Loading...
HomeMy WebLinkAboutPermit M01-144 - WOLFF RESIDENCEMO1-144 Wolff Residence 15222 42 Av S EXPIRED MAR 15 2002 City of Tukwila (206) 431 -3670 Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188 Permit No: M01 -144 Type: B -MECH Category: RES Address: 15222 42 AV S Location: Parcel #: 222304 -9048 Contractor License No: WASHIES990CW TENANT WOLFF RESIDENCE Phone: 98188 OWNER MCHUGH WILLIAM & CHRISTINA Phone: (206)241 -1662 15222 42ND AVE 5, TUKWILA WA 98188 CONTACT CANDACE GALLAGHER Phone: 206 378 -6680 2800 THORNDYKE AVE W, SEATTLE, WA 98199 CONTRACTOR WASHINGTON ENERGY SERVICES CO Phone: 206 282 -4700 2800 THORNDYKE AVE W, SEATTLE 98199 * * * * * * * *** k * * * *'k * ** * * ** * ***k * * * * * * * * * ** k* ****** ****• *•**** *** * *** **• ** *****• * ** Permit Description: LIKE FOR LIKE CHANGE OUT OF 60,000 BTU GAS FURNACE AND NEW 2 -TON A/C UNIT. UMC Edition: 1997 Valuation: Total Permit Fee: **** k*'** k****************************** * * * * * * * * * * * * * * * * ** * ** * * * * * * ** ** Fermi," enter Authorized Signature Date I hereby certify that I have read and examined this permit and know the same,.-to be true and correct. All provisions of law and ordinances govern : ing this work will be complied with, whether specified herein or not The granting of this permit does not presume to give authority to violate or 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 permit. qr Signature r � Gate : UJs3l 1 Print Name:__ rlCk Title: C i nr MECHANICAL PERMIT Status: ISSIIED Issued: 08/31/2001 Expires: 02/27/2002 This permit shall become null and void if the work is not commenced within 180 days from the date of issuance, or if the work is suspended or abandoned for a period of 180 days from the last inspection. EXP RED MAR 15 2002 6,000.00 78.31 ACTIVITY NUMBER: MO1 -144 PROJECT NAME: TAMELA WOLFF SITE ADDRESS: 15222 - 42ND.AVENUE SOUTH XX Original Plan Submittal DATE: 8-27-01 Response to Incomplete Letter # Response to Correction Letter # Revision # After Permit Is Issued DEPARTMENTS: Building Division L 8 .2e •DI Public Works DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Complete Comments: Please Route Approved \PRROUTE.DOC 5/99 TOES /THURS ROUTING: PERMIT COORD COPY PLAN REVIEW /ROUTING SLIP CORRECTION DETERMINATION: CS'S Fire Prevention S.Z8.6 Structural Incomplete n Not Applicable Structural Review Required APPROVALS OR CORRECTIONS: (ten days) Approved El Approved with Conditions n Planning Division Permit Coordinator DUE DATE: 8-28-01 No further Review Required REVIEWER'S INITIALS: DATE: DUE DATE 09 -25 -01 Not Approved (attach comments) n REVIEWER'S INITIALS: DATE: Approved with Conditions REVIEWER'S INITIALS: DUE DATE Not Approved (attach comments) DATE: • � W it 2 00 N w ,. 0 N �; v: • F- O' z H, w w 0. , o N: • 0 F- w w (J r :: ` z o ACTIVITY NUMBER: M01 -144 DATE: 8 -27 -01 PROJECT NAME: TAMELA WOLFF SITE ADDRESS: 15222 - 42 AVENUE SOUTH XX . Original Plan Submittal Response to Incomplete Letter # Response to Correction Letter # Revision # After Permit Is Issued DEPARTMENTS: Building Division Public Works Complete DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Comments: TUES /THURS ROUTING: Please Route Approved \PRROUTE.DOC 5/99 REVIEWER'S INITIALS: Structural Revie Incomplete PLAN REVIEW /ROUTING SLIP CORRECTION DETERMINATION: APPROVALS OR CORRECTIONS: (ten days) Approved n Approved witl<onditions REVIEWER'S INITIALS: Fire Prevention Structural q ired Approved with Conditions REVIEWER'S INITIALS: Planning Division Permit Coordinator DUE DATE: 8-28-01 DATE: Not Applicable No further Review Require DUE DATE 09 -25 -01 n n Not Approved (attac comments) n DATE: f ZS /GM 1 DUE DATE Not Approved (attach comments) DATE: �.... _........,....max: �::� a �.. r. ai:; ir�u..., i,. �. 6s: w,.:.: �a. i.i,.�.i1i;:.u•s+.:�.�....x.i.r .LlJi,.. s..: ,: "u;: d'r;r:.y..�r PERMIT NO.: 1401 -44 -,� MECHANICAL PERMIT APPLICATIONS INSPECTIONS ❑ 00002 Pre - construction ❑ 00050 WSEC Residential ❑ 00060 WA Ventilation/Indoor AQC ❑ 00610 Chimney Installation/AIl Types ❑ 00700 Framing ❑ 01080 Woodstove • 01090 Smoke Detector Shut Off ff 01100 Rough -in Mechanical ❑ 01101 Mechanical Equipment/Controls ❑ 01102 Mechanical Pip/Duct Insul ❑ 01105 Underground Mech Rough -in ❑ 01115 Motor Inspection ❑�,/ 1400 Fire Final Ri 01800 Final Mechanical ❑ 04015 Special -Smoke Control System CONDITIONS Er0001 No changes to plans unless approved by Bldg Div ❑ 0014 Readily accessible access to roof mounted equipment 016 Exposed insulation backing material 0019 All construction to be done in conformance w /approved plans 0002 Plumbing permits shall be obtained through King Co 8027 Validity of Permit 9003 Electrical permits obtained through L & I 0036 Manufacturers installation instructions required on site ❑ "BTU maximum allowed per 1997 WA State Energy Code" ❑ 0041 Ventilation is required for all new rooms & spaces (0005 All permits, insp records & approved plans available ❑ "Fuel burning appliances ❑ "Appliances, which generate...." ❑ "Water heater shall be anchored...." Additional Conditions: TENANT NAME: FEES Plan Reviewer: Permit Tech: et 04exp-ie, Basic Fee (Y/N) Supplemental Fee (Y/N) Plan Check Fee (Y/N) Furnace/Burner to 100,000 BTU (qty) Over 100,000 BTU (qty) Floor Furnace (qty) Suspended/Wall/Floor - mounted Heater (qty) Appliance Vent (qty) Heating/Refrig/Cooling Unit/System (qty) Boiler /Compressor to 3 HP /100,000 BTU (qty) to 15 HP /500,000 BTU (qty) to 30 HP /1,000,000 BTU (qty) to 50 HP /1,750,000 BTU (qty) over 50 HP /1,750,000 BTU (qty) Air Handling Unit to 10,000 cfm (qty) _L__ over 10,000 cfm (qty) Evaporative Cooler (qty) Ventilation Fan (qty) Ventilation System (qty) Hood (qty) Incinerator — Domestic (qty) Incinerator — Comm /Ind (qty) Other Mechanical Equipment (qty) Other Mechanical Fee (enter $$) Add' 1 Fees — Work w/o Permit (Y/N) Insp Outside Normal Hours (hrs) Reinspections (hrs) Miscellaneous Inspections (hrs) Add' l Plan Review (hrs) Date: 5'Z$ ACTIVITY NUMBER: M01 -144 DATE: 8 -27 -01 PROJECT NAME: TAMELA WOLFF SITE ADDRESS: 15222 - 42 AVENUE SOUTH XX Original Plan Submittal Response to Incomplete Letter # Response to Correction Letter # Revision # After Permit Is Issued DEPARTMENTS: Building Division Public Works DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Please Route \PRROUTE.DOC 5/99 PLAN REVIEW /ROUTING SLIP n Fire Prevention Structural Complete 1 I Incomplete Not Applicable TUES /THURS ROUTING: REVIEWER'S INITIALS: Structural Revie Required (6,- APPROVALS OR CORRECTIONS: (ten days) d4 REVIEWER'S INITIALS: Planning Division Permit Coordinator DUE DATE: 8-28-01 Comments: No further Review Required DATE: e-S/ y /0 / DUE DATE 09 -25 -01 Approved n Approved with Conditions n Not Approved (attach comments) DATE: CORRECTION DETERMINATION: DUE DATE Approved n Approved with Conditions Not Approved (attach comments) REVIEWER'S INITIALS: DATE: Project Name /Tenant " c._ ct)0 (l Signature: C Value of Mechanical Equipment: COMO. — Site Address : f � �� j „� �^ p. Ci ial iir. Ta Phone: (f ) 1 L ? ' to Property Owner: )3 , 0 C Street Address: , ) ")' j9,,t, 7 L/ Fax #: ( ) City State/Zip: Fax il: ( ) Contractor: ash • SVr� City /State/Zip: Phone: (a(2/) Sig- -�� Street Address: I hmifd 1 k PALO u ae041( 4 i St / ): Fax ii: ( ) Contact Person: t(C,L Phone: ( pay) 3 C�(000 Street Address: cc rrlrac7r City State /Zip: Fax #: ( ) BUILDING OWNER 0 ' AUTHORIZED AGENT: Signature: C , • �^ Date :o� a!) 0 / O Print name: , 0 C Phone: ) ")' j9,,t, 7 L/ Fax #: ( ) Address: City /State/Zip: CITY OF'JKWILA Permit Center 6300 Southcenter Boulevard, Suite 100 Tukwila, WA 98188 (206) 431 -3670 -OR STAFF l,)SE ONLY Project Number: Permit Number. Mechanical Permit Application Application and plans must be complete in order to be accepted for plan review. Applications will not be accepted through the mail or facsimile. MECHANICAL PERMIT REVIEW AND APPROVAL REQUESTED: (TO BE FILLED OUT BY APPLICANT) Description of work to be done (please be speciific) L r ko w b e (t c u,e. o g L4 /WS .4- NJAD cD4Dr 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 li -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. 1 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 clays upon written request by the applicant as defined in Section 114.4 of the Uniform Mechanical Code (current edition). No application shall be extended more than once. Date application accepted: Date application expires: Application take (initials) 11/2/99 meal pernlil.doc ✓ Submittal Requirements Floor plan and system layout Roof plan required to identify individual equipment and the location of each installation (Uniform Mechanical Code 504 (e)) Details and elevations (for roof mounted equipment) and proposed screening Heat Loss Calculations or Washington State Energy Code Form #H -7 . H.V.A.C. over 2,000 CFM (approximately 5 ton and larger) must be provided with smoke detection shut- off and will be routed to the Fire Prevention division for additional comments (Uniform Mechanical Code 1009). Specifications must be provided to show that replacement equipment complies with the efficiency ratings and other applicable requirements of the Washington State Nonresidential Energy Code. Structural engineer's analysis is required for new and the replacement of existing roof equipment weighing 400 pounds and greater (Uniform Building Code 1632.1). Structural documentation shall be stamped by a Washington State licensed Structural Engineer. Mechanical Permits COMMERCIAL: Two complete sets of drawings and attachments required with application submittal RESIDENTIAL Two . complete sets of attachments required with application submittal Heat Toss calculations or Form H -6. Equipment specifications. Narrative with specification of equipment and chimney type. If.using existing 'chimney, provide a letter by a certified chimney sweep stating that the chimney is in safe condition. 11/2/99 m ►„c NOTE: Water heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. Submittal Requirements New Single Family Residence Change -out or replacement of existing mechanical equipment Narrative of work to be done, including modification to duct work. Installation of Gas Fireplace NOTE :. Water heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. 1 Address: 1 5222 42 AV S Suite Tenant :. WOLFF RESIDENCE Type: B -MECH Par:Gel #: 222304 -9048 CITY OF TUK(WILA k•k•k• k•k' kk' kk• k• k•k oE• k• k* Akkk•k kkk kk' l* •A•k•kk•k *•k•k•kk•k•kk•kkkk *k 1. &*kk *k *•k.A Permit Conditions: 1, permits shall be obtained through the Seattle -King County Department of Publi;cHealth. Plumbing will be inspected by that agency, including all'..gas piping (296- 4722). 4 ; Electrical permits shall be ,obtained through the Washington `State Division..'of Labor and Industrie :s,. and all electrical :work will be inspected by that agency (248 - 6630). No change i 11, b made to the plans unless approved by the Engineer,and the; Divi All per,mits, inspect�ion records, and approved plans shallbe available at the ,joli•'site prior to start of any con struct'iiin These' documents' are Co be maintained and avail able`'&ntl1 . f�i,nal -' inspection approval is granted: ;. A11 COnstructicin to• "done`..in conformance with approved p la,hs and requi remen,tsy_of the Uniform B u i l d i n g Code (1997. Ed i't�i on) as agienided,' Un i if orm., Mechanical . Co.de..(1997 'Ed`it i on) and• 4Wash ig'ton .Sta.te Energy ,Code (1'997.; Ed i t i on) . 6. Vali of Permit. The issuance ofa permit or'; approvai:of pleas, ,specifications,'.and .computations shall nut be con - str' u'ed .to ~be `a permit t fo► , . of an approval of, any violation 5 of i Ta y '.`af the > provi s i ons- " of the 'bu;i i d i ng code or of : any other, ordl nan'ce of the - ` jour i sd;ct i on . , . N i o • prmei t presuming to give authority_ to violate or cancel';the provisions 'of `this codehallkbe valid. 7 Manufacturers installation instr�ucttgns required on site for the bui�i,d ;inspectors review. hereby cent i.f y f. that I have read the sa conditions and will comply with :them as out l t vied ' ;, Al 1 provisions o f law and urd,i nances governing is work will.: compl'ie specified herein or., ,not. te, granting of tii,:i'S,, per mi 5 d'aes not : ,presume to g.i vie authority to i o f ate': or cancel the prov i s,i ons .of :any other c, work or joca l laws egulating construct'i'on `or tie performance of Permit No: M01 -144 Status: ISSUED Applied: 08/27/2001 Issued: 08/31/2001 �,• 1= ..,�.:..C.- Date. .r.�n ., •:td +.. s5 �."... .,Ae.l.., c. 1.., v .Ii ,: C+�� �N,' Y' >.�..1.�:Cti.' 1u}. .. .'l.,'i w ". , ,;;;;qt•LV:i iloYmsgoriTtv*rmirmatv 7rxml%M; TY:.CF WA Reprinted : 08/31/01.09:55 TRANSMIT 4-44-*******40!eAlt•k****:Ar./e-hlt*****A .. *A **Isc**A•• ****** TRANSMIT Number R01011 Amount:: 78.31 08/.31/ 01.0'9:54 Payment%,Metliod: CHECK ,Ao tat ion: W1)1: INCORPORATED In i t SKS Perini Npr: 1101-14'I Type: 11-MECli MECHANICAL PERMIT PErcel No ;' 222304 Site s" '1 5 Z2. 2 42 A V S • . • T 0 1; Et 1 Fees : 78.31 78-31 , Tot al A L.L Pmt: 78.31 13a1 ance: .00 ;014,x 4- *4 t14 -A; +11* * * 2 * * * * * * tk; *14A * * * * q60(1.0f. Deser ipt ion Amount PLAN CHECK R ES 15.66 MECHANICAL - R ES 62.65 ctlte-?41- tv 6 Olt.''' ( ;Vr • ,:t 3620 09/04 97.1.6 TOTAL 78. —„ • H 2 9 o w 2 r g - u, •a; Z 1 WW1 pI— .D a mr, E -9! 11 - Z: LLI ,0 P Z FILE installation and start -up instructions 11, 12 13, 14 SEER SPLIT - SYSTEM AIR CONDITIONERS WITH PURON® REFRIGERANT . • - 591B, 550A 552A, 556A I understand that the Plan Check approvals are NOTE: ad l the?f:htlet eStfuoiioi rti laNi1 •$g)Ig st5tiiq`(het'IC:J� I of installation. i - :• ,,..... This symbpl--> a change since the last issue. SAFETY CONSIDERATIONS Improper histallation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory- authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thor- oughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety information. This is the safety -alert symbol m . 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. ZL WARNING: Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may be more than I disconnect switch. Lock out and tag switch with a suitable warning label. Electrical shock can cause personal injury or death. CAUTION: Puron® systems operate at higher pressures than standard R -22 systems. Do not use R -22 service equipment or components on Puron® equipment. INSTALLATION RECOMMENDATIONS NOTE: In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment. 1. Locate unit away from windows, patios, decks, etc. where unit operation sound may disturb customer. 2. Ensure that vapor and liquid tube diameters are appropriate to capacity of unit. 3. Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends. 4. Leave some slack between structure and unit to absorb vibration. —1— Cancels: 11 550A-18-1 1 IIIII 1i' is IIIIVIII l l! I ql � , I I I I 11 1111 11111111 I LIII I I I111 11111 111.111 I'111III111 1111111 1111III !I�III1IIIIIIJ IIII� I I "!�i l�',�� �' ,��n71'IIIIII 11 550A -18 -2 7 -01 A98515 Fiti. "1- Models 591B, 550A, 552A, and 556A 5. When passing refrigerant tubes through the wall, seal opening with RTV or other pliable silicon -based caulk. (See Fig. 2.) 6. Avoid direct tubing contact with water pipes, duct work, floor joists, wall studs, floors, and walls. 7. Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct contact with tubing. (See Fig. 2.) 8. Ensure that tubing insulation is pliable and completely surrounds vapor tube. 9. When necessary, use hanger straps which are 1 in. wide and conform to shape of tubing insulation. (See Fig. 2.) 10. Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation. When outdoor unit is connected to factory- approved indoor unit, outdoor unit contains system refrigerant charge for operation with ARI rated indoor unit when connected by 15 ft of field- supplied or factory accessory tubing. For proper unit operation, check refrig- erant charge using charging information located on control box cover and/or in the Check Charge section of this instruction. IMPORTANT: Maximum liquid -line size is 3 /8 -in. O.D. for all residential applications including long line. IMPORTANT: Always install the factory- supplied liquid -line filter drier. If replacing the filter drier, refer to Product Data Sheet for appropriate part number. Obtain replacement filter driers from your distributor or branch. INSTALLATION Specifications for this unit in residential new construction market require the outdoor unit, indoor unit, refrigerant tubing sets, metering device, and filter drier listed in presale literature. There Isitot—v-of UNIT BASE PAN DIMENSIONS TIEDOWN KNOCKOUT LOCATIONS A B 22 -1/2 X 27 -1/2 2 -13/16 6 -15/16 30 X 33 5 -1/16 9 -11/16 NOTE: Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL CAULK INSULATION THROUGH THE WALL (AROUND VAPOR HANGER STRAPTh TUBE ONLY) 1" MIN. —0-1 �— SUSPENSION —JOIST LIQUID TUBE VAPOR TUBE INSULATION / —VAPOR TUBE LIQUID TUBE A94028 Fig. 2— Connecting Tubing Installation can be no deviation. Consult the Application Guideline and Service Manual —Air Conditioners and Heat Pumps Using Pu- ron® Refrigerant to obtain required unit changes for specific applications and for R -22 retrofit. I. CHECK EQUIPMENT AND JOB SITE A. UNPACK UNIT Move to final location. Remove carton taking care not to damage unit. B. INSPECT EQUIPMENT File claim with shipping company prior to installation if shipment is damaged or incomplete. Locate unit rating plate on unit corner panel. It contains information needed to properly install unit. Check rating plate to be sure unit matches job specifications. II. INSTALL ON A SOLID, LEVEL MOUNTING PAD If conditions or local codes require the unit be attached to pad, tie down bolts should be used and fastened through knockouts provided in unit base pan. Refer to unit mounting pattern in Fig. 3 to determine base pan size and knockout hole location. On rooftop applications, mount on level platform or frame. Place unit above a load- bearing wall and isolate unit and tubing set from structure. Arrange supporting members to adequately support unit and minimize transmission of vibration to building. Consult local codes governing rooftop applications. Roof mounted units exposed to winds above 5 mph may require wind baffles. Consult the Application Guideline and Service Manual —Air Conditioner with Puron® Refrigerant for wind baffle construction. NOTE: Unit must be level to within ±2° (±3/8 in. /ft) per compressor manufacturer specifications. III. CLEARANCE REQUIREMENTS When installing, allow sufficient space for airflow clearance, wiring, refrigerant piping, and service. Allow 30 -in. clearance to service end of unit and 48 in. above unit. For proper airflow, a 6 -in. —2— 3 .13IN. DIA TIEDOWN KNOCKOUTS (2) PLACES IN BASEPAN DIMENSIONS (IN.) A97375 Fig. 3— Clearance Requirements clearance on 1 side of unit and 12 in. on all remaining sides must be maintained. Maintain a distance of 24 in. between units. Position so water, snow, or ice from roof or eaves cannot fall directly on unit. On rooftop applications, locate unit at least 6 in. above roof surface. IV. OPERATING AMBIENTS The minimum outdoor operating ambient in cooling mode is 55 °F, and the maximum outdoor operating ambient in cooling mode is 125 °F. V. CHECK INDOOR CHECK -FLO- RATER® PISTON AND INSTALL PISTON RING (STANDARD ON 591B, 550A, 552A) If unit is to be installed with a piston metering device, proceed as follows: 1. Check indoor coil piston to see if it matches the required piston shown on outdoor unit rating plate. If it does not match, replace indoor coil piston with piston shipped with outdoor unit. The piston shipped with outdoor unit is correct for any approved indoor coil combination. 2. After correct piston is installed, locate neoprene piston ring shipped in piston bag. Install piston ring behind metering piston as shown in Fig. 4. The piston ring ensures that piston stays seated during all operating conditions. VI. INSTALL TXV NOTE: ALL 556A UNITS MUST BE INSTALLED WITH THE TXV THAT COMES STANDARD WITH THE UNIT —NO EXCEPTIONS! The thermostatic expansion valve is specifically designed to operate with Puron ®. Do not use an R -22 TXV. An existing R -22 TXV must be replaced with a factory- approved TXV specifically designed for Puron ®. NOTE: FK4 and FC4 fan coils are equipped with an R -22 TXV) If an FK4 or an FC4 fan coil is used with a Puron® air conditioner, the R -22 TXV must be replaced with a Puron® TXV or with the accessory piston body kit and piston shipped with outdoor unit. A. TXV INSTALLATION IMPORTANT: The TXV should be mounted as close to the indoor coil as possible and in a vertical, upright position. Avoid mounting the inlet tube vertically down. Valve is more susceptible to malfunction due to debris if inlet tube is facing down. A factory- approved filter drier must be installed in the liquid line. INSTALLING TXV IN PLACE OF PISTON 1. Pump system down to 2 psig and recover refrigerant. 