Loading...
The URL can be used to link to this page
Your browser does not support the video tag.
Home
My WebLink
About
Permit M01-167 - HATTON RESIDENCE
M01467 Hatton Residence 3935 S 113 St fi City of Tukwila Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188 Permit No: M01-167 Type: r3 -MECH Category: RES Address: 3935 S 113 ST Location: Parcel it: 335140-0105 Contractor License No: WASHIES07403 TENANT HATTON RESIDENCE 3935 S 113 ST, TUKWILA, WA 98168 OWNER HATTON RALPH L 3935 S 113TH, SEATTLE WA 98168 CONTACT CANDICE GALLAGHER 2800 THORNDYKE AV W, SEATTLE, WA 98199 CONTRACTOR WASHINGTON ENERGY SERVICES CO 2800 THORNDYKE AV W, SEATTLE, WA 98199 ***************: k*•*********•*****•***** ** * ** * ** * *** **** * ***** ** ** * * * ** *fit ****** Permit Description: NEW 80,000 BTU GAS FURNACE UMC Edition: 1997 Valuation: Total Permit Fee: ******************************************* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** _ a-) Permit Center Authorized Signature I hereby :. certify that I have read and examined this permit and know the same to Abe true and correct. All provisions of law and ordinances governing this work wi 11 be complied with, whether specified herein or riot. 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. T am authorized to sign For and obtain this building permit. Signature: Print Name:_ MECHANICAL_ PEPM1 1 Date Phone: (206) 431 -3670 Status: ISSUED Issued: 11/14 /2001. Expires: 05/13/2002 Phone: 206 378 -6680 Phone: 206 - 282 -4700 3,000.00 55.56 _______ Date: Date 1 1 -11 This permit shall become n u l l 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. ;2£. :� ; ACTIVITY NUMBER: M01 -167 DATE: 10 -17 -01 PROJECT NAME RALPH HATTON SITE ADDRESS: 3936 SOUTH 113 STREET Original Plan Submittal XX Response to Incomplete Letter #1 Response. to Correction Letter # Revision # After Permit Is Issued DEPARTMENTS: 7 Build ivision Att” 1 Public Works DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Complete Ii Incomplete Comments: TUES /THURS ROUTING: Please Route Approved n \PRROUTE.DOC 5/99 PERMIT COORD COPY PLAN REVIEW /ROUTING SLIP Fire Prevention Structural Structural Review Required APPROVALS OR CORRECTIONS: (ten days) CORRECTION DETERMINATION: Approved n Approved with Conditions REVIEWER'S INITIALS: REVIEWER'S INITIALS: Planning Division Permit Coordinator DUE DATE: 10-1 8-01 n Not Applicable n No further Review Required DUE DATE 11 -15 -01 DATE: Approved with Conditions Not Approved (attach comments) n REVIEWER'S INITIALS: DATE: DUE DATE Not Approved (attach comments) n DATE: Revision submittals must be submitted in person at the Permit Center. Revisions will not be accepted through the mail, fax, etc. Date: 1910 ( Plan Check/Permit Number: MO 1 -167 City of Tukwila Department of Community Development - Permit Center 6300 Southcenter Blvd, Suite 100 Tukwila, WA 98188 (206)431 -3670 • Response to Incomplete Letter # _1_ ❑ Response to Correction Letter # E Revision # after Permit is Issued Project Name: Ralph Hatton Project Address: 3936 South 113 Street Contact Person: Candice Gallagher Summary of Revision t 3 (k. C \ U L Phone Number: \r\ (- *0 \oca -VAoQ RECEIVED CITY ©F TUKWILA Sheet Number(s): "Cloud" or highlight all areas of revision including date of revision Received at the City of Tukwila Permit Center by: Entered in Sierra on / " -17 -O/ 09/27/01 100 1 PERMIT CENTER September 27, 2001 Ms. Candace Gallagher Washington Energy Services 2800 Thorndyke Avenue West Seattle, WA 98199 RE: Letter of Incomplete Application #1 Development Permit Application Number M01 -167 Ralph Hatton — 3936 South 113t Street Dear Ms. Gallagher: This letter is to inform you that your permit application received at the City of Tukwila Permit Center on September 25, 2001, is determined to be incomplete. Before your permit application can begin the plan review process the following items need to be addressed. Building Division: Ken Nelson Plans Examiner at (206)431 -3670, if you have any questions regarding the following: 1. Is this a replacement of other? 2. What room or space will it be located it? The City requires that four (4) complete sets of revised plans be resubmitted with the appropriate revision block. if your revision does not require revised plans but requires additional reports or other documentation, please submit four (4) copies of each document. 1n order to better expedite your resubmittal a `Revision Sheet' must accompany every resubmittal. 1 have enclosed one for your convenience. Revisions must be made in person and will not be accepted through the mail or by a messenger service. if you have any questions, please contact me at the Permit Center at (206) 433 -7165. Sincerely, Stefania Spencer Permit Technician encl File: Permit File No. M01 -167 City of Tukwila Steven M. Mullet, Mayor Department of Community Development Steve Lancaster; Director 6300 Southcenter Boulevard, Suite #100 • Tukwila, Washington 98188 • Phone: 206-431-3670 • Fax: 206 - 431 -3665 • •s,a.6.4..:.4.,cc:u. srh.. .w. ..,...,..,.. x.x.a.. DEPARTMENTS: Building Division Public Works Complete n Fire Prevention Structural DETERMINATION OF COMPLETENESS: (Tues., Thurs.) TUES /THURS ROUTING: Please Route n Structural Review Required REVIEWER'S INITIALS: \PRROUTE.DOC 5/99 CORRECTION DETERMINATION: Approved n Approved with Conditions Li REVIEWER'S INITIALS: n PLAN REVIEW /ROUTING SLIP ACTIVITY NUMBER: M01 -167 PROJECT NAME: RALPH HATTON SITE ADDRESS: 3936 SOUTH 113 STREET Original Plan Submittal Response to Correction Letter # DATE: 10 -17 -01 XX Response to Incomplete Letter #1 Revision # After Permit Is Issued Planning Division Permit Coordinator DUE DATE: 10-18-01 Incomplete n Not Applicable No further Review Required APPROVALS OR CORRECTIONS: (ten days) DUE DATE 11 -15 -01 Comments: DATE: Approved n Approved wi nditions Not Approved (attach com nts) REVIEWER'S INITIALS: DATE: O DUE DATE Not Approved (attach comments) n DATE: z ce o (poi cow: cow w o` ga o w zj o •O H. W I v: Mt O: u �. U = 1- Z 1 PERMIT NO.: MECHANICAL PERMIT APPLICATIONS INSPECTIONS ❑ 00002 Pre- construction ❑ 00050 WSEC Residential ❑ 00060 WA Ventilation /Indoor AQC ❑ 00610 Chimney Installation /All Types ❑ 00700 Framing ❑ 01080 Woodstove ❑ i 01090 Smoke Detector Shut Off 01 100 Rough -in Mechanical 01101 Mechanical Equipment/Controls ❑ 01102 Mechanical Pip /Duct Insul ❑ 01 105 Underground Mech Rough -in ❑ 01 115 Motor Inspection ❑ 1400 Fire Final 01800 Final Mechanical ❑ 04015 Special -Smoke Control System CONDITIONS Additional Conditions: 0001 No changes to plans unless approved by Bldg Div ❑ 0014 Readily accessible access to roof mounted equipment ❑ f 0016 Exposed insulation backing material 0019 All construction to be done in conformance w /approved plans 0002 Plumbing permits shall be obtained through King Co 0027 Validity of Permit 0003 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...." TENANT NAME: FEES 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) I- (eating /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) 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' l Fees — Work w/o Permit (Y/N) Insp Outside Normal Hours (hrs) Reinspections (hrs) Miscellaneous Inspections (hrs) Add'I Plan Review (hrs) Plan Reviewer: Permit Tech: Date: It Date: 18/0/ ACTIVITY NUMBER: M01 -167 DATE: 9 -25 -01 PROJECT NAME: RALPH HATTON SITE ADDRESS: 3935 SOUTH 113 STREET XX Original Plan Submittal Response to Incomplete Letter # Response, to Correction Letter # Revision # After Permit Is Issued DEPARTMENTS: Atn Building Division 9 / Public Works DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Complete Comments: TUES /THURS ROUTING: Please Route REVIEWER'S INITIALS: DATE: APPROVALS OR CORRECTIONS: (ten days) Approved REVIEWER'S INITIALS: CORRECTION DETERMINATION: Approved REVIEWER'S INITIALS: \PRROUTE,DOC 5/99 II I PERMITCon PLAN REVIEW7��YNG SLIP ,j6 ,CxiC Structural Review Required Approved with Conditions Fire Prevention a t .t1.a I Structural Planning Division Permit Coordinator DUE DATE: 9-27-01 Incomplete JZI Not Applicable No further Review Required DUE DATE 10 -25 -01 Not Approved (attach comments) DATE: DUE DATE Approved with Conditions I ] Not Approved (attach comments) n DATE: PLAN REVIEW /ROUTING SLIP ACTIVITY NUMBER: M01 -167 DATE: 9 -25 -01 PROJECT NAME: RALPH HATTON SITE ADDRESS: 3935 SOUTH 113 STREET XX .Original Plan Submittal Response to Incomplete Letter # Response toCorrection Letter # Revision # After Permit Is Issued DEPARTMENTS: Building Division Public Works 14; Fire Prevention Structural DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Comments: Please Route Approved \PRROUTE.DOC 5/99 REVIEWER'S INITIALS: Structural Review Required APPROVALS OR CORRECTIONS: (ten days) CORRECTION DETERMINATION: Approved with Conditions REVIEWER'S INITIALS: Planning Division Permit Coordinator DUE DATE: 9-27-01 DUE DATE 10 -25 -01 n Complete Incomplete Not Applicable ri y lJ -� 46S a re pl a Gewt e t k 4 a .Z- r �}- rcnw► a- sPaie_ L&1( ; - I, Il bud-e41 ilA TUES /THURS ROUTING: No further Review equir d DATE: Approved ri Approved with Conditions Not Approved (attach comments) REVIEWER'S INITIALS: DATE: DUE DATE Not Approved (attach comments) DATE: ACTIVITY NUMBER: M01 -167 DATE: 9 -25 -01 PROJECT NAME: RALPH HATTON SITE ADDRESS: 3935 SOUTH 113 STREET 'XX Original. Plan Submittal Response to Incomplete Letter # Response to Correction Letter # Revision # After Permit Is Issued DEPARTMENTS: Building Division Public Works n DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Complete Comments: TUES /THURS ROUTING: Please Route PLAN REVIEW /ROUTING SLIP Structural Incomplete n K Structural Review Required REVIEWER'S INITIALS: (% APPROVALS OR CORRECTIONS: (ten days) \PRROUTE.DOC 5/99 Fire Prevention NA Planning Division Permit Coordinator DUE DATE: 9-27-01 Not Applicable No further Review Required DATE: f Z �I DUE DATE 10 -25 -01 Approved n Approved with Conditions Not Approved (attach comments) REVIEWER'S INITIALS: DATE: CORRECTION DETERMINATION: DUE DATE Approved Approved with Conditions n Not Approved (attach comments) REVIEWER'S INITIALS: DATE: Y. Project Name /Tenant: 12c' h Value of ech anical Equipment: ! Site Address : o 1 1 I U I State /Zip: Tax Parcel Numb r: Property Owner: -- , h � t �„ Lt� � ""�� 1 ' _ ne4 3 Fax #: ( Phone: ( ,) l � 2t 4V to � '"' �.�J l Street Address: ,,.t 1 City State /Zip: 3 1-te 04,-a-6-.507, Fax #: ( ) Contractor: � r Phone: )W GCDSD 4 Street Addre � -� Clad ^ K..y ° • (��� • 0 � � l` ; -� Q � y St / �-�� ^ '`�`'� Fax #: ( ) n:� Contact Person: (k1 C Cam, Q . —Q40. aa- Ph one: �� s,...7 S — c.Qcew) Street Address: aA� t JtU City State /Zip: Fax 11: ( ) BUILDING OWNER OR AUTHORIZED ENT: Signature: 9 ! '`1 C.—.-/-N Date: c/ Print name: r ; c_Y Phone: (, ' _ ne4 3 Fax #: ( ) Address: i S g f City /State /Zip: Mechanical Permit Application MECHANICAL PERMIT REVIEW AND APPROVAL REQUESTED: (TO BE FILLED OUT BY APPLICANT) Description of work to be done (please be specific): Pq.co s 3-ru Current copy of Washington State Department of Labor and Industries Valid Contractor's License. If not available at the time of application, a copy of this license will be required before the permit is issued OR submit Form H -4, "Affidavit in Lieu of Contractor Registration ". Building Owner /Authorized Agent: If the applicant is other than the owner, registered architect/engineer, or contractor licensed by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the permit will be required as part of this submittal. I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER PENALTY OF PERJURY BY THE LAWS OF THE STATE OF WASHINGTON, AND I AM AUTHORIZED TO APPLY FOR THIS PERMIT. Expiration of Plan Review - Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The building official may extend the time for action by the applicant for a period not exceeding 180 days upon written request'by the applicant as defined in Section 114.4 of the Uniform Mechanical Code (current edition). No application shall be extended more than once. Date application accepted: 9 —o% SIP •a I //2 /vv mcch permit. doe CITY OF Tr VWILA Permit Center 6300 Southcenter Boulevard, Suite 100 Tukwila, WA 98188 (206) 431 -3670 Application and plans must be complete in order to be accepted for plan review. Applications will not be accepted through the mail or facsimile. Date application expires: -.