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Permit M01-114 - VACCA RESIDENCE
MO1-1 14 Vacca Residence 14435 56 Av City of Tukwila _ (206) 431 -3670 Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188 Permi yiNi gQriE1 Address: 14435 56 AV S Location: Parcel #: 336590 -0075 Contractor License No: WASHIES07403 * * *. * * * * * ** MECHANICAL PERMIT Category: RES Expires: 12/25/ TENANT JIM VACCA 14435 - 56TH AV S, TUKWILA WA 98168 OWNER VACCA VINCENZO 14435 56TH S, SEATTLE WA 98168 CONTACT CANDICE GALLAGHER 2800 THORNDKE, SEATTLE WA 98199 CONTRACTOR WASHINGTON ENERGY SERVICES CO 2800 THORNDYKE AV W, SEATTLE, WA 98199 Phone: Phone: 206- 378 -6680 Phone: 206 -282 -4700 **** ***** ** ** ******* fr****** * ** ** * * **** **** * *****•k ** *** *** k **** ***** * * * * *`k ** Permit Description: NEW 80000 BTU GAS FURNACE, ELECTRIC TO GAS CONV. UMC Edition: 19 Valuation: Total Permit Fee: 3,000.00 47.88 * * * * * ** qtr*********** * * * * * * * * * ** * * * * * * * ** * * * * * ** * * ** rized Si,gnatu e Date hereby certify teat I have read and examined this permit and know the same to:';be.- tr..ue and correct. All provisions of law and ordinances governing this work will be complied with, whether specified herein or not The granting`:of this permit does not presume to give authority to violate or cance 1.the,provisions of any other state or local laws regulating construction' or the performance of work. I am authorized to sign for and obtain this building; permit. 12.. a .-- � 1 e C L I Print Name: . Q, ` Title: This permit shall become null and void if the work is not commenced within 180 days from the date of issuance, or if the work is suspended or abandoned for a period of 180 days from the last inspection. ...r.. ♦...a��_._i.. �..:.Y"i:i... �..., L,: ..y,a.- ...... i.wa.:ti ...... w. . ✓�t..,........_.i�.:Li::- `..u.. �._.n. �.w..�u.�r'+�i..�wr.� � w. u+.✓: t+:+. �' 1-` �. ar._ �...a.e_.i.�+..,.w......su.l. —. ...w ..ri:.u... �.a Project Name/Tenant: j‘ M .. a�j 'iN 1 l. �. . :11 :.I} i tti i:f.� ,�. x.,.:.1 :�is, f . .4"... . °,,.... i. .,:;!! �1,,�''EI': ..?,C.� 1, r'. '1,.r ., _i�; : ACC �0.� �. e1 Value of Mechanical Equipment: Thor) Date. Site Address : )4l43 ` �J s / ,�,.. , /y ( fin Tax arcel Nu l berb o Property Owner: . vQ,C�CL� Phone: (x(p ) -o4i 0m�1 Address: �" tiy\ Street Address: c 1-41- City/State/Zip: City State/Zip: Fax #: ( ) Contractor: r Sh . Q Phone: ( p)� ti — am �� Street Addre Ci ty �, Sta e/Zi.�p, Fax #: ( ) Contact Person: Co , c� -- � I I aC l Phone: (' j6) 3- �, Q ► z � (_) Street Address: t^ t City State/Zip: Fax #: ( ) . . ........ , i .. �. . ... . .... � .. . .. .._ .. , ... ..� 1 ..� , . i 1 �: e:,:T. y'. :'i19J B U I talir lO ;1 ' ..:r. L i'. %4 �.,v :1l: .. a�j 'iN 1 l. �. . :11 :.I} i tti i:f.� ,�. x.,.:.1 :�is, f . .4"... . °,,.... i. .,:;!! �1,,�''EI': ..?,C.� 1, r'. '1,.r ., _i�; : Signature: - �. e1 �r Date. 0 / Print name: 0 AP, I/� � i v - 1 C 1 Phone: ( � e/ . Fax #: ) Address: �" tiy\ s City/State/Zip: OF TKWILA Permit Center 6300 Southcenter Boulevard, Suite 100 Tukwila, WA 98188 (206) 431 -3670 Mechanical Permit Application Application and plans must be complete in order to be accepted for plan review. Applications will not be accepted through the mail or facsimile. MECHAf�ICAL °..P,ERMITe APPROVAL:REQUESTED:;40 BEiF/tLED;0UT'BYAPPLIC'ANTj Description of work to be done (please be specific): ' STAFF USE ONLY Project Number. Permit Number : .. 'n -- A - a yo Current copy of Washington State Department of Labor and Industries Valid Contractor's License. If not available at the time of application, a copy of this license will be required before the permit is issued OR submit Form H-4, "Affidavit in Lieu of Contractor Registration ": Building Owner /Authorized Agent: If the applicant is other than the owner, registered architect/engineer, or contractor licensed by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the permit will be required as part of this submittal. I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER PENALTY OF PERJURY BY THE LAWS OF THE STATE OF WASHINGTON, AND l AM AUTHORIZED TO APPLY FOR THIS PERMIT. Expiration of Plan Review - Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The building official may extend the time for action by the applicant for a period not exceeding 180 days upon written request by the applicant as defined in Section 114.4 of the Uniform Mechanical Code (current edition). No application shall be extended more than once. Date application accepted: — - o f Date application expires: / -o 1 Application taken by: (initials) 11/2/99 mech perrnll.doc ✓ Submittal Requirements Floor plan and system layout Roof plan required to identify individual equipment and the location of each installation (Uniform Mechanical Code 504 (e)) Details and elevations (for roof mounted equipment) and proposed screening Heat Loss Calculations or Washington State Energy Code Form #H -7 H.V.A.C. over 2,000 CFM (approximately 5 ton and larger) must be provided with smoke detection shut- off and will be routed to the Fire Prevention division for additional comments (Uniform Mechanical Code 1009). Specifications must be provided to show that replacement equipment complies with the efficiency ratings and other applicable requirements of the Washington State Nonresidential Energy Code. Structural engineer's analysis is required for new and the replacement of existing roof equipment weighing 400 pounds and greater (Uniform Building Code 1632.1). Structural documentation shall be stamped by a Washington State licensed Structural Engineer. Mechanical Permits COMMERCIAL: Two complete sets of drawings and attachments required with application submittal NOTE: Water heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. RESIDENTIAL: Two complete sets of attachments required with application submittal Submittal Requirements 11/2/99 ndscpnu.dac- New Single Family Residence Heat Toss calculations or Form H -6. Equipment specifications. Change -out or replacement of existing mechanical equipment 1 Narrative of work to be done, including modification to duct work. Installation of Gas Fireplace NOTE: Water = heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. Narrative with specification of equipment and chimney type. If using existing chimney; provide a letter by a certified chimney sweep stating that the chimney is in safe condition. • Signature: Ont-Name CITY OF TUKWILA Address: 14435 56 AV S ' Suite: Tenant: JIM VACCA Status: ISSUED Type: S-MECH Applied: 06/28/2001 Parcel #: 336590-0075 Issued: 06/28/2001 **Al i k***k * A *********A**kA*k*Itk***k**AAk***kAkkAlfkkk . ****k*kkh**kkk4k***kk4.4.1 ( Permit Conditions: 1 No changes will be made t� the plans unless approved by the 2 Engineer and the Tukwila Building Division. 2. All permits, jnspection records, and approved plans shall be available at the job site prior to the start of any con- struction. These documents .are to be maintained andavail- able until final inspection approval is aranted. All constructiOn to be done in conformance with approved plans and reguirents of the UnifOrm'Buildina Code (1997 Edition) as amended, Uniform Mechanical Code (1997 Edition), and WashlngtOnState,Energy Code (1997 Edition). 4. Validity /of Permit.' The issuance of a permit or approval planspecificationt.,,- and computations shall not be con- , strued;t0 be , p14 . permtt . ,for,.or an approval of any violation' of any af the proviSions, of the building code or of any other ordinance of the iurisdictiOn. No permit presuming to give author to violate or cancel the provisions of this code "shall , be valid. 5. MahJAacturers . installation inwtictions required on site for:uthe:buildlng inspectors review. I hereby that I have read these'conditions and will comply, , with theth outlined. All provisions of law and ordinances governing -- this work'"011 coMplied with whether specified herein or not The granting'-of this permit does not presume to give authority to violate or cancel the provisions of any other work or local laws reaulating ConstrUction'or the performance of work. Date: Permit No: M01-114 ' • • - •,.^b.ty,•• ,yme.nt : a tiri% 1t'fi rigir ro?of *; .iV, ,11..1r.- ` C :,ia'' "^ r y i w yh • rz r. "it 7v �rrty S';5� ik't w �.t r - A. . a j 2' r�. t � ro ;i r . F *{%el. r a h 4•Y. itti •11%9 '*')/ * *A * * *** * ** *** ****fir * ***:kk *fin * **:4*A: * ** * t CITY OF TUKWILA. WA , • *** **•h**A** •k ****•h *.A***:1*A* AA:k* * ***** l ** * * *k** * *****•k **A* * *:1 � TRANSMIT Numb R0100821 Amount: 47�47.88 06/28i01 11e45 Paymer4 ; Methodn CHECK Notation: WASHINGTON ENG a Init: 3(D ei^mit .No: M0.1-114 Type: 8-MECH MECHANICAL PERMIT a rce1 No: ...33.6590 - 0075 ite Add 4J Address: 1443'. 36 AV J Total Fees. 47 ;88 Total .ALL Pmts: fl.a1«nce. * * * * * * * * * * * * * *•* * * * *.*•* * * * * ** •** *A• * * * *** * * * * *** * * * * * * * * **A*11* 7t ** Account Cade Description 3.5t 00/345,,J)30 PLAN CHECK - RES 3030 00/3.22 1`'0a MECHANICAL - RES 47.88 47.88 „00 P 'ec : V acres Typ f In lion: A re bat calleH: Date wanted: 7 70/ a. m : Special instructions: • n uigta, / P z p 3 Approved per applicable codes. INSPECTION RECOr . 1 1 ;t , Retain a copy with permit INSPECTION NO. CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd, #100, Tukwila; WA 98188 COMMENTS: /`Jm e ivn 3 0,0 ! ,o T C 00C 11 tr■ �- -0 T rra ;a i r s'irvr:'z ahwJ at 1 • r l ! f J r ., PERMIT NO. (206)431 -3670 Corrections required prior to approval. $47.00 REINSPECTION FEE REQUIRED. Prior to inspection, fee mustbp.•.paid,, at 6300 Southcenter Blvd., Suite 100. CaII to schedule reinspection. `. Receipt No: Date: Projec ‘,:f . ,- -.. * J1 /V1 4 ' 3 ' ,:itifAriipecron: 0 # ' flo ''. iil hPfi AdIr . ate called: Of Special instructions: Date wanted: /Of a Re , C....e Phppg: ( 3/ 57 INSPEtTION REC Retain a copy with permit INSPECTION NO. CITY OF TUKWILA BUILDING DIYISI Approved per applicable codes. lqspecto . Date: (2136)431-3670 rrections required prior to approval. COMMENTS: Correcitrwk.s $ 2.. L -4 e wtin 1,01-e — rAveL PP tine El $47.00 REINSPECTION FEE REQUIRED. Prior to inspection, fee must be paid 6300 Southcenter Blvd.; Suite 100.. Call to schedule reinspection. Date: Receipt No: '''101.-',114,:ii..tiiiseetgw2.allavaass.4ii. Pro • - c a t: / :. J Type of In ction:: A e • s 413.5 5 , , • ' 1Date.ca ed • /` / Special i structions:. - Date wanted: 7'. 'M a:m. / Requester: , -A i Ua c Ph a c6 0748 - 0477 1 INSPECTION REC Retain a copy with permit INSPECTION NO. CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd, #100, Tukwila, WA ,9818 PERMIT NO. a Approved per applicable codes.. 2TCorrections required prior to approval. COMMENTS: IU GL4 t InC � )1P(4v \(f 1 Ic� 3_) UP ► 4 \ I, e ■r 1.1 ain -p v yvl 1 (v1Gt k ? r � r1 ►J 4001 I f r,� c,rari vex C - t �Pr Sr\MA) I VP n or C One ev\-t c \rIA+ i Uri 7C1 r,-kuILA-low `N\ r\ hnuwti o-P tl { 1�l IA ow Inspector: Date: --• 5 , Q a $47.00 REINSPECTION FEE REQUIRED. Prior to inspection, fee must be paid at 6300 Southcenter Blvd., Suite 100• Call to schedule reinspection. Receipt No: Date: � MY��3�'-t�3�- fC�.�.���di J�t ^ . 21 .���11:�) l kY h �t��wl Day& Night WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal in- jury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. — Installation and service must be performed c by a qualified installer, service agency or the gas supplier. MDH ...._ ■ RECEIVE TV OF 11) PERMIT CE Condensing Gas Furnace Model 340MAV 350MAV, and 355MAV USER'S' INFORMA TlO. \ MANUAL FOR THE OPERA TI ON !J7Y, AND (/,,' WELCOME TO A NEW GENERATION OF COMFORT Congratulations! In Tight of rising energy costs, the Plus 90TM, 340MAV, and Plus 90P" Multipoise, Gas - Fired, Condensing Furnaces are among the soundest investments today's home- owner can make. Your new furnace is truly a triumph of technology in home heating. A revolu- tionary design employs 2 heat exchangers to "squeeze" out the maxi- mum amount of heat from the fuel con- sumed. In fact, your new furnace is so efficient, Over 90 %* of the heat gener- ated during combustion is captured and delivered inside your home. That is more than a 33 %* increase in heating efficiency over conventional furnaces. These are among the most energy -effi- cient furnaces you can buy today. They also are among the safest and most dependable. We are proud of the tech- nological advances incorporated into the design of these furnaces. With only minimal care, your new furnace will deliver many years of money- saving home comfort and enjoyment. Spend just a few minutes with this manual to learn the operation of your new fur - nace and the small amount of mainte- nance it takes to help keep it operating at peak efficiency year after year. • The output capacity and any representations of sllld sncy fax this funs are based on standard Dsprtmsnt of Energy Met procedures. INSTALLATION DATA Date Installed Dealer Name Address City State Zip Telephone FURNACE Product No Model No Serial No MODELS 340MAV (SHOWN) AND 350MAV FIXED - CAPACITY FURNACES 1 MODEL 355MAV VARIABLE - CAPACITY FURNACE SPLIT-SYSTEM 2 Product No. Model No Serial No. INDOOR COIL: Product No. Model No. Serial No FURNACE COMPONENTS 0 0 0 0 0 6 0 0 9 10 m m m m 16 m ID 19 20 Air filter and retainer. Control center. Combustion -air intake connection to ensure contaminant -free air (right or left side). Burner sight glass for viewing burner flame. Burner assembly (inside). Operates with energy - saving inshot burners and hot surface ignitor for safe, dependable heating. Redundant gas valve. Safe, efficient. Features 1 gas control with 2 intemal shutoff valves. Vent outlet. Uses PVC pipe to carry vent gases from the furnace's combustion system (right or left side). . Inducer motor. Pulls hot flue gases through the heat exchangers, maintaining negative pressure for added safety. Blower access panel safety interlock switch. Condensate drain connection. Collects moisture condensed from burned gases for disposal into home drain system. Heavy -duty blower. Circulates air across the heat exchangers to transfer heat into the home. Secondary condensing heat exchanger (inside). Wrings out more heat through condensation. Constructed with Polypropylene- laminated steel to ensure durability. Primary serpentine heat exchanger (inside). Stretches fuel dollars with the S- shaped heat -flow design. Solid construction of corrosion- resistant aluminized steel means reliability. 3 -amp fuse provides electrical and component protection. Light emitting diode (LED) on control center. Code lights are for diagnosing fumace operation and service requirements. Pressure switch(es) ensure adequate flow of flue products through furnace and out vent system. Rollout switch (manual reset) to prevent overtemperature. Junction box for 115 -v electrical power supply. Transformer (24v) behind control center provides low - voltage power to furnace control center and thermostat. Limit switch (manual reset) on 355MAV only. 3 MODELS 340MAV AND 350MAV FURNACES (UPFLOW POSITION) 2 12 18 5 11 16 9 8 MODEL 355MAV FURNACE ( UPFLOW POSITION) 17 3 12 5 14 15 13 7 19 3 IMPORTANT FACTS Your gas furnace uses air from outside the home for combustion and venting. It is not to be installed using in -house air. Therefore, both pipes must terminate outside the structure and must not be obstructed in any way. 5 • To minimize the possibility of seri- ous personal injury, fire, damage to your furnace, or improper operation, carefully follow these safety rules: • Keep the area around your furnace free of combustible materials, gaso- line, and other flammable liquids and vapors. • Do not cover the furnace, store trash or debris dear it, or in any way block the flow of fresh air to the unit. • A furnace installed in an attic or other insulated space must be kept free and clear of insulating material. Examine the furnace area when install- ing the furnace or adding more insula- tion. Some insulation materials may be combustible. NOTE: Do not use this furnace if any part has been under water. Immedi- ately call a qualified service technician to inspect the furnace and to replace any part of the control system and any gas control which has been under water. NOTE: The qualified installer or agency must use only factory- authorized replacement parts, kits, and accessories when modifying this product. q ff•F J l This furnace contains SAFETY DEVICES which must be MANU- ALLY RESET. If the furnace is left un- attended for an extended period of time, have it checked periodically for proper operation. This precaution will prevent problems associated with no heat, such as frozen water pipes, etc. See "Before You Request a Service Call" section in this manual. SAFETY CONSIDERATIONS Installing and servicing of heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heat- ing 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. Observe safety precautions in this manual, on tags, and on labels attached to the fur- nace and other safety precautions that may apply. 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. Understand the signal words DAN- GER, 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 hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. STARTING YOUR FURNACE Instead of a continuously burning pilot flame which wastes valuable energy, 4 6 your furnace uses an automatic, hot surface ignition system to light the burners each time the thermostat starts your furnace. Follow these important safeguards: 7 • Never attempt to light the burners manually with a match or other source of flame. • Read and follow the operating instructions on the furnace, especially the item that reads as follows: Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step. • If a suspected malfunction occurs with your gas control system, such as the burners not lighting when they should, refer to the shutdown proce- dures on the furnace, or in the "Shut- ting Down Your Furnace" section and call your dealer as soon as possible. A WARNING If overheating occurs or the gas valve fails to shut off the gas supply, turn off the man- ual gas valve to the furnace BEFORE turning off the elec- trical supply. (See Fig. 9.) Fail- ure to follow this warning could result In a fire or explo- sion, and personal Injury or death. • CHECK AIR FILTER: Before attempting to start your furnace, be sure the furnace air filter is clean and in place. See "Performing Routine Main- tenance" section in this manual. Then proceed as follows: STEPS FOR STARTING YOUR FURNACE 1. Set your roam thermostat to the lowest temperature setting. (See Fig. 8.) ' i3 ".x rw 40 ON oFF 8 9 10 2. (lose the external manual gas valve. (See Fig. 9.) 3. Turn off electrical supply to the furnace. (See Fig. 10.) 4. Remove the main furnace door. (See Fig. 11.) 5. Turn control knob on the gas valve to the OFF position and wait 5 minutes. (See Fig. 12.) Then smell for gas, including near the floor. If you smell gas, STOP! Follow operating instructions on furnace access door. 6. After waiting 5 minutes, turn con- trol knob on the gas valve to the ON position. (See Fig. 13.) 7. Replace main furnace door. (See Fig. 14.) 8. Turn on electrical supply to the furnace and wait 1 minute. (See Fig. 15.) 9. Open the external manual gas valve. (See Fig. 16.) 10. Set room thermostat to a tempera- ture slightly above room tempera- ture. This will automatically signal the furnace to start. 