2. Remove hex nut from piston body. Use backup wrench on fan coils. 3. Remove and discard factory- installed piston. Be sure teflon seal is in place. 4. Reinstall hex nut. Finger tighten nut plus 1/2 turn. NOTE: If the piston is not removed from the body, TXV will not function properly. m CAUTION: To prevent damage to the unit, use a brazing shield and wrap TXV with wet cloth or use heat sink material. 5. Install TXV on indoor coil liquid line. Sweat swivel adapter to inlet of indoor coil and attach to TXV outlet. Use backup wrench to avoid damage to tubing or valve. Sweat inlet of TXV, marked "IN" to liquid line. Avoid excessive heat which could damage valve. 6. Install vapor elbow with equalizer adapter to suction tube of line set and suction connection to indoor coil. Adapter has a I /4 -in. male connector for attaching equalizer tube. 7. Connect equalizer tube of TXV to 1 /4 -in. equalizer fitting on vapor line adapter. 8. Attach TXV bulb to horizontal section of suction line using clamps provided. Insulate bulb with field- supplied insula- tion tape. See Fig. 5 for correct positioning of sensing bulb. 9. Proceed with remainder of unit installation. REPLACING TXV ON R -22 INDOOR COIL 1. Pump system down to 2 psig and recover refrigerant. 2. Remove coil access panel and fitting panel from front of cabinet. 3. Remove TXV support clamp using a 5 /16 -in. nut driver. Save the clamp. 4. Remove R -22 TXV using a backup wrench on flare connections to prevent damage to tubing. 5. Using wire cutters, cut equalizer tube off flush with vapor tube inside cabinet. 6. Remove bulb from vapor tube inside cabinet. 7. Braze equalizer stub -tube closed. Use protective barrier as necessary to prevent damage to drain pan. IMPORTANT: Route the equalizer tube of Puron® TXV through suction line connection opening in fitting panel prior to replacing fitting panel around tubing. 8. Install TXV with 3 /8 -in. copper tubing through small hole in service panel. Use wrench and backup wrench, to avoid damage to tubing or valve, to attach TXV to distributor. 9. Reinstall TXV support clamp (removed in item 3). 10. Attach TXV bulb to vapor tube inside cabinet, in same location as original was when removed, using supplied bulb clamps (nylon or copper). See Fig. 5 for correct positioning of sensing bulb. 11. Route equalizer tube through suction connection opening (large hole) in fitting panel and install fitting panel in place. 12. Sweat inlet of TXV, marked "IN" to liquid line. Avoid excessive heat which could damage valve. 13. Install vapor elbow with equalizer adapter to vapor line of line set and vapor connection to indoor coil. Adapter has a 1 /4 -in. male connector for attaching equalizer tube. —3— PISTON RETAINER PISTON RING PISTON PISTON BODY I LIQUID LINE STRAINER I APPROX 2" LONG --10. 10 O'CLOCK 2 O'CLOCK SUCTION TUBE 8 O'CLOCK FLARE ADAPTER STRAP VII. MAKE PIPING CONNECTIONS FIELD CONNECTION STRAINER STRAINER LABEL (AFFIX TO LIQ. LINE NEAR STRAINER LOCATION Fig. 4— Check - Flo - Rater® Components (550A, 552A, 591B Only) SENSING BULB Fig. 5— Position of Sensing Bulb A01019 4 O'CLOCK 7 /a IN. OD & SMALLER LARGER THAN 7 /a IN. OD A81032 14. Connect equalizer tube of TXV to 1 /4 -in. equalizer fitting on vapor line adapter. Use backup wrench to prevent damage to equalizer fitting. 15. Proceed with remainder of unit installation. CAUTION: Remove indoor coil piston if unit is to be installed on system with a TXV metering device. WARNING: Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid personal injury or death. Use all service ports and open all flow- control devices, including solenoid valves. ACCESSORY REQUIRED FOR LOW- AMBIENT APPLICATIONS (BELOW 55 °F) REQUIRED FOR LONG-LINE APPLICATIONS* (OVER 50 FT) REQUIRED FOR SEA COAST APPLICATIONS (WITHIN 2 MILES) Crankcase Heater Yes Yes No Evaporator Freeze Thermostat Yes No No Winter Start Control Vest No No Accumulator No No No Compressor Start Assist Capacitor and Relay Yes Yes No MotorMaster® Control, or Low - Ambient Pressure Switch Yes No No Wind Baffle See Low - Ambient Instructions No No Coastal Filter No No Yes Support Feet Recommended No Recommended Llquid -Line Solenoid Valve or Hard Shutoff TXV No See Long -Line Application Guideline No Ball Bearing Fan Motor Yes No No UNIT SIZE LIQUID VAPOR VAPOR (LONG LINE) Connection Diameter Tube Diameter Connection Diameter Tube Diameter Connection Diameter Tube Diameter 018, 024 3/8 3/8 5/8 5/8 5/8 3/4 030, 036 3/8 3/8 3/4 3/4 3/4 7/8 042, 048 3/8 3/8 7/8 7/8 7/8 1 -1/8 060 3/8 3/8 7/8 1 -1/8 7/8 1 -1/8 TABLE 1— REFRIGERANT CONNECTIONS AND RECOMMENDED LIQUID AND VAPOR TUBE DIAMETERS (IN. NOTES: 1. Tube diameters are for lengths up to 50 ft. For tubing lengths greater than 50 ft, consult the App 'cation Guideline and Service Manual —Air Conditioners and Heat Pumps Using Puron®. 2. Do not apply capillary tube Indoor coils to these units. • For Tubing Sets between 50 and 175 ft, refer to the Application Guideline and Service Manual —Air Conditioners and Heat Pumps Using Puron®. Only when low- pressure switch Is used. Required for low - ambient controller (full modulation feature) and MotorMaster® Control only. CAUTION: Do not leave system open to atmosphere any longer than minimum required for installation. POE oil in compressor is extremely susceptible to moisture absorption. Always keep ends of tubing sealed during installation. CAUTION: If ANY refrigerant tubing is buried, provide a 6 in. vertical rise at service valve. Refrigerant tubing lengths up to 36 in. may be buried without further special consideration. Do not bury lines over 36 in. in length. ZL CAUTION: To prevent damage to unit or service valves observe the following: • Use a brazing shield. • Wrap service valves with wet cloth or use a heat sink material. Outdoor units may be connected to indoor section using accessory tubing package or field- supplied refrigerant grade tubing of correct size and condition. For tubing requirements beyond 50 ft, substan- tial capacity and performance losses can occur. Following the recommendations in the Application Guideline and Service Manual —Air Conditioners and Heat Pumps Using Puron® Refrig- erant will reduce these losses. Refer to Table 1 for field tubing diameters. Refer to Table 2 for accessory requirements. There are no buried -line applications greater than 36 in. TABLE 2 ACCESSORY USAGE If refrigerant tubes or indoor coil are exposed to atmosphere, they must be evacuated to 500 microns to eliminate contamination and moisture in the system. A. OUTDOOR UNIT CONNECTED TO FACTORY - APPROVED INDOOR UNIT Factory refrigerant charge is for a 15 ft line set. Outdoor unit contains correct system refrigerant charge for operation with ARI rated indoor unit. Check refrigerant charge for maximum effi- ciency. The charge must be adjusted based on the actual line set,. length. Add or subtract 0.6 oz/ft for line sets longer or shorter than 15 ft. 1 B. INSTALL LIQUID -LINE FILTER DRIER CAUTION: Installation of filter drier in liquid line is required. Refer to Fig. 6 and install filter drier as follows: 1. Braze 5 -in. connector tube to liquid service valve. Wrap filter drier with damp cloth. 2. Braze filter drier between connector tube and liquid tube to indoor coil. Flow arrow must point towards indoor coil. C. REFRIGERANT TUBING Connect vapor tube to fitting on outdoor unit vapor service valves. Connect liquid tube to filter drier. (See Fig. 6 and Table 1.) Use refrigerant grade tubing. LIQUID -LINE FILTER- DRIER CONNECTOR TUBE LIQUID SERVICE VALVE Fig. 6— Liquid -Line Filter Drier D. SWEAT CONNECTION A95509 CAUTION: To avoid valve damage while brazing, ser- vice valves must be wrapped in a heat - sinking material such as a wet cloth. Use refrigerant grade tubing. Service valves are closed from factory and ready for brazing. After wrapping service valve with a wet cloth, braze sweat connections using industry accepted meth- ods and materials. Consult local code requirements. Refrigerant tubing and indoor coil are now ready for leak testing. This check should include all field and factory joints. E. EVACUATE REFRIGERANT TUBING AND INDOOR COIL CAUTION: Never use the system compressor as a vacuum pump. Refrigerant tubes and indoor coil should be evacuated using the recommended deep vacuum method of 500 microns. The altemate triple evacuation method may be used if the procedure outlined below is followed. Always break a vacuum with dry nitrogen. DEEP VACUUM METHOD The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method is the most positive way of assuring a system is free of air and liquid water. (See Fig. 7.) TRIPLE EVACUATION METHOD The triple evacuation method should only be used when vacuum pump is only capable of pumping down to 28 in. of mercury vacuum and system does not contain any liquid water. Refer to Fig. 8 and proceed is as follows: I . Pump system down to 28 in. of mercury and allow pump to continue operating for an additional 15 minutes. 2. Close service valves and shut off vacuum pump. 3. Connect a dry nitrogen cylinder and regulator to system and open until system pressure is 2 psig. 4. Close service valve and allow system to stand for 1 hr. During this time, dry nitrogen will be able to diffuse throughout the system absorbing moisture. 5. Repeat this procedure as indicated in Fig. 8. System will then be free of any contaminants and water vapor. —5— 5000 4500 4000 N 3500 C 3000 IX 2500 2000 1500 1000 500 0 1 2 3 4 5 6 7 MINUTES Fig. 7 —Deep Vacuum Graph (EVACUATE) • 'BREAK VACUUM WITH DRY NITROGEN • I WAIT 1 • (EVACUATE • 'BREAK VACUUM WITH DRY NITROGEN I • 1 WAIT' • 'EVACUATE' • CHECK FOR TIGHT, DRY SYSTEM (IF IT HOLDS DEEP VACUUM) • I CHARGE SYSTEM ' Fig. 8— Triple Evacuation Method VIII. MAKE ELECTRICAL CONNECTIONS LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM A95424 A95425 WARNING: To avoid personal injury or death, do not supply power to unit with compressor terminal box cover removed. Be sure field wiring complies with local and national fire, safety, and electrical codes, and voltage to system is within limits shown on unit rating plate. Contact local power company for correction of improper voltage. See unit rating plate for recommended circuit protection device. NOTE: Operation of unit on improper line voltage constitutes abuse and could affect unit reliability. See unit rating plate. Do not install unit in system where voltage may fluctuate above or below permissible limits. NOTE: Use copper wire only between disconnect switch and unit. NOTE: Install branch circuit disconnect of adequate size per NEC to handle unit starting current. Locate disconnect within sight from and readily accessible from unit, per Section 440 -14 of NEC. A. ROUTE GROUND AND POWER WIRES Remove access panel to gain access to unit wiring. Extend wires from disconnect through power wiring hole provided and into unit control box. m WARNING: The unit cabinet must have an uninter- rupted or unbroken ground to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. Failure to follow this warning can result in an electric shock, fire, or death. B. CONNECT GROUND AND POWER WIRES Connect ground wire to ground connection in control box for safety. Connect power wiring to contactor as shown in Fig. 9. DISCONNECT PER N. E. C. AND /OR LOCAL CODES FIELD POWER ' . WIRING FIELD GROUND WIRING f 0 GROUND LUG Fig. 9 — Line Power Connections CONTACTOR A91056 C. CONNECT CONTROL WIRING Route 24v control wires through control wiring grommet and connect leads to control wiring. (See Fig. 10.) Use No. 18 AWG color- coded, insulated (35 °C minimum) wire. If thermostat is located more than 100 ft from unit, as measured along the control voltage wires, use No. 16 AWG color -coded wire to avoid excessive voltage drop. All wiring must be NEC Class 1 and must be separated from incoming power leads. Use furnace transformer, fan coil transformer, or accessory trans- former for control power, 24v/40va minimum. NOTE: Use of available 24v accessories may exceed the mini- mum 40 -va power requirement. Determine total transformer load- ing and increase the transformer capacity or split the load with an accessory transformer as required. IX. COMPRESSOR CRANKCASE HEATER When equipped with a crankcase heater, furnish power to heater a minimum of 24 hr before starting unit. To furnish power to heater only, set thermostat to OFF and close electrical disconnect to outdoor unit. A crankcase heater is required if refrigerant tubing is longer than 50 ft. Refer to the Application Guideline and Service Manual —Air Conditioner and Heat Pump Using Puron® Refrigerant. X. INSTALL ELECTRICAL ACCESSORIES Refer to the individual instructions packaged with kits or acces- sories when installing. XI. START -UP 0* CAUTION: To prevent compressor damage or personal injury, observe the following: • Do not overcharge system with refrigerant. • Do not operate unit in a vacuum or at negative pressure. • Do not disable low- pressure switch. In scroll compressor applications: • Dome temperatures may be hot. CAUTION: To prevent personal injury wear safety glasses, protective clothing, and gloves when handling refrigerant and observe the following: • Back seating service valves are not equipped with Schrader valves. Fully back seat (counter clockwise) valve stem before removing gage port cap. • Front seating service valves are equipped with Schrader valves. CAUTION: Do not vent refrigerant to atmosphere. Re- cover during system repair or final unit disposal. Follow these steps to properly start up the system: 1. After system is evacuated, fully back seat (open) liquid and vapor service valves. 2. Unit is shipped with valve stem(s) front seated (closed) and caps installed. Replace stem caps after system is opened to refrigerant flow (back seated). Replace caps finger -tight and tighten with wrench an additional 1/12 turn. 3. Close electrical disconnects to energize system. 4. Set room thermostat at desired temperature. Be sure set point is below indoor ambient temperature. 5. Set room thermostat to COOL and fan control to ON or AUTO mode, as desired. Operate unit for 15 minutes. Check system refrigerant charge. A. SEQUENCE OF OPERATION Turn on power to indoor and outdoor units. Transformer is energized. On a call for cooling, thermostat makes circuits R -Y and R -G. Circuit R -Y energizes contactor, starting outdoor fan motor and compressor circuit. R -G energizes indoor unit blower relay, starting indoor blower motor on high speed. When thermostat is satisfied, its contacts open, de- energizing contactor and blower relay. Compressor and motors stop. If indoor unit is equipped with a time -delay relay circuit, the indoor blower will run an additional 90 sec to increase system efficiency. XII. CHECK CHARGE A. UNIT CHARGE Factory charge and charging method are shown on unit informa- tion plate. Puron® refrigerant cylinders contain a dip tube which allows liquid refrigerant to flow from cylinder in upright position. Charge Puron® units with cylinder in upright position and a commercial -type metering device in manifold hose. Charge refrigerant into suction line. NOTE: Charge must be adjusted in accordance with unit rating plate, ±0.6 oz/ft of 3 /8 -in. liquid line above or below 15 ft, respectively, EXAMPLE: To calculate additional charge requried for a 25 -ft line set: 25 ft - 15 ft = 10 ft X 0.6 oz/ft = 6 oz of additional charge. B. COOLING ONLY PROCEDURE UNITS WITH COOLING MODE PURON® TXV Units installed with cooling mode TXV require charging by the subcooling method. 1. Operate unit a minimum of 10 minutes before checking charge. 2. Measure liquid service valve pressure by attaching an accurate gage to service port. 3. Measure liquid line temperature by attaching an accurate thermistor type or electronic thermometer to liquid line near outdoor coil. 4. Refer to unit rating plate for required subcooling tempera- ture. 5. Refer to Table 3. Find the point where required subcooling temperature intersects measured liquid service valve pres- sure. 6. To obtain required subcooling temperature at a specific liquid line pressure, add refrigerant if liquid line tempera- ture is higher than indicated or reclaim refrigerant if temperature is lower. Allow a tolerance of ± 3 °F. UNITS WITH INDOOR PISTONS Units installed with indoor pistons require charging by the super- heat method. The following procedure is valid when indoor airflow is within ± 21 percent of its rated CFM. 1. Operate unit a minimum of 10 minutes before checking charge. 2. Measure suction pressure by attaching an accurate gage to suction valve service port. 3. Measure suction temperature by attaching an accurate thermistor type or electronic thermometer to suction line at service valve. 4. Measure outdoor air dry-bulb temperature with thermom- eter. 5. Measure indoor air (entering indoor coil) wet -bulb tempera- ture with a sling psychrometer. 6. Refer to Table 4. Find outdoor temperature and evaporator entering air wet -bulb temperature. At this intersection, note superheat. 7. Refer to Table 5. Find superheat temperature located in item 6 and suction pressure. At this intersection, note suction line temperature. 8. If unit has a higher suction line temperature than charted temperature, add refrigerant until charted temperature is reached. 9. If unit has a lower suction line temperature than charted temperature, reclaim refrigerant until charted temperature is reached. 10. When adding refrigerant, charge in liquid form into suction service port using a flow - restricting device. 11. If outdoor air temperature or pressure at suction valve changes, charge to new suction line temperature indicated on chart. XIII. FINAL CHECKS IMPORTANT: Before leaving job, be sure to do the following: 1. Ensure that all wiring and tubing is secure in unit before adding panels and covers. Securely fasten all panels and covers. 2. Tighten service valve stem caps to 1/12 -turn past finger tight. 3. Leave User's Manual with owner. Explain system operation and periodic maintenance requirements outlined in manual. 4. Fill out Dealer Installation Checklist and place in customer file. CARE AND MAINTENANCE For continuing high performance and to minimize possible equip- ment failure, periodic maintenance must be performed on this equipment. Frequency of maintenance may vary depending upon geographic areas, such as coastal applications. See Users Manual for informa- tion. LIQUID PRESSURE AT SERVICE VALVE (PSIG) REQUIRED SUBCOOLING TEMPERATURE (°F) 8 10 12 14 16 18 189 58 56 54 52 50 48 195 60 58 56 54 52 50 202 62 60 58 56 54 52 208 64 62 60 58 56 54 215 66 64 62 60 58 56 222 68 66 64 62 60 58 229 70 68 66 64 62 60 236 72 70 68 66 64 62 243 74 72 70 68 66 64 251 76 74 72 70 68 66 259 78 76 74 72 70 68 266 80 78 76 74 72 70 274 82 80 78 76 74 72 283 84 82 80 78 76 74 291 86 84 82 80 78 76 299 88 86 84 82 80 78 308 90 88 86 84 82 80 317 92 90 88 86 84 82 326 94 92 90 88 86 84 335 96 94 92 90 88 86 345 98 96 94 92 90 88 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 120 118 116 114 112 110 474 122 120 118 116 114 112 486 124 122 120 118 116 114 499 126 124 122 120 118 116 511 128 126 124 122 120 118 OUTDOOR TEMP ( °F) EVAPORATOR ENTERING AIR TEMPERATURE (°F WB) 50 52 54 56 58 60 62 64 66 68 70 72 74 76 55 9 12 14 17 20 23 26 29 32 35 37 40 42 45 60 7 10 12 15 18 21 24 27 30 33 35 38 40 43 65 — 6 10 13 16 19 21 24 27 30 33 36 38 41 70 — — 7 10 13 16 19 21 24 27 30 33 36 39 75 — — — 6 9 12 15 18 21 24 28 31 34 37 80 — — — — 5 8 12 15 18 21 25 28 31 35 85 — — — — — — 8 11 15 19 22 26 30 33 90 — — — — — — 5 9 13 16 20 24 27 31 95 — — — — — — — 6 10 14 18 22 25 29 100 — — — — — — — — 8 12 15 20 23 27 105 — — — — — — — — 5 9 13 17 22 26 110 — — — — — — — — — 6 11 15 20 25 115 — — — — — — — — — — 8 14 18 23 TABLE 3- REQUIRED LIQUID-LINE TEMPERATURE ( °F TABLE 4- SUPERHEAT CHARGING Where a dash ( —) appears, do not attempt to charge system under these conditions or re rigerant s ugging may occur. Charge must be weighed in. NOTE: Superheat 'F Is at low-side service port. —8— oth ru BRYANT BRYANT NON - PROGRAMMABLE NON - PROGRAMMABLE THERMOSTAT SINGLE -STAGE AIR THERMOSTAT MODEL AC FURNACE CONDITIONER MODEL AC 24 VAC HOT 24 VAC COM INDOOR FAN aG - HEAT STAGE 1 IW/W11. - - --W COOL STAGE 1(Y/Y2 BRYANT PROGRAMMABLE THERMOSTAT SINGLE -STAGE AIR MODEL AC FURNACE CONDITIONER 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOT USED 24 VAC COM NOT USED NOT USED OPTIONAL OUTDOOR _ SENSOR CONNECTION 1 ^ 71- W/W1 Y /Y2 O /W2 1/W 0 24 VAC HOT HEAT STAGE 1 COOL STAGE 1 INDOOR FAN 1.