PLUS 95S -- MODEL 355CAV
DIRECT--VENT 4--WAY MULTIPOISE
CONDENSING GAS FURNACE
WITH PERFECT SENSET PERFECT HUMIDITYT
SERIES A
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
This furnace can be vented as a direct vent (2--pipe) or as an
optional ventilated combustion air application.
ama
CERTIFIED
Furnaces installed in Canada must use Vent Systems that are
certified to the Standard for Type BH Gas Venting Systems,
ULC--S636.
ISO 9001:2000
ULC--S636 certified plastic vent system material or the
components of ULC--S636 certified vent systems must not be
interchanged with other vent systems or unlisted pipe/fittings.
REGISTERED
Vent components supplied with the furnace and components in
factory authorized vent kits may be used with ULC--S636
certified vent systems.
The ULC--S636 certified plastic components, and specified
As an ENERGY STAR® Partner,
Bryant Heating & Cooling has
determined that this product
meets the ENERGY STAR®
guidelines for energy efficiency.
primers and glues of the certified system must be from a
single--system manufacturer and not mixed with other system
manufacturer’s vent system parts.
AIRFLOW
The first 3 ft. (.91 M) of the venting system must be readily
accessible for inspection.
Some Provinces may require the combustion air system to be
ULC--S636 certified.
UPFLOW
NOTE: Please retain these instructions with the furnace after
installation for future reference.
TABLE OF CONTENTS
HORIZONTAL
LEFT
HORIZONTAL
RIGHT
PAGE
DOWNFLOW
AIRFLOW
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 3
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS . . 7
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Upflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Downflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Horizontal Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Horizontal Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air for Combustion and Ventilation . . . . . . . . . . . . . . . . . . 26
Combustion Air Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Vent Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
START--UP, ADJUSTMENTS, AND SAFETY CHECK . . . 43
CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
AIRFLOW
AIRFLOW
A93041
Fig. 1 -- Furnace Orientation
!
CAUTION
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit damage.
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure. This furnace can be vented as either a direct vent
(2--pipe) furnace or as an optional ventilated combustion air
application.
A direct vent system shall be installed in accordance with
the direct vent (2--pipe) procedures in the Combustion Air
and Vent Pipe Systems section within this instruction. For
optional ventilated combustion air applications, refer to the
ventilated combustion air option procedures in the same
section.
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.
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highlight suggestions which will result in enhanced installation,
reliability, or operation.
SAFETY CONSIDERATIONS
!
CAUTION
!
CAUTION
FURNACE RELIABILITY HAZARD
CUT HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing and gloves when
handling parts.
Application of this furnace should be indoors with special
attention given to vent sizing and material combustion air
requirements, gas input rate, air temperature rise, unit
leveling, and unit sizing.
The 355CAV Condensing Gas--Fired Furnaces are CSA
(formerly AGA and CGA) design--certified for natural and
propane gases (see furnace rating plate) and for installation in
alcoves, attics, basements, closets, utility rooms, crawlspaces, and
garages. The furnace is factory--shipped for use with natural gas.
A CSA listed gas conversion kit is required to convert furnace for
use with propane gas.
!
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
See Fig. 3 for required clearances to combustibles.
Maintain a 1--in. (25.4 mm) clearance from combustible materials
to supply air ductwork for a distance of 36 inches horizontally
from the furnace. See NFPA 90B or local code for further
requirements.
These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring.
These furnaces are suitable for installation in a structure built on
site or a manufactured building completed at final site. The
design of this furnace line is NOT CSA design--certified for
installation in recreation vehicles, manufactured (mobile) homes
or outdoors.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified installer, service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified installer or agency must use only
factory--authorized and listed kits or accessories when
modifying this product.
This furnace is designed for continuous return--air minimum
temperature of 60_F db or intermittent operation down to 55_F
db such as when used with a night setback thermostat. Return--air
temperature must not exceed 80_F db. Failure to follow these
return air limits may affect reliability of heat exchangers, motors
and controls. (See Fig. 4.)
Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with unit and other safety
precautions that may apply.
These 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.
Install this furnace only in a location and position as specified in
LOCATION and INSTALLATION sections of these instructions.
Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in the
Combustion Air and Vent piping sections of these instructions.
These instructions cover the minimum requirements and conform
to existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as
a minimum for a safe installation.
Wear safety glasses and work gloves. Have a fire extinguisher
available during start--up and adjustment procedures and service
calls.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections as specified in the GAS PIPING section of
these instructions.
Recognize safety information. This is the safety--alert symbol
.
When you see this symbol on the furnace and in
instructions or manuals, be alert to the potential for personal
injury.
Always install the furnace to operate within the furnace’s
intended rise range with a duct system which has an external
static pressure within the allowable range as specified in the SET
TEMPERATURE RISE section of these instructions.
Understand the signal words DANGER, WARNING, and
CAUTION. 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 a hazard
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to
When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by ducts sealed to the
furnace casing and terminating outside the space containing the
furnace.
3
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26 15⁄16"
26 1
28 1
⁄2"
26 15⁄16"
⁄
4"
AIRFLOW
A
26 1
⁄4"
24 1
⁄2"
22 5⁄16"
19"
22 5⁄16"
9⁄16"
TYP
13⁄16"
13/16"
D
13/16"
2-IN. COMBUSTION-
AIR CONN
5
⁄
8"
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
OUTLET
OUTLET
CONDENSATE DRAIN
TRAP LOCATION
2-IN. COMBUSTION-
AIR CONN
HORIZONTAL LEFT)
5⁄16"
7
(DOWNFLOW &
⁄
8-IN. DIA
HORIZONTAL RIGHT)
POWER CONN
1
1
⁄
2-IN. DIA
⁄
2-IN. DIA
OR ALTERNATE
1
GAS CONN
GAS CONN
⁄
2-IN. DIA GAS CONN
2-IN. VENT CONN
7
⁄
8-IN. DIA
33 1
TYP
⁄
4
"
POWER CONN
32 5
TYP
⁄
8
"
1
1
⁄
2-IN. DIA THERMOSTAT
⁄
2-IN. DIA
THERMOSTAT ENTRY
ENTRY
30 13⁄16"
29 11⁄16"
7
22 11⁄16"
39 7
⁄8"
30 1
⁄2"
⁄
8-IN. DIA
2-IN. VENT CONN
ACCESSORY
POWER ENTRY
TYP
27 5
⁄8"
CONDENSATE
DRAIN TRAP
LOCATION
22 11⁄16"
27 9⁄16"
TYP
(ALTERNATE
UPFLOW)
24 1
⁄2"
14 1
TYP
⁄
2
"
SIDE INLET
SIDE INLET
17 5⁄16"
18 1
⁄4"
9 7⁄16"
TYP
1"
INLET
E
11⁄4
1"
"
CONDENSATE
DRAIN LOCATION
(UPFLOW)
22 1
⁄
4" TYP
7⁄16"
CONDENSATE
DRAIN LOCATION
(UPFLOW)
23 1
⁄
4" TYP
11/16"
11/16"
SIDE INLET
24 3⁄16"
BOTTOM INLET
11⁄16"
26 15⁄16" TYP
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer’s recommendations for equivalent diameters.
2. Minimum return-air opening at furnace:
1
a. For 800 CFM–16-in. round or 14
/
2
1
x 12-in. rectangle.
1
b. For 1200 CFM–20-in. round or 14
c. For 1600 CFM–22-in. round or 14
/2
x 19
/2-in. rectangle.
1
1
/2
x 23
/4-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data
literature for specific use of single side inlets. The use of both side inlets, a
combination of 1 side and the bottom, or the bottom only will ensure adequate
return air openings for airflow requirements above 1800 CFM.
A05124
Dimensions (In. / mm)
UNIT SIZE
042060
042080
060080
060100
060120
A
D
E
17---1/2 / 444.5
21 / 533.4
15---7/8 / 403.2
19---3/8 / 492.1
19---3/8 / 492.1
19---3/8 / 492.1
22---7/8 / 581.0
16 / 406.4
19---1/2 / 495.3
19---1/2 / 495.3
19---1/2 / 495.3
23 / 584.2
21 / 533.4
21 / 533.4
24---1/2 / 622.3
Fig. 2 -- Dimensional Drawing
A gas--fired furnace for installation in a residential garage must be
installed as specified in the Hazardous Locations section of these
instructions and Fig. 5.
S
S
Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the en-
trainment of drywall dust into combustion air, which
can cause fouling and plugging of furnace components.
The furnace may be used for construction heat provided that the
furnace installation and operation complies with the first
CAUTION in the LOCATION section of these instructions.
The temperature of the return air to the furnace is
maintained between 55_F (13_C) and 80_F (27_C),
with no evening setback or shutdown. The use of the
furnace while the structure is under construction is
deemed to be intermittent operation per our installation
instructions.
This gas furnace may be used for construction heat provided that:
S
The furnace is permanently installed with all electrical
wiring, piping, air filters, venting and ducting installed
according to these installation instructions. A return air
duct is provided, sealed to the furnace casing, and ter-
minated outside the space containing the furnace. This
prevents a negative pressure condition as created by the
circulating air blower, causing a flame rollout and/or
drawing combustion products into the structure.
S
S
S
The air temperature rise is within the rated rise range on
the furnace rating plate, and the firing rate has been set
to the nameplate value.
The filters used to clean the circulating air during the
construction process must be either changed or
thoroughly cleaned prior to occupancy.
S
The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the struc-
ture without thermostatic control.
The furnace, ductwork and filters are cleaned as
necessary to remove drywall dust and construction
4
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debris from all HVAC system components after
construction is completed.
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.
These furnaces are shipped with the following materials to assist
in proper furnace installation. These materials are shipped in the
main blower compartment.
S
After construction is complete, verify furnace operating
conditions including ignition, input rate, temperature
rise and venting, according to the manufacturer’s
instructions.
If this furnace is installed with a direct--vent (combustion air and
flue) system, a factory accessory termination kit must be installed.
INSTALLATION
This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft.
(0 - 2,135m).
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 Inches Clearance To Combustible Construction as described below.
This furnace requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC,
PVC-DWV, CPVC, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be
installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).
Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),excepté queles fournaises de 140 taille
sont pour altitudes comprises entre 0 - 2,135m (0 - 7,000pi).
Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel.
Cette fournaise à air pulsé est pour installation à l´intérieur dans un bâtiment construit sur place. Cette fournaise à air pulse peut être installée dans une maison
préfabriquée (maison mobile) si prescrit par la plaque signalétique et si l' on utilise une trousse specifiée par le fabricant.
Cette fournaise peut être installée sur un plancher combustible dans un enfoncement ou un placard en observant les Dégagement Minimum En Pouces Avec
Éléments De Construction Combustibles.
Cette fournaise nécessite un système d´évacuation spécial. La méthode d´installation et la liste des pièces nécessaires figurent dans les instructions d´installation. Cette
fournaise doit s´utiliser avec la tuyauterie des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ABS-DWV et elle ne peut pas être ventilée conjointment avec d´autres
appareils à gaz. Épaisseur de la construction au travers de laquelle il est possible de faire passer les tuyaux d'aération (admission/évacuation): 24 po (600 mm)
maximum, 3/4 po (19mm) minimum (y compris la toiture).
For upflow and downflow applications, furnace must be installed level, or pitched within 1/2" of level. For a
horizontal application, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper
drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.
LEVEL (0")
1/2" MAX
MIN 1/4" TO 1/2" MAX
TO
Pour des applications de flux ascendant et descendant, la fournaise doit être installée de niveau ou inclinée à
pas plus de 1/2" du niveau. Pour une application horizontale, la fournaise doit être inclinée entre minimum
1/4" et maximum 1/2" du niveau pour le drainage approprié. En cas d´installation en position horizontale,
consulter les renseignements IMPORTANTS sur le support dans le manuel d´installation.
UPFLOW OR
DOWNFLOW
FRONT
FRONT
HORIZONTAL
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
This furnace is approved for UPFLOW, DOWNFLOW and
HORIZONTAL installations.
ALL POSITIONS:
Minimum front clearance for service 24 inches (610mm).
DOWNFLOW POSITIONS:
For installation on combustible floors only when installed on special base No. KGASB0201ALL,
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.
HORIZONTAL POSITIONS:
Cette fournaise est approuvée pour l´installation HORIZONTALE
et la circulation d´air VERS LE HAUT et VERS LE BAS.
*
†
1"
Clearance arrows
do not change with
furnace orientation.
Les fléches de dégagement
ne change pas avec
Line contact is permissible only between lines formed by intersections of top and two sides
of furnace jacket, and building joists, studs, or framing.
Clearance shown is for air inlet and air outlet ends.
120 and 140 size furnaces require 1 inch bottom clearance to combustible materials.
l
´orientation de la
générateur d´air chaud.
§
Ø
0"
§
0"
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS DE
CONSTRUCTION COMBUSTIBLES
E
D
B
A
A
I
S
C
E
R
S
C
E
R
K
R
T
I
O
E
I
C
E
A
S
E
N
POUR TOUS LES POSITIONS:
R
A
U
N
F
R
T
T
U
Dégagement avant minimum de 610mm (24 po) pour l'entretien.
POUR LA POSITION COURANT DESCENDANT:
N
O
F O
*
†
R
N
F
A
V
A
S
E
L
Pour l
pièce nº KGASB0201ALL, l
serpentin, pièce nº KCAKC.
´
installation sur le plancher combustible seulement quand on utilise la base spéciale,
È
R
N
V
I
I
T
R
C
E
´ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de
E
E
E
E
F
A
T
D
T
R
I
S
S
O
*
N 24
MIN
N
V
O
T
T
A
C
N
0"
POUR LA POSITION HORIZONTALE:
3"
Le contact n´est permis qúentre les lignes formées par les intersections du dessus et des
§
deuxcôtés de la chemise de la fournaise, et des solives, des montants ou de la charpente du
bátiment.
Vent clearance to
combustibles 0".
§
La distance indiquée concerne l´extrémité du tuyau d´arrivée d´air et l´extrémité du tuyau de
sortie d air.
´
0"Ø
†
Clearance in inches
Dégagement (po).
0 (po) Dégagement
d´évent avec combustibles.
Ø
Pour les fournaises de 120 et 140 taille, 1 po (25mm) dégagement des matériaux combusitbles
est requis au-dessous.
328068-201
REV.
B
(LIT TOP
)
A04116
Fig. 3 -- Clearances to Combustibles
5
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Installer Packet Includes:
CODES AND STANDARDS
Installation, Start---up, and Operating Instructions
Service and Maintenance Instructions
User’s Information Manual
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction in Canada.
Warranty Certificate
Loose Parts Bag includes:
Quantity
Collector Box or Condensate trap extension tube
Inducer housing drain tube
1
1
2
1
1
1
1
1
1
2
3
2
1
In the United States and Canada, follow all codes and standards
for the following:
1/2---in CPVC street elbow
Safety
Drain tube coupling
S
US: National Fuel Gas Code (NFGC) NFPA
54--2006/ANSI Z223.1--2006 and the Installation
Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B
Drain tube coupling grommet
Gas line grommet
Vent pipe grommet
Combustion---air pipe grommet
Gas line entry hole filler plug
Power entry hole filler plug
S
CANADA: National Standard of Canada, Natural Gas
and Propane Installation Code
(CAN/CSA--B149.1--05) CSA B149.1--05
General Installation
Condensate trap hole filler plug
Vent and combustion---air intake hole filler plug
Combustion---air pipe perforated disk assembly
S
US: NFGC and the NFPA 90B. For copies, contact the
National Fire Protection Association Inc., Batterymarch
Park, Quincy, MA 02269; or for only the NFGC
contact the American Gas Association, 400 N. Capitol,
N.W., Washington DC 20001.
S
A manufactured (Mobile) home installation must
conform with the Manufactured Home Construction
and Safety Standard, Title 24 CFR, Part 3280, or when
this standard is not applicable, the Standard for
80 / 27 C
Manufactured Home Instllation (Manufactured Home
Suites, Communities, and Set--Ups), ANSI/NCS A225.1,
and/or CAN/CSA--z240, MH Series Mobile Homes.
S
CANADA: CAN/CSA--B149.1--05. For a copy,
contact Standard Sales, CSA International, 178
Rexdale Boulevard, Etobicoke (Toronto), Ontario,
M9W 1R3, Canada.
60 / 16 C
Combustion and Ventilation Air
S
US: Section 9.3 of the NFGC, Air for Combustion and
Ventilation.
S
CANADA: Part 8 of the CAN/CSA--B149.1--05,
Venting Systems and Air Supply for Appliances.
A06745
Fig. 4 -- Return--Air Temperature
Duct Systems
S
US and CANADA: Air Conditioning Contractors
Association (ACCA) Manual D, Sheet Metal and Air
Conditioning Contractors National Association
(SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers
(ASHRAE) 2005 Fundamentals Handbook Chapter 35.
Acoustical Lining and Fibrous Glass Duct
S
US and CANADA: current edition of SMACNA,
NFPA 90B as tested by UL Standard 181 for Class I
Rigid Air Ducts.
Gas Piping and Gas Pipe Pressure Testing
S
US: NFGC; chapters 5, 6, 7, and 8 and national
plumbing codes.
S
CANADA: CAN/CSA--B149.1--05 Parts 4, 5, 6, and 9.
18-IN. MINIMUM
TO BURNERS
In the state of Massachusetts:
S
S
S
This product must be installed by a licensed plumber or
gas fitter.
A93044
Fig. 5 -- Installation in a Garage
When flexible connectors are used, the maximum
length shall not exceed 36 inches.
The furnace shall be installed so that the electrical components are
protected from water.
For accessory installation details, refer to applicable installation
literature.
When lever type gas shutoffs are used they shall be
T--handle type.
6
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drain and pressure tubes are connected as shown in Fig. 7. See
appropriate application instructions for these procedures.
S
The use of copper tubing for gas piping is not approved
by the state of Massachusetts.
Electrical Connections
!
CAUTION
S
US: National Electrical Code (NEC) ANSI/NFPA
70--2005.
PROPERTY DAMAGE HAZARD
S
CANADA: Canadian Electrical Code CSA C22.1.
Failure to follow this caution may result in property
damage.
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS
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.
!
CAUTION
UNIT DAMAGE HAZARD
NOTE: In Canada, installations shall be in accordance with
current CAN/CSA--B149.1--05 and/or local codes.
Failure to follow this caution may result in damage to unit
components.
UPFLOW APPLICATION
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing
to protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are 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.
An upflow furnace application is where furnace blower is located
below combustion and controls section of furnace, and
conditioned air is discharged upwards.
Condensate Trap (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 section for drain tube extension details. (See Fig. 6.)
3. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
Condensate Trap Tubing (Factory--Shipped Orientation)
NOTE: See Fig. 7 or tube routing label on main furnace door to
confirm location of these tubes.
TO
DISCHARGING
YOUR
BODY’S
ELECTROSTATIC CHARGE TO GROUND.
1. Collector Box Drain, Inducer Housing Drain, Relief Port,
and Pressure Switch Tubes.
4. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
a person’s hand during grounding will be satisfactorily
discharged.
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 identifed as follows: collector box drain
tube (blue label), inducer housing drain tube (violet label
or molded), relief port tube (green label), and pressure
switch tube (pink label).
5. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example;
DO NOT move or shuffle your feet, DO NOT touch
ungrounded objects, etc.).
2. Condensate Trap Drain Tube
6. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before
touching control or wires.
7. Use this procedure for installed and uninstalled
(ungrounded) furnaces.
8. Before removing a new control from its container,
discharge your body’s electrostatic charge to ground to
protect the control from damage. If the control is to be
installed in a furnace, follow items 1 through 5 before
bringing the control or yourself into contact with the
furnace. Put all used AND new controls into containers
before touching ungrounded objects.
The condensate trap drain connection must be extended
for field attachment by doing the following:
f. Determine location of field drain connection. (See Fig.
2 or 7.)
