HomeMy WebLinkAboutPermit M01-109 - MELLICK JANEENCity of Tukwila
Permit No: MO1 -109
Type: B -MECH
Category: RES
Address: 4802 S 150 ST
Location: 4802 S 150 ST
Parcel #: 004200 -0215
Contractor License No:
MECHANICAL PERMIT
TENANT JANEEN MELLICK
4802 S 150 ST, TUKWILA WA
OWNER DOYLE JOHN & PAMELA
4802 S 150TH ST, SEATTLE WA 98188
CONTACT CANDICE GALLAAGHER
2800 THORNDYKE AV W, SEATLLE 98199
INSTALLNEW 60,000 GAS FURNACE AND NEW GAS FIREPLAC
E INSERT.
Phone:
(206) 431 -3670
Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188
Status: ISSUED
Issued: 06/18/2001
Expires: 12/15/2001
Phone: 206 -378 -6680
************************************* ****: k**** * ** * * * * * ** * *** * * * *•k * ** * * **k **
Permit Description:
UMC Edition: 1997 Valuation: 5,000.00
Total Permit Fee: 61.19
• k*****'*********'*********** * ** * * * * ** * * *, * ** * * * * * * * * * * * * * **
t Center ;A ho i zeal S i gnatur Date.
ereby certify th -t •I have: -:read and examined this permit and know the
same ti%- ,`_be .true and co.rrect..: All provisions of law and' ordinances
;,
governing th'is!.work willbe .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 state or local laws regulating
construction or the performance of work. I am authorized to sign for and
obtain this building permi
t i Cam_
Date: Lp 1 E 1 0-(
.:. � . r
C� Tit1e: -
This permit shall:.)e'c_ome null and void if•the work is not commenced within
180 -days from the date ..of issuance, or if the work As suspended or
.abandoned for a period. of 180..days from the last. inspection.
Project Name/Tenant: �
m " d t C
Value of M Equipment:
Site Address : 3
_IK_.
"`�j11 + !
Tax_ P�arF� er js
Property Owner:
>)on
i: CY
Phone: (Xi& )
au a- -ia3(i
Street Address: N
City State/Zip:
Fax #: ( )
Contractor: t( ,,,.
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Phone: (o) Z) i (---
Street Addres CID
6 Avi GO ` ��y �
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Fax #: ( )
Contact .Person:
Phone: ( Q
Street Address:
v - - " ` City State/Zip:
Fax #: ( )
{ B' - g IL`I SIG OWNER "O `' UTHORIZEI AGENP :. " „ f . 1 a ei, (: • :
, .. ; r 1 ; .. ... t
• Signature: // CI Q r -- t ( — .
Date:
I ( �
Print name: • 0 ( 1 d6C V
7
Phone: ( p�9 - M43
Fax #: ( )
Address: t
City/State/Zip:
Mechanical Permit Application
.11/'/99
mach permif.duc
CITY OF T KWILA
Permit Center
6300 Southcenter Boulevard, Suite 100
Tukwila, WA 98188
(206) 431 -3670
STAFF USE ONLY
Project Number.
Permit (Number.
Application and plans must be complete in order to be accepted for plan review.
Applications will not be accepted through the mail or facsimile.
MECHANICAL. PERMIT; REVIEW AND APPROVAL REQUE :'(TO RE FILLED;OUT'BY:APPLICANT)
Description of work to be done (please be specific):
NA.° DECD t rQ�F1-
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 I 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 appl 'on accepted:
— ls
Date application expires:
1=
Application taken by: (initials)
4 -4
✓
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
ESIDENTIAL: Two complete sets of attachments required with application submittal
11/2/99
nilscpnil.doc
Submittal Requirements
New Single Family Residence
Heat loss calculations or Form H -6.
Equipment specifications.
Change - out or replacement of existing mechanical equipment
Narrative of work to be done, including modification to duct work.
a. ;1 . % fGarFiceplace
, � y t
Ric -an xhi
t tS % wi gq mne
7.� @ N ia' 4x '''0" �r. 1 w
�
ne ; p a le ter 40 cer„tiliednc .imney s
....
•
tating thatu ex mne
E.'•, �Y: i? 'FP..?'?'.y.,YV.n :n >.. YTM.ys'+�
r, w tia'k?i- ^g44g4=1 :.:t'L'�L: .k:� i1';:w.w :;75: r; £c 7, 4: , sn - wr.. v jJ
ME: Water heaters and vents are included in the Uniform Mechanical Code — please include any water
heaters or vents being installed or replaced.
NOTE: Water heaters and vents are included in the Uniform Mechanical Code — please include any water
heaters or vents being installed or replaced.
CITY OF TUK:WILIA
A ddress: 4102 S 15 ST Fermi t No: M01-109
S uit e
Tenant: JANEEN MELLICF: Status: ; ISSUED
Type: 8 -MECH Applied: 06/18/2001
arcel . #: 004200 -0215 Issued: 06/18/2001
•k : •k A •k •k •k ;k •k •k •k 'k •k •k •k ' :k •k k 'k k •k •k k ' k * k •k k k •k k •k •k •k •k * 'k k k k •k ' k ' k •k •k 'k ;4 k •N •k ' k •k 4 •k • • 4 • •k • k k •k •k •k •k •k •k •k k k 4 k •4 k k `4 :4
'Permit Conditions:
No changes will be made to the plans unless approved by the
Engineer and the : Tukwila:= Bui"ldina Division.
A1:1 :permi ts. ;inspect Son re,cords`. ''anii•' ' plans sha I I be
aVai'lableat the Job.,site prior.. -t,e the start. " of . con -
struction Thes e : documents , "re t he ma inta•ined and -
avai. -
•abi;e "until : final inspection is. granted
A ll: constr uc;i to,: be "done in conformance with approved
plan.' and reauIremerits of the Uniform Buil i no Code {1997
Edit ion as ' amen ie;d + Uniform Mechanical Gode (1997''Ed i t i on) T ,.
and =Was i ngton State Energy Code i 1997 Edition )
ValIdit�j of. •:Permit Tiya issuance of a permit, or apprrova
pec;it.ica and;camputL tionr shall not be • con
qtr ued 't.o be: a pe'rmizt for or an " "approva I of, an y ci ',,vio:latio
• of; on :.of. °'.the r ovi iti "ns,_..of.: the building code or�f, any 1
o ti e t he: iuris 6tion. No permit: presuhmi .to
+give a"uthori:tv .v:iolate or :;cancel; the Druvis ions of `this:
codeJ shal l tbe valid . •
Manufacturers 'irista1lation i,nst•ru,cti.ons required on site •
foritt bui`ldi,ng inspector .:rev
hereb
y : c.er t i f v 'that I. have read the ne C o n d i t i o n s and will comp l y
ith `.:therl a out'l. ined. All provis,ion; of.. law and ordinances govern
h iw;. :work w31 be`: ,compl_i ed with , Z
„`wheth+r _.ueu. " it ie'ci herein or not
he ranti'`rlg cif thi `permit • does not pr esume to ,give a u,,thority t
lolate or `cancel. t'he •provisions of •arty, other. .work ''l
or.ocal;`1 ''aws.'
egg l at ing co`nstruct;i ors "or the performance of work
nat 6re.:
i
■
l :.
•A *k* *A ***c * * *A **4•t ** 1*•k :Pe+ .1*44* t ** ** ** ** *h•k•* *at•A ** 4t. ***4t14 tic ** t 1/4.tli*0
i;Y OF TUKWI'LA SSA.; TR WSMfl'
k'4s4A4* * ** •4** * ' ** A`*A *4 kk**** il• k, t*:%** k * **.4 * *A•k•A **A* *.1 *I **
R'F1+ :I Number;. .R0100781 ',Amount: 61.19 06/18/01 10;21.
Paament Method: CHECK No .t WDF ItiCOIII'0RATED 'nit: J'Il?.
P6r.tiiyt „:No ..MO1 1(9 Tv I1LCHANIGAL PE12I1IT
PEtrcel:: N`a .004200 021
e: A,dd00 o 4)30 a', 1.at?. S.T:
Location: 4802 8 15:0 5T:
,
fetal reps 61.1' •
'Pkvment :•:. :Tota,1 ALL Pints a : 61.19_
Balance; .00
It ? *k.* *cy t h•* :h. 14: :dt * If •k I .,: k Ir
*•**istit'tl , * k **•k4c t�t.''
*44c*IrA.i *is•k,*11I *• A' *A*:k iM
I**c 4fir . I4c*
A ccou,n t G. Des -i ' ' p t : 1 on f rnoun
- :0 00/3.�
4 .8n0 PLAN 'CHECK RES 12.24'
0 00/322.100 MECHA.NI.CAL IiES 48..
Project: ,A CAI CC '
Type of Inspection:
Address:
4$02 — � l c5 -I
Date called:
Special instructions:
�Vi1 k ey tit
C DUK'y 1 imiCV4
Date wa ted: / j
i
p.m. a.m.
Requester:
R equester:
Phone:
INSPECTION NO.
Approved per applicable codes.
INSPECTION RECORD MO (-1 OGj
Retain a copy with permit I "' �t
CITY OF TUKWILA BUILDING DIVISION
6300 Southcenter Blvd, #100, Tukwila, WA 98188
PERMIT NO.
(206)431 -3670
Corrections required prior to approval.
COMMENTS:
r(.c Sol
Gt
/Ville /leo
th -/riJf d 1 �I
(od coo l4-1
AA FYI at/,
6cttl ic
W . �S
Gt V �, Ii
� � �S 64 2 - 7/ /S /
Inspector:
Date:
El $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:
L !y1i
Installation, Start -Up, 350MAV
and Operating Instructions Series E &F
DELUXE 4 WAY MULTIPOISE
FIXED - CAPACITY DIRECT -VENT
CONDENSING GAS FURNACE
I
A93040
NOTE: Read the entire instruction manual before starting the
installation.
This symbol -a indicates a change since the last issue.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS
INTRODUCTION 2
Codes and Standards 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 4
APPLICATIONS 4
General 4
Upflow Applications 4
Downflow Applications 6
Horizontal Left (Supply -Air Discharge) Applications 7
Horizontal Right (Supply -Air Discharge) Applications 9
LOCATION 11
General 11
Furnace Location Relative to Cooling Equipment 12
Hazardous locations 12
INSTALLATION 12
Leveling Legs (If Desired) 12
Installation in Upflow and Downflow Applications 13
Installation in Horizontal Applications 14
Air Ducts 14
Filter Arrangement 15
Bottom Closure Panel 16
Gas Piping 17
Electrical Connections 17
Direct Venting 19
Condensate Drain 28
Sequence of Operation 31
START -UP PROCEDURES 33
General 33
Prime Condensate Trap With Water 33
Purge Gas Lines 34
Adjustments 34
Check Safety Controls 38
Checklist 39
—I—
a
AIRFLOW
Cancels: II 350M -40 -10
AIRFLOW
U
AIRFLOW
Fig. 1— Multipoise Orientations
RATING
EFFICIENCY
CERTIFIED
ama
II 350M -40-12
10-00
HORIZONTAL
RIGHT
0 9 001 SP-
REGISTERED QUALITY SYSTEM
M01- l 09
A93041
SAFETY CONSIDERATIONS
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 Z223.1 -1999 and the Installation Standards, Warm
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 9013. In Canada, refer to the current edition of the
UNIT SIZE
A
D
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
2e N.
26 A
24 A
2211.'
24N. COMBUSTION.
AIR CORN
WIN. DIA
GAS CONN
24N. VENT CONN
N.M. DIA THERMOSTAT
ENTRY
22 "M'
SIDE INLET I ET
21 AAe TYP
SIDE INLET
l �
1
1L4•
CONDENSATE DRAIN
S TRAP LOCATION
HORIZONTAL LEFT)
'WIN. DIA
POWER CONN
(WIN. DIA
ACCESSORY
POWER ENTRY
"""'''.•••• CONDENSATE
DRAIN TRAP TA..
LOCATION 27 rre
(ALTERNATE 24 4'
11 11 17 M.'
CONDENSATE
DRAIN LOCATION
(UPFLOW)
2714' TYP
CAN /CGA- B149.1- 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 the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand these signal words; DANGER, WARNING, and
CAUTION. These words are used with the safety -alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which would result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation
INTRODUCTION
The model 350MAV, Series E and F Furnaces are available in
sizes 40,000 through 138,000 Btuh input capacities.
It
ey
f
I I 33'A'
3211' TYP
30 ,M,
f 0AE
NOTES: 1. Minimum return-air openings at furnace. based on metal duct. If flex duct is used,
see flax duct manufacturer's recommendations for equivalent diameters.
2. Minimum return-air opening at furnace:
a. For 800 CFM -16dn. round or 141/4 x 12 -in. rectangle.
b. For 1200 CFM- 20 -in. round or 141/4 x 19'/rin. rectangle.
c. For 1600 CFM-22-in. round or 141, x 231.•in. rectangle.
d. For airflow requirements above 1800 CFM. see Air Delivery table in Product Data
literature for specific use of single aide 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.
DIMENSIONS (IN.)
Fig. 2— Dimensional Drawing
—2—
AIRFLOW
A
CONDENSATE DRAIN
TRAP LOCATION
(DONNFLOW C
HORIZONTAL RIGHT
OR ALTERNATE
?IN. DIA GAS CONN
30'A'
CONDENSATE
DRAIN LOCATION
TYP
' POWER CONN
� WIN. DIA
THERMOSTAT ENTRY
24N. VENT CONN .
21 LI
21 %-
26 A
22 M.•
OUTtET 1'''
• -I—F
M,-
24N. COI.IaUSTION•
NR CONN
SIDE INLET
*IL 01A
GAS CONN
22 A' TYP -4
(UPFlO'N) 24 Am'
DIMPLE LOCATORS BOTTOM INLET
FOR HORIZONTAL
HANGING
A99111
The 350MAV Multipoise Condensing Gas -Fired Furnaces are
C.S.A. (A.G.A. and C.G.A.). certified for natural and propane
gases and for installation in alcoves, attics, basements, closets,
utility rooms, crawlspaces, and garages. The furnace is factory-
shipped for use with natural gas. A C.S.A. (A.G.A. and C.G.A.)
listed gas conversion kit is required to convert furnace for use with
propane gas. The 350MAV 040 through 120 size units are C.S.A.
(A.G.A. and C.G.A.) approved for use in manufactured (mobile)
homes when factory accessory conversion kit is used. The 140 size
unit 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
A
J
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 furnaces are shipped with the following materials to assist in
proper furnace installation. These materials are shipped in the main
blower compartment.
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.
Installer Packet includes:
Installation, Startup, and Operating Instructions
Service and Maintenance Instructions
User's Information Manual
Warranty Certificate
Loose Parts Bag includes
Pressure tube extension
Collector Box or condensate trap extension tube
Inducer housing drain tube
1/2-in CPVC street elbow
Drain tube coupling
Drain tube coupling grommet
Vent and combustion -air pipe support
Condensate trap hole filler plug
Vent and combustion -air intake hole filler plug
Combustion -air pipe perforated disk assembly
Vent Pipe Extension
Quantity
1
1
1
2
1
2
3
2
1
1•
' ONLY supplied with some furnaces.
Fig. 3— Clearances to Combustibles
—3—
A00308
TUBE
Furnace Is shipped front factory In uptiow configuration. Pressure
Tube location when used
(Slower access prat removed) *• PIESSEE
, xWCma 10KTAe O , co
1• 1 • I
OOUECTasam RSe —; "'°
3 ;�1 mi DWI
ROUTING
tube and drain tubs muting MUST
in UPFLOW application
mutardera TteE
/WI
match the diagrams
,
below.
w rA WOKS
RIG
COUECrOAOROwrTM
ALE a 11117E arrwss
MIXER aw1111E
/
Mg = .
E
gssfw
sarnllDlESGnano MUM rase Herr 1'
(eo fOOOlEaoReosa,a,TA14 •
mina gar CPOIRaE 1 w u ,-�
mist - -_
.'�
yea
pllg awsrt mom
F - maExxE TOP
— ., m
m1ECTa NCRi eE(OMEro
COMMA KR C4I TAE
A LP
mdD6OF mw —
1`_•
. ,Ir�
4
, .I
• F
1
WWI
FDDW*LnD aANCrrto
f�C7 N3OF yrDOWrnEE �— ,
mEaEnPEE'+ GRAIN avrlaa
r/cr
ngDe5T5UDEKTORSSPRAD �1 PC SWEET SW a
GM
ear ONI1 MR
le1A)
mIECTaaOa TAE
reu
mlECTCRICR1l!
a EX1BMa1R�
+ RE K
mdEMe7MI
OuwnaE
Tube location when used is
DOWNFLOW application
CJwR I
I m1ELTa
Rl+cam DD
h(CTa
n T O[0141 •4 ° ° ■
m1EC101e E$Tt Tl aI RIG
(�15a�.�=7.� • f
aos lF,, —t; I
EXRlflw RAE 'I �:�'� muCTOR
I E%,eeralME
ou3EEtOMICC oRrN
TUN
i s 6V WE WWII • _ lI
1 1 C
�E , � I .!r ".,
w t ' m1/CTa
•'d ,, - 1 i�r „ I �
auPlReE •
(�• — :,i4-
maI,G — 2 ° - 1
cG aE 1110
S'WERE/CLOMP( PESSAE • r i 0 I mlw Ic. BOX
rEE1SE UK ASSDAV RAE ,A
rFA
oCu:ER URROOVr1RaE(WIER
Tube location when used on
HORIZONTAL - LEFT application
mlECta eD•aM1T1JE
eLuF&A WE RAPED)
MDR ECIRCUE
OiVlTlarar07l WE
CalECla BOX PUN
5
aEwve
Tube location when used
HORIZONTAL - RIGHT application
rat mleClceoao
, mi1001e01
'•
� ,,-
v. ,r'" �� I:
L�i +
I . -�
( ► ►!•'
on
INER ME
MR Pe*
RJOURTIV aOEItiDCAFDIOC
C* ie�i
IIIINCRECICISURI Isa
PRESUME REICRI:Kt ROC ;SWAILY «
a..{�; ►�`r. COLLECTOR eoa
—-
R1u
°"
; 1
"
— p-�
R
O ' MEtctaN
° -1 . • wurtA wawa
mLLCTisaft
ExElsrvRaE
COQMYEnW
CCULCtaeOl ElnUbO CRAM
��
�
- WN NE.I�tEI
O • l a• •
1 '' :
tlm • • Y
WRIER°CLOUSE •
I � /
-�
WARTIME
CCLA G
, E S,,T \
.?_-27 'E'
mTaD. —
T�taEER
( n MlaAlafe401M
';
:Rh
cOieiRET11M
EE `
, OM
RN Walt
NOTE: I
I. M taing must W cmrnoed sects* and ratted to mod hr and traps.
2. Prawn using must always slope aaey hem prowl) we wwtdl to Ctlleaa Ira co anion
3. 1•07.120MAL -LEFT instasaas Mare tee wiener into trews lay to Os rdocaed
ts Irstallaron Irstruas la fury deists.
pr awn a trap Rehr to i ur
as sho n.
bermel the Educes housing snot Uw timer mall to 324999'201 REV. C
A
J
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 furnaces are shipped with the following materials to assist in
proper furnace installation. These materials are shipped in the main
blower compartment.
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.
Installer Packet includes:
Installation, Startup, and Operating Instructions
Service and Maintenance Instructions
User's Information Manual
Warranty Certificate
Loose Parts Bag includes
Pressure tube extension
Collector Box or condensate trap extension tube
Inducer housing drain tube
1/2-in CPVC street elbow
Drain tube coupling
Drain tube coupling grommet
Vent and combustion -air pipe support
Condensate trap hole filler plug
Vent and combustion -air intake hole filler plug
Combustion -air pipe perforated disk assembly
Vent Pipe Extension
Quantity
1
1
1
2
1
2
3
2
1
1•
' ONLY supplied with some furnaces.