� r -d0. "' STAFF I)SE ONI Y Project Number. Permit Number. Plots-/67 Application taken by: (initials) see Z W tY 0 w = w � a w Z = F- F- O Z I— W W U O 0 O I— W 2 1- L -L - O .. Z W U= O Z ✓ Submittal Requirements Floor plan and system layout Roof plan required to identify individual equipment and the location of each installation (Uniform Mechanical Code 504 (e)) Details and elevations (for roof mounted equipment) and proposed screening Heat Loss Calculations or Washington State Energy Code Form #H -7 H.V.A.C. over 2,000 CFM (approximately 5 ton and larger) must be provided with smoke detection shut- off and will be routed to the Fire Prevention division for additional comments (Uniform Mechanical Code 1009). Specifications must be provided to show that replacement equipment complies with the efficiency ratings and other applicable requirements of the Washington State Nonresidential Energy Code. Structural engineer's analysis is required for new and the replacement of existing roof equipment weighing 400 pounds and greater (Uniform Building Code 1632.1). Structural documentation shall be stamped by a Washington State licensed Structural Engineer. Mechanical Permits COMMERCIAL: Two complete sets of drawings and attachments required with application submittal NOTE: Water heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. RESIDENTIAL: Two complete sets of attachments required with application submittal 11/1/99 ink puu.doc Submittal Requirements New Single Family Residence Heat Toss calculations or Form H -6. Equipment specifications. Change - out or replacement of existing mechanical equipment 1 Narrative of work to be done, including modification to duct work. Installation of Gas Fireplace 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. NOTE: Water heaters and vents are included in the Uniform Mechanical Code — please include any water heaters or vents being installed or replaced. Address: 3935 5 113 ST Permit No: M01-167 Suite: lenant: HATTON RESIDENCE Status: ISSUED lype: B-MECH Applied: 09/25/2001 Parcel ft: 335140-0105 Ic3sued: 11/14/2001 ************************************************************************A** Z Permit Conditions: 1. Plumblng permits shall be obtained through the Seattle-King w rt m - CountY,pepartment of Public Health. Plumbing will be 6 D inspected by that agency, , including all gas piping _Jo 00 (296-4722). U)13.1 I li 2. Electrical permitshail be'obtained through the Washington State Division,;.0Laborand-Inddstrles and-all electrical work will be insPectedby%that agency (248663(5). /. , No changesWill be Made to the plans unless approved by the Engineer and:AheIukwila Buliding piviSfon. ' • ;. All permit.,' ispectiop!recordand approved,plans shallbe • lab thejob,$)te prior to the start oE any'con- structi* -.These dOcumenWare to be maintained -and avail- • able untri f 1 rial in'spection approval is granted. 5. All cdwitructton,to be'dOne inbonformance with approved plansandTheybirements_of the Uniform Building Code (1997 - Editton) as UntformMechantcal.Code (1997 Edition), and Washlngton State . tnergy Code (1997 Edttion). 4 • 'Validity of Permit 'The Is4lanOe6f' a permit or approval of • " planisnspec1 IAC:atiohs4 and cOmputations not be con- strOd‘to ,ippel :permit for, or an approval of, any violation of anY'of provisios of the building code or of any - otheordinance the No presuming to give:adthOrltY to violatelor cancel‘the provisions of this code shalT,..be, valid. Manufacturers installation instructions required on site for the inspectors review. hereby certi fy that I have read these conditions and will comply with 'them as butlined.-::, of law and ordinances governing — this work will1;6 with, whether specified herein or • nOt. ai! does not,presumpto give authority to the provisions 0:fany.,;:bther work or 1pCal -. .regulating:conStruettOn;'Or, the performance , :or.). work. ' Print Name: CITY OF TUKWILA Date uj U. < Z UJ uj 0 C.) co 0 — 0 111 w I 0 IL. 6 Z u) - 0 t • **************************************************************** CITY OF TUKWILA, WA TRANSMIT **************************************************************** TRANSMIT Number: R0101461 Amount: 55.56 11/14/01 15:24 •Payment Method: CHECK Notation: WASHINGTON ENERG Init: KAS Permit No: M01-167 Type: B-MECH MECHANICAL PERMIT Parcel No: 335140-0105 Site Address: 3935 S 113 ST Total Fees: 55.56 'This Payment 55.56 Total ALL Pmts: 55.56 Balance: .00 Account Code Description Amount •000/345.830 PLAN CHECK - RES 11.11 ca0.022A0p MECHANICAL - RES 44.45 • •k".0t'; 1 /16 : 6 .TOTAL • • 55.;,56•-,. • • 1 • , • - INSPECTION RECORD Retain a copy with perm 1NSFECTlONi4O. :. 1TY OF K1N14"BILT.DING DIVISION 300SP #190, Tukwila WA 98188 . • . OVeitPet:apPlicable:Codes. • „.. (206)431-3670 e S. ecial instructions: e of Inmection / 6 (5 4 Date caM ; / e l0/ 0 a Date want r , i I 31/0? ..ri. C. (tola &tot 3 86 orrections-requitectprior to approval. • : • "..;,; $47.09 REINSpECTIO 1 E REQUIRED. Prior to inspection, fee must be paid t'6300 8 vd., Suite 100. Call to schedule reinspection. ReCeipt NO: Date: i'`,}4. ate ermit No. S PARATE PERMIT EQUIRED FOR: 11 P ECHANICAL LECTRICAL LUMBING AS PIPING OF TUKWI :. LDING DIVISI e N 1 unde subje plans adopt tracto Installation sketch Include: Location of... CFumace CAWH OChimney =A/C unit .Registers .Current equip =Key valve Ocombustion air grills OT•stat OMeter :EAC OCrawai access Routes of... OVenting CGss pipe ::Duct work CE:ectries! CCondensate :Linesets OWater pipes OReilef stand that the Plan Check approvals are to errors and omissions and approval of oes not authorize the violation of any of con- d code or ordinance. po approved plans acknowledged. 's copy of ap p 1 v c lea MO w c 0 � "',it J � s WW1. RDm 1 + At) NO OLODE, F" / 5 la'? Ca/ i s Se e T ' 7 S' ti // 4G % -; 7 ei •� (� -c.� SKETCH INCOMPLETE LT R# . 0; L To E ms Si" ,/ /i.,,ic7 RECEIVED CITY OF TUKWILA � �� 1 ^^ r ., t,r ! /_j PERMIT CENTER r wflcS \ � Lc/ LI 0 ecc, tiin,ls, 1 J ' ' } N W W 0 g J u. Q co 3 D o 0 co Wi . V LL O ; w z o ' z INCOMPLETE LTR# RECEIVED CITY OF TUKWILA PERMIT CENTER M (01 • Z C..) O 0 U) U) WI U) uj 0 g < co n a w z o z I- LL! uj n 0 c.) 0 O I- W W • 0 F-- — u_ , cl) = O 1— z 3 co J orn c< 7 m NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. installation, start -up, 355MAV and operating instructions DELUXE 4 -WAY MULTIPOISE VARIABLE - CAPACITY DIRECT -VENT CONDENSING GAS FURNACE Series E & F A93040 NOTE: Read the entire instruction manual before starting the installation. This symbol -a 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 I 1 -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 ENERGY STAR® guidelines for en- ergy efficiency. Cancels: 11 355M-40-8 a EFFICIENCY RATING CERTIFIED ama REGISTERED QUALITY SYSTEM AIRFLOW II 355M-40-9 2 -01 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 RIVeD 37 Adjustments TY( �F'reIR (!I(,A 38 -43 Set Gas Input Rate 38-43 Set Temperature Rise 1 i'' , 9 43 11i( 1 PERMIT CENTER INO /-4 7 Set Thermostat CHECK SAFETY Check Primary Check Pressure CHECKLIST Heat Anticipator 43 CONTROLS 43 -44 Limit Control 43-44 Switch 44 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 9013. In Canada, refer to the current edition of the CAN /CGA- B149.1- and .2 -M95 National Standard of Canada, Natural Gas and Propane Installation Codes ( NSCNGPIC). Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls. Recognize safety information. This is the safety -alert symbol® . When you see this symbol on 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 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— t 5. Use this procedure for installed and uninstalled (un- grounded) furnaces. 6. Before removing a new control from its container, dis- charge your body's electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 5 before bringing the control or yourself into contact with the furnace. Put all used AND new controls into containers before touching ungrounded objects. 7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage. INTRODUCTION The 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 residence completed at final site. These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply -air discharge direction) applica- tions as shown in Fig. 1. See details in Applications section. These furnaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main . blower compartment. 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 1 Collector box or condensate trap extension tube Inducer housing drain tube 1 /2 -in. CPVC street elbow 2 Drain tube coupling 1 Drain tube coupling grommet 1 Vent and combustion -air pipe support 2 Combustion -air pipe perforated disk assembly 1 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. 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 f i 14 'h - TYP 1 26 "Air 26'W 24 W 22 ?Is 2 -IN. COMBUSTION - AIR CONN — 3 -1N. DIA GAS CONN 2- IN. VENT CONN 14-IN. DIA THERMOSTAT ENTRY 22 "As' SIDE INLET 1' TYP SIDE INLET 26 "As " TYP CONDENSATE DRAIN TRAP LOCATION (DOWNFLOW & HORIZONTAL LEFT) IN. DIA POWER CONN 3b DIA ACCESSORY POWER ENTRY CONDENSATE 1 DRAIN TRAP 27 As" LOCATION TYP (ALTERNATE 24'h" UPFLOVV) 17 456' VAC TVP CONDENSATE DRAIN LOCATION (UPFLOW) NOTES: 29 "As' 27 5A' TYP 1 I I 33 'A" 32sn• 30 'AC TYP AIRFLOW A D OUTLET CI O 0 O 0 O INLET 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 'f -IN. DIA GAS CONN 30'h 18' /+ CONDENSATE DRAIN LOCATION (UPFLOW) DIMPLE LOCATORS FOR HORIZONTAL HANGING 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 retum -air opening at furnace: a. For 800 CFM- 16-in. round or 141/2 x 12 -in. rectangle. b. For 1200 CFM- 20 -in. round or 14'/2 x 19'h -in. rectangle. c. For 1600 CFM- 22 -in. round or 14'/: x 23' /. -in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM. °As TYP 4 %A-IN. DIA }� POWER CONN — 'h-IN. DIA THERMOSTAT ENTRY 2- IN.VENTCONN 28'h 26 Ile 26'N' 22 'As' 19' I O UTLET 2 -IN. COMBUSTION - AIR CONN • zz' 'ie• -• —•- SIDE INLET 1 -.1— 22 1/4•TYP --� 4 %s ' 24 'As" s•{ "As" BOTTOM INLET NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. DIA GAS CONN 1" 39 A99112 INSTALLATION This forced air furnace is equipped for use with natural gas al altitudes 0 - 10,000 ft (0.3,050m). An accessory kit, suppled by the nenrfadurer, shall be used to convert to propane gas use or may be required for soma natural gas applications. This furnace Is for Indoor installation in a building constructed on site. This amaze may be installed in a manufactured (mobile) home when stated on rating plate and using factory authorized kit This furnace may be installed on combustible flooring in alcove or doset at minimum dearance from corn ustide material. This appliance requires a spedal venting system Refer to the Installation instruction for parts list and method of installation. This funace is for use with schedule -40 PVC, PVC DWV, or ABS -DVW pipe, and must not be vented in cannon with other gas -fired appliances. Construction Through which venVair intake pipes may be installed Is madman 24 inches (600 mm), minimum 3/4 Inches (19 mm) thickness (inducing roofing materials). MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION 325400 -201 REV. A (i-IT. TOP) LEVEL (0") 1/2" MAX Furnace must be installed level, or pitched forward within 1/2 Inch of level for proper drainage. Failure will result in equipment or property damage. See Installation Manual for IMPORTANT unit support details on horizcntal UPFLOW OR applications. DOWNFLOW ALL POSITIONS: * Minimum front dearance for service 30 incites (762mm). DOWNFLOW POSITIONS: t For installation on mnbustide floors only when installed on special base No. KGASB0201ALL, Coil Assemdy, Part No. Cos or CK5, a Coil Casing, Part No. KCAKC. HORIZONTAL POSITIONS: R Clearance shown Is for air Inlet and air outlet end. Une contact is pemisside only between lines fomned by intersections of top and two sides of furnace Jacket, and building joists, studs, a from rg. 0 120 sae Furnace mgtire 1 inch bottom dearance to combustible materials. 1 LE T (0") 1/2 " MAX F s FRONT HORIZONTAL This furnace is approved fa UPFLOW, DOWNFLOW and HORIZONTAL Installatiau. 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. m 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— A99103 LL 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. I. All drain and pressure tubes are connected as shown in Fig. 5. See appropriate application instructions for these procedures. re W 0 WO u. Z ; O , UJ 2 3: 0. O NI C1 1--: W O lil co I- O z BLOWER SHELF r FURNACE DOOR CONDENSATE TRAP (INSIDE) ALTERNATE DRAIN TUBE LOCATION CONDENSATE TRAP DRAIN TUBE LOCATION UPFLOW APPLICATIONS DRAIN CONN SLOT FOR SCREW HORIZONTAL APPLICATION (OPTIONAL) 1 1 /2 3 /4 1'/4 WIRE TIE GUIDES (WHEN USED) FRONT VIEW � T�- s FIELD - 26/4 SIDE 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 DOWNFLOW AND ALTERNATE EXTERNAL UPFLOW APPLICATIONS —5— 1 FRONT VIEW SIDE VIEW 4 IA 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 t/4 FIELD DRAIN CONN 4 END VIEW FRONT VIEW HORIZONTAL APPLICATIONS 4 A93026 Fig. 4— Condensate Trap 2. Condensate Trap Drain Tube The condensate trap drain connection must be extended for field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2 or 5.) NOTE: If internal filter 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. 