NOTE: If internal filter or side filter/media cabinet is used, drain
tube should be located to opposite side of casing from return duct
attachment to assist in filter removal.
g. Remove and discard casing drain hole plug button from
desired side.
h. Install drain tube coupling grommet (factory--supplied in
loose parts bag) in selected casing hole.
9. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
i. Slide drain tubecoupling (factory--supplied in looseparts
bag) through grommet so long end of coupling faces
blower.
j. Cement 2 factory--supplied 1/2--in. (12.7mm) street
CPVC elbows to rigid drain tube connection on
condensate trap. (See Fig. 7.) These elbows must be
cemented together and cemented to condensate trap drain
connection.
INTRODUCTION
The model 355CAV Direct Vent, Upflow, Gas--Fired, Category
IV, condensing furnace is available in model sizes ranging in
input capacities of 60,000 to 120,000 Btuh.
APPLICATIONS
General
Some assembly and modifications are required for furnaces
installed in any of the four applications shown in Fig. 1. All
7
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FURNACE
DOOR
BLOWER SHELF
CONDENSATE
TRAP
FURNACE
DOOR
CONDENSATE
TRAP (INSIDE)
FURNACE
SIDE
FURNACE
SIDE
7
(124mm)
4
8
4
3
4
3
(146mm)
(146mm)
5
1
4
5
4
4
26
3
4
1
1
FIELD
DRAIN
CONN
FIELD
DRAIN
CONN
26
4
1
2
(667mm)
(19mm)
(667mm)
(38mm)
ALTERNATE DRAIN
TUBE LOCATION
SIDE VIEW
FRONT VIEW
END VIEW
FRONT VIEW
CONDENSATE TRAP
DRAIN TUBE LOCATION
HORIZONTAL
APPLICATIONS
DOWNFLOW AND ALTERNATE
EXTERNAL UPFLOW APPLICATIONS
UPFLOW APPLICATIONS
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
1/4 OD
COLLECTOR BOX TO
TRAP RELIEF PORT
1
(88mm)
1
2
1/2 OD
INDUCER HOUSING
DRAIN CONNECTION
3
(19mm)
4
5/8 OD
COLLECTOR BOX
DRAIN CONNECTION
1
(181mm)
7
8
8
SCREW HOLE FOR
UPFLOW OR DOWN-
FLOW APPLICATIONS
(OPTIONAL)
3
(44mm)
(3mm)
1
4
7
WIRE TIE
GUIDES
(WHEN USED)
1
2
4
1/2 IN. PVC OR CPVC
(57mm)
FRONT VIEW
SIDE VIEW
A07459
Fig. 6 -- Condensate Trap
NOTE: Failure to use CPVC elbows may allow drain to kink,
preventing draining.
!
WARNING
k. Connect larger diameter drain tube and clamp
(factory--supplied in loose parts bag) to condensate trap
and clamp securely.
l. Route tube to coupling and cut to appropriate length.
m. Attach tube to coupling and clamp securely.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Casing hole filler cap must be installed in blower shelf
hole when condensate trap is relocated to prevent
combustion products being drawn in from appliances in
the equipment room.
Condensate Trap (Alternate Upflow Orientation)
An alternate location for the condensate trap is the left--hand side
of casing. (See Fig. 2 and 8.)
NOTE: If the alternate left--hand side of casing location is used,
the factory--connected drain and relief port tubes must be
disconnected and modified for attachment. See Condensate Trap
Tubing (Alternate Upflow Orientation) section for tubing
attachment.
4. Install condensate trap into left--hand 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).
To relocate condensate trap to the left--hand side, perform the
following:
Condensate Trap Tubing (Alternate Upflow Orientation)
1. Remove three tubes connected to condensate trap.
NOTE: See Fig. 8 or tube routing label on main furnace door to
confirm location of these tubes.
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.
8
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PLUG
COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
CAP
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (GREEN
ROUTES BEHIND
INDUCER)
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (GREEN)
CONDENSATE
TRAP
CONDENSATE
TRAP
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (VIOLET)
COUPLING (LEFT
DRAIN OPTION)
FIELD-INSTALLED
FACTORY-
SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FIELD-INSTALLED
FACTORY-
FACTORY-
SUPPLIED
SUPPLIED
DRAIN TUBE
½ - IN. CPVC STREET
COUPLING (LEFT
DRAIN OPTION)
ELBOWS (2) FOR
LEFT DRAIN OPTION
A07274
A07281
Fig. 7 -- Factory--Shipped Trap Location
(Shown with Blower Access Panel Removed)
Fig. 8 -- Alternate Trap Location
Pressure Switch Tubing
1. Collector Box Drain Tube
The LOWER collector box pressure tube (pink label) is factory
connected to the pressure switch and should not require any
modification.
Connect collector box drain tube (blue label) to
condensate trap.
NOTE: On 17--1/2--in. (444.5mm) wide furnaces ONLY, cut
tube between corrugated sections to prevent kinks.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace
door to check for proper connections.
2. Inducer Housing Drain Tube
Upper Collector Box and Inducer Housing (Unused) Drain
Connections
a. Remove and discard LOWER (molded) inducer housing
draintubewhichwas previouslyconnected tocondensate
trap.
Upper Collector Box Drain Connection
Attached to the UPPER collector box drain connection is a
factory--installed corrugated, plugged tube (blue and white
striped label). This tube is plugged to prevent condensate leakage
in this application. Ensure this tube is plugged.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace
door to check for proper connections.
b. 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.
c. Determine appropriate length, then cut and connect tube.
d. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
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.
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, then cut and connect tube.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace
door to check for proper connections.
Condensate Trap Field Drain Attachment
Condensate Trap Freeze Protection
Refer to Condensate Drain section for recommendations and
procedures.
Refer to Condensate Drain Protection section for
recommendations and procedures.
9
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COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (GREEN)
PLUG
CAP
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (PINK)
PLUG
COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)
COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)
COLLECTOR BOX
TUBE EXTENSION
COLLECTOR BOX
TUBE EXTENSION
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (VIOLET)
CONDENSATE
TRAP
CONDENSATE
COLLECTOR BOX
EXTENSION
DRAIN TUBE
DRAIN TUBE
COUPLING
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (VIOLET)
A07276
A07277
Fig. 9 -- Condensate Trap
Fig. 10 -- Factory--Shipped Trap Location
(Shown with Blower Access Panel Removed)
DOWNFLOW APPLICATIONS
Condensate Trap Tubing
A downflow furnace application is where furnace blower is
located above combustion and controls section of furnace, and
conditioned air is discharged downwards.
NOTE: See Fig. 9 or 10 or tube routing label on main furnace
door to check for proper connections.
Condensate Trap Location
1. Collector Box DrainTube
The condensate trap must be removed from the factory--installed
blower shelf location and relocated in selected application
location as shown in Fig. 2, 9, or 10.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
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.
1. Remove three tubes connected to condensate trap.
c. Connect LOWER collector box drain connection to
condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotaing trap.
(3.) Condensate Trap Located on Left Side of Casing
3. Remove casing hole filler cap from casing hole. (See Fig.
2 and 10.)
4. Install casing hole filler cap (factory--supplied in loose
parts bag) into blower shelf hole where trap was removed.
(a.)Connect LOWER collector box drain tube (blue
and white striped label) to condensate trap.
Tube does not need to be cut.
(b.)Clamp tube to prevent any condensate leakage.
(4.) Condensate Trap Located on Right Side of Casing
!
(a.)Install drain tube coupling (factory--supplied in
loose parts bag) into collector box drain tube
(blue and white striped label) which was
previously plugged.
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
(b.)Connect
larger
diameter
drain
tube
(factory--supplied in loose parts bag) to drain
tube coupling, extending collecor box drain tube
for connection to condensate trap.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the equipment
room.
(c.)Route extended collector box drain tube
between gas valve and inlet housing as shown in
Fig. 10.
(d.)Determine appropriate length and cut.
(e.)Connect to condensate trap.
5. Install condensate trap into left--hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabls snap into locking position.
2. Inducer Housing Drain Tube
a. Remove factory--installed cap and clamp from LOWER
inducer housing drain connection.
6. Fill unused condensate trap casing holes with plastic filler
caps (factory--supplied in loose parts bag).
10
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b. Remove and discard UPPER (molded) inducer housing
draintubewhichwas previouslyconnected tocondensate
trap.
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)
AUXILIARY “J” BOX
CONDENSATE
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (VIOLET)
COLLECTOR BOX
TUBE EXTENSION
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
EXTENSION
DRAIN TUBE
COLLECTOR BOX
TUBE (PINK)
DRAIN TUBE
COUPLING
A07278
Fig. 11 -- Horizontal Left Tube Configuration
c. Install cap and clamp on UPPER inducer housing drain
conection where molded drain tube was removed.
d. Use inducer housing drain tube (violet label and
factory--supplied in loose parts bag) to connect LOWER
inducer housing drain connection to the condensate trap.
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. 9 or 10 or tube routing label on man furnace
door to check for proper connections.
e. Connect inducer housing drain connection to condensate
trap.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label)
attached to pressure switch.
2. Extend collector box pressure tube (green label) which
was previously connected to condensate trap relief port
connection by splicing to small diameter tube
(factory--supplied in loose parts bag).
(1.) Condensate Trap Located on Left Side of Casing
(a.)Determine appropriate length and cut.
(b.)connect tube to condensate trap.
(c.)Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
3. Connect collector box pressure tube (green label) to
pressure switch connection labeled COLLECTOR BOX.
(a.)Route inducer yhousing drain tube (violet label)
directly from inducer housing to condensate
trap.
(b.)Determine apprpriate length and cut.
(c.)Connect tube to condensate trap.
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.
(d.)Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection
procedure.
6. Determine appropriate length, cut, and connect tube.
7. Clamp tube to relief port connection.
Condensate Trap Field Drain Attachment
Condensate Trap Freeze Protection
Refer to Condensate Drain section for recommendations and
procedures.
Pressure Switch Tubing
Refer to Condensate Drain Protection section for
recommendations and procedures.
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.
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. The tube
MUST be disconnected and used or the condensate trap relief
port tube. The other collector box pressure tube (green label)
11
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A 3-IN. MINIMUM CLEARANCE
TO COMBUSTION-AIR INTAKE
IS REQUIRED.
COMBUSTION – AIR
INTAKE
VENT
VENT
COMBUSTION–AIR
INTAKE
A 12-IN. MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT) VENT SYSTEMS
TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
A 12-IN. MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT) VENT SYSTEMS
TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
30-IN. MIN
WORK AREA
30″ MIN
3
WORK AREA
5
⁄
″
4
3
5
⁄
″
4
MANUAL
SHUTOFF
GAS VALVE
MANUAL
SHUTOFF
GAS VALVE
ACCESS OPENING
FOR TRAP
ACCESS OPENING
FOR TRAP
DRAIN
SEDIMENT
TRAP
DRAIN
SEDIMENT
TRAP
CONDENSATE
TRAP
CONDENSATE
TRAP
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
A96184
A93031
Fig. 13 -- Attic Location and Working Platform for
Ventilated Combustion Air Applications
Fig. 12 -- Attic Location and Working Platform for Direct
Vent (2--Pipe) Application
Condensate Trap Tubing
!
NOTE: See Fig. 11 or tube routing label on main furnace door
to check for proper connections.
CAUTION
PROPERTY DAMAGE
1. Collector Box DrainTube
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.
Failure to follow this caution may result in property
damage.
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.
b. Connect large diameter drain tube and clamp
(factory--supplied in loose parts bag) to drain tube
coupling, extending collecor box drain tube.
c. Route extended tube (blue label) to condensate trap and
cut to appropriate length.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
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.
(a.)Remove and discard LOWER (molded) inducer
housing drain tube which was previously
connected to condensate trap.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
(b.)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.
1. Remove three tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotaing trap.
3. Remove casing hole filler cap from casing hole. (See Fig.
2 or 11.)
4. Install casing hole filler cap (factory--supplied in loose
parts bag) into blower shelf hole where trap was removed.
(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 condensate trap by splicing to
small diameter tube (factory--suppled in loose parts bag).
!
WARNING
b. Route extended collector box pressur tube to relief port
connectio on condensate trap.
CARBON MONOXIDE POISONING HAZARD
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.
Condensate Trap Field Drain Attachment
Failure to follow this warning could result in personal
injury or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the equipment
room.
Refer to Condensate Drain section for recommendations and
procedures.
Pressure Switch Tubing
The LOWER collector box pressure tube (pink label) is factory
connected to the High Pressure Switch for use when furnace is
installed in UPFLOW applications. This tube MUST be
disconnected, extended rerouted, and then reconnected to the
pressure switch in HORIZONTAL LEFT applications for 060
and 080 heating input furnaces.
5. Install condensate trap into left--hand side casing hole by
inserting tube connection stubs through casing hole an
rotating until tabls snap into locking position.
6. Fill unused condensate trap casing holes with plastic filler
caps (factory--supplied in loose parts bag).
NOTE: See Fig. 11 or tube routing label on main furnace door
to check for proper connections.
Modify tube as described below.
12
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1. Disconnect collector box pressure tube (pink label)
attached to High Pressure Switch.
2. Use smaller diameter tube (factory--suppled in loose pars
bag) to extend tube disconnected in Item 1.
Condensate Trap Location
PLUG
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX TUBE (PINK)
CAP
3. Route extended tube:
AUXILIARY “J” BOX RELOCATED HERE
a. Behind inducer housing.
b. Between blower shelf and inducer housing.
4. Determine appropriate lenght, cut, and reconnect tube to
High Pressure Switch connections labeled COLLECTOR
BOX.
Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for
recommendations and procedures.
Construct a Working Platform
CONDENSATE
TRAP
COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 12 or 13.)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (VIOLET)
!
CAUTION
COLLECTOR BOX
EXTENSION TUBE
UNIT OPERATION HAZARD
A07279
Failure to follow this caution may result in intermittent unit
operation.
Fig. 14 -- Horizontal Right Tube Configuration
The condensate trap MUST be installed below furnace. See
Fig. 6 for dimensions. The drain connection to condensate
trap must also be properly sloped to an open drain.
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 14.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
NOTE: A 12--in. (304.8mm) minimum offset pipe section is
recommended with short (5 to 8 ft or 1.5 M to 2.4 M) vent
systems. This recommendation is to reduce excessive condensate
droplets from exiting the vent pipe. (See Fig. 12, 13, or 44.)
1. Remove three tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotaing trap.
HORIZONTAL RIGHT
(SUPPLY-AIR DISCHARGE) APPLICATIONS
!
WARNING
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.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
!
CAUTION
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the equipment
room.
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property
damage.
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.
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 right--hand side casing hole by
inserting tube connection stubs through casing hole an
rotating until tabls snap into locking position.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory--supplied in loose parts bag).
NOTE: The auxiliary junction box (J--box ) MUST be relocated
to opposite side of furnace casing. (See Fig. 14.) See Electrical
Connection section for J--box relocation.
LEVEL (0″)
FRONT
FRONT
TO
MIN 1⁄4″
TO
1⁄2″ MAX
1⁄2″ MAX
UPFLOW OR DOWNFLOW
HORIZONTAL
A02146
Fig. 15 -- Proper Condensate Drainage
13
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Condensate Trap Tubing
Condensate Trap Freeze Protection
NOTE: See Fig. 14 or tube routing label on main furnace door
to check for proper connections.
Refer to condensate Drain Protection section for
recommendations and procedures.
Construct a Working Platform
1. Collector Box DrainTube
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 12 or 13.)
a. Remove factory--installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was previously
connected to condensate trap.
!
CAUTION
c. Connect LOWER collector box drain tube (blue and
white striped label) to condensate trap. Tube does not
need to be cut.
UNIT OPERATION HAZARD
Failure to follow this caution may result in intermittent unit
operation.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
The condensate trap MUST be installed below furnace. See
Fig. 6 for dimensions. The drain connection to condensate
trap must also be properly sloped to an open drain.
(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.
NOTE: A 12--in. (304.8mm) minimum offset pipe section is
recommended with short (5 to 8 ft or 1.5 m to 2.4 m) vent
systems. This recommendation is to reduce excessive condensate
droplets from exiting the vent pipe. (See Fig. 12, 13, or 44.)
(c.)Install cap and clamp on UPPER inducer
housing drain connection where molded drain
tube was removed.
(d.)Use inducer housing drain extension tube (violet
label and factory--suppled in loose parts bag) to
connect LOWER inducer housing drain
connection to condensate trap.
LOCATION
General
This furnace must
S
be installed so the electrical components are protected
from water.
(e.)Determine appropriate length, cut, and connect
tube to condensate trap.
S
not be installed directly on any combustible material
other than wood flooring (refer to SAFETY
CONSIDERATIONS).
(f.)Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
Refer to Pressure Switch Tubing section for
recommendations and procedures.
Condenste Trap Field Drain Attachment
S
S
S
be located so combustion--air and vent pipe maximum
lengths are not exceeded. Refer to Table 7.
be located where available electric power and gas
supplies meet specifications on the furnace rating plate.
Refer to Condensate Drain section for recommendations and
procedures.
be attached to an air distribution system and be located
as close to the center of the distribution system as
possible. Refer to Air Ducts section.
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 connect to the pressure switch in
DOWNFLOW or HORIZONTAL RIGHT applications.
S
be provided with ample space for servicing and
cleaning. Always comply with minimum fire
protection clearances shown on the furnace
clearance--to--combustibles label. (See Fig. 3.)
This furnace may be located in a confined space without special
provisions for dilution or ventilation air.
NOTE: For upflow/downflow applications install furnace so that
it is level or pitched and forward within 1/2--in. (12.7mm) for
proper furnace operation. For horizontal applications pitch
1/4--in. (6mm) minimum to 1/2--in. (12.7mm) maximum forward
to ensure proper condensate drainage from secondary heat
exchangers. (See Fig. 15.)
When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by ducts sealed to
furnace casing. The ducts terminate outside the space containing
the furnace to ensure there will not be a negative pressure
condition within equipment room or space.
NOTE: See Fig. 14 or tube routing label on main furnace door
to check for proper connections.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label)
attached to pressure switch.
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--suppled in loose parts bag.)
3. Connect collector box pressure tube (green label) to
pressure switch connection labeled COLLECTOR BOX.
4. Use remaining small diameter tube (factory--suppled in
loose parts bag) to extend collector box pressure tube
(pink label) which was previously connected to pressure
switch.
5. Route this extende tube (pink label) to condensate trap
relief port connection.
6. Determine appropriate lenght, cut, and connect tube.
7. Clamp tube to relief port connection.
14
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!
WARNING
FRONT
FIRE OR DEATH HAZARD
Failure to follow this warning could result in property
damage, personal injury, or death.
Do not install furnace on its back. (See Fig. 16.) Safety
control operation will be adversely affected. Never connect
return--air ducts to back of furnace.
B
A
C
K
BACK
The furnace and its return air system shall be designed and
installed so that negative pressure created by the air circulating
fan cannot affect another appliance’s combustion air supply or act
to mix products of combustion with circulating air, and that the
air circulating fan of the furnace, if installed in an enclosure
communicating with another fuel--burning appliance not of the
direct--vent type, shall be operable only when any door or panel
covering an opening in the furnace fan compartment or in a return
air plenum on ducts is in the closed position.
FRONT
A93043
Fig. 16 -- Prohibit Installation on Back
!
CAUTION
!
CAUTION
UNIT DAMAGE HAZARD
UNIT DAMAGE HAZARD
This gas furnace may be used for construction heat
provided that:
Failure to follow this caution may result in minor property
or unit damage.
--The furnace is permanently installed with all electrical
wiring, piping, air filters, venting and ducting installed
according to these installation instructions. A return air duct
is provided, sealed to the furnace casing, and terminated
outside the space containing the furnace. This prevents a
negative pressure condition as created by the circulating air
blower, causing a flame rollout and/or drawing combustion
products into the structure.