11. When the furnace receives the start signal, the hot surface igni- tor at the main burners is auto- matically heated for 15 to 20 sec. When the microprocessor control verifies that there is sufficient heat to ignite, the gas valve per- mits gas to flow to the main burn- ers. After ignition and a time delay of about 35 sec, your blower will start at low speed until the control 5 11 12 13 makes the necessary adjustments to operate the blower at either the low- or high -fire speed. NOTE: If the burners fail to ignite after 4 attempts, the furnace control system will lock out. If lockout occurs, main burners fail to light, or blower does not come on, shut down the furnace and call your dealer for service. 12. Set your thermostat to the temper- ature that satisfies your comfort requirements. SUGGESTION: Setting the ther- mostat back a few degrees and compensating for the difference with warmer clothing can make a big difference in your fuel con- sumption on extremely cold days. The few degrees at the top of your thermostat "comfort level" are the most costly degrees to obtain. When room temperature drops below the temperature selected on the thermostat, the furnace will be switched on automatically. When the room temperature reaches the degree selected on the thermostat, the furnace will be switched off automatically. Some thermostats have a FAN mode with 2 selections, AUTO and ON. When thermostat is set to AUTO, the furnace blower cycles on and off, controlled by the thermostat. In ON mode, the furnace blower runs continu- ously. This keeps the temperature level in your home more evenly balanced. It also continuously fil- ters the indoor air. ON OFF 14 15 16 SHUTTING DOWN YOUR FURNACE Should you need to shut down your furnace for service or maintenance, you will need to turn the furnace off. LEX ON OFF 17 18 The following procedures must be followed: 1. Set your room thermostat to the lowest temperature setting. (See kig. 17.) 2. Close the external manual gas valve. (See Fig. 9.) 3. Tum off electrical supply to the furnace. (See Fig. 18.) 4. Remove main furnace door. (See Fig. 11.) 5. Turn control knob on the gas valve to OFF position. (See Fig. 19.) 6. Replace main furnace door. (See Fig. 14.) 7. If the furnace is being shut down because of a malfunction, call your dealer as soon as possible. d CAUTION Furnace Is not to be installed, operated, and then turned off and left turned off in an unoc- cupied structure during winter. (See winterizing procedures in maintenance section). PERFORMING ROUTINE MAINTENANCE With proper maintenance and care, your furnace will operate economically and dependably. Instructions for basic main- tenance are found on this and the follow- ing pages. However, before beginning maintenance, follow these safety pre- cautions: 19 WARNING Tum off electrical power sup- ply to your furnace before re- moving the main furnace door to service or perform mainte- nance. Failure to follow this warning could result in per- sonal injury or death. A CAUTION Although special care has been taken to minimize sharp edges, be extremely careful when handling parts or reach- ing into the furnace. FILTERING OUT TROUBLE A dirty air filter will cause a loss of airflow in your duct system. When excessive loss of airflow occurs, the furnace may cycle on its safety controls. If this condition is left unattended, the furnace will eventu- ally lock out. It is recommended that the furnace air filter be checked every 3 or 4 weeks and cleaned if necessary. A CAUTION Never operate your furnace without the air filter in place. Doing so may damage the fur- nace blower motor. An accu- mulation of dust and lint on internal parts of your furnace can cause a loss of efficiency. 6 The air filter is normally located in the blower compartment. (See Fig. 3 or 4.) If air filter has been installed in another location, contact your dealer for instructions. To inspect, clean, and/or replace the air filter(s), follow these steps: 1. Turn off electrical supply to the furnace. (See Fig. 18.) 2. Remove main furnace door. (See Fig. 20.) 3. Remove blower access panel. (See Fig. 21.) NOTE: It will be necessary to remove 1 screw. 20 21 22 23 FURNACE CASING WIDTH (it) FILTER SIZE (IN.) FILTER TYPE 17.1/2 (1) 16 x 25 x t Cleanable 21 (1)20x25x1 Cleanable 24.1/2 (2) 16 x 25 x 1 Cleanable 4. Remove air filter from furnace. • AIR FILTER(S) LOCATED IN BOTTOM: a. Slide filter retainer sideways until it is free of latch. (See Fig. 22.) b. Slide air filter out of furnace. (See Fig. 23.) • AIR FILTER LOCATED IN SIDE: 1. Remove filter retainer from latch. (See Fig. 24.) 2. Gently remove air filter and care- fully turn the dirty side up (if dirty) to avoid spilling dirt from the fil- ter. (See Fig. 25.) 24 25 5. Inspect the filter. If torn, replace it. NOTE: If washable filter that was shipped with the furnace has been replaced with an electronic air cleaner (EAC), refer to the EAC Owner's Man- ual for maintenance information. 6. Wash filter (if dirty) in a sink, bathtub, or outside with a garden hose. Always use cold tap water. A mild liquid detergent may be used if necessary. Spray water through filter in the opposite direction of airflow. Allow filter to dry. 7. Reinstall clean air filter. 8. Reinstall filter retainer. 9. Replace blower access panel and main furnace door. (See Fig. 26 and 27.)Turn on electrical supply to the furnace. If your furnace air filter needs to be replaced, be sure to use the same size and type of filter that was originally supplied. Use the furnace filter table and compare your furnace size with the proper filter size. FURNACE AIR FILTER TABLE • Furnace with a side return-air inlet may have a dif- ferent filter size. Measure the filter to obtain the correct size. 26 27 COMBUSTION AREA AND VENT SYSTEM Visually inspect the combustion area and vent system before each heating season. Make sure that all PVC pipes leading into the combustion area and vent are free from any cracks and sags. Also check the combustion -air intake and vent pipes on the outside of your home for blockage. When dirt, soot, scale, or rust is allowed to build up, your furnace can suffer a loss of efficiency and perform improperly. Accumulations on the main burners can result in firing out of normal sequence. This delayed igni- tion creates an alarmingly loud sound. CAUTION If your furnace makes an espe- cially loud noise when the main burners light, shut down your furnace and call your dealer. 7 To inspect the combustion area and vent system, you will need a flashlight. Refer to Fig. 3 or 4, and proceed as follows: 1. Turn off gas and electrical sup- plies to the furnace and remove the main furnace door. (See Fig. 9, 10, and 11.) 2. Remove burner enclosure front. (See Fig. 28 or 29.) Inspect the gas burners and ignitor area for dirt, rust, or scale. i. CAUTION If dirt, rust, soot, or scale accu- mulations are found, call your dealer. Do not operate your fumace. sx 28 29 3. Inspect the combustion -air and vent pipes for sags, holes, cracks, or disconnections. A DANGER If holes are found in the pipes or if any portion has become disconnected, toxic fumes can escape into your home. DO NOT OPERATE YOUR FURNACE. Cali your dealer for service. 4. Reinstall burner enclosure front. 5. If you); furnace is free of the above conditions, replace main furnace door and turn on electrical and gas zz F IX 2 RU 0 O co 0 w . • u. I O ua � z° uj O N ' ILI U I— f- u. O li z = O z supplies to your furnace. (See Fig. 14, 15, and 16.) 6. Start the furnace and observe its operation. Watch the burner flames to see if they are clear blue, almost transparent. (See Fig. 30.) If you observe a suspected malfunction, or the burner flames are not clear blue, call your dealer. HEADING SOUTH FOR THE WINTER? DON'T FORGET YOUR FURNACE! 30 CAUTION If the furnace Is installed in an unconditioned space where the ambient temperatures may be 32 °F or lower, freeze protec- tion measures must be taken. Since the furnace uses a condensing heat exchanger, some water will accu- mulate in the unit as a result of the heat transfer process. Therefore, once it has been operated, it cannot be turned off and left off for an extended period of time when temperatures will reach 32° F or lower unless winterized. Fol- low these procedures to winterize your furnace: 1. Obtain propylene glycol (RV/ swimming pool antifreeze or equivalent). A CAUTION Do not use ethylene glycol (Prestone 11 antifreeze coolant or equivalent). Failure of plas- tic components will occur. 2. Turn off electrical supply to the furnace. (See Fig. 18.) 3. Remove main furnace door. (See Fig. 20.) 4. Remove upper inducer housing drain connection cap. (See Fig. 31.) n 31 32 5. Connect field - supplied 1 /2 -in. ID tube to upper inducer housing drain connection. 6. Insert field - supplied funnel into tube. 7. Pour 1 quart of antifreeze into funnel /tube. Antifreeze should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 32.) 8. Remove funnel and tube from inducer housing and 8 replace drain connection cap and clamp. 9. Replace main furnace door. (See Fig. 27.) A CHECK-UP CHECKLIST Your furnace represents an important investment in your family's comfort and your home's value. To keep it performing properly and as a preven -. tative to future problems, have a trained service specialist give your fur- nace a professional check -up annually. The following checklist can be used as a guideline to proper service: • Inspect all flue gas passages, burn- ers, heat exchangers, coupling box(es), and inducer assembly. • Inspect all combustion -air and vent piping inside structure and pipe termi- nations outside the structure. • Check gas pipes leading to and inside of your furnace for leaks. • Inspect and clean the blower motor and wheel. NOTE: The inducer and blower motors are pre - lubricated and require no addi- tional lubrication. These motors can be identified by the absence of oil ports on each end of the motor. • Inspect and change or clean air fil- ter(s) if necessary. • Inspect all supply - and return -air ducts for obstructions, air leaks, and insulation. Remedy any problem when necessary. • Inspect the return-air duct connec- tion(s) at the furnace to ensure it is physically sound, sealed to the furnace casing, and terminates outside the space containing the furnace. • Inspect electrical wiring, connec- tions, and components for loose connections. • Perform an operational checkout to determine whether your furnace is working properly and if it requires adjustments. • Inspect all condensate drain tubes and condensate trap assembly for leaks. The condensate removal system should be cleaned annually by a quali- fied service agency. Refer to the Ser- vice and Maintenance Instructions for further information. • Examine the physical support of the • furnace. The support should be sound with no cracks, sagging, gaps, etc. around the base. FAULT CODE FAULT CODE DESCRIPTION CHECKLIST 13 or 33 ' Limit Switch Lockout M Check for dirty air filter. M Check for blocked return-air or supply -air grilles. 14 or 34 Ignition Lockout or Ignition Proving Fault M Check to be sure manual shutoff valve in gas supply pipe is in the open position. (Follow start -up pence- dure if you open gas line.) NOTE: Turn off the electrical supply and remove access doors before continuing with this checklist. M Check to be sure control knob on gas valve is m ON position. (Follow start -up procedures if you must reset dial to ON.) 24 Furnace Fuse Open 14 Check for blown fuse and possible that in 24-v wiring. 31 Pressure Switch Not Closed 14 Check to make sure that all PVC pipes leading into the combustion -air intake and vent/exhatut are fine from any cracks and sags. Mao check the combustion -air intake and vent/exluu+t pipes on the outside of your home for blockage. 12, 21, 22, or23 Any Other Fault Code M Call dealer for service. No Fault Code Signaled Furnace Fails to Operate and No Fault b Signaled M Check thermostat for proper temperature setting. M Check for blown fuses and circuit broken. • M Check to be sure blower access panel is properly in place. • Check furnace for any obvious signs of deterioration. BEFORE YOU REQUEST A SERVICE CALL If your furnace is not operating or not performing properly, you may save the expense of a service call by check- ing a few things yourself before calling for service. FOR INSUFFICIENT AIRFLOW: • Check for dirty air filter(s). • Check for blocked return-air or sup- ply -air grilles throughout your home. Ensure they are open and unobstructed. If problem still exists, call your dealer for service. IF FURNACE FAILS TO OPERATE: Follow this checklist step by step, advancing to the next step only if fur- nace fails to start. • Check thermostat for proper tem- perature. Is thermostat set above room temperature? • Is thermostat set to HEAT? • Check fuses and circuit breakers. Is electrical supply on? • Is manual shut-off valve in gas supply pipe in open position? (Follow start -up procedures if you open gas valve.) NOTE: Turn off electrical supply before continuing with checklist. • Is control knob on gas valve in ON position? (Follow start-up procedures if you must reset knob to ON.) • Check manual reset flame rollout switch located on the burner box. (See Fig. 3 or 4.) If furnace has experi- enced high temperature conditions, this switch will shut off the furnace. Reset it by pushing the button on the switch. If it trips again, shut down the furnace and call for service. See "Shutting Down Your Furnace" sec- tion in this manual. MODEL 340MAV AND 350MAV DIAGNOSTIC CHART (See Fig. 3.) • Check for obstructions around the vent termination. If your furnace still fails to operate, call your service representative. For your convenience, record the fur- nace product and serial numbers on page 2. Should you ever require ser- vice, you will have ready access to the information needed by your service representative. This furnace has an LED operation and fault code display to aid the installer, service technician, or home- owner while installing or servicing the unit. The LED code can be seen by removing the access door and viewing LED(s) through the view port in the blower access panel. NOTE: Removing the blower access panel or turning off the 115 -v electrical power supply will terminate LED diag- nostic code display. To decipher the meaning of the LED code, and suggested action, the follow- ing cross - reference can be used. NOTES: I. Light on continuously means control has powcr and working properly. 2. The fault code is a 2 digit number. The first digit is determined by the number of short flashes of the Tight and the second digit is determined by number of long flashes of the Tight. 9 FAULT CODE FAULT CODE DESCRIPTION CHECKLIST 12 Blower Calibration Lockout M Check for dirty air filter. M Check for blocked return -air or supply -air gril les. M Turn electrical supply off, then back on. Set the thermostat to all for heat. 13 or 33 Limit Switch Lockout 14 or 34 Ignition Lockout or Ignition Proving Fault M Check to be sure manual shutoff valve in gas supply pipe is in open position. (Follow .tart -up procedure if you open gas line.) NOTE: Turn off t remove electrical supply and nove access doom before continuing with this • M Check to be sure control knob on gas valve is in ON position. (Follow start -up procedures if you must reset dial to ON). M Check for disconnected ground wire. 24 • Furnace Fuse Open M Check for blown fuse and possible short in 24-v wiring. 31, 32, or 43 Pressure Switch Fault M Check to nuke sure that alt PVC pipes leading into the combustion -air intake and van /exhaust are free �m cracks and sags. Also check the combustion,air intake and vent/e: haunt pipes on the outside of Y home for mac' 42 Inducer Outside Valid Speed Range 44 Blower Calibration Fault 14 Check for ditty air filter(s). 14 Check for blocked return- or supply -air grilles. NOTE: In zoned applications, fault 44 may flash during operation when a single zone is calling for heat. When other zones all for heat, or the unit cycles, the fault should clear itself. Call for service if fault 12 develops. 21,22,23, or 41 Any Other Fault Code or Either of the Red Lights On Continuously M Call dealer for service. No Fault Code Signaled Furnace Fails to Operate and No Fault is Signaled 14 Check themrostat for proper ternperature setting. 14 Be sure thermostat is set to HEAT. M Check for blown fuses and circuit breakers. 14 Check to be sure blower access panel is properly in place. ) MODEL 355MAV DIAGNOSTIC CHART (See Fig. 4.) NOTES: 1. Red light 1 on continuously means furnace is operating in emergency heat. 2. Red light 2 on continuously means the microprocessor board has malfunctioned. 3. Yellow Tight on continuously means furnace is operating in high hat. 4. Green Tight on continuously means furnace is operating in low heat. 5. The fault code is a 2 digit number. The first digit is determined by the number of flashes of the yellow light and the second digit is determined by number of flashes of the green light. 1995 BOP Co. lndpls, IN 46206 • Printed in U.S.A. Catalog No. BDP•3334.003 Cancels:OM05.19 0M05 -21 8.95 installation, start -up, and operating instructions DELUXE 4 -WAY MULTIPOISE FIXED - CAPACITY DIRECT -VENT CONDENSING GAS FURNACE 350MAV Series D (LIMITED) A93040 NOTE: Read the entire instruction manual before starting the installation. Index Page DIMENSIONAL DRAWING 2 SAFETY CONSIDERATIONS 3 Clearances to Combustibles 3 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ....3 -4 INTRODUCTION 4 APPLICATIONS 4-11 General 4 Upflow Applications 5 -7 Downflow Applications 7 -8 Horizontal Left (Supply -Air Discharge) Applications 8 -10 Horizontal Right (Supply -Air Discharge) Applications...10 -1 1 LOCATION 11 -13 General I 1 -12 Furnace Location Relative to Cooling Equipment 12 Hazardous Locations 13 INSTALLATION 13 -17 Leveling Legs (If Desired) 13 Installation In Upflow and Downflow Applications 13 Installation In Horizontal Applications 13 Filter Arrangement 13 -15 Bottom Closure Panel 15 -16 Gas Piping 16 -17 AIR DUCTS 17 General 17 Ductwork Acoustical Treatment 17 Supply Air Connections 17 Retum Air Connections 17 ELECTRICAL CONNECTIONS 18 -19 115 -v Wiring 18 24 -v Wiring 19 Accessories 19 DIRECT VENTING 19 -29 Removal of Existing Furnaces from Common Vent Systems 19 -21 Combustion -Air and Vent Piping 21 -27 Concentric Vent and Combustion -Air Termination Kit Installation 27 -29 Multiventing and Vent Termination 29 CONDENSATE DRAIN 29 -31 General 29 Application 31 Condensate Drain Protection 31 SEQUENCE OF OPERATION 31 -36 —1— As an ENERGY STAR® Partner, Bryant Heating & Cooling Systems has de- termined that this product mats the ENERGY STAR® guidelines for en- ergy efficiency. MDI -� I Cancels: New EFFICIENCY HATING CERTIFIED ama AIRFLOW 11 350M-40-11 1 -00 REGISTERED QUALITY SYSTEM AIRFLOW Fig. 1— Multipolse Orientations Heating Mode 32 Cooling Mode 32 Continuous Blower Mode 32 Continuous Blower Speed selection from Thermostat 32 -35 Heat Pump Mode 35 Component Test 35 -36 START -UP PROCEDURES 36-44 General 36 Prime Condensate Trap With Water 36 Purge Gas Lines 36 Adjustments 36-44 Set Gas Input Rate 36-43 Set Temperature Rise 43-44 Adjust Blower Off Delay (Heat Mode) 44 Set Thermostat Heat Anticipator 44 CHECK SAFETY CONTROLS 44-45 Check Primary Limit Control FEIV W 44 C � Check Pressure Switch 45 CHECKLIST , r 45 id a . !S PER MIT CENTER A93041 UNIT SIZE A 1) E 040-08 17 -1/2 15-7/8 16 040-12 17 -1/2 15-7/8 16 060-08 17 -1/2 15-7/8 16 060-12 17 -1/2 15-7/8 16 060-16 17 -1/2 15-7/8 16 080-12 17 -1/2 15-7/8 16 080-16 17 -1/2 15-7/8 16 080-20 21 19-3/8 19-1/2 100-16 21 19-3/8 19-1/2 100-20 21 19-3/8 19-1/2 120-20 24-1/2 22 -7/8 23 140-20 24-1/2 22 -7/8 23 i 14 A• TYP i SIDE INLET 22% 24N. COMBUSTION- AIR CONN 'A-IN. DIA GAS CONN 2- INVENT CONN 1 DIA THERER THERMOSTAT 22':5. 