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General

Service Bulletin
Cold Header Cracks
AUC*, CUC*, TUC*, AUX*, TUX*, AUY*, TUY* Upflow 90+ Gas Furnaces
ORDER No: FURN-SVB10A-EN

DATE: October 27, 2003

Introduction

The purpose of this bulletin is to advise customers of a problem with 90+ AFUE gas furnaces.
The problem is cracking of the cold header. This may also be called the recuperative coil
drain pan. The action described in this bulletin is not being taken to address a safety concern.

CAUTION:

Units installed above finished construction that develop cracks may leak water,
resulting in potential property damage. The corrections recommended in this bulletin
are necessary to ensure cold header integrity of units in the distribution chain and
installed units. These should be checked prior to start up and owner usage.

Discussion

The cause of the cracks has been determined to be oil contamination causing the Noryl plastic
to weaken and become brittle. The source of the oil has been traced to residual oil from the
primary heat exchanger forming process. A new oil was introduced into the process fiscal
week 21 of 2003 (3211* beginning date code) which is incompatible with the plastic cold
header. This was corrected on 10/21/2003, so the ending date code is 3432*.
Symptoms of failures are water leaking from the unit, or failure to close the pressure switch
with vent lengths in allowable range.

WARNING
Service checks and diagnostic procedures described in this bulletin are intended to be
performed by trained, qualified personnel. Some checks may be required to be
performed with voltage present and the hazard of moving parts also exists in these
situations. Failure to follow warnings and cautions in this bulletin may result in
personal injury or death.

2003 American Standard Inc. All Rights Reserved

FIELD CORRECTIVE ACTION


Uninstalled Warehouse Inventory: (Distributor and Dealer)
To prevent dissatisfied owners, the condition of field inventory needs to be confirmed
prior to releasing to dealers and / or installation. The options for doing so are listed
below:
1) Open and inspect (Upflow models only)(see procedure at the end of this bulletin)
Our investigations have revealed the failures soon after exposure to oil, so if
the furnace arrives to a field distribution site without cracks and passes the
leak test, it is OK to sell.
There may be several options for conducting inspections:
(1) Contract with a dealer to do the inspections.
(2) Train and use warehouse help.
(3) Hire temporary help from local workforce (i.e.: Vocational students)
DSO's will need to utilize Remedy or similar organization to facilitate
payment for services.
(4) Coordinate with After Sale Support for assistance.

The Field Service Representative or Dealer Support Specialist should direct


and supervise the training and inspection. Several distributors have confirmed
the ability to check 6 to 10 furnaces per hour by using a "batch" method. We
would expect offices to use and achieve similar results, so we will provide
allowances for one furnace every 10 minutes, or 6 furnaces per hour
minimum.
After testing, dry out the furnaces using a wet/dry vacuum or other suitable
method.
All furnaces that pass the water leak test must be marked with a 1-inch
diameter, green dot just above the carton corner label on both adjacent
corners. Good furnaces can then be placed back into inventory.
Mark the carton of leaking furnaces with a 1-inch diameter, red dot just above
the carton corner label on both adjacent corners.
Re-package the leaking furnaces in preparation for return to Trenton for
rework.
Maintain model and serial number records of furnaces reworked, both leaks
and good ones and forward to David Small in Tyler.

Arriving shipments of upflow models prior to 3433* will also need to be inspected
unless cartons are marked with a one inch green dot placed near the carton label.

FURN-SVB10A-EN

2) Return to Trenton. (IWDs Only) Some may choose not to conduct inspections. Contact
Customer Service in St. Louis or After Sale Support for directions. (All units previously
inspected and found to be defective must be re-boxed and returned to Trenton for repair).

