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Bryant 355MAV Furnace User Manual

1. HORIZONTAL LEFT DISCHARGE HORIZONTAL RIGHT DISCHARGE A96187 Fig 36 Combustion Air and Vent Pipe Connections N CAUTION Combustion air must not be taken from inside structure because inside air is frequently contaminated 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 products 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 N 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 N WARNING All combustion air and vent pipes must be airtight and watertight Pipes must also terminate exactly as shown in Fig 39 40 41 42 or 43 Failure to follow this warning could result in property damage personal injury or death 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 undesirabl
2. O FR Es L jim LA 5 S oso 3 16 att COMBUSTION AIR PIPE O F TRAP 102 am TO OPEN A93035 Fig 38 Intake Housing Plug Fitting Drain 2 Attach vent pipe to furnace as follows a Determine location of vent pipe connection to inducer housing as shown in Fig 36 for application b Reposition elastomeric rubber inducer housing outlet cap and clamp to appropriate unused inducer housing connection Tighten clamp N WARNING Inducer housing outlet cap must be installed 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 c Install pipe support factory supplied in loose parts bag into selected furnace casing vent pipe hole Pipe support should be positioned at bottom of casing hole 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 plug factory supplied in lo
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4. SW AND BLOWER OFF DELAY SETUP SWITCHES MODEL PLUG A99097 A93053 Fig 32 EAC Terminals on Control Center 4 Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so appliance shall operate continuously 5 Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 6 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 burning appliance to their previous conditions of use 7 If improper venting is observed during any of above tests the venting system must be corrected Vent system or vent connectors may need to be resized For any other appliances when resizing vent systems or vent connectors system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSCNGPIC B Combustion Air and Vent Piping GENERAL Combustion air and vent pipe fittings primers and solvents must conform to American National Standards Institute ANSI standards and American Society for Testing and Materials ASTM standards See Table 6 for approved materials for use in the U S A See Table 7 for maximum pipe lengths and Fig 39 40 41 42 and 43 for exterior piping arrangements In Canada construct all
5. A87226 Fig 43 Sidewall Termination of Less than 12 in NOTE Shaded parts in Fig 39 40 41 42 and 43 are considered to be termination 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 39 or 40 Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system EXTENDED EXPOSED SIDEWALL PIPES Sidewall combustion air and vent pipe terminations may be extended beyond area shown in Fig 42 or 43 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 furnace model 3 Determine required insulation thickness for exposed pipe lengths NOTE 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 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 requ
6. B Condensate Trap Tubing NOTE See Fig 11 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 COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE GREEN COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE PINK AUXILARY J BOX RELOCATED HERE J 4 J l CONDENSATE TRAP B COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED INDUCER HOUSING DRAIN TUBE VIOLET COLLECTOR BOX EXTENSION TUBE A00214 Fig 11 Horizontal Right Tube Configuration b Install removed clamp and plug into UPPER collector box drain tube blue label which was previously connected 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 d Clamp tube to prevent any condensate leakage Inducer Housing Drain Tube a Remove factory installed plug from LOWER collector box drain tube blue and white striped label b Remove and discard UPPER molded inducer housing drain tube which was previously connected to condensate trap c Install cap and clamp on UPPER inducer housing drain connection where molded dr
7. Failure to follow this warning could result in fire explosion personal injury or death N 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 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 valve See Fig 26 w GAS nr SUPPLY SJ MANUAL SHUTOFF VALVE Ex REQUIRED oM a TRAP UNION A93324 Fig 26 Typical Gas Pipe Arrangement N CAUTION If a flexible connector is required or allowed by authority having jurisdiction black iron pipe shall be installed at gas valve and extend a minimum of 2 in outside furnace casing An accessible manual shutoff valve MUST be installed upstream of furnace gas controls 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 24 NOTE The gas valve inlet press tap connection is suitable to use as test gage connection providing test pressure
8. green label to High Pressure Switch connection labeled COLLECTOR BOX Use remaining smaller diameter tube factory supplied in loose parts bag to extend collector box pressure tube pink label which was previously connected to pressure switch Route this extended tube pink label to condensate trap relief port connection 14 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 recommendations and procedures F Construct a Working Platform Construct working platform where all required furnace clearances are met See Fig 3 and 10 Z CAUTION The condensate trap MUST be installed 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 minimum length of 5 ft See Table 6 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 See Fig 10 or 29 LOCATION PROCEDURE 1 GENERAL When a furnace is installed so that supply ducts carry air to areas outside the space containing the furnace return air must also be handled by ducts sealed to furnace casing The ducts terminate outside the space containing the furnace to ensure there will no
9. 90 ELBOWS ALTITUDE FT UNIT SIZE WS ur sw TYPE w x p 2 pn w s 6 m waza p onn af e o o 13 042060 2 Pipe or 2 1 in 40 042080 2 Pipe or 2 in on mur masm 060080 Concentric m 2 Pipe or Di os e 060120 oin 8t v v w TERMINATION PIPE DIA NUMBER OF 90 ELBOWS ALTITUDE FT UNIT SIZE Aurea vwrszm TYPE Mapa m 2 Pipe or Zin m er a 8 D T gt L Conentic 2 fof o o 70 3001 to 3000 042080 2 Pipe or 2 in 060080 Concentric coido 2 Pipe or 2 in 2 4 ss ao 25 2 5 Concentric 060150 2 Pipe or 3 in Concentric TERMINATION PIPE DIA NUMBER OF 90 ELBOWS ALTITUDE FT UNIT SIZE amosen vwrsze TD IN waw 2 Pipe or Zin Concentric im 2 Pipe or Zin Concentric 042080 ZPpeorza L a 25 o 1s 0 5 _Na_ 060080 Concentric m 2 Pipe or 2n Concentric m Z Pipe or in Concentric 0 to 2000 See notes at end of table NOTE Do not count elbows or pipe sections in terminations or within furnace See shaded areas in Fig 40 41 42 43 and 44 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 7 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
10. DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas valve See Fig 56 Piping should be pressure tested in accordance with NFGC local and national plumbing and gas codes before furnace is attached In Canada refer to current edition of NSCNGPIC 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 we 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 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 MO 9C reaMINALS FIELD SUPPLIED WIRE DISCONNECT k NS m m B _ HEATIN B ___ 208 230 OR ONLY I EM E 1 Y lt i gt a E 460 V ST THREE PHASE epit D a 4 aa ie Io e 208 230 V 84 FORME rz f 9 349 eJre 4e e SINGLE 115 V AUXILIARY pron Di L J PHASE FIELD SUPPLIED J BOX Oe 11 Le loin DISCONNECT NOTE i CONDENSING SWITCH 9 ONE 24 V TWO WIRE FURNACE luta CONTROL BLOCK CENTER ur i i Connect Y or Y Y2 terminal as shown for prope
11. NOILSNEWOOD NI Z 9 ZZ O gj 9 4 zZ t 92 h EE lt lt 2 lt V 98 A A 9g INSTALLATION This forced air furnace is equipped for use with natural gas at altitudes 0 10 000 ft 0 3 050m An accessory kit supplied by the manufacturer shall be used to convert to propane gas use or may be required for some natural gas applications This furnace is for indoor installation in a building constructed on site This furnace may be installed in a manufactured mobile home when stated on rating plate and using factory authorized kit This furnace may be installed on combustible flooring in alcove or closet at minimum clearance from combustible material This appliance 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 PVC DWV or ABS DWW 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 Furnace must be installed level or LEVEL 0 pitched forward within 1 2 inch of level 1 2 MAX for proper drainage Failure will result in equipment or property damage See f Installation Manual for IMPORTANT unit support details on horizontal UPFLOW OR applicat
12. Prepurge begins 25 sec after high pressure switch closes 44 2 Blower on The blower motor is turned on IMMEDIATELY and slowly increases to maximum speed as soon as a call for heat is received No blower calibration occurs Electronic Air Cleaner The EAC 1 terminal does not operate in emergency heat mode Humidifier The HUM terminal is energized IMMEDIATELY Ignitor warm up The HSI is energized for a 17 sec warm up period after prepurge period is completed ON nN W Ignition sequence After HSI warm up period has completed the gas valve is energized permitting gas flow to burners where it is ignited After 5 sec the HSI is de energized and a 2 sec flame sensing period begins NOTE Emergency heat mode only operates in high heat 7 Flame sensing When burner flame is sensed control center holds gas valve open If burner flame is not sensed control center de energizes gas valve and ignition sequence is repeated NOTE Ignition sequence repeats 3 additional times before lockout occurs Lockout automatically resets after 3 hr or can be manually reset by turning 115 v or 24 v power off not at thermostat for 3 sec minimum then turning on again Fault codes will not flash in emergency heat mode 8 Blower off delay When thermostat is satisfied the R W W1 signal is terminated de energizing gas valve stopping gas flow to burners and HUM terminal is de energized The blower stops immediately 9 Post pu
13. Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC 1853 8 1 aus apne Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase 19 19 20 20 Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box Upflow Applications Lu 24 1 8 23 5 8 24 3 4 Downflow Applications on Non Combustible Flooring 23 1 2 19 5 8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 9 Downflow Applications on Combustible Flooring Using KGASB Subbase 23 3 4 20 3 8 Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 44mm 1 3 4 44mm 94 A89014 Fig 17 Leveling Legs WAS VA A PLENUM OPENING B D FLOOR OPENING A96283 Fig 18 Floor and Plenum Opening Dimensions Rae C ee ee ee FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING NC DOWNFLOW PA SUBBASE SHEET METAL PLENUM H4 amp FLOOR y OPENING 4220222 223a A96285 Fig 19 Furnace Plenum and Subbase Installed on a Combustible Floor NOTE Remove furnace perforated supply air duct flanges when they interfere with mating flanges on coil or downflow subbase To remove perforated supply air duct flanges use wide duct pliers duct flange tool or hand seamers to bend flange back and forth until
14. Trap 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 yearly heat value average at installed altitude from local gas supplier b Obtain yearly specific gravity average from local gas supplier c Verify furnace model Table 13 can only be used for model 355MAV furnaces d Find installation altitude in Table 13 NOTE For Canada altitudes of 2000 to 4500 ft use U S A altitudes of 2001 to 3000 ft in Table 13 e Find closest natural gas heat value and specific gravity in Table 13 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 6 in wc for high heat 1 5 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 the proper input rate g 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 Remove caps that conceal adjustment screws for low and high h
15. and Trap Location NOTE Failure to use CPVC elbows may allow drain to kink and prevent 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 6 NOTE If the alternate left hand side of casing location is used the factory connected drain and relief port tubes must be disconnected 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 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 condensate trap casing holes with plastic filler caps factory supplied in loose parts bag D Condensate Trap Tubing Alternate Upflow Orientation NOTE See Fig 6 or tube routing label on main furnace door to confirm lo
16. 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 23 For bottom return air applications filter may need to be cut to fit some furnace widths Install filter as shown in Fig 24 NOTE Remove and discard bottom closure panel when bottom inlet is used WASHABLE FILTER FILTER a RETAINER d A93045 Fig 23 Filter Installed for Side Inlet PROCEDURE 6 BOTTOM CLOSURE PANEL These furnaces are shipped with bottom enclosure 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 the following 1 Tilt or raise furnace and remove 2 screws holding front filler panel See Fig 25 2 Rotate front filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall front filler panel and screws PROCEDURE 7 GAS PIPING Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the United States 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 22 21 IN WIDE 1712 IN WIDE CASINGS ONLY CASINGS ONLY SUPPORT RO