1'A• 1• 23 TYP SIDE INLET 26'35. TYP 26 '95.• 26 A 24 '!• CONDENSATE DRAIN TRAP LOCATION (DDWNFLOW ti HORIZONTAL LEFT) 14-IN. DIA POWER CONN 'MN. DIA P� EERRY DRAIN TRAP I CONDENSATE I I 2731.• LOCATION TYP 241• 1731.• 9 'M• TYP CONDENSATE DRAIN LOCATION (UPFLOW) 20'M' 273.• TYP 1 1 33W 32 W TYP 30 "he TYP 4 AIRFLOW A '• I 1 OUiLEr f n A� • 'I f�"''�7 f�'' hi DIMENSIONS (IN.) Fig. 2— Dimensional Drawing CONDENSATE DRAIN TRAP LOCATION OW a HOR ALRIGHT) OR ALTERNATE .IN. DIA GAS CONN 1 30 'A• 1 110A• 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: a. For 800 CFM- 16-in. round or 14'h x 12-in. rectangle. b. For 1200 CFM- 20-in. round or 141/2 x 191/2-in. rectangle. c. For 1600 CFM- 22-in. round or 14V x 23' /.-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. 28 h• 26'35 26' W 22 35. • 19' OUTLET COMBUSTION- AIR AI CONN Pt-IN. DIA GAS CONN D 'AaN DIA POWER CONN t -IN. DIA THERMOSTAT ENTRY its l 24N.VENT CONN V r- - ._._. NI I SIDE INLET I 1 1 i I 1 ' • ;NOTICE: IF THE DOCUMENT IN THISFRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. 3s.• CONDENSATE DRAIN �1...--- 22'A'A.• ( UPFLOW) LOCATION 243E "A.• FOR NORWOW RS BOTTOM INLET FOR HOR¢ONrAL HANGING 39 A' A99111 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 clearance from combustible material. This appliance requires a special venting system. Refer to the installation Instructions for parts list and method of installation. This furnace is for use with schedule -40 PVC, PVC-DWV, 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). Furnace must be installed level, or pitched forward within 1/2 Inch LE TO (O ") 1/2" MAX 1 of level for proper drainage. Failure will result in equipment or property damage. See Installation Manual for IMPORTANT unit 1 support details on horizontal applications UPFLOW OR DOWNFLOW LETo (0 1/2" MAX T ") —1 HORIZONTAL FRONT FRONT MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION ALL POSITIONS: * Mimimum front clearance for service 30 inches (762mm). tt 140 size furnaces require 1 inch back clearance to combustible materials. DOWNFLOW POSITIONS: t For installation on combustible floors only when instatled on special base No. KGASB0201ALL, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC. HORIZONTAL POSITIONS: 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 end. 0 120 and 140 size Furnaces require 1 inch bottom clearance to combustible materials. 324999 -201 REV. B (LIT) This furnace is approved HORIZONTAL Installations, t O , a A K Sk o� 0" Clearance In Inches for UPFLOW, 0 t DOWNFLOW �� r R o N T 0 m „ and § ss e- 0" s e Rv c E 3 rr MIN 3" Vent clearance to combustibles 0”. SAFETY CONSIDERATIONS Fig. 3— Clearances Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified person- nel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as clean- ing and replacing air filters. All other operations must be per- formed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply. Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA 54- 1999 /ANSI Z223.I -1999 and the Installation Standards, Warm Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B. In Canada, refer to the current edition of the CAN /CGA -B 149.1- and .2 -M95 National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls. Recognize safety information. This is the safety -alert symbol& . When you see this symbol on unit or in instructions and manuals, be alert to potential for personal injury. Understand the signal words DANGER, WARNING, and CAU- TION. These words are used with the safety -alert symbol. DAN- GER identifies most serious hazards which will result in severe —3— A99230 to Combustibles personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS CAUTION: Electrostatic discharge can affect electronic components. Take precautions during fumace 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 fumace, the control, and the person at the same electro- static potential. 1. Disconnect all power to the furnace. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE e CONTROL PRIOR TO DISCHARGING YOUR BODY'S ELECTROSTATIC CHARGE TO GROUND. 2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person's hand during grounding will be satisfactorily discharged. 3. After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (for example; DO NOT move or shuffle your feet, DO NOT touch un- grounded objects, etc.). 4. If %ou touch ungrounded objects (recharge your body with static electricity), firmly touch furnace again before touch- ing control or wires. 5. Use this procedure for installed and uninstalled (un- grounded) furnaces. 6. Before removing a new control from its container, dis- charge your body's electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 5 before bringing the control or yourself into contact with the furnace. Put all used AND new controls into containers before touching ungrounded objects. 7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage. INTRODUCTION The 350MAV, Series D Limited Furnaces are available in sizes 40,000 through 138,000 Btuh input capacities. The 350MAV Multipoise Condensing Gas -Fired Furnaces are A.G.A. /C.G.A. design certified for natural and propane gases and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory- shipped for use with natural gas. An A.G.A. /C.G.A. listed gas conversion kit is required to convert furnace for use with propane gas. The 350MAV 040 through 120 sizes are A.G.A. /C.G.A. approved for use in manufactured (mobile) homes when factory accessory conversion kit is used. The 140 size is NOT approved for use in manufactured (mobile) homes. These furnaces are suitable for installation in a residence built on site or a manufactured residence completed at final site. The design of this furnace line is NOT A.G.A. /C.G.A. certified for installation in recreation vehicles or outdoors. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. These fumaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment. Installer Packet includes: Installation, Start-Up, and Operating Instructions Service and Maintenance Instructions User's Information Manual Warranty Certificate Loose Parts Bag includes: Pressure tube extension Collector box or condensate trap extension tube Inducer housing drain tube 1 /2 -in. CPVC street elbow Drain tube coupling Drain tube coupling grommet Quantity 1 2 l Vent and combustion -air pipe support 2 Combustion -air pipe perforated disk assembly 1 Vent Pipe Extension 1* * ONLY supplied with some furnaces. These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply -air discharge direction) applica- tions as shown in Fig. I. See details in Applications section. This furnace must be installed with a direct -vent (combustion air and flue) system and a factory accessory termination kit. In a direct -vent system, all air for combustion is taken directly from the outside atmosphere and all flue products are discharged to the outside atmosphere. See furnace and factory accessory termination kit instructions for proper installation. Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B. For copies of the NFGC and NFPA 9013 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 St., NW, Wahington DC 20001. Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. Contact Standard Sales CSA International, 178 Rexdale Boulevard, Etobicoke, (Toronto) Ontario, Canada M9W I R3, Canada. Installation must comply with regulations of serving gas supplier and local building, heating, plumbing or other codes in effect in the area in which installation is made. In absence of local codes, installation must comply with the NFGC in the United States and the NSCNGPIC in Canada.. These instructions cover minimum requirements for a safe instal- lation and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept pace with changing residential construction practices. We require these instructions as a minimum for a safe installation. CAUTION: Application of this furnace should be in- doors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing. Improper installation or misapplication of furnace can require excessive servicing or cause prema- ture component failure. m WARNING: Improper installation, adjustment, alter- ation, 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. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. For accessory installation details, refer to applicable installation literature. APPLICATIONS I. GENERAL Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain and pressure tubes are connected as shown in Fig. 5. See appropriate application instructions for these procedures. BLOWER SHELF CONDENSATE TRAP (INSIDE) 3 /4 FURNACE DOOR I - sISI FIELD 26'/4 DRAIN ALTERNATE DRAIN % CONN TUBE LOCATION CONDENSATE TRAP DRAIN TUBE LOCATION UPFLOW APPLICATIONS SLOT FOR SCREW HORIZONTAL APPLICATION (OPTIONAL) 1 1 WIRE TIE GUIDES (WHEN USED) FRONT VIEW SIDE VIEW DOWNFLOW AND EXTERNAL UPFLOW 11. UPFLOW APPLICATIONS An upflow furnace application is where furnace blower is located below combustion and controls section of furnace, and conditioned air is discharged upwards. A. Condensate Trap Location (Factory- Shipped Orientation) The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications. A factory- supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment. See Condensate Trap Tubing (Factory- Shipped Orientation) section for drain tube extension details. B. Condensate Trap Tubing (Factory- Shipped Orientation) NOTE: See Fig. 5 or tube routing label on main furnace door to confirm location of these tubes. 1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These tubes can be identified by their connection location and also by a color label on each tube. These tubes are identified as follows: collector box drain tube (blue label), inducer housing drain tube (violet label or molded), relief 'port tube (green label), and pressure switch tube (pink label). CONDENSATE TRAP f 7V8 L 7 /8 —5— FURNACE SIDE 1 1 /2 4 RI FRONT VIEW ALTERNATE APPLICATIONS % OD COLLECTOR BOX TO TRAP RELIEF PORT 1 OD INDUCER HOUSING DRAIN CONNECTION % OD COLLECTOR BOX DRAIN CONNECTION SCREW HOLE FOR UPFLOW OR DOWN - FLOW APPLICATIONS (OPTIONAL) 2 I 1/2-IN. PVC OR CPVC SIDE VIEW FURNACE DOOR FURNACE SIDE 4 T 11 4 1M2 -� FIELD DRAIN CONN END VIEW FRONT VIEW HORIZONTAL APPLICATIONS 4 A93026 Fig. 4—Condensate Trap 2. Condensate Trap Drain Tube The condensate trap drain connection must be extended for field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2 or 5.) NOTE: If internal filter is used, drain tube should be located to opposite side of casing of return duct attachment to assist in filter removal. b. Remove and discard casing drain hole plug button from desired side. c. Install drain tube coupling grommet (factory- supplied in loose parts bag) in selected casing hole. d. Slide drain tube coupling (factory- supplied in loose parts bag) through grommet ensuring long end of coupling faces blower. e. Cement 2 factory- supplied 1 /2 -in. street CPVC elbows to the rigid drain tube connection on the condensate trap. (See Fig. 5.) These elbows must be cemented together and cemented to condensate trap drain connection. NOTE: Failure to use CPVC elbows may allow drain to kink and prevent draining. f. Connect larger diameter drain tube and clamp (factory- supplied in loose parts bag) to condensate trap and clamp securely. g. Route tube to coupling and cut to appropriate length. h. Attach tube to coupling and clamp securely. PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) INDUCER HOUSING (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX DRAIN TUBE) COLLECTOR BOX DRAIN TUBE (BLUE) FIELD- INSTALLED FACTORY - SUPPLIED DRAIN TUBE COUPLING (LEFT DRAIN OPTION) FIELD - INSTALLED FACTORY - SUPPLIED DRAIN TUBE FIELD - INSTALLED FACTORY - SUPPLIED } h -IN. CPVC STREET ELBOWS (2) FOR LEFT DRAIN OPTION 0 FIELD - INSTALLED FACTORY - SUPPLIED DRAIN TUBE COUPLING (RIGHT DRAIN OPTION) A94163 Fig. 5— Factory- Shipped Upflow Tube Configuration (Shown With Blower Access Panel Removed) C. Condensate Trap Location (Alternate Upflow Orientation) An alternate location for the condensate trap is the left -hand side of casing. (See Fig. 2 and 6.) NOTE: If the alternate left -hand side of casing location is used, the factory - connected drain and relief port tubes must be discon- nected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for tubing attachment. To relocate condensate trap to the left -hand side, perform the following: 1. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 6.) 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. install condensate trap into left -hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position. D. Condensate Trap Tubing (Alternate Upflow Orientation) NOTE: See Fig. 6 or tube routing label on main furnace door to confirm location of these tubes. 1. Collector Box Drain Tube V PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (BLUE) CONDENSATE --ID- TRAP INDUCER HOUSING DRAIN TUBE (VIOLET) A94164 Fig. 6— Alternate Upflow Tube Configuration and Trap Location Connect collector box drain tube (blue label) to condensate trap. NOTE: On 17- 1 /2 -in. wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring. 2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing drain tube which was previously connected to conden- sate trap. b. Use inducer housing drain extension tube (violet label and factory- supplied in loose parts bag) to connect LOWER inducer housing drain connection to the con- densate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. 3. Relief port Tube a. Connect relief port tube (green label) to condensate trap. b. Extend this tube (if required) by splicing to small diameter tube (factory- supplied in loose parts bag). c. Determine appropriate length, cut, and connect tube. E. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. F. Pressure Switch Tubing The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch and should not require any modification. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. G. Upper Collector Box and Inducer Housing (Unused) Drain Connections 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. 5 or 6 or tube routing label on main furnace door to check for proper connections. UPPER INDUCER HOUSING DRAIN CONNECTION Attached to the UPPER (unused) inducer housing drain connection is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. H. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. III. DOWNFLOW APPLICATIONS A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and conditioned air is discharged downwards. A. Condensate Trap Location The condensate trap must be removed from the factory- installed blower shelf location and relocated in selected application location as shown in Fig. 2, 7, or 8. COLLECTOR BOX DRAIN TUBE (BLUE) CAP PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX EXTENSION TUBE CONDENSATE — - TRAP INDUCER HOUSING DRAIN TUBE (VIOLET) a Fig. 7— Downflow Tube Configuration (Left -Hand Trap Installation) A94165 —7— To relocate condensate trap from the blower shelf to desired location, perform the following: I. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole. (See Fig. 2, 7, or 8.) 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Install condensate trap into desired casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position. B. Condensate Trap Tubing NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections. 1. Collector Box Drain Tube a. Remove factory- installed plug from LOWER collector box drain tube (blue and white striped label). b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was connected to condensate trap. c. Connect LOWER collector box drain connection to condensate trap. (1.) Condensate Trap Located on Left Side of Casing (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. (2.) Condensate Trap Located on Right Side of Casing CO TUBE Illpr COUPLING COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX EXTENSION TUBE INDUCER HOUSING DRAIN TUBE (VIOLET) 1— CONDENSATE 3 TRAP COLLECTOR BOX EXTENSION DRAIN TUBE Fig. 8— Downflow Tube Configuration (Right -Hand Trap Installation) PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE) A94166 1 (a.) Install drain tube coupling (factory- supplied in loose parts bag) into collector box drain tube (blue and white striped label) which was pre- viously plugged. (b.) Connect larger diameter drain tube (factory- supplied in loose parts bag) to drain tube coupling, extending collector box drain tube for connection to condensate trap. (c.) Route extended collector box drain tube di- rectly from collector box drain to condensate trap as shown in Fig. 8. (d.) Determine appropriate length and cut. (e.) Connect to condensate trap. (f.) Clamp tube to prevent any condensate leakage. 2. Inducer Housing Drain Tube a. Remove factory- installed cap and clamp from LOWER inducer housing drain connection. b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to conden- sate trap. c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed. d. Use inducer housing drain tube (violet label and factory- supplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap. e. Connect inducer housing drain connection to condensate trap. (1.) Condensate Trap Located on Left Side of Casing (a.) Determine appropriate length and cut. (b.) Connect tube to condensate trap. (c.) Clamp tube to prevent any condensate leakage. (2.) Condensate Trap Located on Right Side of Casing (a.) Route inducer housing drain tube (violet label) directly from inducer housing to condensate trap as shown in Fig. 8. (b.) Determine appropriate length and cut. (c.) Connect tube to condensate trap. (d.) Clamp tube to prevent any condensate leakage. 3. Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure. C. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. D. Pressure Switch Tubing One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications. NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections. Relocate tubes as described below. 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. —8— 2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connec- tion by splicing to small diameter tube (factory- supplied in loose parts bag). 3. Connect collector box pressure tube (green label) to pres- sure switch connection labeled COLLECTOR BOX. 4. Extend collector box pressure tube (pink label) which was previously connected to pressure switch by splicing to remaining small diameter tube (factory- supplied in loose parts bag). 5. Route this extended tube (pink label) to condensate trap relief port connection. 6. Determine appropriate length, cut, and connect tube. 7. Clamp tube to relief port connection. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. IV. HORIZONTAL LEFT (SUPPLY -AIR DISCHARGE) APPLICATIONS A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, and conditioned air is discharged to the left. CAUTION: Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling. NOTE: In Canada, installations shall be in accordance with current NSCNGPIC and/or local codes. NOTE: The auxiliary junction box (J -Box) MUST be relocated to opposite side of furnace casing. (See Fig. 9.) See Electrical Connection section for J -Box relocation. A. Condensate Trap Location The condensate trap must be removed from the factory- installed blower shelf location and relocated in selected application location as shown in Fig. 2 or 9. To relocate condensate trap from the blower shelf to desired location, perform the following: 1. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 9.) 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position. B. Condensate Trap Tubing NOTE: See Fig. 9 or tube routing label on main furnace door to check for proper connections. I. Collector Box Drain Tube a. Install drain tube coupling (factory- supplied in loose parts bag) into collector box drain tube (blue label) which was previously connected to condensate trap. b. Connect large diameter drain tube and clamp (factory- supplied in loose parts bag) to drain tube coupling, extending collector box drain tube. AUXILIARY 'U" BOX RELOCATED HERE CONDENSATE TRAP e PLUG COLLECTOR BOX EXTENSION DRAIN TUBE COLLECTOR BOX EXTENSION TUBE DRAIN TUBE COUPLING COLLECTOR BOX TUBE (PINK) RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040, 060, AND 080 HEATING INPUT FURNACES c. Route extended tube (blue label) to condensate trap and cut to appropriate length. i d. Clamp tube to prevent any condensate leakage. 2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing drain tube which was previously connected to conden- sate trap. b. Use inducer housing drain extension tube (violet label and factory- supplied in loose parts bag) to connect LOWER inducer housing drain connection to the con- densate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. 3. Relief Port Tube a. Extend collector box tube (green label) which was previously connected to the condensate trap by splicing to small diameter tube (factory- supplied in loose parts bag). b. Route extended collector box pressure tube to relief port connection on the condensate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. C. Condensate Trap Field Drain Attachment Refer 'to Condensate Drain section for recommendations and procedures. CAP COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) Fig. 9 Horizontal Left Tube Configuration —9— COLLECTOR BOX TUBE (GREEN) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX DRAIN TUBE (BLUE) A93302 D. Pressure Switch Tubing The LOWER collector box pressure tube (pink label) is factory connected to the 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. NOTE: See Fig. 9 or tube routing label on main furnace door to check for proper connections. Modify tube as described below. 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. 2. Use smaller diameter tube (factory- supplied in loose parts bag) to extend tube disconnected in item 1. 3. Route extended tube: a. Behind inducer housing. b. Between blower shelf and inducer housing. c. Behind inducer motor bracket. d. Between inducer motor and pressure switch. 4. Determine appropriate length, cut, and reconnect tube to pressure switch connection labeled COLLECTOR BOX. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. F. Construct a Working Platform Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.) • 711t MANUAL 1SHUTOFF GAS VALVE I SEDIMENT TRAP COMBUSTION – AIR INTAKE NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS. CAUTION: The condensate trap MUST be installed below furnace. See Fig. 4 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain. NOTE: Combustion -air and vent pipes are restricted to a mini- mum length of 5 ft. (See Table 6.) NOTE: A 12 -in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 31.) V. HORIZONTAL RIGHT (SUPPLY -AIR DISCHARGE) APPLICATIONS A horizontal right furnace application is where furnace blower is located to the left of combustion and controls section of furnace, and conditioned air is discharged to the right. CAUTION: Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling. CONDENSATE TRAP NOTE: In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes. A. Condensate Trap Location The condensate trap must be removed from the factory- installed blower shelf location and relocated in selected application location as shown in Fig. 2 or 11. To relocate condensate trap from the blower shelf to desired location, perform the following: —10— VENT DRAIN A 12 -IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM 30" MIN EXITING THE VENT PIPE. WORK AREA ACCESS OPENING FOR TRAP A93031 Fig. 10 —Attic Location and Working Platform I. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 11.) 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position. B. Condensate Trap Tubing NOTE: See Fig. I 1 or tube routing label on main furnace door to check for proper connections. 1. Collector Box Drain Tube a. Remove factory- installed plug from LOWER collector box drain tube (blue and white striped label). b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was previously con- nected to condensate trap. c. Connect LOWER collector box drain tube (blue and white striped label) to condensate trap. Tube does not need to be cut. d. Clamp tube to prevent any condensate leakage. 2. Inducer Housing Drain Tube a. Remove factory- installed cap and clamp from LOWER inducer housing drain connection. b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to conden- sate trap. CAP COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) PLUG COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed. d. Use inducer housing drain extension tube (violet label and factory- supplied in loose parts bag) to connect LOWER inducer housing drain connection to conden- sate trap. e. Determine appropriate length, cut, and connect tube to condensate trap. f. Clamp tube to prevent any condensate leakage. 3. Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure. C. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. D. Pressure Switch Tubing One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications. NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections. Relocate tubes as described below: 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. 2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connec- tion by splicing to small diameter tube (factory- supplied in loose parts bag). 3. Route extended collector box pressure tube behind inducer motor bracket then between inducer motor and pressure switch. INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE Fig. 11 Horizontal Right Tube Configuration —I I— CONDENSATE TRAP A93303 4. Connect collector box pressure tube (green label) to pres- sure switch connection labeled COLLECTOR BOX. 5. Use remaining smaller diameter tube (factory- supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch. 6. Route this extended tube (pink label) to condensate trap relief port connection. 7. Determine appropriate length, cut, and connect tube. 8. Clamp tube to relief port connection. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. F. Construct a Working Platform CAUTION: The condensate trap MUST be installed below furnace. See Fig. 4 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain. Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.) NOTE: Combustion -air and vent pipes are restricted to a mini- mum length of 5 ft. (See Table 6.) NOTE: A 12 -in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 31.) LOCATION I. GENERAL When a furnace is installed so that supply ducts carry air to areas outside the space containing the fumace, return air must also be handled by ducts sealed to furnace casing. The ducts terminate to outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space. Furnace may be located in a confined space without special provisions for dilution or ventilation air. This furnace must be installed so electrical components are protected from water. UPFLOW OR DOWNFLOW HORIZONTAL A93025 NOTE: For proper furnace operation, install furnace so that it is level or pitched forward within 1/2 in. to ensure proper condensate drainage from secondary heat exchangers. A93042 NOTE: These furnaces are designed for a minimum continuous return-air temperature of 60 °F or intermittent operation down to 55 °F such as when used with a night setback thermostat. Retum -air temperature must not exceed a maximum of 85 °F. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls. Locate furnace as close to center of air distribution system as possible. Locate furnace so combustion -air pipe maximum lengths are not exceeded. Refer to Table 6. CAUTION: If these furnaces are used during construc- tion when adhesives, sealers, and/or new carpets are being installed, make sure all combustion and circulating air requirements are followed. If operation of furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine, when burned with combustion air, form acids which will cause corrosion of heat exchangers. Some of these compounds are found in paneling, dry wall adhe- sives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems. • —12— WARNING: Do not install furnace on its back. Safety control operation will be adversely affected. Never con- nect return-air ducts to back of furnace. Failure to follow this warning could result in fire, personal injury, or death. 1■ 32 °F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED A93043 A93058 CAUTION: If these furnaces are installed in an uncon- ditioned space where ambient temperatures may be 32 °F or lower, freeze protection measures must be taken. Provide ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on unit's clear- ance to combustibles label. (See Fig. 3.) Locate furnace where available electric power and gas supplies meet specifications on furnace rating plate. II. 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 must prevent chilled air from entering furnace. If dampers are manually operated, they must be equipped with a means to prevent operation of either unit unless damper is in full -heat or full -cool position. III. HAZARDOUS LOCATIONS WARNING: When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, unit must be installed in accor- dance with requirements of National Fire Protection Association, Inc. INSTALLATION I. LEVELING LEGS (IF DESIRED) When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 12.) Install field- supplied, corrosion- resistant 5 /I6 -in. machine bolts and nuts. 18 -IN. MINIMUM TO BURNERS A93044 A89014 Fig. 12— Leveling Legs NOTE: The maximum length of bolt should not exceed 1 -1/2 in. 1. Position furnace on its back. Locate and drill a 5 /I6 -in. diameter hole in each bottom corner of furnace. (See Fig. 12.) Holes in bottom closure panel may be used as guide locations. 2. For each hole, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.) 3. Install another nut on other side of furnace base. (Install flat washer if desired.) —13— 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. II. INSTALLATION IN UPFLOW OR DOWNFLOW APPLICATIONS NOTE: For downflow applications, this furnace is approved for use on combustible flooring when special base (available from manufacturer) Part No. KGASI30201ALL is used. Special base in not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is used. 1. Determine application being installed from Table 1. 2. Construct hole in floor per dimensions specified in Table 1 and Fig. 13. 3. Construct plenum to dimensions specified in Table 1 and Fig. 13. 4. If downflow subbase (KGASB) is used, install as shown in Fig. 14. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 15. 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 wide duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.) WARNING: Do not bend duct flanges inward as shown in Fig. 16. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 16. NOTE: For 140 size unit when installed in downflow orientation, cut the white jumper wire off between terminals PLI -6 and PL1 -9. Refer to Fig. 24 for location of jumper. Cut jumper close to connector and remove wire to avoid a short circuit. III. INSTALLATION IN HORIZONTAL APPLICATIONS These furnaces can be installed horizontally 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. 17.) Cut hanger bolts (4 each 3 /8 -in. all- thread rod) to desired length. Use 1 X 3 /8 -in. flat washers, 3 /8 -in. lockwashers, and 3 /8 -in. nuts on hanger rods as shown in Fig. 17. Dimples are provided for hole locations. (See Fig. 2.) m CAUTION: The entire length of furnace MUST be supported when furnace is used in a horizontal position to ensure proper draining. When suspended, bottom brace supports sides and center blower shelf. When unit is supported from the ground, blocks or pad should support sides and center blower shelf area. IV. FILTER ARRANGEMENT CAUTION: Never operate unit without a filter or with blower access panel removed. Factory - supplied washable framed filters are shipped in 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. FURNACE CASING WIDTH APPLICATION PLENUM OPENING FLOOR OPENING A B C D 17 -1/2 Upflow Applications 16 24 -1/8 16 -5/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 15-7/8 19 16 -1/2 19 -5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Fumace with or without CD5 or CK5 Coll Assembly or KCAKC Coil Box 15 -1/8 19 16 -3/4 20 -3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Fumace with CD5 or CK5 Coll Assembly or KCAKC Coil Box 15 -1/2 19 16 -1/2 20 21 Upflow Applications 19 -1/2 24 -1/8 20 -1/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 19-3/8 19 20 19 -5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Fumace with or without CD5 or CK5 Coll Assembly or KCAKC Coll Box 18 -5/8 19 20 -1/4 20 -3 /8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Fumace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 19 19 20 20 24.14 Upflow Applications 23 24 -1/8 23 -5/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 22 -7/8 19 23 -1/2 19 -5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Fumace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 -1/8 19 23 -3/4 20 -3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 -1/2 19 23 -1/2 20 FURNACE (OR CASING WHEN USED) ) COMBUSTIBLE FLOORING DOWNFLOW SUBBASE SHEET METAL PLENUM 1 ~— OPENIING A96285 Fig. 14— Furnace, Plenum, and Subbase Installed on a Combustible Floor A PLENUM OPENING B D 4 FLOOR OPENING 111 IVA AI I A96283 Fig. 13 —Floor and Plenum Opening Dimensions TABLE 1—OPENING DIMENSIONS (IN ) —14— FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL n1 �— PLENUM FLOOR OPENING A96284 Fig. 15— Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor FURNACE CASING WIDTH (IN.) FILTER SIZE (IN.)* FILTER TYPE FRAMED Side Retum Bottom Retum 17 -1/2 (1) 16 X 25 X 1t (1) 16 X 25 X 1 Cleanable 21 (1) 16 X 25 X 1 (1) 20 X 25 X if Cleanable 24-1/2 (2) 16 X 25 X It (1) 24 X 25 X 1 Cleanable 1 PERFORATED DISCHARGE DUCT FLANGE Fig. 16 — Duct Flanges (B) ANGLE I IRON OR EQUIVALENT (A) PREFERRED ROD LOCATION (B) ALTERNATE ROD LOCATION • Filters can be field modified by cutting frame as marked and folding to NO desired size. Alternate sizes can be ordered from your distributor or dealer. t Factory- provided with furnace. YES YES A93029 V. BOTTOM CLOSURE PANEL These furnaces are shipped with bottom enclosure panel installed in bottom return-air opening. This panel MUST be in place when side return air is used. (A) LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL 3 /s -IN. HEX NUT (A) \– (B) DWG FOR & WASHER (4) LOCATIONS) REQD PER ROD —t 5— TABLE 2 INFORMATION m CAUTION: Air delivery above 1800 CFM requires that both sides, a combination of 1 side and bottom, or bottom only of furnace be used for return air. NOTE: Side return -air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 18. Bottom retum -air opening may be used with all 4 orientations. Filter may need to be cut to fit some furnace widths. Install filter as shown in Fig. 19. NOTE: Remove and discard bottom closure panel when bottom inlet is used. 5 3 /4 " 1 1 (A) (B) J 13 /ta -IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK NOTES: 1. A 1 In. clearance minimum between top of furnace and combustible material. 2. The entire length of fumace must be supported when furnace is used In horizontal position to ensure proper drainage. Fig. 17 Crawlspace Horizontal Application Sib -IN. ROD ALTERNATE SUPPORT LOCATION 4 -IN. MIN 8 -IN. MAX A93304 To remove bottom closure panel, perform following: 1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 20.) 2. Rotate front filler panel downward to release holding tabs. 3. Remove bottom closure panel. 4. Reinstall front filler panel and screws. WASHABLE FILTER Fig. 18— Filter Installed for Side Inlet 171k -IN. WIDE CASINGS ONLY: INSTALL FIELD - SUPPLIED FILTER FILLER STRIP UNDER FILTER. FILTER FILTER SUPPORT RETAINER Fig. 19— Bottom Filter Arrangement FILTER RETAINER 241 WIDE CASINGS ONLY: CUT AND FOLD FACTORY - PROVIDED FILTERS AS SHOWN TO DESIRED SIZE. 24 + /2" A93045 WASHABLE FILTER A96030 —16— VI. GAS PIPING BOTTOM CLOSURE PANEL I'RONT FILLER PANEL Fig. 20— Removing Bottom Closure Panel A93047 Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 3 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas. CAUTION: Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls. m WARNING: Gas valve shutoff switch MUST be facing forward or tilted upward. Failure to follow this warning could result in property damage or death. Lt WARNING: Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap- and -water solution to check for leakage. A failure to follow this warning could result in fire, explosion, personal injury, or death. m WARNING: Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death. Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight - through section of tee is vertical. Then connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and manual gas shutoff valve. (See Fig. 21.) NOMINAL IRON PIPE INTERNAL DIAMETER LENGTH OF PIPE (FT) 10 20 30 40 50 SIZE (IN.) 1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151 1 1.049 680 465 375 320 285 1 -1/4 1.380 1400 950 770 660 580 1 -1/2 1.610 2100 1460 1180 990 900 GAS SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION TABLE 3— MAXIMUM CAPACITY OF PIPE* • Cubic ft of gas per hr for gas pressures of 0.5 psig (14 -in. wc) or less, and a pressure drop of 0.5 -in, wc (based on a 0.60 specific g avity gas). Ref: Table 10 -2 NFPA 54 -1999. Fig. 21— Typical Gas Pipe Arrangement A93324 CAUTION: If a flexible connector is required or al- lowed by authority having jurisdiction, black iron pipe shall be installed at gas valve and extend a minimum of 2 in. outside furnace casing. An accessible manual shutoff valve MUST be installed upstream of furnace gas controls and within 6 ft of furnace. A I /8 -in. NPT plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of gas supply connection to fumace and downstream of manual shutoff valve. NOTE: The gas valve inlet press tap connection is suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0.5 psig (l4 -in. we) stated on gas valve. (See Fig. 45.) Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace is attached. In Canada, refer to current edition of NSCNGPIC. If pressure exceeds 0.5 psig (14 -in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14 -in. 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. AIR DUCTS I. 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 factory 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. —17— When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. Secure ductwork with proper fasteners for type of ductwork used. Seal supply- and return-duct connections to furnace with code approved tape or duct sealer. Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended. Maintain a I -in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See NFPA 9013 or local code for further requirements. II. DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take -off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 9013 as tested by UL Standard 181 for Class I Rigid air ducts. III. SUPPLY AIR CONNECTIONS Connect supply -air duct to 3 /4 -in. flange on furnace supply -air outlet. The supply -air duct attachment must ONLY be connected to furnace supply - /outlet -air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accesso- ries MUST be connected external to furnace main casing. A. Downflow Furnaces Connect supply -air duct to supply -air opening on furnace. The supply -air duct attachment must ONLY be connected to furnace supply /outlet or air conditioning coil casing (when used), when installed on non - combustible material. When installed on combus- tible material, supply -air duct attachment must ONLY be con- nected to an accessory subbase or factory approved air condition- ing coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing. B. Horizontal Furnaces Connect supply -air duct to supply air opening on furnace. The supply -air duct attachment must ONLY be connected to furnace supply /outlet or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to fumace main casing. IV. RETURN AIR CONNECTIONS A. Upflow Furnaces The return -air duct must be connected to bottom , sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. 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. B. Downflow and Horizontal Furnaces The return -air duct must be connected to return-air opening provided as shown in Fig. 1. DO NOT cut into casing sides or back to attach any portion of return-air duct. Bypass humidifier connec- tions should be made at ductwork or coil casing sides exterior to furnace. 1 ELECTRICAL CONNECTIONS See Fig. 22 for field wiring diagram showing typical field 115 -v and 24 -v wiring. Check all factory and field electrical connections for tightness. AS. WARNING: Blower access panel door switch opens 115 -v power to control center. No component operation can occur. Do not bypass or close switch with panel removed. Failure to follow this warning could result in personal injury or death. CAUTION: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. I. 115-V WIRING Before proceeding with electrical connections, make certain that voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 4 for equipment electrical specifications. Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70 -1999 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 subauthorities having jurisdiction. Use a separate, fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace. See Table 4 for wire size and fuse specifications. A disconnecting means must be located within sight from and readily accessible to furnace. NOTE: Proper polarity must be maintained for 115 -v wiring. If polarity is, incorrect, control center LED status indicator light will flash rapidly and furnace will NOT operate. FIVE WIRE THREE -WIRE HEATING -ONLY BLOWER DOOR SWITCH —� 115 -V FIELD - SUPPLIED DISCONNECT GND AUXILIARY J -BOX FURNACE 24 -V TERMINAL BLOCK i _ -1 NOTE 1 NOTES: 1. 2. 3. —18— ELECTRIC DISCONNECT SWITCH THERMOSTAT TERMINALS CONDENSING UNIT Fig. 22 Standard Heating and Cooling Application Wiring Diagram m I CAUTION: Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. WARNING: The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70 -1999 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death. J -BOX RELOCATION 1. Remove 2 screws holding auxiliary J -box. (See Fig. 23.) 2. Rotate J -box 180° and attach box to right side, using holes provided. m CAUTION: If manual disconnect switch is to be mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components. - - -- FIELD 24 -V WIRING - - -- FIELD 115 -, 208/230 -, 460 -V WIRING — FACTORY 24 -V WIRING — FACTORY 115 -V WIRING FIELD - SUPPLIED DISCONNECT - 208/230- OR – 460 -V – THREE PHASE – 208/230 -V 1 SINGLE PHASE Connect Y- terminal in furnace as shown for proper blower operation. Some thermostats require a "C" terminal connection as shown. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire. A93033 A99440 UNIT SIZE VOLTS- HERTZ- PHASE OPERATING VOLTAGE RANGE MAX UNIT AMPS UNIT AMPACITYt MIN WIRE SIZE MAX WIRE LENGTH (FM MAX FUSE OR CKT BKR AMPS** Max* Min* 040.08 115 -60-1 127 104 6.1 8.4 14 44 15 040-12 115 -60-1 127 104 7.3 10.0 14 37 15 060-08 115-60--1 127 104 6.1 8.4 14 44 15 060-12 115-60--1 127 104 7.1 9.8 14 38 15 060.16 115 -60-1 127 104 9.5 12.8 14 29 15 08¢12 115 -60-1 127 104 7.6 10.4 14 36 15 080-16 115 -60-1 127 104 10.0 13.4 14 28 15 080-20 115-60 -1 127 104 14.1 18.4 12 31 20 100-16 115-60 -1 127 104 10.2 13.5 14 27 15 100-20 115-60--1 127 104 14.8 19.3 12 30 20 120-20 115 -60-1 127 104 14.6 19.1 12 30 20 140-20 115 -60-1 127 104 14.3 18.8 12 30 20 too • Permissible limits of voltage range at which unit will operate satisfacto ily. t Unit ampacity • 125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components' (EAC, humidifier, etc.) full load amps. $ Length shown Is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. • Time -delay type is recommended. II. 24-V WIRING Make field 24 -v thermostat connections at 24 -v terminal block on control center. For proper cooling operation, Y wire from thermo- stat MUST be connected to Y/Y2 terminal on control center, as shown in Fig. 22. The 24 -v terminal board is marked for easy connection of field wiring. (See Fig. 25.) The 24 -v circuit contains a 3 -amp, automotive -type fuse located on control center. (See Fig. 25.) Any electrical shorts of 24 -v wiring during installation, service, or maintenance may cause fuse to blow. If fuse replace- ment is required, use only a fuse of identical size (3 amp). 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. III. ACCESSORIES 1. Electronic Air Cleaner (EAC) Two quick- connect terminals, marked EAC- 1 and EAC -2, are provided for EAC connection (See Fig. 25). These terminals are energized with 115v (I.0 -amp maximum) during blower motor operation. 2. Humidifier (HUM) Quick connect terminal (HUM) and screw terminal (Com) are provided for 24 -v humidifier connection. (See Fig. 25.) HUM terminal is energized with 24v (0.5 -amp maximum) after inducer motor prepurge period. NOTE: A field- supplied, 115 -v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation. DIRECT VENTING The 350MAV Furnaces require a dedicated (one 350MAV furnace only) direct -vent system. In a direct -vent system, all air for combustion is taken directly from outside atmosphere, and all flue products are discharged to outside atmosphere. I. REMOVAL OF EXISTING FURNACES FROM COM- MON VENT SYSTEMS If furnace being replaced was connected to a common vent system with other appliances, the following steps shall be followed with each appliance connected to the venting system placed in opera- tion, while any other appliances connected to the venting system are not in operation: 1. Seal any unused openings in the venting system. TABLE 4- ELECTRICAL DATA -I 9- FACTORY INSTALLED LOCATION ALTERNATE FIELD LOCATION A93051 Fig. 23- Relocating J -Box 2. Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code, ANSI Z223.1 or the CAN /CGA B149 Installation Codes and these instructions. Determine that there is no blockage or restric- tion, leakage, corrosion, and other deficiencies which could cause an unsafe condition. 3. In so far as is practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 5. Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner opera- tion. Use the flame of a match or candle. 6. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace damp- ers, and any other gas - burning appliance to their previous conditions of use. rtt'1"1 r ?j ;;'.:"E.r`t 3?.^ ".i1X( 4 H 1 1"f 11 Wdqggg 2""4 NMI �o 4.1@ +O w P. V P N A u Mr. 0 4§ qq g4ai g g h V H P p 0 hi 0 0 h P i 1 i 'N F _ 1 1 • 1 t 0 1 u COOL I' L L OD a SI a I,i 0 5 6 7 8 91011 11 nononnnn YEL -GRN -RED L 2�1 WHT u fl0 =1111011 Uri gs :7LJ 4 • -. 1 F _J • • 1 A. General 7. If improper venting is observed during any of above tests, the venting system must be corrected. Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSC- NGPIC. II. COMBUSTION - AIR AND VENT PIPING Combustion -air and vent pipe fittings must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785 (schedule -40 PVC), D2665 (PVC -DWV), D2241 (SDR -21 and SDR -26 PVC), D2661 (ABS -DWV), F628 (schedule -40 ABS), or F891 (PVC -DWV cellular core). Pipe cement and primer must conform to ASTM standards D2564 or F493 (PVC or CPVC) or D2235 (ABS). See Table 6 for maximum pipe lengths and Fig. 30, 31, 32, 33, and 34 for exterior piping arrangements. In Canada construct all combustion -air and vent pipes for this unit of CSA or ULC certified schedule -40 PVC, PVC -DWV or ABS -DWV pipe and pipe cement. SDR pipe is NOT approved in Canada. NOTE: Furnace combustion -air and vent pipe connections are sized for 2 -in. pipe. Any pipe size change should be made outside furnace casing in vertical pipe. (See Fig. 26.) This allows proper drainage of vent condensate. Combustion -air and vent pipes must terminate together in same atmosphere pressure zone, either through roof or sidewall (roof termination preferred), using accessory termination kit. See Table 5 for required clearances. Furnace combustion -air and vent pipe connections must be at- tached as shown in Fig. 27. Combustion -air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications. 24 -V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL (24 -VAC 0.5 AMP MAX) 24 -V TRANSFORMER SEC -2 LED OPERATION & DIAGNOSTIC LIGHT 115 -VAC (L2) NEUTRAL CONNECTION BLOWER SPEED SELECTION TERMINALS BLOWER OFF DELAY JUMPER SELECT Fig. 25 Control Center —21— FURNACE NOT IN HORIZONTAL SECTION A93034 Fig. 26— Combustion -Air and Vent Pipe Diameter Transition Location and Elbow Configuration NOTE: Slope combustion -air and vent pipes a minimum of 1/4 in. per linear ft with no sags between hangers. lb. CAUTION: When combustion -air pipe is installed above a suspended ceiling, pipe must be insulated with 3 /8 -in. thick Armaflex -type insulation. Combustion -air pipe should also be insulated when it passes through warm, humid space. It CAUTION: When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as shown in Table 7 with Armaflex -type insulation. INDUCER MOTOR 115 -VAC (L1) CONNECTOR POWER SUPPLY EAC -1 ELECTRONIC AIR CLEANER TERMINALS (115 -VAC 1.0 AMP MAX) PIPE DIAMETER TRANSITION IN VERTICAL SECTION HARNESS CONNECTOR HOT SURFACE IGNITOR CONNECTOR A99417 LOCATION CLEARANCE (FT) U.S.A. Canada Above grade level or above anticl- pated snow depth 1 11' Dryer vent 3 3 From plumbing vent stack 3 3 From any mechanical fresh air Intake 1 6 For fumaces with an Input capacity less than 100,000 Btuh —from any non - mechanical air supply (windows or doors which can be opened) or combustion -air opening 1 1 From service regulator vent, electric and gas meters, and relief equipment 4• 6$ Above grade when adjacent to public walkway Note 3 Note 3 TABLE 5— COMBUSTION -AIR AND VENT PIPE TERMINATION CLEARANCES Horizontal distance. t 18 In. above roof surface In Canada. $ 36 in. to electric meter in Canada only. NOTES: 1. If installing 2 adjacent 355MAV Furnaces, refer to Multi - venting and Vent Terminations section for proper vent configurations. 2. When locating combustion -air and vent terminations, con- sideration must be given to prevailing winds, location, and other conditions which may cause recirculation of the appliance's own flue products or the flue products of adjacent vents. Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of heat exchangers. 3. Vent termination can not terminate less than 2 ft horizontal and 7 ft above public walkway or where condensate vapor or droplets may be a hazard. Lfl CAUTION: Combustion air must not be taken from inside structure because inside air is frequently contami- nated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household prod- ucts. Locate combustion -air inlet as far as possible from swimming pool and swimming pool pump house. Excessive exposure to contaminated combustion air will result in safety and performance related problems. WARNING: Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well- ventilated areas. Avoid breathing in vapor or allow- ing contact with skin or eyes. Failure to follow this warning could result in fire, property damage, personal injury, or death. WARNING: All combustion -air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 30, 31, 32, 33, or 34. Failure to follow this warning could result in property damage, personal injury, or death. NOTE: The minimum combustion -air and vent pipe length (each) for these furnaces is 5 ft. Short pipe lengths (5 -8 ft) may discharge —22— NOTE: Select 1 vent pipe connection and 1 combustion -air pipe connection. AIR COMBUSTION- FLOW COMBUSTION - AIR VENT AIR FLOW AIR UPFLOW COMBUSTION - AIR VENT 1 HORIZONTAL -LEFT DISCHARGE VENT NOTE: Select 1 vent pipe connection and 1 combustion -air pipe connection. VENT COMBUSTION- COMBUSTION - AIR AIR AIR FLOW DOWNFLOW COMBUSTION - AIR VENT AIR FLOW HORIZONTAL -RIGHT DISCHARGE Fig. 27— Combustion -Air and Vent Pipe Connections A96187 water droplets. These droplets may be undesirable, and a I 2-in. minimum offset pipe section is recommended, as shown in Fig. 28, to reduce excessive droplets from exiting vent pipe outlet. B. Combustion -Air and Vent Pipe Diameter Determine combustion -air and vent pipe diameter. 1. Using Table 6, individually determine the combustion -air and vent pipe diameters. Pick the larger of these 2 pipe diameters and use this diameter for both combustion -air and vent pipes. 2. When installing vent systems of short pipe length, use the smallest allowable pipe diameter. Do not use pipe size greater than required or incomplete combustion, flame disturbance, or flame sense lockout may occur. NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 30, 31, 32, 33, and 34. VENT PIPE • ,1 f 12" MIN HORIZONTAL TO ROOF COMBUSTION -AIR PIPE 12" MIN VERTICAL TO ROOF COMBUSTION -AIR PIPE EXAMPLE: An 080 -12 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed in an application requiring 3 elbows and 32 ft of vent pipe, along with 5 elbows and 34 ft of combustion -air pipe. Table 6 indicates this application would allow a 2 -in. diameter vent pipe, but require a 2 -1/2 in. diameter combustion air pipe (2 -in. pipe is good for 35 ft with 3 elbows, but only 30 ft with 5 elbows). Therefore, 2 -1/2 in. diameter pipe must be used for both vent and combustion -air pipes since larger required diameter must always be used for both pipes. If same installation were in Albuquerque, elevation 5250 ft above sea level, installation would require 2 -1/2 in. vent pipe and combustion -air pipe. At 5001- to 6000 -ft elevation, 2 -in. pipe is only good for 17 ft with 5 elbows, and 2 -1/2 in. pipe is good for 70 ft with 5 elbows. C. Combustion -Air and Vent Pipe Attachment NOTE: All pipe joints must be watertight except attachment of combustion -air pipe to inlet housing connection, since it may be necessary to remove pipe for servicing. 1. Attach combustion -air pipe as follows: a. Determine location of combustion -air intake pipe con- nection to combustion -air intake housing as shown in Fig. 27 for application. —23— VENT PIPE VENT PIPE HORIZONTAL TO SIDEWALL COMBUSTION -AIR PIPE VERTICAL TO SIDEWALL NOTE: A 12 In. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. 12" MIN ■ COMBUSTION -AIR PIPE VENT PIPE A96230 Fig. 28 —Short Vent (5 to 8 Ft) System b. Reposition combustion -air intake housing plug fitting in appropriate unused intake housing connection. c. If required, insert perforated disk assembly (factory- supplied in loose parts bag) in intake housing where combustion -air intake pipe will be connected. If half disk set is required, install with shoulder of disk against stop in combustion -air inlet. d. Install pipe support (factory- supplied in loose parts bag) into selected furnace casing combustion -air pipe hole. Pipe support should be positioned at bottom of casing hole. e. Insert 2 -in. diameter pipe into intake housing. NOTE: A 2 -in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing. f. Drill a 1 /8 -in. hole in 2 -in. combustion -air pipe using hole in intake housing as a guide. g. Install a field- supplied No. 6 or No. 8 sheet metal screw into combustion -air pipe. NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur. NOTE: Do not attach combustion -air intake pipe permanently to combustion -air intake housing since it may be necessary to remove pipe for service of ignitor or flame sensor. COMBUSTION -AIR INTAKE HOUSING PLUG FIT- TING ALTITUDE (FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 0 to 2000 024040 036040 2 Pipe or 2 -In. Concentric 1 5 NA NA NA NA NA 1 -1/2 70 70 65 60 60 55 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 20 15 10 5 NA NA 2 70 70 70 70 70 70 036080 048080 060080 2 pipe or 2 -In. Concentric 1 -1/2 10 NA NA NA NA NA 2 55 50 35 30 30 20 2 -1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 5 NA NA NA NA NA 2-1/2 40 30 20 20 10 NA 3 70 70 70 70 70 70 060120 2 Pipe or 3 -In. Concentric 2 -1/2 one disk 10 NA NA NA NA NA 3t 45 40 35 30 25 20 3t no disk 70 70 70 70 70 70 4t no disk 70 70 70 70 70 70 060140 2 Pipe or 3 -In. Concentric 2 -1/2 one disk 5 NA NA NA NA NA 3t one disk 40 35 30 25 20 15 3t no disk 60 56 52 48 44 40 4t no disk 70 70 70 70 70 70 ALTITUDE (FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 2001 to 3000 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 67 62 57 52 52 47 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 17 12 7 NA NA NA 2 70 67 66 61 61 61 036080 048080 060080 2 Pipe or 2 -In. Concentric 2 49 44 30 25 25 15 2 -1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 35 26 16 16 6 NA 3 70 70 70 70 66 61 060120 2 Pipe or 3 -In. Concentric 3 14 9 NA NA NA NA 3t no disk 70 70 63 56 50 43 4t no disk 70 70 70 70 70 70 060140 2 Pipe or 3 -In. Concentric 31 one disk 20 15 10 5 NA NA 3t no disk 39 35 31 27 23 19 4t no disk 70 70 70 70 70 70 ALTITUDE (FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)' NUMBER OF 90° ELBOWS 1 2 3 4 5 6 3001 to 4000 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 64 59 54 49 48 43 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 16 11 6 NA NA NA 2 68 63 62 57 57 56 036080 048080 060080 2 Pipe or 2 -In. Concentric 2 46 41 28 23 22 13 2 1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 33 24 15 14 5 NA 3 70 70 70 66 61 56 060120 2 Pipe or 3 -In. Concentric 3t no disk 65 