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 FIELD - INSTALLED FACTORY - SUPPLIED FACTORY - SUPPLIED 1 h -IN. CPVC STREET DRAIN TUBE ELBOWS (2) FOR COUPLING (RIGHT LEFT DRAIN OPTION DRAIN OPTION) A94213 Fig. 5— Factory- Shipped Upflow Tube Configuration (Shown With Blower Access Panel Removed) h. Attach tube to coupling and clamp securely. C. Condensate Trap Location (Alternate Upflow Orientation) An alternate location for the condensate trap is the left -hand side of casing. (See Fig. 2 and 6.) NOTE: If the alternate left -hand side of casing location is used, the factory- connected drain and relief port tubes must be 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). 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. I. 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 1 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 parts bag). c. Determine appropriate length, cut, and connect tube. E. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. F. Pressure Switch Tubing The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch and should not require any modification. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. G. Upper Collector Box and Inducer Housing (Unused) Drain Connections UPPER COLLECTOR BOX DRAIN CONNECTION Attached to the UPPER collector box drain connection is a factory- installed corrugated, plugged tube (blue and white striped label). This tube is plugged to prevent condensate leakage in this application. Ensure this tube is plugged. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. UPPER INDUCER HOUSING DRAIN CONNECTION Attached to the UPPER (unused) inducer housing drain connection is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped. NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections. H. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. —7— DRAIN TUBE Mr COUPLING 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) f— CONDENSATE TRAP 3 ._, 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: I. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Install casing hole filler cap (factory- supplied in loose parts bag) into blower shelf hole where trap was removed. 4. Install 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. I. Collector Box Drain Tube a. Remove factory- installed plug from LOWER collector box drain tube (blue and white striped label). b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was connected to condensate trap. c. Connect LOWER collector box drain connection to condensate trap. 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 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. I. Disconnect collector box pressure tube (pink label) attached to pressure switch. 2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connec- tion by splicing to small diameter tube (factory - supplied in loose parts bag). 3. Connect collector box pressure tube (green label) to pres- sure switch connection labeled COLLECTOR 130X. 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: I. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Install casing hole filler cap (factory- supplied in loose parts bag) into blower shelf hole where trap was removed. 4. install 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. 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. re qq 2 —J C.) • 0 0 . to Ili • u. W 0; u. dA Z 0 W D • 0 O N 0 H W '. .z V N 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 'U" BOX CONDENSATE TRAP • PLUG cc L CAP 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 ft) 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) 0 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 CAUTION: Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling. — CONDENSATE TRAP NOTE: In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes. 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). —10— VENT DRAIN NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS. Fig. 10 —Attic Location and Working Platform A 12 -IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM N EXITING THE VENT PIPE. K AREA I 1 j j ACCESS OPENING \� I 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 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. Fig. 11 Horizontal Right Tube Configuration —11— COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) AUXILARY "J" BOX RELOCATED HERE , l CONDENSATE TRAP 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 A00214 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. i UPFLOW OR DOWNFLOW HORIZONTAL A93025 NOTE: For proper furnace operation, install furnace so that it is level or pitched forward within 1/2 in. to ensure proper condensate drainage from secondary heat exchangers. MAX 857 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. It 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— /../ ZiS 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 M NIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED II. LOW -FIRE ONLY INSTALLATION A93043 A93058 Lt 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. 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 18 -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 1. 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. 1. 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. 1. Determine application being installed from Table 1. 2. Construct hole in floor per dimensions specified in Table 1 and Fig. 13. 3. Construct plenum to dimensions specified in Table 1 and Fig. 13. 4. If downflow subbase (KGASB) is used, install as shown in Fig. 14. If coil assembly 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 and angle iron supports. (See Fig. 17.) Cut hanger bolts (4 each 3 /8 -in. all- thread rod) to desired length. Use 1 X 3 /8 -in. flat washers, 3 /8 -in. lockwashers, and 3 /8 -in. nuts on hanger rods as shown in Fig. 17. Dimples are provided for hole locations, (See Fig. 2.) kAfa 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 Coil Assembly or KCAKC Coil Box 15 -1/2 19 16 -1/2 20 21 Upflow Applications 19 -1/2 24 -1/8 20 -1/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 19 -3/8 19 20 19 -5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Fumace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 18-5/8 19 20 -1/4 20 -3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coll 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 Coll 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) COMBUSTIBLE FLOORING DOWNFLOW SUBBASE . . SHEET METAL _. PLENUM ..