Fig. 3— Clearances to Combustibles
—3—
A00308
y n
A
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, tire, electrical shock, or
other conditions which may cause personal injury or
property damage. Consult a qualified installer, service
agency, local gas supplier, or your distributor or branch
for information or assistance. The qualified installer or
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 detail, refer to applicable installation
literature.
CODES AND STANDARDS
Before installing the furnace in the United States, refer to the
current edition of the NFGC and the NFPA 90B.
BLOWER SHELF r FURNACE
DOOR
CONDENSATE
TRAP (INSIDE)
ALTERNATE DRAIN
TUBE LOCATION
CONDENSATE TRAP
DRAIN TUBE LOCATION
UPFLOW APPLICATIONS
3 /4
FIELD 26 1/4
DRAIN
CONN
SIDE VIEW
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
1 1 /2
1
WIRE TIE
GUIDES
(WHEN USED)
FRONT VIEW
DOWNFLOW AND
EXTERNAL UPFLOW
CONDENSATE
TRAP
FURNACE
SIDE
1
FRONT VIEW
ALTERNATE
APPLICATIONS
7
7/e 2'/4
SIDE VIEW
4 7 /e
Fig. 4— Condensate Trap
—4—
For copies of the NFGC and NFPA 90B contact the National Fire
Protection Association Inc., Batterymarch Park, Quincy, MA
02269; or the American Gas Association, 1515 Wilson Boulevard,
Arlington, VA 22209.
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 IR3.
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 the absence of local codes,
installation must conform 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.
FURNACE
DOOR FURNACE
SIDE
126 r � i
4
FIELD
D CONN RAIN
% OD
COLLECTOR BOX TO
TRAP RELIEF PORT
' OD
INDUCER HOUSING
DRAIN CONNECTION
% OD
COLLECTOR BOX
DRAIN CONNECTION
SCREW HOLE FOR
UPFLOW OR DOWN -
FLOW APPLICATIONS
(OPTIONAL)
1/2-IN. PVC OR CPVC
HORIZONTAL
APPLICATIONS
4 n 53'4
if-
4
END VIEW FRONT VIEW
A93026
4.
r
•
�-
RECAUTIONS
• = ' t • - an affect electronic
crionfifiti. during furnace installation
and servicing to protect the furnace electronic control.
Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the
procedure. These precautions will help to avoid exposing
the control to electrostatic discharge by putting the
furnace, the control, and the person at the same electro-
static potential.
I. Disconnect all power to the furnace. DO NOT TOUCH
THE CONTROL OR ANY WIRE CONNECTED TO THE
CONTROL PRIOR TO DISCHARGING YOUR BODY'S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
a person's hand during grounding will be satisfactorily
discharged.
3. After touching the chassis you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch un-
grounded objects, etc.).
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch furnace again before
touching 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 I 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.
APPLICATIONS
I. Collector Box Drain, Inducer Housing Drain, Relief Port,
and Pressure Switch Tubes.
These tubes should be factory attached to condensate trap
and pressure switch ready for use in UPFLOW applications.
These tubes can be identified by their connection location
and also by a color label on each tube. These tubes are
identified as follows: collector box drain tube (blue label),
inducer housing drain tube (violet label or molded), relief
port tube (green label), and pressure switch tube (pink
label).
2. Condensate Trap Drain Tube
The condensate trap drain connection must be extended for
field attachment by doing the following:
a. Determine location of field drain connection. (See Fig. 2
or 5.)
NOTE: If internal filter or side Filter /Media Cabinet is used, drain
tube should be located to opposite side of casing of return duct
attachment to assist in filter removal.
b. Remove and discard casing drain hole plug button from
desired side.
c. Install drain tube coupling grommet (factory- supplied in
loose parts bag) in selected casing hole.
d. Slide drain tube coupling (factory- supplied in loose parts
bag) through grommet ensuring long end of coupling
faces blower.
e. Cement 2 factory- supplied 1 /2 -in. street CPVC elbows to
the rigid drain tube connection on the condensate trap.
(See Fig. 5.) These elbows must be cemented together
and cemented to condensate trap drain connection.
NOTE: Failure to use CPVC elbows may allow drain to kink and
prevent draining.
f. Connect larger diameter drain tube and clamp (factory-
supplied in loose parts bag) to condensate trap and clamp
securely.
g. Route tube to coupling and cut to appropriate length.
h. Attach tube to coupling and clamp securely.
C. Condensate Trap Location (Alternate Upflow Orien-
tation)
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 Upf low Orientation) section for tubing attachment.
To relocate condensate trap to the left -hand side, 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. Install casing hole filler cap (factory- supplied in loose parts
bag) into blower shelf hole where trap was removed.
4. Install condensate trap into left -hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
–� 5. Fill unused condensate trap casing holes with plastic filler
caps (factory- supplied in loose parts bag).
D. Condensate Trap Tubing (Alternate Upflow Orienta-
tion)
NOTE: See Fig. 6 or tube routing label on main furnace door to
confirm location of these tubes.
I. GENERAL
Some assembly and modifications are required for furnaces
installed in any of the 4 applications shown in Fig. I. All drain and
pressure tubes are connected as shown in Fig. 5. See appropriate
application instructions for these procedures.
II. 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 Orien-
tation)
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 Orienta-
tion) I. Collector Box Drain Tube
NOTE: See Fig. 5 or tube routing label on main furnace door to Connect collector box drain tube (blue label) to condensate
confirm location of these tubes. trap.
Corporate Office: 2800 Thorndyke Avenue West • Seattle, WA 98199
— 5—
Ph (206) 282 -4700 • Fx (206) 378 -6600 • (800) 398 -HOME • www.washingtonenergy.com • Lic. No. WASHIES07403
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
(MOLDED)
(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
CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD- INSTALLED
FACTORY- SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
Fig. 5— Factory- Shipped Upflow Tube
Configuration
(Shown with Blower Access Panel Removed)
A94163
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.
A
—6—
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
CONDENSATE —a
TRAP
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
O
0 0
i
A94164
Fig. 6— Alternate Upflow Configuration and Trap Location
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.
rt
u'•1',''- i,Y -d';Y a's;`_;1'�;.` :jai: Ytii. >,. :: \.tY „:.., a ... > {..
M
•
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 --6'
TRAP
INDUCER HOUSING
DRAIN TUBE (VIOLET)
Fig. 7— Downflow Tube Configuration (Left- Hand de4165
Trap Installation)
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.
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,
.7, or 8).
—4 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.
Relocate tubes as described below.
I. Collector Box Drain Tube
a. Remove factory- installed plug from LOWER collector
box drain tube (blue and white striped label).
—7—
CO TUBE Igir
COUPLING
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE)
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)
f— CONDENSATE
3 TRAP
N.__
COLLECTOR BOX
EXTENSION
DRAIN TUBE
Fig. 8— Downflow Tube Configuration (Right - Han ? 166
Trap Installation)
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
(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.
I. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connec-
tion by splicing to small diameter tube (factory- supplied in
loose parts bag).
3. Connect collector box pressure tube (green label) to pres-
sure switch connection labeled COLLECTOR BOX.
4. 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) AP-
PLICATIONS
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.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
A. Condensate Trap Location
The condensate trap must be removed from the factory- installed
blower shelf location and relocated in selected application location
as shown in Fig. 2 or 9.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory- supplied in loose parts
A bag) into blower shelf hole where trap was removed.
4. Install condensate trap into left -hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
—� 5. Fill unused condensate trap casing holes with plastic filler
caps (factory- supplied in loose parts bag).
B. Condensate Trap Tubing
NOTE: See Fig. 9 or tube routing label on main furnace door to
check for proper connections.
1. Collector Box Drain Tube
a. Install drain tube coupling (factory- supplied in loose
parts bag) into collector box drain tube (blue label)
which was previously connected to condensate trap.
b. Connect large diameter drain tube and clamp (factory-
supplied in loose parts bag) to drain tube coupling,
extending collector box drain tube.
c. Route extended tube (blue label) to condensate trap and
cut to appropriate length.
d, Clamp tube to prevent any condensate leakage.
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 Attachments
Refer to Condensate Drain section for recommendations and
procedures.
—8—
m
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.
t
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.
I. 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 I.
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.)
AUXILIARY "J" BOX —\
CONDENSATE -
TRAP
PLUG
-L
CAP
m
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
Fig. 9 Horizontal Left Tube Configuration
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 28.)
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.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC Installation Codes and/or local codes.
NOTE: The auxiliary junction box (J -Box) MUST be relocated to
opposite side of furnace casing. (See Fig. II) See Electrical
Connection section for J -Box relocation.
COLLECTOR BOX
ii /—
DRAIN TUBE
(BLUE AND WHITE STRIPED)
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
DRAIN TUBE (BLUE)
A00215
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 I I.
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. Install casing hole filler cap (factory- supplied in loose parts
bag) into blower shelf hole where trap was removed.
4. Install condensate trap into left -hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory- supplied in loose parts bag).
B. Condensate Trap Tubing
NOTE: See Fig. I I or tube routing label on main furnace door toff
check for proper connections.
I. 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.
MANUAL
SHUTOFF
GAS VALVE
SEDIMENT
TRAP
COMBUSTION — AIR
INTAKE
CONDENSATE
TRAP
VENT
DRAIN
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
Fig. 10 —Attic Location and Working Platform
—10--
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.
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
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
,,, „. , :...
•
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. I I or tube routing label on main furnace door to
check for proper connections.
Relocate tubes as described below.
I. 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.
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 (pit&
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
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 10.)
PLUG
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
CAP
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
Fig. 11— Horizontal Right Tube Configuration
— I I—
m
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 I2 -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 28.)
I. GENERAL
When a furnace is installed so that supply ducts carry air to areas
outside the space containing the furnace, return air must also be
handled by ducts sealed to furnace casing. The ducts terminate
outside the space containing the furnace to ensure there will 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.
Locate furnace as close to center of air distribution system as
possible.
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.
NOTE: These furnaces are designed for a minimum continuous
return-air temperature of 60 °F or intermittent operation down to
55 °F such as when used with a night setback thermostat. Return-air
temperature must not exceed a maximum of 85 °F. Failure to
follow these return -air temperature limits may affect reliability of
heat exchangers, motors, and controls.
Locate furnace so combustion -air pipe maximum lengths are not
exceeded. Refer to Table 6.
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX TUBE (PINK)
AUXILARY "J" BOX RELOCATED HERE
CONDENSATE
TRAP
LOCATION
A00214
UPFLOW OR DOWNFLOW
LEVEL (0 ")
O
r/h" MAX
FRONT
HORIZONTAL
A93043
m
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.
P.
—12—
m
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.
32 °F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
A93058
m
CAUTION: If these furnaces are installed in an uncon-
ditioned space where the 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 units clearance
and combustibles label. (See Fig. 3.) Locate furnace where
available electric power and gas supplies meet specifications on
furnace rating plate.
1
18 -IN. MINIMUM
TO BURNERS
A93044
m
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.
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
This section alerts you to hazardous locations for installation of
this furnace.
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 /16 -in. machine bolts and nuts.
NOTE: The maximum length of bolt should not exceed 1 -1/2 in.
I. Position furnace on its back. Locate and drill a 5 /16 –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.)
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.
—13—
A89014
II. INSTALLATION�IN AND- Legs AP-
PLICATIONS
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when special base (available from
manufacturer) Part No. KGASB0201 ALL is used. Special base 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.)
Lb.
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 PLI -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 I X 3 /8 -in. flat washers,
3 /8 -in, lock washers, and 3 /8 -in. nuts on hanger rods as shown in
Fig. 17. Dimples are provided for hole locations. (See Fig. 2.)
FURNACE
CASING
WIDTH
APPLICATION
PLENUM OPENING
FLOOR OPENING
A
B
C
D
17112
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
Furnace with or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box
•
15 -118
19
16 -3/4
20 -3/8
Downflow Applications on Combustible Flooring NOT Using
KGASB Subbase
Furnace with or without CD5 or CK5 Coil 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
Furnace with or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box
18-5/8
19
20 -1/4
20-3/8
Downflow Applications on Combustible Flooring NOT Using
KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box
19
20
20
0
24-112
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
Furnace 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 or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box
22 -1/2
19
23-1/2
20
•
B D
AFAVA
A
PLENUM
OPENING
FLOOR
OPENING
C
Fig. 13 —Floor and Plenum Opening Dimensions
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.
TABLE 1— OPENING DIMENSIONS (IN.
A96283
—14—
FURNACE
(OR COIL USED)
COMBUSTIBLE
FLOORING
1411
DOWNFLOW
:! SUBBASE
SHEET METAL
PLENUM
r._ FLOOR
OPENING
A96285
Fig. 14— Furnace, Plenum, and Subbase Installed on a
Combustible Floor
IV. AIR DUCTS
A. General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
5
FURNACE
CO5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
SHEET METAL
PLENUM
PERFORATED
DISCHARGE DUCT
FLANGE
FLOOR , .
OPENING
A96284
Fig. 15— Furnace, Plenum, and Coil Assembly or Coil
Box Installed on a Combustible Floor
210•
MIN
Fig. 16 —Duct Flanges
NO
YES
YES
A93029
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.
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.
—15—
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 90B or local code for further requirements
B. Ductwork Acoustical Treatment
Metal duct systems that do not have a 90 degree elbow and 10 ft
of main duct to the first 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 18 standard on fibrous glass ducts. Both
acoustical lining and fibrous ductwork shall comply with NFPA
90B as tested by UL Standard 181 for Class I Rigid air ducts.
C. 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.
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.
HORIZONTAL FURNACES
Connect supply -air duct to supply air opening on furnace. The
supply -air duct attachment must ONLY be connected to furnace
supply /outlet or air conditioning coil casing (when used). DO NOT
cut main furnace casing to attach supply side air duct, humidifier,
or other accessories. All accessories MUST be connected external
to furnace main casing.
0. Return Air Connections
UPFLOW FURNACES
The return -air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. I. Bypass humidifier may be attached into
unused side return air portion of the furnace casing. DO NOT
connect any portion of return-air duct to back of furnace casing.
DOWNFLOW AND HORIZONTAL FURNACES
The return-air duct must be connected to return-air opening
provided 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.
V. FILTER ARRANGEMENT
WARNING: Never operate unit without a filter or with
filter access door removed. Failure to follow this warning
can cause fire, personal injury, or death
–3 The air filter arrangement will vary due to application, furnace
orientation, and filter type. The filter may be installed in an
external Filter /Media cabinet (if provided) or the furnace blower
compartment. Factory supplied washable filters are shipped in the
blower compartment.
AIR FILTER LOCATED IN BLOWER COMPARTMENT
FURNACE
CASING
WIDTH (IN.)
FILTER SIZE (IN.)'
FILTER
TYPE
Side Return
Bottom Return
17 -1/2
(1) 16 X 25 X it
(1) 16 X 25 X it
Cleanable
21
(1) 16 X 25 X 1
(1) 20 X 25 X 1t
Cleanable
24-1/2
(1 or 2) 16 X 25 X 1
(1) 24 X 25 X it
Cleanable
•
ANGLE
IRON OR
EQUIVALENT
(B)
(A) ROD LOCATION
USING DIMPLE
LOCATORS
(SEE DIMENSIONAL
DWG FOR
LOCATIONS)
(A) PREFERRED ROD LOCATION
(B) ALTERNATE ROD LOCATION
TABLE 2— FILTER INFORMATION
3 /e -IN. HEX NUT
& WASHER (4)
REQD PER ROD
-4 If a factory- supplied external Filter /Media cabinet is provided,
instructions for its application, assembly, and installation are
packaged with the cabinet. The Filter /Media cabinet can be used
with the factory- supplied washable filter or a factory- specified
high- efficiency disposable filter (see cabinet instructions).
-) If installing the filter in the furnace blower compartment, deter-
mine location for filter and relocate filter retaining wire if
necessary. See Table 2 to determine correct filter size for desired
filter location. Table 2 indicates filter size, location, and quantity
shipped with this furnace. See Fig. 2 for location and size of
bottom grid side return -air openings.
• Filters may be field modified by cutting filter material and support rods (3) in
filters. Alternate sizes and additional filters may be ordered from your dealer.
t Factory- provided with furnace.
(A) - v- (B)
—
DRAIN
(A)
13 Me -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 furnace must be
supported when furnace is used In horizontal
position to ensure proper drainage.
Fig. 17— Crawlspace Horizontal Application
3b -IN. ROD
ALTERNATE SUPPORT
LOCATION 4 -IN. MIN
8 -IN. MAX
A93304
CAUTION: Use care when cutting support rods in filters
to protect against flying pieces and sharp rod ends. Wear
safety glasses, gloves, and appropriate protective cloth-
ing. Failure to follow this caution could result in personal
injury.
CAUTION: For airflow requirements above 1800 CFM,
see Air Delivery table in Product Data literature for
specific use of single side inlets. The use of both side
inlets, a combination of I side and the bottom, or the
bottom only will ensure adequate return air openings for
airflow requirements above 1800 CFM.
NOTE: Side return -air openings can ONLY be used in UPFLOW
configurations. Install filter(s) as shown in Fig. 18. Bottom
return -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.
WASHABLE
FILTER
Fig. 18— Filter Installed for Side Inlet
1714 -IN. WIDE
CASINGS ONLY:
INSTALL FIELD - SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
FILTER
SUPPORT
FILTER
RETAINER
Fig. 19— Bottom Filter Arrangement
FILTER
RETAINER
A93045
WASHABLE
FILTER
A00213
—17—
VI. BOTTOM CLOSURE PANEL
These furnaces are shipped with bottom enclosure panel installed
in bottom return-air opening. This panel MUST be in place when
side return air is used.
To remove bottom closure panel, perform following:
I. 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.
VII. GAS PIPING
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 I hanger every 6 R. Joint
compound (pipe dope) should be applied sparingly and only to
male threads of joints. Pipe dope must be resistant to propane gas.
i
i t
FRONT FILLER
PANEL
BOTTOM
CLOSURE
PANEL
Fig. 20— Removing Bottom Closure Panel
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. .
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.
A93047
NOMINAL
IRON
PIPE
INTERNAL
DIAMETER
F LENGTH OF PIPE
(T)
SI2E
(IN.)
10
20
30
40
50
(IN.)
112
0.622
175
120
97
82
73
314
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
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.
TABLE 3— MAXIMUM CAPACITY OF PIPE*
Cubic R of gas per hr for gas pressures of 0.5 psig (14 -In. wc) or less and a
pressure drop of 0.5-in we (based on a 0.60 specific gravity gas).
Ref: Table 10-2 NFGC.
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.)
a-
GAS
SUPPLY
MANUAL (i
SHUTOFF
VALVE
(REQUIRED) ,i' 'I
SEDIMENT-
TRAP UNION
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
furnace 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 (I4 -in. we) stated on gas valve. (See Fig. 44.)
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
rt
—18—
from furnace and capped before pressure test. If test pressure is
equal to or less than 0.5 prig (14 -in. we), turn off electric shutoff
switch located on gas valve before test. It is recommended that
ground joint union be loosened before pressure testing. After all
connections have been made, purge lines and check for leakage.
VIII. 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.
Lt.
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.
A. 115 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.
ELECTRIC
DISCONNECT
SWITCH
COPPER
WIRE ONLY
A93033
CAUTION: Do not connect aluminum wire between
disconnect switch and furnace. Use only copper wire.