58 51 44 38 31 4t no disk 70 70 70 70 70 70 060140 2 Pipe or 3 -In. Concentric 3t one disk 11 6 NA NA NA NA 3t no disk 30 26 22 18 14 10 4t no disk 70 70 70 70 70 70 See notes on page 26. —24— TABLE 6— MAXIMUM ALLOWABLE PIPE LENGTH (FT) ALTITUDE (FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)' NUMBER OF 90° ELBOWS 1 2 3 4 5 6 4001 to 5000$ 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 60 55 50 45 44 39 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 15 10 5 NA NA NA 2 64 59 58 53 52 52 036080 048080 060080 2 Pipe or 2 -In. Concentric 2 44 39 26 21 20 11 2 -1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 31 22 13 12 NA NA 3 70 70 67 62 57 52 060120 2 Pipe or 3 -In. Concentric 3t no disk 53 46 40 33 26 20 4t no disk 70 70 70 70 70 70 060140 2 Pipe or 3 -In. Concentric 3t no disk 21 17 13 9 5 NA 4t no disk 69 64 59 54 49 44 ALTITUDE (FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)' NUMBER OF 90° ELBOWS 1 2 3 4 5 6 5001 to 6000$ ' 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 57 52 47 42 40 35 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 14 9 NA NA NA NA 2 60 55 54 49 48 47 036080 048080 060080 2 Pipe or 2 -In. Concentric 2 41 36 23 18 17 8 2 -1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 29 21 12 11 NA NA 3 70 67 62 57 52 47 060120 2 Pipe or 3 -In. Concentric 3t no disk 42 35 29 22 15 9 4f no disk 70 70 70 70 70 70 060140 2 Pipe or 3 -In. Concentric 3t no disk 12 8 NA NA NA NA 4t no disk 42 37 32 27 22 17 ALTITUDE (FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.) NUMBER OF 90° ELBOWS 1 2' 3 4 5 6 6001 to 7000$ 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 53 48 43 38 37 32 2 70 70 68 67 66 64 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 13 8 NA NA NA NA 2 57 52 50 45 44 43 036080 048080 060080 2 Pipe or 2 -In. Concentric 2 38 33 21 16 15 6 2 -1/2 70 70 68 67 66 64 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 27 19 10 9 NA NA 3 68 63 58 53 48 43 060120 2 Pipe or 3 -In. Concentric 3t no disk 31 24 18 11 NA NA 4t no disk 70 70 70 70 67 62 060140 2 Pipe or 3 -In. Concentric 4t no disk 17 12 7 NA NA NA ALTITUDE(FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.) NUMBER OF 90° ELBOWS 1 2 3 4 5 6 7001 to 8000$ 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 49 44 39 34 33 28 2 66 65 63 62 60 59 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 12 7 NA NA NA NA 2 53 48 46 41 40 38 036080 048080 060080 2 Pipe or 2 -In. Concentric 2 36 31 19 14 12 NA 2 -1/2 66 65 63 62 60 59 048100 060100 2 Pipe or 3 In. Concentric 2-1/2 25 17 8 7 NA NA 3 63 58 53 48 43 38 060120 2 Pipe or 3 -In. Concentric 3t no disk 20 13 7 NA NA NA 4t no disk 61 56 51 46 41 36 060140 NA See notes on page 26. —25— TABLE 6— MAXIMUM ALLOWABLE PIPE LENGTH (FT) Continued ALTITUDE (FT) UNIT SIZE TERMINATION PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 8001 to 9000$ 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 46 41 36 31 29 24 2 62 60 58 56 55 53 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 11 6 NA NA NA NA 2 49 44 42 37 35 34 036080 048080 060080 2 pipe or 2 -In. Concentric 2 33 28 17 12 10 NA 2 -1/2 62 60 58 56 55 53 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 23 15 7 5 NA NA 3 59 54 49 44 39 34 060120 2 Pipe or 3 -In. Concentric 3t no disk 10 NA NA NA NA NA 4t no disk 35 30 25 20 15 10 060140 NA ALTITUDE (FT) UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 9001 to 10,000$ ' 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 42 37 32 27 25 20 2 57 55 53 51 49 47 024060 036060 048060 2 Pipe or 2 -In. Concentric 2 45 40 38 33 31 29 036080 048080 060080 2 Pipe or 2-In. Concentric 2 30 25 14 9 7 NA 2 -1/2 57 55 53 51 49 47 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 21 13 5 NA NA NA 3 54 49 44 39 34 29 060120 2 Pipe or 3 -In. Concentric 4t no disk 10 5 NA NA NA NA 060140 NA TABLE 6— MAXIMUM ALLOWABLE PIPE LENGTH (FT) Continued • Disk usage — Unless otherwise specified, use perforated disk assembly (factory- supplied in loose parts bag). If one disk is slated, separate 2 halves of perforated disk assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box. t Wide radius elbow. $ Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction. NA—Not Allowed; pressure switch will not make. NOTES: 1. Do not use pipe size greater than those specified in table or Incomplete combustion, flame disturbance, or flame sense lockout may occur. 2. Size both the combustion -air and vent pipe independently, then use the larger 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 fumace 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. 6. Use 3 -in. diameter vent termination kit for installations requiring 4 -in diameter pipe. The combustion -air intake plug fitting must be installed in unused combustion -air intake housing. This fitting must be attached by using RTV sealant, or by drilling a 1 /8 -in. hole in fitting, using hole in intake housing as a guide. Install a field- supplied No. 6 or No. 8 sheet metal screw. NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur. A plugged drain connection has been provided on this fitting for use when moisture is found in combustion -air intake pipe and combustion box. NOTE: Moisture in combustion -air intake may be result of improper termination. Ensure combustion -air intake pipe is similar to that shown in Fig. 30, 31, 32, 33, or 34 so it will not be susceptible to areas where light snow or other sources of moisture could be pulled in. If use of this drain connection is desired, drill out fitting's tap plug with a 3 /16 -in. drill and connect a field- supplied 3 /8 -in. tube. This tube should be routed to open condensate drain for fumace and A/C (if used), and should be trapped. (See Fig. 29.) 2. Attach vent pipe as follows: a. Determine location of vent pipe connection to inducer housing as shown in Fig. 27 for application. b. Reposition elastomeric (rubber) inducer housing outlet cap and clamp to appropriate unused inducer housing connection. Tighten clamp. —26— 3/16" DRILL TRAP COMBUSTION – AIR INTAKE HOUSING BURNER BOX 3/8" ID TUBE TO OPEN DRAIN COMBUSTION – AIR PIPE Fig. 29— Intake Housing Plug Fitting Drain A93035 LE WARNING: Inducer housing outlet cap must be in- stalled and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. c. Install pipe support (tactory- supplied in loose parts bag) into selected furnace casing vent pipe hole. Pipe support should be positioned at bottom of casing hole. d. Be certain that mating surfaces of inducer housing connection, elastomeric coupling, and 2 -in. diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2 -in. diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it bottoms on the internal stop. Tighten both clamps to secure the pipe to inducer housing. Tighten the clamp screws to 15 in.-lb. of torque. WARNING: Vent pipe must be installed and fully seated against inducer housing internal stop. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. NOTE: A 2 -in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing. VENT EXTENSION PIPE Furnaces with 100,000 Btuh or larger inputs are supplied with a PVC vent extension pipe (2 -in. diameter by 12 -in. long). This pipe has a built -in channel to assist vent condensate disposal. When this vent extension pipe is supplied, it must be used to connect the field vent pipe to 'furnace inducer housing on ALL upflow and downflow applications. NOTE: See label on vent extension pipe for proper installation. This pipe may be shortened if an elbow is used to connect vent extension tube to field- installed vent pipe. 3. Working from furnace to outside, cut pipe to required length(s). 4. Deburr inside and outside of pipe. 5. Chamfer outside edge of pipe for better distribution of primer and cement. 6. Clean and dry all surfaces to be joined. 7. Check dry fit of pipe and mark insertion depth on pipe. NOTE: It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint. 8. After pipes have been cut and preassembled, apply gener- ous layer of cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat. 9. While cement is still wet, twist pipe into socket with 1/4 turn. Be sure pipe is fully inserted into fitting socket. 10. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint. 11. Handle pipe joints carefully until cement sets. 12. Support combustion -air and vent piping a minimum of every 5 R (3 ft for SDR -21 or -26 PVC) using perforated metal hanging strap. 13. Slope combustion -air and vent pipes toward furnace a minimum of 1/4 in. per linear 11 with no sags between hangers. 14. Use appropriate methods to seal openings where vent and combustion -air pipes pass through roof or side wall. III. CONCENTRIC VENT AND COMBUSTION-AIR TERMINATION KIT INSTALLATION NOTE: If these instructions differ from those packaged with termination kit, follow kit instructions. —27— Combustion -air and vent pipes must terminate outside structure. A factory accessory termination kit must be installed in 1 of the installations shown in Fig. 30, 31, 32, 33, or 34. Four termination kits are available. 1. The 2 -in. termination bracket kit is for 1 -in., 1 -1/2 in., and 2 -in. diameter 2 -pipe termination systems. 2. The 3 -in. termination bracket kit is for 2 -1/2 in., 3 -in., and 4 -in. diameter 2 -pipe termination systems. 3. The 2 -in. concentric vent/air termination kit is for I -in., 1 -1/2 in., 2 -in., and 2 -1/2 in. diameter pipe systems when single penetration of wall or roof is desired. 4. The 3 -in. concentric vent/air termination kit is for 2 -1/2 in., 3 -in., and 4 -in. diameter pipe systems when single penetra- tion of wall or roof is desired. NOTE: Shaded parts in Fig. 30, 31, 32, 33, and 34 are considered to be termination. These components should NOT be counted when determining pipe diameter. Roof termination is preferred since it is less susceptible to damage, has reduced chances to take in contaminants, and has less visible vent vapors. (See Fig. 30 or 31.) Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system. A. Extended Exposed Sidewall Pipes Sidewall combustion -air and vent pipe terminations may be extended beyond area shown in Fig. 33 or 34 in outside ambient by insulating pipes as indicated in Table 7. 1. Determine combustion -air and vent pipe diameters, as stated above, using total pipe length and number of elbows. 2. Using winter design temperature (used in load calculations), find appropriate temperature for your application and fur- nace model. 3. Determine required insulation thickness for exposed pipe lengths. NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 6. B. Two -Pipe Termination Kit 1. Determine location for termination. Consideration of the following should be made when determining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table 5. b. Termination kit should be positioned where vent vapors will not damage plants /shrubs or air conditioning equip- ment. c. Termination kit should be positioned so that it will not be affected by wind eddy (such as inside building corners) or allow recirculation of flue gases, airborne leaves, or light snow. d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc. e. Termination kit should be positioned where vent vapors are not objectionable. 2. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size being used. 3. Loosely install elbow in bracket and place assembly on combustion -air pipe. Roof terminations — Loosely install pipe coupling on prop- erly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 30. 1rMAXIMU fur BRACKET VERTICAL SEPARATION BETWEEN COMBUSTION AIR AND VENT 8 3 /4" FOR 3" KIT 6 3 /4" FOR 2" KIT MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. COMBUSTION AIR MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. A93054 Fig. 31— Concentric Vent and Combustion -Air Roof Termination (Preferred) - 90 BRACKET .,7- VENT OVERHANG OR ROOF 12" MINIMUM • 12 IN. SEPARATION • ' .BETWEEN BOTTOM OF .':' AIR AND ,,ij�;:.- BOTTOM OF VENT MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, COMBUSTION -AIR WHICHEVER IS GREATER. Fig. 30 — Roof Termination (Preferred) _— 90 BRACKET —lb- COUPLING VENT COMBUSTION Y AIR OVERHANG OR ROOF 12" MINIMUM COMBUSTION -AIR (ELBOW PARALLEL TO WALL) OVERHANG OR ROOF 12" MINIMUM ~ 1" MAXIMUM A87224 - MAINTA N 12 IN. - , CLEARANCE ABOVE C PA D E ANTI SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. A93055 Fig. 32— Concentric Vent and Combustion -Air Side Termination 12 IN. SEPARATION BETWEEN BOTTOM OF .' *COMBUSTION AIR AND --BOTTOM OF VENT MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. A87225 A87226 Fig. 33— Sidewall Termination of 12 in. or More — Fig. 34— Sidewall Termination of Less than 12 in. UNIT SIZE WINTER DESIGN TEMPERATURE (°F) MAX PIPE DIAMETER (IN.) WITHOUT INSULATION WITH 3/8 -IN. OR THICKER INSULATIONt 040 20 2 45 70 0 2 28 70 -20 2 10 58 060 20 2 65 70 0 2 35 70 -20 2 20 70 080 20 2 -1/2 70 70 0 2 -1/2 47 70 -20 2 -1/2 28 70 100 20 3 70 70 0 3 50 70 -20 3 28 70 120 20 4 70 70 0 4 48 70 -20 4 23 70 , 140 20 4 70 70 0 4 57 70 -20 4 30 70 i • Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 6. t Insulation thickness based on R value of 3.5 per in. For applications using combustion -air pipe option, indi- cated by dashed lines in Fig. 30, install 90° street elbow into 90° elbow, making U- fitting. A 180° U- fitting may be used. Sidewall terminations — Install bracket as shown in Fig. 33 or 34. For applications using vent pipe option indicated by dashed lines in Fig. 33, rotate vent elbow 90° from position shown in Fig. 33. 4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. 5. Check required dimensions as shown in Fig. 30, 33, or 34. C. Concentric Vent/Air Termination Kit 1. Determine location for termination. Consideration of the following should be made when determining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table 5. b. Termination kit should be positioned where vent vapors will not damage plants /shrubs or air conditioning equip- ment. c. Termination kit should be positioned so it will not be affected by wind eddy (such as inside building corners) or that may allow recirculation of flue gases, airborne leaves, or Tight snow. d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc. e. Termination kit should be positioned where vent vapors are not objectionable. 2. Cut one 4 -in. diameter hole for 2 -in. kit, or one 5 -in. diameter hole for 3 -in. kit. 3. Loosely assemble concentric vent/air termination compo- nents together using instructions in kit. 4. Slide assembled kit with rain shield REMOVED through hole. to TABLE 7— MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH (FT) WITH AND WITHOUT INSULATION IN WINTER DESIGN TEMPERATURE AMBIENT* —29— SO NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole. Roof terminations — Locate assembly through roof to ap- propriate height as shown in Fig. 31. Sidewall terminations — Locate assembly through sidewall with rain shield positioned no more than I -in. from wall as shown in Fig. 32. 5. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. 6. Check required dimensions as shown in Fig. 31 or 32. IV. MULTIVENTING AND VENT TERMINATIONS When 2 or more 350MAV Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 350MAV furnaces. When 2 or more 350MAV furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 35, 36, 37, 38, or 39, but next vent termination must be at least 36 in. away from first 2 terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension "A" in Fig. 35, 36, 37, 38, and 39 represents distance between pipes or rain shields, as touching or 2 -in. maximum separation. CONDENSATE DRAIN I. GENERAL Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications. Condensate trap MUST be used for all applications. An external trap is not required when connecting the field drain to this condensate trap. The field drain connection (condensate trap or drain tube coupling) is sized for 1 /2 -in. CPVC, I /2 -in. PVC, or 5 /8 -in. ID tube connection. Drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certified schedule 40 CPVC or PVC drain pipe, fittings, and cement. A93056 Fig. 36— Concentric Vent and Combustion -Air Roof Termination (Dimension "A" is Touching or 2 -In. Maximum Separation) A96128 Fig. 35— Rooftop Termination (Dimension "A" is Touching or 2 -In. Maximum Separation) lb COMBUSTION AIR CO MBUSTION AIR COMBUSTION AIR A96129 Fig. 38— Sidewall Termination of 12 in. or Less (Dimension "A" is Touching or 2 -In. Maximum Separation) —30— COMBUSTION AIR A93057 Fig. 37— Concentric Vent and Combustion -Air Side Termination (Dimension "A" is Touching or 2 -In. Maximum Separation) VENT COMBUSTION AIR t A r - " - 1" MAXIMUM (TYP) A VENT VENT.-- • COMBUSTION AIR— A96130 Fig. 39— Sidewall Termination of More Than 12 in. (Dimension "A" is Touching or 2 -In. Maximum Separation) POINWEINIENEENEs 0 When a condensate pump is required, select a pump which is approved for condensing furnace applications. To avoid conden- sate spillage, select a pump with an overflow switch. Furnace condensate is mildly acidic, typically in the pH range of 3.2 to 4.5. Due to 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. 32 °F M NIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED A93058 CAUTION: Unit must not be installed, operated, and then turned off and left in an unoccupied structure during cold weather when temperature drops to 32 °F and below unless drain trap and drain line have adequate freeze protection. See Service and Maintenance Instructions for winterizing procedure. II. APPLICATION The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, field - supplied trap prior to the fumace drain connection. All drain connections (furnace, A /C, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment's drain. See Fig. 40 for example of possible field drain attachment using 1 /2 -in. CPVC or PVC tee for vent and A/C or humidifier drain connection. Outdoor draining of the fumace is permissible if allowed by local codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining. WARNING: Caution should be taken to prevent drain- ing where slippery conditions may cause personal inju- ries. Excessive condensate draining may cause saturated soil conditions which may result in damage to plants. III. CONDENSATE DRAIN PROTECTION Freezing condensate left in condensate trap and drain line may cause cracks, and possible water damage may occur. If freeze protection is required, use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40 °F self - regulating, shielded, and waterproof heat tape. See Installation Instructions supplied with accessory or heat tape manufacturer's recommenda- tions. 1. Fold heat tape in half and wrap on itself 3 times. —3 I — OPEN STAND PIPE FOR NC OR HUMIDIFIER DRAIN TEE TO OPEN DRAIN A94054 Fig. 40 Example of Field Drain Attachment 2. Locate heat tape between sides of condensate trap back. (See Fig. 41.) 3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig. 41.) 4. Wrap field drain pipe with remaining heat tape, approxi- mately 1 wrap per ft. 5. When using field- supplied heat tape, follow heat tape manufacturer's instructions for all other installation guide- lines. CONDENSATE TRAP WIRE TIE(S) HEAT TAPE (3 WRAPS MINIMUM) Fig. 41— Condensate Trap Heat Tape SEQUENCE OF OPERATION A93036 CAUTION: Furnace control must be grounded for proper operation, or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. Using schematic diagram, follow sequence of operation through different modes. (See Fig. 24.) Read and follow wiring diagram carefully. NOTE: If I I5 -v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates for 90 sec when power is restored before heating cycle is resumed. 