17. 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 5 NOTE If internal filter or side Filter Media Cabinet is used drain tube should be located to opposite side of casing of 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 through grommet ensuring long end of coupling faces blower e Cement 2 factory supplied 1 2 in street CPVC elbows to the rigid drain tube connection on the condensate trap See Fig 5 These elbows must be cemented together and cemented to condensate trap drain connection 7 PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE GREEN CONDENSATE TRAP INDUCER HOUSING DRAIN TUBE VIOLET A94214 Fig 6 Alternate Upflow Configuration
18. 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 3 in and 4 in diameter pipe systems when single penetration of wall or roof is desired 37 MAINTAIN 12 IN 305 mm 18 IN 457 mm FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN 610 mm ABOVE ROOF A93054 Fig 40 Concentric Vent and Combustion Air RoofTermination Preferred OVERHANG OR ROOF eee NEM wc und a 805 n MO S 12 305 mm MINIMUM arn ee 41 MAXIMUM COMBUSTION AIR MAINTAIN 12 IN 305 mm CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER A93055 Fig 41 Concentric Vent and Combustion Air SideTermination OVERHANG OR ROOF 12 MINIMUM ee 12 IN SEPARATION TT BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE COMBUSTION AIR WHICHEVER IS GREATER A87225 Fig 42 Sidewall Termination of 12 in or More OVERHANG OR ROOF 12 MINIMUM COUPLING 7 m a 12 IN SEPARATION lt T BETWEEN BOTTOM OF tL COMBUSTION AIR AND BOTTOM OF VENT Be MAINTAIN 12 IN E COE CLEARANCE it L7 ABOVE HIGHEST ANTICIPATED SNOW COMBUSTION AIR LEVEL OR GRADE ELBOW PARALLEL WHICHEVER IS TO WALL GREATER z lt aa
19. mode NOTE The continuous fan speed is the same as low heat speed unless it is field adjusted to another desired airflow See Continuous Fan Setup Switches section There is also a chart on wiring diagram See Fig 30 c Electronic Air Cleaner The EAC 1 terminal is energized whenever blower operates regardless of operating mode 2 Operating with continuous fan R G and call for heat R W W1 is received Same as heat pump mode except blower on delay is 10 sec less than heat mode After call for heat R W W1 is terminated the blower remains operating at low heat speed for selected blower off delay before resuming continuous fan speed 3 Operating with continuous fan R G and call for cooling R Y Y2 is received See Cooling Mode section After call for cooling R Y Y2 is terminated the blower remains operating at cooling speed for 90 sec before resuming continuous fan speed PROCEDURE 8 COMPONENT TEST All components are functionally operated except gas valve with component test feature This feature helps diagnose a system problem in case of a component failure NOTE Setup switch SW 1 MUST be in OFF position or Fault Code 22 setup error will occur NOTE NO thermostat signal may be present at control center and all blower time delay off periods must be completed To initiate component test feature proceed with the following 46 VARIABLE SPEED THERMIDISTAT CONDENSING 2 SPEED CONTROL FURNACE HEAT PUMP RVS COO
20. period is completed 3 Ignitor warm up After prepurge period HSI is energized for 17 sec 4 Ignition sequence After HSI warm up period is completed the gas valve is energized permitting gas flow to the burners where it is ignited After 5 sec the HSI is de energized and a 2 sec flame sensing period begins 5 Flame sensing When burner flame is sensed control center holds gas valve open If burner flame is not sensed control center de energizes gas valve and ignition sequence is repeated 6 Blower off period Ten sec after gas valve is energized the blower stops for 25 sec to allow heat exchangers to warm up 7 Blower on delay After blower off period blower starts NOTE The blower starts at approximately 400 500 RPM After 20 sec the motor is turned off for 1 10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system The microprocessor then determines blower RPM required to provide proper airflow for heating mode 45 VARIABLE SPEED THERMIDISTAT CONDENSING 2 SPEED CONTROL FURNACE AIR CONDITIONER HEAT STAGE 2 ore COOL STAGE 1 Y1w2 HEAT STAGE 1 W W1 COOL STAGE 2 v2 24 VAC HOT REL DEHUMIDIFY 24 VAC COMM A l HUMIDIFIER HUMIDIEY 77 SOLENOID VALVE bu 94 VAC N A r 3 OUTDOOR LA OUTDOOR 7 SENSOR j CONNECTION s2 r i A01473 Fig 51 Wiring Schematic for 2 Speed Application with Thermidista
21. 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 COMBUSTION AIR AND VENT PIPE ATTACHMENT NOTE All pipe joints must be watertight 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 to furnace as follows a Determine location of combustion air intake pipe connection to combustion air intake housing as shown in Fig 36 for application b Reposition combustion air intake housing plug fitting in appropriate unused intake housing connection c If required insert perforated disk assembly factory supplied in loose parts bag in intake housing where combustion air intake pipe will be connected If half disk set is required install with shoulder of disk against stop in combustion air inlet d Install pipe support factory supplied in loose parts bag into selected furnace casing combustion air pipe hole Pipe support should be positioned at bottom of casing hole e Insert 2 in diameter pipe into intake housing f Install casing
22. 0 CFM x x x X Indicates allowable selection OFF A95198 Fig 53 Example of Setup Switch in OFF Position A99118 Fig 54 Inducer Housing Drain Tube NOTE The CF switches are factory set to provide continuous fan airflow equal to low heat mode 5 Replace main furnace door and blower access panel C Setup Switches SW The control center has 8 setup switches that may be set to meet the application requirements Position these setup switches for the appropriate requirement 1 Remove main furnace door and blower access panel 2 Locate setup switches on control center See Fig 31 3 See Table 11 for setup switch description See Fig 30 4 Replace main furnace door and blower access panel Table 11 Setup Switch Description SETUP NORMAL DESCRIPTION SWITCH NO POSITION OF USE SW 1 Turn switch to ON for fault history display No thermostat signal FLT can be present for fault history display SW 2 Turn switch to ON to lock furnace in low heat mode only or LOW OFF when using a 2 stage thermostat with a R W W1 and R W2 sig nals SW 3 Turn switch to ON when a bypass humidifier is used This com BPH OFF pensates for higher return air temperature and provides 15 per cent more airflow in low heat mode only SW 4 Turn switch to ON to bypass microprocessor control Furnace EMER HEAT OFF will operate at high heat only with main blower and inducer mo tor operating at maximum RPM NO safeties are bypas
23. 1 percent during the off delay period when the DE jumper is connected The DE jumper is only removed to enable the DEHUM input for use with a thermidistat or humidistat for dehumidification purposes B Two Speed Applications For details on 2 speed cooling applications refer to Fig 51 PROCEDURE 6 HEAT PUMP MODE A Single Speed Applications When furnace is operating in heat pump heating mode R Y Y2 and R G circuits are closed energizing heat pump and blower operates at cooling speed When heat pump defrost is required R W W1 circuits close starting gas heat cycle and blower adjusts to low heat speed 1 Prepurge period tThe inducer motor is turned on and slowly comes up to speed When low pressure switch closes inducer motor RPM is noted by microprocessor and a 25 sec prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is then used to determine required RPM necessary to operate inducer in low heat mode NOTE The heat cycle can start in either high or low heat If a high heat cycle is initiated inducer continues increasing its speed after low pressure switch closes When high pressure switch closes inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is used to determine required RPM necessary to operate inducer in high heat mode 2 Humidifier The HUM terminal is energized after inducer prepurge
24. ARNING The furnace casing 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 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 electrical shock fire or death J BOX RELOCATION 1 Remove 2 screws holding auxiliary J box See Fig 29 2 Rotate J box 180 and attach box to left side using holes provided Z 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 B 24 V Wiring Make field 24 v thermostat connections at 24 v terminal block on control center Y wire from thermostat MUST be connected to Y terminal on control center as shown in Fig 27 for proper cooling operation The 24 v terminal board is marked for easy connection of field wiring See Fig 30 The 24 v circuit contains a 3 amp automotive type fuse located on control center See Fig 31 Any electrical shorts of 24 v wiring during installation service or maintenance may cause fuse to blow If fuse replacement is required use only a fuse of identical size 3 amp NOTE Use AWG No 18 color coded copper thermostat wire for lengths up to 100 ft F
25. Arrangemetnt Bottom Closure Panel Gas Piping Electrical GO LH TS Cti Om STIS TT TREO TE S c uS M Dm 24 V Wiring VNE 61st 10 chs eRe on RV E Be ne Oe SUE TEUER EN ERE SU EE Fee EATER ee E Qani durs ee ore ere ree eee oer ere rere Incem D M Removal of Existing Furnaces from Common Vent Systems 7 Combustion Air and Vent Piping ss 232 Concentric Vent and Combustion Air Termination Kit Installation Multiventing and Vent Ferminations 6 to exorti er cus n en EO ENERO NO IRR NUI REN eE E e ER eee En esee Fo Eee epa tpud 41 Condensate DT T I uu E EE E a 41 General a uber EUER 41 Condensation Drain PEIOecOn 3 3 o nre eie EE Epoca ter rhet e ese ih c EDO EE HR EE PR Due ans e ISO e Er tendue 43 SEQUENCE OF OPERATION nnnm mre aee e e ae Ce GERE seeds Hee E ee shi D ntm E E nement Retenir semi IRR REIR 44 SOMMEIL C Heating Mode Heating Mode Two Stage Emergency Heat Mode ry Cooling c nsn E E E E ENE E E E A N EA Single Speed Applications seiren anses Aa en E E ee RE i Pct AE E red ate eee ee eie ated Two Speed Applications PE Heat Pump MOG sivecceseziscsscscsseidaseqscesersceaes aara aniatra eaat POE EE ei RD EEVEE EESTE EEEE NE ne M Single Speed Appli
26. CUIT INDUCTOR SPLICE CONNECTOR 5 CIRCUIT BLOWER POWER CONNECTOR 16 CIRCUIT BLOWER CTRL CONNECTOR MANUAL SWITCH FAULT DISPLAY SPST N O MANUAL SWITCH LOW HEAT SPST N O MANUAL SWITCH BYPASS HUMIDIFIER SPST N O MANUAL SWITCH EMERGENCY HEAT SPST N O MANUAL SWITCH MULTIPLE ZONE SPST N O COMPONENT TEST SPST N O MANUAL SWITCH BLOWER OFF DELAY SPST N O TRANSFORMER 115VAC 24VAC JUNCTION UNMARKED TERMINAL PCB TERMINAL FACTORY CONNECTED FACTORY WIRING 115 VAC FACTORY WIRING 24 VAC FIELD WIRING 115 VAC CONDUCTOR ON PCB FIELD WING SCREW TERMINAL TERMINAL BLOCK MARKED TERMINAL FIELD EARTH GROUND EQUIPMENT GROUND FIELD SPLICE PCB TERMINAL FIELD CONNECTION PLUG RECEPTACLE za Fig 30 Unit Wir DEHUM HUM Q2 8 G v2 w wwt O WHEN USED DE PL24 LGPS goo NOTE A1 QT H WHEN USED PL1 1 If any of the original equipment wire is replaced use wire rated for 105 C Use only copper wire between the disconnect switch and the furnace junction box JB This wire must be connected to furnace sheet metal for control to prove flame Symbols are electrical representation only Solid lines inside circuit board PCB are printed circuit board traces and are not depicted as shown in the legend Replace
27. DITIONING ADJUSTABLE TONNAGE AUXILIARY LIMIT SWTICH OVERTEMP MANUAL RESET SPST N C CONTINUOUS FAN ADJUSTABLE CFM MAIN MICROPROCESSOR amp CIRCUITRY IGNITION MICROPROCESSOR amp CIRCUITRY DEHUMIDIFY ENABLE IF DE CONNECTION PROVIDED REMOVE JUMPER TO ENABLE DEHUM INPUT DEHUMIDIFICATION CONNECTION 24VAC 02 AMPS ELECTRONIC AIR CLEANER CONNECTION 115 VAC 1 5 AMP MAX ELECTRONIC AIR CLEANER CONNECTION COMMON FLAME ROLLOUT SWITCH MANUAL RESET SPST N C FLAME PROVING SENSOR ELECTRODE FUSE 3 AMP AUTOMOTIVE BLADE TYPE FACTORY INSTALLED FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE FIELD INSTALLED amp SUPPLIED EQUIPMENT GROUND GAS VALVE GAS VALVE RELAY DPST N O GAS VALVE HIGH STAGE OPERATOR HIGH HEAT PRESSURE SWITCH SPST N O HOT SURFACE IGNITOR 115 VAC HOT SURFACE IGNITOR RELAY SPST N O 24VAC HUMIDIFIER CONNECTION 5 AMP MAX HUMIDIFIER RELAY SPST N O BLOWER ACCESS PANEL INTERLOCK SWITCH SPST N O INDUCTOR NOTE 7 JUNCTION BOX LIGHT EMITTING DIOES FOR STATUS CODES LOW GAS PRESSURE SWITCH SPST N O LOW HEAT PRESSSURE SWITCH SPST N O LIMIT SWITCH AUTO RESET N C MOTOR ICM INDUCER MOTOR ICM BLOWER PRINTED CIRCUIT BOARD 11 CIRCUIT CONNECTOR 4 CIRCUIT PRESSURE SWITCH CONNECTOR 5 CIRCUIT BLOWER MTR CONNECTOR 2 CIRCUIT HSI CONNECTOR 6 CIRCUIT MODEL PLUG 3 CIRCUIT COMM CONNECTOR 12 CIRCUIT INDUCER MTR CONNECTOR 2 CIRCUIT HSI CONNECTOR 9 CIRCUIT BLOWER ADAPTER CONNECTOR 1 CIR
28. DS 3 INSTALL FIELD SUPPLIED EXTEND 1 4 ON EACH FILTER FILLER STRIP SIDE OF FILTER AND UNDER FILTER REST ON CASING FLANGE WASHABLE FILTER FILTER RETAINER SUPPORT A00290 Fig 24 Bottom Filter Arrangement FRONT FILLER PANEL A93047 Fig 25 Removing Bottom Closure Panel 93 e Table 3 Maximum Capacity of Pipe NOMINAL IRON INTERNAL LENGTH OF PIPE FT PIPE DIAMETER x MNEMORRPERD SIZE IN 10 20 30 40 50 IN x 1 n 9 3 T 35 L 3 CL 25 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 NFGC 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 N CAUTION Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls N WARNING Gas valve shutoff switch MUST be facing forward or tilted upward Failure to follow this warning could result in property damage or death N WARNING Never purge a gas line into a combustion chamber Never use matches candles flame or other sources of ignition for purpose of checking leakage Use a soap and water solution to check for leakage
