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Bryant 4-Way User's Manual

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2. TWO STAGE TWO SPEED THERMIDISTAT FURNACE AIR CONDITIONER THERMIDISTAT TWO STAGE TWO SPEED FURNACE HEAT PUMP HEAT STAGE 2 NOTE 11 wo RVS COOLING OW2 L COOL STAGE 1 YUW2 ___________ LL L 1 w2 HEAT STAGE 1 WWI __________ ww HEAT COOL STAGE 1 YAW2 __________ YT 1 L Yi COOL STAGE 2 viva NOTE 12 Viva l l _ Y2 HEAT STAGE 3 WWI ___________ L W2 EAN 8 FURNACE Otay 3 HEAT COOLSTAGE2 Yv2 NOTE 32 viva LJ Y2 COMPRESSOR HI 24VACHOT R Jal JT SR ees L R EE ERR ws DEHUMIDIFY DHUM ____________ 24VACHOT R J_ 4 Jr RES ise zt R 24VAC COMM _________ LL L C DEHUMIDIFY DAUM 4 DHUM 24 COMM C Ja Com L L J e HUM 1 HUMIDIFY HUM HUMIDIFIER 24 VAC HUMIDIFIER a HUMIDIFY HUM ________ ME N A B 24 VAC N A B TA OUTDOOR m L M OUTDOOR EE SENSOR 51 OUTDOOR T SENSOR OUTDOOR pare SENSOR CONNECTION 52 SENSOR CONNECTION See notes 2 5 8 10 11 and 12 _ See notes 1 2 3 4 6 8 9 10 12 13 15 A00276 A00278 Fig 51 Two Stage Furnace with
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4. COMBUSTION COMBUSTION AIR AIR AIR FLOW UPFLOW DOWNFLOW COMBUSTION COMBUSTION AIR AIR VENT VENT AIR FLOW AIR FLOW HORIZONTAL LEFT DISCHARGE HORIZONTAL RIGHT DISCHARGE 96187 Fig 34 Combustion Air and Vent Pipe Connections NOTE The minimum combustion air and vent pipe length each for these furnaces is 5 ft Short pipe lengths 5 8 ft may discharge water droplets These droplets may be undesirable and a 12 in minimum offset pipe section is recommended as shown in Fig 35 to reduce excessive droplets from exiting vent pipe outlet B Combustion Air and Vent Pipe Diameter Determine combustion air and vent pipe diameter 1 Using Table 7 individually determine the smallest combustion air and vent pipe diameters Pick the larger of these 2 pipe diameters and use this diameter for both combustion air and vent pipes 2 When installing vent systems of short pipe length use the smallest allowable pipe diameter Do not use pipe size greater than required or incomplete combustion flame disturbance or flame sense lockout may occur NOTE Do not count elbows or pipe sections in terminations or within furnace See shaded areas in Fig 37 38 39 40 and 41 A y 4 12 MIN VENT PIPE ING Wa COMBUSTION AIR PIPE HORIZONTAL TO ROOF YA COM
5. WIRE TIE GUIDES WHEN USED FRONT VIEW Ya OD COLLECTOR BOX TO TRAP RELIEF PORT OD INDUCER HOUSING DRAIN CONNECTION 5 OD COLLECTOR BOX DRAIN CONNECTION SCREW HOLE FOR UPFLOW OR DOWN FLOW APPLICATIONS OPTIONAL Ve IN PVC OR CPVC SIDE VIEW A93026 Fig 6 Condensate Trap 1 Collector Box Drain Inducer Housing Drain Relief Port and Pressure Switch Tubes These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications These tubes can be identified by their connection location and also by a color label on each tube These tubes are identified as follows collector box drain tube blue label inducer housing drain tube violet label or molded relief port tube green label and pressure switch tube pink label 2 Condensate Trap Drain Tube The condensate trap drain connection must be extended for field attachment by doing the following a Determine location of field drain connection See Fig 2 or 7 NOTE If internal filter or side filter media cabinet is used drain tube should be located to opposite side of casing from return duct attachment to assist in filter removal b Remove and discard casing drain hole plug button from desired side c Install drain tube coupling grommet factory supplied in loose parts bag in selected casing hole d Slide drain tube coupling factory supplied in loose parts bag thro
6. 23 Furnace combustion air and vent pipe connections must be at tached as shown in Fig 34 Combustion air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications CAUTION When combustion air pipe is installed above a suspended ceiling pipe must be insulated with 3 8 in thick Armaflex type insulation Combustion air pipe should also be insulated when it passes through a warm humid space CAUTION When vent pipe is exposed to temperatures below freezing such as when it passes through an unheated space or when a chimney is used as a raceway pipe must be insulated as shown in Table 8 with Armaflex type insulation CAUTION Combustion air must not be taken from inside structure because that air is frequently contami nated by halogens which include fluorides chlorides bromides and iodides These elements are found in aerosols detergents bleaches cleaning solvents salts air fresheners adhesives paint and other household prod ucts Locate combustion air inlet as far as possible from swimming pool and swimming pool pump house Excessive exposure to contaminated combustion air will result in safety and performance related problems TABLE 6 COMBUSTION AIR AND VENT PIPE TERMINATION CLEARANCES CLEARANCE FT LOCATION U S A Canada Above grade level or above antici 1 1 pated snow depth Dryer Water heater vent See Note 5 See Note 5
7. nnnm SW2 nnn nmn AIR CONDITIONING A C AIRFLOW SETUP SWITCHES gt HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX ACRDJ AIR CONDITIONING RELAY DISABLE JUMPER 24 V THERMOSTAT TERMINALS FLASH UPGRADE CONNECTOR FACTORY ONLY STATUS AND COMM LED LIGHTS FUSE 3 AMP SEC 2 SEC 1 PL3 ECM BLOWER HARNESS CONNECTOR 3 AMP FUSE nnnnnnnnnnunn TRANSFORMER 24 VAC CONNECTIONS VS HSI HI LO 115 VAC L2 NEUTRAL CONNECTIONS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX PL1 LOW VOLTAGE MAIN 115 VAC L1 LINE PL2 HOT SURFACE HARNESS CONNECTOR VOLTAGE CONNECTIONS IGNITER amp INDUCER MOTOR CONNECTOR 02278 Fig 32 Control Center TABLE 5 APPROVED COMBUSTION AIR AND VENT PIPE FITTING AND CEMENT MATERIALS ASTM SPECIFICATION MARKED ON MATERIAL MATERIAL FITTINGS SOLVENT CEMENT AND PRIMERS DESCRIPTION D1527 ABS Schedule 40 D1785 PVC Schedule 40 For ABS For ABS PVC SDR 21 amp SDR 26 PVC Fittings Schedule 40 ABS Fittings Schedule 40 For PVC For PVC ABS Fittings DWV at Schedule 40 IPS sizes PVC Fittings DWV CPVC Fittings Schedule 40 CPVC Schedule 40 CPVC SDR For CPVC Eoi For CPVC ABS Cellular Core DWV at Schedule 40 IPS sizes For PVC Primer For PVC PVC Cellular Core Schedule 40 amp DWV
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10. vi COOL STAGE 1 YIY2 _________ eva ess L Y HEAT STAGE 2 WAWI __________ LT wa FURNACE LO FAN G __________ 6 HEAT COOL STAGE 1 _________ YN2 l l Y COMPRESSOR 24VACHOT R __________ R FAN G 4 G DEHUMIDIFY BRUM ___________ 28 R pepe H 1 DEHUMIDIFY _____________ DHUM 24VAC COMM C __________ L J C Uu 24VAC COMM C J 4 Com 1 L HUM SL EM i HUM Shoes HUMIDIFIER E HUMIDIFY _______ 1 24 HUMIDIFIER HUMIDIFY HUM ______ 24 VAC EN NA B 781 OUTDOOR m F L OUTDOOR E1 St JJ OUTDOOR SENSOR OUTDOOR SENSOR SENSOR SENSOR CONNECTION tol sicnt Spee CONNECTION S _ See notes 2 5 7 10 and 11 _ See notes 1 2 4 6 7 9 10 11 and 15 A00275 A00277 Fig 52 Two Stage Furnace with Single Speed Heat Pump Dual Fuel Fig 50 Two Stage Furnace with Single Speed Air Conditioner
11. INDUCER HOUSING MOLDED DRAIN TUBE BEHIND COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TE TUBE GREEN 1 FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE COUPLING LEFT DRAIN OPTION FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE FIELD INSTALLED FACTORY SUPPLIED FIELD INSTALLED FACTORY SUPPLIED Ve IN CPVC STREET DRAIN TUBE ELBOWS 2 FOR COUPLING RIGHT LEFT DRAIN OPTION DRAIN OPTION A94213 Fig 7 Factory Shipped Upflow Tube Configuration Shown With Blower Access Panel Removed WARNING Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated Failure to follow this warning could result in electrical shock fire personal injury or death 4 Install condensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 5 Fill unused condenstate trap casing holes with plastic filler caps factory supplied in loose parts bag D Condensate Trap Tubing Alternate Upflow Orientation NOTE See Fig 8 or tube routing label on main furnace door to confirm location of these tubes 1 Collector Box Drain Tube Connect collector box drain tube blue label to condensate trap NOTE On 17 1 2 in wide furnaces ONLY cut tube between corr
12. Furnace must operate within ranges of temperature rise specified on the furnace rating plate Determine air temperature rise as follows Place thermometers in return and supply ducts as near furnace as possible Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings This practice is particularly important with straight run ducts 99118 Fig 60 Inducer Housing Drain Tube 42 2 When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE Temperature rise can be determined for low heat opera tion by placing setup switch SW1 2 on furnace control in ON position For high heat operation place setup switch SW1 2 in OFF position and jumper R W2 on furnace control DO NOT forget to return setup switch to OFF position and remove R W2 jumper upon completion of testing See Fig 32 for switch and terminal location 3 This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on furnace rating plate If temperature rise is outside this range proceed as follows a Check gas input for low and high heat operation b Check derate for altitude if applicable c Check all return and supply ducts for excessive restric tions causing static pressure greater than 0 5 in wc d Ensure Low Heat Rise Adjust switch
13. 3 Determine required insulation thickness for exposed pipe lengths NOTE Pipe length ft specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 7 B Two Pipe Termination Kit 1 Determine location for termination Consideration of the following should be made when determining an appropriate location for termination kit a Comply with all clearance requirements as stated in Table 6 b Termination kit should be positioned where vent vapors will not damage plants shrubs or air conditioning equip ment c Termination kit should be positioned so it will not be affected by wind eddy such as inside building corners or accumulation of airborne leaves or light snow or allow recirculation of flue gases 29 d Termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones balls etc e Termination kit should be positioned where vent vapors are not objectionable 2 Cut 2 holes 1 for each pipe of appropriate size for pipe size being used 3 Loosely install elbow in bracket and place assembly on combustion air pipe Roof terminations Loosely install pipe coupling on prop erly cut vent pipe Coupling must be positioned so bracket will mount as shown in Fig 37 For applications using combustion air pipe option indicated by dashed lines in Fig 37 install 90 street elbow into 90 elb
14. From plumbing vent stack 3 3 From any mechanical fresh air intake See Note 4 See Note 6 For furnaces with an input capacity of 100 000 Btuh or less from any non mechanical air supply windows or doors which can be opened or combustion air opening For furnaces with an input capacity greater than 100 000 Btuh from any non mechanical air supply windows or doorswhich can be opened or combustion airopening From service regulator vent electric and gas meters and relief equipment See Note 6 See Note 6 Above grade when adjacent to public walkway T 18 in above roof surface NOTES See Note 3 See Note 3 1 If installing 2 adjacent furnaces refer to Multiventing and Vent Terminations section for proper vent configurations 2 When locating combustion air and vent terminations consideration must be given to prevailing winds location and other conditions which may cause recirculation of the appliance s own flue products or the flue products of adjacent vents Recirculation can cause poor combustion inlet condensate problems and accelerated corrosion of heat exchangers 3 Vent termination can not terminate less than 2 ft horizontal and 7 ft above public walkway or where condensate vapor or droplets may be a hazard 4 Vent termination must be at least 3 feet above any forced draft inlets within 10 feet horizontal Vent termination must be at least 3 feet horizontal from other direct ven
15. PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B D Upflow Applications Downflow Applications on Non Combustible Flooring Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box Upflow Applications Downflow Applications on Non Combustible Flooring Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box Upflow Applications Downflow Applications on Non Combustible Flooring Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box i PERFORATED DISCHARGE DUCT FLANGE NO YES YES A93029 Fig 22 Duct Flanges be suspended from each corner by hanger bolts and angle iron supports See Fig 23 Cut hanger bolts 4 each 3 8 in all thread rod to desired length Use 1 X 3 8 in flat washers 3 8 in lockwashers and 3 8 in nuts on hanger rods as shown in
16. Fig 44 Concentric Vent and Combustion Air Side Termination Dimension A is Touching or 2 In Maximum Separation 0 T 7 COMBUSTION AIR 96130 Fig 46 Sidewall Termination of More Than 12 in Dimension A is Touching or 2 In Maximum Separation thermostat is still calling for gas heating The amber LED light will flash code 12 during the 90 second period after which the LED will be ON continuous as long as no faults are detected After the 90 second period the furnace will respond to the thermostat normally The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED 93058 Fig 47 Freeze Protection CAUTION Unit must not be installed operated and then turned and left off in an unoccupied structure during cold weather when temperature drops to 32 F or below unless drain trap and drain line have adequate freeze protection See Service and Maintenance Instructions for winterizing procedure See Fig 47 OPEN STAND PIPE FOR A C OR HUMIDIFIER DRAIN TEE CONSE TO OPEN DRAIN A94054 Fig 48 Example of Field Drain Attachment CONDENSATE TRAP WIRE TIE S HEAT TAPE 8 WRAPS MINIMUM A A93036 Fig 49 Condensate Trap Heat Tape control CPU tr
17. furnace ALTERNATE SUPPORT LOCATION 4 IN MIN 8 IN MAX e 13 16 IN MAX ALTERNATE SUPPORT LOCATION FROM BACK 1 A 1 In clearance minimum between top of furnace and combustible material 2 The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage A93304 Fig 23 Crawlspace Horizontal Application 16 Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 in horizontally from the furnace See NFPA 90B or local code for further requirements For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks B Ductwork Acoustical Treatment Metal duct systems that do not have a 9
18. 20 000 BTUH HIGH HEAT 13 000 BTUH LOW HEAT PER BURNER DERATED 2 1000 FT ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE AT ALTITUDE rig Mnfld Press ues Mnfld Press po Mnfld Press ss times Mnfld Press ft Btu cu ft High Low High Low High Low High Low U S A Only HEHE Sd 3 4 1 4 3 5 1 5 45 3 6 1 5 U S A Only 3 7 11 5 3 8 1 6 lw U S A Only Ls 745 38718 Orifice numbers shown in BOLD factory installed 44 Fig 65 illustrates an easy method of obtaining thermostat amp draw measurements The amp reading should be taken after blower motor has started and furnace is operating in low heat 1 To operate furnace in low heat turn setup switch SW1 2 to ON position See Fig 32 and connect ammeter leads across thermostat subbase R W 2 See thermostat manufacturer s instructions for adjusting the heat anticipator and for varying heating cycle length NOTE When using an electronic thermostat set cycle rate for 3 cycles per hr 3 Return setup switch SW1 2 to OFF position and replace thermostat on subbase LOW FIRE ADJUSTMENT ALLEN SCREW UNDER CAP ON OFF SWITCH HIGH FIRE ADJUSTMENT ALLEN SCREW INLET UNDER CAP PRESSURE TAP BURNER ENCLOSURE REFERENCE PRESSURE MANIFOLD PRESSURE TAP A97386 Fig 62 Redundant Automatic Gas Valve BURNER N Y Fig
19. 63 Burner Orifice A93059 CAUTION DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive AA burner noise and misdirection of burner flames This can result in flame impingement of burners and heat exchang ers causing failures See Fig 63 CHECK SAFETY CONTROLS gt This section covers the safety controls that must be checked before the installation is complete The flame sensor gas valve and pressure switches were all checked in the Start up procedure section as part of normal operation 1 CHECK PRIMARY LIMIT CONTROL This control shuts off the gas control system and energizes the air circulating blower motor if furnace overheats 1 The recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes As soon as limit control has shut off burners a 33 status code will appear on furnace control The return air opening should be quickly unblocked to permit normal air circulation By using this method to check the limit control it can be established that the limit is functioning properly and the furnace will operate safely if there is a restricted return air duct or motor failure If the limit control does not function during this test the cause must be determined and corrected CHECK PRESSURE SWITCHES This control proves operation of the draft inducer Check switch