If these furnaces are installed in an unconditioned space
where ambient temperatures may be 32_F (0_C) or lower,
freeze protection measures must be taken. See Condensate
Drain Protection section and Fig. 17.
--The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the structure
without thermostatic control.
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
--The temperature of the return air to the furnace is
maintained between 55_F (13_C) and 80_F (27_C), with
no evening setback or shutdown. The use of the furnace
while the structure is under construction is deemed to be
intermittent operation per our installation instructions.
--The air temperature rise is within the rated rise range on
the furnace rating plate, and the firing rate has been set to
the nameplate value.
o
32 F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
--The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
--The furnace, ductwork and filters are cleaned as necessary
to remove drywall dust and construction debris from all
HVAC system components after construction is completed.
--After construction is complete, verify furnace operating
conditions including ignition, input rate, temperature rise
and venting, according to the manufacturer’s instructions.
A93058
Fig. 17 -- Freeze Protection
Furnace Location Relative to Cooling Equipment
The cooling coil must be installed parallel with or on downstream
side of furnace to avoid condensation in heat exchanger. When
installed parallel with a furnace, dampers or other means used to
control flow of air shall be adequate to prevent chilled air from
entering furnace. If dampers are manually operated, they must be
equipped with a means to prevent operation of either unit unless
damper is in full--heat or full--cool position.
15
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Hazardous Locations
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.
!
WARNING
Installation in Upflow or Downflow Applications
FIRE, EXPLOSION, INJURY OR DEATH
HAZARD
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when special base (available from
Manufacturer) Part No. KGASB is used. Special base is not
required when this furnace is installed on Manufacturer’s Cased
Coil Assembly or when Manufacturer’s Coil Box is used.
Improper location or inadequate protection could result in
fire or explosion.
When furnace is installed in a residential garage, it must be
installed so that burners and ignition sources are located a
minimum of 18 in. (457.2mm) above floor. The furnace
must be located or protected to avoid physical damage by
vehicles. When furnace is installed in a public garage,
airplane hangar, or other building having a hazardous
atmosphere, unit must be installed in accordance with
requirements of National Fire Protection Association, Inc.
(See Fig. 5.)
1. Determine application being installed from Table 1.
2. Construct hole in floor per dimensions specified in Table 1
and Fig. 19.
3. Construct plenum to dimensions specified in Table 2 and
Fig. 19.
4. If special base (KGASB) is used, install as shown in Fig.
20.
5. If Manuracturer’s Cased Coil Assembly or Manufacturer’s
Coil Box is used, install as shown in Fig. 21.
5⁄16″
NOTE: Remove furnace perforated discharge duct flanges when
they interfere with mating flanges on coil on downflow subbase.
To remove furnace perforated discharge duct flange, use hand
scanners, wide duct pliers or duct flange tool to bend flange back
and forth until it breaks off. Be careful of sharp edges. (See Fig.
22.)
5⁄16″
1 3⁄4″
!
CAUTION
1 3⁄4″
UNIT MAY NOT OPERATE HAZARD
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
5⁄16″
Do not bend duct flanges inward as shown in Fig. 22. This
will affect airflow across heat exchangers and may cause
limit cycling or premature heat exchanger failure. Remove
duct flange completely or bend it inward a minimum of
210_F (99_C) as shown in Fig. 22.
5⁄16″
1 3⁄4″
1 3⁄4″
Installation in Horizontal Applications
These furnaces can be installed in either horizontal left or right
discharge position. In a crawlspace, furnace can either be hung
from floor joist or installed on suitable blocks or pad. Furnace
can be suspended from each corner by hanger bolts and angle
iron supports. (See Fig. 23.) Cut hanger bolts (4 each 3/8--in.
all--thread rod) to desired length. Use 1 X 3/8--in. flat washers,
3/8--in. lock washers, and 3/8--in. nuts on hanger rods as shown
in Fig. 23. Dimples are provided for hole locations. (See Fig. 2.)
A89014
Fig. 18 -- Leveling Legs
INSTALLATION
Leveling Legs (If Desired)
When furnace is used in upflow position with side inlet(s),
leveling legs may be desired. (See Fig. 18.) Install field--supplied,
corrosion--resistant 5/16--in.(7.9mm) machine bolts and nuts.
!
CAUTION
NOTE: The maximum length of bolt should not exceed 1--1/2
in. (38.1mm).
UNIT MAY NOT OPERATE HAZARD
1. Position furnace on its back. Locate and drill a 5/16--in.
(7.9mm) diameter hole in each bottom corner of furnace.
(See Fig. 18.) Holes in bottom closure panel may be used
as guide locations.
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
The entire length of furnace MUST be supported when
furnace is used in a horizontal position to ensure proper
draining. When suspended, bottom brace supports sides
and center blower shelf. When unit is supported from the
ground, blocks or pad should support sides and center
blower shelf area.
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.)
16
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FURNACE
FACTORY SUPPLIED
CASED COIL OR COIL BOX
COMBUSTIBLE
FLOORING
A
PLENUM
OPENING
B
D
SHEET METAL
PLENUM
FLOOR
OPENING
C
FLOOR
OPENING
A96283
A07586
Fig. 19 -- Floor and Plenum Opening Dimensions
Fig. 21 -- Furnace, Plenum, and Coil Assembly or Coil Box
Installed on a Combustible Floor
FURNACE
PERFORATED
DISCHARGE DUCT
FLANGE
(OR OTHER MANUFACTURER S
COIL CASING WHEN USED)
NO
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
YES
SHEET METAL
PLENUM
FLOOR
OPENING
210¡
MIN
YES
A93029
A07585
Fig. 22 -- Duct Flanges
Fig. 20 -- Furnace, Plenum, and Subbase Installed on a
Combustible Floor
17
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3
/
8-IN. ROD
ANGLE
IRON OR
EQUIVALENT
3
5
/ ″
4
ALTERNATE SUPPORT
LOCATION 4-IN. MIN
8-IN. MAX
(B)
(A)
DRAIN
(B)
(A)
(B)
(A) ROD LOCATION
USING DIMPLE
LOCATORS
13/16-IN. MAX
ALTERNATE SUPPORT
LOCATION FROM BACK
3
/
8-IN. HEX NUT
& WASHER (4)
REQD PER ROD
(A)
(B)
(SEE DIMENSIONAL
DWG FOR
LOCATIONS)
NOTES:
1. A 1 In. clearance minimum between top of
furnace and combustible material.
(A) PREFERRED ROD LOCATION
(B) ALTERNATE ROD LOCATION
2. The entire length of furnace must be
supported when furnace is used in horizontal
position to ensure proper drainage.
A93304
Fig. 23 -- Crawlspace Horizontal Application for Direct Vent/2--Pipe Installation and for Ventilated Combustion Air Installation
18
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Table 1 – Opening Dimensions (in./mm)
APPLICATION
FURNACE
CASING
WIDTH
PLENUM OPENING
FLOOR OPENING
(APPROVED FACTORY SUPPLIED CASED COILS AND COIL BOX:
CD5, CKR, CAPVP, CARVP, CAPMP, CARMP, CNPVP, CNRVP, AND
KCAKC)
A
B
C
D
16 in./
406 mm
15--7/8 in./
403 mm
24--1/8 in./
613 mm
19 in./
16--5/8 in./
422 mm
16--1/2 in./
419 mm
24--3/4 in./
629 mm
19--5/8 in./
498 mm
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
483 mm
17 ½ in.
445 mm
15--1/8 in./
384 mm
19 in./
483 mm
16--3/4 in./
425 mm
20--3/8 in./
518 mm
Downflow applications on combustible flooring (KGASB sub-
base required)
Downflow Applications on Combustible Flooring with Factory
supplied cased coil or Factory supplied coil box (KGASB
subbase not required)
15--1/2 in./
394 mm
19 in./
483 mm
16--1/2 in./
419 mm
20 in./
508 mm
19--1/2 in./
495 mm
19--3/8 in./
492 mm
18--5/8 in.
473 mm
24--1/8 in./
613 mm
19 in./
483 mm
19 in./
20--1/8 in./
511 mm
20 in./
508 mm
20--1/4 in./
514 mm
24--3/4 in./
629 mm
19--5/8 in./
498 mm
20--3/8 in./
518 mm
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
21 in./
533 mm
Downflow applications on combustible flooring (KGASB sub-
base required)
483 mm
Downflow Applications on Combustible Flooring with Factory
supplied cased coil or Factory supplied coil box (KGASB
subbase not required)
19 in./
483 mm
19 in./
483 mm
20 in./
508 mm
20 in./
508 mm
23 in./
584 mm
22--7/8 in./
581 mm
24--1/8 in./
613 mm
19 in./
23--5/8 in./
600 mm
23--1/2 in./
597 mm
24--3/4 in./
629 mm
19--5/8 in.
498 mm
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
483 mm
24--1/2 in./
622 mm
22--1/8 in./
562 mm
19 in./
483 mm
23--3/4 in./
603 mm
20--3/8 in./
518 mm
Downflow applications on Combustible flooring (KGASB
subbase required)
Downflow Applications on Combustible Flooring with Factory
supplied cased coil or Factory supplied coil box (KGASB
subbase not required)
22--1/2 in./
572 mm
19 in./
483 mm
23--1/2 in./
597 mm
20 in./
508 mm
Ductwork Acoustical Treatment
AIR DUCTS
Metal duct systems that do not have a 90 degree elbow and 10 ft
(3 m) of main duct to the first branch take--off may require
internal acoustical lining. As an alternative, fibrous ductwork may
be used if constructed and installed in accordance with the latest
edition of SMACNA construction standard on fibrous glass
ducts. Both acoustical lining and fibrous ductwork shall comply
with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid
air ducts.
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.
Supply Air Connections
Upflow Furnaces
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air must also be handled by a duct(s) sealed to
the furnace casing and terminating outside the space containing
the furnace.
Connect supply--air duct to 3/4--in. (19.0mm)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.
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.
Downflow Furnaces
Flexible connections should be used between ductwork and
furnace to prevent transmission of vibration. Ductwork passing
through unconditioned space should be insulated to enhance
system performance. When air conditioning is used, a vapor
barrier is recommended.
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.
Supply air opening duct flanges must be modified per Fig. 22.
Maintain a 1--in. (25.4mm) clearance from combustible materials
to supply air ductwork for a distance of 36 in. (914.4mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the air stream. The cover attachment shall prevent leaks.
Horizontal Furnaces
Connect supply--air duct to supply--air opening on furnace. The
supply--air duct attachment must ONLY be connected to furnace
supply/outlet or air conditioning coil casing (when used). DO
NOT cut main furnace casing to attach supply side air duct,
19
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humidifier, or other accessories. All accessories MUST be
connected external to furnace main casing.
Return Air Connections
!
CAUTION
CUT HAZARD
!
Failure to follow this caution may result in personal injury.
WARNING
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.
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
Never connect return--air ducts to the back of the furnace.
Return air duct connections on furnace side(s) permitted in
upflow applications only.
!
CAUTION
UNIT MAY NOT OPERATE
Upflow Furnaces
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
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.
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 one side and the bottom, or the bottom only will ensure
adequate return air openings for airflow requirements above
1800 CFM.
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.
Table 2 – Filter Information
Filter Arrangement
AIR FILTER LOCATED IN BLOWER COMPARTMENT
!
Furnace
Filter Size (In./mm)
WARNING
Filter Type
Framed
Casing Width
Side
Return
Bottom
Return*
FIRE, CARBON MONOXIDE AND POISONING
HAZARD
17---1/2 in.
(445 mm.)
(1) 16 x 25 x 1
(in.){
406 x 635 x 25
(mm)
(1) 16 x 25 x 1{
406 x 635 x 25
(mm)
Cleanable
Failure to follow this warning could result in personal
injury, death or property damage.
(1) 16 x 25 x 1*
406 x 635 x 25
(mm)
(1) 20 x 25 x 1{
508 x 635 x 25
(mm)
Cleanable
Never operate unit without a filter or with filter access door
removed.
21
(533 mm.)
(1 or 2)
16 x 25 x 1*
406 x 635 x 25
(mm)
(1) 24 x 25 x 1{
610 x 635 x 25
(mm)
24---1/2
(622 mm.)
Cleanable
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.
* Filters may be field modified by cutting filter material and support rods (3) in filters.
Alternate sizes can be ordered from your distributor or dealer
{ Factory---provided with the furnace
If a factory--supplied external Filter/Media cabinet is provided,
instructions for its application, assembly, and installation are
packaged with the cabinet. The Filter/Media cabinet can be used
with the factory--supplied washable filter or a factory--specified
high--efficiency disposable filter (see cabinet instructions).
If installing the filter in the furnace blower compartment,
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.
20
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NOTE: Remove and discard bottom closure panel when bottom
inlet is used.
WASHABLE
FILTER
Bottom Closure Panel
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
side return air is used.
FILTER
RETAINER
To remove bottom closure panel, perform following:
1. Tilt or raise furnace and remove two screws holding front
filler panel. (See Fig. 26.)
2. Rotate front filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall front filler panel and screws.
Gas Piping
Gas piping must be installed in accordance with national and
local codes. Refer to NFGC in the U.S. Canadian installations
must be made in accordance with CAN/CSA--B149.1--05 and all
authorities having jurisdiction. Gas supply line should be a
separate line running directly from meter to furnace, if possible.
Refer to Table 3 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of one
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.
A93045
Fig. 24 -- Filter Installed for Side Inlet
NOTE: Side return--air openings can ONLY be used in Upflow
configurations. Install filter(s) as shown in Fig. 24.
For bottom return--air applications, filter may need to be cut to fit
some furnace widths. Install filter as shown in Fig. 25.
21-IN. WIDE
CASINGS ONLY:
171⁄2-IN. WIDE
CASINGS ONLY:
SUPPORT RODS (3)
EXTEND 1/4" ON EACH
SIDE OF FILTER AND
REST ON CASING FLANGE
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
3″
1
24 / ″
2
-- Connect gas pipe to furnace using a backup wrench to
avoid damaging gas controls.
-- Gas valve shutoff switch MUST be facing forward or
tilted upward.
1
″
-- Never purge a gas line into a combustion chamber.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically
for the detection of leaks to check all connections.
-- Use proper length of pipe to avoid stress on gas
control manifold.
-- If a flexible connector is required or allowed by
authority having jurisdiction, black iron pipe shall be
installed at furnace gas valve and extend a minimum
of 2 in. (50.8mm) outside furnace casing.
--Protect gas valve from water and debris. Gas valve
inlet and/or inlet piping must remain capped until gas
supply line is permanently installed to protect the valve
from moisture and debris. Also, install a sediment trap
in the gas supply piping at the inlet to the gas valve.
WASHABLE
FILTER
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. 27.)
An accessible manual shutoff valve MUST be installed external
to furnace casing and within 6 ft (1.8 m)of furnace. A 1/8--in.
NPT (3.2mm) plugged tapping, accessible for test gauge
connection, MUST be installed immediately upstream of gas
supply connection to furnace and downstream of manual shutoff
valve.
FILTER
RETAINER
FILTER
SUPPORT
A00290
Fig. 25 -- Bottom Filter Arrangement
Gas line grommet (factory--supplied loose parts bag) should be
used when installing gas piping. Gas line entry hole filler plug
should be installed in unused gas line entry hole. (See Fig. 28.)
21
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BOTTOM
CLOSURE
PANEL
FRONT FILLER
PANEL
A93047
Fig. 26 -- Removing Bottom Closure Panel
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
A93324
Fig. 27 -- Typical Gas Pipe Arrangement
COMBUSTION-AIR PIPE GROMMET
UNUSED 1-3/4 -IN.
DIAMETER GAS
CONN. HOLE
COMBUSTION
-AIR PIPE
GAS LINE
VENT PIPE
GAS LINE ENTRY
HOLE FILLER PLUG
GAS LINE GROMMET
VENT PIPE GROMMET
NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER
PLUGS ARE INCLUDED IN FACTORY-SUPPLIED
LOOSE PARTS BAG
A05057
Fig. 28 -- Casing Pipe Grommets
22
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Table 3 – Maximum Capacity of Pipe*
!
WARNING
NOMINAL
IRON
PIPE
SIZE
(IN.)
1/2
3/4
1
1 --- 1 / 4
1 --- 1 / 2
LENGTH OF PIPE (FT/M)
INTERNAL
UNIT MAY NOT OPERATE
DIAMETER
20/
6.1
30/
9.1
40/
12.2
50/
10/
3.0
(IN.)
Failure to follow this caution may result in intermittent
unit operation.
15.2
0.622
0.824
1.049
1.380
1.610
175
360
680
1400
2100
120
250
465
950
1460
97
200
375
770
1180
82
73
Furnace control must be grounded for proper operation
or control will lock out. Control is grounded through
green/yellow wire connected to gas valve and burner
box screw.
170
320
660
990
151
285
580
900
* Cubic ft of gas per hr for gas pressure of 0.5 psig (14---in. wc) or less, and a pressure
drop of 0.5---in. wc (based on a 0.60 specific gravity gas). Ref: Table 9---2 NFPA
54---2002.
115--v Wiring
NOTE: The gas valve inlet pressure tap connection is suitable to
use as test gauge connection providing test pressure DOES NOT
exceed maximum 0.5 psig (14--in. wc) stated on gas valve. (See
Fig. 60.)
Before proceeding with electrical connections, make certain that
voltage, frequency, and phase correspond to that specified on
furnace rating plate. Also, check to be sure that service provided
by power supply is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 4 for equipment
electrical specifications.
Make all electrical connections in accordance with National
Electrical Code (NEC) ANSI/NFPA 70--2005 and any local codes
or ordinances that might apply. For Canadian installations, all
electrical connections must be made in accordance with Canadian
Electrical Code CSA C22.1 or authorities having jurisdiction.
Field--supplied wiring shall conform with the limitations of 63_F
(33_C) rise.
The furnace must be electrically grounded in accordance with
local codes; or in the absence of local codes, with the National
Electric Code ANSI/NFPA 70 and/or the Canadian Electric Code,
CSA C22.1, Part I, if an external electrical source is utilized.
Piping should be pressure and leak tested in accordance with
NFGC in the United States or CAN/CSA--B149.1--05 in Canada,
local, and national plumbing and gas codes before the furnace has
been connected. If pressure exceeds 0.5 psig (14--in. wc), gas
supply pipe must be disconnected from furnace and capped
before pressure test.
If test pressure is equal to or less than 0.5 psig (14--in. wc), turn
off electric shutoff switch located on gas valve before test. It is
recommended that ground joint union be loosened before
pressure testing. After all connections have been made, purge
lines and check for leakage at furnace prior to placing it into
service.
The gas supply pressure shall be within the maximum (13.6--in.
wc) and minimum (4.5--in.wc) inlet supply pressures marked on
the rating plate with the furnace burners ON at HI--HEAT and
OFF.
Use a separate 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 or furnace is not grounded properly, furnace
control status code indicator light will flash rapidly and furnace
will NOT operate.
Electrical Connections
See Fig. 29 for field wiring diagram showing typical field 115--v
and 24--v wiring. Check all factory and field electrical
connections for tightness.
!
!
WARNING
WARNING
FIRE HAZARD
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Failure to follow this warning could result in personal
injury or death.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire. (See Fig. 30.)
Blower access door switch opens 115--v power to furnace
control. No component operation can occur. Do not bypass
or close switch with panel removed.