29. E HORIZONTAL UPFLOW APPLICATIONS EXTERNAL UPFLOW APPLICATIONS APPLICATIONS SLOT FOR SCREW HORIZONTAL APPLICATION ob OP TONAL COLLECTOR BOX TO j s ammi aay RELIEF PORT V2 OD INDUCER HOUSING J E H DRAIN CONNECTION 5 8 OD 19mm i COLLECTOR BOX DRAIN CONNECTION SCREW HOLE FOR UPFLOW OR DOWN 5mm 7 FLOW APPLICATIONS y RETIE i V OPTIONAL GUIDES gt 2 Pe 1 2 IN PVC OR CPVC WHEN USED 57mm FRONT VIEW SIDE VIEW A93026 Fig 4 Condensate Trap ELECTROSTATIC DISCHARGE ESD PRECAUTION PROCEDURE Z CAUTION Electrostatic discharge can affect electronic components Follow the Electronic Discharge Precautions Procedure listed below during furnace and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are 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 electrostatic potential 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 Firmly touch the clean unpainted metal surface of the furnace chassis which is close to the control Tools held in hand during grounding will be discharged After touching the chassis you may proceed to s
30. ER collector box pressure tube pink label is factory connected to the pressure switch and should not require any modification NOTE See Fig 9 or tube routing label on main furnace door to check for proper connections E Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommendations and procedures F Construct a Working Platform Construct working platform where all required furnace clearances are met See Fig 3 and 10 COMBUSTION AIR INTAKE VENT A 12 IN 305 mm MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT 5 TO 8 FT 1 5 TO 2 4 M VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE 30 762 mm MIN d f S s dg MANUAL a HUTOFF ACCESS OPENING GAS VALVE FOR TRAP SEDIMENT THAR CONDENSATE 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 10 Attic Location and Working Platform Z CAUTION The condensate trap MUST be installed 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 minimum length of 5 ft See Table 6 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 f
31. Gations iciaccssssssaverseseconsassccepesscssessedeosenteessecstesescsns ev cutsussossveatvns san sevnensveateipnevaaseconsssesedat socvsstoesssvasnocosuessdeoneasteucensa EEE ERER Two Speed Applications Continuous Fan Mod Lu inni Ee E REM tes tie rip Un al aasma SS ia S nein Qiu enn eode etes Component Test Bypass Humidifier Mode Dehumidification Mode YA Bon START UP PROCEDURES V V General 3s Select Setup Switch POSITOS sime REID Ute ped DU IINE EI od tidie get dette rd o RH ORI HERR Air Conditioning A C Setup SWiteheSuu itte te pera xi e REN BERNER VERRE RENE rest pei VIEN D KE in net en sn 48 Continuous Fan CF Setup Switches 149 Setup Switches SW 149 Prime Condensate Trap with Water 01 Puige Gas Lines na riti d Adjustments aol Set Gas Input Rate x21 Set Temperature Rise u 57 Set Thermostat Heat Anticipator s ic iscscccsecsessecsessesseteessesseesessessesiessssisesiosvncsessnesteayecusssedsosvestecdedbeisoibachevseeseesesiesscesssssqoied ta ESE SETEN iR r VEERE 58 Check Safety Controls sis Check Primary Limit Controls eicere pne nie ner en Ene ed dr din E Mia tin isa 58 Che
32. Installation Start up and Operating Instructions Deluxe 4 Way Multipoise 355MAV Variable Capacity Direct Vent Series F Condensing Gas Furnace As an ENERGY STAR Partner Bryant Heating amp Cooling Systems has determined that this product meets the ENERGY STARS guidlines for energy efficiency CERTIFIED D 9001 82 REGISTERED QUALITY SYSTEM NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERXTIONS irrito Pe i a EUH E Rare tO EE IP Ert rH EE HARE ERE HERI SE sdeshelsediviesigesnesdssigtscsestsnerdis veces 3 INTRODUCTION L T Ie 3 CODES AND STANDARDS IH SPERO UPR NEU NU PE EPI IR USD sentent ess gs MGE TENE EERE EE AE i heel Le ipe NER egerat p sedere pes 3 ELECTROSTATIC DISCHARGE ESD PRECAUTION PROCEDURE c sciscsscesccsesstetscacsecdeosserneneoreeesenssseseassesdenvesscaouednsesoeseseusedessasucoseasosvesvieseses 6 APPLICATIONS sii General nene n0 Upflow Uu 7 Condensate Trap Location Factory Shipped Orientation 7 Condensate Trap Tubing Factory Shipped Orientation E Condensate Trap Location Alternate Upflow Orientation EE E EEE 7 Condensate Trap Tubing Alternate Upflow Orientation usaha EXTR ORNARE ei ee ini nr ee 8 Condensate Trap Field Drain Attachment 529 Pres
33. LING HEAT COOL STAGE 1 Y1 W2 COMPRESSOR LO wz HEAT STAGE 3 FURNACE LWW1 E STAGE 2 COMPRESSOR HI 24 VAC HOT RE DEHUMIDIFY 24 VAC COMM l HUMIDIFIER HUMIDI Y SOLENOID VALVE AVAC N A Li OUTDOOR Lj OUTDOOR E SENSOR i ENSOR CONNECTION s2 p 4 A01474 Fig 52 Wiring Schematic for 2 Speed Heat Pump Application with Thermidistat Control Dual Fuel Leave 115 v power to furnace turned on Remove main furnace door Remove blower access panel Move setup switch SW 6 to ON position tho SY d Manually close blower access panel door switch Use a piece of tape to hold switch closed A WARNING Blower access panel door switch opens 115 v power to control center No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in personal injury or death When items 1 5 have been completed the following will occur 1 The control center goes through a brief self test This self test takes approximately 2 sec to complete After door switch is closed red microprocessor LED briefly comes on Then green LED comes on for 1 sec followed by 1 sec where both green and yellow LEDs are on During this time the microprocessor is checking itself 2 Inducer motor operates for 20 sec at low speed operates for 20 sec at high speed then turns off Hot surface ignitor is energized for 15 sec then d
34. LLATION IN UPFLOW AND DOWNFLOW APPLICATIONS NOTE For downflow applications this furnace is approved for use on combustible flooring when special base available from manufacturer Part No KGASB0201 ALL is used Special base is not required when this furnace is installed on manufacturer s Coil Assembly Part No CDS or CK5 or Coil Box Part No KCAKC is used 1 Determine application being installed from Table 1 Construct hole in floor per dimensions specified in Table 1 and Fig 18 2 3 Construct plenum to dimensions specified in Table 1 and Fig 18 4 If downflow subbase KGASB is used install as shown in Fig 19 If Coil Assembly Part No CDS or CK5 or Coil Box Part No KCAKC is used install as shown in Fig 20 1497 Table 1 Opening Dimensions in FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Lx pomum cm Upflow Applications 24 1 8 16 5 8 24 3 4 Downflow Applications on Non Combustible Flooring 15 7 8 16 1 2 19 5 8 Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC 1519 i9 1673 4 neus Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC 15 1 2 i 16 1 2 29 Coil Box Upflow Applications 19 1 2 24 1 8 20 1 8 24 3 4 Downflow Applications on Non Combustible Flooring 19 3 8 19 5 8 Downflow Applications on Combustible Flooring Using KGASB
35. ONS 18 IN 457 2 mm MINIMUM TO BURNERS A93044 Fig 16 Installation in a Garage A WARNING When the furnace is installed in a residential garage the burners and ignition sources must be located at least 18 in above the floor The furnace must be located or protected to avoid physical damage by vehicles When the furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere the furnace must be installed in accordance with the National Fire Protection Association Inc requirements See Fig 16 INSTALLATION PROCEDURE 1 LEVELING LEGS IF DESIRED When furnace is used in upflow position with side inlet s leveling legs may be desired See Fig 17 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 furnace on its back Locate and drill a 5 16 in diameter hole in each bottom corner of furnace See Fig 17 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 PROCEDURE 2 INSTA
36. R W W1 and W2 thermostat connections to terminate call for heat B Set Temperature Rise CAUTION Temperature rise must be within limits specified on unit rating plate Recommended operation is at midpoint of rise or above Failure to follow this caution may result in overheating the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate BURNER FLAME X BURNER emer Fig 58 Burner Flame A89020 EXAMPLE 100 000 Btuh input furnace installed at 4300 ft Derate Furnace Input Rate Furnace Input Rate i ds at Sea T evel X Multiplier at Installation Factor Altitude 700 000 x o S 91 000 Table 14 Altitude Derate Multiplier for U S A FT OF DERATE FACTOR FOR U S A Derate multiplier factor is based on midpoint altitude for altitude range Furnace must operate within the temperature rise ranges specified on the furnace rating plate Determine the air temperature as follows 1 Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see heat exchangers so that radiant heat does not affect thermometer readings This practice is particularly important with straight run ducts 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 fire operation by placing setup switch SW 2 on control cen
37. R W WI1 signal alone is received low heat is energized This method overrides microprocessor control of high or low heat NOTE When using 2 stage thermostat operation with R W W1 and R W2 signals setup switch SW 2 MUST be in ON position The heat cycle operates as stated in Heating Mode section To allow for greater comfort 2 stage thermostat control is recommended when zone systems are used PROCEDURE 4 EMERGENCY HEAT MODE NOTE The furnace should not be operated in emergency heat mode for extended periods of time Operation is only recommended to provide heat until replacement components can be obtained or fault resolved In this mode the microprocessor is bypassed and motors operate at full speed with high heat operation The heat exchangers motors and electronics can be overstressed and may reduce the life of components if operated for an extended period NOTE No safeties are bypassed when using emergency heat mode Emergency heat mode can be selected using setup switch SW 4 SW 4 should be used when a fault condition exists or difficult to resolve problems occur This allows heating until fault can be corrected In emergency heat mode the normal heat mode outlined in Heating Mode section is not followed The following sequence will occur When thermostat calls for heat the R W W 1 circuits close 1 Prepurge period tThe inducer motor is turned on IMMEDIATELY operating at maximum speed closing low and high pressure switches
38. STALLED FACTORY SUPPLIED DRAIN TUBE COUPLING LEFT DRAIN OPTION FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE FIELD INSTALLED FIELD INSTALLED FACTORY SUPPLIED FACTORY SUPPLIED 1U2 IN CPVC STREET DRAIN TUBE ELBOWS 2 FOR COUPLING RIGHT LEFT DRAIN OPTION DRAIN OPTION A94213 Fig 5 Factory Shipped Upflow Tube Configuration Shown with Blower Access Panel Removed PROCEDURE 2 UPFLOW APPLICATIONS In an upflow application the blower is located below the burner section 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 B Condensate Trap Tubing Factory Shipped Orientation NOTE See Fig 5 or tube routing label on main furnace door to confirm location of these tubes 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
39. a s S aS o i 4 di gt Z 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 Move setup switch SW 2 to OFF position after completing low heat adjustment g Jumper R and W2 thermostat connections on control center See Fig 31 This keeps furnace locked in high heat operation h Turn high heat adjusting screw 5 64 hex Allen wrench counterclockwise out to decrease input rate or clockwise in to increase rate NOTE DO NOT set high heat manifold pressure less than 3 2 in we or more than 3 8 in we for natural gas If manifold pressure is outside this range change main burner orifices 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 58 eee Table 13 Model 355MAV Orifice Size and Manifold Pressure for Correct Input Continued Tabulated Data Based on 20 000 Btuh High Heat 13 000 Btuh Low Heat per Burner Derated 2 Percent for Each 1000 ft Above Sea Level cane Ve ee ee E 058 0 66 no Pressure no Pressu
40. aged 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 determine 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 jore FILTER SIZE IN wiwa WIDTH IN TER 17 1 2 1 16 X25 X 1t 1 16 X25 X 1f Cleanable 1 16 X25 X1 1 20 X 25 X 1f Cleanable 24 1 2 1 or 2 16 X25 X1 1 24 X25 X 1t Cleanable Filters may be field modified by cutting filter material and support rods 3 in filters Alternate sizes and additional filters may be ordered from your dealer Factory provided with furnace N CAUTION Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends Wear safety glasses gloves and appropriate protective clothing Failure to follow this caution could result in personal injury N 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
41. ain 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 condensate trap e Determine appropriate length cut and connect tube to condensate trap f Clamp tube to prevent any condensate leakage 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 disconnected 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 HORIZONTAL RIGHT applications NOTE See Fig 11 or tube routing label on main furnace door to check for proper connections Relocate tubes as described below 1 2 Disconnect collector box pressure tube pink label attached to pressure switch Extend collector box pressure tube green label which was previously connected to condensate trap relief port connection by splicing to small diameter tube factory supplied in loose parts bag 3 Connect collector box pressure tube