3) Release to Dealer. To meet critical needs like emergency medical situations,


property closings, etc.; and with documented DSS/FSR approval, the furnace may
be released to the dealer with the understanding they must check the
furnace prior to installation. Inform the dealer of the simple water checking
method described in the following pages.
Installed Units
1) Units installed over finished construction (ceilings, finished flooring, etc.) must be
checked prior to final occupancy. This is to prevent possible water damage to the
structure. Units that have already been started and operating normally are not
suspect and do not need to be re-visited.
If possible, vertical units can be checked by pouring water down the vent pipe.
The method described for warehouse leak checking may be used, but only if
the furnace can be tilted forward.
Or, the furnace can be started and operation observed. A manometer should
be attached to the furnace to measure system vacuum and measurements
compared to the pressure switch settings. (Included in this bulletin). If the
system vacuum is within normal limits and (after adequate run time) no water
leaks are observed, the furnace is OK. For example:
A *UX080C942 has a closing differential pressure of 1.30 W.C. and an opening
differential pressure of -1.15 .04 W.C.. This means the draft inducer must create at
least 1.30 W.C. pressure differential across the pressure switch. This would be the
minimum pressure differential expected if the installation has maximum vent length.
Experience shows that, with no vent, the pressure differential is usually about -0.3
W.C. even deeper vacuum (-1.6 W.C. in our example).
Therefore, if the pressure differential is not enough to close the pressure switch, or
barely closes it with less than maximum vent length, a cracked cold header may be
suspect. Another diagnostic is to watch the pressure differential when the main blower
comes on. A significant drop in system vacuum when the main blower comes on may
indicate a cracked cold header. The pressure switch may actually even be blown
open. Note: Small drops (0.01 to 0.05 W.C.) may be normal, due to voltage drop
when the main blower energizes. In addition, models with variable-speed draft
inducers may compensate enough with smaller leaks so that a significant change in
pressure will not be evident.
Another method would be to connect a sensitive manometer to the pressure switch
as in the previous check, but use a manometer with a 1 W.C. or lower scale. Turn on

FURN-SVB10A-EN

the circulating air blower and look for a positive pressure reading on the manometer.
This would indicate leakage into the cold header.
2) If a cold header leak is discovered, replace the complete heat exchanger. Cold Headers
are not field replaceable.

Parts Ordering Information


Use the following table to review the heat exchangers involved in this Service Bulletin.
MOD
HEAT EXCHANGER
*UC080*942
EXC01278
*UX080C942
EXC01278
*UY080R9V3
EXC01278
*UC040*924
EXC01281
*UX040C924
EXC01281
*UC060*936
EXC01282
*UX060C936
EXC01282
*UY060R9V3
EXC01311
*UC100*948
EXC01360

MOD
HEAT EXCHANGER
*UX100C948
EXC01360
*UY100R9V4
EXC01360
*UC120*960
EXC01405
*UX120C960
EXC01405
*UY120R9V5
EXC01405
*UC100*960
EXC01425
*UX100C960
EXC01425
*UX080C960
EXC01604

*The first digit may an A or T, the 7th digit may be A,C, or R. Obtain the required parts
from your local IWD or Trane Parts Center.

Product Changes

Again, the heat exchanger forming lubricant was changed back to the original formula
on 10/21/03. The affected date code range is 3211* to 3432*
We have been checking units at TNDC and are marking good units with a 1 inch
diameter green dot on the carton above the corner label.

Questions
Dealers and servicers should contact their local Field Service Representative or Dealer
Support Specialist with any questions. FSRs, DSSs and distribution personnel should
contact the Product Technical Service department in Tyler, TX (903-581-3009) or Trenton, NJ
(609-588-4247) with questions regarding this Service Bulletin. E-mail can be sent to

customer-information.tyler@trane.com
Reference this service bulletin in the subject line.

Trane
A business of American Standard
Companies
www.trane.com
For more information, contact your local
district office or e-mail us at
comfort@trane.com

Literature Order Number

FURN-SVB10A-EN

File Number

SV-UN-FURN-SVB10A-EN-102703

Supersedes

New

Stocking Location

Electronic Only

Trane has a policy of continuous product data and product improvement and reserves the right
to change design and specifications without notice. Only qualified technicians should perform the
installation and servicing of equipment referred to in this bulletin.

FURN-SVB10A-EN

Cold Header Leak Test Configuration


Pour water here.

Attach field condensate


hose to trap in vertical
position.
Use tape or rubber band
to secure the hose to the
draft inducer.

Elevate the back of the furnace


4" to 6 to ensure water does
not enter the recuperative coil
and that the cold header is
completely filled.