20. ASHRAE 2001 Fundamentals Handbook Chapter 34 V ACOUSTICAL LINING AND FIBROUS GLASS DUCT US and CANADA current edition of SMACNA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts VI GAS PIPING AND GAS PIPE PRESSURE TESTING 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch a clean unpainted metal surface of the furnace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily discharged 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity for example DO NOT move or shuffle your feet DO NOT touch un grounded objects etc 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touch ing control or wires 5 Use this procedure for installed and uninstalled un grounded furnaces 6 Before removing a new control from its container dis charge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 5 before bringing the control or yourself into contact with the furnace Put all used AND new controls into containers
21. Fig 23 Dimples are provided for hole locations See Fig 2 ANGLE IRON OR i EQUIVALENT A ROD LOCATION USING DIMPLE LOCATORS SEE DIMENSIONAL 3 84 HEX NUT DWG FOR amp WASHER 4 LOCATIONS REQD PER ROD A PREFERRED ROD LOCATION NOTES B ALTERNATE ROD LOCATION CAUTION The entire length of furnace MUST be supported when furnace is used in a horizontal position to ensure proper draining When suspended bottom brace supports sides and center blower shelf When unit is supported from the ground blocks or pad should support sides and center blower shelf area IV AIR DUCTS A General Requirements The duct system should be designed and sized according to accepted national standards such as those published by Air Conditioning Contractors Association ACCA Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guide lines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design static pressure When a 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 must also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the
22. NOTE Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole Roof terminations Locate assembly through roof to ap propriate height as shown in Fig 38 Sidewall terminations Locate assembly through sidewall with rain shield positioned no more than 1 in from wall as shown in Fig 38 5 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping 6 Check required dimensions as shown in Fig 38 or 39 IV MULTIVENTING AND VENT TERMINATIONS When 2 or more 355MAV Furnaces are vented near each other each furnace must be individually vented NEVER common vent or breach vent 355MAV furnaces When 2 or more 355MAV ee a LC pe S HUP xut CX E US ass 18 MAXIMUM SS lt os BRACKET 2 5 A Soc gt e lt Ss GoUPuNG a9 Z 55 COMBUSTION 7 VERTICAL SEPARATION S e dap 2 S RIA NG A MAINTAIN 12 IN MINIMUM ee ce CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE ROOF Fig 37 Roof Termination Preferred cS ss TS Se we SNS lt gt lt gt S HS 7 7 MAINTAIN 12 IN 18 IN FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE ROOF A93054 Fig 38 Concentric Vent and Combustion Air Roof Termination Preferred OVERHANG OR ROOF 12 MINIMUM Ec 12 IN SEPARATION BETWEEN BOTTO
23. ONLY SUPPORT RODS 3 EXTEND 1 4 ON EACH SIDE OF FILTER AND REST ON CASING FLANGE 17 2 1 WIDE CASINGS ONLY INSTALL FIELD SUPPLIED FILTER FILLER STRIP UNDER FILTER WASHABLE FILTER Fie FILTER FILTER RETAINER SUPPORT A00290 Fig 25 Bottom Filter Arrangement 18 4 Reinstall front filler panel and screws G Gas Piping Gas piping must be installed in accordance with national and local codes Refer to NFGC in the U S Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction Gas supply line should be a separate line running directly from meter to furnace if possible Refer to Table 3 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to propane gas TABLE 3 MAXIMUM CAPACITY OF PIPE NOMINAL IRON PIPE SIZE IN 1 2 0 622 3 4 0 824 1 1 049 1 1 4 1 380 1 1 2 1 610 Cubic ft of gas per hr for gas pressures of 0 5 psig 14 in wc or less and a pressure drop of 0 5 in wc based on a 0 60 specific gravity gas Ref Table 9 2 NFPA 54 2002 A CAUTION Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls WAR
24. SW1 3 on furnace control is in ON position when a bypass humidifier is used See Fig 32 for switch location e Check Troubleshooting Guide for Variable Speed 2 Stage Electronic Condensing Furnaces Series H and later C Set Thermostat Heat Anticipator When using a non electronic thermostat the thermostat heat anticipator must be set to match the amp draw of components in the R W WI circuit Accurate amp draw measurements can be obtained only at the thermostat subbase terminals R and W gt The thermostat and anticipator should NOT be in the circuit while measuring current If thermostat has no subbase the thermostat must be disconnected from and W W1 wires during current measurement HELLE LLL JO 99119 Fig 61 Filling Condensate Trap TABLE 11 ORIFICE SIZE AND MANIFOLD PRESSURES FOR GAS INPUT RATE TABULATED DATA BASED ON 20 000 BTUH HIGH HEAT 13 000 BTUH LOW HEAT PER BURNER DERATED 2 1000 FT ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft U S A Altitudes 2001 to 3000 or Canada Altitudes 2001 to 4500 U S A and Canada U S A and Canada c o lt o 2 U S A Only U S A Only U S A Only Orifice numbers shown in BOLD are factory installed TABLE 11 ORIFICE SIZE AND MANIFOLD PRESSURES FOR GAS INPUT RATE TABULATED DATA BASED ON
25. Sizing Table Cycle Rate 3 Cycles per Hr Selected Pipe Sloped To Furnace Safety Controls Check Operation Pipe Insulation Primary Limit Over Ceilings r Pressure Switches Low Ambient Exposed Pipes 2002 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 48 Printed in U S A 355m4010 Catalog No 5335 516
26. TO SIDEWALL NOTE A 12 In minimum offset pipe section is recommended with short 5 to 8 ft vent systems This recommendation is to reduce excessive condensate droplets from exiting the vent pipe A96230 Fig 35 Short Vent 5 to 8 Ft System 25 ALTITUDE UNIT SIZE TABLE 7 MAXIMUM ALLOWABLE PIPE LENGTH FT NUMBER OF 90 ELBOWS TERMINATION TYPE PIPE DIAMETER IN 0 to 2000 Altitude 042040 2 Pipe or 2 In Concentric 1 1 2 2 042060 2 Pipe or 2 In Concentric 1 1 2 2 042080 060080 2 Pipe or 2 In Concentric 1 1 2 2 060100 2 Pipe or 2 In Concentric 2 060120 Unit Size 2 Pipe or 3 In Concentric Termination Type Pipe Diameter In Number of 90 Elbows 3 4 2001 to 3000 042040 2 Pipe or 2 In Concentric 1 1 2 35 30 2 70 70 042060 2 Pipe or 2 In Concentric 1 1 2 2 35 30 70 70 042080 060080 2 Pipe or 2 In Concentric 1 1 2 2 16 11 70 70 060100 2 Pipe or 2 In Concentric 2 30 25 70 70 060120 2 Pipe or 3 In Concentric 3 3t 12 NA 62 61 Altitude Unit Size Termination Type Pipe Diameter In Number of 90 Elbows 3 4 3001 to 4000 042040 2 Pipe or 2 In Concentric 1 1 2 32 27 2 70 70 042060 2 Pip
27. Two Speed Air Conditioner gt Fig 53 Two Stage Furnace with Two Speed Heat Pump Dual Fuel cg DUAL FUEL TWO STAGE SINGLE SPEED THERMOSTAT FURNACE HEAT PUMP RVS GOOLING OW Ll sestertia pictas E HEAT STAGE 3 YAW2 __ __ rwa FURNACE HI Y1 HEAT STAGE 2 WAWI ___________ es w2 FURNACE LO HEAT COOL STAGE 1 YIY2 __________ Y COMPRESSOR G L 24VACHOT R ________ BIS MI PAN R DHUM 24VAC COMM C __________ COM EN KE EH C NA B HUM RVSSENSING L 781 a OUTDOOR EA OUTDOOR petes SENSOR SENSOR CONNECTION S2 J_ See notes 1 2 4 11 14 15 and 16 A00279 Fig 54 Dual Fuel Thermostat with Two Stage Furnace and Single Speed Heat Pump DUAL FUEL TWO STAGE TWO SPEED THERMOSTAT FURNACE HEAT PUMP RVS COOLING O W2 ________________________________ J w2 HEAT COOL STAGE 1 Y1 W2 ____________ al
28. before touching ungrounded objects 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage INTRODUCTION The model 355MAV 4 way multipoise Gas Fired Category IV direct vent condensing furnace is available in model sizes ranging in input capacities of 40 000 to 120 000 Btuh APPLICATIONS I GENERAL Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig 1 drain and pressure tubes are connected as shown in Fig 7 See appropriate application instructions for these procedures CAUTION Local codes may require a drain pan under A entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling US NFGC chapters 5 6 7 and 12 and national plumbing codes NOTE In Canada installations shall be in accordance with CANADA NSCNGPIC Parts 3 4 5 A B E G and H current NSCNGPIC and or local codes UPFLOW APPLICATIONS VII ELECTRICAL CONNECTIONS US National Electrical Code NEC ANSI NFPA 70 2002 CANADA Canadian Electrical Code CSA C22 1 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are
29. box drain tube di rectly from collector box drain to condensate trap as shown in Fig 10 d Determine appropriate length and cut e Connect to condensate trap f Clamp tube to prevent any condensate leakage 2 Inducer Housing Drain Tube a Remove factory installed cap and clamp from LOWER inducer housing drain connection b Remove and discard UPPER molded inducer housing drain tube which was previously connected to conden sate trap c Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed d Use inducer housing drain tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to the condensate trap e Connect inducer housing drain connection to condensate trap 1 Condensate Trap Located on Left Side of Casing a Determine appropriate length and cut b Connect tube to condensate trap c Clamp tube to prevent any condensate leakage 2 Condensate Trap Located on Right Side of Casing a Route inducer housing drain tube violet label directly from inducer housing drain to conden sate trap as shown in Fig 8 b Determine appropriate length and cut c Connect tube to condensate trap d Clamp tube to prevent any condensate leakage 3 Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure C Condensate Trap Field Drain Attachment Refer to Condensate Dra
30. by the furnace to areas outside the space containing the furnace the return air shall also be handled by ducts sealed to furnace casing The ducts terminate outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space CAUTION Do not operate this furnace during con struction If the furnace is required for temporary heating of buildings or structures under construction use clean outside air free of chlorine and fluorine compounds for combustion and ventilation These compounds form acids that corrode the heat exchangers These compounds are found in paneling and dry wall adhesives paints thin ners masonry cleaning materials and many other sol vents The furnace and its return air system shall be designed and installed so that negative pressure created by the air circulating fan cannot affect another appliance s combustion air supply or act to mix products of combustion with circulating air and that the air circulating fan of the furnace if installed in an enclosure commu nicating with another fuel burning appliance not of the direct vent type shall be operable only when any door or panel covering an opening in the furnace fan compartment or in a return air plenum on ducts is in the closed position WARNING Do not install furnace on its back Safety control operation will be adversely affected Never con AN nect return air du
31. clearances are met See Fig 3 and 12 COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED AUXILIARY J BOX ES CONDENSATE 3 TRAP COLLECTOR BOX TUBE GREEN INDUCER HOUSING COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX EXTENSION DRAIN TUBE DRAIN TUBE COUPLING COLLECTOR BOX TUBE PINK RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 060 AND 080 HEATING INPUT FURNACES DRAIN TUBE VIOLET COLLECTOR BOX DRAIN TUBE BLUE 02288 gt Fig 11 Horizontal Left Tube Configuration 10 COMBUSTION AIR INTAKE MANUAL SHUTOFF GAS VALVE SEDIMENT TRAR CONDENSATE TRAP VENT A 12 IN MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT 5 TO 8 FT VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM 30 MIN EXITING THE VENT PIPE ACCESS OPENING FOR TRAP NOTE LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS A93031 Fig 12 Attic Location and Working Platform CAUTION The condensate trap MUST be installed below furnace See Fig 6 for dimensions The drain connection to condensate trap must also be properly sloped to an open drain NOTE Combustion air and vent pipes are restricted to a mini mum length of 5 ft See Table 7 NOTE A 12
32. combustion air intake may be result of improper termination Ensure combustion air intake pipe termina tion is similar to that shown in Fig 37 38 39 40 or 41 so it will not be susceptible to areas where light snow or other sources of moisture could be pulled in If use of this drain connection is desired drill out fitting s tap plug with a 3 16 in drill and connect a field supplied 3 8 in tube This tube should be routed to open condensate drain for furnace and A C if used and should be trapped See Fig 36 2 Attach vent pipe as follows a Determine location of vent pipe connection to inducer housing as shown in Fig 34 for application b Reposition elastomeric rubber inducer housing outlet cap and clamp to appropriate unused inducer housing connection Tighten clamp WARNING Inducer housing outlet cap must be in stalled and fully seated against inducer housing Clamp must be tightened to prevent any condensate leakage Failure to follow this warning could result in electrical shock fire personal injury or death 28 c Install pipe support factory supplied in loose parts bag into selected furnace casing vent pipe hole Pipe support should be positioned to bottom of casing hole WARNING Vent pipe must be installed and fully seated against inducer housing internal stop Clamp must be tightened to prevent any condensate leakage Failure to follow this warning could result in electrical shock
33. excessive condensate droplets from exiting the vent pipe See Fig 12 or 35 LOCATION l GENERAL This furnace must be installed so the electrical components are protected from water not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS be located so combustion air and vent pipe maximum lengths are not exceeded Refer to Table 7 belocated where available electric power and gas supplies meet specifications on the furnace rating plate be attached to an air distribution system and be located as close to the center of the distribution system as possible Refer to Air Ducts section be provided with ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustibles label See Fig 3 This furnace may be located in a confined space without special provisions for dilution or ventilation air NOTE For upflow downflow applications install furnace so that it is level or pitched forward within 1 2 in for proper furnace operation For horizontal applications pitch 1 4 in minimum to 1 2 in maximum forward to ensure proper condensate drainage from secondary heat exchangers See Fig 14 LEVEL 07 TO V MAX UPFLOW OR DOWNFLOW HORIZONTAL A02146 Fig 14 Proper Condensate Drainage When a furnace is installed so that supply ducts carry air circulated
34. field drain See Fig 61 5 Remove funnel and tube from inducer housing and replace drain connection cap and clamp Notes for Fig 50 57 IV PURGE GAS LINES If not previously done purge the lines after all connections have been made and check for leaks WARNING Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use Ala commercially available soap solution made specifically for the detection of leaks to check all connections Failure to follow this warning could result in fire explosion personal injury or death V ADJUSTMENTS A Set Gas Input Rate Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft In the U S A the input rating for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level In Canada the input rating must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level gt Adjust manifold pressure to obtain input rate Furnace input rate must be within 2 percent of input on furnace rating plate 1 Determine natural gas orifice size and manifold pressure for correct input a Obtain average heat value at installed altitude from local gas supplier b Obtain average specific gravity from local gas supplier c Verify furnace model Table 11 can only be used for model 355MAV Furnaces d Find installation altitude in Table 11 NOTE For Canada altitudes of 2000
35. furnace casing combustion air pipe hole Pipe support should be positioned to bottom of casing hole e Insert 2 in diameter pipe into intake housing NOTE A 2 in diameter pipe must be used within the furnace casing Make all pipe diameter transitions outside furnace casing f Install casing hole filler cap factory supplied in loose parts bag in unused combustion air pipe casing hole 2 Drill a 1 8 in hole in 2 in combustion air pipe using hole in intake housing as a guide h Install a field supplied No 6 or No 8 sheet metal screw into combustion air pipe NOTE DO NOT OVERTIGHTEN SCREW Breakage of intake housing or fitting may cause air leakage to occur NOTE Do not attach combustion air intake pipe permanently to combustion air intake housing since it may be necessary to remove pipe for service of igniter or flame sensor COMBUSTION AIR INTAKE HOUSING PLUG FITTING The combustion air intake plug fitting must be installed in unused combustion air intake housing This fitting must be attached by using RTV sealant or by drilling a 1 8 in hole in fitting using hole in intake housing as a guide Install a field supplied No 6 or No 8 sheet metal screw NOTE DO NOT OVERTIGHTEN SCREW Breakage of intake housing or fitting may cause air leakage to occur A plugged drain connection has been provided on this fitting for use when moisture is found in combustion air intake pipe and combustion box NOTE Moisture in