� I ' f K3 OTHER NON - PROGRAMMABLE SINGLE -STAGE AIR AC THERMOSTAT FURNACE CONDITIONER • • 4 SEE NOTE 2 SEE NOTE 2 SEE NOTE 2 A97359 A97361 A97367 —9— 24 VAC HOT 24 VAC COM HEAT STAGE 1 (W/W1I - COOL STAGE 11 Y/Y2 I' - INDOOR FAN D-- BRYANT PROGRAMMABLE THERMOSTAT MODEL AC 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOT USED 24 VAC COM NOT USED NOT USED OPTIONAL OUTDOOR - SENSOR CONNECTION Fig. 10— Typical 24v Circuit Connections 1 ^ f W /W1 Y/Y2 - O/W2 0 0 FA, FB, FC, FD, FF FAN CO L I IO CON NER FA, FB, FC, FD, FF AIR FAN COIL CONDITIONER OTHER FA, FB, FC, NON - PROGRAMMABLE FD, FF AIR AC THERMOSTAT FAN COIL CONDITIONER 24 VAC HOT D HEAT STAGE 1 IJ COOL STAGE 1 INDOOR FAN ❑G - NOTE 2 A97360 SEE NOTE 2 A97362 SEE NOTE 2 A97366 BRYANT NON-PROGRAMMABLE THERMOSTAT MODEL AC 24 VAC HOT nR - 24 VAC COM I C 7 HEAT STAGE 1 Fk COOL STAGE 1 FY - 2 - 1- INDOOR FAN I G 1- OTHER NON-PROGRAMMABLE FK4C AIR AC THERMOSTAT FAN COIL CONDITIONER 24 VAC HOT HEAT STAGE 1 COOL STAGE 1 INDOOR FAN F71 1 FAN COIL CONDITIONER SEE NOTE 2 SEE NOTE 2 A97363 A97365 BRYANT PROGRAMMABLE THERMOSTAT MODEL AC 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOT USED 24 VAC COM NOT USED NOT USED OPTIONAL OUTDOOR _ SENSOR CONNECTION I f O /W2 (Y1 /W21 E3 0 Fig. 10— Typical 24v Circuit Connections (Continued) —10— 4C FAN COIL CONDITIONER SEE ' NOTE 2 A97364 NOTES: 1. BRYANT THERMOSTAT WIRING DIAGRAMS ARE ONLY ACCURATE FOR MODEL NUMBERS TSTAT 2. WIRING MUST CONFORM TO NEC OR LOCAL CODES. 3. SOME UNITS ARE EQUIPPED WITH PRESSURE SWITCH(ES), TEMPERATURE SWITCH, OR 5- MINUTE COMPRESSOR CYCLE PROTECTION. CONNECT 24V FIELD WIRING TO FACTORY- PROVIDED STRIPPED LEADS. 4. A LIQUID -LINE SOLENOID VALVE IS REQUIRED ON SOME UNITS. SEE SPECIFIC UNIT INSTRUCTIONS. 5. THERMOSTATS ARE FACTORY CONFIGURED WITH 5- MINUTE COMPRESSOR CYCLE PROTECTION AND 4 CYCLES PER HOUR LIMIT. SEE THERMOSTAT INSTALLATION INSTRUCTIONS FOR DETAILS. 6. TO STAGE ELECTRIC RESISTANCE HEAT, CONSULT OUTDOOR THERMOSTAT INSTALLATION INSTRUCTIONS. SUPERHEAT TEMP (•F) SUCTION PRESSURE AT SERVICE PORT (PSIG) 107.8 112.2 116.8 121.2 126.0 130.8 138.8 140.8 145.8 0 35 37 39 41 43 45 47 49 51 2 37 39 41 43 45 47 49 51 53 4 39 41 43 45 47 49 51 53 55 6 41 43 45 47 49 51 53 55 57 8 43 45 47 49 51 53 55 57 59 10 45 47 49 51 53 55 57 59 61 12 47 49 51 53 55 57 59 61 63 14 49 51 53 55 57 59 61 63 65 16 51 53 55 57 59 61 63 65 67 18 53 55 57 59 61 63 65 67 69 , 20 55 57 59 61 63 65 67 69 71 22 57 59 61 63 65 67 69 71 73 24 59 61 63 65 67 69 71 73 75 26 61 63 65 67 69 71 73 75 77 28 63 65 67 69 71 73 75 77 79 30 65 67 69 71 73 75 77 79 81 32 67 69 71 73 75 77 79 81 83 34 69 71 73 75 77 79 81 83 85 36 71 73 75 77 79 81 83 85 87 38 73 75 77 79 81 83 85 87 89 40 75 77 79 81 83 85 87 89 91 TABLE 5— REQUIRED SUCTION -LINE TEMPERATURE PURON® (R -4l0A) QUICK REFERENCE GUIDE • Puron® refrigerant operates at 50 -70 percent higher pressures than R -22. Be sure that servicing equipment and replacement components are designed to operate with Puron® • Puron® refrigerant cylinders are rose colored. • Puron® refrigerant cylinders have a dip tube which allows liquid to flow out of cylinder in upright position. • Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400. • Puron® systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose when charging into suction line with compressor operating • Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low -side retard. • Use hoses with 700 psig service pressure rating. • Leak detectors should be designed to detect HFC refrigerant. • Puron ®, as with other HFCs, is only compatible with POE oils. • Vacuum pumps will not remove moisture from oil. • Do not use liquid -line filter driers with rated working pressures less than 600 psig. • Do not leave Puron® suction line filter driers in line longer than 72 hours. • Do not install a suction -line filter drier in liquid line. • POE oils absorb moisture rapidly. Do not expose oil to atmosphere. • POE Oils may cause damage to certain plastics and roofing materials. • Wrap all filter driers and service valves with wet cloth when brazing. • A factory approved liquid -line filter drier is required on every unit. • Do NOT use an R -22 TXV. • If indoor unit is equipped with an R -22 TXV, it must be changed to a Puron® TXV. • Never open system to atmosphere while it is under a vacuum. • When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter driers. Evacuate to 500 microns prior to recharging. • Do not vent Puron® into the atmosphere. • Do not use capillary tube coils. • Observe all warnings, cautions, and bold text. —11---- O 2001 Bryant Heating 8 Cooling Systems 7310 W. Morris St. Indianapolis, IN 48231 -12- Printed In U.S.A. 550a182 Catalog No. 5355.015 i z p Bryant installation, start -up, 355MAV and operating instructions Series E & F DELUXE 4 -WAY MULTIPOISE VARIABLE - CAPACITY DIRECT -VENT CONDENSING GAS FURNACE A93040 NOTE: Read the entire instruction manual before starting the installation. This symbol —> indicates a change since the last issue. Index Page DIMENSIONAL DRAWING 3 SAFETY CONSIDERATIONS 2 Clearances to Combustibles 4 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 2 INTRODUCTION 2-4 APPLICATIONS 4 -11 General 4 Upflow Applications 5 -7 Downflow Applications 7 -8 Horizontal Left (Supply -Air Discharge) Applications 8 -9 Horizontal Right (Supply -Air Discharge) Applications 9-11 LOCATION 11 -13 General 11 -12 Low -Fire Only Installation 12 Furnace Location Relative to Cooling Equipment 13 Hazardous Locations 13 INSTALLATION 13 -15 Leveling Legs (If Desired) 13 Installation In Upflow or Downflow Applications 13 Installation In Horizontal Applications 13 -15 AIR DUCTS 15 -18 General Requirements 15 -16 Ductwork Acoustical Treatment 16 Supply Air Connections 16 Return Air Connections 16 Filter Arrangement 16 Bottom Closure Panel 16 -17 Gas Piping 17 -18 ELECTRICAL CONNECTIONS 18 -22 115 -v Wiring 18 -19 24 -v Wiring 19 Accessories 19 DIRECT VENTING 22 -30 Removal of Existing Furnaces from Common Vent Systems 22 -23 Combustion -Air and Vent Piping 23 -28 Concentric Vent and Combustion -Air Termination Kit Installation 28 -30 Multiventing and Vent Terminations 30 CONDENSATE DRAIN 30 -32 General 30 —1— As an ENERGY STAR® Partner, Bryant Heating & Cooling Systems has de- termined that this product meets the, %EMIRGY ST/1eA l ib6InU.forcn- I,) e. 7 -• Cancels: II 355M -40 -8 G CERT I EFFICIENCY RATING CERTIFIED ama REGISTERED QUALITY SYSTEM AIRFLOW HORIZONTAL RIGHT II 355M -40 -9 2 -01 AIRFLOW AIRFLOW Fig. 1— Multipoise Orientations A93041 Application 30 Condensate Drain Protection 30 -32 SEQUENCE OF OPERATION 32 -35 Self -Test Mode 32 Heating Mode 32 -33 Heating Mode —Two Stage 33 Emergency Heat Mode 33 Cooling Mode 33 -34 Heat Pump Mode 34 Continuous Fan Mode 34 -35 Component Test 35 Bypass Humidifier Mode 35 Dehumidification Mode 35 Zone Mode 35 START -UP PROCEDURES 35 -43 General 35 -36 Select Setup Switch Positions 36 -37 Prime Condensate Trap With Water 37 Purge Gas Lines 37 Adjustments 38 -43 Set Gas Input Rate 38-43 Set Temperature Rise 43 Mop - : :i.:G.:t::ti�'.,d Set 'Thermostat Heat Anticipator 43 CHECK SAFETY CONTROLS 43 -44 Check Primary Limit Control 43-44 Check Pressure Switch 44 CHECKLIST 44 -45 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 90B. In Canada, refer to the current edition of the CAN /CGA- BI49.I- and .2 -M95 National Standard of Canada, Natural Gas and Propane Installation Codes ( NSCNGPIC). Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls. Recognize safety information. This is the safety -alert symbol® . When you see this symbol on unit or in instructions and manuals, be alert to potential for personal injury. Understand the signal words DANGER, WARNING, and CAU- TION. These words are used with 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. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS m CAUTION: Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are 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. 1. 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 (recharge your body with static electricity), firmly touch furnace again before touch- ing control or wires. —2— 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. INTRODUCTION The 355MAV Multipoise Condensing Gas -Fired Furnaces are CSA (A.G.A. and C.G.A.) certified for natural and propane gases and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory- shipped for use with natural gas. An A.G.A. /C.G.A. listed gas conversion kit is required to convert furnace for use with propane gas. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No: KCAKC is used. The design of this furnace line is not CSA (A.G.A. and C.G.A.) certified for installation in mobile homes, recreation vehicles, or outdoors. These furnaces are suitable for installation in a residence built on site or a manufactured residents completed at final site. These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply .sir discharge direction) applica- tions as shown in Fig. I. See details in Applications section. These furnaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment. Installer Packet includes: Installation, Start-Up, and Operating Instructions Service and Maintenance Procedures User's Information Manual Warranty Certificate Loose Parts Bag includes: Quantity Pressure tube extension Collector box or condensate trap extension tube Inducer housing drain tube 1 /2 -in. CPVC street elbow 2 Drain tube coupling Drain tube coupling grommet I' Vent and combustion -air pipe support 2, Combustion -air pipe perforated disk assembly Condensate trap hole filler plug 3 Vent and combustion -air intake hole filler plug 2 This furnace must be installed with a direct -vent (combustion air and flue) system and a factory accessory termination kit. In a direct -vent system, all air for combustion is taken directly from the outside atmosphere and all flue products are discharged to the outside atmosphere. See furnace and factory accessory termination kit instructions for proper installation. Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B. For copies of the NFGC and NFPA 90B contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or 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. 1 R3. L UNIT SIZE A D E 042040` 24 -1/2' 22 -7/8' 23' 042060 17 -1/2 15 -7/8 16 042080 21 19 -3/8 19-1/2 060080 21 19 -3/8 19 -1/2 060100 21 19 -3/8 19 -1/2 060120 24-1/2 22 -7/8 23 t 14 h" TYP 26 lie" 26 W 24 W 22 ;is" 2-IN. COMBUSTION - AIR CONN Y- IN. DIA GAS CONN� 24N. VENT CONN »-IN. DIA THERMOSTAT ENTRY 22 tine SIDE INLET 1' /i 1' 23 % TYP SIDE INLET 26'S/m "TYP V 8 ' CONDENSATE DRAIN TRAP LOCATION (DOWNFLOW ORIZONTAL LEFT) 3b-IN. DIA POWER CONN h-IN. DIA ACCESSORY POWER ENTRY DRAIN TRAP 1 27 As" CONDENSATE LOCATION TYP 24 I 17 35e" 9'/ " CONDENSATE DRAIN LOCATION ( UPFLOW) "he" 1 32 5 2 30e " TY P 29 27 W TYP AIRFLOW A D OUTLET OC=C=zi INLET �yie• �- E — Le. NOTES: 1. Minimum retum -air openings at fumace, based on metal duct. If flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters. 2. Minimum return-air opening at furnace: a. For 800 CFM- 16-in. round or 14 x 12 -in. rectangle. b. For 1200 CFM- 20 -in. round or 14'h x 19'h -in. rectangle. c. For 1600 CFM- 22 -in. round or 1412x 23'4 -in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate retum air openings for airflow requirements above 1800 CFM. DIMENSIONS (IN.) • - ••. . These dimensions reflect the wider casing for the Trophy (96.6 percent AFUE) fumace. — Fig. 2— Dimensional Drawing CONDENSATE DRAIN TRAP LOCATION (DOWNFLOW & HORIZONTAL RIGHT) OR ALTERNATE 'k -IN. DIA GAS CONN 30 '2" 18 'N CONDENSATE DRAIN LOCATION (UPFLOW) DIMPLE LOCATORS FOR HORIZONTAL HANGING od TYP 28 W 26 26 22 'As" — 19" OUTLET 2 -IN. COMBUSTION - AIR CONN WIN. DIA GAS CONN 'h-IN. DIA } \ POWER CONN WIN. DIA THERMOSTAT ENTRY ih f - 2- IN. VENT CONN I I 1 I SIDE INLET 1 1 I I i fi•— •— •- -- •— •- -- • —• —d.. k s- -- 22 % "TYP -- 41 7,5" BOTTOM INLET NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THISNOTICE ITIS DUE TO THE QUALITY OF THE DOCUMENT. ...1 3,,," t 24 VW' "he" ' 39' - A99112 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. 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. Fig. 3 Clearances to Combustibles —4— INSTALLATION This forced air furnace Is equipped for use with natural gas al attitudes 0 - 10,000 ft (0 - 3,050m). M accessory kit, supplied by the manufacturer, shah be used to convert to propane gas use or may be required for some natural gas applications. This furnace Is for indoor installation In a bulking constructed on site. This furnace may be Installed In a manufactured (mobile) home when stated on rating plate and using fadory authorized kit. This furnace may be Installed cn combustible flooring in alcove or closet at minimum dearance from combustible malaial. This appliance requires a spedal venting system. Refer to the Installation Instnxlions for parts list and method of Installatoa This f mace is for use with schedule -40 PVC, PVC-DVW, or ABS•DWV pipe, and must not be vented In corrrmn with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximtrn 24 inches (600 rum), ninimum 3/4 Inches (19 mm) thickness (including roofing materials). Furnace must be installed level, or pitched forward within 1/2 lnch of level for proper drainage. Failure will result In equipment or property damage. See Installation Manual for IMPORTANT unit support details on horizontal applications. UPFLOW OR DOWNFLOW MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION ALL PosmoNS: * Minimum front desrance for service 30 inches (762w). DOWNFLOW POSmONS: t Fa installation an combusti ble floors only when installed on spedal base Na KGPSB0201A11, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC. HORIZONTAL POSITIONS: aearahce shown is for air Inlet and air outlet end. Line canted Is permissible only between lines formed by intesedions of top and two sides of furnace jacket, and buildingjdsts, studs, orfraning. 0 120 size Furnace require 1 inch bottom dearance to ocmbustible materials 325400 -201 REV. A (LIT. TOP) LEVEL (0 ") 1/2"MAX T LE T (0 ") 1n" MAX HORIZONTAL This furnace Is approved fa (PFLOW, DWMFLCwand HORIZONTAL Installations. A99103 WARNING: Improper installation, adjustment, alter- ation, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory- authorized and listed kits or accessories when modifying this product. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. For accessory installation details, refer to applicable installation literature. APPLICATIONS I. GENERAL Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain and pressure tubes are connected as shown in Fig. 5. See appropriate application instructions for these procedures. BLOWER SHELF r FURNACE DOOR CONDENSATE TRAP (INSIDE) 3 /4 4- 1 FIELD 26'/4 DRAIN ALTERNATE DRAIN \ CONN TUBE LOCATION CONDENSATE TRAP DRAIN TUBE LOCATION UPFLOW APPLICATIONS SLOT FOR SCREW HORIZONTAL APPLICATION (OPTIONAL) 1 WIRE TIE GUIDES (WHEN USED) FRONT VIEW 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 Orientation) The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications. A factory- supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment. See Condensate Trap Tubing (Factory- Shipped Orientation) section for drain tube extension details. B. Condensate Trap Tubing (Factory- Shipped Orientation) NOTE: See Fig. 5 or tube routing label on main furnace door to confirm location of these tubes. 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). CONDENSATE TRAP FURNACE SIDE 11/2 4 SIDE VIEW FRONT VIEW DOWNFLOW AND ALTERNATE EXTERNAL UPFLOW APPLICATIONS —5— SIDE VIEW 1 /4 OD COLLECTOR BOX TO TRAP RELIEF PORT INDUCER HOUSING DRAIN CONNECTION % OD COLLECTOR BOX DRAIN CONNECTION SCREW HOLE FOR UPFLOW OR DOWN - FLOW APPLICATIONS (OPTIONAL) 1/2-IN. PVC OR CPVC FURNACE DOOR FURNACE SIDE 26 1 /4 FIELD DRAIN CONN 4 4 HORIZONTAL APPLICATIONS - a 59 4 END VIEW FRONT VIEW A93026 Fig. 4— Condensate Trap 2. Condensate Trap Drain Tube The condensate trap drain connection must be extended for field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2 or 5.) NOTE: If internal filter 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 so long end of coupling faces blower. e. Cement 2 factory- supplied 1 /2 -in. street CPVC elbows to rigid drain tube connection on condensate trap. (See Fig. 5.) These elbows must be cemented together and ce- mented to condensate trap drain connection. NOTE: Failure to use CPVC elbows may allow drain to kink, preventing draining. f. Connect larger diameter drain tube and clamp (factory- supplied in loose parts bag) to condensate trap and clamp securely. g. Route tube to coupling and cut to appropriate length. ai PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) INDUCER HOUSING (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX DRAIN TUBE) COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) FIELD - INSTALLED FACTORY - SUPPLIED DRAIN TUBE COUPLING (LEFT DRAIN OPTION) FIELD - INSTALLED FACTORY - SUPPLIED DRAIN TUBE FIELD - INSTALLED FACTORY - SUPPLIED 1 1/2 -IN. CPVC STREET ELBOWS (2) FOR LEFT DRAIN OPTION CONDENSATE FIELD - INSTALLED FACTORY - SUPPLIED DRAIN TUBE COUPLING (RIGHT DRAIN OPTION) A94213 Fig. 5— Factory- Shipped Upflow Tube Configuration (Shown With Blower Access Panel Removed) h. Attach tube to coupling and clamp securely. C. Condensate Trap Location ( Altemate Upflow Orientation) An alternate location for the condensate trap is the left -hand side of casing. (See Fig. 2 and 6.) NOTE: If the alternate left -hand side of casing location is used, the factory- connected drain and relief port tubes must be discon- nected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for tubing attachment. To relocate condensate trap to the left -hand side, perform the following: 1. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Install casing hole filler cap (factory- supplied in loose parts bag) into blower shelf hole where trap was removed. 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Fill unused condenstate trap casing holes with placstic filler caps (factory- supplied in loose parts bag). PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (GREEN) CONDENSATE — ►' TRAP INDUCER HOUSING DRAIN TUBE (VIOLET) A94214 Fig. 6— Alternate Upflow Tube Configuration and Trap Location D. Condensate Trap Tubing (Alternate Upflow Orientation) NOTE: See Fig. 6 or tube routing label on main furnace door to confirm location of these tubes. 1. Collector Box Drain Tube Connect collector box drain tube (blue label) to condensate trap. NOTE: On 17- 1 /2 -in. wide furnaces ONLY, cut tube between corrugated sections to prevent kinks. 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 conden- sate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. 3. Relief' Port Tube a. Connect relief port tube (green label) to condensate trap. COLLECTOR BOX DRAIN TUBE (BLUE) CAP PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX EXTENSION TUBE CONDENSATE —0•- TRAP INDUCER HOUSING DRAIN TUBE (VIOLET) A94215 Fig. 7— Downflow Tube Configuration (Left-Hand Trap Installation) b. Extend this tube (if required) by splicing to small diameter tube (factory- supplied in loose pans bag). c. Determine appropriate length, cut, and connect tube. E. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. F. Pressure Switch Tubing The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch and should not require any modification. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. G. Upper Collector Box and Inducer Housing (Unused) Drain Connections UPPER COLLECTOR BOX DRAIN CONNECTION Attached to the UPPER collector box drain connection is a factory- installed corrugated, plugged tube (blue and white striped label). This tube is plugged to prevent condensate leakage in this application. Ensure this tube is plugged. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. UPPER INDUCER HOUSING DRAIN CONNECTION Attached to the UPPER (unused) inducer housing drain connection is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. H. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. —7— DRAIN TUBE Mr COUPLING O 7 COLLECTOR BOX TUBE (GREEN) PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX EXTENSION TUBE INDUCER HOUSING DRAIN TUBE (VIOLET) �-- CONDENSATE TRAP COLLECTOR BOX EXTENSION DRAIN TUBE A94216 Fig. 8— Downflow Tube Configuration (Right -Hand Trap Installation) 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. Install casing hole filler cap (factory- supplied in loose parts bag) into blower shelf hole where trap was removed. 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Fill unused condenstate trap casing holes with placstic filler caps (factory- supplied in loose parts bag). B. Condensate Trap Tubing NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections. 1. Collector Box Drain Tube a. Remove factory- installed plug from LOWER collector box drain tube (blue and white striped label). b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was connected to condensate trap. c. Connect LOWER collector box drain connection to condensate trap. i +SNa�w' >'.A W;r::lt%:4d.'S14 ° •' ICY' 1m4i�?: t. fes+RrvSnta:tiY.a'.1:ii7.4.