UNIT
SIZE
VOLTS-
HERTZ-
PHASE
OPERATING
VOLTAGE RANGE
MAX
UNIT
AMPS
UNIT
AMPACITYt
MIN
WIRE
SIZE
MAX WIRE
LENGTH
(FT)*
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
080-12
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
m
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
I. Remove 2 screws holding auxiliary J -box. (See Fig. 23.)
2. Rotate 1-box 180° and attach box to left side, using holes
provided.
eLK
115 -V
FIELD - SUPPLIED
DISCONNECT
FIVE
WIRE
THREE -WIRE
HEATING -
ONLY
AUXILIARY
J -BOX
CONTROL
BOX
FURNACE
NOTE 2
24 -V
TERMINAL
BLOCK
NOTE 1
NOTES: 1. Connect 1i-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
Fig. 22- Heating and Cooling Application Wiring Diagram
TABLE 4- ELECTRICAL DATA
Permissible limits of voltage range at which unit will operate satisfactorily.
t Unit ampacity = 125 percent of la gest operating component's full load amps plus 100 percent of all other potential operating components' (EAC, humidifier, etc.) full bad
amps.
t Length shown is a measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
' Time -delay type is recommended.
-19-
TWO
WIRE
CAUTION: If manual disconnect switch is to be
Lt mounted on furnace, select a location where a drill or
fastener will not contact electrical or gas components.
B. 24 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 terminal on control center, as shown
in Fig. 22. The 24 -v terminal board is marked for easy connection
of field wiring. (See Fig. 24.) 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 replacement is
required, use only a fuse of identical size (3 amp).
- --- FIELD24 -V WIRING
- - -- FIELD 115-, 208/230 -, 460 -V WIRING
FACTORY 24 -V WIRING
FACTORY 115-V WIRING
THERMOSTAT
TERMINALS
CONDENSING
UNIT
FIELD - SUPPLIED
DISCONNECT
208/230- OR
460-V
- THREE
PHASE
- 208/230 -V
I. PINGLE
PHASE
A98209
•
ALTERNATE
FIELD
LOCATION
FACTORY
INSTALLED
LOCATION
A00212
Fig. 23 Relocating J -Box
• 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. '
C. Accessories
I. Electronic Air Cleaner (EAC)
Two quick- connect terminals marked EAC- I and EAC -2
are provided for EAC connection. (See Fig. 25.) These
terminals are energized with 115 -v, (1.5 -amp maximum)
during blower motor operation.
2. Humidifier (HUM)
A quick- connect terminal (HUM) and screw terminal (Com)
are provided for 24 -v humidifier connection. (See Fig. 24.)
HUM terminal is energized with 24 -v (0.5 -amp maximum)
after inducer pressure switch closes.
NOTE: A field- supplied, 115 -v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
IX. DIRECT VENTING
The 350MAV Furnaces require a dedicated (one 3501vMAV furnace
only) direct -vent system. In a direct -vent system, all air for
combustion is taken directly from outside atmosphere, and all flue
products are discharged to outside atmosphere.
A. Removal of Existing Furnaces from Common Vent
Systems
If furnace being replaced was connected to a common vent system
with other appliances, the following steps shall be followed with
each appliance connected to the venting system placed in opera-
tion, while any other appliances connected to the venting system
are not in operation:
I. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal
pitch as required in the National Fuel Gas Code, ANSI
Z223.1 or 24 the CAN /CGA 8149 Installation Codes and
these instructions. Determine that there is no blockage or
restriction, leakage, corrosion, and other deficiencies which
could cause an unsafe condition.
3. 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.
—20—
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.
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.
B. Combustion - Air and Vent Piping
GENERAL
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 -2I and
SDR -26 PVC), D2661 (ABS -DWV), F628 (schedule -40 ABS),
F891 (PVC -DWV cellular core), or F441 (schedule -40 CPVC
pipe) and F438 (schedule -40 CPVC fittings). 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.
NOTE: Slope combustion -air and vent pipes a minimum of 1/4
in. per linear ft with no sags between hangers,
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.
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.
(,) 0
) W.
LU
W
u.
Q :
N �
d,
Z �,
Z0
ui
O
N ; :
0 I—
W
Z
V N
0 1 '
Z
m
-:;-
o
m rn
,-I o
moo
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—lZ—
1111°
A 11111111 111111
53
oG
[kW)
f cl
LOCATION
CLEARANCE (FT)
U.S.A.
Canada
Above grade level or above
anticipated snow depth
1
1t
Dryer vent
3
3
From plumbing vent stack
3
3
From any mechanical fresh air Intake
1
6
For furnaces with an input capacity of
100,000 Btuh or less —from any non -
mechanical air supply (windows or doors
which can be opened) or combustion -air
opening
1
1
For furnaces with an input capacity greater
than 100,000 Btuh or less —from any non -
mechanical air supply (windows or doors
which can be opened) or combustion -air
opening
1
3
From service regulator vent, electric and
gas meters and relief equipment
4•
4
Above grade when adjacent to public
walkway
Note 3
Note 3
NOT IN
HORIZONTAL
SECTION
O
O
® 00
I I
O
HOT SURFACE
IGNITOR CONNECTOR
FURNACE
o HARNESS CONNECTOR
° SEC -1
3 -AMP FUSE � I n=
�-9
PIPE DIAMETER
TRANSITION IN
VERTICAL SECTION
Fig. 26— Combustion -Air and Vent Pipe Diameter
Transition Location and Elbow Configuration
A93034
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.
BLOWER OFF DELAY
ADJUSTMENT SWITCH
C•`7
C:1
Y
W
Co
24V
HU
ooh
O 0 0 24 -V TRANSFORMER SEC -2
r i COOL -� I SPARE -1
HEAT �°
Q J � SPARE -2
Q �L �ll 4�k EAC -1 (BLACK)
115 -VAC (L2) NEUTRAL
CONNECTION
INDUCER MOTOR
CONNECTOR
Fig. 25 Control Center
1 _ i 24 -V THERMOSTAT
�f TERMINALS
HUMIDIFIER TERMINAL
(24 -VAC 0.5 AMP MAX)
J LED OPERATION &
DIAGNOSTIC LIGHT
BLOWER SPEED
SELECTION TERMINALS
EAC- ELECTRONIC AIR CLEANER
TERMINALS (115 -VAC 1 AMP MAX)
EAC -2 (WHITE)
A00292
TABLE 5— COMBUSTION -AIR AND VENT PIPE TERMI-
NATION 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 350MAV Furnaces, refer to Mulliventing and Vent
Terminations section for proper vent configurations.
2. When locating combustion -air and vent terminations, consideration must be
given to prevailing winds, location, and other conditions which may cause .
recirculation of the appliance's own flue products or the flue products of
adjacent vents. Recirculation can cause poor combustion, inlet condensate
problems, and accelerated corrosion of heat exchangers.
3. Vent termination can not terminate less than 2 ft horizontal and 7 ft above
public walkway or where condensate vapor or droplets may be a hazard.
NOTE: Select 1 vent pipe connection and
I combustion -air pipe connection.
AIR
FLOW
COMBUSTION- . COMBUSTION -
AIR
AIR
FLOW
COMBUSTION -
AIR VENT
UPFLOW
HORIZONTAL -LEFT DISCHARGE
NOTE: Select I vent pipe connection end
I combustion•air pipe connection.
VENT
COMBUSTION- COMBUSTION -
AIR AIR AIR
FLOW
DOWNFLOW
COMBUSTION -
AIR
VENT
L
E 1
F E>
HORIZONTAL -RIGHT DISCHARGE
A96187
Fig. 27— Combustion -Air and Vent Pipe Connections
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
water droplets. These droplets may be undesirable, and a I2 -in.
minimum offset pipe section is recommended, as shown in Fig. 28,
to reduce excessive droplets from exiting vent pipe outlet.
COMBUSTION -AIR AND VENT PIPE DIAMETER
Determine combustion -air and vent pipe diameter.
I. 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.
—23—
EXAMPLE: An 036080 size furnace located in Indianapo-
lis, 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 eleva-
tion, 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.
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.
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. Install casing hole filler cap (factory- supplied in loose
parts bag) in unused combustion -air pipe casing hold.
g. Drill a 1 /8 -in. hole in 2 -in, combustion -air pipe using
hole in intake housing as a guide.
h. Install a field- supplied No. 6 or No. 8 sheet metal screw
into 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 FITTING
The combustion -air intake plug fitting must be installed in unused
combustion -air intake housing. This fitting must be attached by
using RTV sealant, or by drilling a I /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.
1
UO :
co 0
to W .
W0
17.
I— O, .
Z HI
UJ W
O l—
= I
—
Z'
V N '.
~
2
J
VENT PIPE
VERTICAL TO ROOF
' 12" MIN
HORIZONTAL TO ROOF
COMBUSTION -AIR PIPE
Fig. 28 — Short Vent (5 to 8 Ft) System
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, and 34 so it will not be 3/8' ID TUBE
susceptible to areas where light snow or other sources of moisture
could be pulled in.
If use of this drain connection is desired, drill out fitting's tap plug
with a 3/16 -in. drill and connect a field- supplied 3 /8 -in. tube. This
tube should be routed to open condensate drain for furnace and
A/C (if used), and should be trapped. (See Fig. 29.) DRILL
2. Attach vent pipe as follows:
a. Determine location of vent pipe connection to inducer
housing as shown in Fig. 27 for application. TRAP
b. Reposition elastomeric (rubber) inducer housing outlet
cap and clamp to appropriate unused inducer housing
connection. Tighten clamp.
Lt.
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 (factory- supplied in loose parts bag)
into selected furnace casing vent pipe hole. Pipe support
should be positioned at bottom of casing hole.
VENT PIPE
—24—
COMBUSTION -AIR PIPE
3116'
TO OPEN
DRAIN
12" MIN
—IN-
VENT P I P E I
COMBUSTION -AIR PIPE i 11,A1 � COMBUSTION -AIR PIPE
HORIZONTAL TO SIDEWALL •
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.
VENT PIPE
COMBUSTION — AIR
INTAKE HOUSING
BURNER
BOX
Fig. 29— Intake Housing Plug Fitting Drain
A96230
COMBUSTION —
AIR PIPE
A93035
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
ALTITUDE (FT)
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)'
NUMBER OF 90' ELBOWS
1
2
3
4
5
6
0 to 2000
040 -08
040 -12
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
060-08
060-12
060 -16
2 Pipe or 2 -In
Concentric
1-1/2
20
15
10
5
NA
NA
2
' 70
70
70
70
70
70
080 -12
080-16
080 -20
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
100 -16
100-20
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
120 20
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
140 -20
2 Pipe or 3 -in.
Concentric
2 -112 one disk
5
NA
NA
NA
NA
NA
P. 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
040 -08
040 -12
2 Pipe or 2 -in
Concentric
1 -1/2
67
62
57
52
52
47
2
70
70
70
70
70
70
2 Pipe or 2 -in
Concentric
1 -1/2
17
12
7
NA
NA
NA
060-08
060 -12
060 -16
2
70
67
66
61
61
61
080 -12
080-16
080-20
2 Pipe or 2 -in
Concentric
2
49
44
30
25
25
15
2 -1/2
70
70
70
70
70
70
100-16
100 -20
2 Pipe or 3 -in
Concentric
2 -1/2
35
26
16
16
6
NA
3
70
70
70
70
66
61
120 -20
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
140 -20
2 Pipe or 3 -in.
Concentric
3t 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
040 -08
040-12
2 Pipe or 2 -in
Concentric
1-1/2
64
59
54
49
48
43
2
70
70
70
70
70
70
060-08
060-12
060-16
2 Pipe or 2 -in
Concentric
1-1/2
16
11
6
NA
NA
NA
2
68
63
62
57
57
56
080-12
080 -16
080 -20
2 Pipe or 2 -in
Concentric
2
46
41
28
23
22
13
2-1/2
70
70
70
70
70
70
100 -16
100 -20
2 Pipe or 3 -in
Concentric
2 -1/2
33
24
15
14
5
NA
3
70
70
70
66
61
56
120-20
2 Pipe or 3 -in.
Concentric
3t no disk
65
58
51
44
38
31
41 no disk
70
70
70
70
70
70
140-20
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___
—25—
TABLE 6— MAXIMUM ALLOWABLE PIPE LENGTH (FT
!g2'. i
to W
W 0
g a
W .
Z F
;
0�
0 I—•
W ,
IL .Z
CU c o
0 '
Z....
ALTITUDE (FT)
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
NUMBER OF 90' ELBOWS
1
2
3
4
5
6
4001 to 5000$
•
040-08
040-12
2 Pipe or 2 -In
Concentric
1 -1/2
60
55
50
45
44
39
2
70
70
70
70
70
70
060-08
060 -12
060 -16
2 Pipe or 2-In
Concentric
1-1/2
15
10
5
NA
NA
NA
2
64
•
59
58
53
52
52
080 -12
080 -16
080-20
2 Pipe or 2 -in
Concentric
2
44
39
26
21
20
11
2 -1/2
70
70
70
70
70
70 ,
100 -16
100 -20
2 Pipe or 3 -In
Concentric
2 -1/2
31
22
13
12
NA
NA
3
70
70
67
62
57
52
120 -20
2 Pipe or 3 -in.
Concentric
3t no disk
53
46
40
33
26
20
4t no disk
70
70
70
70
70
70
140 -20
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$
040 -08
040-12
2 Pipe or 2 -in
Concentric
1 -112
57
52
47
42
40
35
A 2
70
70
70
70
70
70
060-08
060-12
060 -16
2 Pipe or 2 -in
Concentric
1-1/2
14
9
NA
NA
NA
NA
2
60
55
54
49
48
47
080-12
080 -16
080 -20
2 pipe or 2 -in
Concentric
2
41
36
23
18
17
8
2 -112
70
70
70
70
70
70
100 -16
100-20
2 Pipe or 3 -in
Concentric
2 -1/2
29
21
12
11
NA
NA
3
70
67
62
57
52
47
120 -20
2 Pipe or 3 -in.
Concentric
3t no disk
42
35
29
22
15
9
4t no disk
70
70
70
70
70
70
140 -20
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$
040-08
040-12
2 Pipe or 2 -in
Concentric
1 -1/2
53
48
43
38
37
32
2
70
70
68
67
66
64
060 -08
060-12
060-16
2 Pipe or 2 -in
Concentric
1-1/2
13
8
NA
NA
NA
NA
2
57
52
50
45
44
43
080-12
080-16
080-20
2 Pipe or 2-in
Concentric
2
38
33
21
16
15
6
2 -1/2
70
70
68
67
66
64
100 -16
100 -20
2 Pipe or 3 -in
Concentric
2 -1/2
27
19
10
9
NA
NA
3
68
63
58
53
48
43
120 -20
2 Pipe or 3 -in.
Concentric
3t no disk
31
24
18
11
NA
NA
4t no disk
70
70
70
70
67
62
140 -20
2 Pipe or 3-1n.
• 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$
040 -08
040 -12
2 Pipe or 2 -in
Concentric
1 -1/2
49
44
39
34
33
28
2
66
65
63
62
60
59
060 -08
060-12
060 -16
2 Pipe or 2 -in
Concentric
1 -1/2
12
7
NA
NA
NA
NA
2
53
48
46
41
40
38
080 -12
080 -16
080-20
2 Pipe or 2 -in
Concentric
2
36
31
19
14
12
. NA
2-1/2
66
65
63
62
60
59
100 -16
100 -20
2 Pipe or 3 -in
Concentric
2-1/2
25
17
8
7
NA
NA
3
63
58
53
48
43
38
120 -20
2 Pipe or 3 -in.
Concentric
3t no disk
20
13
7
NA
NA
NA
4t no disk
61
56
51
46
41
36
140 -20
NA
See notes on page___
TABLE 6 MAXIMUM ALLOWABLE PIPE LENGTH ( FT) ( CONTINUED
—26--
ALTITUDE (FT)
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)
NUMBER OF 90' ELBOWS
1
2
3
4
5
6
8001 to 9000
.
040-08
040-12
2 Pipe or 2 -In
Concentric
1 -1/2
46
41
36
31
29
24
2
62
60
58
58
55
53
060.08
060 -12
060-16
2 Pipe or 2 -in
Concentric
1-1/2
11
6
NA
NA
NA
NA
2
49
44
42
37
35
34
080 -12
080-16
080 -20
2 Pipe or 2 -in
Concentric
2
33
28
17
12
10
NA
2 -1/2
62
60
58
56
55
53
100-16
100 -20
2 Pipe or 3 -in
Concentric
2 -1/2
23
15
7
5
NA
NA
3
59
54
49
44
39
34
120 -20
2 Pipe or 3 -in.
Concentric
3t no disk
10
NA
NA
NA
NA
NA
4t no disk
35
30
25
20
15
10
140-20
NA
ALTITUDE (FT)
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)'
NUMBER OF 90' ELBOWS
1
2
3
4
5
6
9001 to 10,000*
040-08
040-12
2 Pipe or 2 -in
Concentric it
1-1/2
42
37
32
27
25
20
2
57
55
53
51
49
47
060-08
060 -12
060 -16
2 Pipe or 2 -in
Concentric
2
45
40
38
33
31
29
080-12
080 -16
080 -20
2 Pipe or 2 -in
Concentric
2
30
25
14
9
7
NA
2 -1/2
57
55
53
51
49
47
100 -16
100 -20
2 Pipe or 3 -in
Concentric
2 -1/2
21
13
5
NA •
NA
NA
3
54
49
44
39
34
29
120 -20
2 Pipe or 3•in.
Concentric
4t no disk
10
5
NA
NA
NA
NA
140 -20
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 stated, separate 2 halves of perforated disk
assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box.
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 furnace casing and at the vent termination should not be included in vent length or elbow count.
5, The minimum pipe length is 5 ft for all applications.
8. Use 3-in. diameter vent termination kit for installations requiring 4 -in diameter pipe.
fully into inducer housing connection until it bottoms on 4. Deburr inside and outside of pipe.
the internal stop. Tighten both clamps to secure the pipe
to inducer housing. Tighten the clamp screws to 15
in. -lb. of torque.
e. Install casing hole filler cap (factory- supplied in loose
parts bag) in unused combustion -air pipe casing hold.
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 and larger inputs are supplied with a
PVC vent extension pipe (2 -in, diameter by I2 -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 down-
flow 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).
—27—
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 I /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.
U
• Ng
N a
C3:
11 . 1 ; :
.O F-
W W
V
1
Z '
I 1. Handle pipe joints carefully until cement sets.
12. Support combustion -air and vent piping a minimum of
every 5 ft (3 It for SDR -2I or -26 PVC) using perforated
metal hanging strap.
13. Slope combustion -air and vent pipes toward furnace a
minimum of 1/4 in. per linear ft with no sags between
hangers.
14. Use appropriate methods to seal openings where vent and
combustion -air pipes pass through roof or side wall.
C. CONCENTRIC VENT AND COMBUSTION -AIR TER-
MINATION KIT INSTALLATION
NOTE: If these instructions differ from those packaged with
termination kit, follow kit instructions.
Combustion -air and vent pipes must terminate outside structure. A
factory accessory termination kit must be installed in 1 of the
installations shown in Fig. 30, 31, 32, 33, and 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 t+
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.
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. Pipes located in unconditioned
space cannot exceed total allowable pipe length as specified in
Table 6.
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.
-28-
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.
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.
CONCENTRIC VENT /AIR TERMINATION KIT
I. 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 comers)
or that may allow recirculation of flue gases, airborne
leaves, or light snow.
d. Termination kit should be positioned where it will not be
damaged by or subjected to foreign objects, such as
stones, balls, etc.
e. Termination kit should be positioned where vent vapors
are not objectionable.
2. Cut one 4 -in. diameter hole for 2 -in. kit, or one 5 -in.
diameter hole for 3 -in. kit.
