides of the
furnace casing and building joists, studs, or framing.
SUBBASE CROSS SECTION
TABLE 1
FLOOR OPENING PLENUM OPENING
CABINET
RETURN
WIDTH DUCT WIDTH
"A"
"B"
"C"
"D"
17-1/2"
21"
16-1/4"
19-3/4"
23-1/4"
16-5/8" 20-1/8"
20-1/8" 20-1/8"
23-5/8" 20-1/8"
15-5/8"
19-1/8"
22-5/8"
19-3/8"
19-3/8"
19-3/8"
24-1/2"
18-CD22D1-8
7
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
The furnace may be placed horizontally in a crawl space
on a pad or other noncombustible material which will
raise the unit for sufficient protection from moisture.
The furnace must be supported at both ends and the
middle when installed horizontally.
Provisions for combustion and ventilation air shall be
made in accordance with latest edition of Section 5.3,
Air for Combustion and Ventilation, of the National
Fuel Gas Code, ANSI Z223.1 — CAN/CGA B149.1 or ap-
plicable provisions of the local building codes. Special
conditions created by mechanical exhausting of air and
fireplaces must be considered to avoid unsatisfactory
furnace operation.
4
OUTSIDE AIR IS RECOMMENDED
The use of indoor air for most applications is acceptable,
unless there is the presence of corrosive chemicals
or contamination. Certain types of installation will
require the use of outside air for combustion.
The following types of installations will require use of
OUTDOOR AIR for combustion, due to chemical expo-
sures:
UPFLOW/
HORIZONTAL
SHOWN
* Commercial buildings
* Buildings with indoor pools
The furnace must also be elevated a minimum of 6
inches to allow clearance for the condensate drain to
exit the cabinet in the horizontal position.
The horizontal furnace may also be suspended from the
joists using 3/8" all-thread rods with pieces of angle iron
underneath the furnace to form a hanging rack at both
ends and the midpoint. The rods need to be of sufficient
length to allow for proper clearances from combustible
materials. The angle iron needs to be at least 32" in
length to allow for access to service panels.
* Furnaces installed in “confined” laundry rooms
* Furnaces installed in “confined” hobby or craft rooms
* Furnaces installed near chemical storage areas.
Exposure to the following substances in the combustion
air supply will also require OUTDOOR AIR for combus-
tion:
* Permanent wave solutions
* Chlorinated waxes and cleaners
* Chlorine based swimming pool chemicals
* Water softening chemicals
* Deicing salts or chemicals
* Carbon Tetrachloride
5
* Halogen type refrigerants
50 CU. FT. OR MORE
PER 1000 BTU/HR. INPUT
ALL EQUIP. INSTALLED
* 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
UNCONFINED
Furnace locations may be in a “confined space” or an
“unconfined space”.
AIR FOR COMBUSTION AND VENTILATION
If these furnaces are installed in a nondirect vent capac-
ity then the adequate flow of combustion and ventilat-
ing air must not be obstructed from reaching the fur-
nace. Air openings provided for combustion air must be
kept free of obstructions which restrict the flow of air.
Airflow restrictions affect the efficiency and safe opera-
tion of the furnace. Keep this in mind should you
choose to remodel or change the area which contains
your furnace. Furnaces must have a free flow of air for
proper performance.
Unconfined space is defined in Figure 5. These spaces
may have adequate air by infiltration to provide air for
combustion and ventilation. Buildings with tight
construction (for example, weather stripping, heavily
insulated, caulked, vapor barrier, etc.), may need addi-
tional air to be provided as described for confined space.
Confined spaces are installations with less than 50 cu.
ft. of space per 1000 BTU/ hr input from all equipment
installed. Air for combustion and ventilation require-
ments can be supplied from inside the building as in
Figure 8 or from the outdoors, as in Figure 9.
8
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
MINIMUM AREA IN SQUARE FEET
8
6FOR UNCONFINED SPACE INSTALLATIONS
FURNACE
WITH 8 FT. CEILING
MAXIMUM BTUH MINIMUM AREA IN SQUARE FEET
INPUT RATING
OF UNCONFINED SPACE
60,000
80,000
100,000
120,000
375
500
625
875
1. All air from inside the building as in Figure 8: The
confined space shall be provided with two perma-
nent openings communicating directly with an addi-
tional room(s) of sufficient volume so that the com-
bined volume of all spaces meets the criteria for an
unconfined space. The total input of all gas utiliza-
tion equipment installed in the combined space
shall be considered in making this determination.
Refer to Table 2 for minimum open areas require-
ments.
9
7
CONFINED
SPACE
2. All air from outdoors as in Figure 9: The confined
space shall be provided with two permanent open-
ings, one commencing within 12 inches of the top
and one commencing within 12 inches of the bot-
tom of the enclosure. The openings shall communi-
cate directly, or by ducts, with the outdoors or
spaces (crawl or attic) that freely communicate with
the outdoors. Refer to Table 2, for minimum open
areas requirements.
TABLE 2
MINIMUM FREE AREA IN SQUARE INCHES
EACH OPENING (FURNACE ONLY)
Furnace
Air From Outside
Air
From
Inside
Maximum
BTUH/INPUT
Rating
Vertical
Horizontal
Duct
Duct
60,000
80,000
100,000
120,000
100
100
100
120
15
20
25
30
30
40
50
60
18-CD22D1-8
9
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
DUCT CONNECTIONS
PREPARATION FOR UPFLOW BOTTOM AND SIDE
Air duct systems should be installed in accordance with RETURN AIR FILTER INSTALLATION
standards for air conditioning systems, National Fire
All return air duct systems should provide for installa-
tion of return air filters.
Protection Association Pamphlet No. 90. They should
be sized in accordance with ACCA Manual D or which-
ever is applicable.
1. Determine the appropriate position to set the
furnace in order to existing supply and return
ductwork.
Central furnaces, when used in connection with cooling
units, shall be installed in parallel or on the upstream
side of the cooling coil to avoid condensation in the heat
exchanger. With a parallel flow arrangement, the damp-
ers or other means used to control flow of air shall be
adequate to prevent chilled air from entering the fur-
nace, and if manually operated, must be equipped with
means to prevent operation of either unit unless the
damper is in full heat or cool position.
On any job, flexible connections of nonflammable mate-
rial may be used for return air and discharge connections
to prevent transmission of vibration. Though these units
have been specifically designed for quiet, vibration free
operation, air ducts can act as sounding boards and could,
if poorly installed, amplify the slightest vibration to the
annoyance level.
When the furnace is located in a utility room adjacent
to the living area, the system should be carefully de-
signed with returns to minimize noise transmission
through the return air grille. Although these furnaces
are designed with large blowers operating at moderate
speeds, any blower moving a high volume of air will
produce audible noise which could be objectionable
when the unit is located very close to a living area. It is
often advisable to route the return air ducts under the
floor or through the attic. Such design permits the in-
stallation of air return remote from the living area
(i.e. central hall).
When the furnace is installed so that the supply ducts
carry air circulated by the furnace to areas outside the
space containing the furnace, the return air shall also
be handled by a duct(s) sealed to the furnace and termi-
nating outside the space containing the furnace.
2. The return air filter and rack are shipped in either
the bottom or side location. Remove the filter and
filter rack by first turning the two latches on the
blower door and tilting the door forward to remove.
Remove the filter by sliding it out of the rack.
Compress the spring loaded filter rack to disengage
the retaining pins/screws from the furnace sides
and slide the filter rack out.
The filter rails are spring loaded for automatic
adjustment to allow standard size, locally obtainable
replacement filters. The filter rack itself slides to
adjust to the required width needed for bottom or
side return.
3. For upflow side return installations, remove the
insulation around the opening in the blower compart-
ment.
4. The side panels of the upflow furnace include
locating notches that are used as guides for cutting
an opening for return air, refer to Figure 10 and the
outline drawing on page 5 for duct connection
dimensions for various furnaces.
5. If a 3/4" flange is to be used for attaching the air
inlet duct, add to cut where indicated by dotted
lines in Figure 10. Cut corners diagonally and bend
outward to form flange.
6. If flanges are not required, and a filter frame is
installed, cut between locating notches (See Figure
10).
7. The bottom panel of the upflow furnace must be
removed for bottom return air. After removing the
filter and filter rack, lay the furnace on its back.
Remove the two 5/16" hex screws securing the front
of the bottom channel to the cabinet. Rotate the
channel downward (or remove by lowering the front
edge of the channel and pulling forward). Slide the
bottom return air panel out of the cabinet. Rotate
the front channel to its original position and rein-
stall the two 5/16” screws.
RETURN AIR DUCT SYSTEMS
Where there is no complete return duct system, the re-
turn connection must be run full size from the furnace
to a location outside the utility room, basement, attic,
or crawl space.
Do Not install return air through the back of the furnace
cabinet
Do Not install return air through the side of the furnace
cabinet on horizontal applications.
8. The filter retainer is factory supplied for upflow bot-
tom return. Use the filter retainer on side or bot-
tom if filter is to be used within the furnace cabinet
on upflow only installations.
NOTE:
Minimum return air temperature is 55° F.
All return air duct systems should provide for installa-
tion of return air filters.
10
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
9. 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 horizon-
tal applications.
TABLE 3
MODELS
NUMBERS
CABINET
WIDTH
FILTER
QTY & SIZE
*UX1B040A9H21B
*UX1B060A9H31B
*UX1B080A9H31B
17-1/2"
1 - 17" X 25" X 1"
*UX1C100A9H41B
21"
1 - 20" X 25" X 1"
1 - 24" X 25" X 1"
10. Connect duct work to furnace. See Outline Drawing
for supply and return duct size and location. Flex-
ible duct connectors are recommended to connect
both supply and return air ducts to the furnace. If
only the front of the furnace is accessible, it is
recommended that both supply and return air
plenums are removable.