36. furnace prior to placing it into service The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON at HI HEAT and OFF ELECTRICAL CONNECTIONS See Fig 28 for field wiring diagram showing typical field 115 v and 24 v wiring Check all factory and field electrical connections for tightness 19 CAUTION Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire connected to gas valve and burner box screw 1 115 V WIRING Before proceeding with electrical connections make certain that voltage frequency and phase correspond to that specified on furnace rating plate Also check to be sure that service provided by power supply is sufficient to handle load imposed by this equipment Refer to rating plate or Table 4 for equipment electrical specifications Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2002 and any local codes or ordinances that might apply For Canadian installations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authorities having jurisdiction gt Field supplied wiring shall conform with the limitations of 63 F 33 C rise Use a separate branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace See Table 4 for wir
37. held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electro static potential 552 upflow furnace application is where furnace blower is located below combustion and controls section of furnace and conditioned air is discharged upwards A Condensate Trap Location Factory Shipped Orientation The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications A factory supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment See Condensate Trap Tubing Factory Shipped Orientation section for drain tube extension details See Fig 6 B Condensate Trap Tubing Factory Shipped Orientation NOTE See Fig 7 or tube routing label on main furnace door to confirm location of these tubes BLOWER SHELF FURNACE DOOR CONDENSATE TRAP INSIDE CONDENSATE TRAP FURNACE DOOR FURNACE IDE FURNACE 5 14 Eel Iu A FIELD 26 V4 110 FIELD DRAIN DRAIN ALTERNATE DRAIN CONN CONN TUBE LOCATION CONDENSATE TRAP SIDE VIEW FRONT VIEW END VIEW FRONT VIEW DRAIN TUBE LOCATION DOWNFLOW AND ALTERNATE HORIZONTAL UPFLOW APPLICATIONS EXTERNAL UPFLOW APPLICATIONS APPLICATIONS SLOT FOR SCREW HORIZONTAL APPLICATION OPTIONAL
38. in minimum offset pipe section is recommended with short 5 to 8 ft vent systems This recommendation is to reduce excessive condensate droplets from exiting the vent pipe See Fig 12 or 35 V HORIZONTAL RIGHT SUPPLY AIR DISCHARGE APPLICATIONS A horizontal right furnace application is where furnace blower is located to the left of combustion and controls section of furnace and conditioned air is discharged to the right CAUTION Local codes may require a drain pan under A entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling NOTE In Canada installations shall be in accordance with current NSCNGPIC Installation Codes and or local codes NOTE The auxiliary junction box J box MUST be relocated to opposite side of furnace casing See Fig 13 See Electrical Connection section for J box relocation A Condensate Trap Location The condensate trap must be removed from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 or 13 To relocate condensate trap from the blower shelf to desired location perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed WARNING Casing hole filler ca
39. loose parts bag b Route extended collector box pressure tube to relief port connection on condensate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage PLUG C Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures D Pressure Switch Tubing The LOWER collector box pressure tube pink label is factory connected to the High Pressure Switch for use when furnace is installed in UPFLOW applications This tube MUST be discon nected extended rerouted and then reconnected to the pressure switch in HORIZONTAL LEFT applications for 060 and 080 heating input furnaces NOTE See Fig 11 or tube routing label on main furnace door to check for proper connections Modify tube as described below 1 Disconnect collector box pressure tube pink label attached to High Pressure Switch 2 Use smaller diameter tube factory supplied in loose parts bag to extend tube disconnected in item 1 3 Route extended tube a Behind inducer housing b Between blower shelf and inducer housing 4 Determine appropriate length cut and reconnect tube to High Pressure Switch connection labeled COLLECTOR BOX E Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures F Construct a Working Platform Construct working platform where all required furnace
40. operation as follows 1 Turn off 115 v power to furnace 2 Remove control access door and disconnect inducer motor 12 pin wire harness at inducer motor 3 Turn on 115 v power to furnace Set thermostat to call for heat When pressure switches are functioning properly status code 42 will flash on furnace control approximately 20 sec after thermostat BURNER FLAME N BURNER A MANIFOLD A89020 Fig 64 Burner Flame TABLE 12 ALTITUDE DERATE MULTIPLIER FOR U S A DERATE MULTIPLIER FACTOR 1 00 ALTITUDE FT 0 2000 2001 3000 3001 4000 4001 5000 5001 6000 6001 7000 7001 8000 8001 9000 9001 10 000 Derate multiplier factors are based on midpoint altitudes for altitude ranges switch is closed If either a status code 31 or 32 is flashed 6 Reconnect inducer motor wire harness Reinstall furnace when inducer motor is disconnected the furnace will shut access door itself down immediately Determine the reason pressure 7 Turn on 115 v power to furnace switches did not function properly and correct the condi P tion 8 Reset thermostat to desired temperature 5 Turn off 115 v power to furnace CHECKLIST TABLE 13 GAS RATE CU FT HR 1 Put away tools and instruments Clean up debris SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL fH 2 Verify flame rollout manual reset switch has continuity REVOLUTION cu ft cu ft c
41. seamers wide duct pliers or duct flange tool to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 22 WARNING Do not bend duct flanges inward as shown in Fig 22 This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure Remove duct flange completely or bend it inward a minimum of 210 as shown in Fig 22 Ill INSTALLATION IN HORIZONTAL APPLICATIONS These furnaces can be installed in either horizontal left or right discharge position In a crawlspace furnace can either be hung from floor joist or installed on suitable blocks or pad Furnace can A89014 Fig 18 Leveling Legs PLENUM OPENING D FLOOR OPENING p Su LAUS MEI penes 96283 Fig 19 Floor and Plenum Opening Dimensions un ULP ILI ain ER T FURNACE FURNACE OR COIL CASING WHEN USED CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING NC DOWNFLOW Nl A A SUBBASE A la SHEET N SHEET METAL A TENUN Ar PLENUM A FLOOR A FLOOR 3 OPENING OPENING A96284 A96285 Fig 20 Furnace Plenum and Subbase Fig 21 Furnace Plenum and Coil Installed on a Combustible Floor Assembly or Coil Box Installed on a Combustible Floor TABLE 1 0OPENING DIMENSIONS IN FURNACE
42. there is a demand for dehumidification the furnace blower motor BLWM will drop the blower airflow to 8696 of high cooling airflow High cooling airflow is based on the A C selection shown in Fig 58 c Cooling off delay When the call for cooling is satis fied and there is a demand for dehumidification the cooling blower off delay is decreased from 90 seconds to 5 seconds V SUPER DEHUMIDIFY MODE Super Dehumidify mode can only be entered if the furnace control is in Thermidistat mode and there is a demand for dehumidifica tion The cooling operation described in item 3 above also applies to operation with a Thermidistat The exceptions are listed below a Low cooling When the R to Y1 circuit is closed R to G circuit is open and there is a demand for dehumidifica tion the furnace blower motor BLWM will drop the blower airflow to 65 of low cooling airflow for a maximum of 10 minutes each cooling cycle or until the R to G circuit closes or the demand for dehumidification is satisfied Low cooling airflow is the true on board CF selection as shown in Fig 58 b High cooling When the R to Y Y2 cicuit is closed R to G circuit is open and there is a demand for dehumidi fiation the furnace blower motor BLWM will drop the blower to 65 of high cooling airflow for a maximum of 10 minutes each cooling cycle or until the R to G circuit closes or the demand for dehumidification is satisfied High cooling airflow is based on the A C
43. to 4500 ft use U S A altitudes of 2001 to 3000 ft in Table 11 1 Heat pump MUST have a high pressure switch for dual fuel applications Refer to outdoor equipment Installation Instructions for additional information and setup procedure Select the ZONE position on the two speed heat pump control Dip switch No 1 on Thermidistat should be set in OFF position for air conditioner installations This is factory default Dip switch No 1 on Thermidistat should be set in ON position for heat pump installations 2 3 4 Outdoor Air Temperature Sensor must be attached in all dual fuel applications 5 6 7 Dip switch No 2 on Thermidistat should be set in OFF position for single speed compressor operation This is factory default Dip switch No 2 on Thermidistat should be set in ON position for two speed compressor operation 9 Configuration Option No 10 Dual Fuel Selection must be turned ON in all dual fuel applications 10 NO connection should be made to the furnace HUM terminal when using a Thermidistat 11 Optional connection If wire is connected dip switch SW1 2 on furnace control should be set in ON position to allow Thermidistat Thermostat to control furnace staging 12 Optional connection If wire is connected ACRDJ jumper on furnace control should be removed to allow Thermidistat Thermostat to control outdoor unit staging 13 Furnace must control its own high stage heating operation via fu
44. vac whenever the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y1 or R to G and Yl and Y2 circuits are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Fig 32 IV THERMIDISTAT MODE See Fig 50 53 for Thermidistat connections The dehumidification output DHUM on the Thermidistat should be connected to the furnace control thermostat terminal DHUM When there is a dehumidify demand the DHUM input is activated which means 24 vac signal is removed from the DHUM input terminal In other words the DHUM input logic is reversed The DHUM input is turned ON when no dehumidify demand exists Once 24 vac is detected by the furnace control on the DHUM input the furnace control operates in Thermidistat mode If the DHUM input is low for more than 48 hours the furnace control reverts back to non Thermidistat mode The cooling operation described in item 3 above applies to operation with a Thermidistat The exceptions are listed below a Low cooling When the R to G and Y1 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower airflow to 8696 of low cooling airflow which is the true on board CF selection as shown in Fig 58 b High cooling When the R to G and Y Y2 circuit is closed and
45. will vary due to application furnace orientation and filter type The filter may be installed in an external Filter Media cabinet if provided or the furnace blower compartment Factory supplied washable filters are shipped in the blower compartment If a factory supplied external Filter Media cabinet is provided instructions for its application assembly and installation are packaged with the cabinet The Filter Media cabinet can be used with the factory supplied washable filter or a factory specified high efficiency disposable filter see cabinet instructions If installing the filter in the furnace blower compartment deter mine location for filter and relocate filter retaining wire if necessary See Table 2 to determine correct filter size for desired filter location Table 2 indicates filter size location and quantity shipped with this furnace See Fig 2 for location and size of bottom and side return air openings TABLE 2 FILTER INFORMATION AIR FILTER LOCATED IN BLOWER COMPARTMENT Furnace Casing Width In Filter Size In Side Return 17 1 2 1 16 X 25 X 11 21 1 16 X25 X1 1 20 X 25 X 11 Cleanable 1 or 2 16 X 25 X 1 1 24 X 25 X 11 Cleanable Filters may be field modified by cutting filter material and support rods 3 in filters Alternate sizes can be ordered from your distributor or dealer T Factory provided with furnace Filter Type Framed Bottom Return 1 16 X 25 X 11 Cle
46. wobei l Y1 COMPRESSOR LO HEAT STAGE 3 ____________ SWINE zT Iw2 FURNACE HEAT COOL STAGE 2 J NOTE 12 viva L l Y2 COMPRESSOR HI FAN G ____________ 6 24VACHOT R Llj AER belassen J R DHUM 24VAC COMM C _________ zJ NA B RVSSENSING L 781 m OUTDOOR L OUTDOOR SENSOR SENSOR CONNECTION S2 J EN See notes 1 2 3 4 12 13 14 15 and 17 Fig 55 Dual Fuel Thermostat With Two Stage Furnace and Two Speed Heat Pump To set the desired cooling airflow Remove main furnace door and blower access door 2 Locate A C setup switches on frunace control See Fig 32 3 Determine air conditioning tonnage used 4 Use Fig 58 or wiring schematic to determine proper setup position of A C switches See Fig 31 and 59 NOTE Excessive airflow caused by improper A C switch setup may cause condensate blow off in cooling mode 5 Replace main furnace door and blower access door NOTE EAC 1 terminal is energized whenever blower operates HUM terminal is only energized when blower is energized in heating A00280 38 TWO STAGE TWO STAGE TWO SPEED THERMOSTAT FURNACE AIR CONDITIONER w2
47. 0 degree elbow and 10 ft of main duct to the first branch take off may require internal acoustical lining As an alternative fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts C Supply Air Connections UPFLOW FURNACES Connect supply air duct to 3 4 in flange on furnace supply air outlet The supply air duct attachment must ONLY be connected to furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accesso ries MUST be connected external to furnace main casing DOWNFLOW FURNACES Connect supply air duct to supply air opening on furnace The supply air duct attachment must ONLY be connected to furnace supply outlet or air conditioning coil casing when used when installed on non combustible material When installed on combus tible material supply air duct attachment must ONLY be con nected to an accessory subbase or factory approved air condition ing coil casing DO NOT cut main furnace casing to attach supplyside air duct humidifier or other accessories All accesso ries MUST be connected external to furnace main casing Supply air opening duct flanges must be modified per Fig 2
48. 0120 Concentric 3t 35 33 Disk usage Unless otherwise stated use perforated disk assembly factory supplied in loose parts bag t Wide radius elbow t Vent sizing for Canadian installations over 4500 ft 1370m above sea level are subject to acceptance by the local authorities having jurisdiction NA Not Allowed pressure switch will not make NOTES 1 Do not use pipe size greater than those specified in table or incomplete combustion flame disturbance or flame sense lockout may occur 2 Size both the combustion air and vent pipe independently determine the smallest diameter allowed by the table for each pipe then use the larger diameter for both pipes 3 Assume two 45 elbows equal one 90 elbow Long radius elbows are desirable and may be required in some cases 4 Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count 5 The minimum pipe length is 5 ft for all applications MEE aa a Determine location of combustion air intake pipe con nection to combustion air intake housing as shown in Fig 34 for application b Reposition combustion air intake housing plug fitting in appropriate unused intake housing connection c Insert perforated disk assembly factory supplied in intake housing where combustion air intake pipe will be connected d Install pipe support factory supplied in loose parts bag into selected