42. at blower operates at low heat speed for 60 sec when power is restored before heating cycle is resumed 43 PROCEDURE 1 SELF TEST MODE The control center goes through a brief self test whenever 115 v or 24 v power is interrupted The self test takes approximately 2 sec to complete After power is restored red microprocessor LED briefly comes on Then green LED comes on for 1 sec followed by 1 sec where both yellow and green LEDs are on During this time the microprocessor is checking itself PROCEDURE 2 HEATING MODE When thermostat calls for heat R W W1 circuit closes 1 Prepurge period The inducer motor is turned on and slowly comes up to speed When low pressure switch closes inducer motor RPM is noted by microprocessor and a 25 sec prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is then used to determine required RPM necessary to operate inducer in low heat mode NOTE The heat cycle can start in either high or low heat If a high heat cycle is initiated the inducer continues increasing its speed after low pressure switch closes When high pressure switch closes inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is then used to determine required RPM necessary to operate inducer in high heat mode 2 Humidifier HUM The HUM terminal is energized after the inducer prepurge p
43. bustion air pipe NOTE DO NOT OVERTIGHTEN SCREW Breakage to 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 ignitor 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 to 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 combustion air intake may be result of improper termination Ensure combustion air intake pipe termination is similar to that shown in Fig 39 40 41 42 and 43 so it will not be susceptible to areas where light snow or other sources of moisture could be pulled in 35 Table 7 Maximum Allowable Pipe Length ft Continued TERMINATION PIPE DIA NUMBER OF 90 ELBOWS ALTITUDE FT UNIT SIZE WS ur sur TYPE ony w 2 Pipe or Din Concentric m 2 Pipe or Zin Concentric 042080 2 Pipe or Zin 060080 Concentric m Z Pipe or Zin Concentric Concentri
44. c TERMINATION PIPE DIA a E s S s zm za E 2 2 L L Concentric 042060 os sae Concentric 9001 to 10 0007 042080 2 Pipe or 2 in 060080 Concentric 060100 2 Pipe or 2 in Concentric Ce Disk usage Unless otherwise specified use perforated disk assembly factory supplied in loose parts bag TWide radius elbow Vent sizing for Canadian installations over 4500 ft 1370 m 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 then use the larger of these two diameters 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 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 38 COMBUSTION AIR INTAKE HOUSING 3 8 ID TUBE BURNER ga BOX
45. cation 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 corrugated sections to prevent kinks from occurring 2 Inducer Housing Drain Tube a Remove and discard LOWER molded inducer housing drain tube which was previously connected to condensate 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 the condensate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage 3 Relief Port Tube 8 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 High Pressure Switch and should not require any modification NOTE See Fig 5 or 6 or tube routing label on main furnace door to check for proper connections G Upper Collector Box and Inducer Housing Unused Drain Connections 1 Upper Collector Box Drain Connection Attached to the UPPER collector box drain connection is a factory i
46. cause must be determined and corrected B Check Pressure Switches This control proves operation of the draft inducer Check switch 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 ND tA THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER 10 7 k FROM UNIT 24 V CONTROL TERMINALS E 5 0 AMPS ON AMMETER _ 0 5 AMPS FOR THERMOSTAT EXAMPLE SO TURNS AROUND JAWS ANTICIPATOR SETTING A96316 Fig 59 Amp Draw Check with Ammeter Turn on 115 v power to furnace Set thermostat to call for heat When pressure switches are functioning properly fault code 42 will flash on control center approximately 10 sec after thermostat switch is closed If either a fault code 31 or 32 is flashed when ICM inducer motor is disconnected the furnace will shut itself down immediately Determine the reason pressure switches did not function properly and correct the condition Turn off 115 v power to furnace Reconnect inducer motor wire harness Reinstall furnace access door Turn on 115 v power to furnace Reset thermostat to desired temperature PROCEDURE 7 CHECKLIST ND nN gt N Put away tools and instruments Clean up debris Verify manual reset switch has continuity Verify that blower and control access doors are pr
47. ce is required during construction use clean outside air for combustion and ventilation Compounds of chlorine and fluorine when burned with combustion air form acids which will cause corrosion of heat exchangers Some of these compounds are found in paneling dry wall adhesives paints thinners masonry cleaning materials and many other solvents commonly used in the construction process Excessive exposure to contaminated combustion air will result in safety and performance related problems Provide ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on unit s clearance to combustibles label See Fig 3 Locate furnace where available electric power and gas supplies meet specifications on furnace rating plate A93043 Fig 14 Prohibit Installation on Back 320F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED NE j NS A93058 Fig 15 Freeze Protection N WARNING Do not install furnace on its back See Fig 14 Safety control operation will be adversely affected Never connect return air ducts to back of furnace Failure to follow this warning could result in fire personal injury or death CAUTION If this furnace is installed in an unconditioned space where the ambient temperatures may be 32 F or lower freeze protection measures must be taken See Fig 15 PROCEDURE 2 LOW FIRE ONLY INSTALLATION Thi
48. ck Press rs SWiteheS osinn E 59 OE a E a E EE E E E E E E E EEE 59 NE NS AIRFLOW gt g UPFLOW HORIZONTAL HORIZONTAL RIGHT DOWNFLOW AIRFLOW AIRFLOW v AIRFLOW A93041 Fig 1 Multipoise Orientations SAFETY CONSIDERATIONS 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 Follow all safety codes In the United States follow all safety codes including the National Fuel Gas Code NFGC NFPA No 54 1999 ANSI Z223 1 1999 and the Installation Standards Warm Air Heating and Air Conditioning Systems NFPA 90B ANSI NFPA 90B In Canada refer to the current edition of the CAN CGA B149 1 and 2 M00 National Standard of Canada Natural Gas and Propane Installation Codes NSCNGPIC 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
49. cles or outdoors These furnaces are suitable for installation in a structure built on site or a manufactured residence completed at final site 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 applications as shown in Fig 1 See details in Applications section These furnaces are shipped with the following materials to assist in proper furnace installation These materials are shipped in the main blower compartment 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 termination kit instructions for proper installation Z CAUTION Application of this furnace should be indoors 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 premature component failure N WARNING Improper installation adjustment alteration service maintenance or use can cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal inj
50. combustion air and vent pipes for this unit of CSA or ULC certified schedule 40 PVC PVC DWV or ABS DWV pipe and pipe cement SDR pipe is NOT approved in Canada HUM G R 24V DADA 2 X2 C2 2 2 W2 Com W Wi Y Y2 DE CONNECTION SEC SEC E DEUM i OOOO BBB HHH HBBBEBER 7 ee 000 i Wc DE CONNECTION LOCATION A99098 Fig 33 355MAV Variable Speed Furnace Control VARIABLE SPEED THERMIDISTAT CONDENSING FURNACE 24VAC HOT R R DEHUMIDIFY DHUM DEHUM DE NOTE 1 24 VAC COMM C Com NOTE 1 Remove DE Connection To Enable DEHUM Input A98295 Fig 34 Thermidistat Connection NOTE Furnace combustion air and vent pipe connections are sized for 2 in pipe Any pipe size change should be made outside furnace casing in vertical pipe See Fig 35 This allows proper drainage of vent condensate Combustion air and vent pipes must terminate together in same atmosphere pressure zone either through roof or sidewall roof termination preferred using accessory termination kit See Table 5 for required clearances Furnace combustion air and vent pipe connections must be attached as shown in Fig 37 Combustion air intake plug fitting and inducer h
51. d or combustion air opening From service regulator vent electric and gas meters and relief equipment 4 Above grade when adjacent to public walkway Horizontal distance T 18 in above roof surface in Canada 36 in to electric meter in Canada only NOTES 1 If installing 2 adjacent 355MAV furnaces refer to Multiventing and Vent Terminations section for proper vent configurations 2 When locating combustion air and vent terminations consideration must begiven 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 vent appliances intake unless otherwise specified by manufacturer Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code the current edition of the National Fuel Gas Code and the vent or liner manufacturer s installation instructions Care must be taken to prevent the exhaust gases from one appliance from conta
52. d 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 PROCEDURE 4 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 Guidelines 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 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 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 barri
53. e and a 12 in minimum offset pipe section is recommended as shown in Fig 37 to reduce excessive droplets from exiting vent pipe outlet I 12 MIN 305mm 12 MIN 305mm lt i VENT PIPE sn VENT PIPE a COMBUSTION AIR PIPE COMBUSTION AIR PIPE HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL Y A COMBUSTION AIR PIPE p VENT PIPE lt COMBUSTION AIR PIPE NU aa 12 MIN uk SOLID VENT PIPE VERTICAL TO ROOF VERTICAL TO SIDEWALL NOTE A 12 in 304 8mm minimum offset pipe section is recommended with short 5 to 8 ft 1 5 to 2 5M vent systems This recommendation is to reduce excessive condensate droplets A96230 Fig 37 Short Vent 5 to 8 ft System 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 allowed for each pipe 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 Table 7 Maximum Allowable Pipe Length ft TERMINATION PIPE DIA NUMBER OF
54. e DEHUM input See Fig 33 and 34 When a dehumidify demand exists the furnace control reduces the blower airflow by 21 percent to 315 CFM per ton during continuous fan or cooling operation PROCEDURE 9 DIRECT VENTING The 355MAV furnaces require a dedicated one 355MAV furnace only direct vent system In a direct vent system all air for combustion is taken directly from outside atmosphere and all flue products are discharged to outside atmosphere A Removal of Existing Furnaces from Common Vent Systems If furnace being replaced was connected to a common vent system with other appliances the following steps shall be followed with each appliance connected to the venting system placed in operation while any other appliances connected to the venting system are not in operation 1 Seal any unused openings in the venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 or 24 the CAN CGA B149 Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 If practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as ran
55. e energized 3 Main blower motor operates for 20 sec at low speed operates for 20 sec at high speed then turns off 4 After component operation test is completed 1 or more fault codes 11 22 41 or 42 will flash See service label on back of main furnace door for explanation of fault codes NOTE To repeat component test turn setup switch SW 6 to OFF and then back to ON After component test perform the following 1 Release blower panel access door switch and turn setup switch SW 6 to OFF position 2 If applicable replace blower access panel and check LED status by removing plug in blower access panel 3 Reinstall main furnace door if all LEDs are off indicating furnace is ready to operate when a signal from thermostat is received PROCEDURE 9 BYPASS HUMIDIFIER MODE When setup switch SW 3 BPH is in ON position RPM calculated for low heat is multiplied by 1 15 for all furnace model sizes This compensates for increased return air temperature caused by bypassed air supply PROCEDURE 10 DEHUMIDIFICATION MODE A dehumidification input is provided via a 1 4 in male quick connect terminal labeled DEHUM located next to the transformer secondary connections When there is a dehumidify demand the DEHUM input is activated which means 24 vac signal is removed from the DEHUM input terminal In other words the DEHUM input logic is reversed the DEHUM input is turned ON when no dehumidify demand exists and is turned OFF when demand exis