1. HEATING MODE When wall thermostat calls for heat, R -W circuit closes. Furnace control performs a self - check, verifies pressure switch contacts are open, and starts inducer motor. 1. Prepurge period —As inducer motor comes up to speed, pressure switch contacts close to begin a 15 -sec prepurge period. 2. Ignitor warm up —At end of prepurge period, ignitor is energized for a 1 7-sec ignitor warm -up period. 3. Ignition sequence —When ignitor warm -up period is com- pleted, gas valve opens, permitting gas flow to burners where it is ignited. After 5 sec, ignitor is de- energized and a 2 -sec flame - sensing period begins. HUM terminal on control center is energized with gas valve. See Accessories — Humidifier section. 4. Flame sensing —When burner flame is sensed, control begins blower on delay period and continues holding gas valve open. If burner flame is not sensed, control center de- energizes gas valve and ignition sequence is repeated. NOTE: Ignition sequence repeats 3 additional times before a lockout occurs. Lockout automatically resets after 3 hr or can be manually reset by turning off 115v (not at thermostat) for 3 sec minimum, then turning it on again. 5. Blower on delay —Sixty sec after burner flame is proven (40'sec if jumper has been cut for 140 size unit in downflow orientation), blower motor is energized on heating speed. Simultaneously, electronic air cleaner terminal EAC -1 is energized. 6. Blower off delay —When thermostat is satisfied, circuit between R -W is opened, de- energizing gas valve (stopping gas flow to burners) and humidifier. Blower motor and electronic air cleaner remains energized 90, 135, 180, or 225 sec (depending on blower off time selection). Furnace is factory shipped set for a 135 -sec blower off delay. 7. Post purge — Inducer motor remains energized 15 sec after burners are extinguished (5 sec if jumper has been cut for 140 size unit in downflow orientation). 11. COOLING MODE 1. Single -Speed Outdoor Unit -See Figs. 22, 42 and 44. The thermostat closes the R to G and Y circuits. The R -Y /Y2 circuit starts the outdoor unit, and the R to G and Y/Y2 circuits start furnace blower motor on COOL speed. Electronic air cleaner EAC -I terminal is energized with 115v whenever blower is operating. When thermostat is satisfied, R to G and Y /Y2 circuits are opened. The outdoor unit stops and the furnace blower continues operating on COOL speed for an additional 90 sec. Jumper Y /Y2 to DHUM on the furnace control 10 reduce cooling off delay to 3 sec from 90. See figure 25. 2. Two -Speed Outdoor Unit without Thermidistat -See figure 46. The thermostat closes the R to G and Y 1 circuits for low cooling and the R to G, Y I and Y /Y2 circuits for high cooling. The R to YI circuit starts the outdoor unit on low cooling and the R to G and Y1 circuits start the furnace blower on FAN speed. The R to Y1 and Y2 circuits start the outdoor unit on high cooling and the R to G, YI and Y2 circuits start the furnace blower on COOL speed. —32— If the R to Y2 circuit opens with the R to G and Y1 circuits still closed, the outdoor unit will drop to low cooling and the furnace control will drop the blower speed to FAN. When the R to G and Y1 circuit open, the furnace blower continues operating on FAN speed for an additional 90 sec. To set the cooling off delay to 3 sec instead of 90, connect a jumper between the Y /Y2 and DHUM thermostat con- nects on the furnace control. 3. Two -Speed Cooling Unit with Thermidistat -See Figs. 43 and 45. 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 menas 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 and is tumed OFF when demand exists. Once 24 vac is detected by the furnace control on the DHUM input, the control operates in Thermidistat mode. The thermostat closes the R to G and Y 1 circuits for low cooling and the R to G, Y1 and Y /Y2 circuits for high cooling. The R to Y1 circuit starts the outdoor unit on low cooling and the R to G and Yl circuits start the furnace blower on FAN speed. The R to Y1 and Y2 circuits start the outdoor unit on high cooling and the R to G, Y I and Y2 circuits start the furnace blower on COOL speed. lithe R to Y2 circuit opens with the R to G and Y1 circuits still closed, the outdoor unit will drop to low cooling and the furnace control will drop the blower speed to FAN. When the thermostat is satisfied, the R to G and Yl circuits are opened. The outdoor unit stops. When there is a dehumidy demand, the cooling blower off delay is decreased from 90 to 3 sec. In Two -Speed Cooling with only the R to G and Y1 circuits closed and there is a demand for dehumidification, the furnace control blower speed will remain at FAN speed. 1n high cooling with a demand for dehumidification, the furnace control will drop the blower speed from COOL to HEAT for a maximum of 10 minutes before reverting back to COOL speed. If there is still a demand for dehumidifi- cation after 20 minutes, the control will drop the blower speed back to HEAT speed. This alternating 10- minute cycle will continue as long as there is a call for cooling. If the DHUM input is low for more than 48 hours, the control reverts back to non - Thermidistat operation. III. CONTINUOUS BLOWER MODE When R -G circuit is made, blower motor operates at FAN speed. NOTE: Electronic air cleaner EAC -I terminal is energized with 115v whenever blower is operating. If a call for heat (R -W) occurs while thermostat is in continuous blower mode, blower stops to allow furnace heat exchangers to heat up more quickly, then restarts on HEAT speed at end of blower on delay period of 60 sec (40 sec if jumper has been cut for 140 size unit in downflow orientation). Blower reverts to FAN speed after heating cycle is completed. If a call for cooling (R -Y /Y2) occurs while thermostat is in continuous blower mode, blower changes from continuous blower speed (FAN speed) to COOL speed. When thermostat cooling call is satisfied, R -Y opens and blower operates an additional 90 sec at COOL speed before reverting back to continuous operation (FAN speed). IV. CONTINUOUS BLOWER SPEED SELECTION FROM THERMOSTAT To select different continuous blower speeds from the room thermostat, momentarily turn off the FAN switch or pushbutton on the room thermostat for 1 -3 seconds after the blower is operating. • se THERMIDISTAT N/A N/A HEAT STAGE 1 COOL STAGE 1 FAN I - -- 24 VAC HOT RD- --- DEHUMIDIFY HU - -- 24 VAC COMM HUMIDIFY N/A OUTDOOR SENSOR – CONNECTION O/W2 ESE 0 EN EEII Fig. 42— Single -Stage Furnace with 1 -Speed Air Conditioner THERMIDISTAT HUMIDIFY N/A O/W2 N/A COOL STAGE 1 HEAT STAGE 1 COOL STAGE 1 FAN G=F _ - — 24 VAC HOT - -- DEHUMIDIFY HU - -- 24 VAC COMM 0 —33— FURNACE 1 -SPEED CONTROL AIR CONDITIONER OM O HUM HUMIDIFIER ,; (24VAC) OUTDOOR — — SENSOR See notes 5, 7, and 10 FURNACE 2 -SPEED CONTROL AIR CONDITIONER OM 11 HUM IR B Lid en 0 E3 5LI FIUMIDIFIERI_R (24VAC) O UTDOOR OUTDOOR 1 - - SENSOR SENSOR J CONNECTIO See notes 5, 8, and 10 Fig. 43— Single -Stage Furnace with 2 -Speed Air Conditioner A99435 A99436 • 0 THERMIDISTAT RVS COOLING N/A 1/W HEAT STAGE 2 (FURNACE) HEAT /COOL STAGE 1 (COMPRESSOR) FAN 24 VAC HOT DEHUMIDIFY 24 VAC COMM HEAT /COOL STAGE 1 (COMPRESSOR LO) HEAT STAGE 3 (FURNACE) HEAT /COOL STAGE 2 (COMPRESSOR HI) .Q/W2 HUMIDIFY ® -- HUMIDIFIER I (24 VAC) N/A OUTDOOR SENSOR — CONNECTION THERMIDISTAT RVS COOLING FAN HUMIDIFY N/A 77-- SENSOR i .Q/W2 24 VAC HOT — — — DEHUMIDIFY Fit - -- 24 VAC COMM — FURNACE 1 -SPEED CONTROL HEAT PUMP DHUM` HUM FURNACE CONTROL DHUMI a HUM �- -- J See notes 1, 4, 6, 7, 9, and 10. 2 -SPEED HEAT PUMP 5LI HUMIDIFIERF_Q_ (24VAC) I OUTDOOR OUTD OUTDOOR SENSOR SENSOR CONNECTION Fin- See J notes 1, 2, 3, 4, 6, 8, 9, and 10. Fig. 44— Single -Stage Furnace with 1 -Speed Heat Pump (Dual Fuel) Fig. 45— Single -Stage Furnace with 2 -Speed Heat Pump (Dual Fuel) A99437 A99438 W. N LL; W O J` u. W . Z � H O ': Z CV O N 0 I_ W W Liti W Z 0 z • TWO-STAGE THERMOSTAT The control will shift the blower speed from factory setting of FAN to HEAT speed. Momentarily turning off the FAN switch again at the thermostat will shift the continuous blower speed selection from HEAT to COOL. Repeating the procedure will cause the control to shift from COOL to FAN speed. The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption. V. HEAT PUMP MODE When installed with a heat pump, furnace control automatically changes blower on delay timing sequence to avoid no blower operation time during demand defrost cycles. When W -Y1, W -Y/Y2, W-Y I -G, or W- Y /Y2 -G thermostat inputs are received at the same time at furnace control center, control starts blower in HEAT speed. Then a gas heat mode begins. Blower remains operating at HEAT speed for 15 sec or until end of prepurge period, then blower shuts off until end of ignitor warm up and trial for ignition periods (a total of 24 sec). Blower restarts at HEAT speed. When R -W thermostat call disappears, control completes inducer post -purge period of 15 sec (5 sec if jumper has been cut for 140 size unit in downflow orientation) and changes to cooling speed after a,2 -sec delay. If W-Y I-G or W- Y /Y2 -G thermostat signals should disappear simultaneously, blower remains on for selected heating blower off delay period (90, 135, 180, or 225 sec), and the inducer goes through 15 sec post -purge period (5 sec if jumper has been cut for 140 size unit in downflow orientation). If W -Y1 or W -Y/Y2 thermostat signals should disappear, leaving G thermostat signal, blower remains on in HEAT speed for the selected blower off -dealy period and inducer remains on for 15 sec to complete post -purge period (5 sec if jumper has been cut for 140 size unit in downflow orientation). After the blower off-delay is completed, the control switches the blower to FAN speed. 2 -SPEED FURNACE AIR CONDITIONER CONTROL OR HEAT PUMP Heat Pump only - O . Heath l ump -- y YIY - ZJ — DHUM OM - - -l]HUM • I I_ gLIHUMIDIFIERI_S1 (24VAC) See notes 1, 2, and 9. Fig. 46— Single -Stage Furnace with 2 -Speed Outdoor Unit Notes: 1. Heat pump must have a high pressure switch for dual fuel applications. 2. Refer to out odor equipment Installation Instructions for proper setup. 3. Select the "zone" position on the 2-speed heat pump control, 4. Outdoor air sensor must be attached in all dual fuel applications. 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 2 -speed compressor operation. 9. Configuration Option No. 10 "Dual Fuel Selection" must be tumed ON In all dual fuel applications. 10. No connection should be made to the furnace HUM terminal when using a Thermidistat. A99439 Control initiates a 90 -sec blower only on period before starting another heat pump cycle if there is a power interruption. Anytime control senses false flame, control locks out of heating mode. This reaction occurs because control ignores W input due to false flame signal and, as a result, sees only Y1 and/or Y /Y2 input and goes into cooling mode blower off delay. All other control functions remain in standard format. NOTE: EAC -1 terminal is energized whenever blower operates. HUM terminal is only energized when gas valve is energized. VI. COMPONENT TEST A. Component Test Sequence NOTE: Alt components are functionally operated except the gas valve. When component test is initiated, the following sequence of events occurs: 1. LED flashes a status code 4 times. 2. Inducer motor starts and continues to run for remainder of component test. 3. Hot surface ignitor energized. 4. Main blower operates at FAN speed for 10 sec, then turns off. 5. Main blower operates at HEAT speed for 10 sec, then turns off. 6. Main blower operates at COOL speed for 10 sec, then turns off. 7. Inducer motor stops. Component test can be initiated by one of the following proce- dures. is energized for 15 sec, then de- 1 e B. Initiating Component Test By Removing Main Limit Switch Wire NOTE: NO thermostat signal may be present at control center and all blower time delay off periods must be completed. 1. Leave 115 -v power to furnace turned on. 2. Remove main furnace door. 3. Look into blower access panel sight glass for current LED status. NOTE: Leave blower access panel installed to maintain power to control center to view current LED status. 4. BRIEFLY remove either wire from the main limit switch until the LED goes out, then reconnect it. m CAUTION: Make sure limit switch wire does not con- tact any metallic component such as the gas valve. If wire is shorted, 3 -amp fuse on control center will blow. NOTE: If wire to main limit is disconnected longer than 4 sec, the control senses limit circuit is open. Main blower will start and status retrieval request will be ignored. 5. When above items have been completed, the component test sequence will occur as described in the Component Test Sequence section above. NOTE: Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting. 6. After component test is completed and LED is ON continu- ously indicating the furnace is ready to operate when a signal from the thermostat is received, replace main furnace door. C. Initiating Component Test By Jumpering Control TEST Terminal 1. Remove main furnace door. 2. Remove blower access panel. 3. Manually close blower access panel door switch. Use a piece of tape to hold switch closed. WARNING: Blower access panel door switch opens 115 -v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death. 4. BRIEFLY short (jumper) TEST, 3 /16 -in. quick- connect terminal on control center (behind the Y/Y2 terminal) and the CoM terminal on thermostat connection block. (See Fig. 25.) NOTE: If TEST to CoM terminals are jumpered longer than 2 sec, LED will flash rapidly, and retrieval request will be ignored. 5. When above items have been completed, the component test, sequence will occur as described in the Component Test Sequence section above. NOTE: Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting. 6. After component test is completed and furnace is operating properly, release blower access panel door switch, replace blower access panel, and replace main furnace door. START -UP PROCEDURES I. GENERAL 1. Furnace must have a I15 -v power supply properly con- nected and grounded. Proper polarity must be maintained for correct operation. —36— NOTE: Proper polarity must be maintained for 115 -v wiring. If polarity is incorrect, control center LED status indicator light will flash rapidly and furnace will not operate. 2. Thermostat wire connections at terminals R, W, G, YI and Y/Y2 must be made at 24 -v terminal block on control center. 3. Natural gas service pressure must not exceed 0.5 psig (14 -in. wc), but must be no less than 0.16 psig (4.5 -in. wc). 4. Blower access panel must be in place to complete 24-v electrical circuit to furnace. CAUTION: These furnaces are equipped with a manual reset limit switch in burner box. This switch will open if an overheat condition (rollout) occurs in bumer enclo- sure. Correct inadequate combustion -air supply or im- proper venting condition and reset switch. DO NOT jumper this switch. Before operating furnace, check each manual reset switch for continuity. If necessary, press button to reset switch. II. PRIME CONDENSATE TRAP WITH WATER m CAUTION: Condensate trap must be PRIMED or proper draining may not occur. The condensate trap has 2 internal chambers which can ONLY be primed by pour- ing water into the inducer drain side of condensate trap. 1. Remove upper inducer housing drain connection cap. (See Fig. 47.) 2. Connect field- supplied I /2 -in. ID tube to upper inducer housing drain connection. 3. Insert field- supplied funnel into tube. 4. Pour I quart of water into funnel /tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 48.) 5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp. III. PURGE GAS LINES If not previously done, purge lines after all connections have been made and check for leaks. WARNING: Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap- and -water solution to check for leakage. Failure to follow this warning could result in fire, explosion, per- sonal injury, or death. IV. ADJUSTMENTS A. Set Gas Input Rate Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. In the U.S.A., the input ratings for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level. In Canada, the input ratings must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level. Furnace input rate must be within ±2 percent of input on fumace rating plate adjusted for altitude. 1. Determine natural gas orifice size and manifold pressure for correct input. • A99118 Fig. 47— Inducer Housing Drain Tube a. Obtain average yearly heat value (at installed altitude) from local gas supplier. b. Obtain average yearly specific gravity from local gas supplier. c. Verify furnace model and size. Table 8 can only be used for model 350MAV furnaces with heating sizes of 040 through 120. Table 9 can only be used for model 350MAV furnaces with a 140 heating size. d. Find installation altitude in Table 8 or 9. NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 8 or 9. e. Find closest natural gas heat value and specific gravity on Table 8 or 9. f. Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation. EXAMPLE: (0 -2000 ft altitude using Table 8) Heating value = 1050 Btu/cu ft Specific gravity = 0.62 Th6refore: Orifice No. 45 Manifold pressure 3.6 -in. wc * Furnace is shipped with No. 45 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate. Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY. 2. Adjust manifold pressure to obtain input rate. NOTE: Manifold pressure must always be measured with burner enclosure front REMOVED. Gas meter must always be clocked with burner enclosure front INSTALLED. —37— A99119 Fig. 48—Filling Condensate Trap a. Remove burner enclosure front. b. Remove cap that conceals adjustment screw for gas valve regulator. (See Fig. 49.) c. Turn adjusting screw, counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure. NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft. For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc. m CAUTION: DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overtire and heat exchanger failures. NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr -free and squarely aligned orifice hole is essential for proper flame characteristics. d. Replace gas valve regulator adjustment screw cap. e. Replace burner enclosure front and verify adjusted gas input rate using method outlined in item 3. f. Look through sight glass in burner enclosure and check burner flame. Burner flame should be clear blue, almost transparent. (See Fig. 50.) 3. Verify natural gas input rate by clocking gas meter. NOTE: Be sure all pressure tubing, combustion -air and vent pipes, and burner enclosure front are in place when checking input by clocking gas meter. ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT IE T) SPECIFIC GRAVITY OF NATURAL. GAS 0.58 0.60 0.62 0.64 0.66 Orifice No Id ire Orifice No Id re Orifice No Id re Orifice No. d -e Orifice No. Manifold Pressure U.S.A. and Canada 0 to 2000 925 975 1025 1075 1100 43 43 44 44 44 44 r t o n 1n N CO CO co CO CO r) 43 43 43 44 44 44 CD CO v h CO CO ri ri ri ri ri ri 42 43 43 44 44 44 44 N A CO CD CO N II I ri ri ri ri ri ri ri'. 