23
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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
TERMINALS
W
C
R
G
Y
FIVE
WIRE
FIELD-SUPPLIED
DISCONNECT
THREE-WIRE
HEATING
ONLY
208/230- OR
460-V
THREE PHASE
W/W1
GND
GND
GND
115-V
SINGLE
PHASE
NOTE
3
W2
R
208/230-V
SINGLE
PHASE
G
C
AUXILIARY
J-BOX
115-V
FIELD-SUPPLIED
DISCONNECT
SWITCH
GND
NOTE 1
CONDENSING
UNIT
Y/Y2
TWO WIRE
NOTES:
24-V
TERMINAL
BLOCK
FURNACE
CONTROL
CENTER
1. Connect Y or Y/Y2 terminal as shown for proper cooling operation.
2. Proper polarity must be maintained for 115-v wiring.
3. Use W2 with 2-stage thermostat when zoning.
4. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
5. Some thermostats require a "C" terminal connection as shown.
A98325
Fig. 29 -- Heating and Cooling Application Wiring Diagram
Table 4 – Electrical Data
MAXIMUM
WIRE
LENGTH}
MAXIMUM
OPERATING VOLTAGE
MAXIMUM
V O LT S ---
H E R T Z ---
PHASE
FUSE OR CKT
BKR
MINIMUM
WIRE SIZE
RANGE
UNIT
UNIT SIZE
AMPS
Maximum*
Minimum*
AMPS**
042060
042080
060080
060100
060120
1 1 5 --- 6 0 --- 1
1 1 5 --- 6 0 --- 1
1 1 5 --- 6 0 --- 1
1 1 5 --- 6 0 --- 1
1 1 5 --- 6 0 --- 1
127
127
127
127
127
104
104
104
104
104
8.96
8.96
14
14
12
12
12
30 ft. / 9.1 m
30 ft. / 9.1 m
31 ft. / 9.4 m
31 ft. / 9.4 m
31 ft. / 9.4 m
15
15
20
20
20
14.06
14.06
14.06
* Permissible limits of voltage range at which unit will operate satisfactorily.
{
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 as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
** Time---delay type is recommended.
!
WARNING
ELECTRIC
DISCONNECT
SWITCH
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in electrical
shock, fire, or death.
COPPER
WIRE ONLY
The cabinet MUST have an uninterrupted or unbroken
ground according to NEC ANSI/NFPA 70--2005 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.
ALUMINUM
WIRE
A93033
Fig. 30 -- Disconnect Switch and Furnace
24
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Factory Installed J--Box Location
24--v wiring
Install power entry hole filler plugs (factory--supplied in loose
parts bag) in unused power entry holes. (See Fig. 31.)
Make field 24--v thermostat connections at 24--v terminal block
on furnace control. Y wire from thermostat MUST be connected
to Y/Y2 terminal on control, as shown in Fig. 19, for proper
cooling operation. The 24--v terminal block is marked for easy
connection of field wiring. (See Fig. 33.) The 24--v circuit
contains a 3--amp, automotive--type fuse located on furnace
control. (See Fig. 33.)
FACTORY
INSTALLED
LOCATION
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) and type. The
furnace control will flash status code 24 when fuse needs
replacement.
POWER ENTRY HOLE
FILLER PLUG (FACTORY-
SUPPLIED LOOSE PARTS BAG)
DIAMETER POWER
UNUSED 7/8-IN.
ENTRY HOLES
A05113
NOTE: Use AWG No. 18 color--coded copper thermostat wire
for lengths up to 100 ft. For wire lengths over 100 ft, use AWG
No. 16 wire.
A05113
Fig. 31 -- Factory Installed J--Box Location
NOTE:
reference Fig. 52--59.
For additional thermostat connection diagrams,
J--Box Relocation
1. Remove two screws holding auxiliary J--box. (See Fig.
32.)
2. Rotate J--box 180_ and attach box to left side, using holes
Accessories
1. Electronic Air Cleaner (EAC)
The furnace control EAC terminals are energized with
115v (1.0--amp maximum) during blower operation.
Connect an accessory Electronic Air Cleaner (if used)
using 1/4--in. female quick connect terminals to the two
male 1/4--in. quick--connect terminals on the control board
marked EAC--1 and EAC--2. The terminals are rated for
115VAC, 1.0 amps maximum and are energized during
blower motor operation. (See Fig. 33.)
provided.
ALTERNATE
FIELD
LOCATION
FACTORY
INSTALLED
LOCATION
NOTE: Low stage airflow may slightly increase the trace
amount of ozone created by an electronic air cleaner. Individual
sensitivity levels to ozone, along with other operating
characteristics of electronic air cleaners may affect the amount
noticed by an individual. Refer to the air cleaner manufacturer’s
installation instructions for more information regarding ozone
and ozone reduction methods available for your air cleaner.
!
CAUTION
UNIT DAMAGE HAZARD
A00212
Failure to follow this caution may result in unit component
damage.
Fig. 32 -- J--Box Relocation
DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistatt, Zone Controller or
similar device. See Thermidistatt, Zone Controller,
thermostat, or controller manufacturer’s instructions for
proper connection.
3. Install power entry hole filler plugs (factory--supplied
loose parts bag) in unused power entry holes. (See Fig.
31.)
!
WARNING
2. Humidifier (HUM)
FIRE OR ELECTRICAL SHOCK HAZARD
Connect an accessory 24 VAC, 0.5 amp maximum
humidifier (if used) to the 1/4--in. male quick--connect
HUM terminal and COM--24V screw terminal on the
control board thermostat strip. The HUM terminal is
energized when blower is energized in heating. (See Fig.
33.)
Failure to follow this warning could result in personal
injury, death, or property damage.
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.
NOTE:
If modulating dampers are used, blower motor
automatically compensates for modulating dampers. 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.
25
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Removal of Existing Furnaces from Common Vent Systems
!
When an existing Category I furnace is removed or replaced, the
original venting system may no longer be sized to properly vent
the remaining attached appliances. An improperly sized Category
I venting system could cause the formation of condensate in the
furnace and vent, leakage of condensate and combustion
products, spillage of combustion products into the living space,
etc.
WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
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.
AIR FOR COMBUSTION AND VENTILATION
!
CAUTION
In Canada, construct all combustion--air and vent pipes for this
unit of CSA or ULC listed schedule--40 PVC, PVC--DWV or
ABSDWV pipe and pipe cement. SDR pipe is NOT approved in
Canada.
FURNACE RELIABILITY HAZARD
Failure to follow this caution could result in premature
component failure.
This furnace can be vented as either a direct vent (2--pipe)
furnace or as an optional ventilated combustion air
application. A direct vent system shall be installed in
accordance with the direct vent (2-- pipe) procedures in the
Combustion Air and Vent Pipe Systems section within this
supplemental instruction. For optional ventilated
combustion air applications, refer to the ventilated
combustion air option procedures in the same section.
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.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
All combustion--air and vent pipes must be airtight and
watertight. Pipes must also terminate exactly as shown in
Fig. 36 for direct vent (2--pipe) system or Fig. 37 for
ventilated combustion air option.
An abandoned masonry chimney may be used as a raceway for
properly insulated and supported combustion--air (when
applicable) and vent pipes. Each furnace must have its own set of
combustion--air and vent pipes and be terminated individually, as
shown in Fig. 36 for Direct Vent (2--Pipe) system or Fig. 37 for
ventilated combustion air option.
Combustion--Air and Vent Pipe Systems
General
Vent system or vent connectors of other appliances 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 CAN/CSA--B149.1--05.
A furnace shall not be connected to a chimney flue serving a
separate appliance designed to burn solid fuel.
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 contaminating the combustion air of other gas appliances.
Do not take combustion air from inside the chimney when using
the Ventilated Combustion Air option.
The 355CAV furnaces can be vented as either a direct vent
furnace or as an optional ventilated combustion air application. A
direct vent system shall be installed in accordance with the direct
vent (2--pipe) procedures in the following Combustion Air and
Vent Pipe Systems section. For optional ventilated combustion air
applications, refer to the ventilated combustion air option
procedures in the same section. Common venting prohibited.
Direct Vent / 2--Pipe System
In a direct--vent (2--pipe) system, all air for combustion is taken
directly from outdoor atmosphere, and all flue products are
discharged to outdoor atmosphere. Combustion--air and vent
pipes must terminate together in the same atmospheric pressure
zone, either through the roof or a sidewall (roof termination
preferred). A factory accessory vent termination kit MUST be
used in a direct vent (2--pipe) system. See Fig. 34 for required
clearances.
!
CAUTION
UNIT MAY NOT OPERATE HAZARD
Failure to follow this caution may result in intermittent unit
operation.
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 6 with Armaflex--type insulation.
Ventilated Combustion Air Option Materials
In a ventilated combustion air option, the vent terminates and
discharges the flue products directly to the outdoors similar to a
direct vent system. See Fig. 35 for required clearances. All air for
combustion is piped directly to the furnace from a space that is
well ventilated with outdoor air (such as an attic or crawl space)
and the space is well isolated from the living space or garage.
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. The transition has to be made as close to
the furnace as reasonably possible. (See Fig. 38.)
Materials
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 5 for approved materials for use in
the U.S.A.
26
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Table 5 – Approved Combustion--Air and Vent Pipe, Fitting and Cement Materials
SOLVENT
ASTM
SPECIFICATION
MATERIAL
PIPE
FITTINGS
DESCRIPTION
CEMENT
(MARKED ON
MATERIAL)
D1527
AND PRIMERS
ABS
PVC
For ABS
Pipe
Pipe
—
—
—
—
—
—
Solvent
Cement
—
—
—
Solvent
Cement
—
—
—
—
—
Solvent
Cement
Schedule40
Schedule40
For ABS
D1785
D2235
D2241
D2466
D2468
D2564
PVC
PVC
ABS
Pipe
—
—
—
SDR21 & SDR26
Schedule40
Schedule40
For PVC
Fittings
Fittings
—
For PVC
—
D2661
D2665
F438
F441
F442
ABS
PVC
CPVC
CPVC
CPVC
For CPVC
Pipe
Pipe
—
Pipe
Pipe
—
Fittings
Fittings
Fittings
—
—
—
DWV at Schedule40 IPS sizes
DWV
Schedule40
Schedule40
SDR
F493
For CPVC
Cellular Core DWV at Schedule40
F628
F656
F891
ABS
For PVC
PVC
Pipe
—
—
—
—
—
Primer
—
IPS sizes
For PVC
Cellular Core Schedule40 &
DWV
Pipe
Installation Guidelines for Combustion Air Pipe and Vent
Pipe
piping and vent piping a minimum of every 5 ft (1.5 m)(3
ft (.91 m) for SDR--21 or --26 PVC) using perforated
metal hanging strap.
It is recommended that all pipes be cut, prepared, and
preassembled before permanently cementing any joint.
12. Slope combustion air piping and vent piping downward
towards furnace a minimum of 1/4--in. per linear ft with no
sags between hangers.
1. Attach combustion air pipe and vent pipe per instructions
in sections “Combustion Air Pipe” and “Vent Pipe.”
13. Horizontal portions of the venting system shall be installed
so as to prevent the accumulation of condensate.
2. Working from furnace to outside, cut pipe to required
length(s).
14. Use appropriate methods to seal openings where
combustion air pipe and vent pipe pass through roof or
sidewall.
3. Deburr inside and outside of pipe.
4. Chamfer outside edge of pipe for better distribution of
primer and cement.
Combustion--Air and Vent Pipe Diameter
5. Clean and dry all surfaces to be joined.
6. Check dry fit of pipe and mark insertion depth on pipe.
Determine combustion--air and vent pipe diameter.
1. Using Table 7, individually determine the diameter of the
combustion--air and vent pipe allowed. If different, pick
the larger of these two 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.
7. 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 pipe 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.
8. While cement is still wet, twist pipe into socket with 1/4
turn. Be sure pipe is fully inserted into fitting socket.
9. Wipe excess cement from joint. A continuous bead of
cement will be visible around perimeter of a properly
made joint.
NOTE: Do not count elbows or pipe sections in terminations or
within furnace.
NOTE: A 2--in. diameter pipe must be used within furnace
casing. Make all pipe diameter transitions outside furnace casing.
10. Handle pipe joints carefully until cement sets.
11. Horizontal portions of the venting system shall be
supported to prevent sagging. Support combustion air
27
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USER INTERFACE
OR ADVANCED
PRODUCT
MONITOR
CONNECTOR
CONTINUOUS FAN
(CF) AIRFLOW
SETUP SWITCHES
SW4 SETUP
SWITCHES
OAT
CONNECTOR
MODEL PLUG
CONNECTOR
SW1 SETUP
SWITCHES AND
BLOWER OFF-
DELAY
AIR CONDITIONING
(A/C) AIRFLOW
SETUP SWITCHES
HUMIDIFIER
TERMINAL (24-VAC
0.5 AMP MAX.
ACRDJ – AIR
CONDITIONING
RELAY DISABLE
JUMPER
24-V THERMOSTAT
TERMINALS
FLASH
UPGRADE
CONNECTOR
(FACTORY
ONLY)
STATUS AND COMM
LED LIGHTS
PL3 – ECM BLOWER
HARNESS
3-AMP FUSE
CONNECTOR
TRANSFORMER 24-VAC
CONNECTIONS
BOARD SERIAL
NUMBER
115-VAC (L2) NEUTRAL
CONNECTIONS
EAC-1 TERMINAL
(115 -VAC 1.0 AMP MAX.)
PL1 – LOW VOLTAGE MAIN
HARNESS CONNECTOR
115-VAC (L1) LINE
VOLTAGE CONNECTIONS
PL2 – HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
EXAMPLE:
V12 HK42FZ022 3407
SOFTWARE
VERSION
NUMBER
PART
NUMBER
DATE
CODE
A07422
Fig. 33 -- Furnace Control
28
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12 inches (30 cm) for applieances >10,000 Btuh(3 kW)
and < 100,000 Btuh(30kW), 36 inches (91cm) for
appliances > 100,000 Btuh(30kW)
A06675
Fig. 34 -- Direct Vent Termination Clearance
29
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A05013
Fig. 35 -- Ventilated Combustion Air Vent Termination Clearance
30
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Roof Termination (Preferred)
At least 36 in.
Concentric Vent and Combustion Air
Roof Termination (preferred)
A
Vertical separation
between combustion
air and vent
8 3/4 in. for 3 in. kit
6 3/4 in. for 2 in. kit
A
At least
36 in.
Maintain 12 in.
min. clearance above
highest anticipated
snow level, maximum of
24 in. above roof
18 in. maximum
Maintain 12 in. min.
clearance above
highest anticipated
snow level
Maximum of 24 in.
above roof
1
in. maximum (typ) from wall to inlet
Abandoned masonry
used as raceway
(per code)
12 in. minimum from
overhang or roof
Note: "A" denotes 0 to < 2 in.
Between the first 2 vents
Third vent must be > 36 in. away
A
t le
a
.
3
st
6
A
in
Maintain 12 in.
min. clearance above
highest anticipated
snow level or grade
whichever is greater
12 in. min from
overhang or roof
(typ)
Concentric Vent
and Combustion - Air
Side Termination
A
At least 36 in.
12 in. separation
between bottom of
combustion air and
bottom of vent (typ)
90°
Side wall termination
of less than 12 in. above highest snow level
A
Maintain 12 in.
.
min. clearance above
highest anticipated
snow level or grade
At least 36 in
whichever is greater (typ)
A05090
Fig. 36 -- Combustion Air and Vent Termination for Direct Vent (2--pipe) System
Roof Termination (Preferred)
Vent
Maintain 12 in.
minimum clearance
above highest anticipated
snow level maximum of
24 in. above roof.
Abandoned masonry
used as raceway
(per code)
12 in. min. from
overhang or roof
6 in. minimum clearance
between wall and end of vent pipe.
10 in. maximum pipe length
Maintain 12 in.
minimum clearance
above highest anticipated
snow level or grade
whichever is greater
12 in. min. from
overhang or roof
Sidewall Termination
with Straight Pipe (preferred)
90°
Maintain 12 in.
minimum clearance
above highest anticipated
snow level or grade
whichever is greater.
Side wall termination
with 2 elbows (preferred)
A05091
Fig. 37 -- Vent Pipe Termination for Ventilated Combustion Air System
31
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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
FLOW
COMBUSTION-
AIR
COMBUSTION-
AIR
FURNACE
VENT
VENT
VENT
VENT
NOT IN
HORIZONTAL
SECTION
COMBUSTION-
AIR
COMBUSTION-
AIR
PIPE DIAMETER
TRANSITION IN
VERTICAL SECTION
AIR
FLOW
UPFLOW
DOWNFLOW
A93034
COMBUSTION-
AIR
Fig. 38 -- Combustion Air and Vent Pipe Transition
Location and Elbow Configuration
COMBUSTION-
AIR
VENT
VENT
AIR
FLOW
AIR
FLOW
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in intermittent unit
operation.
When installing combustion air and vent system of short
pipe length, the smallest allowable pipe diameter must be
used.
HORIZONTAL-LEFT DISCHARGE
HORIZONTAL-RIGHT DISCHARGE
A96187
Fig. 39 -- Combustion Air and Vent Pipe Connections
!
CAUTION
NOTE: All pipe joints must be cemented except attachment of
combustion--air pipe to inlet housing connection, since it may be
necessary to remove pipe for servicing.
UNIT CORROSION HAZARD
Failure to follow this caution may result in unit component
damage.
NOTE: A 2--in. diameter pipe must be used within the furnace
casing. Make all pipe diameter transitions outside furnace casing.
Excessive exposure to contaminated combustion air may
result in safety and performance related problems.
Combustion air must not be taken from inside structure
because that 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.
Attachment of Combustion Air Pipe
NOTE: Combustion air pipe system has the same diameter and
same length as the vent pipe as mentioned in section
“Combustion-- --Air and Vent Pipe Diameter.”
1. Determine location of combustion--air intake pipe
connection to combustion--air intake housing as shown in
Fig. 39 for application.
2. Verify combustion--air intake housing plug fitting is
installed in appropriate unused intake housing connection.
3. Install combustion--air pipe grommet (factory--supplied in
loose parts bag) into selected furnace casing combustionair
pipe hole.
4. Determine the number of combustion air disk halves to be
installed in the combustion air intake housing. Insert
perforated disk half or assembly (factory supplied in loose
parts bag) in intake housing where combustion--air intake
pipe will be connected.
EXAMPLE: This 80,000 BTUH furnace located in Indianapolis,
elevation 650 ft above sea level, could be installed as a direct
vent/2--pipe system that requires 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. According
to Table 7, 1--1/2--in. diameter pipe is good for 20 ft with 3
elbows, but only 10 ft with 5 elbows. Therefore, 2--in. diameter
pipe must be used for both vent and combustion--air pipes since
the largest required diameter must always be used for both pipes.
If the same installation was made in Albuquerque, elevation 5250
ft above sea level, installation would require 2-- in. diameter 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 are required.
5. Insert assembled combustion air inlet pipe into intake
housing as shown in Fig. 39.
NOTE: Do not cement combustion air intake pipe permanently
to combustion air intake housing since it may be necessary to
remove pipe for service of igniter or flame sensor.
6. Drill a 1/8--in. hole in 2--in, combustion air pipe using the
hole in intake housing as a guide.
COMBUSTION AIR PIPE
General
7. Install a field--supplied No. 6 or No. 8 sheet metal screw
into combustion air pipe.
Furnace combustion--air connection must be attached as shown in
Fig. 39. Combustion--air intake housing plug may need to be
relocated in some applications.
32
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COMBUSTION AIR
INTAKE HOUSING
!
CAUTION
3/8" ID TUBE
BURNER
BOX
UNIT CORROSION HAZARD
Failure to follow this caution may result in reduced furnace
component life.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements may corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
3/16"
DRILL
COMBUSTION
AIR PIPE
4″
MIN
TRAP
TO OPEN
DRAIN
The combustion air pipe cannot be terminated in attics or
crawlspaces that use ventilation fans designed to operate during
the heating season. If ventilation fans are present in these areas,
the combustion air pipe must terminate outdoors as a Direct
Vent/2-- Pipe system.
A93035
Fig. 40 -- Intake Housing Plug Fitting Drain
8. Install casing hole filler cap (factory--supplied in loose
parts bag) in unused combustion air pipe casing hole.
!