*UX1D120A9H51B
24-1/2"
*First letter may be "A" or "T"
**NOTE: For upflow 5 ton airflow models where the airflow
requirement exceeds 1800 CFM - Modles will require return air
openings and filters on: (1) both sides, or (2) one side and the
bottom, or (3) just on the bottom
NOTE: For upflow 5 ton airflow models where the
airflow requirement exceeds 1800 CFM - Models will
require return air openings and filters on: (1) both
sides, or (2)1 side and the bottom, or (3) just the
bottom.
RETURN AIR FILTERS
TYPICAL UPFLOW RETURN
AIR FILTER INSTALLATIONS
furnaces require high velocity type air filters. The
filters may be installed within the furnace blower
compartment for UPFLOW furnaces in either a BOT-
TOM or SIDE (left side or right side) return air inlet.
Some filters may need to be trimmed for side or bottom
filter use.
The furnace and the bottom filter rack installation can
be seen in Figure 11.
The furnace filter in the bottom or side configuration
can be removed by simply turning the two latches on
the blower door and tilting the door forward.
OPTIONAL FILTER RACK INSTALLATION FOR BOT-
TOM RETURN
UPFLOW FURNACE ONLY
0
LOCATING
CUT OUT
FOR SIDE
FILTER
NOTCHES PRO-
The following checklist should be used when installing
a bottom return filter on an upflow furnace:
VIDED FOR SIDE
RETURN CUTOUT
a. Remove the filter.
b. Remove the filter rack.
c. Remove the bottom panel.
FRONT
of Furnace
e. With the filter removed, the filter rack is com-
pressed and then inserted into the bottom of the
furnace. The retaining screw/pin on each side
inserts into engagement holes at the bottom of
the furnace cabinet side. See Figure 12.
SEE OUTLINE DRAWING
*
q
f. Reinstall the furnace filter in the bottom posi-
tion by inserting the chamfer end first into the
filter rack
w
Filter Rack
Retaining
Screw/Pin
Furnace
Cabinet
Side
Filter
Rack
Airflow
Engagement Hole
For Filter Rack
Installation With
Bottom Return
BOTTOM FILTER RACK INSTALLATION
Bottom Panel
18-CD22D1-8
11
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
FILTER RACK INSTALLATION FOR SIDE RETURN AIR
ON UPFLOW FURNACES (Left or Right)
Furnace
Blower
Deck
Engagement Hole
For Filter Rack
Installation With
Side Return
t
BLOWER
DECK
The following checklist should be used when installing
a right or left side return filter on an upflow furnace:
Furnace
Cabinet
Side
a. Remove the filter.
b. Remove the filter rack.
c. Leave the bottom panel in place.
Filter
Rack
Assembly
Filter Rack
Retaining
Screw/Pin
e
e. Make side cutout by following the directions in
the “Return Air Duct Connections” section on
page 10.
Filter
Rack
e. Compress the filter rack and reinstall in the
side position on the furnace. Confirm that the
upper retaining pin/screw locks into the engage-
ment hole in the blower deck and the lower pin/
screw rests against the side of the bottom panel.
See Figures 13-16.
Furnace
Cabinet
Side
y
f. Reinstall the furnace filter in the side position by
inserting the chamfer end first into the filter
rack.
Filter Rack
Retaining
Screw/Pin
Engagement Hole
For Filter Rack
Installation With
Bottom Return
SIDE
CUTOUT
e
RETAINING
PIN
(Both Sides)
Conversion kits for horizontal filters are BAYFLTR203
for 17 1/2" width cabinets, BAYFLTR204 for 21" width
cabinets, and BAYFLTR205 for 24" width cabinets.
These include filters and brackets necessary for hori-
zontal filters. In addition, optional door kit
SPRINGS
BAYFLTR206 is also available. See Figures 17 and 19.
RETURN AIR FILTERS FOR UPFLOW FURNACE IN
HORIZONTAL CONFIGURATION
BOTTOM
PANEL
INSTALLED
FILTER
RACK
RAILS
When the Upflow Furnace is installed in the horizontal
configuration, the return air filters must be installed
exterior to the furnace cabinet. Remote filter grilles
may be used for homeowner convenience or the filters
may be installed in the duct work upstream of the fur-
nace. See Figure 17.
Typical Upflow Left Side Return Filter Rack Installation
SIDE
CUTOUT
r
RETAINING
PIN
(Both Sides)
u
SPRINGS
BOTTOM
FILTER
PANEL
RACK
RAILS
INSTALLED
Optional door kit
BAYFLTR206
Typical Horizontal Filter Installation
Typical Upflow Right Side Return Filter Rack Installation
12
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER
INSTALLATIONS
ALTERNATE UPFLOW FILTER CLIP/
BRACKET INSTALLATION - KIT09224
These furnaces require high velocity type air filters.
Downflow furnace filters must be located outside the
furnace cabinet. Typical installations are shown in Fig-
ure 19. Tables 4, 5 and 6 provide information for instal-
lation of the filter retaining brackets shipped with
downflow furnaces.
1. Determine the location to be used. The furnace
cabinet has dimples for location of the alternate fur-
nace clips (Side return only). Pre-drill clearance
holes with a 3/16" drill. Bottom return holes are
pre-drilled. See Figure 18.
2. Install the clips in front and rear of the desired loca-
tion using the screws provided. The filter clip with
the leaf spring mounts in the rear of the cabinet.
TABLE 4
MODELS
NUMBERS
FILTER
QTY & SIZE
CABINET
WIDTH
*DX1B040A9H21B
*DX1B060A9H31B
*DX1B080A9H31B
17-1/2"
2 - 14" X 20" X 1"
i
REAR
*DX1C100A9H41B
*DX1D120A9H51B
21"
2 - 16" X 20" X 1"
2 - 16" X 20" X 1"
24-1/2"
SIDE
-OUT
CUT
*First letter may be "A" or "T"
TABLE 5
LOCATING FILTER RETAINER BRACKETS IN DUCTWORK
RETURN
DUCT
FILTER
CABINET
WIDTH
DIMENSION DIMENSION
BRACKET
LOCATION*
"A"
"B"
WIDTH
ALTERNATE FILTER
CLIPS LOCATION
17-1/2"
21"
16-1/4"
19-3/4"
23-1/4"
15"
19-1/2"
22"
14"
14"
14"
14-3/8"
13-1/8"
13-5/8"
24-1/2"
* LOCATION DIMENSION IS FROM END OF DUCT AGAINST THE FURNACE TO THE
SCREW HOLES FOR THE BRACKET.
Optional door kit
BAYFLTR206
o
Airflow
DOWNFLOW
DOWNFLOW/
HORIZONTAL
TABLE 6
MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR
UPFLOW/HORIZONTAL AND DOWNFLOW/ HORIZONTAL FURNACES
UNIT LOCATION
VERTICAL
CLOSET
HORIZONTAL
CLOSET
HORIZONTAL
ALCOVE / ATTIC
FURNACE SURFACE
SIDES
BACK
TOP
0"
0"
1"
3"
0"
1"
3"
1"
3"
0"
0"
6"
1"
FRONT
VENT
18"
0"
NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"
18-CD22D1-8
13
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliances
not connected to the common venting system. Turn
on any exhaust fans, such as range hoods and bath-
room exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan, close
fireplace dampers.
4. Follow the lighting instructions. Place the appliance
being inspected in operation. Adjust thermostat so
appliance will operate continuously.
5. Test for spillage at the draft hood relief opening af-
ter 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a ciga-
rette, cigar, or pipe.
GENERAL VENTING
THIS FURNACE MUST BE VENTED TO THE OUT-
DOORS.
THESE FURNACES ARE INDUCED DRAFT VENTED
AND MUST NOT BE CONNECTED TO ANY VENT
SERVING ANOTHER APPLIANCE. PLEASE NOTE
THAT THESE FURNACES USE POSITIVE-PRES-
SURE VENT SYSTEMS.
Proper venting is essential to obtain maximum effi-
ciency from a condensing furnace. Proper installation of
the vent system is necessary to assure drainage of the
condensate and prevent deterioration of the vent
system.
American Gas Association has certified the design of
condensing furnaces for a minimum of 0" clearance
from combustible materials with a single wall plastic
vent pipe.
The recommended system is assembled from 2", 2-1/2",
or 3" plastic pipe and fittings (See Table 7, page 12).
Where the system is routed to the outdoors through an
existing masonry chimney containing flue products
from another gas appliance, or where required by local
codes, then 3" venting of Type 29-4C stainless steel
must be used in place of PVC material.
6. After it has been determined that each appliance re-
maining connected to the common venting system
properly vents when tested as outlined above, re-
turn door, windows, exhaust fans, fireplace dampers
and any other gas-burning appliance to their previ-
ous conditions of use.
If improper venting is observed during any of the above
tests, the remaining common venting system must be
corrected. Correction of the remaining common vent
system should be done by referring to the latest edition
of the National Fuel Gas Code (ANSI Z223.1) • CAN/
CGA B149.1 Installation Codes or “Exhibit J” of
ANSI Z21.47 • CAN/CGA-2.3 Standards. The following
are general steps to be used to correct or resize a re-
maining vent system when a furnace which may not be
common vented is removed from the system:
a. Determine the Btu per hour input of all remain-
ing appliances attached to the venting system.
b. Determine the diameter, rise, and lateral of the
existing venting system, as well as quantity and
type of bends.
These furnaces have been classified as CATEGORY IV
furnaces in accordance with the latest edition of
ANSI Z21.47 • CAN/CGA-2.3 Standards. Category IV
furnaces operate with positive vent pressure and with a
vent gas temperature less than 140° F above the
dewpoint. These conditions require special venting sys-
tems, which must be gas tight and water tight.
NOTE:
When an existing furnace is removed from a venting
system serving other gas appliances, the venting sys-
tem is likely to be too large to properly vent the re-
maining attached appliances.