56. eat gas valve regulators See Fig 56 c Move setup switch SW 2 on control center to ON position See Fig 31 This keeps furnace locked in low heat operation d Jumper R and W W1 thermostat connections on control center to start furnace e Turn low heat adjusting screw 5 64 hex Allen wrench counterclockwise out to decrease input rate or clockwise in to increase input rate 51 Table 13 Model 355MAV Orifice Size and Manifold Pressure for Correct Input Tabulated Data Based on 20 000 Btuh High Heat 13 000 Btuh Low Heat per Burner Derated 2 Percent for Each 1000 ft Above Sea Level NL 0 66 FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold no Pressure no Pressure no Pressure no Pressure no Pressure 3 4 1 4 3214 NH TEEN ee m T FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold no Pressure no Pressure no Pressure no Pressure no Pressure n cond to 3000 a Fe 2000 to e e FT BTU CU FT Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold no Pressure no Pressure no Pressure no Pressure no Pressure 3001 to 4000 Orifice numbers 45 are factory installed 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 U S A and Canad
57. ed 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 connection by splicing to small diameter tube factory supplied in loose parts bag 3 Connect collector box pressure tube green label to pressure 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 Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommendations and procedures PROCEDURE 4 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 Z 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 rem
58. ensate 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 condensate 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 corrosive nature of this condensate a condensate pH neutralizing filter may be desired Check with local authorities to determine if a pH neutralizer is required A96128 A93056 Fig 45 Concentric Vent and Combustion Air Roof Termination Dimension A is Touching or 2 in Maximum Separation B 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 All 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 siphonin
59. er is recommended 20 COMBUSTION AIR INTAKE NON DIRECT VENT 1 PIPE APPLICATION COMBUSTION AIR PIPE DIRECT VENT 2 PIPE ul APPLICATION ALL SIZES F _ I 3 IN MINIMUM CLEARANCE TO a Len COMBUSTION AIR INTAKE IS REQUIRED as NON DIRECT VENT 1 PIPE L jn gt in l Ta il ANGLE E IRON OR m EQUIVALENT ALTERNATE SUPPORT LOCATION 4 IN 102mm MIN 8 IN 208mm MAX B zi A ROD LOCATION USING DIM LOC 13 46 IN 21mm MAX PLE ATORS m SEE DIMENSIONAL 8 8 IN HEX NUT A B ALTERNATE SUPPORT WG FOR amp WASHER 4 LOCATION FROM BACK LOCATIONS REQD PER ROD NOTES 1 A 1 In 25mm clearance minimum between A PREFERRED ROD LOCATION top of furnace and combustible material B ALTERNATE ROD LOCATION 2 The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage 3 For non direct vent 1 pipe application bottom side combustion air entry cannot be used when furnace is installed with hangers as shown A93304 Fig 22 Crawlspace Horizontal Application 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 B Ductwork Acoustical Treatment Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first bra
60. er on delay The blower starts 60 sec after flame sense if cycle started in low heat or 35 sec after flame sense if cycle started in high heat NOTE The blower starts at approximately 400 500 RPM After 20 sec the motor is turned off for 1 10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system The microprocessor then determines blower RPM required to provide proper airflow for heating mode 8 Electronic Air Cleaner The EAC 1 terminal is energized whenever the blower operates 9 Blower off delay When thermostat is satisfied the R W W1 signal is terminated de energizing gas valve stopping gas flow to burners and HUM terminal is de energized The blower reduces its speed to low heat RPM The blower and EAC remain operating 90 135 180 or 225 sec depending on blower off time selection The furnace is factory set for a 90 sec blower off delay 10 Post purge tThe inducer continues operating for 15 sec after gas valve is de energized PROCEDURE 3 HEATING MODE TWO STAGE The control center provides 2 stage heating using a single stage thermostat The control center maximizes comfort while optimizing efficiency to meet the demands of conditioned area when a thermostat R W W1 signal is received If thermostat control over furnace staging is desired a 2 stage thermostat can be used When control center receives a thermostat R W W1 and R W2 signal high heat is energized and when a
61. eriod is completed 3 Ignitor warm up At end of prepurge period the hot surface ignitor HSI is energized for a 17 sec HSI warm up period 4 Ignition sequence After HSI ignitor warm up period is completed the gas valve opens permitting gas flow to burners where it is ignited After 5 sec the HSI is de energized and a 2 sec flame sensing period begins NOTE The initial heat mode after 115 v or 24 v power interruption will be LOW HEAT Low heat remains energized for 16 minutes before high heat is initiated providing thermostat is still calling for heat After initial cycle the microprocessor evaluates the length of low and high heat operating times and calculates optimum length of low and high heat for next heat cycle This accommodates the heat load requirement seen as a result of thermostat operating time 5 Flame sensing When burner flame is sensed the control center holds gas valve open and begins blower on delay period NOTE Ignition sequence repeats 3 additional times before a lockout occurs Lockout automatically resets after 3 hr or can be manually reset by turning 115 v or 24 v power off not at thermostat for 3 sec minimum then turning on again 6 Inducer speed operation If cycle starts in low heat inducer speed reduces slightly after flame sense If cycle starts in high heat inducer speed increases 15 sec after flame sense The reduction in speed in low heat is to optimize combustion for maximum efficiency 7 Blow
62. ervice 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 ungrounded objects etc If you touch ungrounded objects firmly touch a clean unpainted metal surface again before touching control or wires 5 Use this procedure for installed and uninstalled ungrounded furnaces Before removing a new control from its container discharge your body s charge to ground If the control is to be installed in a furnace follow items 1 through 4 before bringing the control or yourself in contact with the furnace Put all used and new controls into containers before touching ungrounded objects An ESD service kit available from commercial sources may also be used to prevent ESD damage APPLICATIONS PROCEDURE 1 GENERAL Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig 1 All drain and pressure tubes are connected as shown in Fig 5 See appropriate application instructions for these procedures b PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK INDUCER HOUSING MOLDED DRAIN TUBE BEHIND COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE GREEN at FIELD IN
63. et furnace run for 3 minutes in low heat operation 7 rm m me Measure time in sec for gas meter to complete 1 revolution Note reading k Refer to Table 15 for cubic ft of gas per hr l Multiply gas rate cu ft hr by heating value Btu cu ft ON OFF LOW FIRE SWITCH ADJUSTMENT ALLEN SCREW UNDER CAP HIGH FIRE ADJUSTMENT ALLEN SCREW INLET UNDER CAP PRESSURE TAP BURNER ENCLOSURE REFERENCE PRESSURE TAP MANIFOLD PRESSURE TAP A97386 Fig 56 Redundant Automatic Gas Valve x BURNER ORIFICE x A93059 Fig 57 Burner Orifice m Move setup switch SW 2 to OFF position and jumper R and W2 thermostat connections See Fig 31 This keeps furnace locked in high heat operation Repeat items h through k 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 15 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
64. g of the equipment s drain See Fig 49 for example of possible field drain attachment using 1 2 in CPVC or PVC tee for vent and A C or humidifier drain connection Z CAUTION Unit must 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 15 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 N WARNING Caution should be taken to prevent draining where slippery conditions may cause personal injuries Excessive condensate draining may cause saturated soil conditions which may result in damage to plants C Condensation 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 120 v and 40 F self regulating shielded and waterproof heat tape See Installation Instructions supplied with accessory or heat tape manufacturer s recommendations s A93057 Fig 46 Concentric Vent and Combustion Air Side Termination Dimension A is Touching or 2 in Maximum Separation A96129 Fig 47 Sidewall Terminatio
65. ge hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 27 i o FUSED DISCONNECT SWITCH WHEN REQD ore yo WW1 Com we S SEC 2 SEC peru AC AND CF IC AND CF SELECT CHART AC CF SELECT CHART 1200 CFM IDEFAULTIDEFAULT 1 1 2 600 1400 TON CFM CFM Fut OFF DELAY SELECTION CHART TO 115 VAC FIELD DISCONNECT SCHEMATIC DIAGRAM rh ERUPMENT GROUND NATURAL GAS amp PROPANE DC OWEI SW 4 EMER HEAT B2 mi Sro m o mco 2 1600 TON CFM 2 1 2 2000 TON CFM ME COMP TEST EE o gt m BLOWER OFF DELA PLO HSI dire 2S 88 mm EAC EAC 2 P1 H 115VAC i P2 TRAN 24VAC SE C2 AIR CON
66. her using instructions in kit 4 Slide assembled kit with rain shield REMOVED through hole Roof terminations Locate assembly through roof to appropriate height as shown in Fig 40 Sidewall terminations Locate assembly through sidewall with rain shield positioned no more than 1 in from wall as shown in Fig 41 NOTE Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole 5 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping 6 Check required dimensions as shown in Fig 40 or 41 D 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 furnaces are vented near each other 2 vent terminations may be installed as shown in Fig 44 45 46 47 or 48 but the 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 44 45 46 47 and 48 represents distance between pipes or rain shields as touching or 2 in maximum separation PROCEDURE 10 CONDENSATE DRAIN A General Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applies Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications Cond
67. hole filler cap factory supplied in loose parts bag in unused combustion air pipe casing hole 31 Table 7 Maximum Allowable Pipe Length ft Continued TERMINATION PIPE DIA NUMBER OF 90 ELBOWS ALTITUDE FT UNIT SIZE WS ur sw TYPE us 042040 2 Pipe or 2 in ee Em 2 Pipe or Zin Concentric ns 042080 mesm ae gt 18 1 8 NA mu ws 060080 Concentric 2 Pipe or 2n Concentric Concentric TERMINATION PIPE DIA NUMBER OF 90 ELBOWS ALTITUDE FT UNIT SIZE 3 Ameen vwrsze TUTO ay an 2 Pipe or Zin Concentric me 2 Pipe or 2in Concentric 042080 2 Pipe or 2dn 060080 Concentric wa 2 Pipe or 2 in Concentric Concentric TERMINATION PIPE DIA NUMBER OF 90 ELBOWS ALTITUDE FT UNIT SIZE Ameen ours TON QN wa Z Pipe or Zin Concentric m 2 Pipe or 2dn Concentric i 042080 2 Pipe or Zin 060080 Concentric Pasa is L2 E31 24 232323 Concentie TERMINATION PIPE DIA NUMBER OF 90 ELBOWS ALTITUDE FT UNIT SIZE oe ud IN awan Z Pipe or in m 2 Pipe or 2dn Concentric 040080 2 Pipe or Zin 060080 Concentric uos ewar e e 2 e u Le Lu Concenizie NOTE A 2 in diameter pipe must be used within the furnace casing Make all pipe diameter transitions outside furnace casing See notes at end of table g 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 com
68. ions DOWNFLOW HORIZONTAL MINIMUM INCHES CLEARANCE TO This furnace is approved for UPFLOW DOWNFLOW and COMBUSTIBLE CONSTRUCTION Renn Peels ALL POSITIONS Clearance arrows Mimimum front clearance for service 30 inches do not change with 762mm furnace orientation DOWNFLOW POSITIONS OP PLENUM T For installation on combustible floors only when installed on special base No KGASBO201 ALL Coil Assembly Part No CD5 or CK5 or Coil Casing Part No KCAKC HORIZONTAL POSITIONS Clearance shown is for air inlet and air outlet end Line contact is permissible only between lines formed by intersections of top and two sides of furnace jacket and building joists studs or framing 120 size Furnace require 1 inch bottom clearance to combustible materials FE BOTTOM 325400 201 REV A 0 LT TOP Clearance in inches t9 Vent clearance to combustibles 0 A99103 Fig 3 Clearances to Combustibles INSTALLER PACKET INCLUDES Installation Startup and Operating Instructions Service and Maintenance Instructions User s Information Manual Warranty Certificate Loose Parts Bag includes Pressure tube extension Collector Box or condensate trap extension tube Inducer housing drain tube 1 2 in CPVC street elbow Drain tube coupling Drain tube coupling grommet Vent and combustion air pipe support Combustion air pipe perforated disk assembly Condensate trap hole filler plug Vent and combustion a
69. ir intake hole filler plug 1 1 1 2 1 il 2 1 3 2 Before installing the furnace in Canada refer to the current edition of the NSCNGPIC Contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario Canada M9W 1R3 Installation must comply with regulations of serving gas supplier and local building heating plumbing or other codes in effect in the area in which installation is made In absence of local codes installation must comply with the NFGC in the United States and the NSCNGPIC in Canada These instructions cover minimum requirements for a safe installation 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 pace with changing residential construction practices We require these instructions as a minimum for a safe installation ER BLOWER SHELF FURNACE DOOR CONDENSATE CONDENSATE TRAR FURNACE TRAP INSIDE FURNACE DOOR FURNACE SIDE l i U ei Te i ic r 4 fg 124mm 102mm 4 i i 1 4 15 a Saat r sH i o s 2 T jimm 44 146mm L dH 102mm LX DE n r a FIELD 1 FIELD Aon DRAIN 38mm DRAIN ALTERNATE DRAIN CONN CONN TUBE LOCATION CONDENSATE TARP SIDE VIEW FRONT VIEW END VIEW FRONT VIEW DRAIN TUBE LOCATION DOWNFLOW AND ALTERNAT