�YiTr} Jae }iw� M�ifyiirR S;.t+}�ai;;,:•, (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 drain to conden- sate trap as shown in Fig. 8. (b.) Determine appropriate length and cut. (c.) Connect tube to condensate trap. (d.) Clamp tube to prevent any condensate leakage. 3. Relief Port Tube r1rarr40 0w Refer to Pressure Switch Tubing section for connection procedure. C. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. D. Pressure Switch Tubing One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications. This tube MUST be dis- connected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory —8— connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZON- TAL RIGHT applications. NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections. Relocate tubes as described below. 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. 2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connec- tion by splicing to small diameter tube (factory- supplied in loose parts bag). 3. Connect collector box pressure tube (green label) to pres- sure switch connection labeled COLLECTOR BOX. 4. Extend collector box pressure tube (pink label) which was previously connected to pressure switch by splicing to remaining small diameter tube (factory- supplied in loose parts bag). 5. Route this extended tube (pink label) to condensate trap relief port connection. 6. Determine appropriate length, cut, and connect tube. 7. Clamp tube to relief port connection. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. IV. HORIZONTAL LEFT (SUPPLY -AIR DISCHARGE) APPLICATIONS A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, and conditioned air is discharged to the left. CAUTION: Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling. NOTE: In Canada, installations shall be in accordance with current NSCNGPIC and /or local codes. 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 tiller cap (factory- supplied in loose parts bag) into blower shelf hole where trap was removed. 4. install casing hole filter cap into blower shelf hole where trap was removed. 5. Fill unused condenstate trap casing holes with placstic 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. CONDENSATE TRAP f 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 conden- sate 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 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 condensate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. C. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. AUXILIARY "J" BOX =E —9— 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 D. 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. 9 or tube routing label on main furnace door to check for proper connections. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. F. Construct a Working Platform Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.) 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 11) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 29.) 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. COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) 1• 1% pc: 11 11 i4 • 0 COLLECTOR BOX TUBE (GREEN) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX DRAIN TUBE (BLUE) A00215 MANUAL SHUTOFF GAS VALVE SEDIMENT TRAP COMBUSTION – AIR INTAKE CONDENSATE TRAP DRAIN VENT NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS. 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. 9.) See Electrical Connection section for J -box relocation. A. Condensate Trap Location The condensate trap must be removed from the factory- installed blower shelf location and relocated in selected application location as shown in Fig. 2 or 11. To relocate condensate trap from the blower shelf to desired location, perform the following: 1. Remove 3 tubes connected to condensate trap. 2, Remove trap from blower shelf' by gently pushing tabs inward and rotating trap. 3. Install casing hole filler cap (factory- supplied in loose parts bag) into blower shelf hole where trap was removed. 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Fill unused condenstate trap casing holes with placstic filler caps (factory- supplied in loose parts bag). Fig. 10 — Attic Location and Working Platform —10— 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 B. Condensate Trap Tubing NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections. 1. Collector Box Drain Tube a. Remove factory- installed plug from LOWER collector box drain tube (blue and white striped label). b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was previously con- nected to condensate trap. c. Connect LOWER collector box drain tube (blue and white striped label) to condensate trap. Tube does not need to be cut. d. Clamp tube to prevent any condensate leakage. 2. Inducer Housing Drain Tube a. Remove factory- installed cap and clamp from LOWER inducer housing drain connection. b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to conden- sate trap. 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. COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE Fig. 11 Horizontal Right Tube Configuration f. Clamp tube to prevent any condensate leakage. 3. Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure. C. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. D. Pressure Switch Tubing One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications. This tube MUST be dis- connected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZON- TAL RIGHT applications. NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections. Relocate tubes as described below. 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. 2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connec- tion by splicing to small diameter tube (factory- supplied in loose parts bag). 3. Connect collector box pressure tube (green label) to pres- sure switch connection labeled COLLECTOR BOX. 4. Use remaining small diameter tube (factory- supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch. 5. Route this extended tube (pink label) to condensate trap relief port connection. —1 1— COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) — AUXILARY "J" BOX RELOCATED HERE CONDENSATE TRAP A00214 6. Determine appropriate length, cut, and connect tube. 7. Clamp tube to relief port connection. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. F. Construct a Working Platform Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.) 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 29.) LOCATION 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. LEVEL (0 ") TO Ih" MAX FRONT UPFLOW OR DOWNFLOW LE TEL (0 ") t/" MAX A93025 NOTE: For proper furnace operation, install furnace so that it is level or pitched forward within 1/2 in. to ensure proper condensate drainage from secondary heat exchangers. FRONT HORIZONTAL MAX 85°F -u l� MIN 55 °F A93042 NOTE: These furnaces are designed for a minimum continuous return-air temperature of 60 °F or intermittent operation down to 55 °F such as when used with a night setback thermostat. 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 lengths are not exceeded. Refer to Table 6. 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 the construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems. Provide ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on unit's clear- ance to combustibles label. (See Fig. 3.) Locate furnace where available electric power and gas supplies meet specifications on furnace rating plate. — 12— WARNING: Do not install furnace on its back. Safety control operation will be adversely affected. Never con- nect return-air ducts to back of furnace. Failure to follow this warning could result in fire, personal injury, or death. 32 °F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED LL CAUTION: If these furnaces are installed in an uncon- ditioned space where ambient temperatures may be 32 °F or lower, freeze protection measures must be taken. II. LOW-FIRE ONLY INSTALLATION A93043 A93058 This 355MAV furnace can be installed to operate in the low -fire only heating mode when sized using the low -fire heating capacity. This is accomplished by placing setup switch SW -2 in the ON position to provide only low -fire -heat operation. See Fig. 25 and Table 10. With this setup, high -fire operation will not occur. When the model no. on the furnace rating plate is followed by an asterisk ( *), the furnace has an alternate low -fire only efficiency rating as listed in the GAMA and CEC directories. This alternate rating will be listed as the furnace model number followed by an ( -L) suffix. CAUTION: The furnace can operate in the high -fire mode when certain fault conditions occur. The following precautions should be taken: 1. Size gas piping based on the high -fire input. 2. Check the high -fire input and adjust it per the main literature instructions. NEVER assume the high -fire input rate is not important for low- fire -only installation. III. 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. IV. HAZARDOUS LOCATIONS 1S -IN. MINIMUM TO BURNERS A93044 WARNING: When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, unit must be installed in accor- dance with requirements of National Fire Protection Association, Inc. INSTALLATION I. LEVELING LEGS (IF DESIRED) When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 12.) Install field- supplied, corrosion- resistant 5 /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. —13— A89014 Fig. 12— Leveling Legs NOTE: Bottom closure must be used when leveling legs are used. See Bottom Closure Panel section. II. INSTALLATION IN UPFLOW OR DOWNFLOW APPLICATIONS NOTE: This furnace is approved for use on combustible flooring when special base (available from manufacturer) Part No. KGASB020IALL 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. I. 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 CD5 or CK5 or Coil Box KCAKC is used, install as shown in Fig. 15. NOTE: Remove furnace perforated, discharge duct flanges when they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.) WARNING: Do not bend duct flanges inward as shown in Fig. 16. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 16. 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 add angle iron supports. (See Fig. 17.) Cut hanger bolts (4 each 3 /8 -in. all- thread rod) to desired length. Use 1 X 3 /8 -in. flat washers, 318 -in. lockwashers, 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 17-1/2 Upflow Applications 16 24 -1/8 16 -5/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 15 -7/8 19 16 -1/2 19 -5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Fumace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 15 -1/8 19 16 -3/4 20 -3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Fumace with CD5 or CK5 Coll Assembly or KCAKC Coil Box 15 -1/2 19 16 -1/2 20 21 Upflow Applications 19 -1/2 24 -1/8 20 -1/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 19 -3/8 19 20 19 -5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Fumace with or without CD5 or CK5 Coil Assembly or KCAKC CoII Box 18 -5/8 19 20 -1/4 20 -3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Fumace with CD5 or CK5 Coll Assembly or KCAKC Coil Box 19 19 20 20 24-1/2 Upflow Applications 23 24 -1/8 23 -5/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 22 -7/8 19 23 -1/2 19 -5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Fumace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 -1/8 19 23 -3/4 20 -3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Fumace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 -1/2 19 23 -1/2 20 FURNACE (OR CASING WHEN USED) R COMBUSTIBLE FLOORING DOWNFLOW SUBBASE SHEET METAL PLENUM _ FLOOR —� OPENING — A96285 Fig. 14— Furnace, Plenum, and Subbase Installed on a Combustible Floor A96283 Fig. 13 —Floor and Plenum Opening Dimensions TABLE 1— OPENING DIMENSIONS (IN.) —14— FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR —.- OPENING n J A96284 Fig. 15— Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor PERFORATED DISCHARGE DUCT FLANGE Fig. 16 —Duct Flanges ANGLE IRON OR EQUIVALENT (B) (A) LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL 3 /a -IN. HEX NUT DWG FOR WASHER (4) ROD LOCATIONS) (A) PREFERRED ROD LOCATION (B) ALTERNATE ROD LOCATION NO YES YES A93029 (A) (B) DRAIN Fig. 17— Crawlspace Horizontal Application —15— CAUTION: The entire length of furnace MUST be supported when furnace is used in a horizontal position to ensure proper draining. When suspended, bottom brace supports sides and center blower shelf. When unit is supported from the ground, blocks or pad should support sides and center blower shelf area. IV. AIR DUCTS A. General Requirements The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE). Or consult factory The Air Syslents 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 fumace, 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. 13 /16-IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK NOTES: 1. A 1 In. clearance minimum between top of fumace and combustible material. 2. The entire length of furnace must be supported when fumace is used in horizontal position to ensure proper drainage. 3 43-IN. ROD ALTERNATE SUPPORT LOCATION 4 -IN. MIN 8 -IN. MAX A93304 FURNACE CASING WIDTH (IN.) FILTER SIZE (IN.)* FILTER TYPE FRAMED Side Retum Bottom Retum 17 -112 (1) 16 X 25 X 1t (1) 16 X 25 X 1t Cleanable 21 (1) 16 X 25 X 1 (1) 20 X 25 X 1t Cleanable 24-112 (1 or 2) 16 X 25 X 1 (1) 24 X 25 X 1t Cleanable tt11�1101 min�1. nnrnr nrmrmmm� alRilrR"" " Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended. Maintain a 1 -in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See NFPA 90B or local code for further requirements. 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 standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts. C. Supply Air Connections UPFLOW FURNACES Connect supply -air duct to 3 /4 -in. flange on furnace supply -air outlet. The supply -air duct attachment must ONLY be connected to furnace supply - /outlet -air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accesso- ries MUST be connected external to furnace main casing. DOWNFLOW FURNACES Connect supply -air duct to supply -air opening on furnace. The supply -air duct attachment must ONLY be connected to furnace supply \outlet or air conditioning coil casing (when used), when installed on non - combustible material. When installed on combus- tible material, supply -air duct attachment must ONLY be con- nected to an accessory subbase or factory approved air condition- ing coil casing. DO NOT cut main furnace casing to attach supplyside air duct, humidifier, or other accessories. All accesso- ries MUST be connected external to furnace main casing. HORIZONTAL FURNACES Connect supply -air duct to supply air opening on furnace. The supply -air duct attachment must ONLY be connected to furnace supply /outlet or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing. D. Return Air Connections UPFLOW FURNACES The return -air duct must be connected to bottom , sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. Bypass humidifier may be attached into unused side return air portion of the furnace casing. DO NOT connect any portion of return-air duct to back of furnace casing. 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. The air filter arrangement will vary due to application 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. —16— If a factory- supplied extemal Filter /Media cabinet is provided, instructions for its application, assembly, and installation are packaged with the cabinet. The Filter /Media cabinet can be used with the factory- supplied washable filter or a factory- specified high - efficiency disposable filter (see cabinet instructions). If installing the filter in the furnace blower compartment, deter- mine location for filter and relocate filter retaining wire if necessary. See Table 2 to determine correct filter size for desired filter location. Table 2 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings. TABLE 2— FILTER INFORMATION Filters may be field modified by cutting filter material and support rods (3) in filters. Altemate sizes can be ordered from your distributor or dealer. t Factory- provided with fumace. CAUTION: Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropiate protective clothing. Failure to follow this caution could result in personal injury. L CAUTION: For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM. NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 18. For bottom return-air applications, 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. VI. BOTTOM CLOSURE PANEL These furnaces are shipped with bottom closure panel installed in bottom return -air opening. This panel MUST be in place when side return air is used. WASHABLE FILTER Fig. 18 Filter Installed for Side Inlet FILTER RETAINER A93045 NOMINAL IRON INTERNAL LENGTH OF PIPE (FT) PIPE DIAMETER 10 20 30 40 50 S IZ E (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 To remove bottom closure panel, perform following: 1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 20.) 2. Rotate front filler panel downward to release holding tabs. 3. Remove bottom closure panel. 4. Reinstall front filler panel and screws. 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 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas. 171 - IN.WIDE CASINGS ONLY: INSTALL FIELD - SUPPLIED FILTER FILLER STRIP UNDER FILTER. 21 -IN. WIDE CASINGS ONLY: SUPPORT RODS (3) EXTEND 1/4" ON EACH SIDE OF FILTER AND REST ON CASING FLANGE FILTER SUPPORT FILTER RETAINER Fig. 19 — Bottom Filter Arrangement WASHABLE FILTER A00290 —I 7— TABLE 3— MAXIMUM CAPACITY OF PIPE* Cubic ft of gas per hr for gas pressures of 0.5 psi9 (14 -in. wc) or less, and a pressure drop of 0.5 -in. wc (based on a 0.60 specific gravity gas). Ref: Table 10.2 NFPA 54 -1999. ®� CAUTION: Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls. 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. WARNING: Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death. Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight - through section of tee is vertical. Then connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and manual gas shutoff valve. (See Fig. 21.) 10 FRONT FILLER PANEL BOTTOM CLOSURE PANEL Fig. 20— Removing Bottom Closure Panel A93047 Fig. 21— Typical Gas Pipe Arrangement m 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 1 /8 -in. NPT plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve. NOTE: The gas valve inlet press tap connection is suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0.5 psig (14 -in. wc) stated on gas valve. (See Fig. 47.) Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace has been attached. In Canada, refer to current edition of NSCNGPIC. If pressure 115 -V SINGLE PHASE GAS SUPPLY MANUAL SHUTOFF VALVE (REQUIRED)/ TRAP UNION FIVE WIRE THREE -WIRE HEATING ONLY 115 -V AUXILIARY FIELD - SUPPLIED J -BOX DISCONNECT SWITCH FURNACE CONTROL CENTER NOTE 5 A93324 (J (a) rm 24 -V TERMINAL BLOCK J Fig. 22— Heating and Cooling Application Wiring Diagram —18— exceeds 0.5 psig (14 -in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14 -in. wc), turn off electric shutoff switch located on gas valve before test. It is recommended that ground joint union be loosened before pressure testing. After all connections have been made, purge lines and check for leakage. ELECTRICAL CONNECTIONS See Fig. 22 for field wiring diagram showing typical field 1 15 -v and 24 -v wiring. Check all factory and field electrical connections for tightness. 4) WARNING: Blower access panel door switch opens 115 -v power to control center. No component operation can occur. Do not bypass or close switch with panel removed. Failure to follow this warning could result in personal injury or death. CAUTION: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. I. 115 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 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. - - - - FIELD 24 -V WIRING - --- FIELD 115 -, 208/230 -, 460 -V WIRING — FACTORY 24 -V WIRING — FACTORY 115 -, 208/230 -, 460 -V WIRING THERMOSTAT TERMINALS FIELD - SUPPLIED DISCONNECT • • -- •, •-I - •- •GND CONDENSING UNIT 208/230- OR 460 -V THREE PHASE 208/230 -V SINGLE PHASE NOTES: 1. Connect Y or Y/Y2 terminal as shown for proper cooling operation. 2. Proper polarity must be maintained for 115 -v wiring. 3. Use W2 with 2 -stage thermostat when zoning. 4. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire. 5. Some thermostats require a "C" terminal connection as shown. A98325 ELECTRIC DISCONNECT SWITCH ALTERNATE FIELD LOCATION COPPER WIRE ONLY CAUTION: Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. 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 1 15 -v wiring. If polarity is incorrect, control center fault code indicator light will flash rapidly and furnace will NOT operate. WARNING: The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70 -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 electric shock, fire, or death. J - BOX RELOCATION 1. Remove 2 screws holding auxiliary J -box. (See Fig. 23.) 