49. 2 HORIZONTAL FURNACES Connect supply air duct to supply air opening on furnace The supply air duct attachment must ONLY be connected to furnace supply outlet or air conditioning coil casing when used DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be connected external to furnace main casing D Return Air Connections WARNING Never connect return air ducts to the back of the furnace Return air duct connections on furnace side s permitted in upflow applications only A failure to follow this warning could result in fire personal injury or death UPFLOW FURNACES The return air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing Bypass humidifier may be attached into unused side return air portion of the furnace casing DO NOT connect any portion of return air duct to back of furnace casing DOWNFLOW AND HORIZONTAL FURNACES The return air duct must be connected to return air opening provided DO NOT cut into casing sides or back to attach any portion of return air duct Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace E Filter Arrangement WARNING Never operate unit without a filter or with A filter access door removed Failure to follow this warning can cause fire personal injury or death The air filter arrangement
50. 2 m w 5091 51 Q bi gt R PS D lin gus y 440 Ul JD uej JUOD oo uonsod 440 ui 5 v Moye IN INBA t 00 oszt szzt osor ooz Q oszt oszt oovt 5221 0601 s48 Zoos lt lt z 0806 gu 8 5221 5221 0501 S 8 00 scs Ba D ELE 090070 I5 5 2 Peasy ee nC Poe Po E S yg og NQL W49 OSE NO GSVELUVHD 28166 MOLUIVIDUO 2 Alem B z aan 81d EE 00 TS 10_ Oct 081 oo OST IS IIO 08045 HESS rai oto 080 lt Eld T6 600 090 SL IS 800 00 Et ZS U 5639 Nid nggon JuVH2 9Md BAON 25 BA NUS HA Ni 8100 55 N3HM N3HM Sd91 VH Lost EXC 123NNOOSIG YA V349 E CHAINH9 235 MB YO SM NYO sa J o L S ILON 25 era 06 EMIO aNnouo Gau Gu NOLL23ES 1N3Wdno3 21 AVC HO MOW OLIVIW3HOS HOLIMS 1 OVASLL OL SH WYHOVIC NOLLO3NNOO COMMUNICATION CONTINUOUS FAN FUTURE CONNECTOR CF AIRFLOW APPLICATIONS MODEL PLUG SETUP SWITCHES CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF DELAY
51. 27 104 13 8 12 32 20 060100 115 60 1 060120 115 60 1 Permissible limits of voltage range at which unit will operate satisfactorily T Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating components EAC humidifier etc full load amps t Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop Time delay type is recommended FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 208 230 460 V WIRING NOTE 5 THERMOSTAT FIVE Q 9 9 TERMINALS FIELD SUPPLIED WIRE i DISCONNECT THREE WIRE NEN D e e aoe HEATING OC Em 208 230 OR ONLY 2m p 460 V THREE PHASE 41 l 4e e HL eve eno 793 115 V NOTE 1 SINGLE lt 2e 43 PHASE eg _ ___ RH e e ne eae ORERE 5 d 208 230 V 84 joco uk 1 9 9 e4rTe gt SINGLE 115 V AUXILIARY nl L e J PHASE FIELD SUPPLIED J BOX CH 11 up GND DISCONNECT Lecce IET CONDENSING SWITCH 347 UNIT 24 N TWO WIRE FURNACE TERMINAL WE PO nones 1 Connect Y or Y Y2 terminal as
52. 58 or wiring schematic to determine proper setup position of CF switches See Fig 31 and 59 5 Replace main furnace door and blower access panel C Setup Switches SW1 The furnace control has 8 setup switches that may be set to meet the application requirements Position these setup switches for the appropriate requirement Remove main furnace door and blower access panel 2 Locate setup switches on furnace control See Fig 32 3 See Table 9 for setup switch description See Fig 31 and 59 4 Replace main furnace door and blower access panel NOTE If a bypass humidifier is used setup switch SW1 3 Low HEAT Rise Adjust should be in ON position This compensates for the increased temperature in return air resulting from bypass NOTE If modulating dampers are used blower motor automati cally compensates for modulating dampers PRIME CONDENSATE TRAP WITH WATER CAUTION Condensate trap must be PRIMED or proper draining may not occur The condensate trap has 2 internal chambers which can ONLY be primed by pour ing water into the inducer drain side of condensate trap 1 Remove upper inducer housing drain connection cap See Fig 60 2 Connect field supplied 1 2 in ID tube to upper inducer housing drain connection 3 Insert field supplied funnel into tube 4 Pour 1 quart of water into funnel tube Water should run through inducer housing overfill condensate trap and flow into open
53. BUSTION AIR PIPE ING 12 MIN VERTICAL TO ROOF EXAMPLE An 042080 size furnace located in Indianapolis elevation 650 ft above sea level could be installed in an application requiring 3 elbows and 17 ft of vent pipe along with 5 elbows and 16 ft of combustion air pipe Table 6 indicates this application would allow a 1 1 2 in diameter vent pipe but require a 2 in diameter combustion air pipe 1 1 2 in pipe is good for 20 ft with 3 elbows but only 10 ft with 5 elbows Therefore 2 in diameter pipe must be used for both vent and combustion air pipes since larger required diameter must always be used for both pipes If same installation were in Albuquerque elevation 5250 ft above sea level installation would require 2 in vent pipe and combustion air pipe At 5001 to 6000 ft elevation 1 1 2 in pipe is not allowed with 5 elbows but 2 in pipe is good for 68 ft with 5 elbows C Combustion Air and Vent Pipe Attachment NOTE pipe joints must be cemented except attachment of combustion air pipe to inlet housing connection since it may be necessary to remove pipe for servicing 1 Attach combustion air pipe as follows 12 MIN VENT PIPE COMBUSTION AIR PIPE HORIZONTAL TO SIDEWALL COMBUSTION AIR PIPE VENT PIPE Cl lt f TY 12 MIN VENT PIPE VERTICAL
54. CATIONS A downflow furnace application is where furnace blower is located above combustion and controls section of furnace and conditioned air is discharged downwards A Condensate Trap Location The condensate trap must be removed from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 9 or 10 To relocate condensate trap from the blower shelf to desired location perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap Agn COLLECTOR BOX TUBE GREEN PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE PINK COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX EXTENSION TUBE INDUCER HOUSING DRAIN TUBE VIOLET 1 CONDENSATE b TRAP COLLECTOR BOK EXTENSION DRAIN TUBE DRAIN TUBE COUPLING A94216 Fig 10 Downflow Tube Configuration Right Hand Trap Installation 3 Remove casing hole filler cap from casing hole See Fig 2 and 10 4 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed WARNING Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated Failure to follow th
55. CAUTION These furnaces are equipped with a manual reset limit switch in burner box This switch opens and shuts off power to the gas valve if an overheat condition flame rollout occurs in burner enclosure Correct inad equate combustion air supply or improper venting condi tion before resetting switch DO NOT jumper this switch Before operating furnace check flame rollout manual reset switch for continuity If necessary press button to reset switch ll SELECT SETUP SWITCH POSITIONS A Air Conditioning A C Setup Switches The air conditioning setup switches are used to match furnace airflow to cooling unit used THERMIDISTAT TWO STAGE SINGLE SPEED THERMIDISTAT TWO STAGE SINGLE SPEED FURNACE AIR CONDITIONER FURNACE HEAT PUMP HEAT STAGE 2 2 NOTE 11 w2 RVS COOLING O W2 __________________________ L N A Y1 W2 Y1 HEAT STAGE 2 __ 11__ w2 FURNACE HI HEAT STAGE 1 WAWI L ____________
56. ES At altitudes above 2000 ft this furnace has been ap proved for a 2 percent derate for each 1000 ft above sea level See Table 12 for derate multiplier factor and example EXAMPLE 100 000 BTUH HIGH HEAT INPUT FURNACE IN STALLED AT 4300 FT Derate X Multiplier Factor 0 91 Furnace Input Rate at Installation Altitude 91 000 Furnace Input Rate at Sea Level 100 000 X CANADA At installation altitudes from 2000 to 4500 ft this furnace must be derated 5 percent by an authorized Gas Conversion Station or Dealer To determine correct input rate for altitude see example above and use 0 95 as derate multiplier factor b Reinstall burner box cover NOTE Clocking gas input rate MUST always be performed with the burner box cover INSTALLED c Check that gas valve adjustment caps are in place for proper input to be clocked d Obtain average heat value at altitude from local gas supplier NOTE Be sure heating value of gas used for calculations is correct for your altitude Consult local gas utility for altitude adjustment of gas heating value e Check and verify orifice size in furnace NEVER AS SUME THE ORIFICE SIZE ALWAYS CHECK AND VERIFY f Turn off all other gas appliances and pilots 2 Turn setup switch SW1 2 to ON position See Fig 32 This keeps furnace locked in low heat operation h Jumper R to W W1 i Let furnace run for 3 minutes in low heat operation j Measure time in sec for gas meter
57. Harv i 2M 22 uM NIVHG MO 4 31VSN30NO9 K 4 2 a H3MOd NNOO INSANE 7 WA 62 AHOSS300V 6 9 06 si YIA NI 1 IWLSOWYSHL HT AHLIN3 NEZ KAT gt JVISOIWH3HL VIC NEZ dAL i NNOO H3MOd E e VIG NEY m Wr IN3A NIZ NNOO SVO NNOO SVO VIQ NIA la NNOO SVO VIC NEZ 31VNH3LTV HO LEE CON VIO NES LHOIH 1VLNOZIHOH HAMOd 7 M Mr NOLLSNEWOOD NI Z 1331 1VINOZIHOH X LER _ SLYSNSGNOO 2 MOTHNMOG d dVHL PU Hune d amu 31VSN3ONOO NNOD HIV lf 61 He a NOILSNEWOO NI 2 976 u ce 9 MO3Hlv iui 86 X a 92 INSTALLATION e misi ean ad furnace is equipped for use with natural gas at altitudes 0 10 000 ft 0 3 050m except 140 size furnaces are only approved for altitudes 0 7 000 ft 0 kit supplied by the manufacturer shall be used to convert to propane gas use or may be required for some natural gas applications x This fumace is feri i n ea ina building constructed on site This furnace may be installed in a manufactured mobile home when stated on rating plate and using factory authorized kit e This furnace may be inst
58. LI NOTE1 w2 s f MEME Stree Se teen D Nb NE CC rere eae eee 2 Y1 WIWA ___________ v2 12 Y2 ic Mee e R 4 R b E R DHUM QU COM ps C HUM See notes 2 11 and 12 A00281 gt Fig 56 Two Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner SINGLE STAGE TWO STAGE TWO SPEED THERMOSTAT FURNACE AIR CONDITIONER W2 PUR cR 2 wiw1 YN2 __ __________ ei 2 GL G Re lees IMER J R DHUM c Re oec oco eise ual C HUM See note 2 A02348 Fig 57 Single Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner B Continuous Fan CF Setup Switches The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode or to select low cooling airflow for two speed cooling units This setup feature allows continuous fan airflow or low cooling airflow to be adjusted To set desired continuous fan airflow or low cooling airflow 1 Remove main furnace door and blower access door 2 Locate CF setup switches on furnace control See Fig 32 3 Determine desired continuous fan airflow or low cooling airflow 4 Use Fig
59. M OF AVE COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER 15 GREATER COMBUSTION AIR 87225 Fig 40 Sidewall Termination of 12 in More A87224 OVERHANG OR ROOF Nn ee NM ee 1271 17 MAXIMUM COMBUSTION AIR MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER 15 GREATER A93055 Fig 39 Concentric Vent and Combustion Air Side Termination OVERHANG OR ROOF 12 MINIMUM LIES P BRACKET COUPLING 12 IN SEPARATION BETWEEN BOTTOM OF 5 COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER 15 GREATER COMBUSTION AIR ELBOW PARALLEL TO WALL A87226 Fig 41 Sidewall Termination of Less than 12 in TABLE 8 MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH FT WITH INSULATION IN WINTER DESIGN TEMPERATURE AMBIENT WINTER DESIGN TEMPERATURE CF MAXIMUM PIPE DIAMETER 042040 INSULATION THICKNESS 3 8 1 2 3 4 042060 042080 060080 060100 060120 Pipe length ft specified for maximum pipe lengths located in unconditioned spaces Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 7 t Insulation thickness based on R value of 3 5 per in
60. N and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation CAUTION Sheet metal parts may have sharp edges or A burrs Use care and wear appropriate protective clothing and gloves when handling parts Failure to follow this caution could result in personal injury The 355MAV Multipoise Condensing Gas Fired Furnaces are C S A design certified for natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A C S A listed gas conversion kit is required to convert furnace for use with propane gas See Fig 3 for required clearances to combustibles Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace See NFPA 90B or local code for further requirements These furnaces SHALL NOT be installed directly on carpeting tile or any other combustible material other than wood flooring In downflow installati
61. NING Gas valve shutoff switch MUST be facing A forward or tilted upward Failure to follow this warning could result in property damage or death LENGTH OF PIPE FT INTERNAL DIAMETER IN WARNING Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use Ala commercially available soap solution made specifically for the detection of leaks to check all connections A failure to follow this warning could result in fire explo sion personal injury or death BOTTOM CLOSURE S PANEL FRONT FILLER PANEL 93047 Fig 26 Removing Bottom Closure Panel WARNING Use proper length of pipe to avoid stress on gas control manifold Failure to follow this warning could result in a gas leak resulting in fire explosion personal injury or death WARNING Blower access door switch opens 115 v power to furnace control No component operation can occur Do not bypass or close switch with panel removed Failure to follow this warning could result in personal injury or death Install a sediment trap in riser leading to furnace Trap can be installed by connecting a tee to riser leading to furnace so straight through section of tee is vertical Then connect a capped nipple into lower end of tee Capped nipple should extend below level of gas controls Place a ground joint union between gas control manifold and manual gas shutoff v
62. Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code 9 After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appliance to their previous conditions of use Vent system or vent connectors may need to be resized For any In Canada construct all combustion air and vent pipes for this unit other appliances when resizing vent systems or vent connectors of CSA or ULC listed schedule 40 PVC PVC DWV or ABS system or connector must be sized to approach minimum size as DWV pipe and pipe cement SDR pipe is NOT approved in determined using appropriate vent sizing table found in th
63. When an existing Category I furnace is removed or replaced the original venting system may no longer be sized to properly vent the remaining attached appliances An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent leakage of condensate and combustion products and spillage of combustion products into the living space etc 00212 Fig 30 Relocating J Box WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Code and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the A venting system are located and other spaces of the building 4 Close fireplace dampers 5
64. When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds at high cooling airflow before transitioning back to continuous blower airflow When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation Continuous Blower Speed Selection from Thermostat To select different continuous blower speeds from the room thermostat momentarily turn off the FAN switch or push button on the room thermostat for 1 3 seconds after the blower motor BLWM is operating The furnace control CPU will shift the continuous blower airflow from the factory setting to the next highest CF selection airflow as shown in Fig 58 Momentarily turning off the FAN switch again at the thermostat will shift the continuous blower airflow up one more increment If you repeat this procedure enough you will eventually shift the continuous blower airflow to the lowest CF selection as shown in Fig 58 The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption Vil HEAT PUMP See Fig 52 55 for thermostat connections When installed with a heat pump the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles Whenever W W1 is energized along with Y1 or Y Y2 the furnace control CPU will transition to o
65. alled on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below PVC DWV CPVC ABS DWV pipe and must not be vented in common with other gas fired appliances Construction through which vent air intake pipes may be installed is maximum 24 inches 600 mm minimum 3 4 inches 19 mm thickness including roofing materials LEVEL 0 TO For upflow and downflow applications furnace must be installed level or pitched within 1 2 of level For a 1 2 horizontal application the furnace must be pitched minimum 1 4 to maximum of 1 2 forward for proper drainage See Installation Manual for IMPORTANT unit support details on horizontal applications DOWNFLOW e This furnace requires a special venting system Refer to the installation instructions for parts list and method of installation This furnace is for use with schedule 40 PVC MIN 1 4 1 2 HORIZONTAL MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION rris furnace is approved for UPFLOW DOWNFLOW and ALL POSITIONS HORIZONTAL installations Mimimum front clearance for service 30 inches 762mm DOWNFLOW POSITIONS T For installation on combustible floors only when installed on special ba KGASB0201ALL Coil Assembly Part No CD5 or 5 or Coil Casing us t No KCAKC Clearance arrows HORIZONTAL POSITIONS Ponor engem Line contact is permissible only betw