70. irements as stated in Table 5 b Termination kit should be positioned where vent vapors will not damage plants shrubs or air conditioning equipment c Termination kit should be positioned so that it will not be affected by wind eddy such as inside building corners or allow recirculation of flue gases airborne leaves or light snow 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 properly cut vent pipe Coupling must be positioned so bracket will mount as shown in Fig 39 For applications using combustion air pipe option indicated by dashed lines in Fig 39 install 90 street elbow into 90 elbow making U fitting A 180 U fitting may be used Sidewall terminations Install bracket as shown in Fig 42 or 43 For applications using vent pipe option indicated by dashed lines in Fig 42 rotate vent elbow 90 from position shown in Fig 42 4 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping 5 Check required dimensions as shown in Fig 39 42 or 43 CONCENTRIC VENT AIR TERMINATION KIT 1 Determine location for termi
71. it breaks off Be careful of sharp edges See Fig 21 A WARNING Do not bend duct flanges inward as shown in Fig 21 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 21 PROCEDURE 3 INSTALLATION IN HORIZONTAL APPLICATIONS These furnaces can be installed horizontally in either horizontal left or right discharge position In a crawlspace the furnace can either be hung from floor joist or installed on suitable blocks or pad Furnace can be suspended from each corner by hanger bolts and angle iron supports See Fig 22 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 lock washers and 3 8 in nuts on hanger rods as shown in Fig 22 Dimples are provided for hole locations See Fig 2 19 Bae ee Ne FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM 222222432 42210222 H amp FLOOR OPENING A96284 Fig 20 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor PERFORATED DISCHARGE DUCT FLANGE NO lt YES 11 LJ I I I 210 DEG MIN YES A93029 Fig 21 Duct Flanges AN CAUTION The entire length of furnace MUST be supporte
72. l Left Tube Configuration 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 A00215 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 2 Inducer Housing Drain Tube a Remove and discard LOWER molded inducer housing drain tube which was previously connected to condensate 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 the condensate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage 3 Relief Port Tube a Extend collector box tube green label which was previously connected to the condensate trap by splicing to small diameter tube factory supplied in loose parts bag b Route extended collector box pressure tube to relief port connection on the condensate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage C Condensate Trap Field Drain Attachments Refer to Condensate Drain section for recommendations and procedures D Pressure Switch Tubing The LOW
73. leads across thermostat subbase R W 56 Table 15 Gas Rate Cu Ft Hr SECONDS SIZE OF TEST DIAL SECONDS SIZE OF DIAL FOR 1 1 2 5 FOR 1 REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION a Ft o 7 1800 85 au s s r 8 u Lo 600 m 9 a p Eum 8 s 2 1 359 s 6 2 r 58 62 24 310 305 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 SW 2 to OFF position and replace thermostat on subbase PROCEDURE 6 CHECK SAFETY CONTROLS A Check Primary Limit Control This control shuts off the combustion 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 2 As soon as limit control has shut off burners a 33 fault code will appear on control center 3 The return air opening should be 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 supply or motor failure If the limit control does not function during this test the
74. minating the combustion air of other gas appliances N 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 Table 6 Approved Combustion Air and Vent Pipe Fitting and Cement Materials SPECIFICATION MARKED ON MATERIAL MATERIAL PIPE FITTINGS SOLVENT CEMENT AND PRIMERS DESCRIPTION D1527 Schedule 40 D1785 PVC Schedule 40 Cement D2241 PVC SDR 21 amp SDR 26 D2466 PVC Schedule 40 D2468 Schedule 40 Cement PVC CPVC CPVC F493 For CPVC For CPVC F628 Cellular Core DWV at Schedule 40 IPS sizes F656 For PV Primer For PVC F891 PVC Cellular Core Schedule 40 amp DWV Fittings Fittings 5 a lt Q Fittings ipe Fittings Fittings Solvent Cement a d Pipe Ea Pipe Q d ipe NOTE Select 1 vent pipe connection and NOTE Select 1 vent pipe connection and 1 combustion air pipe connection 1 combustion air pipe connection AIR COMBUSTION FLOW comBustion AIR AIR VENT VENT Oo l rar N VENT VENT i O COMBUSTION COMBUSTION AIR X AIR b pA FLOW UPFLOW DOWNFLOW COMBUSTION COMBUSTION AIR AIR VENT VENT T H a aa e
75. n installations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authorities having jurisdiction Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace See Table 4 for wire 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 control LED status indicator light will flash rapidly and furnace will NOT operate 25 Table 4 Electrical Data OPERATING MAX MIN VOLTAGE RANGE UNIT tie am WIRE AMPS t sux nex 17 108 o o 115 60 1 104 115 60 1 f 06020 _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 Length shown is a measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop Time delay type is recommended 60 127 60 127 127 127 60 127 27 ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY A93033 Fig 28 Disconnect Switch and Furnace A CAUTION Do not connect aluminum wire between disconnect switch and furnace Use only copper wire See Fig 28 N W
76. n of 12 in or Less Dimension A is Touching or 2 in Maximum Separation A96130 Fig 48 Sidewall Termination of More than 12 in Dimension A is Touching or 2 in Maximum Separation 42 OPEN STAND PIPE FOR A C OR HUMIDIFIER DRAIN TEE AT TO OPEN DRAIN A94054 Fig 49 Example of Field Drain Attachment Fold heat tape in half and wrap on itself 3 times Locate heat tape between sides of condensate trap back See Fig 50 Use wire ties to secure heat tape in place Wire ties can be positioned in notches of condensate trap sides See Fig 50 Wrap field drain pipe with remaining heat tape approximately 1 wrap per ft Q D nn When using field supplied heat tape follow heat tape manufacture s instructions for all other installation guidelines CONDENSATE TRAP WIRE TIE S HEAT TAPE 8 WRAPS MINIMUM A93036 Fig 50 Condensate Trap Heat Tape SEQUENCE OF OPERATION N CAUTION Furnace control must be grounded for proper operation or control will lock out Control is grounded through green wire routed to gas valve and burner box screw Using schematic diagram see Fig 30 follow sequence of operation through different modes This furnace has a new control system Read and follow wiring diagra carefully NOTE If 115 v power supply to furnace or blower access panel switch is interrupted during a call for he
77. nation 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 5 Table 8 Maximum Allowable Exposed Vent Pipe Length ft With and Without Insulationin Winter Design Temperature Ambient UNIT WINTER DESIGN MAXIMUM PIPE 2 ee SIZE TEMPERATURE DIAMETER CF AN 1 2 or THICKER ee ES 042040 042060 042080 060080 060100 t2 Nin t2 t N bis mu 1 N t2 t I D t2 060120 Y 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 8 T Insulation thickness based on R value of 3 5 ft F hr Btu in b Termination kit should be positioned where vent vapors will not damage plants shrubs or air conditioning equipment c Termination kit should be positioned so it will not be affected by wind eddy such as inside building comers or that may allow recirculation of flue gases airborne leaves or light snow 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 components toget
78. nch 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 accessories 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 combustible material supply air duct attachment must ONLY be connected to an accessory subbase or factory approved air conditioning coil casing 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 HORIZONTAL FURNACES Connect supply air duct to supply air opening on furnace The supply air duct attachment must ONLY be connec
79. nstalled 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 5 or 6 or tube routing label on main furnace door to check for proper connections 2 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 5 or 6 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 recommendations and procedures PROCEDURE 3 DOWNFLOW APPLICATIONS A downflow furnace application is where furnace blower is located above combustion and controls section of furnace and conditioned air is discharged downwards 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 L TRAP INDUCER HOUSING DRAIN TUBE VIOLET 4 A94215 Fig 7 Downflow Tube Configuration Left Hand Trap Installation A Condensate Trap Location The condensate tra
80. onditioning tonnage To set the desired cooling airflow 1 Remove main furnace door and blower access panel 2 Locate A C setup switches on control center See Fig 31 3 Determine air conditioning tonnage used 4 Use Table 9 or wiring schematic to determine proper setup position of A C switches See Fig 30 and 53 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 panel NOTE EAC 1 terminal is energized whenever blower operates HUM terminal is only energized when gas valve is energized B Continuous Fan CF Setup Switches The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode This setup feature allows continuous fan airflow to be adjusted To set desired continuous fan airflow 1 Remove main furnace door and blower access panel 2 Locate CF setup switches on control center See Fig 31 3 Determine desired continuous fan airflow 4 Use Table 10 or wiring schematic to determine proper setup position of CF switches See Fig 30 and 54 48 Table 9 Air Conditioning A C Airflow Switch Position AIR A C SETUP CONDITIONER CFM AIRFLOW SWITCH POSITION ALLOWABLE FURNACE MODEL SETUP TONS A CA A C 2 042040 042060 042080 060080 060100 060120 1200 or 3 Tons 3 Tons 3 Tons 5 Tons 5 Tons 5 Tons Default 2000 OFF 1200 CFM 2000 CFM 1200 CFM 2000 CFM 2000 CFM 200
81. only with a 3 AMP fuse Inductor used on all 060 or 20 airflow units Blower on delay gas heating 60 seconds low heat 35 seconds high heat cooling or heat pump 2 seconds Blower off delay gas heating 90 135 180 or 225 seconds cooling or heat pump 90 seconds Ignition lockout will occur after four consecutive unsuccessful trials for ignition Control will auto reset after three hours Factory connected when LGPS not used 322296 101 REV E ing Diagram A00350 EAC ELECTRONIC AIR CLEANER TERMINALS 115 VAC 1 AMP MAX HOT SURFACE IGNITOR CONNECTOR FAN CF SETUP SWITCHES ail m a m CONNECTOR Fig 31 Control Center a CONNECTORS o L EI nunmummmmmun sn Dip PRESSURE SWITCH IZ Ts CONNECTOR z MAIN BLOWER 2 J HUM HUMIDIFIER CONTROL WIRE W TERMINAL CONNECTOR 24 VAC 0 5 AMP MAX TO 24vTHERMOSTAT a le TERMINALS o g DEHUMIDIFY ENABLE DE TRANSFORMER els 24 V CONNECTORS New DEHUMIDIFIER DEHUM MI CONNECTOR J 3 AMP FUSE STATUS AND DIAGNOSTIC OoOO LED LIGHTS NT AP ar CONDITIONING CONTINUOUS IBBBBBERE A A C SETUP SWITCH SETUP SWITCHES
82. ontinuous fan CFM has been selected 2 While blower is operating in either high heat or cooling blower pulse width to blower motor is frozen when blower RPM is within 10 percent of calculated blower RPM for 5 sec START UP PROCEDURES PROCEDURE 1 GENERAL 1 The furnace must have a 115 v power supply properly connected and grounded NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control status indicator light will flash rapidly and the furnace will not operate 2 Thermostat wire connections at terminals R W W1 G and Y Y2 must be made at 24 v terminal block on control center 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 24 v electrical circuit to furnace N CAUTION These furnaces are equipped with a manual reset limit switch in burner box This switch opens if an overheat condition rollout occurs in burner enclosure Correct inadequate combustion air supply or improper venting condition and reset switch DO NOT jumper this switch Before operating furnace check each manual reset switch for continuity If necessary press button to reset switch PROCEDURE 2 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 This furnace will provide 400 CFM per selected air c
83. operly installed Cycle test furnace with room thermostat Check operation of accessories per manufacturer s instructions Review User s Guide with owner Leave literature packet near furnace 58 CHECKLIST INSTALLATION Load Calculation Condensate Drain Unit Level or Pitched Forward Heating Load Btuh Internal Tubing Connections Freeof Kinks and Traps Cooling Load Btuh External Drain Connection Leak tight and Sloped Furnace Model Selection Condensate Trap Primed before Start Up Heat Tape Installed if Required COMBUSTION AND VENT PIPING CHECKLIST START UP Terminal Location Roof or Sidewall Termination Kit 2 Pipe or Concentric Combustion Air Pipe Length Combustion Air Elbow Quantity Gas Input Rate Set Within 2 percent of RatingPlate Vent Pipe Elbow Quantity Temperature Rise Adjusted Pipe Diameter Determined from Sizing Table Pipe Sloped to Furnace Pipe Insulation Thermostat Anticipator Over Ceilings Anticipator Setting Adjusted or Low Ambient Exposed Pipes Cycle Rate 3 Cycles per Hr Selected Safety Controls Check Operaton Primary Limit Pressure Switch 59 2002 CAC BDP 7310 W Morris St Indianapolis IN 46231 355m4011 60 Book Tab 1 6 Catalog No 5335 518