Use hose as a fill gauge.


Fill the draft inducer
and cold header to a
point just below the
draft inducer motor.
Watch the level to see if
it goes down, and look
for leak locations.

Cold Header Leak Reporting


Model

Serial

Leak Location

Record model and serial of all units


tested along with the location of any
leaks. Enter OK if no leak, or
Cracked at _____, Seal Leak at
Cold Header Flange, etc.

IMPORTANT

Tape the Vent Pads to the side of the furnace


before sliding the carton back over the furnace.
This prevents the pad from falling into the
furnace and being left there by the installer.

Furnace Pressure Switch Settings


Closing
Pressure
In W.C.

Opening
Pressure
In W.C.

Factory
Number

Replacement
Number

High
Altitude
Kit

Closing
Pressure
In W.C.

Opening
Pressure
In W.C.

Factory
Number

Replacement
Part

UD-C-A, B, C, D/DD-C, A, B

0.65

0.5 .05

C340071P01

SWT 1255

BAYHALT220

0.56

0.41 04

C340071P03

SWT 1579

UD-C-H/DD-C-C2

0.65

0.5 .05

C340773P01

SWT 1741

BAYHALT238

0.56

0.41 .04

C340773P03

SWT 1830

HI 0.65

0.5 .05

C340071P01

SWT 1255

BAYHALT215

HI 0.56

0.41 .04

C340071P03

SWT 1579

LO 0.31

0.17 .03

C340191P02

SWT 1373

LO 0.31

0.14 .03

C340191P04

SWT 1580

HI 0.65

0.5 .05

C340773P01

SWT 1741

BAYHALT239

HI 0.56

0.41 .04

C340773P03

SWT 1830

LO 0.31

0.17 .03

C340789P02

SWT 1760

LO 0.31

0.14 .03

C340789P04

N/A

UE-A-A, B/DE-A-A, B

0.65

0.5 .05

C330610P01

SWT 1600

BAYHALT224

0.56

0.41 .04

C330610P03

N/A

UE-A-H, K/DE-A-C, K2

0.65

0.5 .05

C340773P01

SWT 1741

BAYHALT238

0.56

0.41 .04

C340773P03

SWT 1830

UJ-A

0.65

0.5 .05

C330610P01

SWT 1600

BAYHALT224

0.56

0.41 .04

C330610P03

N/A

FUA/FCA-A-A

0.65

0.5 .05

C340071P01

SWT 1255

BAYHALT220

0.56

0.41 .04

C340071P03

SWT 1579

FUA/FCA-A-B, C

0.65

0.5 .05

C330610P01

SWT 1600

BAYHALT224

0.56

0.41 .04

C330610P03

N/A

FUA/FCA-A-D, E

0.65

0.5 .05

C340773P01

SWT 1741

BAYHALT238

0.56

0.41 .04

C340773P03

SWT 1830

UC/DC040C

1.55

1.40 .04

C340450P04

SWT 1633

BAYHALT228

1.27

1.09 .04

C340450P08

N/A

UC/DC060C

1.27

1.04 .04

C340450P01

SWT 1630

BAYHALT226

1.02

0.86 .04

C340450P06

N/A

UC/DC080, 120C

1.51

1.39 .04

C340450P03

SWT 1632

BAYHALT225

1.27

1.04 .04

C340450P01

SWT 1630

DC100C948

1.64

1.46 .04

C340450P02

SWT 1631

BAYHALT228

1.27

1.09 .04

C340450P08

N/A

UC100C948

1.55

1.40 .04

C340450P04

SWT 1633

BAYHALT225

1.27

1.04 .04

C340450P01

SWT 1630

UC100C960

1.41

1.23 .04

C340450P09

SWT 1776

BAYHALT240

1.16

1.00 .04

C340450P10

N/A

UX/DX040C, UX100C9601

1.44

1.29 .04

C340545P01

SWT 1669

BAYHALT230

1.21

1.06 .04

C340545P05

N/A

UX060C1

1.09

0.94 .04

C340545P02

SWT 1670

BAYHALT231

0.92

0.77 .04

C340545P06

N/A

DX060C1

1.13

0.98 .04

C340545P12

SWT 1838

BAYHALT241

0.97

0.82 .04

C340545P13

N/A

UX080C9421

1.30

1.15 .04

C340545P03

SWT 1671

BAYHALT232

1.09

0.94 .04

C340545P02

SWT 1670

UX100C9481
UX/DX120C9601

1.55

1.40 .04

C340545P04

SWT 1672

BAYHALT233

1.30

1.15 .04

C340545P03

SWT 1671

DX080C9421

1.52

1.37 .04

C340545P09

SWT 1702

BAYHALT233

1.30

1.15 .04