WARNING
Attachment of Combustion Air Intake Housing Plug Fitting
The combustion--air intake plug fitting must be installed in
unused combustion air intake housing. This fitting must be
attached by using RTV sealant, or by drilling a 1/8--in. hole in
fitting, using hole in intake housing as a guide. Install a
field--supplied No. 6 or No. 8 sheet metal screw.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage of
intake housing or fitting may cause air leakage to occur.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Makeup air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to the
Carbon Monoxide Poisoning Hazard warning at the end of
this section to determine if an adequate amount of make--up
air is available.
A plugged drain connection has been provided on this fitting for
use when moisture is found in combustion air intake pipe and
combustion box.
If use of this drain connection is desired, drill out fitting’s tap
plug with 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, as shown in Fig. 40.
NOTE: Combustion air pipe must have the same diameter as
vent pipe.
NOTE: (Direct Vent/2--Pipe System ONLY). Moisture in
combustion air intake may be a result of improper termination.
Ensure combustion air pipe termination is similar to those as
shown in Fig. 36 so that it will not be susceptible to area where
light snow or others sources of moisture could be pulled in.
An attic or crawlspace may be considered a space that freely
communicates with the outdoors provided there are adequate
permanent ventilation openings directly to outdoors having free
area of at least 1--in.2/4,000 Btuh of total input rating for all gas
appliances in the space.
Combustion Air Termination -- Ventilated Combustion Air
Option
NOTE: In determining the free area of an opening, the blocking
effect of the louvers, grilles, and screens must be considered. If
the free area of a louver or grille design is unknown, it may be
assumed that wood louvers have a 20 percent free area, and metal
louvers or grilles have a 60 percent free area. Screens, when used,
must not be smaller than 1/4--in. mesh. Louvers and grilles must
be constructed so they cannot be closed.
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
S
U.S. Installations: Section 9.3 of the NFGC, Air for
Combustion and Ventilation and applicable provisions
of the local building codes.
S
Canadian Installations: Part 8 of CAN/CS--B149.1--05.
Venting Systems and Air Supply for Appliances and all
authorities having jurisdiction.
!
WARNING
Combustion air is piped directly to the burner box on furnace
using the same materials used to vent the furnace. (See Table 5.)
The combustion air pipe is terminated in an attic or crawl space
that is well ventilated with OUTDOOR AIR and is well isolated
from the living space or garage. If the furnace is installed in a well
ventilated attic, crawlspace or other enclosure, the combustion air
pipe can be terminated in the same space.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
Attic terminations require at least (1) 90 degree elbow, with the
open end pointing horizontally or downward. The open end of
the elbow must be at least 12--in. (304.8mm) above any
insulation or other materials. Screen the elbow with a wire mesh
screen no smaller than 3/8--inch square. (See Fig. 41.)
33
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Crawlspace terminations require the open end of the combustion
air intake pipe to point downward. Maintain 3 inches (76.2mm)
of clearance below the floor joist insulation and 12 inches
(304.8mm) above the grade. Screen the elbow with a wire mesh
screen no smaller than 3/8--in. (9.5mm) square. (See Fig. 42 and
43.)
VENT PIPE
General
Furnace vent connection must be attached as shown in Fig. 39.
!
WARNING
!
WARNING
CARBON MONOXIDE POISONING AND
PROPERTY DAMAGE HAZARD
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Failure to follow the steps outlined below for each
appliance connected to the venting system being placed into
operation could result in carbon monoxide poisoning or
death.
Vent pipes must be airtight.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
NOTE: A 2--in. (50.8mm) diameter pipe must be used within the
furnace casing. Make all pipe diameter transitions outside furnace
casing per Fig. 38.
The minimum vent pipe length for these furnaces is 5 ft. (1.5M)
Short pipe lengths (5--8 ft or 1.5M -- 2.4M) may discharge
condensate droplets. These condensate droplets may be
undesirable. A 12--in. (304.8mm) minimum offset pipe section is
recommended to reduce excessive condensate droplets from
exiting vent pipe outlet. (See Fig. 44.)
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas
Code, ANSI Z223.1--2006/NFPA 54--2006 or the
CSA B149.1, Natural Gas and Propane Installation
Code and these instructions. Determine that there is
no blockage or restriction, leakage, corrosion and
other deficiencies, which could cause an unsafe
condition.
Attachment of Vent Pipe
NOTE: Vent pipe system has the same diameter and same length
as combustion air pipe as mentioned in section “Combustion Air
Pipe and Vent Pipe Diameter.”
3. As far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system are
located and other spaces of the building.
!
CAUTION
4. Close fireplace dampers.
UNIT DAMAGE HAZARD
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts, so they are operating at maximum speed.
Do not operate a summer exhaust fan.
Failure to follow this caution may result in unit component
damage.
Inducer housing outlet cap must be installed and fully
seated against inducer housing. Clamp must be tightened to
prevent any condensate leakage.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. Test for spillage from draft hood equipped
appliances at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle.
Vent pipe must be installed and fully seated against inducer
housing. Clamp must be tightened to prevent any
condensate leakage.
1. Determine location of vent pipe connection to inducer
housing as shown in Fig. 39 for application.
2. Verify synthetic rubber inducer housing outlet cap and
clamp are installed on appropriate unused inducer housing
connection and that clamp is tight.
3. Install vent pipe grommet (factory--supplied in loose parts
bag) into selected furnace casing vent pipe hole. (See Fig.
28.)
8. If improper venting is observed during any of the
above tests, the venting system must be corrected in
accordance with the National Fuel Gas Code, ANSI
Z223.1-- 2006/NFPA 54--2006 and/or CSA B149.1,
Natural Gas and Propane Installation Code.
9. After it has been determined that each appliance
connected to the venting system properly vents when
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other
gas--fired burning appliance to their previous
conditions of use.
4. Be certain that mating surfaces of inducer housing
connection synthetic rubber coupling, and 2--in. diameter
vent pipe are clean and dry. Assemble the synthetic rubber
vent coupling (with 2 loose clamps) onto inducer housing
connection. Insert the 2--in. diameter vent pipe through the
synthetic rubber coupling and fully into inducer housing
connection until it touches a stop inside the inducer
housing outlet. Tighten the screws on both clamps to
15--inlb. of torque.
Combustion Air Termination--Direct Vent / 2--Pipe System
Combustion air pipe must terminate outside the structure with the
vent pipe as shown in Fig. 36. Follow the clearance requirements
shown in Fig. 39. Refer to Vent Termination section for complete
details on termination options.
5. Install casing hole filler cap (factory--supplied in loose
parts bag) in unused vent pipe casing hole.
34
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(304.8mm)
minimum
A06672
Fig. 41 -- Attic Termination
(76.2 mm)
minimum
(304.8 mm)
minimum
A06673
Fig. 42 -- Crawlspace Termination
35
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3” (76.2mm)
minimum
(304.8mm)
minimum
A06674
Fig. 43 -- Crawlspace Termination
36
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12″ MIN
12″ MIN
VENT PIPE
VENT PIPE
COMBUSTION-AIR PIPE
COMBUSTION-AIR PIPE
HORIZONTAL TO ROOF
COMBUSTION-AIR PIPE
HORIZONTAL TO SIDEWALL
COMBUSTION-AIR PIPE
VENT PIPE
12 MIN
″
(304.8mm)
12
″
MIN
VENT PIPE
(304.8mm)
VERTICAL TO ROOF
VERTICAL TO SIDEWALL
NOTE: A 12-in. (304.8mm) minimum offset pipe section is
recommended with short (5 to 8 ft) vent systems. This
recommendation is to reduce excessive condensate droplets
A96230
Fig. 44 -- Short Vent (5 to 8 Ft or 1.5M -- 2.4M) System
NOTE: Starting at furnace, slope vent pipe a minimum of
1/4--in. (6.4mm) per linear ft back toward furnace with no sags
between hangers.
3. Termination or termination kit should be positioned so that
it will not be affected by wind eddy, such as inside
building corners, nor by recirculation of flue gases,
airborne leaves, or light snow.
VENT TERMINATION
General
4. Termination or termination kit should be positioned where
it will not be damaged by or subjected to foreign objects
such as stones, balls, etc.
5. Termination or termination kit should be positioned where
vent vapors are not objectionable.
Combustion--air (direct vent/2--pipe system only) and vent pipe
must terminate outside structure, either through sidewall or roof.
For vent termination clearance, refer to Fig. 34 for Direct Vent/2--
Pipe system and Fig. 35 for Ventilated Combustion Air option.
Roof termination is preferred since it is less susceptible to damage
or contamination, and it has less visible vent vapors. Sidewall
termination 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 pipe termination (direct vent/2--pipe
system only) and vent pipe termination may be extended beyond
area shown in Fig. 36 or in Fig. 37 per application in outside
ambient by insulating pipe as indicated in Table 6.
1. Determine combustion air pipe diameter (direct
vent/2--pipe system only) and vent pipe diameter, as stated
above, using total pipe length and number of elbows.
NOTE: (Direct Vent/2--Pipe system ONLY) A factory accessory
termination kit MUST be used. See section “Vent Termination Kit
(Direct Vent/2--Pipe System Only)” in this instruction.
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
length(s).
When determining appropriate location for termination, consider
the following guidelines:
1. Comply with all clearance requirements stated in Fig. 34
or Fig. 35 per application.
2. Termination or termination kit should be positioned where
vent vapors will not damage plants/shrubs or air
conditioning equipment.
NOTE: Pipe length(ft) specified for maximum pipe lengths
located in unconditioned spaces cannot exceed total allowable
pipe length as specified in Table 6.
37
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Vent Termination Kit (Direct Vent/2--Pipe System Only)
NOTE: Always refer to the instructions in termination kit for the
latest version.
Combustion air and vent pipes MUST terminate outside structure.
A factory accessory termination kit must be installed as shown in
Table 8. There are four options of vent/combustion air
termination kits available as shown in Table 8.
NOTE: Combustion air pipe must have the same diameter as
vent pipe.
Concentric Vent / Combustion Air Termination Kit (Direct
Vent / 2--Pipe System Only
Determine an appropriate location for termination kit using the
guidelines provided in section “Vent Termination: General” in
this instruction.
1. Cut one 4--in. diameter hole for 2--in. kit, or one 5--in.
diameter hole for 3--in. kit.
2. Loosely assemble concentric vent/combustion air
termination components together using instructions in kit.
3. Slide assembled kit with rain shield REMOVED through
hole.
NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole.
Roof terminations--Locate assembly through roof to appropriate
height as shown in Fig. 36 or Fig. 37.
Sidewall terminations--Locate assembly through sidewall with
rain shield positioned no more than 1--in (25.4mm). from wall as
shown in Fig. 36 and Fig. 37.
4. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
5. Check required dimensions as shown.
Two--Pipe Termination Kit (Direct Vent/2--Pipe System Only)
Determine an appropriate location for termination kit using the
guidelines provided in section “Vent Termination: General” in
this instruction.
1. Cut 2 holes, 1 for each pipe, of appropriate size for pipe
size being used.
2. 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. 38.
For applications using combustion--air pipe option, indicated by
dashed lines in Fig. 36, install 90_ street elbow into 90_ elbow,
making a U--fitting. A 180_ U--fitting may be used.
Sidewall terminations--Install bracket as shown in Fig. 36.
For applications using vent pipe option indicated by dashed lines
in Fig. 36, rotate vent elbow 90_ from position shown in Fig. 36
.
3. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
4. Check required dimensions as shown in Fig. 36.
(Direct Vent/2--Pipe System ONLY)--When 2 or more 355CAV
furnaces are vented near each other, 2 vent terminations may be
installed as shown in Fig. 36, but next vent termination must be at
least 36 in. (914.4mm) away from first 2 terminations. It is
important that vent terminations be made as shown in Fig. 36 to
avoid recirculation of flue gases.
38
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Table 6 – Maximum Allowable Exposed Vent Pipe Length (Ft / M) with Insulation in
Winter Design Temperature Ambient*
INSULATION THICKNESS†
WINTER DESIGN
TEMPERATURE
20_F / --6.7_C
MAXIMUM PIPE
UNIT SIZE
042060
DIAMETER (IN.)
0
3/8
1/2
3/4
1
2
30 / 9.1
16 / 4.9
9 / 2.7
55 / 16.8
33 / 10.1
23 / 7.0
65 / 19.8
39 / 11.9
27 / 8.3
70 / 21.3
42 / 12.8
28 / 8.5
70 / 21.3
51 / 15.5
35 / 10.7
61 / 18.6
38 / 11.6
26 / 7.9
70 / 21.4
45 / 13.7
31 / 9.4
70 / 21.3
48 / 14.6
33 / 10.1
70 / 21.3
58 / 17.7
40 / 12.2
70 / 21.3
46 / 14.0
33 / 10.1
70 / 21.3
55 / 16.8
39 / 11.9
70 / 21.3
59 / 18.0
41 / 12.5
70 / 21.3
70 / 21.3
50 / 15.2
70 / 21.3
53 / 16.2
38 / 11.6
70 / 21.3
63 / 19.2
45 / 13.7
70 / 21.3
68 / 20.7
49 / 14.9
70 / 21.3
70 /21.3
59 / 18.0
0_F / --17.8_C
2
-- 2 0 _F / --28.9_C
20_F / --6.7_C
0_F / --17.8_C
-- 2 0 _F / --28.9_C
20_F / --6.7_C
0_F / --17.8_C
-- 2 0 _F / --28.9_C
20_F / --6.7_C
0_F / --17.8_C
-- 2 0 _F / --28.9_C
2
2
37 / 11.2
20 / 6.1
11 / 3.4
41 / 12.5
21 / 6.4
11 / 3.4
49 / 14.9
26 / 7.9
15 / 4.6
042080
060080
2
2
2--1/2
2--1/2
2--1/2
3
060100
060120
3
3
* Pipe length (ft/m) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable
pipe length as specified in Table ?.
†Insulation thickness based on R value of 3.5 per in.
39
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Table 7 – Maximum Allowable Pipe Length (Ft / M)
Direct Vent (2--Pipe Only)
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
Pipe Dia
(IN.)*
ALTITUDE
1
2
3
4
5
6
2 P i p e o r 2 --- In .
1 --- 1 / 2
2
1 --- 1 / 2
2
50 / 15.2
70 / 21.3
30 / 9.14
70 / 21.3
45 / 13.7
70 / 21.3
10 / 3.0
45 / 13.7
70 / 21.3
25 / 7.6
70 / 21.3
40 / 12.9
70 / 21.3
NA
40 / 12.9
70 / 21.3
20 / 6.1
70 / 21.3
35 / 10.7
70 / 21.3
NA
35 / 10.7
70 / 21.3
15 / 4.6
70 / 21.3
30 / 9.1
70 / 21.3
NA
30 / 9.1
70 / 21.3
10 / 3.0
70 / 21.3
25 / 7.6
70 / 21.3
NA
25 / 7.6
70 / 21.3
5 / 1.5
70 / 21.3
20 / 6.1
70 / 21.3
NA
60,000
80,000
100,000
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
0 to 2000
2
2 --- 1 / 2
2 --- 1 / 2 o n e d isk
3 one disk
3 one disk†
2 P i p e o r 3 --- In .
Concentric
120,000
35 / 10.7
70 / 21.3
30 / 9.1
70 / 21.3
15 / 4.8
70 / 21.3
NA
70 / 21.3
NA
70 / 21.3
NA
70 / 21.3
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
Pipe Dia
(IN.)*
1 --- 1 / 2
2
1 --- 1 / 2
2
ALTITUDE
2001 to 3000
ALTITUDE
1
2
3
4
5
6
45 / 13.7
70 / 21.3
26 / 7.9
70 / 21.3
40 / 12.2
70 / 21.3
31 / 9.4
63 / 19.2
40 / 12.9
70 / 21.3
21 / 6.4
70 / 21.3
35 / 10.7
70 / 21.3
26 / 7.9
62 / 18.9
35 / 10.7
70 / 21.3
16 / 4.9
70 / 21.3
30 / 9.1
70 / 21.3
12 / 3.7
62 / 18.9
30 / 9.14
70 / 21.3
11 / 3.4
70 / 21.3
25 / 7.6
70 / 21.3
NA
25 / 7.6
70 / 21.3
6 / 1.8
70 / 21.3
20 / 6.1
70 / 21.3
NA
20 / 6.1
70 / 21.3
NA
70 / 21.3
15 / 4.6
70 / 21.3
NA
60,000
80,000
2
100,000
120,000
2 --- 1 / 2
3 one disk
3 one disk†
Pipe Dia
(IN.)*
61 / 18.6
61 / 18.6
61 / 18.6
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
1
2
3
4
5
6
1 --- 1 / 2
42 / 12.8
37 / 11.2
32 / 9.8
27 / 8.2
22 / 6.7
2 P i p e o r 2 --- In .
Concentric
17 / 5.2
70 / 21.3
NA
70 / 21.3
13 / 4.0
70 / 21.3
NA
60,000
2
1 --- 1 / 2
2
70 / 21.3
25 / 7.6
70 / 21.3
38 / 11.6
70 / 21.3
29 / 8.8
70 / 21.3
20 / 6.1
70 / 21.3
33 / 10.1
70 / 21.3
24 / 7.3
70 / 21.3
15 / 4.6
70 / 21.3
28 / 8.5
70 / 21.3
10 / 3.0
58 / 17.8
70 / 21.3
10 / 3.0
70 / 21.3
23 / 7.0
70 / 21.3
NA
70 / 21.3
5 / 1.5
70 / 21.3
18 / 5.5
70 / 21.3
NA
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
80,000
100,000
120,000
3001 to 4000
2
2 --- 1 / 2
3 one disk
3 one disk†
59 / 18.0
59 / 18.0
57 / 17.4
57 / 17.4
56 / 17.0
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
Pipe Dia
(IN.)*
1 --- 1 / 2
2
1 --- 1 / 2
2
ALTITUDE
4001 to 5000‡
ALTITUDE
5001 to 6000‡
1
2
3
4
5
6
40 / 12.2
70 / 21.3
23 / 7.0
70 / 21.3
36 / 11.0
70 / 21.3
35 / 10.7
70 / 21.3
18 / 5.5
70 / 21.3
31 / 9.4
70 / 21.3
30 / 9.1
70 / 21.3
13 / 4.0
70 / 21.3
26 / 7.9
70 / 21.3
25 / 7.6
70 / 21.3
8 / 2.4
70 / 21.3
21 / 6.4
70 / 21.3
20 / 6.1
70 / 21.3
NA
70 / 21.3
16 / 4.8
70 / 21.3
15 / 9.6
70 / 21.3
NA
68 / 20.7
11 / 3.4
70 / 21.3
60,000
80,000
2
100,000
120,000
2 --- 1 / 2
3 one disk†
56 / 17.1
55 / 16.8
54 / 16.5
53 / 6.2
52 / 15.8
52 / 15.8
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
Pipe Dia
(IN.)*
1 --- 1 / 2
2
1 --- 1 / 2
2
1
2
3
4
5
6
37 / 11.3
70 / 21.3
22 / 6.7
70 / 21.3
33 / 10
32 / 9.8
70 / 21.3
17 / 5.2
70 / 21.3
28 / 8.5
70 / 21.3
27 / 8.2
70 / 21.3
12 / 3.7
70 / 21.3
23 / 7.0
70 / 21.3
22 / 6.7
70 / 21.3
7 / 2.1
70 / 21.3
18 / 5.5
70 / 21.3
17 / 5.2
70 / 21.3
NA
68 / 20.7
13 / 4.0
70 / 21.3
12 / 3.7
70 / 21.3
NA
63 / 19.2
8 / 2.4
70 / 21.3
60,000
80,000
2
100,000
120,000
2 --- 1 / 2
70 / 21.3
3 one disk†
53 / 16.2
52 / 15.8
50 / 15.2
49 / 14.9
48 / 14.6
47 / 14.3
*See notes on next page.
