Trane Gas Furnace Installation Manual
The Trane Gas Furnace is a high-efficiency heating system designed for residential and light commercial applications. This installation manual covers the XC95m, XV95, XB90, and XR80 series models with AFUE ratings from 80% to 97.3%. Below are key sections for safety, installation procedures, electrical connections, gas piping, venting requirements, startup procedures, and troubleshooting guidelines.
Features at a Glance
Key components: Two-stage gas valve, variable-speed blower motor, hot surface ignitor, flame sensor, pressure switches, and integrated control board.
| Feature | Description |
|---|
| Two-stage gas valve | Provides high and low fire operation for improved comfort and efficiency |
| Variable-speed blower | Adjusts airflow for optimal performance and quiet operation |
| Hot surface ignitor | Electronic ignition system for reliable lighting |
| Flame sensor | Monitors burner flame for safety shutdown if no flame detected |
| Pressure switches | Verify proper venting operation before allowing gas valve to open |
| Control board | Integrated furnace controller with diagnostic LED indicators |
| Condensate drain | Removes condensation from high-efficiency models |
| Filter cabinet | Standard 1-inch or optional 4-inch media filter compatibility |
| Service switches | Conveniently located for maintenance safety |
| Access panels | Removable for easy service access to all components |
Safety Precautions
Read all instructions before beginning installation. Follow local codes and manufacturer guidelines.
- Gas line installation: Only qualified technicians should install gas piping.
- Electrical connections: Disconnect power before servicing electrical components.
- Venting: Ensure proper vent sizing and routing to prevent carbon monoxide hazards.
- Combustion air: Provide adequate combustion and ventilation air per code requirements.
- Clearances: Maintain minimum clearances to combustible materials as specified.
WARNING! Failure to follow safety precautions may result in fire, explosion, property damage, personal injury, or death. Gas furnaces produce carbon monoxide - ensure proper venting.
Pre-Installation Requirements
Verify site conditions and gather necessary tools before beginning installation.
- Location selection: Choose level, stable location with adequate service clearances.
- Combustion air: Verify adequate combustion and ventilation air supply.
- Gas supply: Confirm adequate gas pressure and pipe sizing.
- Electrical: Verify proper voltage (120V AC) and dedicated circuit availability.
- Venting path: Plan vent routing with proper slope and termination location.
- Drainage: Plan condensate drain routing for high-efficiency models.
CAUTION! Furnace is heavy; use proper lifting techniques and equipment. Minimum two people required for handling.
Specifications
- Models: XC95m, XV95, XB90, XR80 series
- AFUE Ratings: 80% to 97.3%
- Input BTU/h: 40,000 to 120,000
- Gas Type: Natural gas (propane conversion kits available)
- Gas Pressure: 3.5" WC natural gas, 10" WC propane
- Electrical: 120V AC, 60Hz, 15A circuit
- Blower Motor: Variable-speed ECM
- Venting: Category IV (PVC) for 90%+ AFUE, Category I (metal) for 80% AFUE
- Operating Temp: 32°F to 120°F ambient
- Warranty: Limited lifetime heat exchanger, 10 years parts
Installation Procedures
Follow step-by-step installation sequence for proper furnace setup.
- Position furnace: Place on level surface with proper clearances to combustibles.
- Install filter cabinet: Mount filter rack and install appropriate filter.
- Connect ductwork: Secure supply and return ducts with proper sealing.
- Mount furnace: Secure to floor or platform as required.
- Install condensate drain: Route to approved drain location with trap.
- Install vent piping: Follow Category IV PVC requirements for high-efficiency models.
- Install gas piping: Use black iron pipe with proper sizing and drip leg.
- Make electrical connections: Connect line voltage and thermostat wiring.
Electrical Connections
All electrical work must comply with NEC and local codes.
- Disconnect power at main panel before making any electrical connections.
- Connect line voltage: 120V AC to furnace junction box with proper grounding.
- Connect thermostat: Low voltage wiring (R, W, Y, G, C terminals).
- Connect humidifier: If applicable, use HUM terminal on control board.
- Connect outdoor unit: For AC systems, connect Y and C terminals.
- Verify polarity: Ensure correct hot and neutral connections.
Tip: Use wire nuts and electrical tape for secure connections. Label all wires for future service.
Gas Piping Installation
Gas piping must be installed by qualified technician following local codes.
- Size gas pipe: Use pipe sizing charts based on BTU input and pipe length.
- Install sediment trap: Include drip leg before gas valve connection.
- Use proper fittings: Black iron pipe with thread sealant rated for gas.
- Install shutoff valve: Manual gas valve within 6 feet of furnace.
- Pressure test: Test gas line at 14" WC for 10 minutes with no pressure drop.
- Connect flex line: Use approved gas appliance connector if required.
- Check gas pressure: Verify manifold pressure at gas valve (3.5" WC natural gas).
WARNING! Use leak detection solution to check all connections. Never use open flame to check for leaks.
Venting Requirements
Proper venting is critical for safe furnace operation.
- Category IV venting: Use schedule 40 PVC for 90%+ AFUE models.
- Vent sizing: Follow manufacturer tables based on furnace input and vent length.
- Vent slope: 1/4" per foot back to furnace for condensate drainage.
- Termination: Maintain proper clearances from windows, doors, and air intakes.
- Combustion air: Provide separate combustion air piping for confined spaces.
- Support: Secure vent pipes every 4 feet with proper hangers.
- Sealing: Use PVC cement for all joints in pressure-tight system.
CAUTION! Improper venting can cause carbon monoxide poisoning. Always verify vent system integrity.
Startup and Commissioning
Complete startup sequence to verify proper furnace operation.
- Verify installations: Check all connections, clearances, and component installations.
- Power up: Restore electrical power and verify control board operation.
- Gas verification: Check for gas leaks and verify gas pressure.
- Start sequence: Initiate heating cycle and observe ignition sequence.
- Measure temperatures: Check temperature rise against nameplate specifications.
- Adjust airflow: Set blower speed for proper temperature rise if necessary.
- Check safety devices: Verify operation of limit switches and pressure switches.
- Commission controls: Program thermostat and verify staging operation.
WARNING! Use combustion analyzer to verify proper combustion parameters and CO levels.
Regulatory Information
ANSI Z21.47: Certified for natural gas and propane operation. CSA International: Certified to applicable standards. UL listed: Electrical components UL certified. FCC Part 15: Class B digital device compliance. For technical support, contact Trane Residential Solutions at 1-800-554-6413 or visit www.trane.com. Installation must comply with National Fuel Gas Code (NFPA 54), National Electrical Code (NFPA 70), and local building codes.
Troubleshooting
| Symptom | Possible Cause | Corrective Action |
|---|
| Furnace won't start | Power, thermostat, door switch | Check circuit breaker, thermostat setting, door switch engagement |
| No heat | Gas supply, ignitor, flame sensor | Verify gas valve open, check ignitor operation, clean flame sensor |
| Short cycling | Airflow, filter, limit switch | Check filter, verify proper airflow, test limit switch operation |
| Blower won't run | Motor, capacitor, control board | Check motor voltage, test capacitor, verify control board output |
| Lockout condition | Pressure switch, flame sense | Check venting, verify pressure switch operation, clean flame sensor |
| Condensate backup | Drain line blockage | Clear condensate drain line, check trap, verify proper slope |
| Unusual noises | Blower wheel, inducer motor | Inspect blower wheel balance, check inducer motor bearings |
Reset: Power cycle furnace to clear lockout conditions. Check diagnostic LED codes on control board.
Service: 1-800-554-6413; www.trane.com
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