The following steps shall be followed with each appli-
ance remaining connected to the common venting sys-
tem placed in operation, while the other appliances re-
maining connected to the common venting system are
not in operation.
c. Use the appropriate tables in the latest edition of
the National Fuel Gas Code (ANSI Z223.1 •
CAN/CGA B149.1 Installation Codes or “Exhibit
J” of ANSI Z21.47 • CAN/CGA-2.3 Standards. “Ex-
hibit J” includes examples and drawings of typical
venting systems.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion or other
deficiencies which could cause an unsafe condition.
IMPORTANT:
These furnaces may be installed as Direct Vent (sealed combustion) or as Nondirect vent (single pipe). The furnaces are
shipped DIRECT VENT with sealed combustion.
For DIRECT VENT APPLICATION: The furnaces must be vented to the exterior of the house and combustion air MUST
come through the inlet air pipe FROM OUTSIDE AIR.
For NONDIRECT VENT APPLICATION: The furnace shall be vented to the exterior of the house, but combustion air may
enter from the surrounding area as long as combustion air requirements are met. (See AIR FOR COMBUSTION AND
VENTILATION)
14
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
2. After checking pipe and socket for proper fit, wipe
socket and pipe with cleaner-primer. Apply a liberal
coat of primer to inside surface of socket and out-
side of pipe.
DO NOT ALLOW PRIMER TO DRY BEFORE AP-
PLYING CEMENT.
3. Apply a thin coat of cement evenly in the socket.
Quickly apply a heavy coat of cement to the pipe
end and insert pipe into fitting with a slight twisting
movement until it bottoms out.
4. Hold the pipe in the fitting for 30 seconds to pre-
vent tapered socket from pushing the pipe out of
the fitting.
5. Wipe all excess cement from the joint with a rag.
Allow 15 minutes before handling. Cure time varies
according to fit, temperature and humidity.
PVC VENT FITTING MATERIAL
These fittings are available from your Gas Furnace
Distributors.
Straight Pipe Sections, Couplings, 45° Elbows, 60° El-
bows, 90° Elbows, Vent or Sanitary Tee, or other neces-
sary fittings may be 2", 2½", 3", or 4" diameter. The al-
lowable materials are shown in Table 7.
VENT FITTING MATERIAL – PLASTIC
Gas and liquid tight single wall vent fittings, designed
for resistance to corrosive flue condensate, MUST be
used throughout.
Listed in Table 8 & 9 are 2", 2½", 3", and 4" size fittings
that meet these requirements. The materials listed are
various grades of PVC and ABS plastic.
PIPE JOINTS: All joints must be fastened and sealed to
prevent escape of combustion products into the build-
ing.
TABLE 7
PLASTIC PIPE DESIGNATIONS
PVC
ASTM STANDARD
PIPE TYPE
CELLULAR CORE
DWV PIPE
ALLOWABLE TEMPERATURE
MARKING
ASTM F891
ASTM D2665
ASTM D1785
ASTM D2241
F891
D2665
D1785
D2241
*158
**158
**158
**158
SCH 40, 80, 120
SDR SERIES
CPVC
ABS
ASTM STANDARD
PIPE TYPE
CPVC 41
ALLOWABLE TEMPERATURE
MARKING
ASTM D2846
ASTM F441
ASTM F442
D2846
F441
F442
**212
**212
**212
SCH 40, 80
SDR SERIES
ASTM STANDARD
PIPE TYPE
SCH 40 DWV
ALLOWABLE TEMPERATURE
MARKING
ASTM D2661
ASTM F628
D2661
F628
***180
***180
SCH 40 DWV CELLULAR CORE
*
- Allowable temperatures based on classifications covered in ASTM D4396 [Deflection Temps Under Load (264 PSI)]
** - Allowable temperatures based on classifications covered in ASTM D1784 [Deflection Temps Under Load (264 PSI)]
*** - Allowable temperatures based on classifications covered in ASTM D3965 [Deflection Temps Under Load (264 PSI)]
NOTE:
IMPORTANT:
It is recommended that the first joints from the furnace
be connected and sealed with high temperature RTV.
This will enable the pipes to be removed later without
cutting.
Products installed in Canada must use vent systems
that are certified to the Standard for Type BH Gas Vent-
ing Systems (ULC S636) for Class II-A venting systems
(up to 65°C). Components of the vent system must not
be interchanged with other vent systems or unlisted
pipe or fittings. Plastic components, specified prim-
ers, and glues must be from a single system manufac-
turer and not intermixed with other system
manufacturer's vent system parts. In addition, the first
three feet of the vent pipe must be visible for inspec-
tion.
Be sure to properly support these joints.
BONDING OF PVC
Commercially available solvent cement must be used
to join the pipe and fittings. Follow instructions on the
container carefully.
Procedure for Cementing Joints:
1. Cut pipe square, remove ragged edges and burrs.
Chamfer end of pipe, then clean fitting socket and
pipe joint area of all dirt, grease, moisture or chips.
18-CD22D1-8
15
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
VENT AND INLET AIR CONNECTIONS
WHEN THE FACTORY SUPPLIED "OFF-SET" (2X3
REDUCING COUPLING) IS USED FOR 3" VENT PIPE
INSTALLATION, MAKE SURE THE MARKING "TOP" IS
LOCATED ON THE TOP SIDE OF THE PIPE.
Seal VENT PIPE
with RTV sealant
p
a
LABEL
SAYS
"TOP"
Front of Furnace
Seal INLET AIR PIPE
with RTV sealant
NOTE:
Follow venting instructions carefully when using PVC
cement.
STRAIGHT SIDE MUST BE
ON BOTTOM FOR PROPER
CONDENSATE DRAINAGE.
IMPORTANT:
All joints must be water tight. Flue condensate is some-
what acidic, and leaks can cause equipment damage.
2" TO 3" COUPLING
s
Connection of the pipe and collar of the combustion
air inlet should just be a friction fit. It is recommended
that the inlet air joint be sealed with RTV type sealant
to allow the joint to be separated for possible future ser-
vice. The inlet and vent pipes must be properly sup-
ported throughout the entire length.
Connection of the vent pipe to the vent collar should
also be accomplished using RTV type sealant. This type
sealant provides a connection which remains flexible
and can be separated in the future if service needs re-
quire the removal of the vent pipe for service or clear-
ance.
#CPL00838
FACTORY SUPPLIED ONLY
WITH THE FOLLOWING
MODELS:
UC120 & DC120
UX120 & UY120
UX100 & UY100
UX080C960
ALL DX & DY MODLES
UX3 & DX3
UH3 & DH3
NOTE:
FURNACE
VENT
OUTLET
To ensure proper operation at the vent lengths indi-
cated, the combustion air inlet and vent terminals
should be in the same pressure zone. Terminating the
vent and inlet in different pressure zones will change
the maximum vent lengths and may cause nuisance
tripping of the pressure switch(es). The amount of
change can not be predicted. The selection of the inlet
and outlet terminal locations are the responsibility of
the designer/installer. If the installer chooses separate
pressure zones for the terminals, the combustion air
inlet termination must be in the higher (more positive)
pressure zone.
HORIZONTAL INSTALLATION
(Upflow/ Horizontal or Downflow/ Horizontal)
NOTE:
In horizontal venting when the factory supplied “off-
set” (2X3 reducing coupling) is used for 3” vent pipe
installation, make sure the marking “Top” is located on
the top side of the pipe. The straight side must be on
bottom for proper condensate drainage. This coupling
is factory supplied only with the following models:
*UC120 & *DC120, *UX120 & *UY120 *UX100 & *UY100,
*UX808C960, and all *DX & *DY models.
HORIZONTAL VENTING
NOTE:
Vent
termination
kit
BAYAIR30AVENTA
or
BAYVENT200B may be used instead of the horizontal
and vertical termination options shown in the follow-
ing figures.
16
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
UPFLOW/ HORIZONTAL VENTING TABLE
TABLE 8
MAXIMUM VENT LENGTH:
DIRECT VENT (2 PIPE SYSTEM) -
MAXIMUM TOTAL EQUIVALENT FEET FOR
VENT AND INLET AIR PIPES (See Notes)
NONDIRECT VENT (1 PIPE SYSTEM) -
MAXIMUM TOTAL EQUIVALENT FEET FOR
VENT PIPE ONLY (See Notes)
2" PIPE
& FITTINGS
2-1/2" PIPE
3" PIPE
4" PIPE
2" PIPE
& FITTINGS
2-1/2" PIPE
3" PIPE
4" PIPE
MODEL
& FITTINGS & FITTINGS & FITTINGS
& FITTINGS & FITTINGS & FITTINGS
*UX1B040A9H21B
*UX1B060A9H31B
*UX1B080A9H31B
60
60
50
80
80
80
40
40
100
100
100
100
100
130
130
130
130
130
50
80
80
80
40
40
80
80
80
80
80
130
130
130
130
130
50
40
*UX1C100A9H41B NOT ALLOWED
*UX1D120A9H51B NOT ALLOWED
NOTES: * - First letter may be "A" or "T"
1. The INLET AIR of one pipe systems require the installation of a 90° elbow (to prevent dust and debris from falling straight into thefurnace) and a 2 foot
horizontal or vertical straight pipe section connected before or after the elbow.
2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace).
NOT ALLOWED
NOT ALLOWED
If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See Note 7 below for exception).
The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.
3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH OF EACH
(Vent or Inlet air pipes in two pipe systems).
4. One standard radius 90° elbow is equivalent to 12' of 4" pipe; one SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is
equivalent to 6' of 3" pipe. One SHORT/LONG radius 90° elbow is equivalent to 7½' of 2½" pipe, & 5' of 2" pipe. Two 45° elbows equal one 90°elbow.