40
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Table 9 — Maximum Allowable Pipe Length (Ft / M) (Continued)
NUMBER OF 90_ ELBOWS
Direct Vent (2--Pipe Only)
UNIT SIZE
(BTUH)
ALTITUDE
Termination
Pipe Dia
(IN.)*
1
2
3
4
5
6
Type
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
1 --- 1 / 2
35 / 10.7
70 / 21.3
20 / 6.1
70 / 21.3
31 / 9.4
30 / 9.1
70 / 21.3
15 / 4.6
70 / 21.3
26 / 7.9
70 / 21.3
25 / 7.6
68 / 20.7
10 / 3.0
68 / 20.7
21 / 6.4
68 / 20.7
20 / 6.1
67 / 20.4
5 / 1.5
67 / 20.4
16 / 4.9
67 / 20.4
15 / 4.6
66 / 20.11
NA
62 / 18.9
11 / 3.4
66 / 20.1
10 / 3.0
64 / 19.5
NA
57 / 17.4
6 / 1.8
60,000
80,000
2
1 --- 1 / 2
2
6001 to 7000‡
ALTITUDE
2
100,000
120,000
2 --- 1 / 2
70 / 21.3
64 / 19.5
3 one disk†
49 / 14.9
48 / 14.6
47 / 14.3
45 / 13.7
44 / 13.4
43 / 13.1
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
Pipe Dia
(IN.)*
1
2
3
4
5
6
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
1 --- 1 / 2
32 / 9.8
66 /20.1
18 / 5.5
66 / 20.1
29 / 8.8
66 / 20.1
27 / 8.2
65 / 19.8
13 / 4.0
65 / 19.8
24 / 7.3
65 / 19.8
22 / 6.7
63 / 19.2
8 / 2.4
63 / 19.2
19 / 5.8
63 / 19.2
17 / 5.2
62 / 18.9
NA
62 / 18.9
14 / 4.3
62 / 18.9
12 / 3.7
60 / 18.3
NA
57 / 17.4
9 / 2.7
60 / 18.3
7 / 2.1
59 / 18.0
NA
52 / 15.8
NA
60,000
80,000
2
1 --- 1 / 2
2
7001 to 8000‡
ALTITUDE
2
100,000
120,000
2 --- 1 / 2
59 / 18
3 one disk†
46 / 14.0
44 / 13.4
43 / 13.1
41 / 12.5
40 / 12.2
38 / 11.6
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
Pipe Dia
(IN.)*
1
2
3
4
5
6
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
1 --- 1 / 2
30 / 9.1
62 / 18.9
17 / 5.2
62 / 18.9
27 / 8.2
62 / 18.9
25 / 7.6
60 / 17.8
12 / 3.1
60 / 18.3
22 / 6.7
60 / 18.3
20 / 6.1
58 / 17.7
7 / 2.1
58 / 17.7
17 / 5.2
58 / 17.7
15 / 4.6
56 / 17.1
NA
56 / 17.1
12 / 3.7
56 / 17.1
10 / 3.0
55 / 16.8
NA
51 / 15.5
7 / 2.1
55 / 16.8
5 / 1.5
53 / 16.2
NA
46 / 14.0
NA
60,000
80,000
2
1 --- 1 / 2
2
8001 to 9000‡
ALTITUDE
2
100,000
120,000
2 --- 1 / 2
53 / 16.2
3 one disk†
43 / 13.1
41 / 12.5
39 /11.9
37 / 11.3
35 / 10.7
34 / 10.4
NUMBER OF 90_ ELBOWS
UNIT SIZE
(BTUH)
Termination
Type
Pipe Dia
(IN.)*
1
2
3
4
5
6
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 2 --- In .
Concentric
2 P i p e o r 3 --- In .
Concentric
1 --- 1 / 2
27 / 8.2
57 / 17.4
15 / 4.6
57 / 17.4
24 / 7.3
57 / 17.4
22 / 6.7
55 / 16.8
10 / 3.0
55 / 16.8
19 / 5.8
55 / 16.8
17 / 5.2
53 / 16.2
5 / 1.5
53 / 16.2
14 / 4.3
53 / 16.2
12 / 3.7
51 / 15.5
NA
51 / 15.5
9 / 2.7
51 / 15.5
7 / 2.1
49 / 14.9
NA
46 / 14.0
NA
NA
47 / 14.3
NA
41 / 12.5
NA
47 / 14.3
60,000
80,000
2
1 --- 1 / 2
2
9001 to
10000‡
2
100,000
120,000
2 --- 1 / 2
49 / 14.9
3 one disk†
39 / 11.9
37 / 11.3
35 / 10.7
33 / 10.1
31 / 9.5
29 / 8.8
* Disk usage---Unless otherwise stated, use perforated disk assembly (factory---supplied in loose parts bag).
{ Wide radius elbow.
} Vent sizing for Canadian installations over 4500 ft (1370m) above sea level are subject to acceptance by the local authorities having jurisdiction.
NA---Not Allowed; pressure switch will not make.
NOTES:
1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.
2. Size both the combustion---air and vent pipe independently, determine the smallest diameter allowed by the table for each pipe, then use the larger diameter for both pipes.
3. Assume two 45_ elbows equal one 90_ elbow. Long radius elbows are desirable and may be required in some cases.
4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.
5. The minimum pipe length is 5 ft for all applications.
41
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Table 8 – Vent Termination Kit for Direct Vent / 2--Pipe System
DIRECT VENT (2 PIPE) TERMINATION
KIT
DIAMETER OF COMBUSTION AIR
TERMINATION SYSTEM
AND VENT PIPES (IN INCHES)
1, 1--1/2, 2, or 2--1/2
2--1/2, 3 or 4
1, 1--1/2 or 2
2--1/2, 3 or 4
2in. Concentric Vent Kit
Single Penetration of Wall or Roof
Single Penetration of Wall or Roof
2Pipe Termination System
3in. Concentric Vent Kit
2in. Termination Bracket Kit
3in. Termination Bracket Kit
2Pipe Termination System
Multi--venting and Vent Terminations
Application
When 2 or more 355CAV Furnaces are vented near each other,
each furnace must be individually vented. NEVER common vent
or breach vent 355CAV furnaces.
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 to prevent siphoning of the
equipment’s drain.
CONDENSATE TRAP
OPEN STAND
PIPE FOR
A/C OR
HUMIDIFIER
DRAIN
WIRE TIE(S)
TEE
HEAT TAPE
(3 WRAPS MINIMUM)
TO OPEN
DRAIN
A93036
Fig. 46 -- Condensate Trap Heat Tape
A94054
Fig. 45 -- Example of Field Drain Attachment
See Fig. 45 for example of possible field drain attachment using
1/2--in. CPVC or PVC tee for vent and A/C or humidifier drain
connection.
CONDENSATE DRAIN
General
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.
Condensate trap is shipped installed in the blower shelf and
factory connected for UPFLOW applications. Condensate trap
must be RELOCATED for use in DOWNFLOW and
HORIZONTAL applications.
Condensate trap MUST be used for all applications.
An external trap is not required when connecting the field drain
to this condensate trap.
!
WARNING
PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal
injury or death.
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.
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.
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.
Condensate Drain Protection
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.
Freezing condensate left in condensate trap and drain line may
cause cracks, and possible water damage may occur. If freeze
protection is required, use condensate freeze protection accessory
or equivalent 3 to 6 watt per ft at 120v and 40_F self--regulating,
shielded, and waterproof heat tape. See Installation Instructions
supplied with accessory or heat tape manufacturer’s
recommendations.
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.
1. Fold heat tape in half and wrap on itself 3 times.
42
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2. Locate heat tape between sides of condensate trap back.
(See Fig. 46.)
continuous fan airflow or low--cooling airflow to be adjusted. To
set desired continuous fan airflow or low--cooling airflow:
3. Use wire ties to secure heat tape in place. Wire ties can be
positioned in notches of condensate trap sides. (See Fig.
46.)
1. Remove main furnace door and blower access panel.
2. Locate CF setup switches on furnace control. (See Fig.
33.)
4. Wrap field drain pipe with remaining heat tape,
approximately 1 wrap per ft.
3. Determine desired continuous fan airflow or low--cooling
airflow.
5. When using field--supplied heat tape, follow heat tape
manufacturer’s instructions for all other installation
guidelines.
4. Use Fig. 47 or wiring schematic to determine proper setup
position of CF switches. (See Fig. 48 and Fig. 49.)
5. Replace main furnace door and blower access panel.
START--UP, ADJUSTMENT AND SAFETY
CHECK
AIR CONDITIONING (A/C) OR CONTINUOUS-FAN (CF)
AIRFLOW SELECTION CHART
Step 1 — General
1. Furnace must have a 115--v power supply properly
connected and grounded.
BASED ON 350 CFM/TON (SETUP SWITCH SW1-5 OFF)
SETUP SWITCH SW3 POSITIONS
NOTE: Proper polarity must be maintained for 115--v wiring. If
polarity is incorrect, control status indicator light flashes rapidly
and furnace does not operate.
MODEL
SIZE
DEF.
DEF.
DEF.
525 2
700 2
700
700
875
875 1050 1 1225 1225 1225
1050 1225 1400 1750 1 1750
060, 3.5T080
5T080, 100
120
2. Thermostat wire connections at terminals R, W/W1, G,
and Y/Y2 must be made at 24--v terminal block on furnace
control.
875 2 1050 1225 1400 1750 1 2100
3. Natural gas service pressure must not exceed 0.5 psig (14--
in. wc), but must be no less than 0.16 psig (4.5--in. wc).
4. Blower access panel must be in place to complete 115--v
electrical circuit to furnace.
BASED ON 400 CFM/TON (SETUP SWITCH SW1-5 ON)
SETUP SWITCH SW3 POSITIONS
MODEL
SIZE
060, 3.5T080 DEF.
600 2
800
1000 1200 1 1400 1400 1400
!
CAUTION
5T080, 100
120
DEF.
DEF.
800 2 1000 1200 1400 1600 2000 1 2000
800 1000 2 1200 1400 1600 2000 1 2100
UNIT MAY NOT OPERATE
1. DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION
2. DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION
3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
These furnaces are equipped with a manual reset limit
switch in burner box. This switch opens and shuts off
power to the gas valve if an overheat condition (flame
rollout) occurs in burner enclosure. Correct inadequate
combustion--air supply or improper venting condition
before resetting switch. DO NOT jumper this switch.
A07424
Fig. 47 -- A/C or CF Airflow Selection Chart Based on 350
and 400 CFM/Ton
Setup Switches (SW1)
The furnace control has 8 setup switches that may be set to meet
the application requirements. To set these setup switches for the
appropriate requirement:
Before operating furnace, check flame rollout manual reset switch
for continuity. If necessary, press button to reset switch.
Step 2 — Select Setup Switch Positions
Air Conditioning (A/C) Setup Switches
1. Remove main furnace door and blower access panel.
2. Locate setup switches on furnace control. (See Fig. 33.)
The air conditioning setup switches are used to match furnace
airflow to cooling unit used.
3. See Table 9 for setup switch description. (See Fig. 48 and
Fig. 49.)
To set the desired cooling airflow:
4. Replace main furnace door and blower access panel.
1. Remove main furnace door and blower access panel.
NOTE: If a bypass humidifier is used, setup switch SW1--3
(Low Heat Rise Adjust) should be in ON position. This
compensates for the increased temperature in return air resulting
from bypass.
2. Locate A/C setup switches on furnace control. (See Fig.
33.)
3. Determine air conditioning tonnage used.
4. Use Fig. 47 or wiring schematic to determine proper setup
position of A/C switches. (See Fig. 48 and Fig. 49.)
NOTE:
If modulating dampers are used, blower motor
automatically compensates for modulating dampers.
NOTE: Excessive airflow caused by improper A/C switch setup
may cause condensate blowoff in cooling mode.
Additional Setup Switches (SW4)
The furnace control has 3 additional setup switches labeled SW4.
(See Fig. 33.) Setup switch SW4--2 can be used to lock the
furnace into medium heat. When setup switch SW4--2 is ON the
furnace will remain at medium heat until W/W1 is de--energized
to end a heating cycle or when both W/W1 and W2 are energized.
When both W/W1 and W2 are energized the furnace will run at
high heat. The other 2 setup switches are currently not used for
anything. When setup switch SW4--2 is ON it will over ride setup
switch SW1--2 if it is ON. To activate setup switch SW4--2:
5. Replace main furnace door and blower access panel.
NOTE: EAC--1 terminal is energized whenever blower operates.
HUM terminal is only energized when blower is energized in
heating.
Continuous Fan (CF) Setup Switches
The CF setup switches are used to select desired airflow when
thermostat is in continuous fan mode or to select low--cooling
airflow for two--speed cooling units. This setup feature allows
1. Remove main furnace door and blower access panel.
43
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2. Locate setup switch SW4 on furnace control. (See Fig.
33.)
3. See Table 5 for setup switch description. (See Fig. 40 and
Fig. 49.)
4. Replace main furnace door and blower access panel.
Prime Condensate Trap with Water
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
Condensate trap must be PRIMED or proper draining may
not occur. The condensate trap has two internal chambers
which can ONLY be primed by pouring water into the
inducer drain side of condensate trap.
A04001
Fig. 48 -- Example of Setup Switch in Off Position
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A06677
Fig. 49 -- Wiring Diagram
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A99118
A01050
Fig. 50 -- Inducer Housing Drain Tube
Fig. 51 -- Filling Condensate Trap
Table 9 – Furnace Setup Switch Description
SETUP SWITCH
NO.
NORMAL
POSITION
SWITCH NAME
DESCRIPTION OF USE
Turn ON to retrieve up to 7 stored status codes for troubleshooting
assistance when R thermostat lead is disconnected.
SW1--1
Status Code Recovery
OFF
When SW1--2 and SW4--2 are OFF allows step--modulating opera-
tion with a single stage thermostat. Turn ON when using 2 stage
thermostat to allow Low Heat operation when R to W/W1 closes
and High Heat operation when R to W/W1 and W2 close.
Turn ON to increase Low and Medium Heat airflow by 18 percent.
This compensates for increased return air temperature caused with
bypass humidifier. This also increases the Low and Medium Heat
inducer speed 15 percent
Low Heat Only
(Adaptive Heat Mode when
OFF)
SW1--2
OFF
OFF
Low/Medium Heat Rise Ad-
just
SW1--3
Turn ON to decrease Low Heat airflow 9 percent,
Medium Heat airflow 7 percent,
and High Heat airflow 15 percent for maximum comfort.
Turn ON for 400 CFM per ton. Turn OFF for 350 CFM per ton.
Turn ON to initiate Component Self Test for troubleshooting
assistance when R thermostat lead is disconnected. Turn OFF
when Self Test is completed.
Comfort/Efficiency Adjust-
ment
SW1--4
SW1--5
SW1--6
ON
OFF
OFF
CFM per ton adjust
Component Self Test
SW1--7
and SW1--8
Blower Off Delay time.
See Table 6.
When SW1--2 and SW4--2 are OFF allows step--modulating opera-
tion with a single stage thermostat. Turn ON when using 2 stage
thermostat to allow Medium Heat operation when R to W/W1
closes and High Heat operation when R to W/W1 and W2 close.
Blower OFF delay
ON or OFF
OFF
Medium Heat Only (Adap-
tive Heat Mode
SW4--2
when OFF)
1. Remove upper inducer housing drain connection cap. (See
Fig. 50.)
2. Connect field--supplied 1/2--in. ID tube to upper inducer
housing drain connection.
4. 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. 51.)
3. Insert field--supplied funnel into tube.
46
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Purge Gas Lines
The furnace will start up in either medium--, or high--heat. The
furnace will operate in low--heat after starting and operating for 1
minute at medium--heat before transitioning to low--heat. The
furnace control CPU determines the combined low--heat and
medium--heat on--time (from 0 to 16 minutes) which is permitted
before switching to high heat.
If not previously done, purge the lines after all connections have
been made and check for leaks.
!
CAUTION
If the power is interrupted, the stored history is erased and the
furnace control CPU will select medium--heat for 1 minute,
low--heat for 15 minutes and then switch to high--heat, as long as
the thermostat continues to call for heat. Subsequent selection is
based on stored history of the thermostat cycle times.
FIRE AND EXPLOSION HAZARD
Failure to follow this caution could result in a fire,
explosion, personal injury, or death.
Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections.
The wall thermostat ”calls for heat”, closing the R to W circuit.
The furnace control CPU performs a self--check, verifies the
low--heat and medium--heat pressure switch contacts LPS and
MPS are open, then de--energizes the HPSR relay to close the NC
contact.
Step 3 — Sequence of Operation
1. Inducer Prepurge Period -- The furnace control CPU turns
on inducer motor IDM and slowly increases the inducer
motor speed. After the low--heat pressure switch LPS
closes the furnace control CPU continues to increase the
inducer motor speed until the medium--heat pressure
switch MPS closes. When the medium--heat pressure
switch MPS closes, throttling valve TV is energized,
inducer motor RPM is noted by the furnace control CPU,
and a 25--second prepurge period begins. The RPM is
used to evaluate vent system resistance. This evaluation is
then used to determine the required RPM necessary to
operate the inducer motor during medium--heat prepurge,
the first minute of medium--heat mode, and low--heat
mode.
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in intermittent unit
operation.
Furnace control must be grounded for proper operation, or
control will lock out. Control is grounded through
green/yellow wire routed to gas valve and burner box
screw.
Using the schematic diagram (See Fig. 48), follow the sequence
of operation through the different modes. Read and follow the
wiring diagram very carefully. ! !
NOTE: The heat cycle can start in either high-- or medium--heat.
If a high--heat cycle is initiated, the furnace control CPU will
continue to increase the inducer motor speed after the
medium--heat pressure switch MPS closes. When the
medium--heat pressure switch closes, throttling valve TV is
energized, inducer motor RPM is noted by the furnace control
CPU, and a 25--second prepurge period begins. The RPM is used
to evaluate vent system resistance. This evaluation is then used to
determine the required RPM necessary to operate the inducer
motor in high--heat pre--purge, and high--heat mode.
NOTE: If a power interruption occurs during a call for heat
(W/W1 or W/W1--and--W2), the control will start a 90--second
blower--only ON period two seconds after power is restored, if
the thermostat is still calling for gas heating. The amber LED
light will flash code 12 during the 90--second period, after which
the LED will be ON continuous, as long as no faults are detected.
After the 90--second period, the furnace will respond to the
thermostat normally.
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hotsurface igniter HSI, throttling valve TV, and
gas valve GV.
2. Igniter Warm--Up — At the end of the prepurge period,
the Hot--Surface Igniter HSI is energized for a 17--second
igniter warm--up period.
3. Trial--For--Ignition Sequence
—
When the igniter
warm--up period is completed the main gas valve relay
contact GVR closes to energize the gas valve solenoid
GV--M. The gas valve solenoid GV--M permits gas flow
to the burners where it is ignited. Five seconds after the
GVR closes, a 2-- second Flame--Proving period begins.
The HSI igniter will remain energized until flame is sensed
or until the 2--second flame proving period begins.
If the furnace control CPU selects high--heat operation, the
high--heat gas valve solenoid GV--HI is energized when
the high--heat pressure switch HPS closes.
Single--Stage Thermostat and Step--Modulating Heating
(Adaptive Mode)
See Fig. 29 or Fig. 59 for thermostat connections.
NOTE: Low--heat only switch SW1--2 selects the low--heat only
operation mode when ON. Medium--heat only switch SW4--2
selects medium--heat only operation mode when ON. If both
switches are ON the furnace control will default to medium--heat.
If either or both switches are ON the furnace control will operate
at two--stages only as referenced in Section 2 below. If both
switches are OFF the furnace control will operate in the adaptive
heating mode in response to a call for heat. (See Fig. 33.) When
the W2 thermostat terminal is energized it will always cause
high--heat operation as long as the R to W circuit is closed,
regardless of the setting of the low--heat or medium--heat only
switches.
4. Flame--Proving — When the burner flame is proved at the
flame--proving sensor electrode FSE, the furnace control
CPU begins the blower--ON delay period and continues to
hold the gas valve GV--M open. If the burner flame is not
proved within two seconds, the furnace control CPU will
close the gas valve GV--M, and the furnace control CPU
will repeat the ignition sequence for up to three more
Trials--For--Ignition before going to Ignition--Lockout.