3. Loosely assemble concentric vent/air termination compo-
nents together using instructions in kit.
4. Slide assembled kit with rain shield REMOVED through
hole.
NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole.
Roof terminations- Locate assembly through roof to appropriate
height as shown in Fig. 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.
D. MULTIVENTING AND VENT TERMINATIONS
When 2 or more 350MAV Fumaces are vented near each other,
each furnace must be individually vented. NEVER common vent
or breach vent 350MAV furnaces. When 2 or more 350MAV
1
. Yi& ��T�.: i�riia4!` it `�7��!''h��f::SG�s�.Gt ? %�i�aL'i ;T�Rkti;l'ttir.�`i?��i`i ., ,��.i:..r:;:.1.'�•
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.
COUPLING
32 °F MINIMUM 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.
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.
Fig. 30 — Roof Termination (Preferred)
—
X. CONDENSATE DRAIN
A. General
Condensate trap is shipped installed in the blower shelf and factory
connected for UPFLOW applies Condensate trap must be RELO-
CATED for use in DOWNFLOW and HORIZONTAL applica-
tions.
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.
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
38 pH neutralizing filter may be desired. Check with local
authorities to determine if a pH neutralizer is required.
B. APPLICATION
The fumace, A/C, and humidifier drains may be combined and
drained together. The A/C drain must have an external, field -
supplied trap prior to the furnace drain connection. All drain
connections (furnace, A/C, or humidifier) must be terminated into
an open or vented drain as close to the respective equipment as
possible to prevent 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 furnace is permissible if allowed by local
codes. Caution should be taken when freezing ambient may freeze
drain pipe and prohibit draining.
COMBUSTION a
AIR
A87224
MAINTAIN 12 IN.
(18 IN. FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24 IN. ABOVE ROOF.
COMBUSTION —
AIR
Fig. 31— Concentric Vent and Combustion -Air Roof 1
nation (Preferred)
VENT
OVERHANG OR ROOF
12" MINIMUM
COMBUSTION -AIR
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.
Fig. 33 Sidewall Termination of 12 In. or More
m
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.
C. CONDENSATION DRAIN PROTECTION
Freezing condensate left in condensate trap and drain line may
cause cracks, and possible water damage may occur. if freeze
protection is required, use condensate freeze protection accessory
or equivalent 3 to 6 watt per ft at 120–v and 40 °F self - regulating,
shielded, and waterproof heat tape. See Installation instructions
supplied with accessory or heat tape manufacturer's recommenda-
tions.
1. Fold heat tape in half and wrap on itself 3 times.
2. Locate heat tape between sides of condensate trap back.
(See Fig. 41.)
A87225
—30—
12" MINIMUM ■
1" MAXIMUM
COMBUSTION -AIR
Fig. 32— Concentric Vent and Combustion -Air Side i form-
nation
OVERHANG OR ROOF
VENT
"—MAINTAIN 12 IN.
CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
WHICHEVER IS
GREATER.
12" MINIMUM
cola
■ 90° ®��
BRACKET
COUPLING ��
IOW
feffii
COMBUSTION -AIR
(ELBOW PARALLEL
TO WALL)
OVERHANG OR ROOF
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.
A87228
Fig. 34— Sidewall Termination of Less than 12 In.
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
manufacture's instructions for all other installation guide-
lines.
XI. SEQUENCE OF OPERATION
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.
UNIT
SIZE
WINTER DESIGN
TEMPERATURE
(•F)
MAX PIPE
DIAMETER
(IN I
WITHOUT
INSULATION
WITH 318 -IN. OR
THICKER INSULATIONt
040
20
1.5
51
70
0
1.5
28
70
-20
1.5
•
16
70
20
2
45
70
0
2
22
70
-20
2
10
58
060
20
2
65
70
0
2
35
70
-20
2
20
70
080
20
2
55
55
0
2
48
55
-20
2
30
55
20
2.5
70
70
0
2.5
47
70
-20
2.5
28
70
100
20
p 2.5
40
40
0
•
2.5
40
40
-20
2.5
38
40
20
3
70
70
0
3
50
70
-20
3
28
70
120
'
20
3
70
70
0
3
61
70
-20
3
37
70
20
4
70
70
0
4
48
70
-20
4
23
70
140
20
3
60
60
•
0
3
60
60
-20
3
44
60
20
4
70
70
0
4
57
70
-20
4
30
70
TABLE 7— MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH (FT) WITH AND WITHOUT INSULATION IN WINTER
DESIGN TEMPERATURE AMBIENT'
• 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 (ft_ • •F• hr) /(Btu•in.)
Fig. 35— Rooftop Termination (Dimension
NOTE: If 115 -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.
A. 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.
A96128
"A" is Touching or 2 -in. Maximum Separation)
I. 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 I7 -sec ignitor warm -up period.
3. Ignition sequence -When ignitor warm -up period is com-
pleted, gas valve opens, permitting gas flow to burners
—3 I—
i
a '2
C) Q
CO o W±
N LL'
W O;
u)
W:
F-;
U a
N
0 1–'
w w:
U
IL F
Z •
H
Z
Fig. 36-- Concentric Vent and Combustion -Air Ro2
Termination (Dimension "A" Is Touching or 2 -in. Maximum
Separation)
COMBUSTION AIR
VENT
A
COMBUSTION
AIR
COMBUSTION AIR
p.
A96129
Fig. 38— Sidewall Termination of 12 in. or Less
(Dimension. "A ". Is.Touching or 2,in. Maximum Separation)
were it is ignited. ter sec, ignitor is de-energized an
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 115 -v (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 -I 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.
—32—
COMBUSTION AIR
Fig. 37— Concentric Vent and Combustion -Air Slrto
Termination (Dimension "A" is Touching or 2 -in. Maximum
Separation)
i r
COMBUSTION AIR
VENT
VENT
1" MAXIMUM
(TYP)
COMBUSTION AIR>
A96130
Fig. 39— Sidewall Termination of More than 12 in.
(Dime '. rost t p ur ge Touching
i dr motor em e ne r giz u 13 sec a e nr
burners are extinguished (5 sec if jumper has been cut for
140 size unit in downflow orientation).
B. COOLING MODE
When thermostat calls for cooling, R -G and R -Y circuits close.
R -Y circuit starts outdoor condensing unit, and combined R -Y and
R -G circuit starts furnace blower motor on cooling speed. Elec-
tronic air cleaner EAC -1 terminal is energized with 115 –v when-
ever blower is operating.
When thermostat is satisfied, R -G and R -Y circuits are opened,
furnace blower continues operating on cooling speed for an
additional 90 sec.
C. CONTINUOUS BLOWER MODE
When R -G circuit is made, blower motor operates on heating
speed.
NOTE: Electronic air cleaner EAC -I terminal is energized with
115 –v 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 at end of blower on delay
period of 60 sec (40 sec if jumper has been cut for 140 size unit in
downflow orientation).
OPEN STAND
PIPE FOR •
A/C OR !
HUMIDIFIER
DRAIN
� a
TEE -' i
` a
I'
TO OPEN
DRAIN
Fig. 40 Example of Field Drain Attachment
' CONDENSATE TRAP
WIRE TIE(S)
HEAT TAPE
(3 WRAPS MINIMUM)
Fig. 41— Condensate Trap Heat Tape
Blower reverts to continuous operation after heating cycle is
completed.
Ha call for cooling (R -Y) occurs while thermostat is in continuous
blower mode, blower changes from continuous blower speed
(heating speed) to cooling speed.
When thermostat cooling call is satisfied, R -Y opens and blower
operates an additional 90 see at cooling speed before reverting
back to continuous operation (heating speed).
D. 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 R -W and R -Y
or R -W, R -Y, and R -G thermostat inputs are received at the same
time at furnace control center, control starts blower in heating
A94054
A93036
—33—
speed. Then a gas heat mode begins. Blower remains operating at
heating 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 heating 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 R -W, R -Y, and R -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 R -W and R -Y thermostat
signals should disappear, leaving R -G thermostat signal, blower
remains on in heating speed and inducer remains on for 15 sec (5
sec if jumper has been cut for 140 size unit in downflow
orientation) to complete post -purge period.
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 Y 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.
E. COMPONENT TEST
COMPONENT TEST SEQUENCE
NOTE: All 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 is energized for 15 sec, then de-
energized.
4. Main blower operates at cooling speed for 10 sec, then turns
off.
5. Main blower operates at heating speed for 10 sec, then turns
off.
6. Inducer motor stops.
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.
I. 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.
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.
J
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 testis 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.
INITIATING COMPONENT TEST BY JUMPERING CON-
TROL TEST TERMINAL
I. Remove main furnace door.
2. Remove blower access panel.
3. Manually close blower access panel door switch. Use
apiece 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, 1 /4 -in. quick- connect
terminal on control center (adjacent to the LED diagnostic
light) 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
A
I. GENERAL
I. Furnace must have a 115 -v power supply properly con-
nected and grounded. Proper polarity must be maintained
for correct operation.
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, and Y
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 fumace.
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 burner 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.
—34—
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. 42.)
A99118
Fig. 42— inducer Housing Drain Tube
2. Connect field- supplied l /2 -in. 1D tube to upper inducer
housing drain connection.
3. Insert field - supplied funnel into tube.
4. Pour 1 quart of water into funnel /tube. Water should run
through inducer housing, overfill condensate trap, and flow
into open field drain. (See Fig. 43.)
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.
ARCFSFT ;9`Dixriiw! }oiYi3:1`iFi�, . ...
Fig. 43— Filling Condensate Trap
A99119
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 furnace
rating plate adjusted for altitude.
1. Determine natural gas orifice size and manifold pressure for
correct input.
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.
—35—
EXAMPLE: (0 -2000 ft altitude using Table 8)
Heating value = 1050 Btu/cu ft
Specific gravity = 0.62
Therefore: 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.
a. Remove burner enclosure front.
b. Remove cap that conceals adjustment screw for gas
valve regulator. (See Fig. 44.)
Fig. 44— Redundant Automatic Gas Valve
A00238
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.
CAUTION: DO NOT bottom out gas valve regulator
adjusting screw. This can result in unregulated manifold
pressure and result in excess overfire and heat exchanger
failures.
NOTE: If orifice hole appears damaged or it is suspected to have
been redrilled, check orifice hole with a numbered drill bit of
correct size. Never redrill an orifice. A burr-free and squarely
aligned orifice hole is essential for proper flame characteristics.
1
(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2 PERCENT FOR EACH 1000 FT ABOVE SEA LEVEL)
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
U.S.A. and Canada
0
to
2000
850
43
3.7
43
3.8
42
3.2
42
3,3
42
3.4
875
43
3.5
43
3.6
43
3.7
43
3.8
42
3.2
900
44
3.7
43
3.4
43
3.5
43
3.6
43
3.7
925
44
3.5
44
3.7
44
3.8
43
3.4
43
3.5
950
44
3.4
44
3.5
44
3.6
44
3.7
44
3.8
975
44
3.2
44
3.3
44
3.4
44
3.5
44
3.6
1000
45
3.7
45
3.8
44
3.2
44
3.4
44
3.5
1025
45
3.5
45 .
3.6
45
3.7
44
3.2
44
3.3
1050
45
3,3
45
3.4
• 45
3.6
45
3.7
. -;,45
3.8
1075
45
3.2
45.
3.3
45. :
3.4
45 •
3.5
.,: 45
3.6
1100
47
3.6
47
3.7
45 •
3.2
45 .
3.4
-:'45
3.5
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
U.S.A. and Canada
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
4500
775
43
. 3.8
42
3.2
42
3.3
42
3.4
42
3.5
800
43
3.5
43
3.7
43
3.8
42
3.2
42
3.3
825
44
3.8
43
3.4
43
3.6
43
3.7
43
3.8
850
44
3.6
44
3.7
44
3.8
43
3.5
43
3.6
875
44
3.4
44
3.5
44
3.6
44
3.7
43
3.4
900
44
3.2
44
3.3
44
3.4
44
3.5
44
3.6
925
45
3.7
45
3.8
44
3.2
44
3.3
44
3.4
950
45
3.5
45
3.6
45 :'.
3.7
45 •
3.8
44
3.3
975
45
3.3
45
3.4
45 _
3.5
45
3.6
. 45
3.8
1000
45
3.1
.45
3.2
45
3.4
45
3.5
45
3.6
1025
45
3.0
45 •
3.1
45
3.2
45
3.3
•• 45
3.4
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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 A%uoYSn 1
3001
to
4000
750
43
3.7
43
3.8
42
3.3
42
3.4
42
3.5
775
43
3.5
43
3.6
43
3.7
43
3.8
42
3.2
800
44
3.7
43
3.4
43
3.5
43
3.6
43
3.7
825
44
3.5
44
3.6
44
3.8
43
3.4
43
3.5
850
44
3.3
44
3.4
44
3.5
44
3.7
44
3.8
875
45
3.8
44
3.2
44
3.3
44
3.5
44
3.6
900
45
3.6
45
3.7
45
3.8
44
3.3
44
3.4
925
45
3.4
45 , .
3.5
45
3.6
45
3.7
44
3.2
950
45
3.2
45 .
3.3
45 .
3.4
45 .
3.5
45
3.7
975
45 .
3.0
:.. 45 .
3.2
45
3.3
45
3.4
, 45
3.5
1000
45
2.9
45.
3.0
45
3.1
45
3.2
.45
3.3
TABLE 8 -MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT
FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY
Orifice numbers shown In shading are factory installed.
-36--
( TABULATED
DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2 PERCENT FOR EACH 1000 FT ABOVE SEA LEVEL)
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
U.SA. and Canada
4001
to
5000
750
43
3.4
43
3.5
43
3.7
43
3.8
42
3.2
775
44
3.7
44
3.8
43
3.4
43
3.5
43
3.7
800
44
3.5
44
3.6
44
3.7
44
3.8
43
.4
825
44
3.2
44
3.4
44
3.5
44
3.6
44
3.7
850
45
3.7
.45
3.8
44
3.3
44
3.4
44
3.5
875
45
3.5
45
3.6
, 45 ":
3.7
44
3.2
44
3.3
900
45
3.3
45
3.4
.: 45;-
3.5
45 "
3.6
:.: 45 -.
3.8
925
45
3.1
' 45
3.2
::; 45 .1'
3.3
.;" 45 •"
3.4
. 45 ".-
3.6
950
45 -
3.0
45
3.1
. ' 45 ::..
3.2
.: ,
3.3
-' - ..45;a."
3.4
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU /CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
0.66
Orifice
no.
Manifold
Pressure
Orifice
no.l,
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
U.S.A. and Canada
5001
to
6000
725
43
3.4
43
3.5
43
3.6
43
3.7
43
3.8
750
44
3.6
44
3.7
43
3.4
43
3.5
43
3.6
775
44
3.4
44
3.5
44
3.6
44
3.7
43
3.4
800
44
3.2
44
3.3
44
3.4
44
3.5
44
3.6
825
45
3.6
45
3.7
44
3.2
44
3.3
44
3.4
850
45
3.4
45
3.5
• 45';..
3.6
.•: 45 '
3.8
44
3.2
875
45
3.2
45
3.3
-45, `,:
3.4
. : :. •
3.6
;,.x;46 ,..;
3.7
900
45
3.0
:. 45
3.1
;, '
3.3
45.,,,:
3.4
s;i•:45tt. t
3.5
925
45
2.9
,45
3.0
'"- 45:
3.1
.,..,'45 " :,.
3.2
: 'a45 1 ",
3.3
950
45
2.7
45
2.8
: • 45 ":':•
2.9
:. ' 45.. ,
3.0
:'•s45 ='
3.1
975
45
2.6
45
2.7
45 •
2.8
.- : 45 .
2.9
: ' :45 . ".:
2.9
1000
45
2.5
45
2.5
.' 45 .'
2.6
;. "45
2.7
;:'.45 ,
2.8
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
Amp •Y•s•n I
6001
to
7000
675
43
3.6
43
3.7
43
3.8
42
3.2
42
3.3
700
44
3.8
43
3.4
43
3.6
43
3.7
43
3.8
725
44
3.6
44
3.7
44
3.8
43
3.4
43
3.5
750
44
3.3
44
3.4
44
3.6
44
3.7
44
3.8
775
45
3.8
44
3.2
44
3.3
44
3.4
44
3.5
800
45
3.5
45
3.7
45 r
3.8
44
3.2
44
3.3
825
45
3.3
. 45
3.4
45 •» .
3.6
. 45
3.7
45 "' -:
3.8
850
45
3.1
. 45.
3.2
45 ', ,
3.4
•.. 45
3.5
- 45. •
3.6
875
45
3.0
45
3.1
45
3.2
45
3.3
`,■45
3.4
TABLE 8 -MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (CONTINUED)
FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY
• Orifice numbers shown In shading are factory Installed.
-37-
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
Aiuo •rs•n 1
7001
to
8000
650
43
3.5
43
3.7
43
3.8
42
3.2
42
33
675
44
3.8
43
3.4
43
3.5
43
3.8
43
3.7
700
44
3.5
44
3.6
44
3.8
43
3.4
43
3.5
725
44
3.3
44
3.4
44
3.5
44
3.6
44
3.7
750
45
3.7
45
3.8
44
3.3
44
3.4
44
3.5
775
45
3.5
45.
3.6
:45.
3.7
:451:'•
3.8
44
3.3
800
45
3.3
45
3.4
. 45.
3.5
....-45 ., :,
3.6
‚45 ., •
3.7
825
45
3.1
45
3.2
45
3.3
: 45
3.4
.- - 45 .'
3.5
850
45
2.9
45
3.0
-45. "
3.1
,, "•45 -:
3.2
,.; 45'.x: :.
3.3
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
U.S.A. Only
.
Altitudes
8001
to
9000
625
43
3.5
43
3.6
43
3.8
42
3.2
42
3.3
650
44
3.7
43
3.4
43
3.5
43
3.6
43
3.7
675
44
3.5
44
3.6
44
3.7
44
3.8
43
3.4
700
44
3.2
44
3.3
44
3.4
44
3.6
44
3.7
725
45
3.6
45
3.8
44
3.2
44
3.3
44
3.4
750
45 .
3.4
45
3.5
.. 45
3.6
45:•::
3.8
44
3.2
775
45
3.2
45 ,:
3.3
.45 '.: '
3.4
' .<,„
3.5
:t: ;45:;
3.6
800
45
3.0
45 <"
3.1
" <. 45 ", ::.
3.2
. • 45 .t-_,
3.3
.0' ;f.45: i :
3.4
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
Awo Ys•n I
9001
to
10,000
600
43
3.5
43
3.6
43
3.7
42
3.2
42
3.3
625 •
44
3.7
44
3,8
43
3.5
43
3.6
43
3.7
650
44
3.4
44
3.5
44
3.7
44
3.8
43
3.4
675
44
3.8
44
3.3
44
3.4
44
3.5
44
3.6
700
45 .
3.6
45 :
3.7
,.45.:.::
3.8
44
3.3
44
3.4
725
45
3.3
45
3.4
'• 45..::
3.6
• 45 .
3.7
s.,'45'..'.
3.8
750
45
3.1
45
3.2
45 :;:-
3.3
: :: 45 , :
3.4
:,'- :,45i, .
3.5
775
45
2.9
45
3.0
45 , ":'
3.1
.45
3.2
•;.:45:':: -:
3.3
TABLE 8 -MODEL 350MAV 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, DERATED 2 PERCENT FOR EACH 1000 FT ABOV SEA L
'Orifice numbers shown in shading are factory installed.