84. or wire lengths over 100 ft use AWG No 16 wire NOTE For 2 speed applications refer to Sequence of Operation section C Accessories 1 Electronic Air Cleaner EAC The control center EAC terminals are energized with 115v 1 5 amp maximum during blower operation a Two extension leads are connected to the control center EAC terminals to assist field installation of an EAC See Fig 31 To use these leads proceed with the following 1 Strip EAC power lead insulation approximately 1 4 in 2 Insert stripped end into factory supplied black lead s butt connector and crimp to secure 3 Strip EAC neutral lead insulation approximately 1 4 in 4 Insert stripped end into factory supplied white leads s butt connector and crimp to secure ALTERNATE FIELD LOCATION FACTORY cs INSTALLED T N LOCATION A00212 Fig 29 Relocating J Box NOTE If desired cut butt connectors off factory leads and strip insulation approximately 1 4 in and use field supplied wire nuts to connect b An alternate method to attach EAC lead to control center is the following procedure 1 Remove 2 screws securing the control box to furnace blower shelf 2 Remove and discard 2 factory supplied leads from control center EAC terminals 3 Strip EAC power leads insulation approximately 1 8 in NOTE The control center EAC terminals are sized for 12 gage maximum solid or stranded wire 4 Route EAC leads through right hand wi
85. ose parts bag in unused combustion air pipe casing hole N 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 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 Ac QUAS ON ee m um Sun ue pu ae ROOF ig MAXIMUM OS lt M T BRACKET cS ene a s 5 9 o v VERTICAL SEPARATION lt BETWEEN COMBUSTION VENT AIR AND VENT 8 3 4 FOR 3 KIT lt 6 3 4 FOR 2 KIT s n pu NEU ou SES ANTICIPATED SNOW LEVEL lt gt MAXIMUM OF 24 IN ABOVE ROOF f WB gt 1 gt O o o zi o z A W A87224 Fig 39 Roof Termination Preferred 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 generous layer of cement primer to pipe fitting socket and end of pipe to insertion mark Quickly apply approved cement to end of pi
86. ousing alternate vent cap may need to be relocated in some applications NOTE Slope combustion air and vent pipes a minimum of 1 4 in per linear ft with no sags between hangers N 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 warm humid space An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion air and vent pipes Each furnace must have its own set of combustion air and vent pipes and be terminated individually as shown in Fig 39 40 44 and 45 30 FURNACE NOT IN HORIZONTAL SECTION PIPE DIAMETER TRANSITION IN VERTICAL SECTION A93034 Fig 35 Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration Table 5 Combustion Air and Vent Pipe Termination Clearances LOCATION CLEARANCE FT Above grade level or aboveanticipated snow depth Dryer Water heater vent From plumbing vent stack 1 1 From any mechanical fresh air intake See note 4 For furnaces with an input capacity of100 000 Btuh or less from any non mechanical air supply windows or doorswhich can be opened or combustion air opening For furnaces with an input capacity greaterthan 100 000 Btuh or less from any non mechanical air supply windows or doorswhich can be opene
87. oved from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 or 9 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 4 Install casing hole filler cap into blower shelf hole where trap was removed 5 Fill unused condensate trap casing holes with plastic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 9 or tube routing label on main furnace door to check for proper connections 1 Collector Box Drain Tube COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED PLUG AUXILIARY J BOX CONDENSATE TRAP ZN COLLECTOR BOX TUBE GREEN INDUCER HOUSING E COLLECTOR DRAIN TUBE VIOLET BOX EXTENSION DRAIN TUBE COLLECTOR BOX COLLECTOR BOX DRAIN TUBE BLUE EXTENSION TUBE DRAIN TUBE COUPLING COLLECTOR BOX TUBE PINK RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040 060 AND 080 HEATING INPUT FURNACES Fig 9 Horizonta
88. p must be removed from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 7 or 8 To relocate condensate trap from the blower shelf to desired location perform the following 0 COLLECTOR BOX TUBE GREEN PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX 14 TUBE PINK O Y COLLECTOR BOX s DRAIN TUBE BLUE EN el amp WHITE STRIPED COLLECTOR BOX EXTENSION TUBE Pr ee HOUSING yd le DRAIN TUBE IN VIOLET 1 CONDENSATE TRAP HD COLLECTOR BOX EXTENSION DRAIN TUBE DRAIN TUBE COUPLING A94216 Fig 8 Downflow Tube Configuration Right Hand Trap Installation Remove 3 tubes connected to condensate trap Remove trap from blower shelf by gently pushing tabs inward and rotating trap Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed Install casing hole filler cap into blower shelf hole where trap was removed Un UU N e Fill unused condenstate trap casing holes with placstic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 7 or 8 or tube routing label on main furnace door to check for proper connections Relocate tubes as described below 1 Collector Box Drain T
89. pe and fitting socket over primer Apply cement in a light uniform coat on inside 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 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 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 side wall C 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 39 40 41 42 and 43 Four termination kits are available 1 The 2 in termination bracket kit is for 1 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 3 in and 4 in diameter 2 pipe termination systems 3 The 2 in concentric vent air termination kit is for 1
90. r 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 27 Heating and Cooling Application Wiring Diagram PROCEDURE 8 ELECTRICAL CONNECTIONS See Fig 27 for field wiring diagram showing typical field 115 v and 24 v wiring Check all factory and field electrical connections for tightness N WARNING Blower access panel door switch opens 115 v power to control center 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 N CAUTION Furnace control must be grounded for proper operation or control will lock out Control is grounded through green wire routed to gas valve and burner box screw A 115 V Wiring Before proceeding with electrical connections make certain that voltage frequency and phase correspond to that specified on the furnace rating plate Also check to be sure that service provided by utility 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 Canadia
91. r proper draining may not occur The condensate trap has 2 internal chambers which can ONLY be primed by pouring water into the inducer drain side of condensate trap Remove upper inducer housing drain connection cap See Fig 54 Connect field supplied 1 2 in ID tube to upper inducer housing drain connection Insert field supplied funnel into tube Pour 1 quart of water into funnel tube Water should run through inducer housing overfill condensate trap and flow into open field drain See Fig 55 5 Remove funnel and tube from inducer housing and replace drain connection cap and clamp PROCEDURE 4 PURGE GAS LINES If not previously done purge the lines after all connections have been made and check for leaks L nM A WARNING Never purge a gas line into a combustion chamber Never use matches candles flame or other sources of ignition for the purpose of checking leakage Use a soap and water solution to check for leakage Failure to follow this warning could result in fire explosion personal injury or death PROCEDURE 5 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 A99119 Fig 55 Filling Condensate
92. re grommet 5 Insert EAC stripped leads into control center EAC terminals by depressing terminal s arm with a screwdriver or finger See Fig 32 6 Reinstall control box to furnace blower shelf using 2 screws removed earlier 2 Humidifier HUM Screw terminals HUM and Com are provided for 24 v humidifier connection See Fig 30 The HUM terminal is energized with 24 v 0 5 amp maximum after inducer motor prepurge period NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation 3 Dehumidification DEHUM A dehumidification input is provided via a 1 4 in male quick connect labeled DEHUM located next to the transformer secondary connections When there is a dehumidify demand the DEHUM input is activated which means 24 vac signal is removed from the DEHUM input terminal In other words the DEHUM input logic is reversed the DEHUM input is turned ON when no dehumidify demand exists and is turned OFF when demand exists This logic reversal has come about from historical use of a standard humidistat to do dehumidification since the contacts open on high humidity thus removing the 24 v signal to initiate dehumidification The DEHUM output on the thermidistat control or the humidistat output is connected directly to the DEHUM terminal on the furnace control In addition the DE jumper located next to the DEHUM terminal must be removed to enable th
93. re no Pressure no Pressure no Pressure 34 14 3214 QUE 3414 44 P 44 3 7116 aso as ame as sane 332 4 sana a 3325 SPECIFIC GRAVITY OF NATURAL GAS ee ae a e no Pressure no Pressure no Pressure no Pressure no Pressure 800 T 825 to 850 6000 S 900 25 4n 50 U S A and Canada S 3 s s O Zz S lt n gt 5 5 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS JN no Pressure no Pressure no Pressure no Pressure no Pressure Orifice numbers 45 are factory installed U S A Only 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 N CAUTION DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of burners and heat exchangers causing failures See Fig 57 UNITED STATES At altitudes above 2000 ft this furnace has been approved for a 2 percent derate for each 1000 ft above sea level See Example and Table 14 for derate multiplier factor 53 Table 13 Model 355MAV Orifice Size and Manifold Pressure for Correct Input Continued Tabulated Data Based on 20 000 Btuh High Hea
94. rge Post purge does NOT occur The inducer stops immediately PROCEDURE 5 COOLING MODE A Single Speed Applications When thermostat calls for cooling the R G and R Y Y2 circuits close 1 Cooling unit The cooling unit starts when thermostat R Y signal is received 2 Blower on The control center starts blower immediately when it receives an R Y Y2 and R G signal The blower starts at approximately 400 500 RPM After 20 sec the blower is turned off for 1 10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system The microprocessor then determines blower RPM required to provide selected cooling airflow NOTE In cooling mode the microprocessor adjusts blower RPM to operate at 400 CFM per ton as selected on A C setup switches Airflow will be reduced to 315 CFM per ton when a dehumidification demand exists See Air Conditioning Setup Switches section There is also a chart on wiring diagram See Fig 30 NOTE If Y Y2 thermostat lead is not connected to furnace control center blower motor operates in continuous fan speed and indoor coil freeze up may occur 3 Electronic Air Cleaner The EAC 1 terminal is energized whenever blower operates 4 Cooling unit The cooling unit stops when thermostat R Y signal is terminated 5 Blower off delay When thermostat is satisfied the R Y Y2 and R G signals are terminated and blower remains operating for 90 sec The blower airflow will drop by 2
95. rom exiting the vent pipe See Fig 10 or 32 PROCEDURE 5 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 Z CAUTION Local codes may require a drain pan under 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 11 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 11 To relocate condensate trap from the blower shelf to desired location perform the following 1 Remove 3 tubes connected to condensate trap Remove trap from blower shelf by gently pushing tabs inward and rotating trap Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed Install casing hole filler cap into blower shelf hole where trap was removed Ak D Fill unused condensate trap casing holes with plastic filler caps factory supplied in loose parts bag
96. s 13 Condensate Trap Location m E 13 Condensate Trap Tubing Condensate Trap Field Drain Attachment ote ere teen nent vei verses res re e ee eU Rete Terrae urea een 14 Pressure Switch Tubing ce EM Condensate Trap Freeze Protection Construct a Working Platform Form II 355M 40 11 Cancels New Printed in U S A 03 02 Catalog No 5335 518 LOCATION uuu css css sass ds na A N EER AEE EEEO SR SPTE E EA A EE ENEE REEE EEEN te dent ares Lens a remet entente 15 General Low Fire Only Installation zeit e ER a E ATTE E te dei A a na 17 Furnace Location Relative to Cooling Equipment ss sscsssssncssesvassssascsessssesvesebsvsdcesseosensessetbezssnacensesvestoniestescotsaaossesdogtee NSN NET EAEE CE A E Eaa 17 Hazatdous Locations 2 noon oaa ni a a a a a I M EIU O 18 INSTALLATION SL rr SSS E EE EERE EI OHIO II DERI ain eire 18 Leveline Less If Desired yas V n nmss E 18 Installation in Upflow and Downflow Applications cssscscsscsessosssessesssssessonssvaseseeseciensoesnersesseitonsecsenssndeesessunsseassabeosossecvsotonsseseedondseoseesesseasetos 18 Installation in Horizontal Applications General R quir ments s uuu e E A GNU RA EE EN V PU IN On sapa b noir ra een ree Ductwork Acoustical Treatment Supply Air Connections Return Air Connections Filter
