General

Service Bulletin
Cold Header Cracks
AUC*, CUC*, TUC*, AUX*, TUX*, AUY*, TUY* Upflow 90+ Gas Furnaces
ORDER No: FURN-SVB10B-EN

DATE: September 22, 2005

Supercedes: FURN-SVB10A-EN, FURN-SVB13A-EN

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.

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

Installed Units
When Servicing one of the units affected by this bulletin, symptoms may appear as
not able to close pressure switch or visible condensate leakage from the heat
exchanger area of the product. There are other possible causes for condensate
leakage such as a crack in the inducer transition (RCT00084) between the cold
header and the inducer blower. Follow the diagnostic steps below to determine the
source of operational problems:
1. 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 manometer to the pressure switch

as in the previous check, but use a manometer with a 1 W.C. or lower
scale. Turn on the circulating air blower and look for a positive pressure
reading on the manometer. This would indicate leakage into the cold
header.

FURN-SVB10A-EN

2.
To determine if leakage may be occurring from cracks in the inducer transition
rather than the cold header, remove the inducer motor assembly and the
inducer mounting plate to gain visible access to the transition piece.
(Reference FURN-SVB13B-EN) This part RCT00084 can be replaced to
resolve this failure. It is important to use the correct screws when replacing the
inducer transition. Use the plastics thread cutting (blunt tipped) screws to
attach the transition to the cold header and the thread forming (sharp tipped)
screws for attaching the inducer mounting plate to the inducer transition.

FURN-SVB10A-EN

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 Parts Center.

Product Changes
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*

Questions
Dealers and servicers should contact their local Field Service Representative or Dealer
Support Specialist with any questions.

Literature Order Number

FURN-SVB10A-EN

File Number

SV-UN-FURN-SVB10A-EN-102703

Supersedes

New

Stocking Location

Electronic Only

Trane and American Standard have a policy of continuous product data andproduct
improvement and reserve 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