-38-
( TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 2 PERCENT FOR EACH 1000 FT ABOVE SEA LEVEL)
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
U.S.A. and Canada
0
to
2000
850
41
3.6
41
3.7
41
3.8
40
3,6
40
3.8
875
42
3.8
41
3.5
41
3.6
41
3.7
41
3.8
900
42
3.5
42
3.7
42
3.8
41
3.5
41
3,6
925
42
3.4
42
3.5
42
3.6
42
3.7
42
3.8
950
42
3.2
42
3.3
42
3.4
42
3.5
42
3.6
975
43
3.7
43
3.8
42
3.2
42
3.3
42
3.4
1000
43
3.5
43
3.6
43
3.7
42
3.2
42
3.3
1025
43
3.3
43
3.4
43
3.6.
43
3.7
43
3.8
1050
43
3.2
43
3.3
43
3.4
43
3.5
43
3.6
1075
44
3.5
44
3.6
43 ...
3.2
43
3.3
43
3.4
1100
44
3.3
44
3.4
44
3.5
43
3.2
43 .. •
3.3
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(BTU /CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
0.66
Orifice
no.
Manifold
Pressure
Orif{ee
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
I
I
U.S.A. and Canada
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
4500
775
41
3.7
41
3.8
40
3.6
40
3.7
39
3.6
800
42
3.8
41
3.6
41
3.7
41
3.8
40
3.6
825
42
3.6
42
3.7
41
3.5
41
3.6
41
3.7
850
42
3.4
42
3.5
42
3.6
42
3.7
41
3.5
875
42
3.2
42
3.3
42
3.4
42
3.5
42
3.6
900
43 •
3.7
43
3.8
42
3.2
42
3.3
42
3.4
925
43
3.5
.43 .
3.6
.43:.
3.7
42
3.2
42
3.3
950
43
3.3
`'43
3.4
- 43 :
3.5
43
3.7
43 ..
3.8
975
43
3.1
.• 43
3.3
43
3.4
43
3.5
43 .
3.6
1000
43
3.0
43
3.1
43.
3.2
43
3.3
43 .
3.4
1025
43
2.8
43 •
2.9
43
3.0
43
3.1
43
3.2
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
Awo vr•s•n I
3001
to
4000
750
41
3.6
41
3.8
40
3.6
40
3.7
40
3.8
775
42
3.8
41
3.5
41
3.6
41
3.7
40
3.6
800
42
3.5
42
3.7
42
3.8
41
3.5
41
3.6
825
42
3.3
42
3.4
42
3.6
42
3.7
42
3.8
850
43
3.8
42
3.2
42
3.4
42
3.5
42
3.6
875
43
3.6
. 43
3.7
42
3.2
42
3.3
42
3.4
900
43
3.4
43
3.5
43
3.6
43
3.8
42
3.2
925
43
3.2
43
3.3
43.
3.5
43
3.6
43
3.7
950
43
3.1
43
3.2
43
3.3
43
3.4
43
3.5
975
43
2.9
43
3.0
43 ' .
3.1
43
3.2
43 . ;
3.3
1000
43
2.8
43 •
2.9
43
3.0
43
3.0
43
3.1
TABLE 9 -MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT
FOR USE WITH 140 THROUGH 120 SIZE FURNACES ONLY
• Orifice numbers shown in shading are factory installed.
-39---
( TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DEBATED 2 PERCENT FOR EACH 1000 FT ABOVE SEA LEVEL)
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
U.S.A. and Canada
4001
to
5000
725
41
3.6
41
3.7
41
3.8
40
3.6
40
3.8
750
42
3.7
42
3.8
41
3.6
41
3.7
41
3.8
775
42
3.5
42
3.6
42
3.7
42
3.8
41
3.6
800
42
13
42
3.4
42
3.5
42
3.6
42
3.7
825
42
3.7
42
3.2
42
3.3
42
3.4
42
3.5
850
43
3.5
43
3.6
43 '
3.8
42
3.2
42
3.3
875
43
3.3
43
3.4
43
3.6
. 43 - .
3.7
43 .
3.8
900
43
3.1
43
3.3
43
3.4
43 ..
3.5
43 ` .
3.6
925
43
3.0
43
3.1
43
3.2
43 • _
3.3
. 43 •,.
3.4
950
43
2.8
43
3.9
. 43 ,
3.0
43 •
3.1
- 43 .
3.2
ALTITUDE
RANGE
( FT)
AVG GAS
HEAT VALUE
(BTU /CU FT)
SPECIFIC GRAVITY OF NATURAL GAS
0.58
0.60
0.62
0.64
0.66
Orifice
no.
Manifold
Pressure
Orifice
no.
A Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
Orifice
no.
Manifold
Pressure
U.SA. and Canada
5001
to
6000
700
41
3.5
41
3.7
41
3.8
40
3.6
40
3.7
725
42
3.7
42
3.8
41
3.5
41
3.6
41
3.8
750
42
3.4
42
3.5
42
3.7
42
3.8
41
3.5
775
42
3.2
42
3.3
42
3.4
42
3.5
42
3.7
800
43
3.7
43
3.8
42
3.2
42
3.3
42
3.4
825
43
3.5
43 ,
3.6
•43 ,r
3.7
..43 . , ;,
3.8
42
3.2
850
43
3.3
43 .
3.4
, 43 .,:
3.5
43 s.
3.6
43
3.7
875
43
3.1
43
3.2
..: 43
3.3
::. 43 <. %r.
3.4
:' .; .43 :
3.5
900
43
2.9
43
3.0
. 43 .
3.1
. 43:`'
3.2
,'43 i
3.3
925
43
2.7
43
2.8
43 ..:
2.9
. 43'. , "
3.0
43
3.1
950
43
2.6
43
2.7
43 • ;
2.8
43 :::
2.9
43 •
3.0
975
43
2.5
43
2.6
43. ••
2.6
• . 43 . •
2.7
. 43 -'-
2.8
1000
43
2.3
43
2.4
43
2.5
43 ..
2.6
. • 43 ,,.
2.7
ALTITUDE
RANGE
(FT)
AVG GAS
HEAT VALUE
(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
bap ro•s•n 1
6001
to
7000
650
41
3.8
40
3.6
40
3.7
40
3.8
39
3.7
675
41
3.5
41
3.6
41
3.7
40
3.6
40
3.7
700
42
3.6
42
3.7
41
3.5
41
3.6
41
3.7
725
42
3.4
42
3.5
42
3.6
42
3.7
42
3.8
750
43
3.8
42
3.3
42
3.4
42
3.5
42
3.6
775
43
3.6
43
3.7
43
3.8
42
3.3
42
3.4
800
43
3.4
43 .
3.5
43
3.6
43
3,7
43 •
3.8
825
43
3.2
43 ,
3.3
43 •
3.4
43
3.5
, .. 43 •
3.6
850
43
. 3.0
43 .
3.1
43 :' .-
3.2
43
13
.. 43 .
3.4
875
43
2.8
43
2.9
43....
3.0
43
3.1
:: 43
3,2
TABLE 9-MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (CONTINUED)
FOR USE WITH 140 THROUGH 120 SIZE FURNACES ONLY
'Orifice numbers shown in shading are factory installed.
--40-
4
ALTITUDE
- (FT)
PERCENT
OF DERATE
DERATE MULTIPLIER
FACTOR FOR U.S.A•
0-2000
0
1.00
2001- 3000
4--8
0.95
3001 - 4000
6-8
0.93
4001 - 5000
8-10
0.91
5001 -8000
10-12
0.89
6001 -7000
12 -14
0.87
7001 -8000
14-18
0.85
8001 -9000
16-18
0.83
9001 - 10,000
18-20
0.81
MANIFOLD
BURNER ---t
ORIFICE
BURNER FLAME
O r" .
r,- •
A
I
BURNER
A93059
CAUTION: DO NOT redrill orifices. Improper drilling
(burrs, out -of -round holes, etc.) can cause excesshie
burner noise and misdirection of burner flames. This can
result in flame impingement of burners and heat exchang-
ers causing failures.
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. 45.)
A89020
Fig. 45— Burner Flame
3, Verify natural gas input rate by clocking gas meter.
NOTE: Be sure all pressure tubing, combustion -air and vent
pipes, and burner enclosure front are in place when checking input
by clocking gas meter.
a. Calculate high - altitude adjustment (if required).
UNITED STATES
At altitudes above 2000 ft, this furnace has been ap-
proved for a 2 percent derate for each 1000 ft above sea
level. See Table 10 for derate multiplier factor.
—41—
EXAMPLE:
100,000 Btuh input furnace Installed at 4300 ft.
Furnace Input Rate
at Sea Level
100,000
Derate
X Multiplier
Factor
X 0.91
Furnace Input Rate
= at Installation
Altitude
91,000
TABLE 10- ALTITUDE DERATE MULTIPLIER FOR U.S.A.
Derate multiplier factor is based on midpoint altitude for altitude range.
CANADA
At installation altitudes from 2000 to 4500 ft, this furnace must be
derated 5 percent by an authorized Gas Conversion Station or
Dealer. To determine correct input rate for altitude, see example
above and use 0.95 as derate multiplier factor.
b. 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 1 revolution.
e. Refer to Table 1 I 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 ft altitude)
Furnace input from rating plate is 100,000 Btuh.
Btu heating input = Btu/cu ft X cu ft/hr
Heating value of' gas = 975 Btu/cu ft
Time for 1 revolution of 2-cu ft dial = 70 sec
Gas rate = 103 cu ft/hr (from Table I I)
Btu heating input = 103 X 975 = 100,425 Btuh. In this
example, the orifice size and manifold pressure adjustment
is within ±2 percent of the furnace input rate,
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:
1. Place thermometers in return and supply ducts as close to
furnace as possible, Be sure thermometers do not see heat
exchanger so that radiant heat does not affect readings. This
practice is particularly important with straight -run ducts.
SECONDS
FOR 1
REVOLUTION
SIZE OF TEST DIAL
SECONDS
FOR 1
REVOLUTION
SIZE OF TEST DIAL
1
Cu Fl
2
Cu Ft
5
Cu Ft
I
Cu Ft
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
300
20
180
360
900
60
60
120
21
171
343
857
62
58
116
290
22
164
327
818
64
56
112
281
23
157
313
783
68
54
109
273
24
150
300
750
68
53
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
26
129
257
643
76
47
95
237
29
124
248
621
78
46
92
231
30
120
240
600
80
45
90
225
31
116
232
581
82
44
88
220
32
113
225
563
84
43
86
21e
33
109
218
545
86
42
84
209
34
106
212
529
88
41
'82
205
35
103
206
514
90
40
80
200
36
100
200
500
92
39
78
198
37
97
195
486
94
38
76
192
36
95
189
474
96
38
75
188
39
92
185
462
98
37
74
184
40
90
180
450
100
36
72
180
41
88
176
439
102
35
71
178
42
88
172
429
104
35
69
173
43 •
84
167
419
106
34
68
170
44
82
164
409
108
33
67
167
45
80
160
400
110
33
65
164
46
78
157
391
112
32
64
161
47
76
153
383
116
31
62
155
as
75
150
375
120
30
60
150
49
73
147
367
COLOR
SPEED
FACTORY -
SHIPPED
CONNECTION
Black
High
Cool
Yellow (When Present)
Medium High
Spare
Blue
Medium Low
Heat
Red
Low
Spare
White
Common
Corn
DESIRED HEATING
MODE BLOWER OFF
DELAY (SEC)
SETUP SWITCH POSITION
SW -1
SW -2
90
OFF
OFF
135
ON
OFF
180
OFF
ON
225
ON
ON
TABLE 11 RATE (CU FT /HR)
2. When thermometer dings stabilize, subtract return-air tem-
perature from supply -air temperature to determine air tem-
perature rise.
3. Adjust temperature rise by adjusting blower speed. Increase
blower speed to reduce temperature rise. Decrease blower
speed to increase temperature rise.
m
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 I 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
sped selection.
TABLE 12 SELECTOR
—
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. See Table 13 for position of switches and
Fig. 24 or 25 for location of switches on control center.
TABLE 13— BLOWER OFF DELAY SETUP SWITCH
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. 46 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.
EXAMPLE:
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
HOOK- AROUND
VOLT /AMMETER
10 TURNS
FROM UNIT 24 -VOLT
TERMINAL BLOCK
5.0 AMPS ON AMMETER a 0.5 AMPS FOR THERMOSTAT SETTING
10 TURNS AROUND JAWS
Fig. 46—Amp Draw Check with Ammeter
A60201
V. CHECK SAFETY CONTROLS
This section covers the safety controls that must be checked before
the installation is complete.
A. 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
return -air supply or motor failure. If limit control does not function
during this test, cause must be determined and corrected.
LOAD CALCULATION
Heating Load (Bluh)
Cooling Load (Btuh)
Furnace Model Selection
COMBUSTION AND VENT PIPING
Termination Location
Roof or Sidewall
Termination Kit — 2 Pipe or
Concentric
Combustion -Air Pipe Length
Combustion -Air Elbow Quantity
Vent Pipe Length
Vent Pipe Elbow Quantity
Pipe Diameter Determined from
Sizing Table
Pipe Sloped to Furnace
Pipe Insulation
Over Ceilings
Low - Ambient Exposed Pipes
CHECKLIST — INSTALLATION
B. 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.
—43—
Condensate Drain
Unit Level or Pitched Forward
Internal Tubing Connections Free
of Kinks and Traps
External Drain Connection Leak
Tight and Sloped
Condensate Trap Primed before
Start-Up
Heat Tape Installed if Required
CHECKLIST — START -UP
Gas Input Rate
(Set Within 2 percent of Rating
Plate)
Temperature Rise Adjusted
Thermostat Anticipator
Anticipator Setting Adjusted or
Cycle Rate (3 Cycles per Hr)
Selected
Safety Controls Check Operation
Primary Limit
Pressure Switch
5. Turn off 115-v power to furnace.
6. Reconnect inducer motor leads, reinstall main furnace door,
and turn on 115 -v power supply.
VI. CHECKLIST
I. 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.
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 anctschedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[) Packaged Service Training [ ] Classroom Service Training
SERVICE TRAINING
A94328
02000 Bryant Heating 8 Cooling Systems 1310 W. Morris St. Indianapolis, IN 46231 —.rj
Printed in U.S.A. 350m4012 Catalog No. 5335.007
OSBURN
J - SERIES
Gas Fireplace Inserts
Installation and Operating Instructions
FLUSH
BAY
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property
damage, personal injury or toss of life.
FOR YOUR SAFETY
Do not store or use gasoline, or other flammable vapours and liquids, in the vicinity of this, or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• . Open windows
• Extinguish any open flame
• 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 neighbours phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier call the fire department
WARNING
Improper installation, service, adjustment, alteration, or maintenance can cause injury or property damage. Refer to this
manual. For assistance or additional information, consult a qualified installer, service agency, or the gas supplier.
Please read this manual before installing or using this appliance. Retain this manual for future
reference.
WARNOCK HERSEY
002 — o
Certified for Australia
Patents Pending
Made in Canada
GAS &WOOD
03/24/99 JD2061
fl C A R r H S Y S M I S '
CONTENTS
Page
1.0. INTRODUCTION I
1.1 Specifications 1
1.2 Features 3
1.3 Intended Use 3
1.4 General Safety 4
2.0 OPERATION 4
2.1 Operation Safety 4
2.2 Lighting Instructions 5
2.3 Heat Output Adjustment 7
2.4 Fan Operation 7
2.5 Remote Control Operation 7
3.0 ' • INSTALLATION 7
3.1 Installation & Safety Notes 7
3,2 Unpacking 8
3.3 Installation .9
3.3.1 Minimum Clearances 9
3.3.2 Chimney Liner Or Vent Installation 11
3.3.3 "Gas Line Installation 12
3.3.4 Thermostat, Wall Switch, Or Remote Control Installation 13
3.3.5 Vent, Gas Line, & Wiring Connections 15
3.3.6 Lower Grille Installation 16
3.3.7 Faceplate Installation 17
3.3.8 Firebox Component Installation 18
3.3.9 Initial Firing 21
3.3.9.1 Manifold Pressure Regulator Adjustment 22
3.3.9.2 Pilot Flame Adjustment 22
3.3.9.3 Flue Spillage Test 23
3.3.9.4 Altitude Adjustment 24
MAINTENANCE 24
4.1 Maintenance Safety 24
4.2 Recommended Service 24
4.3 Glass Cleaning 25
4.4 Cleaning Of Brass Plated Surfaces 25
4.5 Cleaning Of Gold Plated Surfaces 25
4.6 Burner & Pilot Cleaning 25
4.7 Fan Replacement & Electrical Schematic 25
4.8 Heater Disassembly & Reassembly 28
5.0 AUSTRALIAN DRESS GUARD 29
6.0 TROUBLE SHOOTING 31
7.0 REPLACEMENT PARTS 34
8.0 OSBURN'S WARRANTY 36
9.0 LABEL INFORMATION 38
ITEM
NATURAL GAS (NG)
PROPANE (LPG)
INPUT: High
30,000 Btu/hr (31.6 MJ/hr)
30,000 Btu/hr (31.6 MJ/hr)
•
Low
21,000 Btu/hr (22.1 MJ/hr)
22,500 Btu/hr (23.7 MJ/hr)
NORTH AMERICAN
Flue Loss: EFFICIENCY: Fan off
74 % ,
77 %
Fan on
77 % _
79 %
OUTPUT: Fan off
22,200 Btu/hr 23.4 MJ/hr)
23,100 Btu/hr 24.4 MJ/hr
Fan on
23.100 Btu/hr (24.4 MJ/hr)
23.700 Btu/hr (25.0 MJ/hr)
AFUE: EFFICIENCY: Fan off
64%
;
AUSTRALIAN
Thermal: EFFICIENCY: Without Fan
63%
63%
.
,� With Fan
•
67%
67%
MANIFOLD PRESSURE:
3.5" w.c. (0.9 kPa)
10.0" w.c. (2.5 kPa)
GAS INLET SUPPLY PRESSURE:
Minimum: 5.0" w.c. (1.2 kPa)
Minimum: 11.0" w.c. 2.7kPa)
{
Normal: 7.0" w.c. (1.7 kPa)
Normal: 13.5" w.c. (3.4 kPa)
Maximum: 13.5" w.c. (3.4 kPa)
Maximum: 13.5" w.c. (3.4 kPa)
ORIFICE SIZE: c i 0 - 2000'
#34 drill ( .111" DIA.)
#51 drill ( .067" DIA.)
•
(Canada only) (a. 2000' - 4500'
#37 drill ( .104" DIA.)
#52 drill ( .064" DIA.)
CONTROL VALVE TYPE:
SIT 820 Nova
SIT 820 Nova
S H I P P I N G WEIGHT:
I l l lb. (50 kg)
111 lb. ( 50 kg)
FLUE OUTLET SIZE:
, 4 "DIA. (102mm)
4 "DIA. (102mm)
FAN:
Variable Speed (110 Volt)
Single Speed (240 Volt)
Dual S ' eed (240 Volt)
n
1.0 INTRODUCTION
1.1 SPECIFICATIONS
TABLE 1 SPECIFICATIONS
NOTE: The efficiency rating of the appliance is a product thermal efficiency rating determined
under continuous operating conditions and was determined independently of any
installed system. AFUE was tested by Manufacturer
Options: Gold Faceplate Green Faceplate
Brass Faceplate Ivory Faceplate
Black Faceplate Ebony Faceplate
Brass Arch Kit Thermostat
Remote Control
/1
tL .
t. .(0
CO W
N LL
WO
g -J
LL Q
N d'
_. •
O. .
( " Z
O•
:0 1-
WW
LL ~O
z
U N;
z
E
14.30'
(36
1 ,;.)J01000000D
1 3.00'
Figure 1
21.50'
(546mm)
31 0U•
(7217mm)
18 M'
(479mn)
16.00'
(406mm)
BAY
21 50'
(5
FLUSH .