66. alve See Fig 27 GAS SUPPLY MANUAL SHUTOFF VALVE REQUIRED 93324 Fig 27 Typical Gas Pipe Arrangement CAUTION If a flexible connector is required or al A lowed by authority having jurisdiction black iron pipe shall be installed at furnace gas control valve and extend a minimum of 2 in outside furnace casing An accessible manual shutoff valve MUST be installed external to furnace casing and within 6 ft of furnace A 1 8 in NPT plugged tapping accessible for test gage connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve NOTE The gas valve inlet pressure tap connection is suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas valve See Fig 62 Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada local and national plumbing and gas codes before the furnace has been connected If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be disconnected from furnace and capped before pressure test If test pressure is equal to or less than 0 5 psig 14 in wc turn off electric shutoff switch located on gas valve before test It is recommended that ground joint union be loosened before pressure testing After all connections have been made purge lines and check for leakage at
67. anable CAUTION Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends Wear safety glasses gloves and appropiate protective clothing Failure to follow this caution could result in personal injury CAUTION For airflow requirements above 1800 CFM see Air Delivery table in Product Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM NOTE Side return air openings can ONLY be used in UPFLOW configurations Install filter s as shown in Fig 24 For bottom return air applications filter may need to be cut to fit some furnace widths Install filter as shown in Fig 25 NOTE Remove and discard bottom closure panel when bottom inlet is used F Bottom Closure Panel These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air is used To remove bottom closure panel perform following 1 Tilt or raise furnace and remove 2 screws holding front filler panel See Fig 26 2 Rotate front filler panel downward to release holding tabs 3 Remove bottom closure panel WASHABLE FILTER AS efi L FILTER T RETAINER A93045 Fig 24 Filter Installed for Side Inlet 21 IN WIDE CASINGS
68. ansformer TRAN inducer motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV l SINGLE STAGE THERMOSTAT AND TWO STAGE HEATING ADAPTIVE MODE See Fig 28 or 57 for thermostat connections NOTE Low heat only switch SW1 2 selects either the low heat only operation mode when ON see item 2 below or adaptive heating mode when OFF in response to a call for heat See Fig 32 When the W2 thermostat terminal is energized it will always cause high heat operation when the R to W circuit is closed regardless of the setting of the low heat only switch This furnace can operate as a two stage furnace with a single stage thermostat because furnace control CPU includes a programmed adaptive sequence of controlled operation which selects low heat or high heat operation This selection is based upon the stored history of the length of previous gas heating periods of the single stage thermostat The furnace will start up in either low or high heat If the furnace starts up in low heat the furnace control CPU determines the low heat on time from 0 to 16 minutes which is permitted before switching to high heat If power is interrupted the stored history is erased When this happens the control CPU will initially select low heat for up to 16 minutes and then switch to high heat as long as the thermostat continues to call for heat Subsequent selection is based on stored history of thermostat cycle times The wall ther
69. ate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures IV HORIZONTAL LEFT SUPPLY AIR DISCHARGE APPLICATIONS A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace and conditioned air is discharged to the left CAUTION Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling NOTE In Canada installations shall be in accordance with current NSCNGPIC and or local codes A Condensate Trap Location The condensate trap must be removed from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 or 11 To relocate condensate trap from the blower shelf to desired location perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Remove casing hole filler cap from casing hole See Fig 2 or 11 4 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed WARNING Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated Failure to follow this warning could result in electrical shock fire personal injury or death 5 Install cond
70. ave expired The component test sequence is as follows a The furnace control CPU turns the inducer motor IDM ON at medium speed and keeps it ON through step c b After waiting 15 seconds the furnace control CPU turns the hot surface igniter ON for 15 seconds then OFF c The furnace control CPU then turns the blower motor BLWM at midrange airflow for 15 seconds then OFF d After shutting the blower motor BLWM OFF the furnace control CPU shuts the inducer motor IDM OFF NOTE The EAC terminals are energized when the blower is operating After the component test is completed 1 or more status codes 11 25 41 or 42 will flash See Service Label on blower access panel or Service Status Code Instructions for explanation of status codes NOTE To repeat component test turn setup switch SW1 6 to OFF and then back ON START UP PROCEDURES 1 GENERAL 1 Furnace must have a 115 v power supply properly nected and grounded NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control status indicator light flashes rapidly and furnace does not operate 2 Thermostat wire connections at terminals R W W1 G and Y Y2 must be made at 24 v terminal block on furnace control 3 Natural gas service pressure must not exceed 0 5 psig 14 in wc but must be no less than 0 16 psig 4 5 in wc 4 Blower access panel must be in place to complete 115 v electrical circuit to furnace
71. cal Treatment Supply Air Connections Return Air Connections esee 17 Filter Arrangement Bottom Closure Panel sese 17 18 Gas PIpIS do bn soe 18 19 ELECTRICAL CONNECTIONS eee 19 21 115 v Wiring wld DANE WATI hiven ga a a NAN a ba an idee i inre 20 ACCESSOTIeS ig ag NG BN E NGA NAN WOOD UU E KERA TAYA 20 21 DIRECT VENTING ge Pan dagan a gena na eterne ens 21 31 Removal of Existing Furnaces from Common Vent Systems 21 Combustion Air and Vent Piping sess 21 29 Concentric Vent and Combustion Air Termination Kit Installation 29 Multiventing and Vent Terminations 29 31 CONDENSATE DRAIN Cancels 355M 40 9 Il 355M 40 10 12 02 EFFICIENCY RATING CERTIFIED ama CERTIFIED As an ENERGY STAR Partner Bryant Heating amp Cooling Systems has de termined that this product the ENERGY REGISTERED QUALITY SYSTEM STAR guidelines for en ergy efficiency AIRFLOW UPFLOW gt DOWNFLOW AIRFLOW AIRFLOW V AIRFLOW Fig 1 Multipoise Orientations a Application st eo rte aime eee ass 31 Condensate Drain Protection 31 SEQUENCE OF OPERATION eee 31 36 Single Stage Thermostat and Two Stage Heating Adaptive Mode i ret ere ete Pres 33 34 Two Stage Thermostat and Two Stage Heating 34 Cool
72. cessory or heat tape manufacturer s recommenda tions 1 Fold heat tape in half and wrap on itself 3 times 2 Locate heat tape between sides of condensate trap back See Fig 49 3 Use wire ties to secure heat tape in place Wire ties can be positioned in notches of condensate trap sides See Fig 49 4 Wrap field drain pipe with remaining heat tape approxi mately 1 wrap per ft 5 When using field supplied heat tape follow heat tape manufacturer s instructions for all other installation guide lines SEQUENCE OF OPERATION CAUTION Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and burner box screw Using schematic diagram follow sequence of operation through different modes See Fig 31 Read and follow wiring diagram carefully NOTE If a power interruption occurs during a call for heat W W1 or W Wl and W2 the control will start a 90 second blower only ON period two seconds after power is restored if the A96128 Fig 42 Rooftop Termination Dimension A is Touching or 2 In Maximum Separation A93056 Fig 43 Concentric Vent and Combustion Air Roof Termination Dimension A is Touching or 2 In Maximum Separation 96129 Fig 45 Sidewall Termination of 12 in or Less Dimension A is Touching or 2 In Maximum Separation 32 COMBUSTION AIR nes 93057
73. ctions Relocate tubes as described below 1 Disconnect collector box pressure tube pink label attached to pressure switch 2 Extend collector box pressure tube green label which was previously connected to condensate trap relief port connec tion by splicing to small diameter tube factory supplied in loose parts bag 3 Connect collector box pressure tube green label to pres sure switch connection labeled COLLECTOR BOX 4 Use remaining small diameter tube factory supplied in loose parts bag to extend collector box pressure tube pink label which was previously connected to pressure switch 5 Route this extended tube pink label to condensate trap relief port connection 6 Determine appropriate length cut and connect tube 7 Clamp tube to relief port connection E Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures F Construct a Working Platform Construct working platform where all required furnace clearances are met See Fig 3 and 12 CAUTION The condensate trap MUST be installed A below furnace See Fig 4 for dimensions The drain connection to condensate trap must also be properly sloped to an open drain NOTE Combustion air and vent pipes are restricted to a mini mum length of 5 ft See Table 7 NOTE A 12 in minimum offset pipe section is recommended with short 5 to 8 ft vent systems This recommendation is to reduce
74. cts to back of furnace Failure to follow this warning could result in fire personal injury or death See Fig 15 N FRONT Fig 15 Prohibit Installation on Back A93043 CAUTION If these furnaces are installed in an uncon ditioned space where ambient temperatures may be 32 F A p y or lower freeze protection measures must be taken See Fig 16 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED TIN 93058 Fig 16 Freeze Protection LOW HEAT ONLY INSTALLATION This 355MAV furnace can be installed to operate in low heat only heating mode when sized using the low heat heating capacity This is accomplished by placing setup switch SW1 2 in the ON position to provide only low heat operation See Fig 32 and Table 9 With this setup high heat operation will not occur When the model no on the furnace rating plate is followed by an asterisk the furnace has an alternate low heat only efficiency rating as listed in the GAMA and CEC directories This alternate rating will be listed as the furnace model number followed by an L suffix CAUTION The furnace can operate in the high heat mode when certain fault conditions occur The following precautions should be taken A 1 Size gas piping based on the high heat input 2 Check the high heat input and adjust it per the main literature instructions NEVER assume the h
75. de of socket to prevent buildup of excess cement Apply second coat 9 While cement is still wet twist pipe into socket with 1 4 turn Be sure pipe is fully inserted into fitting socket 10 Wipe excess cement from joint A continuous bead of cement will be visible around perimeter of a properly made joint 11 Handle pipe joints carefully until cement sets 3 8 ID TUBE 4 p E 3 16 COMBUSTION AIR INTAKE HOUSING DRILL COMBUSTION AIR PIPE MIN Fig 36 Air Intake Housing Plug Fitting Drain 12 Support combustion air and vent piping a minimum of every 5 ft 3 ft for SDR 21 or 26 PVC using perforated metal hanging strap 13 Slope combustion air and vent pipes downward toward furnace a minimum of 1 4 in per linear ft with no sags between hangers 14 Use appropriate methods to seal openings where vent and combustion air pipes pass through roof or sidewall CONCENTRIC VENT AND COMBUSTION AIR TERMINATION KIT INSTALLATION NOTE If these instructions differ from those packaged with termination kit follow kit instructions Combustion air and vent pipes must terminate outside structure A factory accessory termination kit must be installed in 1 of the installations shown in Fig 37 38 39 40 or 41 Four termination kits are available 1 The 2 in
76. e NFGC Canada or NSCNGPIC NOTE Furnace combustion air and vent pipe connections are Il COMBUSTION AIR AND VENT PIPING sized for 2 in pipe Any pipe size change should be made outside furnace casing in vertical pipe See Fig 33 This allows proper A General drainage of vent condensate Combustion air and vent pipes must terminate together in same atmospheric pressure zone either through roof or sidewall roof termination preferred using accessory termination kit See Table 5 for required clearances Combustion air and vent pipe fittings primers and solvents must conform to American National Standards Institute ANSI stan dards and American Society for Testing and Materials ASTM standards See Table 5 for approved materials for use in the U S A See Table 7 for maximum pipe lengths and Fig 37 38 39 40 and NOTE Slope combustion air and vent pipes a minimum of 1 4 41 for exterior piping arrangements in per linear ft with no sags between hangers ure1beiq 12 614 lt
77. e or 2 In Concentric 1 1 2 2 32 27 70 70 042080 060080 2 Pipe or 2 In Concentric 1 1 2 15 10 70 70 060100 060120 2 Pipe or 2 In Concentric 2 Pipe or 3 In Concentric 28 23 70 10 70 NA 58 57 Altitude Unit Size Termination Type Pipe Diameter In Number of 90 Elbows 3 4 4001 to 5000 042040 2 Pipe or 2 In Concentric 1 1 2 30 25 2 70 70 042060 2 Pipe or 2 In Concentric 1 1 2 2 30 25 70 70 042080 060080 2 Pipe or 2 In Concentric 1 1 2 2 13 8 70 70 060100 2 Pipe or 2 In Concentric 2 26 21 70 70 060120 2 Pipe or 3 In Concentric 3t 54 53 Altitude 5001 to 60001 See notes on next page Unit Size 042040 Termination Type 2 Pipe or 2 In Concentric Pipe Diameter In Number of 90 Elbows 3 4 042060 2 Pipe or 2 In Concentric 042080 060080 2 Pipe or 2 In Concentric 060100 2 Pipe or 2 In Concentric 060120 2 Pipe or 3 In Concentric 26 TABLE 7 MAXIMUM ALLOWABLE PIPE LENGTH FT Continued UNIT TERMINATION PIPE DIAMETER NUMBER OF 90 ELBOWS SIZE TYPE IN 2 3 4 5 2 Pipe or 2 In 1 1 2 30 25 20 15 Concentric 2 70 68 67 66 2 Pipe or 2 In 1 1 2 30 25 20 15 Concentr
78. e size and fuse specifications A disconnecting means must be located within sight from and readily accessible to furnace NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect furnace control status code indicator light will flash rapidly and furnace will NOT operate WARNING The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2002 and Canadian Electrical Code CSA C22 1 or local codes to minimize personal injury if an electrical AN fault should occur This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes Do not use gas piping as an electrical ground Failure to follow this warning could result in electric shock fire or death J BOX RELOCATION 1 Remove 2 screws holding auxiliary J box See Fig 30 2 Rotate J box 180 and attach box to left side using holes provided CAUTION If manual disconnect switch is to be mounted on furnace select a location where a drill or fastener will not contact electrical or gas components TABLE 4 ELECTRICAL DATA VOLTS OPERATING MAXIMUM MINIMUM UNIT Mcr VOLTAGE RANGE UNIT WIRE MAXIMUM WIRE MAXIMUM FUSE OR LENGTH FT CKT BKR AMPS SIZE PHASE Maximum Minimum AMPS SIZE 042040 115 60 1 127 104 8 9 14 31 15 042060 115 60 1 127 104 8 9 14 31 15 042080 115 60 1 127 104 8 9 14 31 15 060080 115 60 1 1
79. ea 1050 1225 1225 1225 1050 1225 1400 1750 1750 1 DEFAULT A C AIRFLOW WHEN A C SWITCHES ARE IN OFF POSITION 2 DEFAULT CONT FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION A02335 Fig 58 A C or CF Airflow Selection Chart Based on 350CFM Ton TABLE 9 FURNACE SETUP SWITCH DESCRIPTION SWITCH NAME Status Code Recovery SWITCH NO Adaptive Heat Mode Low Heat Rise Adjust NORMAL POSITION OFF DESCRIPTION OF USE Turn ON to retrieve up to 7 stored status codes for troubleshooting assistance when R thermostat lead is disconnected Allows 2 stage operation with a single stage thermostat Turn ON when using 2 stage thermostat to allow Low Heat opera tion when R to W W1 closes and High Heat operation when R to W W1 and W2 close Turn ON to increase Low Heat airflow by 18 percent This compen sates for increased return air temperature caused with bypass hu midifier Comfort Efficiency Adjustment ON Turn ON to decrease Low Heat airflow by 7 percent and High Heat airflow 8 percent for maximum comfort On 040 unit will decrease Low Heat Airflow 11 percent and High Heat Airflow 10 percent CFM per ton adjust OFF Turn ON for 400 CFM per ton Turn OFF for 350 CFM per ton Component Self Test OFF Turn ON to initiate Component Self Test for troubleshooting assis tance when R thermostat lead is disconnected Turn OFF when Self Test is completed Blower OFF delay ON or OFF Contro