5. The termination tee or bend must be included in the total number of elbows. If the BAYVENT100 termination kit is used, the equivalent length of pipe is 5 feet.
There is zero equivalent length for the BAYVENT200.
6. Pipe adapters are field supplied.
7. 4" pipe may be reduced to 3" for termination with BAYAIR30AVENTA or BAYVENT200 without additional length restriction.
MAXIMUM VENT LENGTH:
DIRECT VENT (2 PIPE SYSTEM) -
MAXIMUM TOTAL EQUIVALENT FEET FOR
VENT AND INLET AIR PIPES (See Notes)
NONDIRECT VENT (1 PIPE SYSTEM) -
MAXIMUM TOTAL EQUIVALENT FEET FOR
VENT PIPE ONLY (See Notes)
2" PIPE
& FITTINGS
2-1/2" PIPE
3" PIPE
4" PIPE
2" PIPE
& FITTINGS
2-1/2" PIPE
3" PIPE
4" PIPE
MODEL
& FITTINGS & FITTINGS & FITTINGS
& FITTINGS & FITTINGS & FITTINGS
*DX1B040A9H21B
*DX1B060A9H31B
*DX1B080A9H31B
60
50
45
80
80
80
80
15
100
100
100
100
60
130
130
130
130
130
50
80
80
80
80
25
80
80
80
80
70
130
130
130
130
130
50
40
*DX1C100A9H41B NOT ALLOWED
*DX1D120A9H51B NOT ALLOWED
NOTES: * - First letter may be "A" or "T"
1. The INLET AIR of one pipe systems require the installation of a 90° elbow (to prevent dust and debris from falling straight into thefurnace) and a 2 foot
horizontal or vertical straight pipe section connected before or after the elbow.
2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace).
NOT ALLOWED
NOT ALLOWED
If different inlet and vent pipe sizes are used, the vent pipe must adhere to the maximum length limit shown in the table above (See Note 7 below for exception).
The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.
3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH OF EACH
(Vent or Inlet air pipes in two pipe systems).
4. One standard radius 90° elbow is equivalent to 12' of 4" pipe; one SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is
equivalent to 6' of 3" pipe. One SHORT/LONG radius 90° elbow is equivalent to 7½' of 2½" pipe, & 5' of 2" pipe. Two 45° elbows equal one 90°elbow.
5. The termination tee or bend must be included in the total number of elbows. If the BAYAIR30VENTA termination kit is used, the equivalent length of pipe is 5 feet.
There is zero equivalent length for the BAYVENT200.
6. Pipe adapters are field supplied.
7. 4" pipe may be reduced to 3" for termination with BAYAIR30AVENTA or BAYVENT200 without additional length restriction.
DOWNFLOW
FURNACE
SINGLE PIPE VENTING
Air Inlet
d
UPFLOW FURNACE
A (0-2') or greater
B (0-2') or greater
A+B = 2' minimum
B
Vent only
to outside
Air Inlet
A
A
A = 2' minimum
Vent only
to outside
18-CD22D1-8
17
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
f
INSIDE
CORNER DETAIL
G
V
H
D
E
V
B
C
I
V
B
B
B
V
V
L
V
M
V
X
F
X
V
V
J
B
K
A
B
V
X
AREA WHERE TERMINAL IS NOT PERMITTED
VENT TERMINAL
AIR SUPPLY INLET
Direct Vent Terminal Clearances
Canadian Installations
US Installations
Clearance above grade, veranda, porch, deck, or
balcony
A=
B=
12 inches (30 cm)
12 inches (30 cm)
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12
inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/<
100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >
100,000 Btuh (30 kw)
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9
inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/<
50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000
Btuh (15 kw)
Clearance to window or door that may be opened
C=
D=
Clearance to permanently closed window
*
*
Vertical clearance to ventilated soffit located above the
terminal within a horizontal distance of 2 feet (61 cm)
from the center line of the terminal
*
*
E=
F=
G=
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
*
*
*
*
*
*
Clearance to each side of center line extended above
meter/regulator assembly
3 feet (91 cm) with a height 15 feet (4.5 m) above the
meter/regulator assembly
H=
I=
*
*
Clearance to service regulator vent outlet
3 feet (91 cm)
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12
inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/<
100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >
100,000 Btuh (30 kw)
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 9
inches (23 cm) for appliances > 10,000 Btuh (3 kw) and =/<
50,000 Btuh (15 kw), 12 inches (30 cm) for appliances > 50,000
Btuh (15 kw)
Clearance to nonmechanical air supply inlet to building
or the combustion air inlet to any other appliance
J=
K=
Clearance to a mechanical air supply inlet
6 feet (1.83m)
7 feet (2.13 m) †
`12 inches (30 cm) ‡
3 feet (91 cm) above if within 10 feet (3m) horizontally
Clearance above a paved sidewalk or paved driveway
located on public property
L=
*
*
M=
Clearance under veranda, porch, deck, or balcony
Notes:
1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.
2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.
†. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings.
‡. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
*
Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.
18
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
Non-Direct Vent Terminal Clearances
Canadian Installations
US Installations
Clearance above grade, veranda, porch, deck, or
balcony
A=
12 inches (30 cm)
12 inches (30 cm)
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12
inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/<
100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >
100,000 Btuh (30 kw)
4 feet (1.2m) below or to the side of opening; 1 foot (0.3m)
above opening.
B= Clearance to window or door that may be opened
C= Clearance to permanently closed window
*
*
*
Vertical clearance to ventilated soffit located above the
D= terminal within a horizontal distance of 2 feet (61 cm)
from the center line of the terminal
*
E= Clearance to unventilated soffit
*
*
*
*
*
*
F=
Clearance to outside corner
G= Clearance to inside corner
Clearance to each side of center line extended above
meter/regulator assembly
3 feet (91 cm) with a height 15 feet (4.5 m) above the
meter/regulator assembly
H=
*
*
I=
Clearance to service regulator vent outlet
3 feet (91 cm)
6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 12
inches (30 cm) for appliances > 10,000 Btuh (3 kw) and =/<
100,000 Btuh (30 kw), 36 inches (91 cm) for appliances >
100,000 Btuh (30 kw)
Clearance to nonmechanical air supply inlet to building
or the combustion air inlet to any other appliance
4 feet (1.2 m) below or to side of opening; 1 foot (300 m) above
opening
J=
K= Clearance to a mechanical air supply inlet
6 feet (1.83m)
7 feet (2.13 m) †
`12 inches (30 cm) ‡
3 feet (91 cm) above if within 10 feet (3m) horizontally
Clearance above a paved sidewalk or paved driveway
located on public property
L=
7 feet (2.13 m)
*
M= Clearance under veranda, porch, deck, or balcony
Notes:
1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.
2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.
†. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings.
‡. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
*
Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.
g
ELBOW AND TEE MUST BE
AS CLOSE TOGETHER
AS POSSIBLE
POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS
18-CD22D1-8
19
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
!
▲
CAUTION
Shield material to be a minimum of 24 gauge stainless
or aluminized sheet metal. Minimum dimensions are
12"x12". Shield must be fastened to both inside and out-
side of wall. Use screws or anchor type fasteners suited
to the outside or inside wall surfaces.
When the vent pipe is exposed to temperatures below
freezing, i.e., when it passes through unheated spaces,
etc., the pipe must be insulated with 1/2 inch (22.7 mm)
thick Armaflex-type insulation or equal. If the space is
heated sufficiently to prevent freezing, then the insula-
tion would not be required. If domestic water pipes are
not protected from freezing then it is assumed the
space meets the condition of a heated space.
NONCOMBUSTIBLE MATERIAL WALL
The hole through the wall must be large enough to maintain
pitch of vent and properly seal.
Use cement mortar seal on inside and outside of wall.
See Figure 29.
HORIZONTAL VENTING THROUGH WALL
These furnaces may be installed as direct vent (as
shipped) or as nondirect vent. Installation must con-
form to national, state, and local codes.
The vent & inlet terminals must be located at least 12"
minimum above normally expected snow accumulation
level.
VENTING THROUGH THE ROOF
When penetrating roof with a 2" PVC vent pipe, a 2"
electrical conduit flashing may be used for a weather
tight seal. Lubricate flexible seal on flashing before PVC
pipe is pushed through the seal. (Field Supplied)
Avoid areas where staining or condensate drippage may
be a problem.
Location of the vent/ wind terminal should be chosen to
meet the requirements of Figure 24 for either direct or
non-direct vent applications.
j
PITCH – Venting through the wall must maintain 1/4"
per foot pitched upward to insure that condensate
drains back to the furnace.
FLUE GAS DEGRADATION – The moisture content
of the flue gas may have a detrimental effect on some
building materials. This can be avoided by using the
roof or chimney venting option. When wall venting is
used on any surface that can be affected by this mois-
ture, it is recommended that a corrosion resistant
shield (24 inches square) be used behind the vent termi-
nal. This shield can be wood, plastic, sheet metal, etc.
Also, silicone caulk all cracks, seams and joints within 3
feet of the vent terminal.
BAYAIR30AVENTA
(Sidewall)
NOTE:
No vent cap as shown in Figure 33 is the preferred
method for vertical vent termination in extremely cold
climates.
In extreme climate conditions, insulate the exposed
pipe above the roof line with Armaflex type insulation.
h
ANCHORS
(4 req.)
VENT
PLATE
VENT
3.2"
12" MINIMUM
TO OVERHANG
k
COMBUSTION
AIR
SCREWS
(4 req.)
VENT
VENT
CAP
MAINTAIN 12" (18" FOR CANADA) MINIMUM
CLEARANCE ABOVE HIGHEST ANTICIPATED
SNOW LEVEL OR GRADE WHICHEVER IS GREATER
BAYVENT200B
COMBUSTIBLE MATERIAL WALL
A minimum clearance of 1" to combustible materials
must be maintained when using single wall stainless
steel venting. See Figure 28.