(Extended)
16.00'
(4C6mm)
17.30'
(439mm) •
21.50'
(546mm)
(3Cmni)
4 20' �
(107mn)
1.80'
(46mm)
FLUSH
2250'
20.50' (572mm)
(521mm)
INSTALLATION CODES
Installation must conform to local codes. In the absence of local codes, installation must conform to the
National Fuel Gas Code, ANSI Z233.1 1988, (in the U.S.), or with the current installation code CAN /CGA
B 149.1 -M86 (in Canada). In Australia, the Australian Gas Association installation code for gas burning
heaters and equipment must be used. The heater, when installed, must be electrically grounded in accordance
with local codes or, in the absence of local codes, with the National Electric Code ANSI/NFPA No. 70 -1990
(in the U.S.) or with the current CSA C22.1 Canadian Electrical Code (in Canada).
/2
1.2 FEATURES
Ignition system:
Standing pilot ignition system with thermopile and thermocouple flame detection and piezo igniter.
Gas control:
Gas control valve type:
Automatic millivolt powered combination gas control valve with variable flame control for
convenience, and on/off switch. Optional remote on/off wall switch, optional wall thermostat, and/or
optional wireless remote control are available. The gas valve does not require electricity from an
external source.
Fan control:
Variable Speed Control:
For units equipped with a fan control, the knob controls the fan speed in connection with a heat
sensitive switch which turns on when the heater reaches operating temperature. Turning the knob
counter - clockwise 4 - turns it to the "OFF" position.
Auto /Off Switch: (Single Speed 240 Volt)
For units equipped with a single speed fan switch, the fan may be switched between the "Automatic"
& the "Off" settings.
High/Off/Low: (Dual Speed 240 Volt)
For units equipped with a double speed fan switch, the fan may be switched between the "High ",
"Off", & the "Low " settings.
Safety controls:
A safety switch will shut the system down in the event of any one of the following conditions:
Incorrectly installed vent system
Blocked vent causing flue spillage
Flow reversal or sustained down draft situation
Drafthood:
The appliance is provided with a drafthood design which minimizes the effects of down drafts or flue
blockages on the quality of combustion. It will vent out of the appliance upon down draft or flue
blockage and, by design, it exhausts to the same pressure zone as the combustion air inlet to the
appliance.
1.3 INTENDED USE
This appliance is intended to be used as a heater, when installed as an insert for code complying masonry, or
listed factory built solid fuel burning fireplaces which meet the minimum requirements as described in detail
in the installation instructions. This insert is certified for installation in a bedroom or a bed sitting room where
the maximum input is within 50 cubic feet per 1000 Btu/hr, (ie. 1250 cubic feet). All bedroom installations
require the use of wall thermostats.
/3
1.4 GENERAL SAFETY
The appliance must be properly connected to a venting system in accordance with local codes. This unit
must not be connected to a chimney or flue serving any other appliance. It is equipped with a safety control
system to protect against improper venting of flue products.
WARNING: Operation of this insert when not connected to a properly installed and
maintained venting system, may result in carbon monoxide poisoning.
Installation and repair should be done by a qualified service person. The appliance should be inspected before
use and at least annually by a professional service technician. Provide adequate clearances around air
openings and allow accessibility clearance for servicing and proper operation. In Australia, a dress guard has
been installed to cover the glass and to protect users against accidental contact with hot surfaces. Do not
operate the appliance without the dress guard in place.
2.0 OPERATION
2.1 OPERATION SAFETY
Inspect the appliance before use. Always keep the appliance area clear and free from combustible materials,
gasoline and other flammable vapours and liquids. Never obstruct the flow of ventilation air. Keep the front
of the appliance clear of all obstacles and foreign materials. Never obstruct or modify the air inlet/outlet
grilles of the fireplace in any manner.
CAUTION: Children and adults should be alerted to the hazards of high surface
temperature and should stay away to avoid bums or contact with hot
surfaces. Young children should be carefully supervised when they are
in the same room as the heater. Clothing or other flammable material
should not be placed on or near the unit.
The glass door and top grille must be properly installed prior to operation. Never operate the unit with the
glass door off or broken since this may cause dangerous indoor air pollution. This unit is not for use with
solid fuel. Do not substitute any parts or materials. Do not abuse the glass door.
/4
AUTO
. OFF
AUJSTRALA
HI
OFF
.LOW
FAN SWITCH 4
SPEED CCNTRCL
CR
PTEZO
!Omit N
BUTTON
VARIABLE CONTROL
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY, READ BEFORE LIGHTING
WHAT TO DO IF YOU SMELL GAS
Figure 2
ACCESS DOOR
(IN OPEN POSITION)
CAS CONTROL
ON
OFF
BURNER
ON /OFF
SWITCH
WARNING: If you do not follow these instructions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
A. This appliance is provided with a standing pilot flame. When lighting the pilot, follow these instructions
exactly:
B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle on the floor.
* Do not try to light any appliance.
* Do not touch any electrical switch: do not use any phone in your home.
Immediately call your gas supplier from a neighbour's phone. Follow the gas suppliers instructions.
If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push
in or turn by hand, do not try to force or repair it; call a qualified service technician. Forcing or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system and any gas control
which has been under water.
/5
LIGHTING PROCEDURE
1. "STOP!" Read thesafety information in the previous section.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. Open the access door, hinged to open downward, by gently pulling the top toward you.
5: Push in the gas control knob slightly and turn clockwise -4 to the "OFF" position (see Figure 3).
OUTLET
INLET PRESSURE
TEST POINT
0
El®
U
PILOT
A
MANIFOLD PRESSURE
TEST POINT
Figure 3
Wait a minimum of five minutes to clear out any residual gas. If you then smell gas, STOP! Follow
"B" in the Lighting Instruction section described on the previous page. If you don't smell gas, go to
the next step.
Press in the gas control knob and turn counter - clockwise 4 - to the "PILOT" position.
8. Push the control knob in all the way and hold it in. Immediately push the piezo ignition button (the
black button second from the left) repeatedly so that it clicks; continue until the pilot ignites.
Maintain pressure on the knob for about one minute after ignition. Then release the knob; if the pilot
flame goes out repeat step 8; if the pilot flame remains on then turn the knob counter - clockwise t-
to the "ON" position.
9 : If the pilot lights, but will not stay on after several tries, turn the gas control knob to the "OFF"
position and call your service technician or gas supplier. If the control knob does not pop out when
released, STOP - shut off the gas supply to the control valve, and IMMEDIATELY call your service
technician or gas supplier.
10. If equipped with a wall switch, select the "ON" position. If equipped with a thermostat or auxiliary
control, set it to the desired setting.
11. Close the access door by lifting it, allowing the springs to pull it closed.
INLET
/6
-`1
SHUTDOWN PROCEDURE
1. To turn off the main burner only, turn off the wall switch, thermostat, or On/Off switch located on
the lower right side behind the access door.
2. For complete shutdown of the appliance, depress the gas control knob and turn it clockwise - to the
"OFF" position.
2.3 HEAT OUTPUT ADJUSTMENT
The valve supplied with the appliance has a HI/LO knob to control the heat output and flame height (see
Figures 2 & 3).
2.4 FAN OPERATION
For units equipped with a fan control knob, the knob is located behind the access door and may be adjusted
to the following settings:
OFF: Turn the control fully counter - clockwise 4- until the switch operates.
Variable Speed Setting:
Turn the &ontrol to the desired setting. When the knob is turned fully clockwise -i the fan will be
set to minimum speed.
For units equipped with a fan switch, the fan may be switched beween the "Off" and "Automatic" settings.
2.5: REMOTE CONTROL OPERATION
An optional hand held remote control kit for turning the unit On and Off is also available. Detailed
instructions for the optional Remote Control are included with the kit.
3.0 INSTALLATION
3.1 INSTALLATION & SAFETY NOTES
rTh
Read all instructions before starting installation and follow them carefully during installation to ensure
maximum benefit and safety. Failure to follow these instructions will void your warranty and may present
a fire hazard. See the Osburn warranty at the back of this manual for disclaimers regarding improper
installation. This fireplace insert and its components are tested and safe when installed in accordance with
this installation manual. This insert must never be installed in direct contact with combustible
construction.
ELECTRICAL GROUNDING NOTE: This heater fan is equipped with a three -prong (grounding) plug.
for your protection against shock hazard and should be plugged directly into a properly grounded three -prong
receptacle. Do not cut or remove the grounding prong from this plug.
/7
WARNING: Do not connect 120 VAC (240 VAC in Australia) to the gas control valve or
its wiring, as this will damage the valve.
3.2 UNPACKING
ADJUSTED. FOR AUSTRALIA ADJUSTED FOR NORTH AMERICA
Figure A
Please check the appliance carefully for any damaged or missing components (specifically check the glass
condition). Report any problems to your dealer. The insert is shipped with the logs and coals in separate
packages inside the firebox. The faceplate, with the levelling screws and the grille kit are packaged
separately. All other standard parts are already in place.
Shutter Adjustment For Australian Units Only:
Before installation the two Shutters on the bottom ouside corners of the Firebox must be checked to ensure
their proper positioning (see Figure A).
3.3 INSTALLATION
For satisfactory results it is necessary to plan certain aspects of the installation prior to the appliance's final
positioning. These include the vent system, the gas piping, and the fan wiring. Combustible surfaces such
as the hearth, mantle and facing must also be planned for.
NOTE: All Installations Require Venting.
(In Australia, a minimum vent length of 11' (3353mm) must be used off the top of the vent collar
of the appliance).
31.00"
(787mm)
TOP VIEW
Minimum enclosures are as follows:
FIREPLACE
OPENING
FRONT VIEW
- i
(406m m) BAY & EXTENDED FLUSH
�- -17.3" FLUSH ONLY
(439mm)
Figure 4
20.50"
(521 mm)
SIOE VIEW
3.3.1 Minimum Clearances
This top venting insert is suitable for installation into masonry fireplaces, or into factory built certified
fireplaces which have a gas line knockout and proper floor clearances.
A masonry fireplace must meet the minimum building code requirements or the equivalent for a safe
installation.
Factory built certified fireplaces and their chimneys must be certified and meet local code requirements. Both
must be free from cracks, blockage, creosote deposits, loose mortar, or other types of deterioration.
Inspect the fireplace to ensure the insert will fit (see Figure 4).
/9
Minimum Clearances To Combustibles
A. Sidewall 10" (254mm) measured from glass
B. Ceiling 34" (864mm) measured from top grille
C. Facing sides 1" (25mm) measured from standard faceplate
top 8.5" (216mm) measured from the top of the grille assembly
D. Floor 2" (51mm) (see Figure 5a)
E. Mantle 12.5" (318mm) measured from top grille to 8" (204mm) mantle
Note: 1. For more mantle options see Figure 6
2. When using paint or lacquer to finish the mantle, such paint or lacquer must be heat resistant to
prevent discolouration.
MANTLE
When installing the unit flush to the flooring, there must be an 16" non - combustible hearth
extension (see Figure 5b).
COMBUSTIBLE TOP FACING
MASONRY FACING
FACEPLATE
TOP GRILLE ASSEMBLY
ZOO
*(51mm)
• INSERT
; XI STi NG
Figure 5a
7
C
MANTLE
COMBUSTIBLE TOP FACING
MASONRY FACING
FACEPLATE
TOP GRILLE ASSEMBLY
INSERT
NON- COMEUSTIBLE
HEARTH EXTENSION
•
•
J
IC" (1C6mm)
Figure 5b
4
FLASHING
12.:0'
(319mm
Figure 6
WALL
3.3.2 CHIMNEY LINER OR VENT INSTALLATION
Figures 7 and 8 show the completed installations into a masonry and into a factory built certified fireplaces.
For Australia, installations and flue materials must comply with AG601 requirements.
Figure 7 FIGURE 8
FLASHING
•4.0' LINER or B —VENT
(nol shown)
�— FACTORY BUILT FIRE =.aCE
The insert must be connected to a flex liner or B -vent suitable for use with gas. The vent must run within
the existing chimney from the outlet collar of the drafthood to the top of the masonry or factory built
chimney. Install the vent according to the manufacturer's instructions. Use a maximum of two offsets; (four
45° elbows), or two 90° elbows. Slope horizontal pipe at least 1/4" (6.4mm) rise per foot of run. Horizontal
runs should not exceed the vertical rise.
3.3.3 Gas Line Installation
• Install supply line using any piping approved for your installation meeting CAN /CGA 6.10, AGA 3, ANSI
Z21.24 or Z21.45. A qualified gas fitter should install the gas line in accordance with all local building
codes. If codes permit, coiled copper tubing may be used for gas supply.
Pressure taps are provided on the gas control for test gauge connections to measure the manifold and
inlet pressures.
This appliance must be isolated from the gas supply piping system by closing its individual manual shut
o$valve during any pressure testing of the gas supply piping system at test pressures equal to or less than
1/2 psig (3.45 kPa).
The appliance and its individual shut off valve must be disconnected from the gas supply piping system
during any pressure testing of the system at test pressures in excess of 1/2 psig (3.45 kPa).
Install the ga line as follows:
The gas line connection on the right side of the insert is shown in Figure 9. An AGA and/or CGA
approved shutoff valve can be installed to the 5" nipple if so desired. Installing the shutoff valve on
the end of the 5" nipple will allow quick accessibility.
WARNING: Do not use an open flame to test for gas leaks.
i
I
12.00
(305mm)
\` GA; CONTROL VALVE
3/87 GAS LINE
5 V1= - -
3.50"
(39mm)
/12
AWG
mm
ft.
m
22
0.6
10
3.0
20
0.8
25
7.6
18
1.0
40
12.2
16
1.3
64
19.5
14
1.6
100
30.5
3.3.4 Thermostat, Wall Switch, Or Remote Control Installation
The burner control switch is located on the right top side of the faceplate (see Figure 2). For your
convenience, the insert can also be operated by a thermostat, a wall switch or a remote control. Millivolt
thermostats and remote control kits are available from any authorized Osburn dealer. Bedroom installations
require the use of a wall thermostat.
NOTE: The thermostat or wall switch MUST be rated for millivolt use. Minimize
splicing in all millivolt wiring & solder all unavoidable splices.
Remote Control Installation: Please refer to instructions included with kit.
Thermostat Or Wall Switch Installation
1.' Mount the or wall switch in the desired location and run "two conductor thermostat
wire" to the heater's lower right hand corner, close to the gas supply line.
TABLE 2 THERMOSTAT WIRE INFORMATION
Purchase "two conductor thermostat wire, " which is not provided, at any local supplier. The gauge
of thermostat wire will determine the maximum wire length and distance at which to locate the
thermostat or wall switch. See Table 2 and the information packaged with thermostat. Be aware that
as the length of wire increases, the probability of adequate operating voltage decreases.
WIRE SIZE MAX. WIRE LENGTH
2a. After the insert is installed and the gas line hooked up, solder a female spade connector to each wire
and join them to the male connectors provided on the rear of the burner switch (see Figure 10), or
2b. Solder a fork connector to each wire and install them to the valve.
3. Check tests can be performed on the valve by using the trouble shooting guide, Section 6.0.
4. This switch may be connected in parallel with a thermostat, wall switch, or remote control (see Figure
11).
/13
INLET
Dc-
Figure 10
THERMOCOUPLE
TO SAFETY SOLENOID
ON BACK OF VALVE
INLET
SWITCH
Figure 11
THERMOCOUPLE
THERMOPILE
THERMOPILE
/14
3.3.5 Vent, Gas Line, & Wiring Connections
Unless it is more easily installed with the insert, install the drafthood separately first as follows:
1. Disconnect the drafthood from the insert and fit its collar to the end of the previously installed vent,
whether the flue -liner is in an existing masonry fireplace or the flue -liner is in an existing factory built
certified fireplace.
2. Wiring:
i) Cut the plastic pull -tie securing the blue wires.
ii) Cut the plastic pull -tie securing the fan power cord to the heater.
Two captive nuts are attached to the air jacket bottom.
i) Remove the two 1/4 " -20 screws (2.5" (64mm) long) provided with the faceplate package.
ii) Turn the screws through the two rear captive nuts to level the unit as required.
4.
Push the drafthood upward to 21" (535mm) above the hearth or fireplace bottom, and start sliding
the insert into the fireplace cavity.
5. > Connect the wiring for the thermostat, wall or faceplate switch, or the remote control as noted in #2
of section 3.3.4.
6. The fan power cord is on the left side of the insert and can be routed to the right if desired. Route
the power cord along the bottom outside edge of the heater, not underneath, nor under any sharp
edges.
7. Push the insert back until the front firebox flanges are 1/4" (6mm) in front of the masonry or factory
built fireplace facing. As the heater is pushed back, pull the drafthood positioning strips firmly toward
the heater front until the drafthood flange is secured under the top clips of the heater (Figure 12).
8. Bend the positioning strips down over the top front edge, cut off the excess strip length, and fold the
strips back over the top flange.
9. Connect the union of the gas supply line.
10. Purge the gas line of air.
11. Test the fz. leaks using an electronic gas leak detector or soapy solution.
WARNING: DO NOT USE AN OPEN FLAME TO TEST FOR GAS LEAKS.
/15
CONTROL
PANEL
CLIP
POSITIONING STRIP
LOWER GRILLE INSTALLATION
Figure 12
1. Pull the control panel forward to release it from the retaining clips.
2. Removethe four screws from the firebox supports.
NOTE: The Contemporary Bay (JG124) lower grille has two adapter plates attached to the
grille assembly. Remove these plates from the grille assembly and attach them to the
firebox supports.
3. Place the lower grille assembly in position against the front of the firebox supports.
Secure the lower grille assembly with the four screws that were previously removed (see Figure 13).
Push the control panel back into position under the retaining clips.
Figure 13
SOX :UFFCF
/16
,->
3.3.7 FACEPLATE INSTALLATION
Figure 16a
Remove the faceplate panels and the edge trim from the packaging and assemble according to the following
instructions:
1. Place the faceplate panels with the finished side down on a flat, soft, nonabrasive surface.
2. Line up the holes of the side and top panels and install the four screws loosely (see Figure 14).
3. Line up the edges of the faceplate top and sides, then tighten all four screws.
4. Assemble the faceplate trim, attaching the mitred corners with the corner brackets (see Figure 15).
Figure 14 Figure 15
5. Slide the assembled trim over the edges of the faceplates.
6a. Snap the eight trim retainers in place (see Figure 16a).
6b. Push the burner switch through the hole in the right hand faceplate trim and connect the two blue
wires to the switch connectors (see Figure 16b).
Figure 16b
/17
7. With the door removed, place the faceplate assembly up to the front of the insert.
8. Secure the faceplate.with the four Philips screws (see Figure 17a).
NOTE: Do not adjust the faceplate depth on the Bay Insert.
FLUSH INSERT ONLY:
9. Adjust the faceplate mounts to the desired setting (see Figure 17b).
SCREWS
ADJUSTABLE FACEPLATE
MOUNT
Figure 17a Figure 17b
3.3.8 Firebox Component Installation
Installing Logs
Proper log placement is very important The logs are designed to be installed in only one position so that
flames do not impinge on them.
Locate the rear log by positioning it between the rear brick panel and the tabs on the rear log support.
REAR BRICK PANEL
REAR LOG LOCATION TAB
FRONT LOG LOCATER
(PILOT ASSEMBLY)
Figure 18
/18
The front log is similarly located, by positioning the large notch against tile pilot bracket.
Installing Coals
n
■
V 0
1.4.
FRONT LOG LOCATION TARS
Both logs should be positioned, first to the rear, then to the left.