--- FLOOR OPENING ti 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 L_ A96284 Fig. 15— Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor 210' PERFORATED DISCHARGE DUCT FLANGE MIN Fig. 16 —Duct Flanges ANGLE IRON OR EQUIVALENT (B) (A) PREFERRED ROD LOCATION (B) ALTERNATE ROD LOCATION NO YES YES A93029 IV. AIR DUCTS (A) LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL 3 /8-IN. HEX NUT-' (A) ` (B) DWG FOR & WASHER (4) LOCATIONS) REQD PER ROD DRAIN. _ J (A) (B) 1 NOTES: 1. A 1 In. clearance minimum between top of furnace and combustible material. 2. The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage. Fig. 17— Crawlspace Horizontal Application —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. 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 Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design static pressure. When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. Secure ductwork with proper fasteners for type of ductwork ued. Seal supply- and return-duct connections to furnace with code approved tape or duct sealer. t I 3 A3-IN. ROD 13 /16 -IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK ALTERNATE SUPPORT LOCATION 4 -IN. MIN 8 -IN. MAX A93304 FURNACE CASING WIDTH (IN.) FILTER SIZE (IN.)* FILTER TYPE FRAMED Side Retum Bottom Return 17 -1/2 (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 11 Cleanable 24-1/2 (1 or 2) 16 X 25 X 1 (1) 24 X 25 X if Cleanable la1111t�1 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 fumace 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. —I6— If a factory- supplied external Filter /Media cabinet is provided, instructions for its application, assembly, and installation are packaged with the cabinet. The Filter/Media cabinet can be used with the factory- supplied washable filter or a factory- specified high- efficiency disposable filter (see cabinet instructions). If installing the filter in the furnace blower compartment, deter- mine location for filter and relocate filter retaining wire if necessary. See Table 2 to determine correct filter size for desired filter location. Table 2 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings. TABLE 2— FILTER INFORMATION Filters may be field modified by cutting flier material and support rods (3) in filters. Alternate sizes can be ordered from your distributor or dealer. t Factory- provided with furnace. 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. LIS 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 PIPE INTERNAL DIAMETER LENGTH OF PIPE (FT) 10 20 30 40 50 SIZE (IN.) (IN.) 1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151 1 1.049 680 465 375 320 285 1.1/4 1.380 1400 950 770 660 580 1.1/2 1.610 2100 1460 1180 990 900 1712 -IN. WIDE CASINGS ONLY: INSTALL FIELD- SUPPLIED FILTER FILLER STRIP UNDER FILTER. FILTER SUPPORT 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, 21 -IN. WIDE CASINGS ONLY: SUPPORT RODS (3) EXTEND 1/4" ON EACH SIDE OF FILTER AND REST ON CASING FLANGE 24 1/ FILTER RETAINER Fig. 19 — Bottom Filter Arrangement WASHABLE FILTER --17— TABLE 3— MAXIMUM CAPACITY OF PIPE* Cubic ft of gas per hr for gas pressures of 0.5 psig (14 -In. wc) or less, and a pressure drop of 0.5 -In. wc (based on a 0.60 specific gravity gas). Ref: Table 10 -2 NFPA 54 -1999. ®I 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.) FRONT FILLER PANEL BOTTOM CLOSURE PANEL A00290 A93047 Fig. 20— Removing Bottom Closure Panel 115 -V SINGLE PHASE GAS SUPPLY if MANUAL SHUTOFF VALVE (REQUIRED)/ TR UNION Fig. 21 Typical Gas Pipe Arrangement 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 fumace. 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 FIVE WIRE THREE -WIRE HEATING ONLY 115 -V AUXILIARY FIELD - SUPPLIED J -BOX DISCONNECT SWITCH FURNACE CONTROL CENTER NOTE 5 A93324 (w2) (R} (G) 24 -V TERMINAL BLOCK _ NOTE NOTE 1 I I I J TWO WIRE THERMOSTAT TERMINALS FIELD - SUPPLIED DISCONNECT • • ♦--� fi- if-f -- — •GND� CONDENSING UNIT 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. 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 115-v and 24 -v wiring. Check all factory and field electrical connections for tightness. LE WARNING: Blower access panel door switch opens 115 -v power to control center. No component operation can occur. Do not bypass or close switch with panel removed. Failure to follow this warning could result in personal injury or death. CAUTION: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. I. 115 - V WIRING Before proceeding with electrical connections, make certain that voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 4 for equipment electrical specifications. Make all electrical connections in accordance with 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 -*FT - Il+ • vGND -- 208/230 - OR 460 -V -- THREE PHASE — }208/230-V - -- SINGLE ___ PHASE A9B325 ELECTRIC DISCONNECT SWITCH ALTERNATE FIELD LOCATION COPPER WIRE ONLY A93033 ml 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 115 -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. Fig. 23 Relocating J - Box 7 — 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 ft. 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) The control center EAC terminals are energized with 115v (1.5 -amp maximum) during blower operation. a. Two extension leads are connected to the control center EAC terminals to assist field installation of an EAC. (See Fig. 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. Strip EAC neutral lead insulation approximately 1/4 (3.) 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: (1.) Remove 2 screws securing the control box to furnace blower shelf. (2.) Remove and discard 2 factory- supplied leads from control center EAC terminals. (3.) Strip EAC power leads insulation approximately 1/8 in. NOTE: The control center EAC terminals are sized for 12 gage maximum, solid or stranded wire. (4.) Route EAC leads through right -hand 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. 