20
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
SUPPORT HORIZONTAL PIPE EVERY 3'
0" WITH THE FIRST SUPPORT AS CLOSE
TO THE FURNACE AS POSSIBLE.
l
;
INDUCED DRAFT BLOWER, HOUSING,
AND FURNACE MUST NOT SUPPORT
THE WEIGHT OF THE FLUE PIPE.
z
NOTE: VENT AND INLET MUST BE SUPPORTED
AT A MAXIMUM OF 3' INTERVALS
SEE VENTING TABLE
STRAPS OR OTHER SUITABLE SUPPORTS
AT MAXIMUM OF 3'-0" INTERVALS
USE ONLY
APPROVED
TERMINATION
COMBUSTION
AIR INLET
UPWARD PITCH -- 1/4" PER FOOT
FIRST SUPPORT SHOULD BE AS
CLOSE TO FURNACE CONNECTION
AS POSSIBLE.
OUTSIDE
WALL
40" UPFLOW OR
DOWNFLOW MODELS
NOTE: ANY FITTINGS PASSING
THROUGH AN UNHEATED SPACE
MUST BE INSULATED.
EE
COMBUSTION
AIR
REDUCING
COUPLING,
FIELD SUPPLIED
IF NEEDED
STRAP
(FIELD SUPPLIED)
RAIN CAP
VENT
2", 2-1/2"
or 3" PIPING
VENT
1" + 1/2"
ELBOW
(FIELD
COMBUSTION AIR
3" PIPING
SUPPLIED)
SEAL ALL
WALL CAVITIES
BAYAIR30AVENTA
BAYVENT200B
18-CD22D1-8
21
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
DOWNWARD VENTING
Furnace may be in vertical
or horizontal configuration.
NOTE:
x
Both venting methods shown in Figure 30 & 31 must
also have the combustion air inlet installed - meeting
dimension requirements of Figure 21.
DOWNWARD VENT
LENGTH IS LIMITED
TO A MAXIMUM OF 15
EQUIVALENT FEET.
c
40 Inch
Upflow or
Downflow
Furnace
Slope 1/4" per ft.
Slope 1/4" per ft.
6" Min.
All horizontal pipes must be supported
at a maximum of 3 foot intervals
v
NOTES:
A) Condensate trap for vent pipe must be a minimum
of 6 inches in height.
B) Condensate trap for vent and inlet pipe must be
connected into a condensate drain pump; an open
or vented drain; or it can be connected to the outlet
hose of the furnace's condensate trap. Outdoor
draining of the furnace and coil condensate is per-
missible if allowed by local codes. Caution should
be taken to prevent drains from freezing or causing
slippery conditions that could lead to personal in-
jury. Excessive draining of condensate may cause
saturated ground conditions that may result in
damage to plants.
MAINTA
(18 IN. F
MINIMU
ABOVE
ANTICIP
LEVEL
24 IN. A
BAYAIR30AVENTA
CONCENTRIC VENT
ROOF TOP APPLICATION
C) The condensate trap should be primed at initial
start up prior to heating season operation.
MAINTAIN 12 IN.
VENT
b
(18 IN. FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24 IN. ABOVE ROOF
VENTING ROUTED THROUGH A MASONRY CHIMNEY
VENT FITTING MATERIAL – STAINLESS STEEL
Gas and liquid tight single wall metal vent fitting, de-
signed for resistance to corrosive flue condensate such
as Type 29-4C MUST be used throughout.
These fittings and fitting accessories are to be supplied
locally.
REMOVE RIBS
FROM CAP
COMBUSTION
AIR
ROOF BOOT
(FIELD SUPPLIED)
SUPPORT
(FIELD SUPPLIED)
DIRECTION OF STAINLESS STEEL FITTING
All stainless steel fitting must be installed with male
end towards the furnace.
ELBOW
All horizontal stainless steel sections must be posi-
tioned with the seam on top.
(FIELD SUPPLIED)
All long horizontal sections must be supported to pre-
vent sagging.
COMBUSTION
AIR
VENT
All pipe joints must be fastened and sealed to prevent
escape of combustion products into the building.
CONCENTRIC VENT
ROOF INSTALLATION
22
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
INSPECTION. The state or local gas inspector of
IMPORTANT:
4.
the side wall horizontally vented gas fueled equipment
shall not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of 248
CMR 5.08(2)(a)1 through 4.
The Commonwealth of Massachusetts requires compliance
with regulation 248 CMR 4.00 and 5.00 for installation of
through – the – wall vented gas appliances as follows:
This appliance requires a special venting system. If
BAYAIR30AVENTA or BAYVENT200B are used, a copy of
the installation instructions for the kit shall remain with
the appliance or equipment at the completion of
installation. The venting system installation instructions
can be obtained from the manufacturer by writing to the
following address:
For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7)
feet above finished grade in the area of the venting,
including but not limited to decks and porches, the
following requirements shall be satisfied:
American Standard, Inc.
1.
INSTALLATION OF CARBON MONOXIDE
6200 Troup Highway
Tyler, TX 75707
Attention: Manager of Field Operations Excellence
DETECTORS. At the time of installation of the side wall
horizontal vented gas fueled equipment, the installing
plumber or gasfitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-
up is installed on the floor level where the gas equipment
is to be installed. In addition, the installing plumber or
gasfitter shall observe that a battery operated or hard
wired carbon monoxide detector with an alarm is installed
on each additional level of the dwelling, building or
structure served by the side wall horizontal vented gas
fueled equipment. It shall be the responsibility of the
property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon
monoxide detectors
a.
In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space or an
attic, the hard wired carbon monoxide detector with alarm
and battery back-up may be installed on the next adjacent
floor level.
b.
In the event that the requirements of this
subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30)
days to comply with the above requirements; provided,
however, that during said thirty (30) day period, a battery
operated carbon monoxide detector with an alarm shall be
installed.
2.
APPROVED CARBON MONOXIDE
DETECTORS. Each carbon monoxide detector as required
in accordance with the above provisions shall comply with
NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3.
SIGNAGE. A metal or plastic identification plate
shall be permanently mounted to the exterior of the
building at a minimum height of eight (8) feet above grade
directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than
one-half (1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
18-CD22D1-8
23
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
SEAL BETWEEN FLANGE, PIPE,
COUPLING AND METAL PANEL
WITH HI TEMP RTV SILICONE SEALANT
,
FLUE PIPE
COUPLING
SUPPORT
FLANGE
CEILING
GALVANIZED FIRESTOP SHOULD
BE FABRICATED WITH 3-7/8" DIA.
HOLE FOR SUPPORT FLANGE
(12" x 12" PANEL OR 12" DIA MIN.)
CLEARANCE ( 0" ACCEPTABLE FOR PVC VENT PIPE )
( 1" ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE )
m TYPE 29-4C STAINLESS STEEL VENTING -
USED THROUGH CHIMNEY THAT VENTS
ANOTHER GAS APPLIANCE
VENTING THROUGH CEILING
STAINLESS
STAINLESSSTEEL
VENTCAP
PVC PLASTIC VENTING - ONLY
THROUGH UNUSED CHIMNEY
(OPTIONAL)
EE CAUTION
.
6 IN. MIN.
STAINLESSSTEEL
VENTCAP
(OPTIONAL)
SUPPORT THE SINGLE WAL
STAINLESS STEEL GAS
VENTING AND CENTER IT IN
THE CHIMNEY OPENING WIT
ANGLES AS SHOWN OR
ANOTHER EQUIVALENT
MANNER.
SEE CAUTION
FLUE PIPE
6 IN. MIN.
SUPPORT THE SINGLE
OUPLING TO SUPPORT
PE FROM ANGLES
R OTHER SUITABLE
UPPORT METHOD
WALL FLUE PIPE AND
CENTER IT IN THE
CHIMNEY OPENING WI
ANGLES AS SHOWN O
ANOTHER EQUIVALEN
MANNER.
COUPLING
AS REQUIRED
FLUE PIPE
NOTE:
HORIZONTAL VENTING
TO VERTICAL VENTING
!
▲
CAUTION
Do NOT run vent through chimney for wood burning
or oil furnaces or incinerators.
If remaining free area between single wall flue pipe
and masonry chimney is to be used for another gas
appliance venting area must be sufficient to vent
that appliance and that appliance must be con-
nected to chimney with separate entry openings.
NOTE:
HORIZONTAL VENTING
TO VERTICAL VENTING
!
▲
CAUTION
Do NOT run vent through chimney for wood burn-
ing or oil furnaces or incinerators or any other gas
appliance.
IMPORTANT –
The single wall flue pipe joints must be sealed.
The 90° elbow connection to vertical pipe must be
sealed to prevent condensate leakage to base of ma-
sonry chimney.
IMPORTANT –
The single wall flue pipe joints must be sealed.
The 90° elbow connection to vertical pipe must be
sealed to prevent condensate leakage to base of ma-
sonry chimney.
24
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
Downflow furnace - The furnace is shipped with the
left side drainage setup. To change the right side drain,
remove the drain lines from the trap, rotate the trap
180° so it exits to the right, reconnect the lines, and run
a 1/2" CPVC pipe from the trap out through the right
side knockout. Use RTV silicone sealant to connect the
CPVC pipe to the trap for ease of removing to clean the
trap.
CONDENSATE DRAIN INSTRUCTIONS
!
▲
CAUTION
IT IS RECOMMENDED THAT A DRAIN PAN BE INSTALLED
UNDERTHE FURNACETO PREVENT PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH FROM LEAKING CONDEN-
SATE.
VERTICAL APPLICATIONS
HORIZONTALAPPLICATIONS
Upflow furnace - The connection tubing for left and
right side drainage is shipped in the blower compart-
ment. Install the connection tubing from the trap to the
side of the unit and trim all excess tubing to avoid
kinks.