2. Rotate J -box 180° and attach box to right side, using holes provided. Flg. 23— Relocating J -Box A93033 FACTORY INSTALLED LOCATION A00212 —19— CAUTION: If manual disconnect switch is to be mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components. II. 24 - V WIRING Make field 24 -v thermostat connections at 24 -v terminal block on control center. Y wire from thermostat MUST be connected to Y terminal on control center, as shown in Fig. 22, for proper cooling operation. 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). NOTE: Use AWG No. 18 color -coded copper thermostat wire for lengths up to 100 fl. For wire lengths over 100 ft, use AWG No. 16 wire. NOTE: For 2 -speed applications, refer to Sequence of Operation section. III. ACCESSORIES 1. Electronic Air Cleaner (EAC) •i The control center EAC terminals are energized with 1.15v (1.5 -amp maximum) during blower operation. a. Two extension leads are connected to the control center EAC terminals to assist field installation of an EAC. (See Fig. 25.) To use these leads, proceed with the following: (1.) Strip EAC power lead insulation approximately 1/4 in. (2.) Insert stripped end into factory- supplied black lead's butt connector and crimp to secure. (3.) Strip EAC neutral lead insulation approximately 1/4 in. (4.) Insert stripped end into factory- supplied white leads's butt connector and crimp to secure. NOTE: If desired, cut butt connectors off factory leads and strip insulation approximately 1/4 in and use field - supplied wire nuts to connect. b. An alternate method to attach EAC lead to control center is the following procedure: Remove 2 screws securing the control box to furnace blower shelf. (2.) Remove and discard 2 factory- supplied leads from control center EAC terminals. c (3.) Strip EAC power leads insulation approximately 1/8 in. NOTE: The control center EAC terminals are sized for 12 gage maximum, solid or stranded wire. (4.) Route EAC leads through right -hand wire grommet. (5.) Insert EAC stripped leads into control center EAC terminals by depressing terminal's arm with a screwdriver or finger. (See Fig. 26.) (6.) Reinstall control box to furnace blower shelf using 2 screws removed earlier. (1.) 2. Humidifier (HUM) Screw terminals (HUM and Cora) are provided for 24 -v humidifier connection. (See Fig. 24.) HUM terminal is energized with 24v (0.5 -amp maximum) after inducer motor prepurge period. SM1D.4 (• NC AN CF SMIRCH POS. SH E C T a r gag DEFPLLTDEFPLLT pp 3 t 3 TON 1200 CFM 1A e o 1.12 TON 603 a,, n __ 3-12 1O4 1400 (FM 1 1 3 121717 2 TON 800 CFI., 1 2 3 pee 4 1ON 1600 cm eAc T Or � 4 Ca1 e I e e TFF 5 TON 2000 M CFM 41I■ 4 111. vw GRNI YET. T h KITE 40 RID 12543 P TS 0S 161514 BS 0 °s BW- (3)2 Th P112 RED 3 1 8 14 6 VK7 rrI r : t �_ rzzzzzizzT FSE 3 PL1 ax 6 1® NM I1 2 PL4 0 YNTT ILK B1 MrI I II( P1 12 P2 ORN PL2 BRN— i• BLU FPS C � NG 1 1 -KM EmEnma ly :rRr.t1� ©© 042040 042050 042!83 PL11 MTR LEGENDI NC ALS F G1 EAC-2 FRS FSE RU1 I R2 GTD CV GVR H FPS H9 HSR HUM II1MR TUC IND .A LIDS L.GPS LPS LS MTR1 MTR2 PCB R.1 P2 PL3 PL4 P15 YR RI PL13 PCB NR COM3IT10NNG ADJUSTABLE TONNAGE) AIDOLNRY UNIT SWITCH OJERTa - MANUAL RESET &PST {NC) COM1NJOU5 FAN (ADAbTABLECFM) MINN LICROPROCESSOR 6CRCULTRt' IGlT1CN MCROPROCESSOR & CIRCUIT R! DENMOFY ENABLE- IFDE CO•EGDON PROVIDED REMOVE JUVPER TO EHABI-E CENJM INPUT DBUADIFICA710N COMEC RON (24VAC .02 AMPS) ELECTRONCNR CLEANER CDNNECDCN 1151PC 15 AMP MAX.) ElECTRONC NR CLEANER COAECRCN (COMMON) RICE ROUOIT WATCH - M ANDIL RESSET, 9'ST -OLC.) RAE PROVING SENSOR ELECTRODE RJSE 3 PAM NJiOMORVE BLADE TYPE FACTORY INSTALLED FUSE OR CRUST BREAKER CURRENT INTERRUPT DEVICE (FLED INSTAW33 8 SUPPLIED) GAS%CU.VE GAS RELAY. OPST -(N.O.) GAS WYE NIGH STAGE OPBTATOR 110-II-EAT PRESSURE SWITCH, &PST -(N0.) HOT SURFACE IO1TOR (NSVAP Hai SURFACE IGNITOR RELAY, SPST{PLO.) 24VAC HUMIDIFIER CONNECTION (5 AP. MAX) HUMIDIRERRELAY. &PST {NO.) BLOWER ACCESS PANEL INTERLOCK MATCH, SPST(N.0) INEIUCTOR AINCDCN BOX U134T EMITTING DOES FOR STATUS COOES LOW GAS PRESSURE SWITCH, &PST(N0.) LOW FEAT PRESSSJRESWITCH, SPST{NO.) UMT9MTCH. AUTO RESET. (NC) MOTOR (104 INDUCER MOTOR 904 9-C,O& R PRINTED aRCIJR BOARD 1117RCUT CCMECTOR 4{7RCUIT PRESSURE 9MTCH CONECTOR &CIRCUIT BUDVER MTR CONVECTOR 2-CIRCUIT HSI C OMECTOR 6COtCUT MODEL ax FUSED OISCCMEITSWITCH (WIN REM NOTE 42 WHT 1234 Hut tom] R ��� Y112 Cou [ �] N CWI (�7 0 ] V72 hl l>Et= BLU SEG21 SEC-1 1 DEMAN P16 RS PL7 PL9 P1.10 PL11 PL12 R-13 SN1 932 SW3 SN4 5115 SY6 5W7-8 TITAN O RED NOTE 46 L I 241p0,'y, (1-4) O to © ® CF A/C T • PL5 321 654 LPS NOTE tt11 NO f,NQfE ORN arM1 MPS BR/ USED) BLOAER OFFDELAY SELECTION CHART od cFF ec CFF 78 OFF 7 OFF 93 SEC 135 SEC 180 SEC, JUNCTION UNMARKED TERMINAL PCB DERMAL (FACTORY COMRECTB3) FACTORY1MPoNG(115 VAC) FACTORY%MRP G (24 VAC) REED WIRINIG(115VAC) CONDUCTOR ON PCB FIELD I WRING SCREW TERRMINAL TERMINAL BLOCK - MARKED TERMINAL FIELD EARTH GROIN) EQUIPMENT GROUND FIELD &PUCE PCB TERMINAL (FIELD CONE:CRON) PLUG RECEPTACLE 225 SEC 3ORCIATCOAL CONVECTOR 12-CIRCUIT INDUCER MTRC MECTOR 2.ORCUT H9 CONECTOR 9ORCUT BLOWER ADAPTER OON1ECTDR 1-CIRCUIT INDUCTOR SPLICE COMECTOR SGRCUTBLUM1ER PO ER COMECTOR 16L1RCUTT BLOWER CTR. CC M ECTO R W AL WATCH, FALLT DISPLAY, SPSTi14.0.) MANUAL SWITCH LOW HEAT, SPST {140.) MANUAL 9MR7t BYFASS HUMID PIER. &PST -(NO) MANUAL SMTOt EMERGENCY FEAT, SPST(N.0) MMMNL SWIM MULTIPLE ZONE, 9'ST -)NO.) COMIPOFENTTEST, SPST {N0.) MANUAL 9MTCH, MOWER OFF-DELAY. SPST {NO TRANSFORMER - 115VAC/24VAC 10115VACFIELDDISWMECT ; 1 `2 Lfw NOTE PL1 r R3 1 CPl2 2 5 1 I2 I1 v 3 45 91 FLAIR OEH11M U FUM (WHEN R EN USED) G Y,Y2 0 V2 0 W W 1 0 0au 0 • DE C CE- C CE?- C4' 7 <4-- 91.93 Uo FRS L5 NS CPU1 E OUPLENTG ROOD SW - 4 EWER FEN CIC FOWER SUPPLY ■ 82 P112 EAC-1 EPC-2 ) R� Dc PPLY { 6 { 2 MTRt PV PCB NOTE d5 PL13 4 CE 4- CC 3 E EZ- L I isommio SCHEMATIC DIAGRAM (NATURAL GAS & PROFANE) PL4 NOTE 46 PL2-4 F12.1 PL1-1 ,2 d 1MT � PL9 HSI I SECA P1 115W P1 IRAN ( 8L2 -2 WM#i1 LCPS LPS N 09 011 �1 T -o p �P (YdEN 11937) O FSE 24V1C NOTEt0 PL1 -7 SEG2 C 1 1 1 1 1 1 10 . • II any of the ongmal eeu'pmcnt warn 's ,placed use wire rater: for 1 05 C 1 Use only copper woe between the discohnect swdc• a •d :ne iv-ace p,ncnon nor 28. 3 This wire must be cormected :0 urhace sheet meta '0 art, :o pre re f. a —e 4 Symbols are 0000n cal representa1or only 5 Soi•d mes msme circuit board PCB are br .tee nrc.. 1 board traces tec oe not 9epgted is ; ^ow^ a fee •qe •e 6' Reouce only wIh a 3 41.19 ruse 7 Inductor used on at. 060 or 26 3 flow units 8 Blower•on delay gas heatinq 60 seconds ow ^eat 35 seeoecs h gr neat coonnq or neat bump :.eco^ds 9. Blower-on delay gas heat eg 90 1 35 '60 or 225 sec orris coo ^g or ^eat o1.n'3 90 seconds Igmtion-roceout wdl xcur After 'our consecutive ,.esuccessrte tnats.tor ,gn Corrror w u wto•reset tter • ^Tee - ca•; 1 actory connected when -GPS not used :22296- RE. E -*Fig. 24 —Unit Wiring Diagram NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. A00350 1 UNIT SIZE VOLTS— HERTZ— PHASE OPERATING VOLTAGE RANGE MAXIMUM UNIT AMPS UNIT AMPACITYt MINIMUM WIRE SIZE MAXIMUM WIRE LENGTH (FT)# MAXIMUM FUSE OR CKT BKR AMPS"" Maximum* Minimum* 042040 115 -60-1 127 104 8.9 12.0 14 31 15 042060 115 -60-1 127 104 8.9 12.0 14 31 15 042080 115 -60-1 127 104 8.9 12.0 14 31 15 060080 115 -60-1 127 104 13.8 17.9 12 32 20 060100 115 -60-1 127 104 13.8 18.1 12 32 20 060120 115 -60-1 127 104 11.6 15.3 12 37 20 EAC- ELECTRONIC AIR CLEANER TERMINALS (115 -VAC 1 AMP MAX) MAIN BLOWER CONTROL WIRE CONNECTOR CONTINUOUS FAN (CF) SETUP SWITCHES ( COMMUNICATION CONNECTOR Fig. 26—EAC Terminals on Control Center A93053 0 CI HOT SURFACE IGNITOR CONNECTOR f fif O 0 l 00000noDona TRANSFORMER 24 -V CONNECTORS —21— G CI CI C O [%7 [] % 101 [7 [ ] [%] eee I � 0. oN laeeaeeee Fig. 25— Control Center TABLE 4— ELECTRICAL DATA 115 -V CONNECTORS PRESSURE SWITCH CONNECTOR HUM- HUMIDIFIER TERMINAL (24 -VAC 0.5 AMP MAX) 24 -V THERMOSTAT TERMINALS DEHUMIDIFY ENABLE (DE) DEHUMIDIFIER (DEHUM) I 3 -AMP FU E STATUS AND DIAGNOSTIC 00001 LED LIGHTS r — AIR CONDITIONING (NC) SETUP SWITCH III SETUP SWITCHES ( SW ) A ND BLOWER OFF D ELAY SETUP SWITCHES MODEL PLUG A99097 • Permissible limits of voltage range at which unit will operate satisfactorily. t Unit ampacity = 125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components' (EAC, humidifier, etc.) full load amps. # Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. ' Time -delay type is recommended. NOTE: A field- supplied, 115 -v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation. 3. Dehumidification (DEHUM) A dehumidification input is provided via a 1 /4 -in. male quick- connect terminal labeled DEHUM located next to the transformer secondary connections. When there is a dehu- midify demand, the DEHUM input is activated, which means 24 vac signal is removed from the DEHUM input terminal. In other words, the DEHUM input logic is reversed. the DEHUM input is turned ON when no dehu- midify demand exists and is turned OFF when demand exists. This logic reversal has come about from historical use of a standard humidistat to do dehumidification since the contacts open on high humidity, thus removing the 24 -v signal to initiate dehumidification. The DEHUM output on the thermidistat control or the humidistat output is connected directly to the DEHUM terminal on the furnace control. In addition, the DE jumper THERMIDISTAT 24 VAC HOT f R �- DEHUMIDIFY 24 VAC COMM [DHUM C Fig. 27- 355MAV Variable Speed Furnace Control VARIABLE -SPEED CONDENSING FURNACE R � f 0 _❑ BBB BBB 09000909 000 oo, 2 x z F 00 00 O -0 DEHUM =DE NOTE 1 Com DE CONNECTION LOCATION NOTE 1 - Remove DE Connection To Enable DEHUM input Fig. 28 Thermidistat Connection A98295 located next to the DEHUM terminal must be removed to enable the DEHUM input. See (Fig. 27 and 28.) When a dehumidify demand exists, the furnace control reduces the blower airflow by 21 percent to 315 CFM per ton during continuous fan or cooling operation. DIRECT VENTING The 355MAV Furnaces require a dedicated (one 355MAV furnace only) direct -vent system. In a direct -vent system, all air for combustion is taken directly from outside atmosphere, and all flue products are discharged to outside atmosphere. —22— DE CONNECTION A99098 I. 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: 1. Seal any unused openings in the venting system. 2. Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code, NFPA 54- 1999 /ANSI Z223.1 -1999 or the CAN /CGA B149 Instal- lation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition. 3. If practical, close all building doors and windows and all doors between the space in which the appliance(s) con- nected 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 shalt operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 5. Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner opera- tion. Use the flame of a match or candle. 6. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace damp- ers, and any other gas- burning appliance to their previous conditions of use. • LOCATION CLEARANCE (FT) U.S.A. Canada Above grade level or above antics- gated snow depth 1 11* Dryer vent 3 3 From plumbing vent stack 3 3 From any mechanical fresh air Intake 1 6 For furnaces with an Input capacity less than 100,000 Btuh —from any non - mechanical air supply (windows or doors which can be opened) or combustion -air opening 1 1 From service regulator vent, electric and gas meters, and relief equipment 4* 4 Above grade when adjacent to public walkway Note 3 Note 3 •• S 7: if improper venting is observed during any of above tests, the venting system must be corrected. Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSC- NGPIC. II. COMBUSTION -AIR AND VENT PIPING A. 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 -21 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. 33, 34, 35, 36, and 37 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. 29.) 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. NOTE: -4Slope combustion -air and vent pipes a minimum of 1/4 in. per linear ft with no sags between hangers. TABLE 5— COMBUSTION -AIR AND VENT PIPE TERMINATION CLEARANCES • Horizontal distance. t 18 in. above roof surface in Canada. # 36 in. to electric meter in Canada only. NOTES: 1. If installing 2 adjacent 355MAV Fumaces, refer to Multiventing and Vent Terminations section for proper vent configurations. 2. When locating combustion -air and vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculation of the appliance's own flue products or the flue products of adjacent vents. Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of heat exchangers. 3. Vent termination can not terminate less than 2 ft horizontal and 7 ft above public walkway or where condensate vapor or droplets may be a hazard. Furnace combustion -air and vent pipe connections must be at- tached as shown in Fig. 30. Combustion -air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications. —23— FURNACE NOT IN HORIZONTAL SECTION NOTE: Select 1 vent pipe connection and 1 combustion -air pipe connection. AIR COMBUSTION- FLOW COMBUSTION - AIR AIR VENT AIR FLOW A93034 Fig. 29— Combustion -Air and Vent Pipe Diameter Transition Location and Elbow Configuration UPFLOW COMBUSTION - AIR VENT O0 HORIZONTAL -LEFT DISCHARGE VENT PIPE DIAMETER TRANSITION IN VERTICAL SECTION NOTE: Select 1 vent pipe connection and 1 combustion -eir pipe connection. VENT COMBUSTION- 1 y COMBUSTiON- VENT AIR AIR FLOW DOWNFLOW AIR COMBUSTiON- AIR VENT 1 AIR FLOW HORIZONTAL -RIGHT DISCHARGE A96187 Fig. 30— Combustion -Air and Vent Pipe Connections ZL CAUTION: When combustion -air pipe is installed above a suspended ceiling, pipe must be insulated with 3 /8 -in. thick Annaflex -type insulation. Combustion -air pipe should also be insulated when it passes through a warm, humid space. CAUTION: When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as shown in Table 7 with Armaflex -type insulation. VENT PIPE VERTICAL TO ROOF CAUTION: Combustion air must not be taken from inside structure because that air is frequently contami- nated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household prod- ucts. Locate combustion -air inlet as far as possible from swimming pool and swimming pool pump house. Excessive exposure to contaminated combustion air will result in safety and performance related problems. WARNING: Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes. Failure to follow this warning could result in fire, property damage, personal injury, or death. 12" MIN HORIZONTAL TO ROOF COMBUSTION -AIR PIPE 12" MIN COMBUSTION -AIR PIPE VENT PIPE VENT PIPE HORIZONTAL TO SIDEWALL COMBUSTION -AIR PIPE VERTICAL TO SIDEWALL NOTE: A 12 In. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. Fig. 31 — Short Vent (5 to 8 Ft) System —24— m WARNING: All combustion -air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 33, 34, 35, 36, or 37. 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 R. Short pipe lengths (5 -8 ft) may discharge water droplets. These droplets may be undesirable, and a 12 -in. minimum offset pipe section is recommended, as shown in Fig. 31, to reduce excessive droplets from exiting vent pipe outlet. B. Combustion - Air and Vent Pipe Diameter Determine combustion -air and vent pipe diameter. 1. Using Table 6, individually determine the combustion -air and vent pipe diameters. Pick the larger of these 2 pipe diameters and use this diameter for both combustion -air and vent pipes. 2. When installing vent systems of short pipe length, use the smallest allowable pipe diameter. Do not use pipe size greater than required or incomplete combustion, flame disturbance, or flame sense lockout may occur. NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 33, 34, 35, 36, and 37. 12" MIN COMBUSTION -AIR PIPE VENT PIPE A96230 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 0 to 2000 042040 2 Pipe or 2 -In. Concentric 1 -1/2 50 45 40 35 30 25 2 70 70 70 70 70 70 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 50 45 40 35 30 25 70 70 70 70 70 70 042080 060080 2 Pipe or 2 -In. Concentric 1 -1/2 2 30 25 20 15 10 5 70 70 70 70 70 70 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 45 40 35 30 25 20 70 70 70 70 70 70 060120 2 Pipe or 3 -In. Concentric 2 -1/2 3 10 NA NA NA NA NA 35 30 15 NA NA NA 3t 70 70 70 70 70 70 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 2001 to 3000 042040 2 Pipe or 2 -In. Concentric 1 -1/2 45 40 35 30 25 20 2 70 70 70 70 70 70 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 45 40 35 30 25 20 70 70 70 70 70 70 042080 060080 2 Pipe or 2 -In. Concentric 1 -1/2 2 26 21 16 11 6 NA 70 70 70 70 70 70 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 40 35 30 25 20 15 70 70 70 70 70 70 060120 2 Pipe or 3 -In. Concentric 3 3t 31 26 12 NA NA NA 63 62 62 61 61 61 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 3001 to 4000 042040 2 Pipe or 2 -In. Concentric 1 -1/2 42 37 32 27 22 17 2 70 70 70 70 70 70 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 42 37 32 27 22 17 70 70 70 70 70 70 042080 060080 2 Pipe or 2 -In. Concentric 1 -1/2 2 25 20 15 10 5 NA 70 70 70 70 70 70 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 38 33 28 23 18 13 70 70 70 70 70 70 060120 2 Pipe or 3 -In. Concentric 3 3t 29 24 10 NA NA NA 59 59 58 57 57 56 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 4001 to 5000$ 042040 2 Pipe or 2 -In. Concentric 1 -1/2 40 35 30 25 20 15 2 70 70 70 70 70 70 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 40 35 30 25 20 15 70 70 70 70 70 70 042080 060080 2 Pipe or 2 -In. Concentric 1 -1/2 2 23 18 13 8 NA NA 70 70 70 70 70 68. . 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 36 31 26 21 16 11, ., 70 70 70 70 70 70 060120 2 Pipe or 3 -In. Concentric 3t 56 55 54 53 52 52 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 5001 to 6000$ 042040 2 Pipe or 2 -In. Concentric 1 -1/2 37 32 27 22 17 12 2 70 70 70 70 70 70 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 37 32 27 22 17 12 70 70 70 70 70 70 042080 060080 2 Pipe or 2 -In. Concentric 1-1/2 2 22 17 12 7 NA NA 70 70 70 70 68 63 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 33 28 23 18 13 8 70 70 70 70 70 70 060120 2 Pipe or 3 -In. Concentric 3t 53 52 50 49 48 47 i 1 a • TABLE 6- MAXIMUM ALLOWABLE PIPE LENGTH (FT) See notes on next page. —25-- ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 6001 to 7000$ 042040 2 Pipe or 2 -In. Concentric 1 -1/2 35 30 25 20 15 10 2 70 70 68 67 66 64 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 35 30 25 20 15 10 70 70 68 67 66 64 042080 060080 2 Pipe or 2 -In. Concentric 1 -1/2 2 20 15 10 5 NA NA 70 70 68 67 62 57 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 31 26 21 16 11 6 70 70 68 67 66 64 060120 2 Pipe or 3 -In. Concentric 3t 49 48 47 45 44 43 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 7001 to 8000$ 042040 2 Pipe or 2 -In. Concentric 1 -1/2 32 27 22 17 12 7 2 66 65 63 62 60 59 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 32 27 22 17 12 7 66 65 63 62 60 59 042080 060080 2 Pipe or 2 -In. Concentric 1-1/2 2 18 13 8 NA NA NA 66 65 63 62 57 52 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 29 24 19 14 9 NA 66 65 63 62 60 59 060120 2 Pipe or 3 -In. Concentric 3t 46 44 43 41 40 38 ALTITUDE UNIT SiZE TERMINATION TYPE PIPE DIAMETER (iN.)• NUMBER OF 90° ELBOWS 1 2 3 4 5 6 8001 to 9000$ 042040 2 Pipe or 2 -In. Concentric 1 -1/2 30 25 20 15 10 5 2 62 60 58 56 55 53 042060 2 Pipe or 2 -in. Concentric 1 -1/2 2 30 25 20 15 10 5 62 60 58 56 55 53 042080 060080 2 Pipe or 2 -In. Concentric 1 -1/2 2 17 12 7 NA NA NA 62 60 58 56 51 46 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 27 22 17 12 7 NA 62 60 58 56 55 53 060120 2 Pipe or 3 -In. Concentric 3t 43 41 39 37 35 34 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER (IN.)' NUMBER OF 90° ELBOWS 1 2 3 4 5 6 9001 to 10000# 042040 2 Pipe or 2 -In. Concentric 1 -1/2 27 22 17 12 7 NA 2 57 55 53 51 49 47 042060 2 Pipe or 2 -In. Concentric 1 -1/2 2 27 22 17 12 7 NA 57 55 53 51 49 47 042080 060080 2 Pipe or 2 -In. Concentric 1 -1/2 2 15 10 5 NA NA NA 57 55 53 51 46 41 060100 2 Pipe or 2 -In. Concentric 2 2 -1/2 24 19 14 9 NA NA 57 55 53 51 49 47 060120 2 Pipe or 3 -In. Concentric 3t 39 37 35 33 31 29 TABLE 6— MAXIMUM ALLOWABLE PIPE LENGTH (FT) Continued • Disk usage— Unless otherwise stated, use perforated disk assembly (factory- supplied in loose parts bag). t Wide radius elbow. $ Vent sizing for Canadian installations over 4500 ft (1370m) above sea level are subject to acceptance by the local authorities having jurisdiction. NA —Not Allowed; pressure switch will not make. NOTES: 1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur. 2. Size both the combustion -air and vent pipe independently, 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. —26— • EXAMPLE: An 042080 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed in an application requiring 3 elbows and 17 ft of vent pipe, along with 5 elbows and 16 ft of combustion -air pipe. Table 6 indicates this application would allow a I- 1 /2 -in. diameter vent pipe, but require a 2 -in. diameter combustion air pipe (1- 1 /2 -in. pipe is good for 20 ft with 3 elbows, but only 10 ft with 5 elbows). Therefore, 2 -in. diameter pipe must be used for both vent and combustion -air pipes since larger required diameter must always be used for both pipes. If same installation were in Albuquerque, elevation 5250 ft above sea level, installation would require 2 -in. vent pipe and combustion -air pipe. At 5001- to 6000 -ft elevation, 1-1/2 - in. pipe is not allowed with 5 elbows, but 2 -in. pipe is good for 68 ft with 5 elbows. C. Combustion -Air and Vent Pipe Attachment NOTE: 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. 