42 43 43 43 44 44 44 44 r) m CD V n IA v CO CO r) CO CO CO CO CO 42 42 43 43 44 44 44 44 N 1p CO CD In CO Cc) 0; co CO CO r)r) 45 45 45 45 3.7 3.5 3.3 3.2 45 45 45 45 3.8 3.6 3.4 3.3 45 45 45 45 3.7 3.6 3.4 3.2 45 45 45 3.7 3.5 3.4 45 45 45 3.8 3.6 3.5 47 3.6 47 3.7 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE AT FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. and Canada I U.S.A. Altitudes 2001 to 4000 or Canada Altitudes 2000 to 4500 775 800 825 850 875 900 925 950 975 1000 1025 43 43 44 44 44 44 CD tC) (D R 42 43 43 44 44 44 W W W W W W 01 V A V N 42 43 43 44 44 44 44 r) E D (D tb (D . N r) CO CO ri ri r) ri 42 42 43 43 44 44 44 • N n 1D h tD M in r) co eo r) r) ri 42 42 43 43 43 44 44 44 to r) OD (D Q CD v. (1 r) co r) r) cn r) r) 45 45 45 45 45 h 1H r) r CI r) r) r) O r) 45 45 45 45 45 CD (D N r r) r) r) r) C9 45 45 45 45 3.7 3.5 3.4 3.2 45 45 45 45 3.8 3.6 3.5 3.3 45 45 45 3.8 3.6 3.4 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure iwo ros•n 3001 to 4000 750 775 800 825 850 875 900 925 950 975 1000 43 43 44 44 44 W W W W W to) i .1 43 43 43 44 44 44 w W (4 C W W N ? m A in in 42 43 43 44 44 44 W W W W W W U1 CO ()1 V W 42 43 43 43 44 44 44 R m (D n 1D rl r) r) r) (o r) C (7 42 42 43 43 44 44 44 44 LO N r LO m (D a M C7 r) r) r) ri (, r) 45 45 45 45 45 45 aD f N W VI r) r) ri r) N 45 45 45 45 45 h h () N O C7 r) r) 01 ri 45 45 45 45 45 CD CO V. r) r 45 45 45 45 3.7 3.5 3.4 3.2 45 45 45 3.7 3.5 3.3 TAI 8-MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) 'Orifice numbers shown in BOLD are factory Installed. -38- ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE - U CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure IIuo .v.s.n 4001 to 5000 25 50 75 800 25 850 75 900 25 950 43 43 44 44 44 Q rs O N ri CO N r) 43 43 44 44 44 CO u) CO CO Q M M M M 42 43 43 44 44 44 N n Q n V7 r) C) (O (7 r) r) r) 42 43 43 44 44 44 44 VI CO 11 CO (O Q N C ) C ri r) r) r) r7 42 42 43 43 44 44 44 • N (• 1f7 ri r) r) ri r) ri ri 45 45 45 45 45 ). h r) r O () r) in in Al 45 45 45 45 45 CO (D V N r r)( VI el 45 45 45 45 3.7 3.5 3.3 3.2 45 45 45 3.6 3.4 3.3 45 45 45 3.8 3.6 3.4 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTUICU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. Only 5001 to 6000 700 725 750 775 800 825 850 875 900 925 950 975 1000 43 43 44 44 44 CD Q (O Q N VI r) C C) C) 43 43 44 44 44 A.- u) ('s u) c ri r) ri r) r) 42 43 43 44 44 44 N (O (O N ('7 r) r) r) r) (o 42 43 43 44 44 44 n (n (s (n co VI r) r) Cl r) r) 42 43 43 43 44 44 44 • Q CO CO V CO .1 N ri r) r) 45 45 45 45 45 45 45 45 W ' N O O/ I. (O u) PI CI PI r) N N N N 45 45 45 45 45 45 45 45 A N el r 0 aD H N r) r) rf ri N N N 45 45 45 45 45 45 45 m V /7 r W m (D (o (7 (o rl N N N 45 45 45 45 45 45 45 al V (I O O) A VA r) () r/ rl N N 45 45 45 45 45 45 N W W W W CO CO - W N V ALTITUDE RANGE (Fn AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure ^luo •Y s.n 6001 to 7000 650 675 700 725 750 775 800 825 850 875 _ 42 43 44 44 44 N (D m (O r) C7 r) M r) r) 42 43 43 44 44 44 1s Q n Q N r) r) r) r) r) r) 42 43 43 44 44 44 Q CO u? c7 r) in C) CM ri 42 42 43 43 44 44 44 Li? N n Q h N r) cM M ri r) r) 42 42 43 43 44 44 44 CO r) CO U) COU) r) r) ri ri ri r) ri 45 45 45 45 45 m h M r O p) ri r) (7 r) 45 45 45 45 3.7 3.4 3.2 3.1 45 45 45 45 3.8 3.6 3.4 3.2 45 45 45 3.7 3.5 3.3 45 45 45 3.8 3.6 3.4 TABL )EL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (Continued) FOR E WITH 040 THROUGH 120 SIZE FURNACES ONLY (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL 'Orifice numbers shown In BOLD are factory installed. -39- tiu.:i'f.'�. <ll Ow.uii:t'.uiti'i . ✓ �vh t.. ♦, ... )- i•SUw1: W.1:4.f.J:IL1.tL,Yb'3.1.wGuA. ` %'K ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE T) SPECIFIC GRAVITY NATURAL GAS 0.66 Or Orifice No. Manifold Pressure Orifice No. old Pressure Or Orifice No. Manifold Pressure Orifice No. ,Id Pressure Orifice No. Manifold Pressure Auo •v s'n 7001 to 8000 700 725 750 775 800 825 850 43 43 44 44 44 n u) co to co ri ri ri ri ri 42 43 43 44 44 cq P v CO v C6 CO 6 6 ri 42 43 43 44 44 44 vnamtnM ri CO CO CO CO CO 42 42 43 43 44 44 to CV CO v CD a ri of CO ri ri ri 42 42 43 43 44 44 44 CD CO n to i. L CiC)(') Cd CO CO Ci 45 45 45 45 45 A n r) — W ri riri6N 45 45 45 45 45 CO CD a N O ri ri ri ri ri 45 45 45 45 n lnel ri ri ri ri 45 45 45 45 3.8 3.6 3.4 3.2 45 45 45 3.7 3.5 3.3 ALTITUDE RANGE (Fn AVG GAS HEAT VALUE ALTITUDE AT TUDE AT LTI ( FT ) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure 1 1 Au° Vs'n 8001 to 9000 600 625 850 675 700 725 750 775 800 43 43 44 44 44 co N I` u7 N r) r) r) r) r) 42 43 43 44 44 M CD tT CD CO CO CO r) r) 42 43 43 44 44 44 ✓ In N It. N CO CO CO CO r) CO 42 42 43 44 44 44 WI N CD aD tD M CO CO CO CO CO CO 42 42 43 43 44 44 44 W CJ W W W (J W IJ A V A V W co 45 45 45 45 3.6 3.4 3.2 3.0 45 45 45 45 CD 'ft r) r) CO ri ri 45 45 45 3.6 3.4 3.2 45 45 45 3.8 3.5 3.3 45 45 3.6 3.4 ALTITUDE RANGE (Fn AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure 1 Aiuo v s•n 9001 to 10,000 575 600 625 650 675 700 725 750 775 43 43 44 44 3.8 3.5 3.7 3.4 _ 42 43 44 44 44 N CO lb to r) ri CO CO ri CO 42 43 43 44 44 • httlh ri tri ri r) ri 42 42 43 44 44 44 In N CD CO N M ri 0) ri ri ri r 42 42 43 43 44 44 CD CO I+ v t0 v CO CO CO ri ri r i 45 45 45 45 45 • to CO ri CO CO 01 45 45 45 45 3.7 3.4 3.2 3.0 45 45 45 45 3.8 3.6 3.3 3.1 45 45 45 3.7 3.4 3.2 45 45 45 3.8 3.5 3.3 TABLE 8 -MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (Continued) FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERAT R EACH 1000 FT ABOVE SEA LEVEL) *Orifice numbers shown In BOLD are factory Installed. -40- Yr 4:1 f .;' r.::: ra;!; u;r,Kiv.++.:no-i +yv,e,:.y,.s.:.. N..., ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTUICU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.80 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure I U.S.A. and Canada 0 to 2000 850 875 10 sn 950 975 1000 1025 1050 1075 1100 42 42 42 42 c? CO N V N C7 C) C7 r) CO 41 42 42 42 al n al fh r) 1 r) r) C7 41 42 42 42 42 CD (O OD CO V' N r) r) r) r) r) r) 41 41 42 42 42 42 CO h CO h tD C7 N (7 r) r) (7 (7 r) r) 40 41 41 42 42 42 42 CO CO CO CO CO N • r) e'7 C7 ri C7 r) 43 43 43 43 3.7 3.5 3.3 3.2 43 43 43 43 3.8 3.6 3.4 3.3 43 43 43 43 3.7 3.6 3.4 3.2 43 43 43 43 3.7 3.5 3.3 3.2 43 43 43 43 3.8 3.6 3.4 3.3 44 44 3.5 3.3 44 44 3.6 3.4 44 3.5 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure I U.S.A. and Canada U.S.A. Altitudes 2001 to 3000 ' or Canada Altitudes 2001 to 4500 775 800 825 850 875 900 925 950 975 1000 1025 41 42 42 42 42 ts CO CD N CO CO r) CO CO 41 41 42 42 42 CD 40 41 41 42 42 42 CO f` c0 CO N r) r) cn c•) ri ri 40 41 41 42 42 42 42 f` CO CO n CD N PI r) C. r) r) r) r) 39 40 41 41 42 42 42 CO CO ti LO CD Ch r) ri r) r) Oi r) r) 43 43 43 43 43 43 W W W W W CO G W V1 V 43 43 43 43 43 43 m m a el r a) ✓ e ) ) r r) rf CV 43 43 43 43 43 W W W C•) W 0 N A 41 V 43 43 43 43 A O M r ri VI ri r) 43 43 43 - 43 3.8 3.6 3.4 3.2 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 . 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure AIup yg•n 3001 to 4000 750 775 800 825 850 875 900 925 950 975 1000 41 42 42 42 3.6 3.8 3.5 3.3 41 41 42 42 42 CO CO t` N VI r) C) ri ri 40 41 42 42 42 42 CO CD aD tD 7 N C r) r) c+) r) r) 40 41 41 42 42 42 h 1 LO t• in r) r) r) r) ri ri 40 40 41 42 42 42 42 CO CO W CO CD N ri ri r) vi r) r) r) 43 43 43 43 43 43 43 Ca c0 N r a) Ca ri ri C°) C7 CV N 43 43 43 43 43 43 A Ct) C) N O a) Col ri rf r) r1 CV 43 43 43 43 43 t0 N M r 0 r) ri ri ri ri 43 43 43 43 43 Ca CO O N O M M ri ri ri 43 43 43 43 3.7 3.5 3.3 3.1 TABLE 9-MODEL 340MAV ORIFICE D MANIFOLD PRESSURE FOR CORRECT INPUT FOR USE WITH 140 SIZE FURNACES ONLY (TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) 'Orifice numbers shown in BOLD are factory Installed. -41- ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTUICU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure ANO •V•s•n 4001 to 5000 725 750 775 800 82s 850 875 900 925 950 41 42 42 42 3.6 3.7 3.5 3.3 41 42 42 42 42 f• CO CD Nr N M C) M C7 () 41 41 42 42 42 CO CO CO C.) 40 41 42 42 42 42 CD n CD CD Q N C'7 CO M c) C ) C+) 40 41 41 42 42 42 CO CO CO n in M C7 C'7 C�) c •) C'7 01 ' 43 43 43 43 43 43 N CO r O CO C7 P) C7 Ch C'7 43 43 43 43 43 CO C7 r CA in C C7 C7 CV 43 43 43 43 43 ' N O N) en C) r) e ? g! l 43 43 43 43 1. in r r M C'.) Ch C 43 43 43 43 3.8 3.6 3.4 3.2 ALT ITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Aluo vs•n 5001 'to 6000 700 725 750 775 800 825 850 875 900 925 950 975 1000 41 42 42 42 3.5 3.7 3.4 3.2 41 42 42 42 3.7 3.8 3.5 3.3 41 41 42 42 42 O CD n N C7 C) C7 M el 40 41 42 42 42 co co CO CD CO M C C+) C7 40 41 41 42 42 42 C.- CO N n 43 43 43 43 43 43 43 43 43 A N C'O r O) A (O N CO N C+) N C) N N CV N N 43 43 43 43 43 43 43 43 43 O CO N O CD 1% CO a r) M C! C l+7 C4 CV N C V 43 43 43 43 43 43 43 43 f• N C'7 r O) m (D lA C9 Ci C7 cn CV CV (V CV 43 43 43 43 43 43 43 43 CD (G N go? ti Co in C7 M CV N CV 43 43 43 43 43 43 43 Is ID CO r O r! P) C+) C7 N CV ALTITUDE RANGE (Fn AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT ( ) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Iwo •vs•n 6001 to 7000 650 675 700 725 750 775 800 825 850 875 41 41 42 42 3.8 3.5 3.6 3.4 40 41 42 42 42 W w 4) (71 ■I O) O) 40 41 41 42 42 r ID CD d' cn Ch Ch CI Ch 40 40 41 42 42 42 CO CD CD P lD CO M Ch C'7 C7 C+) C+) 39 40 41 42 42 42 n !• A CD CD 01 M M M C7 07 43 43 43 43 43 43 CO CO O N O CO O) Ch 0) 4) Cr) CH 43 43 43 43 43 1 H 0) r O) to l+) ei N) CV 43 43 43 43 43 co to a N O ri O) C7 /7 C7 43 43 43 43 1. H r) r P) 0 P) N) 43 43 43 43 3.8 3.6 3.4 3.2 TABLE 9-MODEL 340MAV ORIFICE SIZE AND FOLD PRESSURE FOR CORRECT INPUT (Continued) FOR USE WITH 140 SIZE FURNACES ONLY (TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) Orifice numbers shown In BOLO are factory installed. -42- :L'4;d:t. n:�.?i K��.'.'i ?;�:' sin' k v= r, v: ti::; fk' iMnF!:. Sa3: 4:' r' A;' rif" ai�YbG`: �;. v" i.�;:t "w.i�:';� @.r;k;l�t�;:� "� .•�i:a:�2 %�'4.i,1 <3� ALTITUDE (FT) % OF DERATE DERATE MULTIPLIER FACTOR FOR U.S.A.• 0-2000 0 1.00 2001 -3000 4-6 0.95 3001 - 4000 6-8 0.93 4001 - 5000 8-10 0.91 5001 -6000 10-12 0.89 6001 -7000 12 -14 0.87 7001 -8000 14-16 0.85 8001 -9000 16-18 0.83 9001 - 10,000 18-20 0.81 INLET PRESSURE TAP ON AND OFF SWITCH MANIFOLD PRESSURE TAP Fig. 49 Redundant Automatic Gas Valve BURNER ORIFICE Fig. 50 Burner Flame GAS PRESSURE REGULATOR ADJUSTMENT BURNER ENCLOSURE REFERENCE PRESSURE TAP CAUTION: DO NOT redrill orifices. Improper drilling (burrs, out -of -round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of burners and heat exchang- ers causing failures. A95622 A93059 —43— a. Calculate high- altitude adjustment (if required). UNITED STATES At altitudes above 2000 ft, this furnace has been ap- proved for a 2% derate for each 1000 ft above sea level. See Table 10 for derate multiplier factor. TABLE 10— ALTITUDE DERATE MULTIPLIER FOR U.S.A. Derate multiplier factor Is based on midpoint altitude for altitude range. EXAMPLE: 100,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT. Furnace Input Rate x at Sea Level Derate Multiplier = Factor Furnace Input Rate at Installation Altitude 100,000 X 0.91 = 91,000 CANADA At installation altitudes from 2000 to 4500 ft, this furnace must be Berated 5% by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.95 as derate multiplier factor. b. Turn off all other gas appliances and pilots. c. Start furnace and let operate for 3 minutes. d. Measure time (in sec) for gas meter test dial to complete 1 revolution. e. Refer to Table 11 for cu ft of gas per hr. f. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using natural gas heating value from local gas utility/supplier. EXAMPLE: (0 -2000 11 altitude) Furnace input from rating plate is 100,000 Btuh. Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for 1 revolution of 2 -cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 11) Btu heating input = 103 X 975 = 100,425 Btuh In this example, the orifice size and manifold pressure adjustment is within t2 percent of the furnace input rate. B. Set Temperature Rise CAUTION: Temperature rise must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or above. Failure to follow this caution may result in condensing or overheating the heat ex- changers. Determine and adjust air temperature rise as follows: A89020 1. Place thermometers in return and supply ducts as close to furnace as possible. 13e sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight -run ducts. R..uw1id SECONDS FOR 1 REVOLUTION SIZE OF TES, DIAL SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL 1 cu ft 2 cu ft 5 cu ft 1 cu 8 2 cu ft 5 cu ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 120 300 21 171 343 857 62 116 290 22 164 327 818 64 112 281 23 157 313 783 68 109 273 24 150 300 750 68 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 225 31 116 232 581 82 220 32 113 225 563 84 c) CD 214 33 109 218 545 86 209 34 106 212 529 88 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 98 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 180 41 88 176 439 102 178 42 86 172 429 104 In m 173 43 84 167 419 108 170 44 82 164 409 108 167 45 160 400 110 33 (0 (0 I 164 48 157 391 112 32 161 47 153 383 118 31 155 48 49 150 147 375 367 120 30 150 COLOR SPEED FACTORY - SHIPPED CONNECTION Black High Cool Yellow (When Present) Medium High Spare Blue Medium Low Heat Red Low Fan White Common L2 DESIRED HEATING MODE BLOWER OFF DELAY (SEC) JUMPER POSITION 90 1 -2 135 2 -3 180 3-4 225 4 -5 , TABLE 11 RATE (CU FTIHR) 2. When thermometer readings stabilize, subtract return-air temperature from supply -air temperature to determine air temperature rise. 3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. WARNING: Disconnect 115 -v electrical power before changing speed tap. Failure to follow this warning could result in personal injury. 4. To change blower motor speed selections for heating mode, remove blower motor lead from control center HEAT terminal. (See Fig. 25.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to HEAT terminal. See Table 12 for lead color identification. Recon- nect original lead on SPARE terminal. Follow this same procedure for proper selection of COOL speed selection. t :.lpgw TABLE 12 —SPEED SELECTOR —44— C. Adjust Blower Off Delay (Heat Mode) If desired, the main blower off time delay period may be lengthened or shortened when operating in the heating mode to provide greater comfort. Position shunt jumpers as shown in Table 13 and Fig. 25 for location of switches on control center. TABLE 13— BLOWER OFF DELAY JUMPER POSITION D. Set Thermostat Heat Anticipator Thermostat heat anticipator must be set to match amp draw of components in R -W circuit. Accurate amp draw measurements can be obtained at thermostat subbase terminals R and W. Fig. 51 illustrates an easy method of obtaining these measure- ments. Amp reading should be taken after blower motor has started. See thermostat manufacturer's instructions for adjusting heat anticipator and for varying heating cycle length. THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED G� ©w HOOK- AROUND VOLT /AMMETER 10 TURNS FROM UNIT 24 -VOLT TERMINAL BLOCK EXAMPLE: 5.0 AMPS ON AMMETER - 0.5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS A80201 Fig. 51 —Amp Draw Check with Ammeter CHECK SAFETY CONTROLS I. CHECK PRIMARY LIMIT CONTROL This control shuts off combustion control system and energizes air - circulating blower motor if furnace overheats. Recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes. As soon as limit control has shut off burners, return -air opening should be unblocked to permit normal air circulation. By using this method to check limit control, it can be established that limit is functioning properly and operates if there is a restricted retum -air supply or motor failure. If limit control does not function during this test, cause must be determined and corrected. 11. CHECK PRESSURE SWITCH This control proves operation of draft inducer. Check switch operation as follows: 1. Turn off 115 -v power to furnace. 2. Remove main furnace door and disconnect inducer motor lead wires from wire harness. 3. Turn on 115 -v power to furnace. 4. Set thermostat to call for heat and wait 1 minute. When pressure switch is functioning properly, hot surface ignitor should NOT glow, and control center diagnostic light flashes a Status Code 31. If hot surface ignitor glows when inducer motor is disconnected, shut furnace down immedi- ately. Determine reason pressure switch did not function properly and correct condition. 5. Turn off 115 -v power to furnace. 6. Reconnect inducer motor leads, reinstall main fumace door, and turn on 115 -v power supply. CHECKLIST 1. Put away tools and instruments. Clean up debris. 2. Verify manual reset switch has continuity. 3. Verify that blower and control access doors are properly installed. 4. Cycle test furnace with room thermostat. 5. Check operation of accessories per manufacturer's instruc- tions. 6. Review User's Guide with owner. 7. Leave literature packet near furnace. CHECKLIST — INSTALLATION LOAD CALCULATION Heating Load (Btuh) Cooling Load (Btuh) Furnace Model Selection AIR FOR COMBUSTION AND VENTILATION Unconfined Space Confined Space VENTING NFGC (United States) NSCNGPIC (Canada) Local Codes 1 /4 -in. Upward Slope Joints Secure See Attached Vent Table Instructions CHECKLIST — START -UP Gas Input Rate (Set Within 2 percent of Rating Plate) Temperature Rise Adjusted Thermostat Anticipator Setting Adjusted or Thermostat Cycle Rate (3 cycles per Hr) CHECK SAFETY CONTROLS OPERATION Primary Limit Pressure Switches Draft Safeguard Switch SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All indude video and/or slides, plus companion book. Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog. CALL FOR FREE CATALOG 1-800-962-9212 [ ] Packaged Service Training [ ] Classroom Service Training A94328 A • C 2000 Bryant Heating 8 Cooling Systems 7310 W. Morris St. Indianapolis. IN 40231 _48- Printed in U.S.A. 350m4011 Catalog No. 5335 -006 LICENSE DETAIL INFORMATION Form STATE OF WASHINGTON DEPARTMENT OF LABOR AND INDUSTRIES Specialty Compliance Services Division P. O. Box 44000 Olympia, WA 98504 -4000 THE RESULT OF YOUR INQUIRY FOR LICENSE NUMBER SELECTED IS: Page 1 of 1 It Name WASHINGTON ENERGY SERVICES CO N u- Address 2800 THORNDYKE AVE W 111 O Address ix :3 City SEATTLE N State WA w; Zip 981992997 Phone Number 2062824700 l ~' ▪ w' Effective Date 2/16/01 ▪ 0 Expiration Date 2/16/02 0 � Registration Status ACTIVE w w' Type CONSTRUCTION CONTRACTOR O • z Entity CORPORATION v cn;; Specialty Code GENERAL p Other Specialties UBI Number 602022820 * * * * LICENSE DETAIL INFORMATION Current Filter: None Registration# or License WASHIES990CW *VIEW PRINCIPAL OWNER(S) FOR THIS LICENSE* * * *VIEW CONTRACTOR BOND /SAVINGS INFORMATION * ** * * *CHECK INQUIRY FOR SUMMONS AND COMPLAINTS* * * * * *VIEW CONTRACTOR INSURANCE INFORMATION * * * New inquiry by CITY, NAME, PRINCIPAL OWNER NAME, NUMBER, UBI NUMBER or return to the L &I Construction Compliance Home Page https://wws2.wa.gov/Ini/bbip/TF2Form.asp?License=WASHIES990CW 6/20/01