Place the upper right log on top of the lower logs locating it within the notched portions, and with the bark
side of the log to the right.
The coals should be placed along the coal grate on top of the burner, located in front of and below the front
log (see Figure 20). The coals extend around the log end.
NOTE: There are two denser sets of holes on the front burner - these should not be
covered, as they will offset the visual appearance of the front flames.
WARNING: Do not add any material to the appliance which will come in contact with the
flames, other than that supplied by the manufacturer with the appliance.
.:CAL
";TA
REAR LOG LOCATION TASs
Figure 19
FRONT :LOC
— REAR BRICK CM {i
•
r /
Figure 20
/19
Installing The Lower Door Trim
WARNING: See sections_4.4 & 4.5 before installing the lower door trim
1. Place the lower door assembly upside down on a soft work area.
2. Remove the four retaining screws from the doorframe bottom.
3. Place the lower door trim in position over the door assembly and align the screw holes.
4. Secure the lower door trim with the four screws that were previously removed.
5. Re -attach the door assembly onto the firebox.
LOWER DOOR TRIM
Figure 21
DOOR ASSEMBLY
(UPSIDE DOWN)
Installing The Door
Install the door by assembling its upper hinge slots to the hinge tabs on the top of the firebox. Swing the
door down towards the fireplace and latch at the bottom.
Installing Top Grille Assembly
1. Place the top grille assembly above the door.
2. Push the grille retaining plate into the clips and against the stops on top of the insert (see Figure 22)
NOTE: Improper installation of the top grille assembly may cause tarnishing of the
brass.
/20
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FLUSH
3.3.9 INITIAL FIRING
STOP
RETAINING CLIP
Figure 22
4 00■44
BAY
EETAININC PLATE
STOP
RETAINING CLIP
Wh en lit for the first few times, the appliance may emit an odour resulting from evaporation of paint and
lubricants used in the manufacturing process. Open a door or window for ventilation. Anyone with a
respiratory condition may need to leave the room during the initial firings.
NOTE: It is normal for the appliance to expand and contract while it heats up or cools
down whether this is from a cold start or a steady -state condition where the fan
has come on or off. Under these circumstances it is possible that the
expansion/contraction of the metal parts may produce a ticking sound.
Occasionally, after a cold start, vapour may condense and fog the glass, and the flames may be partially blue.
After a few minutes the moisture will disappear and the flames will become yellow. Visually check the
maximum flame height after warmup (see Figure 23).
/21
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3.3.9.2 Pilot Flame Adjustment
3.3.9.1 Manifold Pressure Regulator Adjustment
The manifold pressure regulator controls gas input and flame height, and is preadjusted at the factory. No
further adjustment is required. Manifold pressure can be verified only (see Figure 3).
For proper operation, the pilot and main burner flames must be steady and not lifting off or floating. The top
3/8" - 1/2" (10 -13mm) of the thermopile should be engulfed by the pilot flame. The flame adjustment
should be performed by a qualified service person only. To adjust the pilot flame, turn the pilot adjustment
screw counter - clockwise t- to increase, and clockwise -4 to decrease the flame. Ensure that the pilot flame
completely engulfs the thermopile (see Figure 24).
THERMOPILE THERMOCOUPLE
Figure 24
3/8" TO 1/2 ".
(10mm TO 13mm)
THERMOPILE
X22
3.3.9.3 FLUE SPILLAGE TEST
A flue spillage test is recommended as part of this installation and should be performed by a qualified service
person only. Hereafter, periodically check the vent draft.
1. Close all the doors and windows in the room.
2. Start all the exhaust fans in the home.
3. Remove the top grille assembly by pulling it forward carefully.
4. Light the heater to the full fire position.
After five to ten minutes, insert a match inside a draft duct opening and ensure that the flame wisps
and smoke are drawn into the duct at the front corner (see Figure 25).
6. If the flame wisps are not drawn into the ducts, turn the heater of ly and determine the cause of the
lack of draft. Do not operate the heater until there Is sufficient draft.
Replace the top grille assembly after the insert cools.
DRAFT DUCT
CRAFT DUCT
/23
4.0 MAINTENANCE
Annual service:
3.3.9.4 ALTITUDE ADJUSTMENT
All valves have been pre -set and certified for installation at elevations from 0 - 2000 feet (1 -610m) above sea
level.
When installing this heater at higher elevations in Canada, it is necessary to decrease the input rating, by
replacing the existing burner orifice with a smaller size for installations over 4500 feet (1372m). The
appliances input should be reduced 4% for each additional 1000 feet (305m) above sea level. For the USA,
derate the heater from sea level according to the gas installation code.
4.1 MAINTENANCE SAFETY
Turn off the gas to the main burner and allow the heater to cool for up to 30 minutes before
servicing. Service and repair should be done by a qualified service person. The appliance should be
inspected before use and at least annually by a professional service technician. More frequent cleaning may
be required due to excessive lint from carpeting, bedding material, etc. It is important that the access door
compartment, burl}er, and circulating air passage -ways be kept clean to provide for adequate combustion and
ventilation air flow. Do not substitute materials or use components other than factory supplied.
4.2 RECOMMENDED SERVICE
1. Examine the venting system periodically.
2. Visually check the burner and pilot flames occasionally. Visually inspect height and colour of flames
(see Figure 24).
. Clean the glass as needed. See section 4.3 for instructions on glass cleaning.
4. Have the appliance inspected annually by a professional service technician.
5. Clean the appliance regularly.
NOTE: Safety screens removed for service must be replaced prior to operating the
heater.
An annual service call should take between 1 -2 hours. Start by disassembling the unit;
take off the glass and remove all the logs, embers, burner, and fan. A small
toothbrush is a handy tool for cleaning the fan. Loosen all the debris on the fan blades
and vacuum it off. Vacuum the whole firebox and all the air passages. Clean the
burner, pilot orifice, main orifice, logs, etc. After everything is clean, check all the
connections and the chassis ground an d reassemble. Fire up the unit and check the
electrical readings of the thermopile /thermocouple. Clean the glass. Check the gas
pressure. Check the draft (the venting system should also be checked).
/24
4.3 GLASS CLEANIN(
The inside of the glass may require periodic cleaning to remove deposits left from impurities in the gas and
combustion air. For best results, use a ceramic glass cleaner or polish. A suitable cleaner is available from
your dealer. Avoid the use of amonia based cleaners such as windex. Do not clean while hot. Do not use
abrasive cleaners. Make sure you clean off the white film on the fireplace glass as soon as possible -
otherwise the glass may deteriorate.
4.4 CLEANING OF BRASS PLATED SURFACES
Special care must be taken to avoid damage to the high temperature coating applied to each brass piece. Do
not touch or attempt to clean the brass on your fireplace when the brass surface is warm.
Wipe only with a soft damp cotton cloth to maintain original brilliance. Caution: Some cleaning agents may
contain chemicals that could harm the high temperature coating on the brass. Paper towels and other abrasive
materials may scratch the surface.
4.5 CLEANING OF GOLD PLATED SURFACES
Take special care and DO NOT use chemical or abrasive cleaners. Wipe only with a soft damp cotton cloth
to maintain original brilliance. CAUTION: Vigorous wiping may damage the gold finish.
4.6 BURNER & PILOT CLEANING
Periodic cleaning is necessary for proper operation.
1. Refer to section 4.8, remove the burner and check that the burner orifice is clean.
2. Visually inspect the pilot. Brush or blow away any dust, lint or foreign debris. If the pilot orifice is
plugged, disassembly may be required to remove any foreign material from the orifice or tubing.
When the appliance is back in service, check the pilot flame pattern with the Figures in section
3.3.9.2. For relighting, refer to the lighting instructions in section 2.2.
4.7 FAN REPLACEMENT & ELECTRICAL SCHEMATIC •
1 Turn off all electrical power to the heater. Unplug fan cord or turn circuit breaker off.
2 Remove the four screws which locate the lower grille assembly, and remove it.
3. Remove the two electrical shield screws and shield (see Figure 26).
4. Remove the two fan bracket to fan base securing screws (see Figure 27).
5. Remove the two fan bracket securing nuts (see Figure 28).
6. Remove the fan wire from the thermal switch.
/25
Figure 28
Disconnect the remaining fan wire at the inline connector.
8. Remove the fan by first rotating it 90° backwards, and then sliding it forward and out.
9. Reassemble in reverse order.
10. See Figure 29 for fan electrical schematic.
11. If the supply cord is damaged it must be replaced by a special cord available from the manuafacturer
or its service agent.
/26
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PAN SWITCH &
SPEED CCNTECL
DUAL SPEED (240 VOLT)
CREENrELLGN
GROUND
' BaOMN
9LUE /NEUTRP4.
Figure 29
KEN
If necessary, the Fan Thermal Switch may be replaced as follows:
Turn off all electrical power to the insert; unplug power cord or turn circuit breaker off.
2. Remove the four screws which locate the lower grille assembly, and remove it.
3. Remove the shield by removing two screws (see Figure 26).
Remove the fan thermal switch mount bracket by loosening two screws but do not remove them.
Disconnect the two wires from the switch.
6. Remove the two screws securing the switch.
7. Remove and replace the thermal switch.
8. Reassemble in the reverse order.
4.8 HEATER DISASSEMBLY & REASSEMBLY
The following procedure is to be performed by qualified service personnel ONLY.
Turn off the gas supply and allow the heater to cool for up to 30 min.
1. Remove the top grille assembly.
2. Remove the door.
3. Remove the lower grille assembly.
4. Remove the logs and coals.
Remove the burner tray assembly as a unit by lifting it up and out.
Undo the gas flexline connection at the gas valve. These fittings are flared and do not require sealant.
Remove the screw securing the pilot assembly to the pilot bracket.
. Remove the four screws securing the pilot cover plate and gasket & then remove them.
Remove the nut securing the orifice to the firebox bottom.
10. Remove the four screws holding the valve bracket to the firebox bottom.
11. Disconnect the thermostat wires from the valve. Once the fasteners are removed, the valve/pilot assembly
can be lowered down and rotated out through the front of the appliance as a complete unit.
12. Reassemble the components in reverse order.
/28
5.0 AUSTRALIAN DRESS GUARD
Figure 30
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NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN
THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT.
. _ _
6.0 TROUBLE SHOOTING
SYMPTOM
I. Pilot will not light after
repeated triggering of
the red piezo ignition
button
POSSIBLE CAUSE
A. No spark a electrode (weak or no heat
source for pilot ignition)
1. Improper ignition 1.
. Poor connections at starter and ignition 2. Reconnect if loose
electrode
Broken ceramic cover on ignition 3. Replace pilot assembly
electrode
Defective piezo igniter
Poor grounding of piezo igniter
B. No gas or low gas pressure
1. Gas line shut off(s) may not be turned on
2. No gas supply (LPG) 2. Check propane tank; you may be out of fuel
Air in gas lines
Gas lines may not be connected 4.
Low pressure may be caused by bent line 5.
Valve control knob not fully depressed in 6.
"PILOT" position
Thermocouple/valve
Weak or improperly located pilot flame
Defective thermocouple
CORRECTIVE ACTION
Align the electrode with 1/8" (3mm) gap to
pilot hood
4. Replace piezo igniter
5. Tighten mounting nut and/or igniter screws
•
. Turn on shut -off valves
Purge gas lines
Connect all gas lines
Check for a kinked line
Fully depress control knob
• Adjust and clean pilot. The flame must
impinge on or engulf the thermocouple, as
shown in Figure 24
. ; Replace thermocouple
•
/31
SYMPTOM
Q Pilot will not stay lit
after following the
lighting instructions
(continued)
not A.
1.
2.
POSSIBLE CAUSE '
Thermocouple/valve (continued)
4. Thermocouple not installed properly
Open wire connection in pilot circuit
. Defective valve
Defective safety circuit
Improperly wired
. Loose or defective connections
3. Defective
(EPU)
Defective spill switch
Valve/Switches
Valve control off
electromagnet power
Defective wall switch or thermostat
. Defective wiring or connections
Excessive length of thermostat wire from
valve to wall switch or thermostat
Wall switch or thermostat incorrectly
wired
7. Defective remote control
8. Mismatched remote control frequencies
unit 3.
Blockage at the burner (line, orifice, or 2.
ports)
CORRECTIVE ACTION
4. Make sure all wire connections at the gas
valve terminals are tight and the
thermocouple is fully inserted into the
mounting bracket
5. Check wire continuity and connections in
the pilot circuit
6. Connect the millivolt meter probes to the
thermopile terminals on the gas valve.
Turn the valve to the "PILOT" position,
depress and light. If the metre reading is
greater than 250 millivolts after 30 seconds,
the thermopile is good. If the pilot does not
stay lit, the valve is defective. Check
section "B" below, before replacing valve
1. Rewire correctly
2. Check continuity, tighten wiring or
connections and repair
Check and replace if required
1. Turn to "ON" position
Check and clean
6. Wire correctly
8. Match frequencies
4. Check continuity & replace if defective
3. Conduct a continuity test or juniper wire
test and replace if defective
4. Conduct a test with a juniper wire and
repair as required
5. Reduce wire length to less than 100 feet, or
increase wire size
7. Check batteries and replace if required
/32
IV. Soot deposits on glass
SYMPTOM
UL Main burner will not A. Valve/Switches (continued)
light (continued)
VL Frequent pilot outage
problem See V
POS BLE CAUSE COkr<ECTIVE ACTION
9. Defective valve
9. Turn valve and "ON /OFF" switch to the
"ON" position. Check with millivolt meter
at terminals TP -TH. Millivolt meter should
read greater than 100 millivolts. If the
reading is OK and the burner does not
come on, replace the gas valve
10. Thermopile may not be generating 10. Recheck using the millivolt meter. The
sufficient voltage (325 mV SIT) pilot flame may not be high enough for the
flame to properly engulf the thermopile. If
so, adjust and reset. If voltage is still
insufficient, replace thermopile
11. Wall switch, thermostat, remote control, 1 I. Follow previous corrective action, check
or wires are defective switch and wiring. Replace where
defective
. Flame impingement on logs I. Adjust the log set to avoid direct flame
impingement. Follow log placement
instructions •
Improper venturi setting 2. Ensure the air shutter is properly set to NG
= .06" (1/16 ") (2mm) and LP = .23"
(
• Foreign material impeding burner 3. Ensure that no foreign material blocks
burner flame ports
Air inlet blocked or restricted 4. Clean air inlets
Vent system is restricted or inadequate 5. Conduct flue spillage test and correct flue
as required
I nsufficient combustion air being 1. Ensure that no foreign material blocks air
supplied inlets and that the burner shutter is correctly
adjusted. Ensure the vent is adequate
Manifold pressure set too high
Vent system restricted
2. Check manifold pressure
3. Check vent system
Flames impinge on
firebox top 1. Vent system is restricted or inadequate 1. Correct flue as required
2. Manifold pressure too high 2. Check manifold pressure as required
/33
COMMON PARTS . • ..
. .COMMON PARTS 1.: . .
PART No.
I DESCRIPTION
J00069
JD105
Front Log
JD0070
Blower Assembly Dual Speed
(240 Volt)
Log Rear
JD0071
CA1023
Log Top
J0030
Bumer Orifice Jam Nut
Log Set
BNO22
J00048
On /Off wires (2/unit)
HG58
Burner Switch On /Off
Piezo Ignitor
HG36
CZ0127
Pilot Assembly LP With Ignitor
HG35
Extension Knob, On /Off
Pilot Assembly NG With Ignitor
J00063
J0006
Pilot Gas Line
HG51
Fan Thermal Switch
Pilot Orifice LP
HG52
HM22
Pilot Orifice NG
HE24
Ignitor Cable
Switch, 2 -Way Rocker, 240V Fan
HE25
Switch, 3 -Way Rocker, 240V Fan
HG37
Thermocouple,
' HE32
Thermodisc Spill Switch
HG25
•
Thermopile
JD072
Valve Assembly LP
JD071
Valve Assembly NG
COMMON PARTS . • ..
PART No.
DESCRIPTION
JD041
Arch Kit Brass
JD105
Blower Assembly Single Speed
(240 Volt)
JD106
Blower Assembly Dual Speed
(240 Volt)
JD007
Blower Assembly North America
CA1023
Burner
CZ0097.
Bumer Orifice Jam Nut
JD0049
Burner Orifice LP
J00048
Burner Orifice NG
HE23
Burner Switch On /Off
CZ037
Coals
CZ0127
Door Gasket
HG60
Extension Knob, On /Off
HG61
Extension Knob, High /Low
J0006
Fan Speed Control
HE57
Fan Thermal Switch
HG55
Flex Gas Line With Fittings
HM22
Grille Springs (2/unit)
HG38
Ignitor Cable
7.0 REPLACEMENT PARTS
When requesting service or replacement parts for your insert, please provide model name, fuel
type, and serial number. All parts listed below may be ordered from an authorized dealer.
J- SERIES
REPLACEMENT PARTS LIST
/34
CONTEMPORARY BAY PARTS
u (JD)
PART No.
DESCRIPTION
JG115
Side Grille Assembly, Black
JG116
Access Door Assembly, Black
JG1008
Louvre, Top Gold
10003
Louvre, Black
JG131
Side Grille Assembly, Gold
JG130
Access Door Assembly, Gold
JG1023
Door Trim Lower Gold
JG1022
Door Trim Upper Gold
JG1018
Door Trim Lower Black
10004
Door Trim Upper Black
JG118
Lower Grille Assembly,Black
JG132
Lower Grille Assembly,Gold
JG120
Upper Grille Assembly, Gold
JG122
Upper Grille Assembly, Black
JH1017
Gold Truss Screw
10006
Black Truss Screw
CONTEMPORARY FLUSH PARTS
(JF)
PART No.
DESCRIPTION
JH107
Access Door Assembly, Black
JH113
Access Door Assembly, Gold
JH1011
Louvre, Top Gold
10005
Louvre, Black
JH1017
Gold Truss Screw
10006
Black Truss Screw
JH1009
Door Trim Lower Gold
JH1010
Door Trim Upper Gold
JH1012
Door Trim Lower Black
10007
Door Trim Upper Black
JH109
Lower Grille Assembly, Black
JH114
Lower Grille Assembly,Gold
JH110
Upper Grille Assembly, Gold
JH112
U • •er Grille Assembl , Black
TRADITIONAL BAY PARTS (JD)
PART No.
DESCRIPTION
JD064
Access Door Assembly
CA109
Door Assembly (1 piece glass)
J0035
Door Assembly (3 piece glass)
JD0080
Door Trim Lower Brass
JD0074
Door Trim Upper Brass
J00077
Gasket Glass Tadpole
J00006
Glass Front
J00007
Glass Sides (2/unit)
JDC36
Grille. Assembly Top
1 JD0028
Louvre Brass Top
TRADITIONAL FLUSH PARTS (JF)
PART No.
DESCRIPTION
JF107
Access Door Assembly
JF116
Door Assembly
JF1008
Door Trim Lower Brass
JF1007 •
Door Trim Upper Brass
JF1006
Gasket Glass Tadpole
JF1005
Glass
JF119
Grille Assembly Top
JF1025
Louvre Brass Top
•
/35
8.0 OSBURN LIMITED WARRANTY & EXTENDED LIFETIME
PROTECTION FOR ALL OSBURN GAS FIREPLACE
PRODUCTS
BASIC WARRANTY
Osburn Manufacturing Inc. (hereafter referred to as Osbum) warrants that your new Osburn gas appliance is free from
manufacturing and material defects for a period of one year from the date of sale, subject to the following conditions and
limitations.