C340545P03

SWT 1671

DX100C9481

1.55

1.40 .04

C340545P04

SWT 1672

BAYHALT234

1.44

1.29 .04

C340545P01

SWT 1669

LO 1.09

0.94 .04

C340545P02

SWT 1670

BAYHALT235

LO 0.92

0.77 .04

C340545P06

SWT 1862

HI 1.76

1.59 .05

C340545P08

SWT 1699

HI 1.44

1.29 .04

C340545P01

SWT 1669

LO 1.30

1.15 .04

C340545P03

SWT 1671

BAYHALT236

LO 1.09

0.94 .04

C340545P02

SWT 1670

HI 1.76

1.59 .05

C340545P08

SWT 1699

HI 1.44

1.25 .04

C340545P01

SWT 1698

LO 1.30

1.15 .04

C340545P03

SWT 1671

BAYHALT237

LO 0.92

0.77 .04

C340545P26

N/A

HI 1.94

1.75 .06

C340545P11

SWT 1710

HI 1.63

1.44 .04

C340545P27

N/A

LO 1.09

0.94 .04

C340545P02

SWT 1670

BAYHALT242

LO 0.92

0.77 .04

C340545P06

SWT 1862

HI 1.63

1.48 .04

C340545P07

SWT 1698

HI 1.30

1.15 .04

C340545P03

SWT 1671

Models

UD-R-A, B/DD-R-A, B

UD-R-H/DD-R-C2

UY/DY060, 080H1
DY120R1
UY100R1

DY100R1

UY120R1

1 The pressure switches for the UX/DX/UY/DY furnaces are differential switches.
2 The mounting method for 80+ furnace pressure switches changed with the introduction of the upflow/horizontal models in the 1st quarter of 1996.
Those changes are reflected in this table.
3 These kits contain both pressure switches.
Note: Switches listed on this page by model number are the latest switch listed as of 3/18/98 and may not have the same set point as the original factory installed switch.
Check T.S.B for the latest changes.
Models may be an A or T or F.

28

Combustion Air Pressure Switch Check Measurement


The combustion air pressure switch proves operation
of the induced draft motor and that adequate air is
provided to ensure complete combustion of the fuel
being supplied to the burner.

If the measured static pressure reading does not meet


the switch specifications, the following items should
be checked:
1. Pressure switch hose/tubing for cracks or loose
connections.

The induced draft motor and vent system performance


can be checked by connecting an inclined manometer
to the pressure switch hose and measuring the
operating static pressure.

2. Inducer wheel for corrosion or loose blades.


3. Inducer for tight bearings or loose inducer wheel.
4. Vent system design (oversized/undersized/long
lateral runs)

The direct vent furnaces have differential pressure


switches and require two connections to the manometer.
See figure below.

5. High altitude switches required at 4,000 ft. or more


above sea level.

The measured static pressure reading should be


compared to the pressure switch specifications. If
the measured static pressure meets or exceeds the
specifications and the switch contacts will not transfer
the following items should be checked:

6. Crack in heat exchanger or leak in cold header.


7. Flue box gaskets leaking.
Note:
The switch setting and the last three digits of the
factory drawing number are stamped on the switch.
Example: PO1, .50" WC.

1. Switch out of calibration


2. Defective pressure switch
3. Moisture in pressure switch tubing

The PO1 and PO2 must not be interpreted as PS1


and PS2 on two stage models.

4. Condensate trap or drain restricted


(90% furnaces)
5. Incorrect switch installed

27