30 for application. b. Reposition combustion -air intake housing plug fitting in appropriate unused intake housing connection. c. Insert perforated disk assembly (factory supplied) in intake housing where combustion -air intake pipe will be connected. d. Install pipe support (factory- supplied in loose parts bag) into selected furnace casing combustion -air pipe hole. Pipe support should be positioned to bottom of casing hole. e. Insert 2 -in. diameter pipe into intake housing. f. Install casing hole filler cap (factory- supplied in loose parts bag) in unused combustion -air pipe casing hole. NOTE: A 2 -in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing. 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 1 /8 -in. hole in fitting, using hole in intake housing as a guide. Install a field- supplied No. 6 or No. 8 sheet metal screw. NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur. A plugged drain connection has been provided on this fitting for use when moisture is found in combustion -air intake pipe and combustion box. —27— NOTE: Moisture in combustion -air intake may be result of improper termination. Ensure combustion -air intake pipe is similar to that shown in Fig. 33, 34, 35, 36, or 37 so it will not be susceptible to areas where light snow or other sources of moisture could be pulled in. If use of this drain connection is desired, drill out fitting's tap plug with a 3 /16 -in. drill and connect a field- supplied 3 /8 -in. tube. This tube should be routed to open condensate drain for furnace and A/C (if used), and should be trapped. (See Fig. 32.) 3/8" ID TUBE 3/16" DRILL TRAP COMBUSTION — AIR INTAKE HOUSING BURNER BOX TO OPEN DRAIN COMBUSTION — AIR PIPE Fig. 32— Intake Housing Plug Fitting Drain A93035 2. Attach vent pipe as follows: a. Determine location of vent pipe connection to inducer housing as shown in Fig. 30 for application. b. Reposition elastomeric (rubber) inducer housing outlet cap and clamp to appropriate unused inducer housing connection. Tighten clamp. WARNING: Inducer housing outlet cap must be in- stalled and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. c. Install pipe support (factory- supplied in loose parts bag) into selected furnace casing vent pipe hole. Pipe support should be positioned to bottom of casing hole. d. Be certain that mating surfaces of inducer housing connection, elastomeric coupling, and 2 -in. diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2 -in. diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it bottoms on the internal stop. Tighten both clamps to secure the pipe to inducer housing. Tighten the clamp screws to 15 in. -lb. of torque. e. Install casing hole filler cap (factory- supplied in loose parts bag) in unused combustion -air pipe casing hole. WARNING: Vent pipe must be installed and fully seated against inducer housing internal stop. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, 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. 3. Working from furnace to outside, cut pipe to required length(s). 4. Deburr inside and outside of pipe. 5. Chamfer outside edge of pipe for better distribution of primer and cement. 6. Clean and dry all surfaces to be joined. 7. Check dry fit of pipe and mark insertion depth on pipe. NOTE: It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint. 8. After pipes have been cut and preassembled, apply gener- ous layer of cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat. 9. While cement is still wet, twist pipe into socket with 1/4 turn. Be sure pipe is fully inserted into fitting socket. 10. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint. 11. Handle pipe joints carefully until cement sets. 12. Support combustion -air and vent piping a minimum of every 5 ft (3 ft for SDR -21 or -26 PVC) using perforated metal hanging strap. 13. Slope combustion -air and vent pipes toward furnace a minimum of 1/4 in. per linear ft with no sags between hangers. 14. Use appropriate methods to seal openings where vent and combustion -air pipes pass through roof or sidewall. III. CONCENTRIC VENT AND COMBUSTION -AIR TERMINATION KIT INSTALLATION NOTE: If these instructions differ from those packaged with termination kit, follow kit instructions. Combustion -air and vent pipes must terminate outside structure. A factory accessory termination kit must be installed in 1 of the installations shown in Fig. 33, 34, 35, 36, or 37. Four termination kits are available. 1. The 2 -in. termination bracket kit is for I -in., 1 -1/2 in., and 2 -in. diameter 2 -pipe termination systems. 2. The 3 -in. termination bracket kit is for 2 -1/2 in. and 3 -in. diameter 2 -pipe termination systems. 3. The 2 -in. concentric vent/air termination kit is for 1 -in., 1 -1/2 in., 2 -in., and 2 -1/2 in. diameter pipe systems when single penetration of wall or roof is desired. 4. The 3 -in. concentric vent/air termination kit is for 2 -1/2 in. and 3 -in. diameter pipe systems when single penetration of wall or roof is desired. NOTE: Shaded parts in Fig. 33, 34, 35, 36, and 37 are considered to be terminations. These components should NOT be counted when determining pipe diameter. Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and has less visible vent vapors. (See Fig. 33 or 34.) Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system. A. Extended Exposed Sidewall Pipes Sidewall combustion -air and vent pipe terminations may be extended beyond area shown in Fig. 36 or 37 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. -28- 2. Using winter design temperature (used in load calculations), find appropriate temperature for your application and fur- nace model. 3. Determine required insulation thickness for exposed pipe lengths. NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 6. B. Two - Pipe Termination Kit 1. Determine location for termination. Consideration of the following should be made when determining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table 5. b. Termination kit should be positioned where vent vapors will not damage plants /shrubs or air conditioning equip- ment. c. Termination kit should be positioned so it will not be affected by wind eddy (such as inside building corners) or accumulation of airborne leaves or light snow, or allow recirculation of flue gases. d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc. e. Termination kit should be positioned where vent vapors are not objectionable. 2. Cut 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. 33. For applications using combustion -air pipe option indicated by dashed lines in Fig. 33, 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. 36 or 37. For applications using vent pipe option indicated by dashed lines in Fig. 36, rotate vent elbow 90° from position shown in Fig. 36. 4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. 5. Check required dimensions as shown in Fig. 33, 36, or 37. C. Concentric Vent/Air Termination Kit 1. Determine location for termination. Consideration of the following should be made when determining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table 5. b. Termination kit should be positioned where vent vapors will not damage plants /shrubs or air conditioning equip- ment. c. Termination kit should be positioned so it will not be affected by wind eddy (such as inside building corners) or accumulation of airborne leaves or light snow, or allow recirculation of flue gases. d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc. MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. X90 BRACKET VENT 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. A93054 Fig. 34— Concentric Vent and Combustion -Air Roof Termination (Preferred) OVERHANG OR ROOF COMBUSTION AIR 12" MINIMUM COMBUSTION -AIR Fig. 36— Sidewall Termination of 12 in. or More Fig. 33 —Roof Termination (Preferred) 12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 121N. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. A87225 A87226 Fig. 37— Sidewall Termination of Less than 12 in. —29— CO BUSTION A87224 OVERHANG OR ROOF 12" MINIMUM MAINTAN 121N. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. A93055 Fig. 35— Concentric Vent and Combustion -Air Side Termination VENT OVERHANG OR ROOF 12" MINIMUM 90 BRACKET r l�� COUPLING el " I � COMBUSTION -AIR (ELBOW PARALLEL O WALL) 12 IN. SEPARATION • BETWEEN BOTTOM OF COMBUSTION AIR AND - ,,M — BOTTOM OF VENT MAINTAIN 121N. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. ..tea ::i:u ::Y.�'l;:A• ;. :�,6d:ti.:7 c ■;'t UNIT SIZE WINTER DESIGN TEMPERATURE ( °F) MAXIMUM PIPE DIAMETER (IN.) INSULATION THICKNESS (IN.)t 0 318 1/2 3/4 1 042040 20 2 21 37 42 50 57 0 2 10 22 25 30 35 -20 2 5 14 17 21 25 042060 20 2 30 55 61 70 70 0 2 16 33 38 46 53 -20 2 9 23 26 33 38 042080 060080 20 2 37 65 70 70 70 0 2 20 39 45 55 63 -20 2 11 27 31 39 45 060100 20 2 -1/2 41 70 70 70 70 0 2 -1/2 21 42 48 59 68 -20 2 -1/2 11 28 33 41 49 060120 20 3 49 70 70 70 70 0 3 26 51 58 70 70 -20 3 15 35 40 50 59 CONDENSATE DRAIN TABLE 7— MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH (FT) WITH 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. f Insulation thickness based on R value of 3.5 per in. 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 ap- propriate height as shown in Fig. 34. Sidewall terminations — Locate assembly through sidewall with rain shield positioned no more than 1 -in. from wall as shown in Fig. 35. 5. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. 6. Check required dimensions as shown in Fig. 34 or 35. IV. MULTIVENTING AND VENT TERMINATIONS When 2 or more 355MAV Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 355MAV furnaces. When 2 or more 355MAV furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 38, 39, 40, 41, or 42, 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. 38, 39, 40, 41, and 42 represents distance between pipes or rain shields, as touching or 2 -in. maximum separation. I. GENERAL Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications. Condensate trap MUST be used for all applications. An external trap is not required when connecting the field drain to this condensate trap. —30— The field drain connection (condensate trap or drain tube coupling) is sized for I /2 -in. CPVC, 1 /2 -in. PVC, or 5 /8 -in. ID tube connection. Drain pipe and fittings must conform to ANSI standards and ASTM D1785 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 pH neutralizing filter may be desired. Check with local authorities to determine if a pH neutralizer is required. Ii. APPLICATION The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, field supplied trap prior to the 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. 43 for example of possible field drain attachment using I /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. WARNING: Caution should be taken to prevent drain- ing where slippery conditions may cause personal inju- ries. Excessive condensate draining may cause saturated soil conditions which may result in damage to plants. III. CONDENSATE DRAIN PROTECTION Freezing condensate left in condensate trap and drain line may cause cracks, and possible water damage may occur. If freeze: protection is required, use condensate freeze protection accessory or equivalent 3 to 6 watt per R at 120v and 40 °F self - regulating,. shielded, and waterproof heat tape. See Installation Instructions supplied with accessory or heat tape manufacturer's recommenda- tions. �:a.8xn�:MSxeye, xus.•..w nrnin�..�a s., ,,, �rrke;ic�x;.di�!� sYie:d3 °�r:�#5 <txWi3 4,44:31 hv'rixla A93056 Fig. 39—Concentric Vent and Combustion-Air Roof Termination (Dimension "A" is Touching or 2-In. Maximum Separation) COMBUSTION AIR r ,C e a ) A96128 Fig. 38—Rooftop Termination (Dimension "A" Is Touching or 2-In. Maximum Separation) COMBUSTION AIR Fig. 41—Sidewall Termination of 12 In. or Less (Dimension "A" is Touching or 2-in. Maximum Separation) A96129 -31- COMBUSTION AIR A93057 Fig. 40—Concentric Vent and Combustion-Air Side Termination (Dimension "A" Is Touching or 2-In. Maximum Separation) k - COMBUSTION AIR Avt- VENT • 1,„. 1" MAXIMUM (TYP) A VENT 44,1•••• COMBUSTION AIR..- A96130 Fig. 42—Sidewall Termination of More Than 12 in. (Dimension "A" is Touching or 2-In. Maximum Separation) . ,N,".1•:, a 0.1 t cle OPEN STAND PIPE FOR A/C OR HUMIDIFIER DRAIN TEE U TO OPEN DRAIN Fig. 43 Example of Field Drain Attachment /\ ,_f L E 32 °F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED A94054 A93058 LL CAUTION: Unit must not be installed, operated, and then turned and left off in an unoccupied structure during cold weather when temperature drops to 32 °F or below unless drain trap and drain line have adequate freeze protection. See Service and Maintenance Procedures for winterizing procedure. 1. Fold heat tape in half and wrap on itself 3 times. 2. Locate heat tape between sides of condensate trap back. (See Fig. 44.) 3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig. 44.) 4. Wrap field drain pipe with remaining heat tape, approxi- mately I wrap per 11. —32— CONDENSATE TRAP WIRE TIE(S) HEAT TAPE (3 WRAPS MINIMUM) Fig. 44 Condensate Trap Heat Tape A93036 5. When using field- supplied heat tape, follow heat tape manufacturer's instructions for all other installation guide- lines. SEQUENCE OF OPERATION LL CAUTION: Furnace control must be grounded for proper operation, or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. Using schematic diagram (see Fig. 24), follow sequence of operation through different modes. This furnace has a new control system. Read and follow wiring diagram carefully. NOTE: If 115 -v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates at low -heat speed for 60 sec when power is restored before heating cycle is resumed. 1. SELF - TEST MODE The control center goes through a brief self -test whenever 115 -v or 24 -v power is interrupted. The self test takes approximately 2 sec to complete. After power is restored, red (microprocessor) LED briefly comes on. Then green LED comes on for 1 sec, followed by 1 sec where both yellow and green LEDs are on. During this time, the microprocessor is checking itself. 11. HEATING MODE When thermostat calls for heat, R -W /W 1 circuit closes. 1. Prepurge period —The inducer motor is turned on and slowly comes up to speed. When low- pressure switch closes, inducer motor RPM is noted by microprocessor, and a 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in low -heat mode. NOTE: The heat cycle can start in either high or low heat. If a high -heat cycle is initiated, the inducer continues increasing its speed after low - pressure switch closes. When high- pressure switch closes, inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in high -heat mode. 2. Humidifier (HUM) —The HUM terminal is energized after the inducer prepurge period is completed. 3. Ignitor warm up—At end of prepurge period, the hot surface ignitor (HSI) is energized for a I 7-sec HSI warm -up period. 4. Ignition sequence —After HSI ignitor warm -up period is completed, the gas valve opens, permitting gas flow to burners where it is ignited. After 5 sec, the HSI is de- energized, and a 2 -sec flame - sensing period begins. NOTE: The initial heat mode after 115 -v or 24 -v power interrup- tion will be LOW HEAT. Low heat remains energized for 16 minutes before high heat is initiated, providing thermostat is still calling for heat. After initial cycle, the microprocessor evaluates the length of low - and high -heat operating times and calculates optimum length of low and high heat for next heat cycle. This accommodates the heat load requirement seen as a result of thermostat operating time. 5. Flame sensing —When burner flame is sensed, the control center holds gas valve open and begins blower on delay period. NOTE: ignition sequence repeats 3 additional times before a lockout occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning 115 -v or 24 -v power off (not at thermostat) for 3 sec minimum, then turning on again. 6. Inducer speed operation —If cycle starts in low heat, inducer speed reduces slightly after flame sense. If cycle starts in high heat, inducer speed increases 15 sec after flame sense. The reduction in speed in low heat is to optimize combustion for maximum efficiency. 7. Blower on delay —The blower starts 60 sec after flame sense if cycle started in low heat or 35 sec after flame sense if cycle started in high heat. NOTE: The blower starts at approximately 400 -500 RPM. After 20 sec, the motor is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide proper airflow for heating mode. 8. Electronic Air Cleaner —The EAC -1 terminal is energized whenever the blower operates. 9. Blower off delay —When thermostat is satisfied, the R -W/W 1 signal is terminated, de- energizing gas valve (stopping gas flow to burners), and HUM terminal is de- energized. The blower reduces its speed to low -heat RPM. The blower and EAC remain operating 90, 135, 180, or 225 sec (depending on blower off time selection). The furnace is factory set for a 90 -sec blower off delay. 10. Post purge —The inducer continues operating for 15 sec after gas valve is de- energized. III. HEATING MODE — TWO STAGE The control center provides 2 -stage heating using a single -stage thermostat. The control center maximizes comfort while optimiz- ing efficiency to meet the demands of conditioned area when a thermostat R -W/W 1 signal is received. If thermostat control over furnace staging is desired, a 2 -stage thermostat can be used. When control center receives a thermostat R -W/W 1 and R -W2 signal, high heat is energized and when a R -W/W 1 signal alone is received, low heat is energized. This method overrides microprocessor control of high or low heat. NOTE: When using 2 -stage thermostat operation with R -W /W 1 and R -W2 signals, setup switch SW -2 MUST be in ON position. The heat cycle operates as stated in Heating Mode section. To allow for greater comfort, 2 -stage thermostat control is recom- mended when zone systems are used. IV. EMERGENCY HEAT MODE NOTE: The furnace should not be operated in emergency heat mode for extended periods of time. Operation is only recom- mended to provide heat until replacement components can be obtained or fault resolved. —33— In this mode, the microprocessor is bypassed and motors operate at full speed with high -heat operation. The heat exchangers, motors, and electronics can be overstressed and may reduce the life of components if operated for an extended period. NOTE: No safeties are bypassed when using emergency heat mode. Emergency heat mode can be selected using setup switch SW -4. SW-4 should be used when a fault condition exists or difficult to resolve problems occur. This allows heating until fault can be corrected. In emergency heat mode, the normal heat mode outlined in Heating Mode section is not followed. The following sequence will occur: When thermostat calls for heat, the R -W /W -1 circuits close. 1. Prepurge period —The inducer motor is turned on IMME- DIATELY operating at maximum speed, closing low- and high- pressure switches. Prepurge begins 25 sec after high - pressure switch closes. 2. Blower on —The blower motor is turned on IMMEDI- ATELY and slowly increases to maximum speed as soon as a call for heat is received. No blower calibration occurs. 3. Electronic Air Cleaner —The EAC- 1 terminal does not operate in emergency heat mode. 4. Humidifier —The HUM terminal is energized IMMEDI- ATELY. 5. Ignitor warm up—The HSI is energized for a 17 sec warm -up period after prepurge period is completed. 