EXTENDED LIFETIME WARRANTY
The heat exchanger, combustion chamber, glowing embers and glass (against thermal breakage only) of every Osburn
gas product are warranted for the life to the original owner, subject to proof of purchase and with the following
conditions and limitations:
1. The new Osburn product must be installed by a qualified gas fitter. The appliance must be installed and operated at
all times in accordance with the installation and operating instructions supplied with the appliance, and installation
must be to local and national codes. Any alteration, willful abuse, accident, over firing, or misuse of the appliance
shall nullify this warranty. Any service call related to improper installation will not be covered under warranty. Note
- Some minor movement of certain parts is normal and is not a defect and therefore, not covered under warranty.
2 The warranty is non - transferable, and is made to the original owner, provided that the purchase was made through
an authorized supplier of Osbum. The serial number must be supplied along with the Bill of Sale, showing date of
purchase, at the time the claim is submitted.
3 This warranty is limited to the repair or replacement of parts(s) only found to be defective in material or
workmanship, provided that such part(s) have been subjected to normal conditions of ute and service, after said
defect has been confirmed by Osburn's, or an authorized representative's, inspection. Defective part(s) must be
shipped back, transportation prepaid, to the accredited representative. Credits will be issued upon receipt of return of
the defective product to Osbum.
4. Osburn may, at its discretion, fully discharge all obligation with respect to this warranty by refunding the wholesale
price of the defective part(s).
5. Any installation, labour, construction, transportation, or other related costs or expenses arising from defective part(s),
repair, replacement, or otherwise of same, will not be covered by this warranty, nor shall Osburn assume
responsibility for same. Further, Osburn will not be responsible for any incidental, indirect or consequent damages,
except as provided by law, and in no event shall they exceed the original purchase price.
All other warranties - expressed or implied - with respect to the product, it's components and accessories, or any
obligations/liabilities on the part of Osburn are hereby expressly excluded.
7. Osburn neither assumes, nor authorizes any third party to assume, on its behalf, any other liabilities with respect to
the sale of this Osbum product.
8. The warranties as outlined within this document do not apply to chimney components or other products made by
other manufacturers when used in conjunction with the installation of this product. Improper use or the use of non -
listed components made by other manufacturers may nullify your warranty. If in doubt, contact your nearest
authorized Osburn supplier.
/36
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•
9. Osburn will not be responsible aW
• down drafts or spillage caused by environmental conditions such as near -by trees, buildings, rooftops, hills
or mountains.
• inadequate ventilation, excessive offsets, or negative air pressure caused by mechanical systems such as
furnaces, fans, clothes dryers, etc.
10. This warranty is void if:
• the appliance has been operated in atmospheres contaminated by chlorine, fluorine and their salts, or other
damaging chemicals.
rz
a: w
UO
• the appliance has any damage to the combustion chamber, heat exchanger or other components due to t N W
111
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li.
0 I-
LU
• the appliance has been subjected to prolonged periods of dampness or condensation.
water, or weather damage which is the result of, but not limited to, improper chimney /venting installation.
• the appliance has been subjected to willful or accidental abuse or misuse.
GLASS DOORS & BRASS OR GOLD PLATED PARTS
Glass doors are warranted against thermal breakage only. To clean glass use a ceramic glass cleaner or polish. Do
not use ammonia based cleaners such as Windex. A suitable cleaner is available from your nearest Hearth
Products dealer. DO NOT CLEAN GLASS WHILE HOT AND DO NOT USE ABRASIVE CLEANERS.
Brass parts will not be covered under this warranty. Brass parts should be cleaned with lemon oil only. Brass
cleaners should not be used. Mortar mix and masonry cleaners may corrode the brass finish. Brass parts may also
be damaged by external chemicals or down draft conditions.
Gold plated parts will not be covered under this warranty. Gold plated surfaces should be cleaned by using water
only and rubbed lightly with a lint -free non - abrasive cloth. Excessive rubbing or polishing may remove the plated
finish.
Discolouration of certain parts is normal and is not a defect, and therefore not covered under warranty.
If warranty service is required....
contact your supplier. Make sure you have your sales receipt and the model/serial number of your Osburn
product.
do not attempt to do any service work yourself. This will void the warranty.
Osburn must authorize service and provide a Warranty Claim Number prior to any warranty related service
calls. Without an authorization number any service work will not be deemed warranty.
/37
00
LISTED FAN TYPE GAS FIRED VENTED ROOM HEATER
RADIATEUR / CIRCULATEUR VENTILE
I ESIED TO. CAN/CGA 2.1 MI6, ANSI Z 21.11.1-1993 GAS
FIRED VENTED BOOM BEATERS, CAN/CGA 2.17•M91 GAS
FIRED APPLIANCES FOR USE Al 111611 Al TITUDES,
CGA P4.1-1996 DRAFT A. WH -GPN OO4 and Wll•GPN-001.
MODEL: VICTORIAN BAY FIREPLACE INSERT
THIS APPLIANCE IS EQUIPPED FOR: NG 0 LP ❑
.a•eu et
\ —/
Do nut place articles on or against hiss appliance.
Du not spray aerosols in the wooly of Mrs appliance
white d is uperahlMJ Do not store flammable materials
new tills appliance
Only for duer:I discharge without dud CONreclron
Centlied Ion installation in a bedroom or a bedsdtulg
room
MINIMUM CLEARANCES TO COMBUSTIBLE
MATERIALS - INSTALLED AS AN INSERT FOR
MASONRY AND ZERO CLEARANCE FIREPLACES:
A Srdewell / La Para lateral.
B Ceding / Le platond
C Facing-side l La lace frontale
lop Haul
D Floor I Lu planchet
E Mantle / Le Tablelle
TO' /250mm
to the door
jusqu'k la pone
34"1865 mm
to top louvre
jusqu'A rauvent
1"/ 25 mm
B.5' /216mm
to faceplate
jusqu 2 la plaque Ironlale
i5' /381 mm
to faceplate
jusqu a la plaque Ironlale
12.5 /318 mm
to top louvre
jusqu a rauvenl
DO NOT REMOVE THIS LABEL
WH 21701
NE PAS ENLEVER CETTE
ETIQUETTE
Candied for use in Canada.
U.S.A. and Australia.
AG103 Centilicale 5505
WARNING: Improper installation, adjustment, service, or maintenance can cause injury or
property damage. Refer to owners manual provided with this appliance. For assletance or
additional information consult a qualified installer serve agency or the gas supplier.
Ne pas placer des articles quelconques sue ou conlre
cat apparel Na pas employer (raerosol pies de cel
apparedlasqudlonclwnne. Ne pas ranger des
natreres inflammables pies de cat apparel.
Pow some dechappemenl Oracle sans gain, de
distribution seulemenl Caddie pour installation dans les
chambres a toucher ou les chambres meublees.
MINIMUM FIREPLACE OPENING
OUVERTURES MINIMUMES DU FOYER
Width / Largeur 32' / 818 mm
Height / Hauteur 20.5' / 521 mm
Depth / Prolondeur 16' / 406 mm
ELEVATION / ALTITUDE FT.
INPUT (LOW) NUM
ALIMENTATION OAS)
INPUT (NIGH) MUM
ALIMENTATION (HAUTE)
ORIFICE SIZES OM
TALES DES ORIFICES
OUTPUT (HIGH) WWI
PRODUCTION (HAUTE)
0-2000
21,000
30.000
34
22.200
2000.4500
20.250
27.000
31
20.000
0.2000
22.500
30.000
50
23.100
700.4500
20.250
27.000
SI
20.800
MANIFOLD PRESSURE (LOW)
PRESSION OE DISTRIBUTION
(BAS)
MANIFOLD PRESSURE (HIGH)
PRESSION OE DISTRIBUTION
(HAUTE)
MINIMUM SUPPLY PRESSURE
PRESSION MINIMAL
ELECIRICAL RATING
ESTIMATION ELECTRIOUE
I! IN WC
0 42 KPA
3SIN WC
81 KPA
SIN WC
t 25 KPA
GAS TYPE/BAZ TYPE
m
ell
GAS &MOD
n [ A • I n
NATURAL/
NATUREL
THIS ROOM HEATER MUST BE INSTALLED IN ACCORDANCE WITH LOCAL CODES IF ANY, IF
NOT, FOLLOW THE CURRENT CAN /CGA B149.1 AND 2 GAS CODES OR ANSI Z223.1 AND 1A 1987
THIS HEATER MUST BE PROPERLY CONNECTED TO A VENTING SYSTEM
THIS HEATER IS EQUIPPED WITH A VENT SAFETY, SHUTOFF SYSTEM
WARNING: OPERATION OF THIS HEATER WHEN NOT CONNECTED TO A PROPERLY INSTALLED
AND MAINTAINED VENTING SYSTEM OR TAMPERING WITH THE VENT SAFETY SHUTOFF
SYSTEM CAN RESULT IN CARBON MONOXIDE (CO) POISONING AND POSSIBLE DEATH.
WARNING: IMPROPER INSTALLATION, ADJUSTMENT, SERVICE, OR MAINTENANCE CAN CAUSE
INJURY OR PROPERTY DAMAGE. REFER TO OWNERS MANUAL PROVIDED WITH THE
APPLIANCE. FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED
INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER.
CE RADIATEUR DOLT ETRE INSTALLS CONFORMEMENT AUX EXIGENCES DES CODES LOCAUX.
S'1L N'EXISTE AUCUN CODE LOCAL, SE CONFORMER A LA NORME CAN1 -B149 EN VIGEUR.
CET APPAREIL DOLT ETRE CORRECTEMENT RACCORDE A UN SYSTEME D'EVENT.
CET APPAREIL EST EOUIPE D'UN SYSTEME DE SECURITE AU NIVEAU DE L'EVENT. HL16✓6V.004
A conversion WI, u supplied by the
manufacturer, shall be used to convert this
room healer to toe alternate fuel. Suitable for
Installation in bedrooms when installed with a
thermostat. see instruction manual.
Sea installation and operating instructions
accompanying appliance. Keep burner and
control compartment clean. Due to high
surface temperatures, keep children, clothing
and furniture away.
TAIs room healer needs fresh air Tor sale
operation and must be installed so there are
provisions for adequate combustion and
ventilation air.
DANGER: Risk of electrical shock.
Disconnect power before servicing unit.
Do not routs power coed beneath Mater.
PROPANE
OSBURN MANUFACTURING INC.
Mad, in Canada by / Fadiqu, au Canada par:
OSBURN MANUFACTURING. 555 Ardersier Road. V,clola. B C VIZ IC8
Ne rein mettle dans respance situe au-dessus de rake.
Pour utilisation avec le gaz natural at le propane. tin,
uouss, deconvelsion lourrlle par N Iabrrcant clot eve utirse
pow passer dun combustible a l'autre.
Mainlerw propras le bruleur et N dompartimwn de
commando Viol Ill insuudions retatuives • rvslaWtion it
au Ionctionnernent qui accompagnent le rarltateur. Acause
de Is temperature ,levels des panlois. lenir eloignes les
enfants, les vetements al less meubles.
Par measure de securile, cis radiateur mauler, de lair trees
et dolt etre instaile de lacon a assurer un approvisronnement
sullisa t lair de combustion al de vawlation.
DANGER: Risque de decharge electriqu,.
Debrancher de le source de courant avant le service
de Pepperell. He pas deployer le ftl d, branchement
en- dessous de l'appareif.
GAS TYPE/BAZ TYPE NATURAL/ PROPANE
NATUREL
NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN
THIS NOTICE IT IS DUE TO THE _ QUALITY OF THE DOCUMENT.
6111 WC
I 49 KPA
100111 WC
2 49 KPA
It IN WC
2 14 KPA
120V. 60HZ. 15A
120V. 60HZ. 1 SA
WD
11.7$IJ0-001A
M.7HJDO0te
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FOR YOUR SAFETY READ
WARNING: II you do not follow these instructions
exactly, a hue or explosion may result causing
property damage, personal injury or loss 01 tile.
A This appliance ruts a starter pilot which must be
toiled by the peso starter. When lighting the pilot.
outlaw mese oe l uclrus eraClly.
1 3 BEFORE t tGI I I ING smell all around the appliance •
area Ion gas tie sire to smell neat 10 the boor because
some gas is ma■ic~ than air and will settle on the boor.
WIIAI TWO) IF YOU SMELL GAS
• lin nut Ill r to light any appliance
• tin nut u.,ab any electric switch. do not use
any leua,e ul your budding
BEFORE LIGHTING
• Immediately call your gas suppler born a
neighbour's phone. Follow the gas supplier's
instructions.
• II you cannot mach your gas suppler. tae the
hue department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. ll the knob will not push rh or
turn by hand. don't by to repau it. call a qualified
service technician. Force or attempted repair may
result in a hue or explosion.
0. Do not use this appliance a any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part 01
the control system and any gas control which has
been under water.
"LIGHTING INSTRUCTIONS
1. STOPI Read the salary nlormalion above on as label.
2. Set the thermostat to lowest selling.
3. Turn all all electric power to the appliance.
4. Open the control access pill.
5. Push in gas control knob slightly and turn clockwise
/Th. lo - OFF•.
NOTE: Knob cannot be turned from to - OFF -
unless knob ie pushed in slightly. Do not torte.
6. Wait live (5) minutes to clear out any gas. t; you
then smell gas. STOP! Follow - B - in the salty
information above on this label. It you don't smell
gas. go to next step.
. 7. Turn knob on gas control coureertlockwise f
to PILOT'.
B. Push in the control knob all the way and hold in.
Immediately push the pieno ignition button (the red
button on the left side) repeateay and the pilot ignites.
Continua to hold ale sorwol knob in for about I
minute alter the pilot is It Release knob and a will
pop backup. Plot should rernarn W. 8 4 goes cur
repeal steps 1.8.
9. Turn gas control knob counwerclockwrse T1
to - ON - .
to. Close the control access grill
I I. Turn on all electric power to the appliance
12 Set thermostat to desired selling.
• It knob does not pop up when released. slop
and immediately call your service technician or
gas suppler.
• II the pilot will not stay le after several Ines.
turn the gas control knob to - OFF - and call
your service technician or gas supplier.
HL12IBV-002A
I Set the mermostal to lowest selling
2 I urn oll ail eteuuc power to the appliance it
service is to be pulumted
7 Open r,e LUnuul access grin
CAUTION: HOT WHILE IN OPERATION. DO NOT TOUCH. KEEP CHILDREN, CLOTHING AND FURNITURE AWAY.
ATTENTION: CHAUD PENDANT LE FONCTIONNEMENT, NE TOUCHEZ PAS. TENIR ELOIGNES LES ENFANTS, LE VETEMENTS ET LES MEUBLES.
TO TURN OFF GAS TO APPLIANCE
a Push in gas control knob slightly and turn
clockwise /Th, to - OFF' Do not torte
5 Close the control access grill.
INSTRUCTIONS D'ALLUMAGE ET DE RALLUMAGE
i Appuyer Movement sur to bouton de control. du
gas. le !owner lusqu has cr oon "OFF (Arrel) et
atlendne 5 minutes.
2. Appuyer Ikgererinent sur le bouton et le tourner
Iusqua to position'PILO1 (Veudleuse) l�
3. Appuyer a land sur to bouton et appuyer sur
rallumeur piezoehecutque rouge pour alkunes to
MOS 003
vedleuse. continuer crappuyer sus le bouton perraant
um minute ou lusgti a ce que la vereeuse reste
aoumee une has que to bouton aura ate rclache
4 Towner he bouton de controle du gas rusqu a U
posdron "ON' IMarchle) f
5. Al rinterrupteur etectrrque s, vous en 'Ames
un.
POUR ETEINDRE L'APPAREIL
1. Pour retende de Iacon temporaire etesndre 2. Pour reteindre de la on durable. appuyer
rrrerrupleur ebrcurque Si vous en utilises un. ou legeramenl sur lo bouton at Is bounty tusqu a ale
lawn Is bouton de connote du gar risque la position 'OFF - .
position - PILOT' tVerlleusel. La veilleuse conenuera
de landowner. L'appared est prat a etre reins en
marche tposaan "0N1.
HL14/1W•002138
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NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN
THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT._
FIREPLACE
v
6. 6.
1. Hearth
:r=
2. FlrsboxlGrate
= tom ow
3. Facing
'' ''
as.
as w =
. w _
4. Damper _
1
5. Smoke Chamber
:. -
- - --
.
.
8. Spark Screen/Doors
�'
•-•. -
,
C�
-
7. Tools == =
■ -
= =
, -
sNw
_
CHIMNEY 7MAW* :
8. Brickwork _ ' �., '` "
li
V
t./'
9. Mortar •. — —1
10. Flue Tiles _ '
rrR CraKw •e1._
11. Flashing Asm au iP =,�..
1
12. CrownlWash • —
_
I
13. Chimney Cover/Cap
14. Height
WOOD STOVE
15. Stove Pipe Condition
18. Stove Condition
(/
•
•
bit
& S " WEEPS sY
HAL HARTMAN
OWNER AND CHIEF SWEEP
"Don't Mak A Chimer /ire"
SAFETY
INSPECTION
SWEEP'S COMMENTS:
SATISFACTION GUARAI Q ED • INSURED
011111.71 28
30866 Il h AVE. S.
FEDERAL WAY. WA. 116001
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• Number of Chimneys:
• Wood Stove:
Type
RECEIPT
DE3CAIPTION
•
XUSTOTAL
TAX
TOTAL
PRICE
4y9s
3 o
NEXT SWEEPING RECOMMENDED
Fireplace and chimney should be inspected yearly for any
structural faults.
Customer ./4
Address *f? S, /5Z
City S State Zip
Phone 56 v?5
Date //—/ Q Time ` le?)
• Type of Chimney:
Sweep or Mason's Signature
CUSTOMER VERIFICATION
❑ P re -fab
asonry
2 3 4
❑ Insert
❑ Free Standing
t have read this form and now understand which areas of my
woodbuming system appear to be satisfactory and which
areas are not satisfactory.
Signed
Would you like me to call you when the next cleaning is due?
❑ Yes 0 N
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November 6, 2001
Ms. Candice Gallagher
Washington Energy Services
2800 Thomdyke Ave W
Seattle, WA 98199
City of Tukwila
Department of Community Development Steve Lancaster, Director
RE: Permit Application No. M01 -109
Location: Mellick Residence
4802 S 150 St.
Dear Permit Holder:
In reviewing our current records the above noted permit has not received a final inspection by the City of
Tukwila Building Division. Per the Uniform Building Code and /or Uniform Mechanical Code, every permit
issued by the Building Official under the provisions of this code shall expire by limitation and become null
and void if the building or work authorized by such permit is not commenced within 180 days from the date
of such permit, or if the building or work authorized by such permit is suspended or abandoned at any time
after the work is commenced for a period of 180 days.
Based on the above, you are hereby advised to:
Sincerely,
'gal Ci ,tea)
Kathryn A. Stetson
Permit Technician
• Call the City Of Tukwila Permit Center at (206) 431 -3670 to schedule a
progress or a final inspection
A progress inspection is intended to determine if substantial work has been accomplished since issuance of
the permit or last inspection; or if the project should be considered abandoned.
If such determination is made, the Building Code does allow the Building Official to approve a one -time
extension up to 180 days. Extension requests must be in writing and provide satisfactory reasons why
circumstances beyond the applicants control have prevented action from being taken.
In the event you do not call for the above inspection or request and receive an extension prior to December
15, 2001, your permit will become null and void and any further work on the project will require a new permit
and associated fees.
Thank you for your cooperation in this matter.
Xc: +P..ermit'File No.M01-109: .
Duane Griffin, Building Official
eivv°
JAN'
Steven M. Mullet, Mayor
6300 Southcenter Boulevard, Suite #100 • Tukwila, Washington 98188 • Phone: 206 -431 -3670 • Fax: 206 -431 -3665