80. eduction in speed in low heat is to optimize combustion for maximum efficiency 6 Blower On delay If the burner flame is proven the blower ON delay for low heat and high heat are as follows Low heat 60 seconds after the gas valve GV M is opened the BLWM is turned ON at low heat airflow High heat 35 seconds after gas valve GV M is opened the BLWM is turned ON at high heat airflow Simultaneously the humidifier terminal HUM and elec tronic air cleaner terminal EAC 1 are energized and remain energized throughout the heating cycle 7 Switching From Low To High Heat If the furnace control CPU switches from low heat to high heat the furnace control CPU will de energize the the high heat pressure switch relay HPSR to close the NC contact and slowly increase the inducer motor speed until the high heat pressure switch HPS closes When the high heat pressure switch HPS closes the high heat gas valve solenoid GV HI is energized and the inducer motor RPM is noted by the furnace control CPU The RPM is used to evaluate vent system resistance This evaluation is then used to determine the required RPM necessary to operate the inducer motor in high heat mode The blower motor BLWM will transition to high heat airflow five seconds after the furnace control CPU switches from low heat to high heat 8 Switching From High To Low Heat The furnace control CPU will not switch from high heat to low heat while the thermostat R to W circuit is clo
81. een lines formed by intersections of top and two sides of furnace jacket and building joists studs or framing Clearance shown is for air inlet and air outlet ends 120 size furnace requires 1 inch bottom clearance to combustible materials 328068 201 REV A Vent clearance to combustibles 0 LIT TOP Clearance in inches M J A02250 Fig 3 Clearances to Combustibles YF AM SWE 85 F gt E AE pen WE AIR MIN 55 F A93044 z Fig 5 Installation in a Garage User s Information Manual A93042 Warranty Certificate _ Loose Parts Bag includes Quantity Fig 4 Return Air Temperature Pressure tube extension 1 These furnaces are shipped with the following materials to assist in Collector box or condensate trap extension tube 1 proper furnace installation These materials are shipped in the main Inducer housing drain tube 1 blower compartment 1 2 in CPVC street elbow 2 Installer Packet includes Drain tube coupling 1 Installation Start Up and Operating Instructions Drain tube coupling grommet 1 Service and Maintenance Procedures Vent and combustion air pipe support 2 Combustion air pipe perforated disk assembly 1 Condensate trap hole filler plug Vent and combustion air intake hole filler plug 2 CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installat
82. emove regulator seal caps that conceal adjustment screws for low and high heat gas valve regulators See Fig 62 c Turn setup switch SW1 2 on control center to ON position See Fig 32 This keeps furnace locked in low heat operation d Jumper W W1 thermostat connections on furnace control to start furnace e Turn low heat adjusting screw 3 32 hex Allen wrench counterclockwise out to decrease input rate or clock wise in to increase input rate NOTE DO NOT set low heat manifold pressure less than 1 3 in wc or more than 1 7 in wc for natural gas If manifold pressure is outside this range change main burner orifices to obtain manifold pressure in this range CAUTION DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics f Turn setup switch SW1 2 to OFF position after complet ing low heat adjustment AIR CONDITIONING AIRFLOW 040 dy T ipd MOD E e 120 MODEL TONS 12 000 BTU HR CFM X INDICATES AN ALLOWABLE SELECTION A C OR CF AIRFLOW SELECTION CHART 040 060 042080 BASED ON 350 CFM TON Cm Cm __ Cm Cm Cm A
83. ensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 6 Fill unused condenstate trap casing holes with plastic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 11 or tube routing label on main furnace door to check for proper connections Collector Box Drain Tube a Install drain tube coupling factory supplied in loose parts bag into collector box drain tube blue label which was previously connected to condensate trap b Connect large diameter drain tube and clamp factory supplied in loose parts bag to drain tube coupling extending collector box drain tube c Route extended tube blue label to condensate trap and cut to appropriate length d Clamp tube to prevent any condensate leakage Inducer Housing Drain Tube a Remove and discard LOWER molded inducer housing drain tube which was previously connected to conden sate trap b Use inducer housing drain extension tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to conden sate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage Relief Port Tube a Extend collector box tube green label which was previously connected to condensate trap by splicing to small diameter tube factory supplied in
84. fire personal injury or death NOTE A 2 in diameter pipe must be used within the furnace casing Make all pipe diameter transitions outside furnace casing d Be certain that mating surfaces of inducer housing connection elastomeric coupling and 2 in diameter vent pipe are clean and dry Assemble the elastomeric rubber vent coupling with 2 loose clamps onto inducer housing connection Insert the 2 in diameter vent pipe through the elastomeric rubber coupling and fully into inducer housing connection until it bottoms on the internal stop Tighten both clamps to secure the pipe to inducer housing Tighten the clamp screws to 15 in Ib of torque e Install casing hole filler cap factory supplied in loose parts bag in unused combustion air pipe casing hole 3 Working from furnace to outside cut pipe to required length s 4 Deburr inside and outside of pipe 5 Chamfer outside edge of pipe for better distribution of primer and cement 6 Clean and dry all surfaces to be joined 7 Check dry fit of pipe and mark insertion depth on pipe NOTE It is recommended that all pipes be cut prepared and preassembled before permanently cementing any joint 8 After pipes have been cut and preassembled apply gener ous layer of cement primer to pipe fitting socket and end of pipe to insertion mark Quickly apply approved cement to end of pipe and fitting socket over primer Apply cement in a light uniform coat on insi
85. furnaces are vented near each other 2 vent terminations may be installed as shown in Fig 42 43 44 45 or 46 but next vent termination must be at least 36 in away from first 2 terminations It is important that vent terminations be made as shown to avoid recirculation of flue gases Dimension A in Fig 42 43 44 45 and 46 represents distance between pipes or rain shields as touching or 2 in maximum separation CONDENSATE DRAIN l GENERAL Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications Condensate trap MUST be used for all applications An external trap is not required when connecting the field drain to this condensate trap The field drain connection condensate trap or drain tube coupling is sized for 1 2 in CPVC 1 2 in PVC or 5 8 in ID tube connection Drain pipe and fittings must conform to ANSI standards and ASTM D1785 D2466 or D2846 CPVC or PVC cement must conform to ASTM D2564 or F493 Primer must conform to ASTM F656 In Canada use CSA or ULC certified schedule 40 CPVC or PVC drain pipe fittings and cement When a condensate pump is required select a pump which is approved for condensing furnace applications To avoid conden sate spillage select a pump with an overflow switch Furnace condensate is mildly acidic typically in the pH range of 3 2 to 4 5 Due to co
86. gency must use only factory authorized and listed kits or accessories when modifying this product Failure to follow this warning could result in electrical shock fire personal injury or death Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified personnel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with unit and other safety precautions that may apply These instructions cover the minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation Wear safety glasses and work gloves Have a fire extinguisher available during start up and adjustment procedures and service calls Recognize safety information This is the safety alert symbol N When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand these signal words DANGER WARNING CAU TIO
87. he main gas valve relay contacts GVR closes to energize the gas valve solenoid GV M The gas valve solenoid GV M permits gas flow to the burners where it is ignited After 5 seconds the igniter HSI is de energized and a 2 second Flame Proving period begins If the furnace control CPU selects high heat operation the high heat gas valve solenoid GV HI is also energized 4 Flame Proving When burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV M open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV M and the furnace control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to Ignition Lockout Lockout will be reset automatically after three hours by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SECI or SEC2 to the furnace control CPU not at WAWI etc If flame is proved when flame should not be present the furnace control CPU will lock out of Gas Heating mode and operate the inducer motor IDM on high speed until flame is no longer proved 5 Inducer Speed Change If the cycle starts in low heat the furnace control CPU reduces the inducer speed slightly after flame sense If cycle starts in high heat the furnace control CPU increases the inducer speed 15 seconds after flame sense The r
88. he thermostat calls for cooling 1 Single Speed Cooling See Fig 28 for thermostat connections The thermostat closes R to G and Y circuits The R to Y circuit starts the outdoor unit and R to G and Y Y2 circuits start the furnace blower motor BLWM on cooling airflow Cooling airflow is based on the A C selection shown in Fig 58 The electronic air cleaner terminal EAC 1 is energized with 115 v when blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuits are opened The outdoor unit will stop and furnace blower motor BLWM will continue operating at cooling airflow for an additional 90 sec Jumper Y Y2 to DHUM to reduce the cooling off delay to 5 seconds See Fig 32 2 Single Stage Thermostat and Two Speed Cooling Adaptive Mode See Fig 57 for thermostat connections This furnace can operate a two speed cooling unit with a single stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation which selects low cooling or high cooling opera tion This selection is based upon the stored history of the length of previous cooling period of the single stage ther mostat NOTE The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to a call for cooling See Fig 32 When in place the furnace control CPU can turn on the air conditioning relay ACR to energize the Y Y2 terminal and
89. ic 2 70 68 67 66 042080 2 Pipe or 2 In 1 1 2 15 10 5 NA ead PON 060080 Concentric 2 70 68 67 62 2 Pipe or 2 In 2 26 21 16 11 Concentric 70 68 67 66 2 Pipe or 3 In Concentric 3t 48 47 45 44 Unit Termination Pipe Diameter Number of 90 Elbows Size Type In 3 4 2 Pipe or 2 In 1 1 2 22 17 Concentric 2 63 62 2 Pipe or 2 In 1 1 2 22 17 Concentric 2 63 62 042080 2 Pipe or 2 In 1 1 2 8 NA 060080 Concentric 2 53 2 Pipe or 2 In 2 19 14 Concentric 63 62 2 Pipe or 3 In Concentric Unit Termination Pipe Diameter Number of 90 Elbows Size Type In 3 4 2 Pipe or 2 In 1 1 2 20 15 Concentric 2 58 56 2 Pipe or 2 In 1 1 2 20 15 Concentric 2 58 56 042080 2 Pipe or 2 In 1 1 2 7 NA 1 060080 2 58 56 2 Pipe or 2 In 2 17 12 Concentric 58 56 2 Pipe or 3 In Concentric Unit Termination Pipe Diameter Number of 90 Elbows Size Type In 3 4 2 Pipe or 2 In 1 1 2 17 12 Concentric 2 53 51 2 Pipe or 2 In 1 1 2 17 12 Concentric 2 53 51 ALTITUDE 042040 042060 060100 060120 Altitude 042040 042060 060100 060120 3t 43 41 Altitude 042040 042060 060100 060120 3t 39 37 Altitude 042040 042060 042080 2 Pipe or 2 In 1 1 2 5 NA 1 to 1 an oer 060080 Concentric 2 53 51 2 Pipe or 2 In 2 14 9 Concentric 53 51 060100 2 Pipe or 3 In 06
90. igh cooling the outdoor unit compressor will shut down for 1 minute while the furnace blower motor BLWM transitions to run at high cooling airflow The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuit are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Fig 32 See Fig 32 3 Two Stage Thermostat and Two Speed Cooling See Fig 56 for thermostat connections NOTE The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat control of the outdoor unit staging See Fig 32 The thermostat closes the to G and Y1 circuits for low cooling or closes to and Y 1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuit starts the furnace blower motor BLWM on low cooling airflow which is the true on board CF selection as shown in Fig 58 R to Yl and Y2 circuits start the outdoor unit on high cooling speed and the to G and Y Y2 circuits start the furnace blower motor BLWM at high cooling ariflow High cooling airflow is based on the A C selection shown in Fig 58 The electronic air cleaner terminal EAC 1 is energized with 115
91. igh heat input rate is not important for low heat only installation FURNACE LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on downstream side of furnace to avoid condensation in heat exchanger When installed parallel with a furnace dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering furnace If dampers are manually operated they must be equipped with a means to prevent operation of either unit unless damper is in full heat or full cool position IV HAZARDOUS LOCATIONS 18 IN MINIMUM TO BURNERS A93044 Fig 17 Installation in a Garage WARNING When furnace is installed in a residential garage it must be installed so that burners and ignition sources are located a minimum of 18 in above floor The furnace must be located or protected to avoid physical A damage by vehicles When furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere unit must be installed in accor dance with requirements of National Fire Protection Association Inc See Fig 17 INSTALLATION l LEVELING LEGS IF DESIRED When furnace is used in upflow position with side inlet s leveling legs may be desired See Fig 18 Install field supplied corrosion resistant 5 16 in machine bolts and nuts NOTE The maximum length of bolt should not exceed 1 1 2 in 1 Position fur
92. in section for recommendations and procedures D Pressure Switch Tubing One collector box pressure tube pink label is factory connected to the pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications This tube MUST be dis connected and used for the condensate trap relief port tube The other collector box pressure tube green label which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZON TAL RIGHT applications NOTE See Fig 9 or 10 or tube routing label on main furnace door to check for proper connections Relocate tubes as described below 1 Disconnect collector box pressure tube pink label attached to pressure switch 9 2 Extend collector box pressure tube green label which was previously connected to condensate trap relief port connec tion by splicing to small diameter tube factory supplied in loose parts bag 3 Connect collector box pressure tube green label to pres sure switch connection labeled COLLECTOR BOX 4 Extend collector box pressure tube pink label which was previously connected to pressure switch by splicing to remaining small diameter tube factory supplied in loose parts bag 5 Route this extended tube pink label to condensate trap relief port connection 6 Determine appropriate length cut and connect tube 7 Clamp tube to relief port connection E Condens
93. ing Mode a Thermidistat Mode eese Super Dehumidify Mode sse Continuous Blower Mode Heat Pump Component Test START UP PROCEDURES 1 4 enn General iR DNE ION ERE SERERE e texte Select Setup Switch Positions es Prime Condensate Trap With Purge Gas Lines eser rer tete desee Adjustments Set Gas Input Rate Set Temperature Rise Set Thermostat Heat Anticipator A CHECK SAFETY CONTROLS eee Check Primary Limit Control Check Pressure Switch CHECKER AS SAFETY CONSIDERATIONS CAUTION Application of this furnace should be in doors with special attention given to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing Improper installation or misapplication of furnace can require excessive servicing or cause prema ture component failure WARNING Improper installation adjustment alter ation service maintenance or use can cause carbon monoxide poisoning explosion tire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agency local gas supplier or your distributor or branch for information or assistance The qualified installer or a