6. Ignition sequence —After HSI warm -up period has com- pleted, the gas valve is energized, permitting gas flow to burners where it is ignited. After 5 sec, the HSI is de- energized, and a 2 -sec flame - sensing period begins. NOTE: Emergency heat mode only operates in high heat. 7. Flame sensing —When burner flame is sensed, control center holds gas valve open. If burner flame is not sensed, control center de- energizes gas valve and ignition sequence is repeated. NOTE: Ignition sequence repeats 3 additional times before lock- out occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning 115 -v or 24 -v power off (not at thermostat) for 3 sec minimum, then turning on again. Fault codes will not flash in emergency heat mode. 8. Blower off delay —When thermostat is satisfied, the R -W/W 1 signal is terminated, de- energizing gas valve (stopping gas flow to burners), and HUM terminal is de- energized. The blower stops immediately. 9. Post purge —Post purge does NOT occur. The inducer stops immediately. V. COOLING MODE A. Single-Speed Applications When thermostat calls for cooling, the R -G and R -Y /Y2 circuits close. 1. Cooling unit —The cooling unit starts when thermostat R -Y signal is received. 2. Blower on —The control center starts blower immediately when it receives an R -Y /Y2 and R -G signal. The blower starts at approximately 400 -500 RPM. After 20 sec, the blower is turned off for 1 /10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide selected cooling airflow. NOTE: In cooling mode, the microprocessor adjusts blower RPM to operate at 400 CFM per ton as selected on A/C setup switches. Airflow will be reduced to 315 CFM per ton when a dehumidifi- cation demand exists. See Air Conditioning Setup Switches section. There is also a chart on wiring diagram. (See Fig. 24.) , NOTE: If Y /Y2 thermostat lead is not connected to furnace control center, blower motor operates in continuous fan speed and indoor coil freeze -up may occur. 3. Electronic Air Cleaner —The EAC -I terminal is energized whenever blower operates. 4. Cooling unit—The cooling unit stops when thermostat R -Y signal is terminated. 5. Blower off delay —When thermostat is satisfied, the R -Y/Y2 and R -G signals are terminated, and blower re- mains operating for 90 sec. The blower airflow will drop by 21 percent during the off -delay period when the DE jumper is connected. The DE jumper is only removed to enable the DEHUM input for use with a thermidistat or humidistat for dehumidification purposes. B. Two - Speed Applications For details on 2 -speed cooling applications, refer to Fig. 45. VARIABLE 2 -SPEED SPEED 2 -SPEED AIR THERMOSTAT THERMOSTAT CONDITIONER Y2 ©- u 0 IwiwfF 1 Y/Y2 0 m Alk AL Fig. 45—Wiring Schematic for 2 -Speed Cooling Applications Vi. HEAT PUMP MODE A. Single -Speed Applications When furnace is operating in heat pump heating mode, R -Y/Y2 and R -G circuits are closed energizing heat pump, and blower operates at cooling speed. When heat pump defrost is required, R-W/W1 circuits close starting gas heat cycle, and blower adjusts to low -heat speed. 1. Prepurge period —The inducer motor is turned on and slowly comes up to speed. When low- pressure switch closes, inducer motor RPM is noted by microprocessor, and a 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in low -heat mode. NOTE: The heat cycle can start in either high or low heat. If a high -heat cycle is initiated, inducer continues increasing its speed after low- pressure switch closes. When high- pressure switch closes, inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is used to determine required RPM necessary to operate inducer in high -heat mode. 2. Humidifier —The HUM terminal is energized after inducer prepurge period is completed. 3. Ignitor warm up —After prepurge period, HSI is energized for 17 sec. 4. Ignition sequence —After HSI warm -up period is com- pleted, the gas valve is energized, permitting gas flow to the burners where it is ignited. After 5 sec, the HSI is de- energized, and a 2 -sec flame - sensing period begins. 5. Flame sensing —When burner flame is sensed, control center holds gas valve open. If burner flame is not sensed, control center de- energizes gas valve, and ignition sequence is repeated. 6. Blower off period —Ten sec after gas valve is energized, the blower stops for 25 sec to allow heat exchangers to warm up. 7. Blower on delay —After blower off period, blower starts. NOTE: The blower starts at approximately 400 -500 RPM. After 20 sec, the motor is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide proper airflow for heating mode. 8. Electronic Air Cleaner —The EAC -1 terminal is energized whenever blower operates. 9. Inducer speed operation —If cycle starts in low heat, inducer speed reduces slightly after the flame sense. If cycle starts in high heat, inducer speed increases 15 sec after flame sense. The reduction in speed in low heat is to optimize combustion for maximum efficiency. 10. Call for heat terminated —When the call for heat is satisfied, the R -W/W1 signal is terminated, de- energizing gas valve (stopping gas flow to burners), and HUM terminal is de- energized. a. R -W/W1 signal terminated with R -Y/Y2 and R -G still present —The blower changes its speed to cooling RPM. b. R -W/W1 with R -Y /Y2 and R -G signals terminated — The blower continues to operate completing a normal heating blower off delay. 11. Post purge —The inducer continues operating for 15 sec after gas valve is de- energized. B. Two -Speed Applications A94302 For details on 2 - speed heat pump applications, refer to Fig. 46. VII. CONTINUOUS FAN MODE 1. Operating with continuous fan only — a. Call for continuous fan —The thermostat closes R -G circuit. b. Blower on —The blower starts immediately. NOTE: The blower starts at approximately 400 -500 RPM. After 20 sec, the motor is turned off for 1 /10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide proper airflow for heating mode. NOTE: The continuous fan speed is the same as low -heat speed unless it is field adjusted to another desired airflow. See Continu- ous Fan Setup Switches section. There is also a chart on wiring diagram. (See Fig. 24.) c. Electronic Air Cleaner —The EAC -1 terminal is ener- gized whenever blower operates, regardless of operating mode. —34— 2. Operating with continuous fan (R -G) and call for heat (R -W /Wl) is received —Same as heat pump mode except blower on delay is 10 sec less than heat mode. After call for heat (R -W/W 1) is terminated, the blower remains operating at low -heat speed for selected blower off delay before resuming continuous fan speed. VARIABLE 2 -SPEED SPEED THERMOSTAT THERMOSTAT 0 m 0 ©- 0 0 Y/Y2 2 -SPEED HEAT PUMP AL 0 A94303 Fig. 46— Wiring Schematic for 2 -Speed Heat Pump Applications 3. Operating with continuous fan (R -G) and call for cool- ing (R -Y/Y2) is received —See Cooling Mode section. After call for cooling (R -Y /Y2) is terminated, the blower remains operating at cooling speed for 90 sec before resuming continuous fan speed. VIII. COMPONENT TEST All components are functionally operated except gas valve with component test feature. This feature helps diagnose a system problem in case of a component failure. NOTE: Setup switch SW -1 MUST be in OFF position or Fault Code 22 (setup error) will occur. NOTE: NO thermostat signal may be present at control center, and all blower time delay off periods must be completed. To initiate component test feature, proceed with the following: 1. Leave 115 -v power to fumace turned on. 2. Remove main furnace door. 3. Remove blower access panel. 4. Turn setup switch SW -6 to ON position. 5. Manually close blower access panel door switch. Use a piece of tape to hold switch closed. WARNING: Blower access panel door switch opens 115 -v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in personal injury or death. When items 1 -5 have been completed, the following will occur: 1. The control center goes through a brief self -test. This self -test takes approximately 2 sec to complete. After door switch is closed, red (microprocessor) LED briefly comes on. Then green LED comes on for 1 sec, followed by 1 sec where both green and yellow LEDs are on. During this time, the microprocessor is checking itself. —35— 2. Inducer motor operates for 20 sec at low speed, operates for 20 sec at high speed, then turns off. 3. Hot surface ignitor is energized for 15 sec, then de- energized. 4. Main blower motor operates for 20 sec at low speed, operates for 20 sec at high speed, then turns off. 5. After component operation test is completed, I or more fault codes (1 1, 22, 44, or 45) will flash. See service label on back of main furnace door for explanation of fault codes. NOTE: To repeat component test, turn setup switch SW -6 to OFF and then back to ON. After component test, perforni the following: I. Release blower panel access door switch and turn setup switch SW -6 to OFF position. 2. If applicable, replace blower access panel and check LED status by removing plug in blower access panel. 3. Reinstall main furnace door if all LEDs are off, indicating furnace is ready to operate when a signal from thermostat is received. IX. BYPASS HUMIDIFIER MODE When setup switch SW -3 BPH is in ON position, RPM calculated for low heat is multiplied by 1.15 for all furnace model sizes. This compensates for increased return-air temperature caused by by- passed air supply. X. DEHUMIDIFICATION MODE A dehumidification input is provided via a 1/4 in. male quick - connect terminal labeled DEHUM located next to the transformer secondary connections. When there is a dehumidify demand, the DEHUM input is activated, which means 24 vac signal is removed from the DEHUM input terminal. In other words, the DEHUM input logic is reversed. the DEHUM input is tumed ON when no dehumidify demand exists and is turned OFF when demand exists. This logic reversal has come about from historical use of a standard humidistat to do dehumidification since the contacts open on high humidity, thus removing the 24 vac signal to initiate dehumidification. The DHUM output on the thermidistat control or the humidistat output is connected directly to the DEHUM terminal on the furnace control. In addition the DE jumper located next to the DEHUM terminal must be removed to enable the DEHUM input. (See Fig. 27 and 28.) When a dehumidify demand exists, the furnace control reduces the blower airflow by 21 percent to 315 CFM per ton during continuous fan or cooling operation. This blower speed reduction compensates for high humidity conditions during cooling operation on all furnace model sizes. Reference ThermidistatTM control Installation, Start -Up, and Op- erating Instructions for further details. XI. ZONE MODE When setup switch SW -5 MZ is in ON position, blower motor control is the same as above except with the following exceptions: 1. While blower is operating in either low heat or continuous fan, the coast down calibration is performed once a minute to update blower RPM for zone damper position changes during a given cycle unless the blower pulse width to blower motor is greater than 60 percent. This prevents nuisance faults from occurring when a high continuous fan CFM has been selected. 2. While blower is operating in either high heat or cooling, blower pulse width to blower motor is frozen when blower RPM is within 10 percent of calculated blower RPM for 5 sec. START-UP PROCEDURES I. GENERAL 1. Furnace must have a 115 -v power supply properly con- nected and grounded. AIR CONDITIONER (TONS) CFM AIRFLOW A/C SETUP ALLOWABLE FURNACE MODEL SETUP SWITCH POSITION NC-1 NC-2 A/C -3 042040 042060 042080 060080 060100 060120 Default 1200 or 2000 OFF OFF OFF 3 Tons 1200 CFM 3 Tons 1200 CFM 3 Tons 1200 CFM 5 Tons 2000 CFM 5 Tons 2000 CFM 5 Tons 2000 CFM 1 -1/2 600 ON OFF OFF X X X — — — 2 800 OFF ON OFF X X X X X X 2 -1/2 1000 ON ON OFF X X X X X X 3 1200 OFF OFF ON X X X X X X 3-1/2 1400 ON OFF ON X X X X X X 4 1600 OFF ON ON — — — X X X 5 2000 ON ON ON — — — X X X CONTINUOUS FAN (CFM) CF SETUP ALLOWABLE FURNACE MODEL SETUP SWITCH POSITION CF -1 CF -2 CF -3 042040 042060 042080 060080 060100 060120 Default OFF OFF OFF 565* 515' 690' 690' 860* 1035' 600 ON OFF OFF X X X — — — 800 OFF ON OFF X X X X X X 1000 ON ON OFF X X X X X X 1200 OFF OFF ON X X X X X X 1400 ON OFF ON X X X X X X 1600 OFF ON ON — — — X X X 2000 ON ON ON — — — X X X X— Indicates allowable selection. TABLE 8 —AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCH POSITION TABLE 9 — CONTINUOUS FAN (CF) AIRFLOW SETUP SWITCH POSITION • Add 15% additional CFM when Bypass Humidifier switch SW -3 on control board is used. X— Indicates allowable selection. NOTE: Proper polarity must be maintained for 115 -v wiring. If polarity is incorrect, control center fault indicator light flashes rapidly and furnace does not operate. 2. Thermostat wire connections at terminals R, W/W I, G, and Y/Y2 must be made at 24 -v terminal block on control center. 3. Natural gas service pressure must not exceed 0.5 psig (14 -in. wc), but must be no less than 0.16 psig (4.5 -in. wc). 4. Blower access panel must be in place to complete 24 -v electrical circuit to furnace. CAUTION: These furnaces are equipped with a manual reset limit switch in burner box. This switch opens if an overheat condition (rollout) occurs in burner enclosure. Correct inadequate combustion -air supply or improper venting condition and reset switch. DO NOT jumper this switch. Before operating furnace, check each manual reset switch for continuity. If necessary, press button to reset switch. II. SELECT SETUP SWITCH POSITIONS A. Air Conditioning (A/C) Setup Switches The air conditioning setup switches are used to match furnace airflow to cooling unit used. This furnace will provide 400 CFM per selected air conditioning tonnage. To set the desired cooling airflow: 1. Remove main furnace door and blower access panel. 2. Locate A/C setup switches on control center. (See Fig. 25.) 3. Determine air conditioning tonnage used. 4. Use Table 8 or wiring schematic to determine proper setup position of A/C switches. (See Fig. 24 and 47.) NOTE: Excessive airflow caused by improper A/C switch setup may cause condensate blow off in cooling mode. —36— 1 OFF A95198 Fig. 47—Example of Setup Switch in OFF Position 5. Replace main furnace door and blower access panel. NOTE: EAC -1 terminal is energized whenever blower operates. HUM terminal is only energized when gas valve is energized. B. Continuous Fan (CF) Setup Switches The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode. This setup feature allows continuous fan airflow to be adjusted. To set desired continuous fan airflow: 1. Remove main furnace door and blower access panel. 2. Locate CF setup switches on control center. (See Fig. 25.) 3. Determine desired continuous fan airflow. 4. Use Table 9 or wiring schematic to determine proper setup position of CF switches. (See Fig. 24 and 48.) NOTE: The CF switches are factory set to provide continuous fan, . airflow equal to low -heat mode. 5. Replace main furnace door and blower access panel. C. Setup Switches (SW) The control center has 8 setup switches that may be set to meet the application requirements. Position these setup switches for the appropriate requirement. SETUP SWITCH NO. NORMAL POSITION DESCRIPTION OF USE SW -1 (FLT) OFF Turn switch to ON for fault history display. No thermostat signal can be present for fault history display. SW -2 (LOW) OFF Tum switch to ON to lock furnace in low -heat mode only or when using a 2 -stage thermostat with R -W/W1 and R -W2 signals. SW -3 (BPH) OFF Turn switch to ON when a bypass humidifier is used. This compensates for higher retum -air temperature and provides 15 percent more airflow in low -heat mode only. SW-4 (EMER HEAT) OFF Turn switch to ON to bypass microprocessor control. Furnace will oper- ate at high heat only with main blower and inducer motor operating at maximum RPM. NO safeties are bypassed. SW -5 (MZ) OFF Tum switch to ON when modulating dampers are used. In this mode, main blower speed is recalculated once every minute while fumace is in low -heat or continuous fan mode. • SW -6 (COMP TEST) OFF Turn switch to ON to initiate component test. Fumace will operate in- ducer motor for 20 sec at low speed, operate inducer motor for 20 sec at high speed, energize HSI for 15 sec, operate blower for 20 sec at low speed, and operate blower for 20 sec at high speed. SW -1 must be in OFF position. No thermostat signal can be present for component test to be initiated. SW -7 and -8 (Blower Off Delay) See Table 11 Adjust switches to provide desired heating mode blower off delay time, 90, 135, 180, or 225 sec. DESIRED HEATING MODE BLOWER OFF DELAY (SEC) SETUP SWITCH (SW -7 AND -8) POSITION SW -7 SW -8 90 OFF OFF 135 ON OFF 180 OFF ON 225 ON ON 1. Remove main furnace door and blower access panel. 2. Locate setup switches on control center. (See Fig. 25.) 3. See Table 10 for setup switch description. (See Fig. 24 and 48.) 4. Replace main furnace door and blower access panel. NOTE: If a bypass humidifier is used, setup switch SW -3 (BPH) should be in ON position. This prevents nuisance limit trips caused by the increased temperature in return air resulting from bypass. NOTE: If modulating dampers are used, setup switch SW -5 (MZ) should be in ON position. This allows furnace control center to compensate for modulating dampers. The control re- calibrates for new system static conditions once every minute while operating in low -heat or continuous fan modes. III. 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. 48.) 2. Connect field- supplied 1 /2 -in. ID tube to upper inducer housing drain connection. 3. Insert field- supplied funnel into tube. 4. Pour 1 quart of water into funnel /tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 49.) 5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp. IV. PURGE GAS LINES If not previously done, purge the lines after all connections have been made and check for leaks. TABLE 10 — SETUP SWITCH DESCRIPTION — TABLE 11— BLOWER OFF DELAY SETUP SWITCH POSITION WARNING: Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap- and -water solution to check for leakage. Failure to follow this warning could result in fire, explosion, personal injury, or death. V. ADJUSTMENTS A. Set Gas Input Rate Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. In the U.S.A., the input rating for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level. In Canada, the input rating must be derated by 5 percent for altitudes of 2000 ft to 4500 11 above sea level. Furnace input rate must be within ±2 percent of input on furnace rating plate. I. Determine natural gas orifice size and manifold pressure for correct input. a. Obtain yearly heat value from local gas supplier. b. Obtain yearly specific gravity average from local gas supplier. c. Verify furnace model. Table 12 can only be used .for model 355MAV Furnaces. d. Find installation altitude in Table 12. NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 11 in Table 12. e. Find closest natural gas heat value and specific gravity in Table 12. average (at installed altitude) t f. Follow heat value and specific gravity lines to point of intersection to find orifice size and low- and high -heat manifold pressure settings for proper operation. EXAMPLE: (0 -2000 ft altitude) Heating value = 1050 Btu /cu 11 Specific gravity = 0.62 Therefore: Orifice No. 45 Manifold pressure: 3.6 -in. wc for high heat I.5 -in, wc for low heat • Furnace is shipped with No. 45 orifices. In this example, all main burner orifices are the correct size and do not need to be changed to obtain proper input rate. g. Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY. 2. Adjust manifold pressure to obtain input rate. a. Remove burner enclosure front. NOTE: Manifold pressure MUST always be measured with the burner box cover REMOVED. b. Remove caps that conceal adjustment screws for low- and high -heat gas valve regulators. (See Fig. 50.) c. Turn setup switch SW -2 on control center to ON position. (See Fig. 25.) This keeps furnace locked in low -heat operation. d. Jumper R and W/W 1 thermostat connections on control center to start furnace. e. Turn low -heat adjusting screw (5/64 hex Allen wrench) counterclockwise (out) to decrease input rate or clock- wise (in) to increase input rate. 0 Fig. 48 Inducer Housing Drain Tube —38— NOTE: DO NOT set low -heat manifold pressure less than 1.3 -in. we or more than 1.7 -in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices. Lt CAUTION: DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overtire and heat exchanger failures. NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr -free and squarely aligned orifice hole is essential for proper flame characteristics. f. Turn setup switch SW -2 to OFF position after complet- ing low -heat adjustment. g. Jumper R and W2 thermostat connections on control center. (See Fig. 25.) This keeps furnace locked in high -heat operation. h. Turn high -heat adjusting screw (5/64 hex Allen wrench) counterclockwise (out) to decrease input rate or clock- wise (in) to increase rate. NOTE: DO NOT set high -heat manifold pressure less than 3.2 -in. wc or more than 3.8 -in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices. i. When correct input is obtained, replace caps that conceal gas valve regulator adjustment screws. Main burner flame should be clear blue, almost transparent. (See Fig. 51.) A99118 A99119 Fig. 49—Filling Condensate Trap ALTITUDE RANGE (FT) AVG GAS AT AT AT ALTI E (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No Manifold Pressure High /Low U.S.A. and Canada 0 to 2000 850 875 900 925 950 975 1000 1025 1050 1075 1100 43 43 44 44 44 44 3.7/1.5 3.5/1.5 3.7/1.6 3.5/1.5 3.4/1.4 3.2/1.3 43 43 43 44 44 44 3.8/1.6 3.6/1.5 3.4/1.4 3.7/1.6 3.5/1.5 3.3/1.4 42 43 43 44 44 44 44 3.2/1.4 3.7/1.6 3.5/1.5 3.8/1.6 3.6/1.5 3.4/1.4 3.2/1.4 42 43 43 43 44 44 44 44 3.3/1.4 3.8/1.6 3.6/1.5 3.4/1.4 3.7/1.6 3.5/1.5 3.4/1.4 3.2/1.3 42 42 43 43 44 44 44 44 3.4/1.4 3.2/1.4 3.7/1.6 3.5/1.5 3.8/1.6 3.6/1.5 3.5/1.5 3.3/1.4 45 45 45 45 3.7/1.6 3.5/1.5 3.3/1.4 3.2/1.3 45 45 45 45 3.8/1.6 3.6/1.5 3.4/1.5 3.3/1.4 45 45 45 45 3.7/1.6 3.6/1.5 3.4/1.4 3.2/1.4 45 45 45 3.7/1.6 3.5/1.5 3.4/1.4 45 45 45 3.8/1.6 3.6/1.5 3.5/1.5 47 3.6/1.5 47 3.7/1.6 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No Manifold Pressure High /Low Orifice No Manifold Pressure High /Low U.S.A. and Canada U.S.A. Altitudes 2001 to 3000 or Canada Altitudes 2000 to 4500 775 800 825 850 875 900 925 950 975 1000 1025 43 43 44 44 44 44 3.8/1.6 3.5/1.5 3.8/1.6 3.6/1.5 3.4/1.4 3.2/1.4 42 43 43 44 44 44 3.2/1.4 3.7/1.5 3.4/1.5 3.7/1.6 3.5/1.5 3.3/1.4 42 43 43 44 44 44 44 3.3/1.4 3.8/1.6 3.6/1.5 3.8/1.6 3.6/1.5 3.4/1.4 3.2/1.4 42 42 43 43 44 44 44 3.4/1.4 3.2/1.4 3.7/1.5 3.5/1.5 3.7/1.6 3.5/1.5 3.3/1.4 42 42 43 43 43 44 44 44 3.5/1.5 3.3/1.4 3.8/1.6 3.6/1.5 3.4/1.4 3.6/1.5 3.4/1.5 3.3/1.4 45 45 45 3.7/1.5 3.5/1.5 3.3/1.4 45 45 45 45 3.8/1.6 3.6/1.5 3.4/1.4 3.2/1.4 45 45 45 45 3.7/1.6 3.5/1.5 3.4/1.4 3.2/1.3 45 45 45 45 3.8/1.6 3.6/1.5 3.5/1.5 3.3/1.4 45 45 45 3.8/1.6 3.6/1.5 3.4/1.4 47 47 3.7/1.6 3.6/1.5 47 3.7/1.6 ALTITUDE RANGE (FT) AVG GAS HE AT VALUE ALTITUDE AT (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice N Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Am) VSYI 3001 to 4000 750 775 800 825 850 875 900 925 950 975 1000 43 43 44 44 44 3.7/1.6 3.5/1.5 3.7/1.6 3.5/1.5 3.3/1.4 43 43 43 44 44 3.8/1.6 3.6/1.5 3.4/1.4 3.6/1.5 3.4/1.4 42 43 43 44 44 3.3/1.4 3.7/1.6 3.5/1.5 3.8/1.6 3.5/1.5 42 43 43 43 44 3.4/1.4 3.8/1.6 3.6/1.5 3.4/1.4 3.7/1.5 42 42 43 43 44 3.5/1.5 3.2/1.4 3.7/1.6 3.5/1.5 3.8/1.6 45 3.8/1.6 44 32/1.4 44 3.3/1.4 44 3.5/1.5 44 3.6/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3. 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.5/1.5 45 3.7/1.5 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4. TABLE 12 —MODEL 355MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (TABULATED DATA BASED ON 20,000 BTUH HIGH HEAT /13,000 BTUH LOW HEAT PER BURNER DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) * • Orifice numbers shown in BOLD are factory installed. ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure High /Low Orifice No Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No Manifold Pressure High /Low Orifice No Manifold Pressure High /Low 725 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 750 43 3.4/1.4 43 3.5/1.5 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 775 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 43 3.7/1.5 4001 800 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 825 44 3.2/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 to 850 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 875 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4 5000 900 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.8/1.6 925 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 950 47 3.5/1.5 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 ALTITUDE AVG GAS HEAT VALUE SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 RANGE (rn AT ALTITUDE (BTU /CU FT) Orifice Manifold Pressure Orifice Manifold Pressure Orifice Manifold Pressure Orifice Manifold Pressure Orifice Manifold Pressure No. High /Low No. High /Low No. High /Low No High /Low N o High /Low 700 43 3.6/1.5 43 3.7/1.6 42 3.2/1.3 42 3.3/1.4 42 3.4/1.4 725 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 750 44 3.6/1.5 44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 775 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 43 3.4/1.4 5001 800 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 825 45 3.6/1.5 45 3.7/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4 ►V to 850 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.8/1.6 44 3.2/1.4 875 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.5 6000 900 47 3.6/1.5 47 3.7/1.6 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 925 47 3.4/1.4 47 3.5/1.5 47 3.7/1.5 45 3.2/1.3 45 3.3/1.4 950 48 3.7/1.6 48 3.8/1.6 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 975 48 3.5/1.5 48 3.6/1.5 48 3.8/1.6 47 3.4/1.4 47 3.5/1.5 1000 48 3.3/1.4 48 3.5/1.5 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 0.66 RANGE (Fr) HEAT VALUE AT ALTITUDE (BTU /CU FT) Orifice Manifold Pressure Orifice Manifold Pressure Orifice Manifold Pressure Orifice Manifold Pressure Orifice Manifold Pressure No. High /Low No High /Low No. HIgh /Low No. High /Low No. High /Low AIuO Arsil 650 42 3.2/1.3 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 42 3.6/1.5 675 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 700 44 3.8/1.6 43 3.4/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 6001 725 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 750 44 3.3/1.4 44 3.4/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 to 775 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5 800 45 3.5/1.5 45 3.7/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 7000 825 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 850 47 3.7/1.6 45 3.2/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 875 47 3.5/1.5 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 TABLE 12 —MODEL 355MAV ORIFICE SI2E AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued (TABULATED DATA BASED ON 20,000 BTUH HIGH HEAT /13,000 BTUH LOW HEAT PER BURNER DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) * • Orifice numbers shown in BOLD are factory installed. —40-- ....`'. ii�........vt l'::..:..'...:. At vA..`:. ��ie�: e.. �lw' Sl. i• i 3S! C.'. p' X': Si/ Y(' i'" a^' i'.{.<}, y( v�."% 3*. N' Yt111• i. Vr.^ V' tM':. iPfR! i.•+ y�:! il' 4i: d\ �?.! vF3f.* A' n-.. Y. l"•. 1Ne'! i!$ b uaY ::Y!•{1YJ.S ^.!i'i ^.S1'Sh J.!1 ALTITUDE RANGE (F ) AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT ( ) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orffice No. Manifold Pressure High /Low Orifice No Manifold Pressure High /Low Orifice No Manifold Pressure High /Low Orifice No ' Manifold High /Low Orifice No. Manifold Pressure High /Lqw /No 'FPs'n 7001 to 8000 625 650 675 700 725 750 775 800 825 850 43 43 44 44 44 3.8/1.6 3.5/1.5 3.8/1.6 3.5/1.5 3.3/1.4 42 43 43 44 44 3.3/1.4 3.7/1.6 3.4/1.4 3.6/1.5 3.4/1.4 42 43 43 44 44 44 3.4/1.4 3.8/1.6 3.5/1.5 3.8/1.6 3.5/1.5 3.3/1.4 42 42 43 43 44 44 3.5/1.5 3.2/1.4 3.6/1.5 3.4/1.4 3.6/1.5 3.4/1.4 42 42 43 43 44 44 44 3.6/1.5 3.3/1.4 3.7/1.6 3.5/1.5 3.7/1.6 3.5/1.5 3.3/1.4 45 45 45 3.7/1.6 3.5/1.5 3.3/1.4 45 45 45 45 3.8/1.6 3.6/1.5 3.4/1.4 3.2/1.3 45 45 45 3.7/1.6 3.5/1.5 3.3/1.4 45 45 45 45 3.8/1.6 3.6/1.5 3.4/1.4 3.2/1.3 45 45 45 3.7/1.6 3.5/1.5 3.3/1.4 47 47 3.6/1.5 3.4/1.4 47 3.5/1.5 47 3.7/1.5 ALTITUDE RANGE (FT) (F AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT) ) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure High /Low Orifice No ' Manifold Pressure High /Low Orifice No Manifold Pressure High /Low Orifice No Manifold Pressure High /Low Orifice No Manifold Pressure High /Low A1uO 'M'S'n 8001 to 9000 600 625 650 675 700 725 750 775 800 43 43 44 44 44 3.8/1.6 3.5/1.5 3.7/1.6 3.5/1.5 3.2/1.4 42 43 43 44 44 3.3/1.4 3.6/1.5 3.4/1.4 3.6/1.5 3.3/1.4 42 43 43 44 44 44 3.4/1.4 3.8/1.6 3.5/1.5 3.7/1.6 3.4/1.5 3.2/1.4 42 42 43 44 44 44 3.5/1.5 3.2/1.4 3.6/1.5 3.8/1.6 3.6/1.5 3.3/1.4 42 42 43 43 44 44 44 3.6/1.5 3.3/1.4 3.7/1.6 3.4/1.5 3.7/1.6 3.4/1.4 3.2/1.4 45 45 45 3.6/1.5 3.4/1.4 3.2/1.3 45 45 45 3.8/1.6 3.5/1.5 3.3/1.4 45 45 45 3.6/1.5 3.411.4 3.2/1.3 45 45 45 3.8/1.6 3.5/1.5 3.3/1.4 45 45 3.6/1.5 3.4/1.4 47 3.6/1.5 47 3.7/1.6 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE ( BTUICU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low AWO Ts'n 9001 to 10,000 575 600 625 650 675 700 725 750 775 43 43 44 44 3.8/1.6 3.5/1.5 3.7/1.6 3.4/1.4 42 43 44 44 3.2/1.4 3.6/1.5 3.8/1.6 3.5/1.5 42 43 43 44 3.3/1.4 3.7/1.6 3.5/1.5 3.7/1.5 42 42 43 44 3.5/1.5 3.2/1.3 3.6/1.5 3.8/1.6 42 42 43 43 3.6/1.5 3.3/1.4 3.7/1.6 3.4/1.4 45 3.8/1.6 44 3.311.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 47 3.7/1.6 45 3.2/1.4 45 3.311.4 45 3.4/1.5 45 3.511.5 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 c TABLE 12 —MODEL 355MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued (TABULATED DATA BASED ON 20,000 BTUH HIGH HEAT /13,000 BTUH LOW HEAT PER BURNER DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) • • Orifice numbers shown in BOLD are factory installed. —41— to ALTITUDE (FT) % OF DERATE DEBATE MULTIPLIER FACTOR FOR U.S.A.• 0 -2000 0 1.00 2001 - 3000 4-6 0.95 3001 -4000 6-8 0.93 4001 - 5000 8-10 0.91 5001 -6000 10-12 0.89 6001 -7000 12 -14 0.87 7001 -8000 14 -16 0.85 8001 -9000 16-18 0.83 9001 - 10,000 18-20 0.81 INLET PRESSURE TAP ON /OFF SWITCH BURNER ENCLOSURE REFERENCE PRESSURE TAP MANIFOLD PRESSURE TAP Fig. 50 Redundant Automatic Gas Valve — BURNER ORIFICE LOW -FIRE ADJUSTMENT ALLEN SCREW (UNDER CAP) HIGH -FIRE ADJUSTMENT ALLEN SCREW (UNDER CAP) A97386 A93059 CAUTION: DO NOT redrill orifices. Improper drilling (burrs, out -of -round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of burners and heat exchang- ers, causing failures. j. Remove jumpers R- to -W /W1 and R -to -W2 3. Verify natural gas input rate by clocking gas meter. NOTE: Be sure all pressure tubing, combustion -air and vent pipes, and burner enclosure front are in place when checking input by clocking gas meter. a. Calculate high - altitude adjustment (if required). 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 13 for derate multiplier factor and example. —42— A89020 Fig. 51— Burner Flame TABLE 13— ALTITUDE DERATE MULTIPLIER FOR U.S.A Derate multiplier facto is based on midpoint altitude for altitude range. EXAMPLE: 100,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT. Derate X Multiplier Factor 100,000 X 0.91 Fumace Input Rate at Sea Level Furnace Input Rate = at Installation Altitude 91,000 CANADA At installation altitudes from 2000 to 4500 ft, this furnace must be derated 5 percent by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.95 as derate multiplier factor. b. Reinstall burner box cover. NOTE: Clocking gas input rate MUST always be performed with, the burner box cover INSTALLED. c. Check that gas valve adjustment caps are in place fo proper input to be clocked. d. Obtain yearly heat value average for local gas supply. NOTE: Be sure heating value of gas used for calculations is correct for your altitude. Consult local gas utility for altitude adjustment of gas heating value. e. Check and verify orifice size in furnace. NEVER AS- SUME THE ORIFICE SIZE. ALWAYS CHECK AND VERIFY. f. Turn off all other gas appliances and pilots. g. Turn setup switch SW -2 to ON position. (See Fig. 25.) This keeps furnace locked in low -heat operation. h. Jumper R- to -W /W I i. Let furnace run for 3 minutes in low -heat operation. 1 SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL 1 cu ft 2 cu ft 5 cu ft 1 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 55 131 327 16 225 450 1125 56 129 321 17 212 424 1059 57 cD CO 126 316 18 200 400 1000 58 124 310 19 189 379 947 59 122 305 20 180 360 900 60 120 300 21 171 343 857 62 116 290 22 164 327 818 64 co In 112 281 23 157 313 783 66 109 273 24 150 300 750 68 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 225 31 116 232 581 82 44 220 32 113 225 563 84 43 co 214 33 109 218 545 86 42 209 34 106 212 529 88 41 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 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 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 184 409 108 33 67 167 45 80 160 400 110 33 mCD 164 46 78 157 391 112 32 161 47 76 153 383 116 31 155 48 49 75 73 150 147 375 367 120 30 150 j. Measure titne (in sec) for gas meter to complete 1 revolution. Note reading. k. Refer to Table 14 for cubic ft of gas per hr. I. Multiply gas rate cu ft/hr by heating value (Btu /cu ft). m. Turn setup switch SW -2 to OFF position and juniper R and W2 thermostat connections. (See Fig. 25.) This keeps furnace locked in high -heat operation. Repeat items h through k for high -heat operation. EXAMPLE: (High -heat operation at 0 -2000 ft altitude) Furnace input from rating plate is 100,000 Btuh Btu heating input = Btu/cu it X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for I revolution of 2 -cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 14) Btu heating input = 103 X 975 = 100,425 Btuh In this example, the orifice size and manifold pressure adjustment is within ±2 percent of the furnace input rate. NOTE: Measured gas inputs (high heat and low heat) must be within ±2 percent of that stated on furnace rating plate when installed at sea level or derated per that stated above when installed at higher altitudes. n. Remove jumper across R, W/W 1, and W2 thermostat connections to terminate call for heat. TABLE 14 RATE CU FT /HR — B. Set Temperature Rise ZL 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. Furnace must operate within range of temperature rise specified on the unit rating plate. Determine air temperature rise as follows: 1. Place thermometers in return and supply ducts as near furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight -run ducts. 2. When thermometer readings stabilize, subtract return-air temperature from supply -air temperature to determine air temperature rise. NOTE: Temperature rise can be determined for low -fire opera- tion by placing setup switch SW -2 on control center in ON position. For high -heat operation, place setup switch SW -2 in OFF position and jumper R -W2 on control center. DO NOT forget to retum setup switch to OFF position and remove R -W2 jumper upon completion of testing. (See Fig. 25 for switch and terminal location.) 3. This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on unit rating plate. if temperature rise is outside this range, proceed as follows: • a. Check gas input for low- and high -heat operation. b. Check derate for altitude if applicable. c. Check all return and supply ducts for excessive restric- tions causing static pressure greater than 0.5 -in. wc. d. Ensure bypass humidifier switch (BPH) setup switch SW -3 on control center is in ON position when a bypass humidifier is used. (See Fig. 25 for switch location.) e. Check Troubleshooting Guide for Variable -Speed 2 -Stage Electronic Condensing Furnaces. C. Set Thermostat Heat Anticipator The thermostat heat anticipator must be set to match the amp draw of components in the R -W /W 1 circuit. Accurate amp draw measurements can be obtained at the thermostat subbase terminals R and W. Fig. 52 illustrates an easy method of obtaining thermostat amp draw measurements. The amp reading should be taken after blower motor has started and furnace is operating in low heat. 1. To operate furnace in low heat, turn setup switch SW -2 to ON position (See Fig. 25) and connect ammeter lead s across thermostat subbase R -W. 2. See thermostat manufacturer's instructions for adjusting•the heat anticipator and for varying heating cycle length. NOTE: When using an electronic thermostat, set cycle rate for 3 cycles per hr. 3. Return setup switch SW -2 to OFF position and replace thermostat on subbase. CHECK SAFETY CONTROLS I. CHECK PRIMARY LIMIT CONTROL This control shuts off the combustion control system and energizes the air - circulating blower motor if furnace overheats. 1. The recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes. • 1,44 ;:,i•• i -;n3'.:i•r;'',.`,- THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.) HOOK - AROUND AMMETER 10 TURNS FROM UNIT 24 -V CONTROL TERMINALS EXAMPLE: 5.0 AMPS ON AMMETER _ 0.5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING A96316 Fig. 52 —Amp Draw Check with Ammeter 2. As soon as limit control has shut off burners, a 33 fault code will appear on control center. 3. The return-air opening should be unblocked to permit normal air circulation. By using this method to check the limit control, it can be established that the limit is functioning properly and the furnace will operate safely if there is a restricted return-air supply or motor failure. If the limit control does not function during this test, the cause must be determined and corrected. —44— II. CHECK PRESSURE SWITCHES This control proves operation of the draft inducer. Check switch operation as follows: 1. Turn off 115 -v power to furnace. 2. Remove control access door and disconnect inducer motor I2-pin wire harness at inducer motor. 3. Turn on 115 -v power to furnace. 4. Set thermostat to call for heat. When pressure switches are functioning properly, fault code 42 will flash on control center approximately 10 sec after thermostat switch is closed. If either a fault code 31 or 32 is flashed when ICM inducer motor is disconnected, the furnace will shut itself down immediately. Determine the reason pressure switches did not function properly and correct the condition. 5. Turn off 115 -v power to furnace. 6. Reconnect inducer motor wire harness. Reinstall furnace access door. 7. Turn on 115-v power to furnace. 8. Reset thermostat to desired temperature. CHECKLIST 1. Put away tools and instruments. Clean up debris. 2. Verify 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 Manual with owner. 7. Leave literature packet near furnace. LOAD CALCULATION Heating Load (Btuh) Cooling Load (Btuh) Fumace Model Selection COMBUSTION AND VENT PIPING Termination Location Roof or Sidewall Termination Kit — 2 Pipe or Concentric Combustion -Air Pipe Length Combustion -Air Pipe Elbow Quantity Vent Pipe Length Vent Pipe Elbow Quantity Pipe Diameter Determined from Sizing Table Pipe Sloped To Fumace Pipe Insulation Over Ceilings Low - Ambient Exposed Pipes CHECKLIST — INSTALLATION 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 Switches - NOTICE: IF THE DOCUMENT IN THIS,FRAME IS LESS CLEAR THAN ' THIS NOTICE IT IS DUE TO THE QUALITY OF. THE DOCUMENT. .: NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. r • SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video -based formats and materials. All include video and/or slides, plus companion book. Classroom Service Training plus "hands -on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog. CALL FOR FREE CATALOG 1 800 - 962 - 9212 [ ] Packaged Service Training [ ] Classroom Service Training 02001 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis. IN 48231 -48- A94328 Printed In U.S.A. 355m409 Catalog No. 5335 -515 n ^' . ' • i • • F625452.000 (8197) F625.052 00 • • • • • - 1 • • • tZ REMOVE SIDE EDGES FIRST. THEN, CREASE AND TEAR THIS STUB ALONG PERFORATION DEPARTMENT OF LABOR INDUSTRIES • REGISTERED AS PROVIDED BY LAW AS CONST CONT GENERAL �� GIST. �. + �-. ,[ P.. DA &I • WASHTNGTON..ENERGY SERVICES, CO. 2800' THORNDYKEJ AVE ,W r ' SEATTLE •WA 98199 -299.7 REGISTERED AS PROVIDED BY LAW AS CONST CONT GENERAL ...REGIST. # EXP. DATE CCO1 WASHIES990CW 02/16/2002 EFFECTIVE'DATE 02/16/2001 WASHINGTON ENERGY SERVICES CO 2800 THORNDYKE AVE W SEATTLE WA 98199 - 2997 Signaturc Issued by DEPARTMENT OF LABOR A, / Detach Anil Unplay l'rrtrttc.ur - - Ctx_r*y end ov-- 'h Eycp (e 1 0/ o q /03 INDrSTRWN Please Remove And Sign Identification Card Before Placing In I3ill1'1)Id 1 January 9, 2002 Ms. Candace Gallagher 2800 Thorndyke Ave W Seattle, WA 98199 RE: Permit Application No. M01 -144 Location: Wolff Residence 15222 42 Av S 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: • 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 applicant's 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 February 27, 2002, 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. Sincerely, Kam Kathryn A. Stetson Permit Technician City of Tukwila Department of Community Development Steve Lancaster, Direct Xc: Permit File No.M01 -144 Duane Griffin, Building Official Steven M. Mullet, May 6300 Southcenter Boulevard, Suite #100 • Tukwila, Washington 98188 • Phone: 206-431-3670 • Fax: 206-4+1-7, Balance :Due: Need Current • Contractor Registration Card: Need to Enter Contractor Information in Sierra: Yes D No • � ....�..a... } v......:.}' i•}}: . }:i.. + •:�ih }:L}:<::2v:i_.: {::: •:. i': v$iii}y ii itt<i�;. } ......... . :.... .. .� -,is; 'v.:.u. °i ...cr.., .,.:+r:n_. L.,� .,, ., �.,. ... ,: t:,. i.a,:li.'a.2,e•;:.i,��: �V >'L.ii „1i:.' ?.:HMu ��iz n.,:h.,t.`: �ir_� %� %rJS;ksi1Y, ;r,'e�tt`�.