2. Humidifier (HUM) `1 Screw terminals (HUM and CoM) are provided for 24 -v humidifier connection. (See Fig. 24.) HUM terminal is energized with 24v (0.5 -amp maximum) after induber motor prepurge period. swrr POE. NCAPD0 SWITCH NOS. SEiECT iT Q Q Q OF [)ffPU.TOffN1T Q Q TON C cm 1 1.12 600 3 3-12 1400 e TON cFM e w e TON C M 1;1 El II TON 018.1 l 1 ' MM WI TON CFM nee OFF 5 TON l3F) CM { I p { –*Fig. 24 —Unit Wiring Diagram 1 1 U44 ; ©�© M©© 062070 067080 060100 060060 060170 GRNrY L T41 NOTE 43 RED 19181 1615(413121 1 ai I3 3 8 6 LEGEND 1 NC ALS F U1 G1 EAC-2 FRS FSE FU7 I FLQ GM GV GVR H FPS FRS HSIR I HUM HJAT2 ILK BA JB LE DS LGP5 LPS 15 MTR7 F R2 1 2 3 4 5 0 ECU- GRNJ,T3- RED VIO YP BL71 PL13 FSE ""'R1 a©fffEFo 3 BLK W4T PL7 PL1 1.5 NAP " ZZ ZZZ'tZ 5 6. . 9 02 01 L,1 PL4 2 WHT ILK AIR COMONING ADJUSTABLE TCN44GE) AUXILIARY UNIT SWTICN O 137TB.Q -MANUAL RESET SPST -45C) COMB NIOUS FAN (ADJUSTABLE CFM) AW N MCROPRDCESSSOR d CIRCUTRY 101111 4 MCROPROGESSOR a CIRCUTRY OE3UMDI FY ENABLE - IF DE CONNECB ON PROVIDED RB+DVE JUMPER M ENIBEOEHMINPUT DBUMUFIOQION CONECIION (24VAC .02 AMPS) ELECTRONIC AJR CLF-ANER CO9ECTION 115 VAC 15 MP MAX.) ELECTRONIC AIR CLEANER CONNEC ION (CO1r8.DN) RM£ ROLLOUT SWITCH- MANUAL RESET, SPSr{N.C) RMIE PROVING SENSOR ELECTRODE RISE 3 ANN, AUTOMOTIVE BLADE TYPE FACTORY INSTALLED FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE (FELD INSTALLED GROUND ®1 GAS VALVE GAS VALVE RELAY, OAST {NO.) GAS VALVE HG-1 STAGE OPERATOR I1G1 FEAT PRESSURE SWTCH SPST{NA.) HOT SURFACE IGTITOR (115 VAC) HDT SURFACE IGNITOR RELAY, SPSf {NO.) 24VAC RIITDIFIER CONNECTION (5 M.Q. MAX) HUMMER RBAY, SPST {NO.) DLCVE RACCESS PANEL INTERLOCK SWTCH SPST{N.O.) INDUCTOR (NOTE 47) JUNCTION BOX UGH' WITTING DICES FOR STATUS CODES LOW GIGS PRESSURE SWITCH. SPST(N.0.) LOW HEAT PRESSURE SWTCH, SPSf -(N0.) UMTSN1ATCl AUTO RESET. (NC) MOTOR SCIA) INDUCER MOTOR (ACM) BLC7NE R PRINTED CIRCUIT BOARD 11-CIRCUIT COMECTOR 4CIRCIT PRESSURE SMTOR CONNECTOR 5CIRCLATBLOWER MIR CDMJCTOR 2-CIRCUIT HS CONNECTOR TOR 6CIR0JITMAODEL PLUG PL6 PV PL9 P110 PL11 PL12 PL13 SW1 SW2 SL3 SN4 5w5 54 SW7-8 IRAN 0 P76 FU1 ZEDS (1 -4) 0 C� • sl CF PL5 FUSED DISC CNAECT SWITCH NOTE 42 WM LA G [0] R [.•7 YTY2 Col co. [l N2 [) DE= I 24VAC-3A 13 2 11 1654, BU WHT 010 III SEG21I SEC-1 ICh DEAN 0 BUJ ->� BLit TRAt4 FPS I [ c B 1 � L� r LFS NOTE611 T L>� o 1 2 3 4 160TEtI11 OfRN RID NOTE #6 RED— BLOWER SELECTION CHART 78 oO OFF 7 OFF OFF OFF 90 SEC. 135 SE 180 SEC. 725 SEC 34ORCUTCOMA CONNECTOR 12-CIRCUIT IN MER MTR CCNECTOR 2-CIRCUIT HSI CXINECTOR 9CIRCUT BLOWER ADAPTER CONECTOR 1CIRCUT INDUCTOR SAUCE CONNECTOR 5CIRCUT BLOWER P'OWS/ CONNECTOR 1607 RCIIIT BLOWER CTRL CONNECTOR MANUAL SWITCH, FAULT DISPLAY, SPST{N10.) MANRYALSWITCH LOW FEAT, SPST {N0.) MANUAL SW1TCFi BYPASS FUMDFIER SPST -(N0.) M'MJALSNITCH EWBRGENCYFEAT, SPST {NO.) MANUAL SWTCH ALWI1PLEZONE. SPST{N0.) COMPONENT TEST, SPSr -(N0.) MIWUAL SNTO{ BLOWER OFF -DaAY, SPSr {NO.) 1RAIJSFORIER- 115VAC24VAC JUN;BON UNMARKED TERMINAL KB TERMINAL (FACTORY CONNECTED) FACTORY VARING (115 VAC) FACTORY WRING (24 VAC) AHD WRING (115 VAC) CONDUCTOR ON PCB FIELD WRING SCREW TERMINAL TERMINAL BLOCK- MARKED TERMINAL FIELD EARTH GROUND EXAMEN] GROUND REED SPLICE PCB IEAMNAL (FED CONNECTION) PLUG RECEPTACLE TO 115 VAC FIELD 0SCONECT `2 l r, r)7 EDIAPA@1Tcacao NOTE 42 �L ■ T r11 PL1 r PI3 1 12 vy 2 3 <4 <4 <b3 <42 <4 7 <4- PL10 IiRA O (WHEN G0 Yrr2 0 W2 0 WIW1 0 co" 0 FRS LS ALS G O • SW - 4 BAER. FEAT FOWER SUPPLY mg EPC-1 EAC-2 P112 nc 4 GUF7 ) r1 Y rl�l • { 2 -(t- PU PCB NOTE AS FL13 8 « 3 CE (4- tt�• SCHEMATIC DIAGRAM (NATURAL GAS & PROFANE) PL4 POLE R.1 -1 MTR1 612-4 R2.1 PL1.1 MTR2 2 PL9 HS SEC-1 Pt i -" 15VPC J F2 1 " 1fUVl " � U 24VAC rAlti NOTE O F5E PL1 -7 SEC-2 R LPS &2 NOTE #11 NOTE #11 11hFiFN ISEDI c 1 1 1 1 1 If any of the ongmal eompment w.rr s •e placed sr wire 'alert '0r 105 C 2 Use only copper wire between the iIscornec: swat^ and •^e furnace 'unction box •JB 3 This wire must be connected to furnace •"eet meta 'or :ortrm to prove `a ^e 4 Symons are electrical representaepr o^ry 5 50114 bees inside pvtud board PCB are pr.nled a t.. t DOard'• ces an0 are not 9ewcted as Seewr n he aged 6 Replace only wdn a 3 AMP 'use 7 Inductor used on all 060 or -20 a.•'Iow unds 6 Blower.on delay gas neatnq 6C seconds .ow neat 35 seconds n,gr. +Cat coounq or neat pump 2 seconds 9 Blower-oft delay gas neaong 90 1 35 1 40 or 225 sec onos coa.'g or ^eat pump 90 seconds 10 Ignnion.loc*oul will occur dvet four consecubre ,success tetas Corfro..wll autareset aver three +dots It cactory connected when LGP5 not ..sect 322296.10' RE' E NOTICE: IF THE DOCUMENT IN THIS FRAME IS LESS CLEAR THAN THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. A00350 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 Fig. 26 Terminals on Control Center COMMUNICATION CONNECTOR HOT SURFACE IGNITOR CONNECTOR Q JCONNECTORS 17 °°°,1 1 A93053 G G TRANSFORMER 24 -V CONNECTORS —2I — O I 00000aooaool 1 C O l0000' n I IC 31 I 3 tal 024 113138889991 Fig. 25— Control Center TABLE 4— ELECTRICAL DATA PRESSURE SWITCH CONNECTOR = I HUM - HUMIDIFIER TERMINAL (24 -VAC 0.5 AMP MAX) 24 -V THERMOSTAT TERMINALS DEHUMIDIFY ENABLE (DE) — DEHUMIDIFIER (DEHUM) CONNECTOR 3 -AMP FUSE STATUS AND DIAGNOSTIC opjl � LED LIGHTS MI AIR CONDITIONING (A/C) SETUP SWITCH SETUP SWITCHES (SW) AND BLOWER OFF DELAY 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 I /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 tumed 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 I 24 VAC COMM R DEHUMIDIFY I DHUM C R 1° 0 0 VARIABLE -SPEED CONDENSING FURNACE DEHUM ED DE NOTE 1 Com NOTE 1 - Remove DE Connection To Enable DEHUM Input Fig. 28— Thermidistat Connection v 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. 0000 BBB 99999999 - -- v - v- 000 OOO, DE CONNECTION LOCATION —22— DE CONNECTION Fig. 27- 355MAV Variable Speed Furnace Control 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/ANS1 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 shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Follow the lighting instructions. Place the appliance being . inspected in operation. Adjust thermostat so appliance shall operate continuously. 5. Test for draft hood equipped appliance spillage at the draft' hood relief opening after 5 minutes of main burner opera- tion. Use the flame of a match or candle. 6. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace damp- ers, and any other gas - burning appliance to their previous conditions of use. LOCATION CLEARANCE (FT) U.S.A. Canada Above grade level or above antici- pated snow depth 1 1 t Dryer vent 3 3 From plumbing vent stack 3 3 From any mechanical fresh air Intake 1 6 For fumaces with an Input capacity less than 100,000 Btuh —from any non- mechanical air supply (windows or doors which can be opened) or combustion -air opening 1 1 From service regulator vent, electric and gas meters, and relief equipment 4* 6t Above grade when adjacent to public walkway Note 3 Not 3 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. 