97. s 355MAV furnace can be installed to operate in the low fire only heating mode when sized using the low fire heating capacity This is accomplished by placing setup switch SW 2 in the ON position to provide only low fire heat operation See Fig 31 and Table 11 With this setup high fire operation will not occur When the model no on the furnace rating plate is followed by an asterisk the furnace has an alternate low fire 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 16 N CAUTION The furnace can operate in the high fire mode when certain fault conditions occur The following precautions should be taken 1 Size gas piping based on the high fire input 2 Check the high fire input and adjust it per the main literature instructions NEVER assume the high fire input rate is not important for low fire only installation PROCEDURE 3 FURNACE LOCATION RELATIVE TO COOLINGEQUIPMENT 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 must 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 the damper is in full heat or full cool position PROCEDURE 4 HAZARDOUS LOCATI
98. sed SW 5 Turn switch to ON when modulating dampers are used In this MZ OFF mode main blower speed is recalculated once every minute while furnace is in low heat or continuous fan mode Turn switch to ON to initiate component test Furnace will oper ate inducer motor for 20 sec at low speed operate inducer motor SW 6 for 20 sec at high speed energize HSI for 15 sec operate blower COMP TEST for 20 sec at low speed and operate blower for 20 sec at high speed SW 1 must be in OFF position No thermostat signal can be present for component test to be initiated SW 7 and SW 8 See Table 12 Adjust switches to provide desired heating mode blower off de Blower Off Delay lay time 90 135 180 or 225 sec Table 12 Blower Off Delay Setup Switch Position DESIRED HEATING SETUP SWITCH SW 7 AND SW 8 POSITION MODE BLOWER OFF DELAY SEC Es OFF x m or on 5t NOTE If a bypass humidifier is used setup switch SW 3 BPH should be in ON position This prevents nuisance limit trips caused by the increased temperature in return air resulting from bypass NOTE If modulating dampers are used setup switch SW 5 MZ should be in ON position This allows furnace control center to compensate for modulating dampers The control re calibrates for new system static conditions once every minute while operating in low heat or continuous fan modes PROCEDURE 3 PRIME CONDENSATE TRAP WITH WATER N CAUTION Condensate trap must be PRIMED o
99. sure Switch Tubing ned Upper Collector Box and Inducer Housing Unused Drain Connections nad Condensate Trap Freeze Protection on rerrete n eR teens sag Downflow Applications aD Condensate Trap EOoGCatlon ee p iof HROU E HE UR eerte de edi ea esr HE eee rien een IUE ti MN RERO etes 9 Condensate Trap Tubing 10 Condensate Trap Field Drain Attachment 2 ccsssessessecssescessoseessessossecsetsesseesestessecsecteasseassstacsestendeessstuedsosessecssessesvadtedvessentoodeesensutsesasseeeass 11 Pressure Switch Tubing Condensate Trap Breeze Protedtiehus iu Sayaq RR On aasawa ek tae Ete veio ERE E asas quas 11 Horizontal Left Supply Air Discharge Applications sn rne eto n D nt ee Y RENNES N 11 Condensate Trap Location oce ie teer ORO IR EMI sade nte a PO YE Inda dual p ecce 11 Condensate Trap Tubing u 11 Condensate Trap Field Drain Attachments cscssccssesssssuessetoessecscepssvesssesnssosseconsnessvesactensssveussuvsessosaveseveunsastensesatsevnsvedpecvesvpsssseaeadssstendbevsetoes 12 Pressure SWitehlubiner uu um uu una a Si Qu SSS D REEL SN ADI iE 12 Condensate Trap Freeze Protecthioi eiae nter ena e IP EE EY FU e D ran a EENE oud sus sek sepa EES E Ea aT EEA EATE 12 Constructa Working Platform y ayu u SS a DRE Ci nera enu nA III 12 Horizontal Right Supply Air Discharge Application
100. t 13 000 Btuh Low Heat per Burner Derated 2 Percent for Each 1000 ft Above Sea Level ALTITUDE AVG GAS r t 165 no Pressure no Pressure no Pressure no Pressure no Pressure 3615 3314 7001 E so 47 3414 47 3515 47 3715 45 3213 45 3314 cuu ne ee hae ee no Pressure no Pressure no Pressure no Pressure no Pressure Altituds 9000 E m no Pressure no Pressure no Pressure no Pressure no Pressure 9001 t 10 000 Orifice numbers 45 are factory installed 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 yearly heat value average for local gas supply 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 Check and verify orifice size in furnace NEVER ASSUME THE ORIFICE SIZE ALWAYS CHECK AND VERIFY Turn off all other gas appliances and pilots Move setup switch SW 2 to ON position See Fig 31 This keeps furnace locked in low heat operation Jumper R to W W1 L
101. t Control 8 Electronic Air Cleaner The EAC 1 terminal is energized whenever blower operates 9 Inducer speed operation If cycle starts in low heat inducer speed reduces slightly after the flame sense If cycle starts in high heat inducer speed increases 15 sec after flame sense The reduction in speed in low heat is to optimize combustion for maximum efficiency 10 Call for heat terminated When the call for heat is satisfied the R W W1 signal is terminated de energizing gas valve stopping gas flow to burners and HUM terminal is de energized a R W W1 signal terminated with R Y Y2 and R G still present The blower changes its speed to cooling RPM b R W W1 with R Y Y2 and R G signals terminated The blower continues to operate completing a normal heating blower off delay 11 Post purge tThe inducer continues operating for 15 sec after gas valve is de energized B Two Speed Applications For details on 2 speed heat pump applications refer to Fig 52 PROCEDURE 7 CONTINUOUS FAN MODE 1 Operating with continuous fan only a Call for continuous fan The thermostat closes R G circuit b Blower on The blower starts immediately NOTE The blower starts at approximately 400 500 RPM After 20 sec the motor is turned off for 1 10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system The microprocessor then determines blower RPM required to provide proper airflow for heating
102. t be a negative pressure condition within equipment room or space Furnace may be located in a confined space without special provisions for dilution or ventilation air This furnace must be installed so electrical components are protected from water LEVEL 0 TO 1 MAX Ve MAX UPFLOW OR DOWNFLOW HORIZONTAL A93025 Fig 12 Furnace Location for Proper Condensate Drainage NOTE For proper furnace operation install furnace so that it is level or pitched forward within 1 2 in to ensure proper condensate drainage from secondary heat exchangers See Fig 12 NOTE These furnaces are designed for a minimum continuous return air temperature of 60 F or intermittent operation down to 55 F such as when used with a night setback thermostat Return air temperature must not exceed a maximum of 85 F Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Fig 13 F yfl SUT MAX 85 F DE RETURN HE AIR SWZ MIN 55 F A93042 Fig 13 Return Air Temperature Locate furnace as close to center of air distribution system as possible Locate furnace so combustion air pipe lengths are not exceeded Refer to Table 6 15 Z CAUTION If these furnaces are used during construction when adhesives sealers and or new carpets are being installed make sure all combustion and circulating air requirements are followed If operation of furna
103. ted 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 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 PROCEDURE 5 FILTER ARRANGEMENT N WARNING Never operate unit without a filter or with filter access door removed Failure to follow this warning can cause fire personal injury or death The air filter arrangement 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 pack
104. ter in ON position For high heat operation place setup switch SW 2 in OFF position and jumper R W2 on control center DO NOT forget to return setup switch to OFF position and remove R W2 jumper upon completion of testing See Fig 31 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 unit 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 restrictions causing static pressure greater than 0 5 in we d Ensure bypass humidifier switch BPH setup switch SW 3 on control center is in ON position when a bypass humidifier is used See Fig 31 for switch location e Check Troubleshooting Guide for Variable Speed 2 Stage Electronic Condensing Furnaces C Set Thermostat Heat Anticipator The thermostat heat anticipator must be set to match the amp draw of components in the R W W1 circuit Accurate amp draw measurements can be obtained at the thermostat subbase terminals R and W Fig 59 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 SW 2 to ON position See Fig 31 and connect ammeter
105. the potential for personal injury Understand these signal words DANGER WARNING CAUTION 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 INTRODUCTION The 355MAV Multipoise Condensing Gas Fired furnaces are CSA A G A and C G A certified for natural and propane gases and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A manufacturer s accessory gas conversion kit is required to convert furnace for use with propane gas These furnaces shall not be installed directly on carpeting tile or any other combustible material other than wood flooring For downflow installations a 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 the manufacturer s coil assembly Part No CDS or CK5 or when Coil Box Part No KCAKC is used The design of this furnace is not CSA A G A and C G A certified for installation in mobile homes recreational vehi
106. ts This logic reversal has come about from historical use of a standard humidistat to do dehumidification since the contacts open on high humidity thus removing the 24 v signal to initiate dehumidification J Table 10 Blower Off Delay Setup Switch SW Position DESIRED HEATING SETUP SWITCH MODE BLOWER OFF DELAY SEC 135 180 225 The DEHUM output on the thermidistat control or the humidistat output is connected directly to the DEHUM terminal on the furnace control In addition the DE jumper located next to the DEHUM terminal must be removed to enable the DEHUM input See Fig 33 and 34 When a dehumidify demand exists the furnace control reduces the blower airflow by 21 percent to 315 CFM per ton during continuous fan or cooling operation This blower speed reduction compensates for high humidity conditions during cooling operation on all furnace model sizes Reference Thermidistat Control Installation Start Up and Operating Instructions for further details PROCEDURE 11 ZONE MODE When setup switch SW 5 MZ is in ON position blower motor control is the same as above except with the following exceptions 1 While blower is operating in either low heat or continuous fan the coast down calibration is performed once a minute to update blower RPM for zone damper position changes during a given cycle unless the blower pulse width to blower motor is greater than 60 percent This prevents nuisance faults from occurring when a high c
107. ube 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 Clamp tube to prevent any condensate leakage 2 Condensate Trap Located on Right Side of Casing Install drain tube coupling factory supplied in loose parts bag into collector box drain tube blue and white striped label which was previously plugged 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 Route extended collector box drain tube directly from collector box drain to condensate trap as shown in Fig 8 Determine appropriate length and cut Connect to condensate trap 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 condensate trap c Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed d Use ind
108. ucer 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 Determine appropriate length and cut Connect tube to condensate trap Clamp tube to prevent any condensate leakage 2 Condensate Trap Located on Right Side of Casing Route inducer housing drain tube violet label directly from inducer housing to condensate trap Determine appropriate length and cut Connect tube to condensate trap 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 disconnected 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 HORIZONTAL RIGHT applications NOTE See Fig 7 or 8 or tube routing label on main furnace door to check for proper connections Relocate tubes as describ
109. ury 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 agency 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 CODES AND STANDARDS Before installing the furnace in the United States refer to the current edition of the NFGC and the NFPA 90B For copies of the NFGC and NFPA 90B contact the National Fire Protetion Association Inc Batterymarch Park Quincy MA 02269 or American Gas Association 1515 Wilson Boulevard Arlington VA 22209 E aa Hulmeig jeuoisuswigq z 5 j eoeuunj 314v 1u o51 d 9 96 Aydos eui 104 Buise9 18pIM eui 4991491 suorsueuuip esau x 8 S LCc aire 021090 cre Sfc 6t o E 001090 Urol 89 61 r l t GENERE 080090 x a a o v mun ui suoijsu uuiq SL L66V W3O 0081 e oqe slu uu uinb i moure 10 sBuiuedo ute uanga eyenbepe unsu IIA juo woyoq y 10 uuolloq eu pue epis JO uoreurquioo e Sje ut epis uloq jo esn eu sl lu epis Buis Jo esn loads 10 n1eJ 1l ejeq 1onpoJg ul ejqe AI8AI8Q 1Y ees W49 0081 e oqe siueujeuinbei moje 104 p ejDuejoe1 urge X Ap 10 PUNO ul z2 4449 0091 104 9 Bue o 1 ur 6 X p 10 punon Ul OZ W4D 002 404 q lBuelo 1 ur z X p 10 punoi ul 9 NJ 008 101

Bryant 355MAV Furnace User Manual

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