Upflow and Downflow furnaces - All horizontal appli-
cations are left side only. It is always recommended that
the auxiliary drain pan be installed under a horizontally
installed evaporator and/or 90% gas furnace. Connect the
auxiliary drain pan to a separate drain line (no trap is
needed in this line).
/
@
Left side
Right side
UPFLOW (VERTICAL)
UPFLOW (VERTICAL)
#
!
Use
extension
hose here
UPFLOW HORIZONTAL
17" UNITS
Use Inducer Drain
hose without
extension
UPFLOW HORIZONTAL 21" & 24" UNITS
(Left side only)
(Left side only)
18-CD22D1-8
25
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
The trap must be repositioned to the exterior of the
cabinet. Remove the trap from its present location and
reposition the trap outside of the unit, through the long
circular hole, next to the secondary recuperative cell.
Remove the larger drain line (from the secondary cell)
and trim to fit between the secondary cell and the new
trap location. On upflow units, plug the hole in the
blower deck where the tube went through.
^
Remove the hose from the induced blower and reposi-
tion into the other drain tap of the inducer, which is lo-
cated 90° clockwise around the inducer. Move the cap
from that drain tap to the unused drain tap. On upflow
units, plug the hole in the blower deck where the tube
went through. This tube on downflow units will need to
be cut to fit between the inducer and the trap. On up-
flow units, this tube may need to be extended, using the
tubing shipped with the furnace.
Cut off curved end of
Inducer drain hose
DOWNFLOW (HORIZONTAL)
Connections must be made to an OPEN/ VENTED
DRAIN. Outdoor draining of the furnace and coil con-
densate is permissible if allowed by local codes. Caution
should be taken to prevent drains from freezing or caus-
ing slippery conditions that could lead to personal in-
jury. Excessive draining of condensate may cause satu-
rated ground conditions that may result in damage to
plants.
$
NOTE:
Use 1/2" or larger PVC or CPVC pipe and fittings as re-
quired for drain connections (fittings, pipe and solvent
cement not provided).
Left
side
NOTE:
A corrosion resistant condensate pump must be used
if a pump is required for a specific drain system.
IMPORTANT:
The condensate drain should be installed with provisions to
prevent winter freeze-up of the condensate drain line. Fro-
zen condensate will block drains, resulting in furnace shut-
down. If the drain line cannot be installed in a conditioned
space, then UL listed heat tape should be applied as re-
quired to prevent freezing (per manufacturer’s instructions).
The heat tape should be rated at 5 or 6 watts per foot at
120 volts. Self-regulating (preferred) or thermostatically
controlled heat tape is required.
DOWNFLOW (VERTICAL)
%
Evaporator and furnace condensate drain piping may
be manifolded together. A primary drain vent stack
must be installed and terminated below the outlet of
the secondary heat exchanger drain connection to pre-
vent water from damaging furnace controls if the pri-
mary drain outlet plugs up. Where the furnace is in-
stalled above a finished ceiling, the primary drain vent
stack must be installed such that overflow from the
vent stack opening will flow into an axillary drain pan
in order to prevent water damage to the finished ceiling
below.
Right
side
DOWNFLOW
(VERTICAL)
Use CPVC tubing from Trap outlet,
over burner box to cabinet exit
26
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
ELECTRICAL CONNECTIONS
Make wiring connections to the unit as indicated on en-
closed wiring diagram. As with all gas appliances using
electrical power, this furnace shall be connected into a
permanently live electric circuit. It is recommended
that furnace be provided with a separate “circuit protec-
tion device” in the electric circuit. The furnace must be
electrically grounded in accordance with local codes or
in the absence of local codes with the National Electri-
cal Code, ANSI/ NFPA 70 or CSA C22.1 Electrical Code,
if an external electrical source is utilized. The inte-
grated furnace control is polarity sensitive. The hot
leg of the 120V power supply must be connected to the
black power lead as indicated on the wiring diagram.
Provision for hooking up an electronic air cleaner and
or humidifier is provided on the integrated control.
Refer to the SERVICE FACTS literature and unit wir-
ing diagram attached to furnace diagram attached to
furnace.
&
If upflow furnace is installed
over a finished ceiling, overflow
from the primary drain vent
stack must flow into an auxillary
drain pan to prevent damage to
the finished ceiling below.
Primary drain vent stack
must terminate below
secondary heat exchanger
condensate drain outlet.
TWINNING FURNACES
These furnaces may be twinned. Twinning requires
that two furnaces with the same configuration, capacity,
and airflow must be used. They shall have common re-
turns with equal pressure drops or ducts with equiva-
lent lengths and sizes. See Field Wiring Diagrams for
proper hookup.
To drain opening
FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE
1 STAGE HEATING
USING A 1 STAGE HEATING THERMOSTAT
NO COOLING
FURNACE
SEE
NOTE 7
TWIN
SEE
NOTE 6
TO 115 V 1 PH.,
60 HZ., POWER
SUPPLY PER
B/C
B/C
LOCAL CODES
HUM SEE
NOTE 5
EAC SEE
NOTE 5
From drawing B341437 Rv 1
18-CD22D1-8
27
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
FIELD WIRING DIAGRAM FOR 1 STAGE FURNACE
1 STAGE HEATING, 1 STAGE COOLING
USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT
(OUTDOOR SECTION WITHOUT TRANSFORMER)
FURNACE
OUTDOOR UNIT
(NO TRANSFORMER)
SEE
NOTE 6
SEE
NOTE 8
B/C
B/C
TO 115 V 1 PH.,
60 HZ., POWER
SUPPLY PER
LOCAL CODES
HUM SEE
NOTE 5
EAC SEE
NOTE 5
From drawing B340388 Rv 2
TWINNING CONNECTION DIAGRAM
FOR TWINNING 1 STAGE FURNACES WITH
SINGLE WIRE TWINNING FEATURE
1 STAGE HEATING ONLY THERMOSTAT
1 STAGE HEAT
ONLY
THERMOSTAT
(WITH FAN SWITCH)
FURNACE NO. 1
FURNACE NO. 2
BLOWER OPERATION OF
UNIT NO. 2 IS SYNCRONIZED
WITH UNIT NO. 1 VIA SIGNALS
FROM TWIN CONNECTION.
TWIN
TWIN
SEE NOTE 4
ISOLATION RELAY
(FIELD SUPPLIED)
SEE NOTE 4
R1
R1
ISOLATION RELAY
SEE NOTE 4
SEE NOTE 3
B/C
B/C
B/C
From Dwg. 21B341422 Rev. 3
28
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
TWINNING CONNECTION DIAGRAM
FOR TWINNING 1 STAGE FURNACES WITH
SINGLE WIRE TWINNING FEATURE
1 STAGE HEAT / 1 STAGE COOL THERMOSTAT
1 STAGE
OUTDOOR UNIT
(WITH TRANSFORMER)
HEATING / COOLING
THERMOSTAT
FURNACE NO. 1
FURNACE NO. 2
BLOWER OPERATION OF
UNIT NO. 2 IS SYNCRONIZED
WITH UNIT NO. 1 VIA SIGNALS
FROM TWIN CONNECTION.
TWIN
TWIN
ISOLATION RELAY
(FIELD SUPPLIED)
SEE NOTE 3
SEE NOTE 4
OUTDOOR UNIT
(NO TRANSFORMER)
R1
ISOLATION RELAY
SEE NOTE 4
R1
SEE NOTE 5
B/C
B/C
B/C
ISOLATION RELAY
(FIELD SUPPLIED)
SEE NOTE 4
From Dwg. 21B341423 Rev. 2
GAS PIPING
NOTE:
Maximum pressure to the gas valve for natural gas is
13.8" W.C. Minimum pressure is 5.0" W.C. Maximum
pressure to the gas valve for propane is 13.8" W.C.
Minimum pressure is 11.0" W.C.
All gas fittings must be checked for leaks using a
soapy solution before lighting the furnace. DO NOT
CHECK WITH AN OPEN FLAME!
The upflow/ horizontal furnace is shipped standard for
left side installation of gas piping. A knockout is pro-
vided on the right side for an alternate gas piping ar-
rangement. See Figure 37.
The installation of piping shall be in accordance with
piping codes and the regulations of the local gas com-
pany. Pipe joint compound must be resistant to the
chemical reaction with liquefied petroleum gases.
Refer to piping Table 10, for delivery sizes. Connect gas
supply to the unit, using a ground joint union and a
manual shut-off valve as shown in Figures 37-39.
National codes require a condensation drip leg to be in-
stalled ahead of the controls as shown in Figures 37-39.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
excess of 1/2 psig (3.5 kPa).
The furnace must be isolated from the gas supply piping
by closing its individual manual shut-off valve during
any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 psig (3.5 kPa).
18-CD22D1-8
29
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
*
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
MAIN MANUAL
SHUTOFF VALVE
MAIN MANUAL
SHUTOFF VALVE
GROUND
UNION
JOINT
GROUND
UNION
JOINT
DRIP
LEG
DRIP
LEG
UPFLOW – LEFT HAND GAS PIPING
UPFLOW – RIGHT HAND GAS PIPING
(
THE DOWNFLOW (VERTICAL) MAY BE INSTALLED LEFT OR RIGHT SIDE GAS PIPING
MAIN MANUAL
SHUTOFF VALVE
)
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
GROUND UNION JOINT
DRIP
LEG
MAIN MANUAL
SHUTOFF VALVE
DRIP
LEG
GROUND
UNION JOINT
AUTOMATIC GAS VALVE
WITH MANUAL SHUTOFF
HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE (UPFLOW SHOWN)
30
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
b.Attach a manifold pressure gauge to the outlet
pressure tap marked "OUT PRESS TAP" on
White-Rodgers gas valve model 36F or boss
marked "OUT P" on White-Rodgers gas valve
model 36G. (See Figure 53 for White-Rodgers gas
valve model 36F and Figure 54 for White-Rodgers
gas valve model 36G.). For the gas valve model
36F, measurement requires removal of the plug
and installation of a barbed fitting. Attach flexible
tubing and a manometer to the barbed fitting.