94. installation start up and operating instructions 355MAV Series DELUXE 4 WAY MULTIPOISE VARIABLE CAPACITY DIRECT VENT CONDENSING GAS FURNACE A93040 NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue Index Page DIMENSIONAL DRAWING 3 SAFETY CONSIDERATIONS eese 2 5 Clearances to Combustibles esee 4 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 5 INTRODUCTION one nh nubere e ERAS 5 APPLICATIONS e aa nennen nennen ne 5 12 General dte roh 5 Upflow Applications 5 8 Downflow Applications 00000esesenenenenenenanenananeananananenen 8 9 Horizontal Left Supply Air Discharge Applications 9 11 Horizontal Right Supply Air Discharge Applications 11 12 LOCATION ep pes General Low Heat Only Installation eese Furnace Location Relative to Cooling Equipment A HaZzardoyis LO0GatO0nS asana KE eene INSTALLATION aaa na nahen aa nennen Leveling Legs If Desired eese Installation In Upflow or Downflow Applications 14 Installation In Horizontal Applications 14 16 AIR DUGIS hr RR MIB EE ES 16 19 General Requirement esses 16 17 Ductwork Acousti
95. ion must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction in Canada In the United States and Canada follow all codes and standards for the following SAFETY US National Fuel Gas Code NFGC NFPA 54 2002 ANSI Z223 1 2002 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA National Standard of Canada Natural Gas and Propane Installation Code NSCNGPIC CSA B149 1 00 GENERAL INSTALLATION US NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or for only the NFGC contact the American Gas Association 400 N Capitol N W Washington DC 2001 CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Tor onto Ontario M9W 1R3 Canada COMBUSTION AND VENTILATION AIR US Section 8 3 of the NFGC Air for Combustion and Ventilation CANADA Part 7 of the NSCNGPIC Venting Systems and Air Supply for Appliances IV DUCT SYSTEMS US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Con tractors National Association SMACNA or American Soci ety of Heating Refrigeration and Air Conditioning Engineers
96. is warning could result in electrical shock fire personal injury or death 5 Install condensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 6 Fill unused condenstate trap casing holes with plastic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 9 or 10 or tube routing label on main furnace door to check for proper connections 1 Collector Box Drain Tube a Remove factory installed plug from LOWER collector box drain tube blue and white striped label b Install removed clamp and plug into UPPER collector box drain tube blue label which was connected to condensate trap c Connect LOWER collector box drain connection to condensate trap 1 Condensate Trap Located on Left Side of Casing Connect LOWER collector box drain tube blue and white striped label to condensate trap Tube does not need to be cut b Clamp tube to prevent any condensate leakage 2 Condensate Trap Located on Right Side of Casing a Install drain tube coupling factory supplied in loose parts bag into collector box drain tube blue and white striped label which was pre viously plugged b Connect larger diameter drain tube factory supplied in loose parts bag to drain tube coupling extending collector box drain tube for connection to condensate trap c Route extended collector
97. l blower Off Delay time Used in conjunction with SW1 8 See Table 10 Blower OFF delay TABLE 10 BLOWER OFF DELAY SETUP SWITCH POSITION DESIRED HEATING MODE BLOWER OFF DELAY SEC ON or OFF SETUP SWITCH SW1 7 AND SW1 8 POSITION 90 120 150 180 g Jumper and W W1 and W2 thermostat connections on furnace control See Fig 32 This keeps furnace locked in high heat operation h Turn high heat adjusting screw 3 32 hex Allen wrench counterclockwise out to decrease input rate or clock wise in to increase rate NOTE DO NOT set high heat manifold pressure less than 3 2 in wc or more than 3 8 in wc for natural gas If manifold pressure is outside this range change main burner orifices to obtain manifold pressures in this range i When correct input is obtained replace caps that conceal gas valve regulator adjustment screws Main burner flame should be clear blue almost transparent See Fig 64 j Remove jumpers R to W W1 and R to W2 3 Verify natural gas input rate by clocking gas meter NOTE Be sure all pressure tubing combustion air and vent pipes and burner enclosure front are in place when checking input by clocking gas meter a Calculate high altitude adjustment if required OFF A95198 Fig 59 Example of Setup Switch in OFF Position 41 Control blower Off Delay time Used in conjunction with SW1 7 See Table 10 UNITED STAT
98. mostat calls for heat closing the to W circuit The furnace control CPU performs a self check verifies the low heat and high heat pressure switch contacts LPS and HPS are open 1 Inducer Prepurge Period The furnace control CPU turns on inducer motor IDM and slowly increases the inducer motor speed When the low heat pressure switch LPS closes inducer motor RPM is noted by the furnace control CPU and a 25 sec prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is then used to determine the required RPM necessary to operate the inducer motor during the low heat prepurge period and low heat mode NOTE The heat cycle can start in either high or low heat If a high heat cycle is initiated the furnace control CPU will de energize the high heat pressure switch relay HPSR to close the NC contact and continues to increase the inducer motor speed after the low heat pressure switch LPS closes When the high heat pressure switch closes inducer motor RPM is noted by the furnace control CPU before the 25 sec prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is then used to determine the required RPM necessary to operate the inducer motor in high heat mode 2 Ignitor Warm Up At end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 sec igniter warm up period 3 Trial For Ignition Sequence When the igniter warm up period is completed t
99. nace on its back Locate and drill a 5 16 in diameter hole in each bottom corner of furnace See Fig 18 Holes in bottom closure panel may be used as guide locations 2 For each hole install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement NOTE Bottom closure must be used when leveling legs are used See Bottom Closure Panel section INSTALLATION IN UPFLOW OR DOWNFLOW APPLICATIONS NOTE This furnace is approved for use on combustible flooring when special base available from manufacturer Part No KGASB0201ALL is used Special base in not required when this furnace is installed on manufacturer s Coil Assembly Part No CD5 or 5 or Coil Box Part No KCAKC is used 1 Determine application being installed from Table 1 2 Construct hole in floor per dimensions specified in Table 1 and Fig 19 3 Construct plenum to dimensions specified in Table 1 and Fig 19 4 If downflow subbase KGASB is used install as shown in Fig 20 If coil assembly CD5 or CK5 or Coil Box KCAKC is used install as shown in Fig 21 NOTE Remove furnace perforated discharge duct flanges when they interfere with mating flanges on coil on downflow subbase To remove furnace perforated discharge duct flange use hand
100. ons factory accessory floor base MUST be used when installed on combustible materials and wood flooring Special base is not required when this furnace is installed on manufacturer s Coil Assembly Part No CD5 or 5 or when Coil Box Part No KCAKC is used These furnaces are suitable for installation in a structure built on site or a manufactured building completed at final site The design of this furnace line is NOT C S A design certified for installation in recreation vehicles or outdoors This furnace is designed for continuous return air minimum temperature of 60 F db or intermittent operation down to 55 F db such as when used with a night setback thermometer Return air temperature must not exceed 85 F db Failure to follow these return air limits may affect reliability of heat exchangers motors and controls See Fig 4 These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications Minor modifications are required when used in DOWNFLOW HORIZONTAL RIGHT or HORIZONTAL LEFT supply air discharge direction applica tions as shown in Fig 1 See details in Applications section This furnace must be installed with a direct vent combustion air and flue system and a factory accessory termination kit In a direct vent system all air for combustion is taken directly from the outside atmosphere and all flue products are discharged to the outside atmosphere See furnace and factory accessory termina
101. or 8 or tube routing label on main furnace door to check for proper connections COLLECTOR BOX DRAIN TUBE BLUE CAP PLUG COLLECTOR BOX TUBE GREEN COLLECTOR BOX TUBE PINK COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX EXTENSION TUBE CONDENSATE TRAP LL INDUCER HOUSING DRAIN TUBE VIOLET v A94215 Fig 9 Downflow Tube Configuration Left Hand Trap Installation G Upper Collector Box and Inducer Housing Unused Drain Connections UPPER COLLECTOR BOX DRAIN CONNECTION Attached to the UPPER collector box drain connection is a factory installed corrugated plugged tube blue and white striped label This tube is plugged to prevent condensate leakage in this application Ensure this tube is plugged NOTE See Fig 7 or 8 or tube routing label on main furnace door to check for proper connections UPPER INDUCER HOUSING DRAIN CONNECTION Attached to the UPPER unused inducer housing drain connection is a cap and clamp This cap is used to prevent condensate leakage in this application Ensure this connection is capped NOTE See Fig 7 or 8 or tube routing label on main furnace door to check for proper connections H Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures Ill DOWNFLOW APPLI
102. ow making U fitting A 180 U fitting may be used Sidewall terminations Install bracket as shown in Fig 40 or 41 For applications using vent pipe option indicated by dashed lines in Fig 40 rotate vent elbow 90 from position shown in Fig 40 4 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping 5 Check required dimensions as shown in Fig 37 40 or 41 C Concentric Vent Air Termination Kit 1 Determine location for termination Consideration of the following should be made when determining an appropriate location for termination kit a Comply with all clearance requirements as stated in Table 6 b Termination kit should be positioned where vent vapors will not damage plants shrubs or air conditioning equip ment c Termination kit should be positioned so it will not be affected by wind eddy such as inside building corners or accumulation of airborne leaves or light snow or allow recirculation of flue gases d Termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones balls etc e Termination kit should be positioned where vent vapors are not objectionable 2 Cut one 4 in diameter hole for 2 in kit or one 5 in diameter hole for 3 in kit 3 Loosely assemble concentric vent air termination compo nents together using instructions in kit 4 Slide assembled kit with rain shield REMOVED through hole
103. p must be installed in blower shelf hole when condensate trap is relocated Failure to follow this warning could result in electrical shock fire personal injury or death 4 Install condensate trap into right hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 5 Fill unused condenstate trap casing holes with plastic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 13 or tube routing label on main furnace door to check for proper connections 1 Collector Box Drain Tube a Remove factory installed plug from LOWER collector box drain tube blue and white striped label b Install removed clamp and plug into UPPER collector box drain tube blue label which was previously con nected to condensate trap c Connect LOWER collector box drain tube blue and white striped label to condensate trap Tube does not need to be cut CAP PLUG COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE GREEN COLLECTOR BOX TUBE PINK AUXILIARY J BOX RELOCATED HERE IS COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED INDUCER HOUSING DRAIN TUBE VIOLET COLLECTOR BOX EXTENSION TUBE 8 CONDENSATE TRAP j A02289 Fig 13 Horizontal Right Tube Configuration d Clamp tube
104. r bring on the blower motor BLWM at cooling airflow low heat airflow or the midrange airflow whichever is the lowest The blower motor BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25 seconds before coming back on at heating airflow When the W W1 input signal disappears the furnace control begins a normal inducer post purge period while changing the blower airflow If Y Y2 input is still energized the furnace control CPU will transition the blower motor BLWM airflow to cooling airflow If Y Y2 input signal disappears and the Y1 input is still energized the furnace control CPU will transition the blower motor BLWM to low cooling airflow If both the Y1 and Y Y2 signals disappear at the same time the blower motor BLWM will remain on at low heat airflow for the selected blower OFF delay period At the end of the blower OFF delay the blower motor BLWM will shut OFF unless G is still energized in which case the blower motor BLWM will operate at continuous blower airflow Vill COMPONENT TEST The furnace features a component test system to help diagnose a system problem in the case of a component failure To initiate the component test procedure ensure that there are no thermostat inputs to the control and all time delays have expired Turn on setup switch SW1 6 See Fig 32 NOTE The component test feature will not operate if the control is receiving any thermostat signals or until all time delays h
105. rnace control algorithm This is factory default 14 The RVS Sensing terminal L should not be connected This is internally used to sense defrost operation 15 DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board This is controlled internally by the Thermidistat Dual Fuel Thermostat 16 Dip switch D on Dual Fuel Thermostat should be set in OFF position for single speed compressor operation This is factory default 17 Dip switch D on Dual Fuel Thermostat should be set in ON position for two speed compressor operation e Find closest natural gas heat value and specific gravity in Table 11 f Follow heat value and specific gravity lines to point of intersection to find orifice size and low and high heat manifold pressure settings for proper operation EXAMPLE 0 2000 ft altitude Heating value 1050 Btu cu ft Specific gravity 0 62 Therefore Orifice No 45 Manifold pressure 3 8 in wc for high heat 1 6 in wc for low heat Furnace is shipped with No 45 orifices In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate Check and verify burner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY 2 Adjust manifold pressure to obtain input rate a Remove burner enclosure front NOTE Manifold pressure MUST always be measured with the burner box cover REMOVED b R
106. rom Low To High Heat If the thermostat R to WI circuit is closed and the R to W2 circuit closes the furnace control CPU will de energize the high heat pressure switch relay HPSR to close the NC contact and slowly increase the inducer motor speed until the high heat pres sure switch HPS closes When the high heat pressure switch closes the high heat gas valve solenoid GV HI is energized and the inducer motor RPM is noted by the furnace control CPU The RPM is used to evaluate vent system resistance This evaluation is then used to determine the required RPM necessary to operate the inducer motor in high heat mode The blower motor BLWM will transition to high heat airflow five seconds after the R to W2 circuit closes 2 Switching From High To Low Heat If the thermostat R to W2 circuit opens and the R to W1 circuit remains closed the furnace control CPU will energize the high heat pres sure switch relay HPSR to open the NC contact and slowly decrease the inducer motor speed to the required low heat RPM When the high heat pressure switch HPS opens the high heat gas valve solenoid GV HI is de energized When the inducer motor IDM reduces pressure sufficiently the high heat pressure switch HPS will open The gas valve solenoid GV M will remain energized as long as the low heat pressure switch LPS remains closed The blower motor BLWM will transition to low heat airflow five seconds after the R to W2 circuit opens Ill COOLING MODE T