Lockout will be reset automatically after three hours, by
momentarily interrupting 115 vac power to the furnace, or
by interrupting 24 vac power at SEC1 or SEC2 to the
furnace control CPU (not at W/W1, G, R, etc.).
This furnace can operate as a step--modulating furnace with a
single--stage thermostat because the furnace control CPU includes
a programmed adaptive sequence of controlled operation, which
selects low--heat, medium--heat, or high--heat operation. This
selection is based upon the stored history of the length of
previous gas--heating periods of the single--stage thermostat.
If flame is proved when flame should not be present, the
furnace control CPU will lock out of Gas--Heating mode
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and operate the inducer motor IDM at full speed until
flame is no longer proved.
Switching from High-- to Medium-- or Low--Heat —
The furnace control CPU will not switch from high--heat
to medium-- or low--heat while the thermostat R to W cir-
cuit is closed when using a single--stage thermostat.
5. Inducer Speed Change
—
If the cycle starts in
mediumheat, the furnace control CPU reduces the inducer
speed slightly after flame sense. If cycle starts in
high--heat, the furnace control CPU increases the inducer
speed after flame sense. The reduction in speed in
medium--heat is to optimize combustion for maximum
efficiency.
8. Blower--Off Delay — When the thermostat is satisfied,
the R to W circuit is opened, de--energizing the gas valve
GV--M, stopping gas flow to the burners, and de--energiz-
ing the throttling valve TV, and humidifier terminal HUM.
The inducer motor IDM will remain energized for a
15--second post--purge period. The blower motor BLWM
and air cleaner terminal EAC--1 will remain energized at
low--heat airflow or transition to low--heat airflow for 90,
120, 150, or 180 seconds (depending on selection at blow-
er--OFF delay switches). The furnace control CPU is facto-
ry--set for a 120--second blower-- OFF delay.
6. Blower--On delay — If the burner flame is proven the
blower--ON delay for medium--heat and high--heat are as
follows:
Medium--heat — 60 seconds after the gas valve GV--M is
opened the blower motor BLWM is turned ON at low-- or
medium--heat airflow.
High--heat — 35 seconds after the gas valve GV--M is
opened the BLWM is turned ON at high--heat airflow.
Simultaneously, the humidifier terminal HUM and elec-
tronic air cleaner terminal EAC--1 are energized and re-
main energized throughout the heating cycle.
Two--Stage Thermostat and Two--Stage Low / High Heating
See Fig. 58 for thermostat connections.
NOTE: In this mode the low--heat only switch SW1--2 must be
ON to select the low--heat only operation mode in response to
closing the thermostat R to W1 circuit. Closing the thermostat R
to W1--and--W2 circuits always causes high--heat operation,
regardless of the setting of the low--heat only switch.
7. Switching from Medium-- to Low--Heat — If the fur-
nace control switches from medium--heat to low--heat, the
furnace control will turn the blower ON at low--heat air-
flow, energize the HPSR relay to open the NC contact, and
slowly decrease the inducer motor speed. When the HPSR
relay is energized and the NC contact opens the throttling
valve TV is deenergized and the gas flow reduces to low--
heat rate.
The furnace will start up in either medium--, or high--heat. The
furnace will operate in low--heat after starting and operating for 1
minute at medium--heat before transitioning to low--heat.
The wall thermostat ”calls for heat”, closing the R to W1 circuit
for low--heat or closing the R to W1--and--W2 circuits for
high--heat. The furnace control performs a self--check, and
verifies the low--heat and medium--heat pressure switch contacts
LPS and MPS are open, then de--energizes the HPSR relay to
close the NC contact.
The start up and shut down functions and delays described above
apply to the 2--stage low/high heating mode as well, except for
switching from high-- to low--heat.
Switching from Low-- to Medium--Heat — If the fur-
nace control CPU switches from low--heat to medium--
heat, the furnace control CPU will de--energize the HPSR
relay to close the NC contact and slowly increase the in-
ducer motor speed until the medium--heat pressure switch
MPS closes. When the medium--heat pressure switch MPS
closes, the throttling valve solenoid TV is energized and
the inducer motor RPM is noted by the furnace control
CPU. The RPM is used to evaluate vent system resistance.
This evaluation is then used to determine the required
RPM necessary to operate the inducer motor in medium--
heat and high--heat mode. The blower motor BLWM will
transition to medium--heat airflow five seconds after the
furnace control CPU switches from low--heat to medium--
heat.
Switching from Low-- to High--Heat — If the furnace
control CPU switches from low--heat to high--heat, the fur-
nace control CPU will de--energize the HPSR relay to
close the NC contact and slowly increase the inducer mo-
tor speed until the medium--heat pressure switch MPS
closes. When the medium--heat pressure switch MPS
closes, the throttling valve solenoid TV is energized and
the inducer motor RPM is noted by the furnace control
CPU. The RPM is used to evaluate vent system resistance.
This evaluation is then used to determine the required
RPM necessary to operate the inducer motor in medium--
and high--heat mode. The blower motor BLWM will tran-
sition to high--heat airflow five seconds after the furnace
control CPU switches from low--heat to high--heat. As the
inducer RPM gradually increases the high--heat pressure
switch HPS closes and the gas valve solenoid GV--HI is
energized.
1. Switching from High-- to Low--Heat — If the thermostat
R to W2 circuit opens, and the R to W1 circuit remains
closed, the furnace control CPU will gradually decrease
the inducer motor speed to the required medium--heat
RPM. When the inducer motor IDM reduces pressure
sufficiently, the highheat pressure switch HPS will open
and the high--heat gas valve solenoid GV--HI will be
de--energized. The gas valve solenoid GV--M will remain
energized as long as the low--heat pressure switch LPS
remains closed. When the inducer motor speed gets within
15% of the required medium--heat RPM the furnace
control CPU will start a 5 second blower airflow change
delay. After the 5 second blower airflow change delay is
completed the blower airflow will transition to
low--heatairflow. At this point the furnace control CPU
will energize the HPSR relay to open the NC contact and
slowly decrease the inducer motor speed to the required
low--heat RPM. When the HPSR relay is energized and
the NC contact opens the throttling valve TV is
de--energized and the gas flow reduces to low--heat rate.
When the inducer motor IDM reduces pressure
sufficiently, the medium--heat pressure switch MPS will
open.
Two--Stage Thermostat and Two--Stage Medium/High
Heating
Switching from Medium-- to High--Heat — If the fur-
nace control CPU switches from medium--heat to high--
heat, the furnace control CPU will gradually increase the
inducer motor speed to the required high--heat RPM. The
blower motor BLWM will transition to high--heat airflow
five seconds after the furnace control CPU switches from
medium--heat to highheat. As the inducer RPM gradually
increases the high--heat pressure switch HPS closes and
the gas valve solenoid GV--HI is energized.
See Fig. 58 for thermostat connections.
NOTE: In this mode the medium--heat only switch SW4--2 must
be ON to select the medium--heat only operation mode in
response to closing the thermostat R to W1 circuit. Closing the
thermostat R to W1--and--W2 circuits always causes high--heat
operation, regardless of the setting of the medium--heat only
switch.
48
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The wall thermostat ”calls for heat”, closing the R to W1 circuit
for medium--heat or closing the R to W1--and--W2 circuits for
high--heat. The furnace control performs a self--check, and
verifies the low--heat and medium--heat pressure switch contacts
LPS and MPS are open, then de--energizes the HPSR relay to
close the NC contact.
The wall thermostat “calls for cooling”, closing the R to G and--
Y circuits. The R to Y1 circuit starts the outdoor unit on
low--cooling speed, and the R to G--and--Y1 circuits starts the
furnace blower motor BLWM at low--cooling airflow which is the
true on--board CF selection as shown in Fig. 47.
If the furnace control CPU switches from low--cooling to high
cooling, the furnace control CPU will energize the air
conditioning relay ACR. When the air conditioning relay ACR is
energized the R to Y1--and--Y2 circuits switch the outdoor unit to
high--cooling speed, and the R to G--and--Y1-- and--Y/Y2 circuits
transition the furnace blower motor BLWM to high--cooling
airflow. High--cooling airflow is based on the A/C selection
shown in Fig. 47.
The start up and shut down functions and delays described above
apply to the 2--stage medium/high heating mode as well, except
for switching from high-- to medium--heat.
1. Switching from High-- to Medium--Heat — If the
thermostat R to W2 circuit opens, and the R to W1 circuit
remains closed, the furnace control CPU will gradually
decrease the inducer motor speed to the required
medium--heat RPM. When the inducer motor IDM
reduces pressure sufficiently, the highheat pressure switch
HPS will open and the high--heat gas valve solenoid
GV--HI will be de--energized. The gas valve solenoid
GV--M will remain energized as long as the low--heat
pressure switch LPS remains closed. When the inducer
motor speed gets within 15% of the required medium--heat
RPM the furnace control CPU will start a 5 second blower
airflow change delay. After the 5 second blower airflow
change delay is completed the blower airflow will
transition to medium--heat airflow.
NOTE: When transitioning from low--cooling to high--cooling
the outdoor unit compressor will shut down for 1 minute while
the furnace blower motor BLWM transitions to run at
high--cooling airflow.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R to G--and--Y circuit are
opened. The outdoor unit stops, and the furnace blower BLWM
and electronic air cleaner terminal EAC--1 will remain energized
for an additional 90 seconds. Jumper Y1 to DHUM to reduce the
cooling off--delay to 5 seconds. (See Fig. 33.)
Cooling Mode
4. Two--Stage Thermostat and Two--Speed Cooling
See Fig. 58 for thermostat connections.
The thermostat “calls for cooling.”
2. Single--Speed Cooling
NOTE: The air conditioning relay disable jumper ACRDJ must
be disconnected to allow thermostat control of the outdoor unit
staging. (See Fig. 33.)
See Fig. 29 for thermostat connections.
The thermostat closes the R to G--and--Y circuits. The R to
Y circuit starts the outdoor unit, and the R to G--and--Y/Y2
circuits start the furnace blower motor BLWM on cooling
airflow. Cooling airflow is based on the A/C selection
shown in Fig. 47.
The electronic air cleaner terminal EAC--1 is energized
with 115 vac when the blower motor BLWM is operating.
When the thermostat is satisfied, the R to G--and--Y
circuits are opened. The outdoor unit will stop, and the
furnace blower motor BLWM will continue operating at
cooling airflow for an additional 90 seconds. Jumper
Y/Y2 to DHUM to reduce the cooling off--delay to 5
seconds. (See Fig. 33.)
The thermostat closes the R to G--and--Y1 circuits for low cooling
or closes the R to G--and--Y1--and--Y2 circuits for high cooling.
The R to Y1 circuit starts the outdoor unit on low cooling speed,
and the R to G--and--Y1 circuit starts the furnace blower motor
BLWM at low--cooling airflow which is the true on--board CF
selection as shown in Fig. 47. The R to Y1--and--Y2 circuits start
the outdoor unit on high--cooling speed, and the
R
to
G--and--Y/Y2 circuits start the furnace blower motor BLWM at
high--cooling airflow. High--cooling airflow is based on the A/C
selection shown in Fig. 47.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
3. Single--Stage Thermostat and Two--Speed Cooling
(Adaptive Mode)
When the thermostat is satisfied, the R to G--and--Y1 or R to
G--and--Y1--and--Y2 circuits are opened. The outdoor unit stops,
and the furnace blower BLWM and electronic air cleaner terminal
EAC--1 will remain energized for an additional 90 seconds.
Jumper Y1 to DHUM to reduce the cooling off--delay to 5
seconds. (See Fig. 33.)
See Fig. 59 for thermostat connections.
This furnace can operate a two--speed cooling unit with a
single--stage thermostat because the furnace control CPU
includes a programmed adaptive sequence of controlled
operation, which selects low--cooling or high--cooling
operation. This selection is based upon the stored history
of the length of previous cooling period of the
single--stage thermostat.
Thermidistat Mode
See Fig. 52--55 for thermostat connections.
The dehumidification output, DHUM on the Thermidistat should
be connected to the furnace control thermostat terminal DHUM.
When there is a dehumidify demand, the DHUM input is
activated, which means 24 vac signal is removed from the
DHUM input terminal. In other words, the DHUM input logic is
reversed. The DHUM input is turned ON when no dehumidify
demand exists. Once 24 vac is detected by the furnace control on
the DHUM input, the furnace control operates in Thermidistat
mode. If the DHUM input is low for more than 48 hours, the
furnace control reverts back to non--Thermidistat mode.
NOTE: The air conditioning relay disable jumper ACRDJ must
be connected to enable the adaptive cooling mode in response to
a call for cooling. (See Fig. 33.) When in place the furnace
control CPU can turn on the air conditioning relay ACR to
energize the Y/Y2 terminal and switch the outdoor unit to
high--cooling.
The furnace control CPU can start up the cooling unit in either
low-- or high--cooling. If starting up in low--cooling, the furnace
control CPU determines the low--cooling on--time (from 0 to 20
minutes) which is permitted before switching to high--cooling.
If the power is interrupted, the stored history is erased and the
furnace control CPU will select low--cooling for up to 20 minutes
and then energize the air conditioning relay ACR to energize the
Y/Y2 terminal and switch the outdoor unit to high--cooling, as
long as the thermostat continues to call for cooling. Subsequent
selection is based on stored history of the thermostat cycle times.
The cooling operation described above also applies to operation
with a Thermidistat. The exceptions are listed below:
1. Low cooling – When the R to G--and--Y1 circuit is closed
and there is a demand for dehumidification, the furnace
blower motor BLWM will drop the blower airflow to 86%
of low cooling airflow which is the true on--board CF
selection as shown in Fig. 47.
49
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2. High cooling – When the R to G--and Y/Y2 circuit is
closed and there is a demand for dehumidification, the
furnace blower motor BLWM will drop the blower airflow
to 86% of high--cooling airflow. High--cooling airflow is
based on the A/C selection shown in Fig. 47.
3. Cooling off--delay – When the “call for cooling” is
satisfied and there is a demand for dehumidification, the
cooling blower--off delay is decreased from 90 seconds to
5 seconds.
When the R to G circuit is opened, the blower motor BLWM will
continue operating for an additional 5 seconds, if no other
function requires blower motor BLWM operation.
Continuous Blower Speed Selection from Thermostat
To select different continuous--blower airflows from the room
thermostat, momentarily turn off the FAN switch or push button
on the room thermostat for 1--3 seconds after the blower motor
BLWM is operating. The furnace control CPU will shift the
continuous--blower airflow from the factory setting to the next
highest CF selection airflow as shown in Fig. 47. Momentarily
turning off the FAN switch again at the thermostat will shift the
continuous--blower airflow up one more increment. If you repeat
this procedure enough you will eventually shift the continuous
blower airflow to the lowest CF selection as shown in Fig. 47.
The selection can be changed as many times as desired and is
stored in the memory to be automatically used following a power
interruption.
Super Dehumidify Mode
Super--Dehumidify mode can only be entered if the furnace
control is in the Thermidistat mode and there is a demand for
dehumidification. The cooling operation described in item 4.
above also applies to operation with a Thermidistat. The
exceptions are listed below:
1. Low cooling – When the R to Y1 circuit is closed, R to G
circuit is open, and there is a demand for dehumidification,
the furnace blower motor BLWM will drop the blower
airflow to 65% of low--cooling airflow for a maximum of
10 minutes each cooling cycle or until the R to G circuit
closes or the demand for dehumidification is satisfied.
Low--cooling airflow is the true on--board CF selection as
shown in Fig. 47.
Heat Pump
See Fig. 54--57 for thermostat connections. When installed with
a heat pump, the furnace control automatically changes the timing
sequence to avoid long blower off times during demand defrost
cycles. Whenever W/W1 is energized along with Y1 or Y/Y2, the
furnace control CPU will transition to or bring on the blower
motor BLWM at cooling airflow, low--heat airflow, or the
midrange airflow, whichever is lowest. The blower motor BLWM
will remain on until the main burners ignite then shut OFF and
remain OFF for 25 seconds before coming back on at heating
airflow. When the W/W1 input signal disappears, the furnace
control begins a normal inducer post--purge period while
changing the blower airflow. If Y/Y2 input is still energized the
furnace control CPU will transition the blower motor BLWM
airflow to cooling airflow. If Y/Y2 input signal disappears and
the Y1 input is still energized the furnace control CPU will
transition the blower motor BLWM to low--cooling airflow. If
both the Y1 and Y/Y2 signals disappear at the same time, the
blower motor BLWM will remain on at low--heat airflow for the
selected blower--OFF delay period. At the end of the
blower--OFF delay, the blower motor BLWM will shut OFF
unless G is still energized, in which case the blower motor
BLWM will operate at continuous blower airflow.
2. High cooling – When the R to Y/Y2 circuit is closed, R to
G
circuit is open, and there is
a
demand for
dehumidification, the furnace blower motor BLWM will
drop the blower airflow to 65% of high--cooling airflow
for a maximum of 10 minutes each cooling cycle or until
the
R
to
G
circuit closes or the demand for
dehumidification is satisfied. High--cooling airflow is
based on the A/C selection shown in Fig. 47.
3. Cooling off--delay – When the “call for cooling” is
satisfied and there is a demand for dehumidification, the
cooling blower--off delay is decreased from 90 seconds to
5 seconds.
Continuous Blower Mode
When the R to G circuit is closed by the thermostat, the blower
motor BLWM will operate at continuous blower airflow.
Continuous blower airflow selection is initially based on the CF
selection shown in Fig. 47. Factory default is shown in Fig. 47.
Terminal EAC--1 is energized as long as the blower motor
BLWM is energized.
During a call for heat, the furnace control CPU will transition the
blower motor BLWM to continuous blower airflow, low--heat
airflow, or the midrange airflow, whichever is lowest. The blower
motor BLWM will remain ON until the main burners ignite then
shut OFF and remain OFF for the blower--ON delay (60 seconds
in medium heat, and 35 seconds in high--heat), allowing the
furnace heat exchangers to heat up more quickly, then restarts at
the end of the blower--ON delay period at low--heat,
medium--heat, or high--heat airflow respectively.
The blower motor BLWM will revert to continuous--blower
airflow after the heating cycle is completed. In high--heat, the
furnace control CPU will drop the blower motor BLWM to
low--heat airflow during the selected blower--OFF delay period
before transitioning to continuous--blower airflow.
When the thermostat “calls for low--cooling”, the blower motor
BLWM will operate at low--cooling airflow. When the thermostat
is satisfied, the blower motor BLWM will operate an additional
90 seconds at low--cooling airflow before transitioning back to
continuous--blower airflow.
Component Test
The furnace features a component test system to help diagnose a
system problem in the case of a component failure. To initiate the
component test procedure, ensure that there are no thermostat
inputs to the control and all time delays have expired. Turn on
setup switch SW1--6. (See Fig. 33)
NOTE: The component test feature will not operate if the control
is receiving any thermostat signals or until all time delays have
expired.
The component test sequence is as follows:
1. The furnace control CPU turns the inducer motor IDM
ON at medium speed and keeps it ON through step 3.
2. After waiting 15 seconds the furnace control CPU turns
the hot surface igniter ON for 15 seconds, then OFF.
3. The furnace control CPU then turns the blower motor
BLWM ON at midrange airflow for 15 seconds, then OFF.
4. After shutting the blower motor BLWM OFF the furnace
control CPU shuts the inducer motor IDM OFF.
NOTE: The EAC terminals are energized when the blower is
operating.
When the thermostat “calls for high--cooling”, the blower motor
BLWM will operate at high cooling airflow. When the thermostat
is satisfied, the blower motor BLWM will operate an additional
90 seconds at high--cooling airflow before transitioning back to
continuous--blower airflow.
After the component test is completed , 1 or more status codes
(11, 25, 41, or 42) will flash. See Service Label on blower access
panel or Service/Status Code Instructions for explanation of
status codes.