For the gas valve model 36G, do not remove the
pressure tap test screw. Using a 3/32" hex
wrench, loosen the pressure tap test screw one
turn and install 5/16" flexible tubing and a ma-
nometer directly onto the outlet pressure boss.
c. Turn on system power and energize valve.
d.Remove the regulator adjustment screw cap on
the gas valve for manifold pressure adjustment.
e.Turn the adjustment nut clockwise to increase
the gas flow rate, and counterclockwise to de-
crease the gas flow rate using a 3/32" hex wench.
f. The final manifold pressure setting shall be as
specified in Table 12 with an input of no more
than nameplate rating and no less than 93% of
the nameplate rating, unless the unit is derated
for high altitude.
!
▲
CAUTION
Use a backup wrench on the gas valve when installing
gas piping to prevent damage to the gas valve and
manifold assembly.
TABLE 10
NATURAL GAS ONLY
TABLE OF CUBIC FEET PER HOUR OF GAS
FOR VARIOUS PIPE SIZES AND LENGTHS
LENGTH OF PIPE
PIPE
SIZE
10
132
278
520
1050
20
30
40
50
60
50
70
46
1/2
3/4
1
92
73
63
56
190
350
730
152
285
590
130
245
520
115
215
440
105
195
400
96
180
370
1-1/4
This table is based on pressure drop of 0.3 inch W.C. and 0.6 SP.GR. gas
TABLE 11
ORIFICE SIZES
MAIN BURNER ORIFICE
DRILL SIZE
INPUT
RATING
BTUH
NUMBER
OF
BURNERS
NAT. GAS
LP GAS
40,000
60,000
80,000
100,000
120,000
2
3
4
5
6
45
45
45
45
45
56
56
56
56
56
g.Replace the regulator adjustment screw cap and
tighten securely.
h.Turn off all electrical power to the system.
i. Remove the manometer and flexible tubing. Re-
move the barbed fitting and replace the plug or
tighten the pressure test screw.
j. Turn on electrical power to the system and ener-
gize valve.
k.Using a leak detection solution or soap suds,
check for leaks at plug or pressure boss screw.
COMBUSTION AND INPUT CHECK
1. Make sure all gas appliances are off except the fur-
nace.
2. Clock the gas meter with the furnace operating (de-
termine the dial rating of the meter) for one revolu-
tion.
3. Match the “Sec” column in the gas flow (in cfh)
Table 13 with the time clocked.
4. Read the “Flow” column opposite the number of sec-
onds clocked.
5. Use the following factors if necessary:
For 1 Cu. Ft. Dial Gas Flow CFH =
Chart Flow Reading ÷2
For 1/2 Cu Ft. Dial Gas Flow CFH =
Chart Flow Reading ÷4
For 5 Cu. Ft. Dial Gas Flow CFH =
10X Chart Flow Reading ÷4
6. Multiply the final figure by the heating value of the
gas obtained from the utility company and compare
to the nameplate rating. This must not exceed the
nameplate rating.
7. Changes can be made by adjusting the manifold
pressure or changing orifices (orifice change may
not always be required). To adjust the manifold
pressure:
a. Turn off all electrical power to the system.
18-CD22D1-8
31
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
Q
!
▲
CAUTION
Input rate changes can be made by adjusting the mani-
fold pressure (min 3.0 - max 3.7 in. W.C. - Natural Gas)
or changing orifices (orifice change may not always be
required). If the desired input rate can not be achieved
with a change in manifold pressure, then the orifices
must be changed. LP installations will require an orifice
change.
Replace and/ or tighten all plugs removed or loosened
when adjusting gas pressure. Leak check the fittings
before placing the furnace into regular service.
Failure to follow this warning could result in fire, ex-
plosion, or property damage.
NOTE:
Installation of this furnace at altitudes above 2,000 ft.
(610m) shall be in accordance with local codes, or in the
absence of local codes, the National Fuel Gas Code,
The manifold pressure must be referenced to the
burner box. The burner box pressure tap equalizes the
gas valve pressure regulator. Manifold pressure is
checked by installing a tee (field supplied) in the tub-
ing, between the tee coming from the burner box tube
and the gas valve, in addition to the regular gas valve
pressure tap on the outlet side of the gas valve. See
Figure 51.
TABLE 13
GAS FLOW IN CUBIC FEET PER HOUR
2 CUBIC FOOT DIAL
SEC. FLOW SEC. FLOW SEC. FLOW SEC. FLOW
8
9
900
800
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
267
257
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
248
240
232
225
218
212
206
200
195
189
185
180
176
172
167
164
160
157
153
150
147
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
144
141
138
136
133
131
129
126
124
122
120
116
112
109
106
103
100
97
82
84
86
88
90
92
94
96
98
100
104
108
112
116
120
124
128
132
136
140
144
88
86
84
82
80
78
76
75
73
72
69
67
64
62
60
58
56
54
53
51
50
!
▲
CAUTION
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Replace manifold pressure tap threaded plug and leak
check after checking/ adjusting manifold gas pressure.
Table 11 lists the main burner orifices used with the fur-
nace. If a change of orifices is required to correct the
furnace input rating refer to Table 14.
TABLE 12
FINAL MANIFOLD PRESSURE SETTINGS
FUEL
PRESSURE
NATURAL GAS
3.5" W.C.
LP GAS
11.0" W.C.
HIGH ALTITUDE DERATE
Input ratings (BTUH) of these furnaces are based on
sea level operation and should not be changed at eleva-
tions up to 2,000 ft.
95
92
90
If the installation is 2,000 ft. or above, the furnace input
rate (BTUH) shall be reduced 4% for each 1,000 ft.
above sea level. The furnace input rate shall be checked
by clocking the gas flow rate (CFH) and multiplying by
the heating value obtained from the local utility sup-
plier for the gas being delivered at the installed altitude.
32
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
TABLE 15
ROTATE THE FRONT
COVER AS SHOWN
W
Orifice
Twist Drill
Size If
ALTITUDE ABOVE SEA LEVEL
INSERT THE TOP
FLANGE OF THE
FRONT COVER
UNDER THE LIP
INSIDE THE BOX
and Orifice Required At Other Elevations
Installed
At Sea
Level
2000 3000 4000 5000 6000 7000 8000 9000 10000
42
43
44
45
46
47
42 43 43 43 44 44 45 46
44 44 44 45 45 46 47 47
45 45 45 46 47 47 48 48
46 47 47 47 48 48 49 49
47 47 47 48 48 49 49 50
47
48
50
50
51
52
ALL SIDE FLANGES
MUST BE OUTSIDE
OF THE BOX
48 48 49 49 49 50 50
51
ROTATE THE FRONT
COVER INWARD
MAKING SURE THAT
ALL SIDE FLANGES
ARE OUTSIDE OF THE
BOX.
54
55
56
57
58
54 55 55 55 55 55 56 56
55 55 55 56 56 56 56 56
56 56 57 57 57 58 59 59
56
57
60
63
64
58 59 59 60 60
61 62 63
59 60 60 61 62 62 63 63
From National Fuel Gas Code - Table F-4
!
▲
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the installation instructions for the
venting system being placed into operation could re-
sult in carbon monoxide poisoning or death.
ANSI Z223.1/ NFPA 54 or National Standard of
Canada, Natural Gas and Propane Installation Code,
CSA B149.1. Installation of this furnace at altitudes
above 2,000 ft. (610m) shall be made in accordance with
the listed high Altitude Conversion Kit available with
this furnace.
START UP AND ADJUSTMENT
PRELIMINARY INSPECTIONS
With gas and electrical power “OFF”
1. Duct connections are properly sealed
2. Filters are in place
IMPORTANT:
Re-install the propane orifices to the same depth as the
orifices supplied with the equipment.
3. Venting is properly assembled
4. Blower door is in place
See Table 15 for help in selecting orifices if orifice
change is required. Furnace input rate and tempera-
ture rise should be checked again after changing ori-
fices to confirm the proper rate for the altitude.
Installations above 4,000 feet may require a pressure
switch change. If required, use the BAYHALT*** Kit
(High Altitude Accessory Kit) listed in PRODUCT DATA.
Flip the switch on main gas valve within the unit to the
“OFF” position. Turn the external gas valve to “ON”.
Purge the air from the gas lines. After purging, Check
all gas connections for leaks with a soapy solution —
DO NOT CHECK WITH AN OPEN FLAME. Allow 5 min-
utes for any gas that might have escaped to dissipate.
LP Gas being heavier than air may require forced venti-
lation. Flip the switch on the gas valve in the unit to
the “ON” position.
TABLE 14
PART NUMBERS FOR REPLACEMENT ORIFICES
DRILL
SIZE
PART
NUMBER
DRILL
SIZE
PART
NUMBER
44
45
46
47
48
49
50
ORF00501
ORF00644
ORF00909
ORF00910
ORF01099
ORF00503
ORF00493
54
55
56
57
58
59
ORF00555
ORF00693
ORF00907
ORF00908
ORF01338
ORF01339
Regulator
Adjustment
E
Outlet Pressure Boss
REINSTALLATION OF THE BURNER BOX COVER
Figure 52 shows the correct way to reinstall the burner
box cover if adjustment or replacement of the flame
sensor, hot surface igniter, or main burner orifices have
required removal of the cover.
Inlet Pressure
Boss (opt.)
On/Off Switch
White-Rodgers 36G gas valve
18-CD22D1-8
33
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
SEQUENCE OF OPERATION
Thermostat call for heat
R
On/Off Switch
R and W thermostat contacts close signaling the control
module to run its self-check routine. After the control
module has verified that the pressure switch contacts
are open and the limit switch(es) contacts are closed,
the draft blower will be energized.