107. rrosive nature of this condensate a condensate pH neutralizing filter may be desired Check with local authorities to determine if a pH neutralizer is required Il APPLICATION The furnace A C and humidifier drains may be combined and drained together The A C drain must have an external field supplied trap prior to the furnace drain connection drain connections furnace A C or humidifier must be terminated into an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment s drain See Fig 48 for example of possible field drain attachment using 1 2 in CPVC or PVC tee for vent and A C or humidifier drain connection 31 Outdoor draining of the furnace is permissible if allowed by local codes Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining WARNING Caution should be taken to prevent drain ing where slippery conditions may cause personal inju ries Excessive condensate draining may cause saturated soil conditions which may result in damage to plants Ill CONDENSATE DRAIN PROTECTION Freezing condensate left in condensate trap and drain line may cause cracks and possible water damage may occur If freeze protection is required use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40 F self regulating shielded and waterproof heat tape See Installation Instructions supplied with ac
108. sed when using a single stage thermostat 342 9 Blower Off delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV M stopping gas flow to the burners and de energizing the humidifier terminal HUM The inducer motor IDM will remain energized for a 15 second post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized at low heat airflow or transition to low heat airflow for 90 120 150 or 180 seconds depending on selection at blower OFF delay switches The furnace control CPU is factory set for a 120 second blower OFF delay TWO STAGE THERMOSTAT AND TWO STAGE HEATING See Fig 56 for thermostat connections NOTE In this mode the low heat only switch SW1 2 must be ON to select the low heat only operation mode in response to closing the thermostat R to W1 circuit Closing the thermostat R to W1 and W2 circuits always causes high heat operation re gardless of the setting of the low heat only switch The wall thermostat calls for heat closing the R to WI circuit for low heat or closing the R to W1 and W2 circuits for high heat The furnace control performs a self check and verifies the low heat and high heat pressure switch contacts LPS and HPS are open The start up and shutdown functions and delays described in item 1 above apply to 2 stage heating mode as well except for switching from low to high heat and vice versa 1 Switching F
109. selection shown in Fig 58 c Cooling off delay When the call for cooling is satis fied and there is a demand for dehumidification the cooling blower off delay is decreased from 90 seconds to 5 seconds VI CONTINUOUS BLOWER MODE When the R to G circuit is closed by the thermostat the blower motor BLWM will operate at continuous blower airflow Continu ous blower airflow selection is initially based on the CF selection shown in Fig 58 Factory default is shown in Fig 58 Terminal EAC 1 is energized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will transition the blower motor BLWM to continuous blower airflow low heat airflow or the midrange airflow whichever is lowest The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower ON delay 60 seconds in low heat and 35 seconds in high heat allowing the furnace heat exchangers to heat more quickly then restarts at the end of the blower ON delay period at low heat or high heat airflow respec tively The blower motor BLWM will revert to continuous blower airflow after the heating cycle is completed In high heat the furnace control CPU will drop the blower motor BLWM to low heat airflow during the selected blower OFF delay period before transitioning to continuous blower airflow When the thermostat calls for high cooling the blower motor BLWM will operate at high cooling airflow
110. shown for proper cooling operation 2 Proper polarity must be maintained for 115 v wiring 3 Use W2 with 2 stage thermostat when zoning 4 If any of the original wire as supplied must be replaced use same type or equivalent wire 5 Some thermostats require a C terminal connection as shown A98325 Fig 28 Heating and Cooling Application Wiring Diagram 24 V WIRING cooling operation The 24 v terminal block is marked for easy Make field 24 v thermostat connections at 24 v terminal block on connection of field wiring See Fig 52 The 24 v circuit contains furnace control Y wire from thermostat MUST be connected to a 3 amp automotive type fuse located on furnace control See Y Y2 terminal on furnace control as shown in Fig 28 for proper Fig 32 Any electrical shorts of 24 v wiring during installation service or maintenance may cause fuse to blow If fuse replace ment is required use only a fuse of identical size 3 amp and type The furnace control will flash status code 24 when fuse needs replacement NOTE Use AWG No 18 color coded copper thermostat wire for lengths up to 100 ft For wire lengths over 100 ft use AWG No ELECTRIC DISCONNECT SZ SWITCH COPPER 16 wire WIRE ONLY NOTE For additional thermostat connection diagrams reference Fig 50 57 m lll ACCESSORIES UN 1 Electronic Air Cleaner EAC The furnace control EAC terminals are energized with 115v 1 0 amp maximum during blo
111. switch the outdoor unit to high cooling The furnace control CPU can start up the cooling unit in either low or high cooling If starting up in low cooling the furnace control CPU determines the low cooling on time from 0 to 20 minutes which is permitted before switching to high cooling If the power is interrupted the stored history is erased and the furnace control CPU will select low cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the Y Y2 terminal and switch the outdoor unit to high cooling as long as the thermostat continues to call for cooling Subsequent selection is based on stored history of the thermostat cycle times The wall thermostat calls for cooling closing the R to G and Y circuits The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuits starts the furnace blower motor BLWM at low cooling airflow which is the true on board CF selection as shown in Fig 58 If the furnace control CPU switches from low cooling to high cooling the furnace control CPU will energize the air conditioning relay ACR When the air conditioning relay ACR is energized the R to Y 1 and Y2 circuits switch the outdoor unit to high cooling speed and the to G and Y1 and Y Y2 circuits transition the furnace blower motor BLWM to high cooling airflow High cooling airflow is based on the A C selection shown in Fig 58 NOTE When transitioning from low cooling to h
112. t appliances intake unless otherwise specified by manufac turer 5 3 ft radius of furnace vent air intake terminal and 1 ft horizontally from vertical centerline of furnace vent air intake terminal 6 Above a meter regulator within 3 feet horizontally of vertical centerline of meter regulator vent outlet to a maximum vertical distance of 15 feet 24 WARNING Solvent cements are combustible Keep away from heat sparks and open flame Use only in well ventilated areas Avoid breathing in vapor or allowing contact with skin or eyes Failure to follow this warning could result in fire property damage personal injury or death WARNING combustion air and vent pipes must be airtight and watertight Pipes must also terminate exactly as shown in Fig 37 38 39 40 or 41 Failure to follow this warning could result in property damage personal injury or death FURNACE LJ NOT IN HORIZONTAL SECTION PIPE DIAMETER TRANSITION IN VERTICAL SECTION A93034 Fig 33 Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration NOTE Select 1 vent pipe connection and 1 combustion air pipe connection NOTE Select 1 vent pipe connection and 1 combustion air pipe connection AIR FLOW AIR VENT VENT 5 1 we
113. termination bracket kit is for l in 1 1 2 in and 2 in diameter 2 pipe termination systems 2 The 3 in termination bracket kit is for 2 1 2 in and 3 in diameter 2 pipe termination systems 3 The 2 in concentric vent air termination kit is for l in 1 1 2 in 2 in and 2 1 2 in diameter pipe systems when single penetration of wall or roof is desired 4 The 3 in concentric vent air termination kit is for 2 1 2 in and 3 in diameter pipe systems when single penetration of wall or roof is desired NOTE Shaded parts in Fig 37 38 39 40 and 41 are considered to be terminations These components should NOT be counted when determining pipe diameter Roof termination is preferred since it is less susceptible to damage has reduced chances to take in contaminants and has less visible vent vapors See Fig 37 or 38 Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system A Extended Exposed Sidewall Pipes Sidewall combustion air and vent pipe terminations may be extended beyond area shown in Fig 40 or 41 in outside ambient by insulating pipes as indicated in Table 8 1 Determine combustion air and vent pipe diameters as stated above using total pipe length and number of elbows 2 Using winter design temperature used in load calculations find appropriate temperature for your application and fur nace model
114. tion kit instructions for proper installation Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections as specified in the GAS PIPING section of these instructions Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in the SET TEMPERATURE RISE section of these instructions When a 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 must also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace A gas fired furnace for installation in a residential garage must be installed as specified in the Hazardous Locations section and Fig 5 The furnace is not to be used for temporary heating of buildings or structures under construction unless the furnace installation and operation complies with first CAUTION in the LOCATION section of these instructions Buimeig jeuoisuawig z 614 eoeuunj 314v 9 96 udoj eui eui 199 jeJ eseu 021090 001090 080090 8 1 9 GIRAS 090cv0 8 2 66 xol 1 3215 LINN
115. to complete 1 revolution Note reading k Refer to Table 13 for cubic ft of gas per hr 1 Multiply gas rate cu ft hr by heating value Btu cu ft m Turn setup switch SW1 2 to OFF position and jumper R and W W1 and 2 thermostat connections See Fig 32 This keeps furnace locked in high heat operation Repeat items i through 1 for high heat operation EXAMPLE High heat operation at 0 2000 ft altitude Furnace input from rating plate is 100 000 Btuh Btu heating input Btu cu ft X cu ft hr Heating value of gas 975 Btu cu ft Time for 1 revolution of 2 cu ft dial 70 sec Gas rate 103 cu ft hr from Table 13 Btu heating input 103 X 975 100 425 Btuh In this example the orifice size and manifold pressure adjustment is within 2 percent of the furnace input rate NOTE Measured gas inputs high heat and low heat must be within 2 percent of that stated on furnace rating plate when installed at sea level or derated per that stated above when installed at higher altitudes n Remove jumper across R W W1 W2 thermostat connections to terminate call for heat B Set Temperature Rise CAUTION Temperature rise must be within limits specified on unit rating plate Operation is within a few degrees of midpoint of rise range when setup switch SW1 4 is OFF Failure to follow this caution may result in overheating the heat exchangers or condensing flue gas in heat exchanger areas not designed for condensate
116. to prevent any condensate leakage 2 Inducer Housing Drain Tube a Remove factory installed cap and clamp from LOWER inducer housing drain connection b Remove and discard UPPER molded inducer housing drain tube which was previously connected to conden sate trap c Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed d Use inducer housing drain extension tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to conden sate trap e Determine appropriate length cut and connect tube to condensate trap f Clamp tube to prevent any condensate leakage 3 Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure C Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures D Pressure Switch Tubing One collector box pressure tube pink label is factory connected to the pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications This tube MUST be dis connected and used for the condensate trap relief port tube The other collector box pressure tube green label which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZON TAL RIGHT applications NOTE See Fig 13 or tube routing label on main furnace door to check for proper conne
117. u ft REVOLUTION cu ft cu ft cu ft 3 Verify that blower and main access doors are properly installed 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instruc tions 6 Review User s Manual with owner 7 Leave literature packet near furnace THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER bw FROM UNIT 24 V CONTROL TERMINALS E 5 0 AMPS ON AMMETER _ 0 5 AMPS FOR THERMOSTAT EXAMEE 10 TURNS AROUND JAWS _ ANTICIPATOR SETTING 96316 Fig 65 Amp Draw Check with Ammeter CHECKLIST INSTALLATION LOAD CALCULATION Condensate Drain Heating Load Btuh Unit Level or Pitched Forward Cooling Load Btuh Internal Tubing Connections Free of Kinks Furnace Model Selection and Traps COMBUSTION AND VENT PIPING External Drain Connection Leak Tight and TE Sloped Termination Location Condensate Trap Primed before Start Up Roof or Sidewall Heat Tape Installed if Required Termination Kit 2 Pipe or Concentric CHECKLIST START UP Combustion Air Pipe Length Gas Input Rate T Set Within 2 percent of Rating Plate Combustion Air Pipe Elbow Quantity Temperature Rise Adjusted Vent Pipe Length Thermostat Anticipator Vent Pipe Elbow Quantity 5 Anticipator Setting Adjusted or Pipe Diameter Determined from
118. ugated sections to prevent kinks 2 Inducer Housing Drain Tube a Remove and discard LOWER molded inducer housing drain tube which was previously connected to conden sate trap cp PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE GREEN CONDENSATE 39 TRAP INDUCER HOUSING DRAIN TUBE VIOLET A94214 Fig 8 Alternate Upflow Tube Configuration and Trap Location b Use inducer housing drain extension tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to conden sate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage 3 Relief Port Tube a Connect relief port tube green label to condensate trap b Extend this tube if required by splicing to small diameter tube factory supplied in loose parts bag c Determine appropriate length cut and connect tube E Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures F Pressure Switch Tubing The LOWER collector box pressure tube pink label is factory connected to the pressure switch and should not require any modification NOTE See Fig 7
119. ugh grommet so long end of coupling faces blower e Cement 2 factory supplied 1 2 in street CPVC elbows to rigid drain tube connection on condensate trap See Fig 7 These elbows must be cemented together and ce mented to condensate trap drain connection NOTE Failure to use CPVC elbows may allow drain to kink preventing draining f Connect larger diameter drain tube and clamp factory supplied in loose parts bag to condensate trap and clamp securely g Route tube to coupling and cut to appropriate length h Attach tube to coupling and clamp securely C Condensate Trap Location Alternate Upflow Orientation An alternate location for the condensate trap is the left hand side of casing See Fig 2 and 8 NOTE If the alternate left hand side of casing location is used the factory connected drain and relief port tubes must be discon nected and modified for attachment See Condensate Trap Tubing Alternate Upflow Orientation section for tubing attachment To relocate condensate trap to the left hand side perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK
120. wer operation Connect an accessory Electronic Air Cleaner if used using CAUTION Do not connect aluminum wire between 1 4 in female quick connect terminals to the two male N disconnect switch and furnace Use only copper wire 1 4 in quick connect terminals on the control board marked See Fig 29 EAC 1 and EAC 2 The terminals are rated for 115VAC 1 0 amps maximum and are energized during blower motor operation See Fig 32 93033 Fig 29 Disconnect Switch and Furnace 20 2 Humidifier HUM WARNING DO NOT connect furnace control HUM gt Connect an accessory 24 VAC 0 5 amp maximum humidi terminal to HUM humidifier terminal on Thermidis fier if used to the 1 4 in male quick connect HUM tat Zone Controller or similar device See Thermidis terminal and Com 24V screw terminal on the control board tat Zone Controller thermostat or controller manufac thermostat strip The HUM terminal is energized when turer s instructions for proper connection blower is energized in heating See Fig 32 DIRECT VENTING LOCATION IN FACTORY D Pe The 355MAV furnaces require a dedicated one 355MAV furnace em only direct vent system In a direct vent system all air for icu combustion is taken directly from outdoor atmosphere and all flue we i a gases are discharged to outdoor atmosphere P REMOVAL OF EXISTING FURNACES FROM 2 COMMON VENT SYSTEMS

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