NOTE: To repeat component test, turn setup switch SW1--6 to
OFF and then back ON.
50
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A06678
Fig. 52 -- Step--Modulating Furnace with Single--Speed Air
Conditioning
A06680
Fig. 54 -- Step Modulating Furnace with Single--Speed Heat
Pump (Dual Fuel)
A06679
Fig. 53 -- Step Modulating Furnace with Two--Speed Air
Conditioner
A06681
Fig. 55 -- Step Modulating Furnace with Two--Speed Heat
Pump (Dual Fuel)
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A06682
Fig. 56 -- Step Modulating Furnace with Single--Speed Heat
Pump
A06684
Fig. 58 -- Two--Stage Thermostat with Step Modulating
Furnace and Two--Speed Air Conditioner
A06683
Fig. 57 -- Dual Fuel thermostat with Step--Modulating
Furnace and Two--Speed Heat Pump
A06685
Fig. 59 -- Single--Stage Thermostat with Step Modulating
Furnace and Two--Speed Air Conditioner
52
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NOTE: Reference Fig. 52--59:
NOTE: For Canadian altitudes of 2000 to 4500 ft, use U.S.A.
altitudes of 2001 to 3000 ft in Table 10.
1. Heat pump MUST have a high pressure switch for dual
fuel applications.
2. Refer to outdoor equipment Installation Instructions for
additional information and setup procedure.
3. Select the “ZONE” position on the two--speed heat pump
control.
4. Outdoor Air Temperature Sensor must be attached in all
dual fuel applications.
e. Find closest natural gas heat value and specific gravity
in Table 10.
f. Follow heat value and specific gravity lines to point of
intersection to find orifice size and low--, medium--, and
high--heat manifold pressure settings for proper
operation.
EXAMPLE: (0 -- 2000 ft altitude)
Heating value = 1050 Btu/cu ft
Specific gravity = 0.62
Therefore: Orifice No. 45
Manifold pressure: 3.8--in. wc for high heat 1.6--in. wc for medium
heat 0.6--in. wc for low heat
* Furnace is shipped with No. 45 orifices. In this example, all main
burner orifices are the correct size and do not need to be changed to
obtain proper input rate.
5. Dip switch No.1 on Thermidistat should be set in OFF
position for air conditioner installations. This is factory
default.
6. Dip switch No. 1 on Thermidistat should be set in ON
position for heat pump installations.
7. Dip switch No. 2 on Thermidistat should be set in OFF
position for single--speed compressor operation. This is
factory default.
8. Dip switch No. 2 on Thermidistat should be set in ON
position for two--speed compressor operation.
g. Check and verify burner orifice size in furnace. NEVER
ASSUME ORIFICE SIZE; ALWAYS CHECK AND
VERIFY.
9. Configuration Option No. 10 “Dual Fuel Selection” must
be turned ON in all dual fuel applications.
2. Adjust manifold pressure to obtain input rate.
HIGH-HEAT
ADJUSTMENT
(UNDER CAP)
10. NO connection should be made to the furnace HUM
terminal when using a Thermidistat.
ON/OFF
SWITCH
11. Optional connection. If wire is connected to W2 on
furnace control board, either dip switch SW1--2 or SW4--2
on furnace control should be set in ON position to allow
Thermidistat/Thermostat to control furnace at 2 stages
Low/High or Medium/High.
BURNER
ENCLOSURE
REFFERENCE
INLET
PRESSURE
TAP
TAP
12. Optional connection. If wire is connected, ACRDJ jumper
on furnace control should be removed to allow
Thermidistat/Thermostat to control outdoor unit staging.
13. Furnace must control its own staging operation via furnace
control algorithm. This is factory default.
14. The RVS Sensing terminal “L” should not be connected.
This is internally used to sense defrost operation.
15. DO NOT SELECT the “FURNACE INTERFACE” or
“BALANCE POINT” option on the two--speed heat pump
control board. This is controlled internally by the
Thermidistat/Dual Fuel Thermostat.
16. Dip switch D on Dual Fuel Thermostat should be set in
OFF position for single--speed compressor operation. This
is factory default.
MEDIUM-HEAT
ADJUSTMENT
(UNDER CAP)
LOW-HEAT
ADJUSTMENT
(UNDER CAP)
17. Dip switch D on Dual Fuel Thermostat should be set in
ON position for two--speed compressor operation.
MANIFOLD
PRESSURE
TAP
Step 4 — Adjustments
Set Gas Input Rate
A07280
Furnace gas input rate on rating plate is for installations at
altitudes up to 2000 ft.
Fig. 60 -- Redundant Automatic Gas Valve
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.
a. Remove burner enclosure front.
NOTE: Manifold pressure MUST always be measured with the
burner box cover REMOVED.
In Canada, the input rating must be derated by 5 percent for
altitudes of 2000 ft to 4500 ft above sea level.
Adjust manifold pressure to obtain input rate.
b. Remove regulator seal caps that conceal adjustment
screws for medium-- and high--heat gas valve regulators.
(See Fig. 60.)
Furnace input rate must be within +2 percent of input rate on
furnace rating plate.
c. Move setup switch SW4--2 on control center to ON
position. (See Fig. 33.) This keeps furnace locked in
medium--heat operation.
d. Jumper R and W/W1 thermostat connections on control
to start furnace.
e. Turn medium--heat adjusting screw counterclockwise
(out) to decrease manifold pressure or clockwise (in) to
increase manifold pressure.
1. Determine natural gas orifice size and manifold pressure
for correct input.
a. Obtain averageheatvalue(at installed altitude) from local
gas supplier.
b. Obtain average specific gravity from local gas supplier.
c. Verify furnace model. Table 10 can only be used for
model 355CAV Furnaces.
d. Find installation altitude in Table 10.
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NOTE: DO NOT set medium--heat manifold pressure less than
1.3-- in. wc or more than 1.7--in. wc for natural gas.
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).
UNITED STATES
Ataltitudesabove2000ft,this furnacehas beenapproved
for 2 percent derate for each 1000 ft above sea level. See
Table 11 for derate multiplier factor and example.
CANADA
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life.
DO NOT bottom out gas valve regulator adjusting screws.
This can result in unregulated manifold pressure and result
in excess overfire and heat exchanger failures.
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 and use 0.95 as derate
multiplier factor.
EXAMPLE: 80,000 BTUH HIGH--HEAT INPUT
FURNACE INSTALLED AT 4,300 FT
Furnace Input Rate at Sea Level X Derate Multiplier
Factor = Furnace Input Rate at Installation Altitude
80,000 X 0.91 = 72,800
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.
(See Fig. 61.)
f. Move setup switch SW4--2 to OFF position after
completing medium--heat adjustment.
g. Jumper R and W/W1 and W2 thermostat connections on
furnace control. (See Fig. 33.) This keeps furnace locked
in high--heat operation.
h. Turn high--heat adjusting screw counterclockwise (out)
to decrease manifold pressure or clockwise (in) to
increase manifold pressure.
b. Reinstall burner box cover.
NOTE: Clocking gas input rate MUST always be performed
with the burner box cover INSTALLED.
c. Check that gas valve adjustment caps are in place for
proper input to be clocked.
d. Obtain average heat value (at altitude) from local gas
supplier.
NOTE: Be sure heating value of gas used for calculations is
correct for your altitude. Consult local gas utility for altitude
adjustment of gas heating value.
NOTE: DO NOT set high--heat manifold pressure less than
3.2--in. wc or more than 3.8--in. wc for natural gas.
i. Remove jumpers R to W/W1 and R to W2.
e. Check and verify orifice size in furnace. NEVER
ASSUME THE ORIFICE SIZE. ALWAYS CHECK
AND VERIFY.
j. Wait for blower off--delay to finish then reset 115--v
power to furnace.
k. Jumper R and W/W1 thermostat connections on control
to start furnace.
f. Turn off all other gas appliances and pilots.
g. Move setup switchSW4--2 toON position.(See Fig.33.)
This keeps furnace locked in medium--heat operation.
l. Wait for the blower to turn ON then check low--heat
manifold pressure. It should be between .5 to .6--in. wc.
This setting should not require adjustment but if it does
remove the low--heat adjustment cap (See Fig. 60) and
turn the low--heat adjusting screw clockwise (in) to
decrease manifold pressure or counterclockwise (out) to
increase manifold pressure. You will only have 15
minutes to make an adjustment if needed. If you need
more time then move setup switch SW1--2 on control
center to ON position (See Fig. 33).
NOTE: DO NOT set low--heat manifold pressure before setting
medium--heat manifold pressure. DO NOT set low--heat manifold
pressure less than .5--in. wc or more than .6--in. wc for natural
gas.
m. When correct manifold pressures are obtained, replace
caps that conceal gas valve adjustment screws. Main
burner flame should be clear blue, almost transparent.
(See Fig. 62.)
BURNER
ORIFICE
n. Remove jumper across R and W/W1. If necessary move
setup switch SW1--2 to the OFF position.
3. Verify natural gas input rate by clocking gas meter.
A93059
Fig. 61 -- Burner Orifice
54
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Table 10 – Orifice Size* and Manifold Pressures for Gas Input Rate
(Tabulated Data Based on 20,000 BTUH High Heat / 13,000 Btuh Med--Heat / 8,000 Btuh Low--Heat per Burner,
Derated 2% / 1000 Ft. Above Sea Level)
A07253
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Orifice Size* and Manifold Pressures for Gas Input Rate
(Tabulated Data Based on 20,000 BTUH High Heat / 13,000 Btuh Med--Heat / 8,000 Btuh Low--Heat per Burner,
Derated 2% / 1000 Ft. Above Sea Level)
A07254
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o. Wait for blower off--delay to finish then reset 115--v
power to furnace.
p. Jumper R and W/W1 thermostat connections on control
to start furnace.
!
CAUTION
UNIT DAMAGE HAZARD
q. Wait for the blower to turn ON then repeatitems ithrough
l for low--heat operation. This setting should not require
adjustment but if it does you will only have 15 minutes
to make the adjustment. If you need more time then move
setup switch SW1--2 on control center to ON position
(See Fig. 33).
Failure to follow this caution may result in component
damage.
DO NOT redrill orifices. Improper drilling (burrs,
out--of--round holes, etc.) can cause excessive burner noise
and misdirection of burner flames. (See Fig. 61.)
NOTE: Measured gas inputs (high heat, medium heat, and low
heat) must be within +/--2 percent of that stated on furnace rating
plate when installed at sea level or derated as stated above when
installed at higher altitudes.
h. Jumper R to W/W1.
i. Let furnace run for 3 minutes in medium--heat operation.
j. Measure time (in sec) for gas meter to complete 1
revolution. Note reading.
BURNER FLAME
BURNER
k. Refer to Table 12 for cubic ft of gas per hr.
l. Multiply gas rate cu ft/hr by heating value (Btu/cu ft).
m. Move setup switch SW4--2 to OFF position and jumper
R and W/W1 and W2 thermostat connections. (See Fig.
33.) This keeps furnace locked in high--heat operation.
Repeat items i through l for high--heat operation.
EXAMPLE: (High--heat operation at 0 -- 2000 ft altitude)
Furnace input from rating plate is 80,000 Btuh
Btuh heating input = Btuh/cu ft X cu ft/hr
Heating value of gas = 975 Btuh/cu ft
Time for 1 revolution of 2--cu ft dial = 88 sec
Gas rate = 82 cu ft/hr (from Table 12)
Btuh heating input = 103 X 975 = 79,950 Btuh
In this example, the orifice size and manifold pressure adjustment
is within +/-- 2 percent of the furnace input rate.
MANIFOLD
A89020
n. Remove jumper across R, W/W1, and W2 thermostat
connections to terminate call for heat.
Fig. 62 -- Burner Flame
ALTITUDE
(FT)
% OF
DERATE
0
DERATE MULTIPLIER
FACTOR FOR U.S.A.*
0—2000
1.00
0.95
0.93
0.91
0.89
0.87
0.85
0.83
0.81
2001—3000
3001—4000
4001—5000
5001—6000
6001—7000
7001—8000
8001—9000
9001—10,000
4—6
6—8
8—10
10—12
12—14
14—16
16—18
18—20
*Derate multiplier factor is based on midpoint altitude for altitude range.
Table 11 – Altitude Derate Multiplier for U.S.A.
57
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Table 12 – Gas Rate cu Ft/Hr
SECONDS
SIZE OF TEST DIAL
SECONDS
SIZE OF TEST DIAL
FOR 1
1
2
5
FOR 1
1
cu ft
72
71
69
68
67
65
64
63
62
61
60
58
56
54
53
51
50
48
47
46
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
31
30
2
cu ft
144
141
138
136
133
131
129
126
124
122
120
116
112
109
106
103
100
97
5
REVOLUTION
10
cu ft
360
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
100
97
cu ft
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
267
257
248
240
232
225
218
212
206
200
195
189
185
180
176
172
167
164
160
157
153
150
147
cu ft
1800
1636
1500
1385
1286
1200
1125
1059
1000
947
900
857
818
783
750
720
692
667
643
621
600
581
563
545
529
514
500
486
474
462
450
439
429
419
409
400
391
383
375
367
REVOLUTION
50
cu ft
360
355
346
340
333
327
321
316
310
305
300
290
281
273
265
257
250
243
237
231
225
220
214
209
205
200
196
192
188
184
180
178
173
170
167
164
161
155
150
11
51
12
52
13
53
14
54
15
55
16
56
17
57
18
58
19
59
20
60
21
62
22
64
23
66
24
68
25
70
26
72
27
74
28
76
95
29
78
92
30
80
90
31
82
88
32
84
86
33
86
84
34
88
82
35
90
80
36
92
78
37
94
76
38
95
96
75
39
92
98
74
40
90
100
102
104
106
108
110
112
116
120
72
41
88
71
42
86
69
43
84
68
44
82
67
45
80
65
46
78
64
47
76
62
48
75
60
49
73
Set Temperature Rise
3. This furnace is capable of automatically providing proper
airflow to maintain the temperature rise within the range
specified on furnace rating plate. If temperature rise is
outside this range, proceed as follows:
!
CAUTION
a. Check gas input for low--, medium--, and high--heat
operation.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in component
damage.
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.
wc.
d. Ensure Low Heat Rise Adjust switch SW1--3 on furnace
control is in ON position when a bypass humidifier is
used. (See Fig. 33 for switch location.)
Temperature rise must be within limits specified on unit
rating plate. Operation is within a few degrees of midpoint
of rise range when setup switch SW1--4 is off.
Furnace must operate within ranges of temperature rise specified
on the furnace rating plate. Determine air temperature rise as
follows:
e. Check Troubleshooting Guide for Variable--Speed Step
Modulating Condensing Furnaces.
Set Thermostat Heat Anticipator
1. Place thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not see heat
exchanger so that radiant heat does not affect readings.
This practice is particularly important with straight--run
ducts.
When using a non--electronic thermostat, 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 only at the thermostat subbase terminals R and W.
The thermostat and anticipator should NOT be in the circuit while
measuring current. If thermostat has no subbase, the thermostat
must be disconnected from R and W/W1 wires during current
measurement.
Fig. 63 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.
2. When thermometer readings stabilize, subtract return--air
temperature from supply--air temperature to determine air
temperature rise.
NOTE: Temperature rise can be determined for low--heat
operation by placing setup switch SW1--2 on furnace control in
ON position. Temperature rise can be determined for
medium--heat operation by placing setup switch SW4--2 on
furnace control in ON position. For high--heat operation, place
setup switch SW1--2 and SW4--2 in OFF position and jumper
R--W2 on furnace control. DO NOT forget to return setup switch
to OFF position and remove R--W2 jumper upon completion of
testing. (See Fig. 33 for switch and terminal location.)
1. To operate furnace in low--heat, turn setup switch SW1--2
to ON position (See Fig. 33) and connect ammeter leads
across thermostat subbase R--W.
2. See thermostat manufacturer’s instructions for adjusting
the heat anticipator and for varying heating cycle length.
58
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NOTE: When using an electronic thermostat, set cycle rate for 3
cycles per hr.
2. Remove control access door and disconnect inducer motor
12--pin wire harness at inducer motor.
3. Turn on 115--v power to furnace.
3. Return setup switch SW1--2 to OFF position and replace
thermostat on subbase.
4. Set thermostat to “call for heat.” When pressure switches
are functioning properly, status code 42 will flash on fur-
nace control approximately 20 sec after thermostat switch
is closed. If either a status code 31 or 32 is flashed when
inducer motor is disconnected, the furnace will shut itself
Check Safety Controls
This section covers the safety controls that must be checked
before the installation is complete. The flame sensor, gas valve,
and pressure switches were all checked in the Start--up procedure
section as part of normal operation.
down immediately.
Determine the reason pressure
switches did not function properly and correct the condi-
tion.
Check Primary Limit Control
This control shuts off the gas control system and energizes the
air--circulating blower motor if furnace overheats.
5. Turn off 115--v power to furnace.
6. Reconnect inducer motor wire harness. Reinstall furnace
access door.
1. The recommended method of checking this limit control is
to gradually block off return air after furnace has been op-
erating for a period of at least 5 minutes.
2. As soon as limit control has shut off burners, a status code
33 will appear on furnace control.
7. Turn on 115--v power to furnace.
8. Reset thermostat to desired temperature.
CHECKLIST
1. Put away tools and instruments. Clean up debris.
2. Verify flame rollout manual reset switch has continuity.
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 duct or motor
failure. If the limit control does not function during this test, the
cause must be determined and corrected.
3. Verify that blower and main access doors are properly
installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instruc-
tions.
Check Pressure Switches
6. Review User’s Manual with owner.
7. Leave literature packet near furnace.
This control proves operation of the draft inducer. Check switch
operation as follows:
1. Turn off 115--v power to furnace.
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK-AROUND
AMMETER
R
Y
W
G
10 TURNS
FROM UNIT 24-V
CONTROL TERMINALS
0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
=
EXAMPLE:
A96316
Fig. 63 -- Amp Draw with Ammeter
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CHECKLIST — INSTALLATION
LOAD CALCULATION
________________
Heating Load (Btuh)
Cooling Load (Btuh)
Condensate Drain
________________
________________
________________
Unit Level or Pitched Forward
________________
________________
________________
Internal Tubing Connections
Free of Kinks and Traps
Furnace Model Selection
External Drain Connection Leak
Tight and Sloped
COMBUSTION AND VENT PIPING
Termination Location
Condensate Trap Primed before
S t a r t --- Up
________________
Vent
Roof
Heat Tape Installed if Required
________________
________________
C H E C K L I S T --- S T A R T --- U P
________________
Gas Input Rate (Set Within 2
percent of Rating Plate)
Sidewall
________________
________________
________________
________________
Combustion---Air
Roof
________________
Temperature Rise Adjusted
Thermostat Anticipator
Sidewall
Attic
________________
________________
Anticipator Setting Adjusted or
Cycle Rate (3 Cycles per Hr)
Selected
________________
________________
Crawl Space
Safety Controls Check Operation
C H E C K L I S T --- S T A R T --- U P
Termination Kit---2 Pipe or
Concentric
________________
________________
________________
________________
Gas Input Rate (Set Within 2
C o m b u st i o n --- A i r P i p e L e n g t h
percent of Rating Plate)
Combustion---Air Pipe Elbow
Quantity
Temperature Rise Adjusted
________________
________________
________________
Vent Pipe Length
Thermostat Anticipator
Vent Pipe Elbow Quantity
________________
________________
Anticipator Setting Adjusted or
Pipe Diameter Determined from
Sizing Table
Cycle Rate (3 Cycles per Hr)
Selected
________________
Pipe Sloped To Furnace
Safety Controls Check Operation
Pipe Insulation
________________
________________
Primary Limit
________________
________________
Over Ceilings
Pressure Switches
Low---Ambient Exposed Pipes
EBryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 09/07
Catalog No. II355CAV--- 0 6 0 --- 2
Replaces: NEW
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
60
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