As the induced draft blower comes up to speed, the
pressure switch contacts will close and the ignitor warm
up period will begin. The ignitor will heat for approxi-
mately 20 seconds, then the gas valve is energized to
permit gas flow to the burners. The flame sensor con-
firms that ignition has been achieved.
After the flame sensor confirms within a 4 second trial
period that ignition has been achieved, the delay to fan
ON period begins timing. After approximately 45 sec-
onds the indoor blower motor will be energized and con-
tinue to run during the heating cycle.
When the thermostat is satisfied, R and W thermostat
contacts open, the gas valve will close, the flames will
extinguish, and the induced draft blower will be de-en-
ergized. The indoor blower motor will continue to run
for the fan off period (Field selectable at 60, 100, 140 or
180 seconds), then be de-energized by the control mod-
ule.
White-Rodgers 36F gas valve
LIGHTING INSTRUCTIONS
!
▲
WARNING
DO NOT attempt to manually light the burner.
Failure to follow this warning could result in property
damage, personal injury or death.
Lighting instructions appear on each unit. Each instal-
lation must be checked out at the time of initial start up
to insure proper operation of all components. Check out
should include putting the unit through one complete
cycle as outlined below.
CONTROL AND SAFETY SWITCH ADJUSTMENTS
LIMIT SWITCH CHECK OUT
Turn on the main electrical supply and set the thermo-
stat above the indicated temperature. The ignitor will
automatically heat, then the gas valve is energized to
permit the flow of gas to the burners. After ignition and
flame is established, the flame control module monitors
the flame and supplies power to the gas valve until the
thermostat is satisfied.
The limit switch is a safety device designed to close the
gas valve should the furnace become overheated. Since
proper operation of this switch is important to the
safety of the unit, it must be checked out on initial
start up by the installer.
To check for proper operation of the limit switches, set
the thermostat to a temperature higher than the indi-
cated temperature to bring on the gas valve. Restrict
the airflow by blocking the return air (disconnecting the
indoor blower may trip the inducer limit). When the
furnace reaches the maximum outlet temperature as
shown on the rating plate, the burners must shut off. If
they do not shut off after a reasonable time and over-
heating is evident, a faulty limit switch is probable and
the limit switch must be replaced. After checking the
operation of the limit control, be sure to remove the pa-
per or cardboard from the return air inlet. Refer to Ser-
vice Facts for additional instructions.
To shut off.
For complete shut-down: Flip the switch on the main
gas valve to the “OFF” position, (See Figure 53 & 54).
Disconnect the electrical supply to the unit.
!
▲
CAUTION
If this is done during the cold weather months, provi-
sions must be taken to prevent freeze-up of all water
pipes and water receptacles.
Failure to follow this warning could result in property
damage.
Whenever your house is to be vacant, arrange to have
someone inspect your house for proper temperature.
This is very important during freezing weather. If for
any reason your furnace should fail to operate damage
could result, such as frozen water pipes.
NOTE TO INSTALLER
Review the following warnings with the owner. Review
contents of USER’S INFORMATION MANUAL with the
owner.
34
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
BURNER BOX TEMPERATURE LIMIT DEVICE
AIRFLOW ADJUSTMENT
Check inlet and outlet air temperatures to make sure All models are equipped with a manual reset tempera-
they are within the ranges specified on the furnace rat- ture limit located on the burner box. In case of exces-
ing nameplate. If the airflow needs to be increased or sive temperature, the limit will open and cause the cir-
decreased, see the wiring diagram for information on cuit to open which shuts off all flow of gas.
changing the speed of the blower motor.
CONDITIONS AFFECTING FURNACE OPERATION
1. EXCESSIVE COMBUSTION PRESSURE (WIND IN
EXCESS OF 40 M.P.H.) VENT OR FLUE BLOCKAGE
If pressure against induced draft blower outlet be-
comes excessive, the pressure switch will open and
shut off the gas valve until acceptable combustion
pressure is again available.
!
▲
WARNING
Disconnect power to the unit before removing the
blower door.
Failure to follow this warning could result in property
damage, personal injury or death.
This unit is equipped with a blower door switch which
cuts power to the blower and gas valve causing shut-
down when the door is removed. Operation with the
door removed or ajar can permit the escape of danger-
ous fumes. All panels must be securely closed at all
times for safe operation of the furnace.
2. LOSS OF FLAME
If loss of flame occurs during a heating cycle, or
flame is not present at the sensor, the flame control
module will close the gas valve. The flame control
module will then recycle the ignition sequence,
then if ignition is not achieved, it will shut off the
gas valve and lock out the system.
INDOOR BLOWER TIMING
Heating: The integrated furnace control module controls
the indoor blower. The blower start is fixed at 45
seconds after ignition. The FAN-OFF period is field
selectable by dip switches at 60, 100, 140, or 180 sec-
onds. The factory setting is 100 seconds (See wiring
diagram).
3. POWER FAILURE
If there is a power failure during a heating cycle,
the system will restart the ignition sequence auto-
matically when power is restored if the thermostat
still calls for heat.
4. GAS SUPPLY FAILURE
Cooling: The fan delay off period is factory set at 0
seconds. The option for 80 second delay off is field
selectable (See wiring diagram).
ROOM AIR THERMOSTAT
HEAT ANTICIPATOR ADJUSTMENT
If loss of flame occurs during a heating cycle, the
system integrated control module will recycle the
ignition sequence, then if ignition is not achieved,
the integrated control module will shut off the gas
valve and lock out the system.
Set the thermostat heat anticipator according to the
current flow measured, or the settings found in the
notes on the furnace wiring diagram (found in the
SERVICE FACTS or inside the furnace casing).
INSTRUCTIONS TO THE OWNERS
In the event that electrical, fuel, or mechanical failures
occur, the owner should immediately turn the gas sup-
ply off at the manual gas valve, located in the burner
compartment. Also turn off electrical power to the fur-
nace and contact the service agency designated by
your dealer.
5. INDUCED DRAFT BLOWER FAILURE
If pressure is not sensed by the pressure switch, the
contacts will remain open and not allow the gas
valve to open, therefore the unit will not start. If
failure occurs during a running cycle, the pressure
switch contacts will open and the gas valve will
close to shut the unit down.
6. CONDENSATE DRAIN BLOCKAGE
If the condensate drain is blocked, either by debris,
improper draining, or by freezing condensate, the
pressure switch will sense the accumulation of con-
densate in the furnace drain pan. The pressure
switch contacts will open and remain open, not al-
lowing unit operation. The unit will not operate un-
til the condensate drain has been cleared, and the
condensate flows freely.
7. RESET AFTER LOCKOUT
When the integrated control module has shut the
system down and gone into lockout, the system
must be manually reset before the unit will restart.
To reset, turn the system power off, then on, then
off and then on again within 30 seconds. This may
be done at the unit’s power source or at the ther-
mostat. The system will not reset unless the proce-
dure off-on-off-on is completed within 30 seconds.
18-CD22D1-8
35
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
8. RESET AFTER BURNER BOX LIMIT SHUTDOWN
If the furnace shuts down, one thing that can be
checked is the burner box temperature limit switch.
It is located on the bottom of the burner box. The
vent and combustion air inlet terminations should
be checked for blockage. If blockage exists, clear
the problem and then the reset button may be de-
pressed. If there is no blockage of the terminations,
the limit switch must be reset by a qualified
servicer.
Carbon monoxide, fire or smoke can cause serious
bodily injury, death, and/ or property damage.
A variety of potential sources of carbon monoxide can be
found in a building or dwelling such as gas-fired clothes
dryers, gas cooking stoves, water heaters, furnaces and
fireplaces. The U.S. Consumer Product Safety Commis-
sion recommends that users of gas-burning appliances
install carbon monoxide detectors as well as fire and
smoke detectors per the manufacturers installation in-
structions to help alert dwelling occupants of the pres-
ence of fire, smoke or unsafe levels of carbon monoxide.
These devises should be listed by Underwriters Labora-
tories, Inc. Standards for Single and Multiple Station
Carbon Monoxide Alarms, UL 2034 or CSA Interna-
tional Standard, Residential Carbon Monoxide Alarming
Devices, CSA 6.19.
NOTE:
The manufacturer of your furnace does not test any de-
tectors and makes no representations regarding any
brand or type of detector.
36
18-CD22D1-8
Download from Www.Somanuals.com. All Manuals Search And Download.
Installer’s Guide
INTEGRATED FURNACE CONTROL ERROR FLASH CODES
Flashing Slow ---
Flashing Fast ---
Continuous ON ---
Normal - No call for Heat
Normal - Call for Heat
Replace IFC
Continuous OFF --- Check Power
2 Flashes ---
System Lockout (Retries or Recycles exceeded)
Draft Pressure Error - Possible problems:
a) Venting problem
b) Pressure switch problem
3 Flashes ---
c) Inducer problem
4 Flashes ---
5 Flashes ---
6 Flashes ---
7 Flashes ---
8 Flashes ---
Open Temperature Limit Circuit
Flame sensed when no flame should be present
115 volt AC power reversed, poor grounding or system voltage too low
Gas valve circuit error
Low flame sense signal
Check Ignitor Circuit and Line "N" to 24VAC "Common" voltage (≤ 2 volts)
[possible grounding problem]
9 Flashes ---
18-CD22D1-8
37
Download from Www.Somanuals.com. All Manuals Search And Download.
Trane
6200 Troup Highway
Tyler, TX 75707
Literature Order Number
File Number
18-CD22D1-8
18-CD22D1-8
18-CD22D1-7
05/08
Supersedes
Date
For more information contact
your local dealer (distributor)
Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right
to change design and specifications without notice.
Download from Www.Somanuals.com. All Manuals Search And Download.
|