Trane XL90 Furnace Manual

The Trane XL90 is a high-efficiency gas furnace with AFUE ratings up to 90%, featuring two-stage heating operation, variable-speed blower motor, durable heat exchanger construction, electronic ignition system, diagnostic LED lights, and compatibility with various thermostat systems. Designed for residential heating applications with natural gas or propane capability. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Two-stage gas valve, variable-speed blower motor, aluminized steel heat exchanger, hot surface ignitor, pressure switches, flame sensor, diagnostic LED, and integrated control board.

Installation Requirements

Unpack and inspect all components. Ensure proper clearances and location requirements.

1. Location: Install in approved areas with proper combustion air and clearances.
2. Venting: Use approved PVC pipe for intake and exhaust; maintain proper slope.
3. Gas connection: Use black iron pipe with proper thread sealant; pressure test required.
4. Electrical: 120V AC power supply with proper grounding and disconnect.
5. Ductwork: Ensure proper sizing and sealing for optimal airflow.

WARNING! Installation must be performed by qualified HVAC technician. Gas furnaces can produce carbon monoxide.

Initial Setup & Startup

Complete installation verification before initial startup.

1. Gas pressure adjustment: Set manifold pressure per specifications.
2. Blower speed settings: Adjust for proper airflow and temperature rise.
3. Thermostat configuration: Compatible with two-stage heating systems.
4. System checkout: Verify all safety controls and proper operation.
5. Customer orientation: Explain operation and maintenance requirements.

CAUTION! Never bypass safety controls. Always verify proper venting before operation.

Technical Specifications

• AFUE Rating: Up to 90% efficiency
• Heating Capacity: Various sizes from 40,000 to 120,000 BTU/h
• Stages: Two-stage heating operation
• Blower Type: Variable-speed ECM motor
• Gas Type: Natural gas or propane (conversion kit required)
• Electrical: 120V AC, 60Hz
• Venting: PVC pipe (2" or 3" diameter)
• Sound Level: Ultra-quiet operation
• Warranty: Limited lifetime heat exchanger warranty

Controls and Operation

Integrated control board manages all furnace functions with diagnostic capabilities.

Thermostat: Compatible with single-stage, two-stage, and programmable thermostats.

Operation: Control board monitors temperature demand, initiates ignition sequence, monitors flame, and controls blower operation. Diagnostic LED provides flash codes for troubleshooting. Two-stage operation provides efficient heating with low-stage for mild conditions and high-stage for extreme cold.

Venting System

Direct vent system using PVC pipe for intake and exhaust.

1. Vent pipe: Use schedule 40 PVC; maintain 1/4" per foot slope toward furnace.
2. Terminations: Keep intake and exhaust separated per code requirements.
3. Clearances: Maintain proper clearances from windows, doors, and air intakes.
4. Length limitations: Follow manufacturer's guidelines for maximum vent lengths.

Tip: Always verify venting integrity with manometer test.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

1. Air filter: Replace every 1-3 months depending on usage and environment.
2. Burner inspection: Clean burners annually; check for proper flame pattern.
3. Heat exchanger: Visual inspection for cracks or damage during annual service.
4. Blower assembly: Clean blower wheel and housing annually.
5. Venting system: Inspect for obstructions and proper drainage.
6. Safety controls: Test pressure switches, flame sensor, and limit switches.

WARNING! Maintenance should be performed by qualified technician. Turn off gas and electrical power before servicing.

Safety Features

Multiple safety systems protect against hazardous conditions.

Care & Cleaning

Turn off power before any cleaning. Keep area around furnace clean and unobstructed.

CAUTION! Never use water or liquid cleaners on electrical components. Keep combustion air intake clear of debris.

Regulatory Information

UL certified for safety standards. ANSI Z21.47 compliant for gas furnace operation. Meets DOE efficiency requirements. Manufactured to ISO 9001 quality standards. For technical support, contact Trane Residential at 1-800-945-5884 or visit www.trane.com.

Troubleshooting

Reset: Turn power off for 30 seconds to reset control board.

Service: 1-800-945-5884; www.trane.com