11. 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 fumace 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: - ,Slope 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 A93034 Fig. 29— Combustion -Air and Vent Pipe Diameter Transition Location and Elbow Configuration NOTE: Select 1 vent pipe connection and 1 combustion -air pipe connection. AIR COMBUSTION- FLOW COMBUSTION - AIR AIR VENT AIR FLOW UPFLOW COMBUSTION - AIR VENT o HORIZONTAL -LEFT DISCHARGE PIPE DIAMETER TRANSITION IN VERTICAL SECTION NOTE: Select 1 vent pipe connection end 1 combustion -air pipe connection. VENT ?:„ COMBUSTION - ` COMBUSTION - AIR AIR AIR FLOW DOWNFLOW COMBUSTION - AIR VENT AIR FLOW HORIZONTAL -RIGHT DISCHARGE A96187 Fig. 30— Combustion -Air and Vent Pipe Connections CAUTION: When combustion -air pipe is installed above a suspended ceiling, pipe must be insulated with 3 /8 -in. thick Armaflex -type insulation. Combustion -air pipe should also be insulated when it passes through 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. m 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. Lt 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. VENT PIPE 12" MIN HORIZONTAL TO ROOF COMBUSTION -AIR PIPE VERTICAL TO ROOF COMBUSTION -AIR PIPE 12" MIN VENT PIPE 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— VENT PIPE 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 11) 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. 1 -..--12" MIN ■ COMBUSTION -AIR PIPE HORIZONTAL TO SIDEWALL COMBUSTION -AIR PIPE VERTICAL TO SIDEWALL 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 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 Ake 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 11 of vent pipe, along with 5 elbows and 16 ft of combustion -air pipe. Table 6 indicates this application would allow a 1- 1 /2 -in. diameter vent pipe, but require a 2 -in. diameter combustion air pipe (1- 1 /2 -in. pipe is good for 20 ft 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 4t 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— 3/8" ID TUBE 3/16" DRILL 1' TRAP TO OPEN DRAIN COMBUSTION — AIR INTAKE HOUSING BURNER BOX NOTE: Moisture in combustion-air intake may be result of improper tennination. 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.) 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 b'ag) 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. Dehurr 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. I11. 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 I -in., 1 -1/2 in., 2 -in., and 2 -1/2 in. diameter pipe systems when single penetration of wall or roof is desired. 4. The 3 -in. concentric vent/air termination kit is for 2 -1/2 in. 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 Tess 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 vapor will not damage plants /shnibs 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. COUPLING VERTICAL SEPARATION BETWEEN COMBUSTION AIR AND VENT 8 "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. 1011 41 1, 181%1 ■ 111wil l b ' COMBUSTION AIR A93054 Fig. 34— Concentric Vent and Combustion -Air Roof Termination (Preferred) VENT OVERHANG OR ROOF 12" MINIMUM l 90 u � a =� BRACKETS � 12 IN. SEPARATION .':BETWEEN BOTTOM OF .• 'COMBUSTION AIR AND —BOTTOM OF VENT MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, COMBUSTION -AIR WHICHEVER IS GREATER. Fig. 36— Sidewall Termination of 12 In. or More Fig. 33 —Roof Termination (Preferred) —29— 90 BRACKET COUPLING—A VENT COMBUSTION AIR A87224 OVERHANG OR ROOF 12" MINIMUM ~ 1" MAXIMUM MAINTA N 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. A93055 Fig. 35— Concentric Vent and Combustion -Air Side Termination OVERHANG OR ROOF 12" MINIMUM 12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND ,at<,:— BOTTOM OF VENT MAINTAIN 121N. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW COMBUSTION -A R LEVEL OR GRADE, (ELBOW O WALL) ARALLEL GREATER. IS A87225 A87226 Fig. 37— Sidewall Termination of Less than 12 In. 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 eats 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. 1 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 fumace 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. CONDENSATE DRAIN I. GENERAL Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications. Condensate trap MUST be used for all applications. An external trap is not required when connecting the field drain to this condensate trap. —30— The field drain connection (condensate trap or drain tube coupling) is sized for I /2 -in. CPVC, I /2 -in. PVC, or 5 /8 -in. ID tube connection. Drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certified schedule 40 CPVC or PVC drain pipe, fittings, and cement. When a condensate pump is required, select a pump which is approved for condensing furnace applications. To avoid conden- sate spillage, select a pump with an overflow switch. Furnace condensate is mildly acidic, typically in the pH range of 3.2 to 4.5. Due to corrosive nature of this condensate, a condensate 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 1 /2 -in. CPVC or PVC tee for vent and A/C or humidifier drain connection. Outdoor draining of the furnace is permissible if allowed by local codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining. WARNING: Caution should be taken to prevent drain- ing where slippery conditions may cause personal inju- ries. Excessive condensate draining may cause saturated soil conditions which may result in damage to plants. III. CONDENSATE DRAIN PROTECTION Freezing condensate left in condensate trap and drain line may cause cracks, and possible water damage may occur. If freeze protection is required, use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40 °F self - regulating; shielded, and waterproof heat tape. See Installation Instructions supplied with accessory or heat tape manufacturer's recommenda- tions. A96128 Fig. 38— Rooftop Termination (Dimension "A" is Touching or 2 -In. Maximum Separation) VENT COMBUSTION AIR A93056 Fig. 39— Concentric Vent and Combustion -Air Roof Termination (Dimension "A" is Touching or 2 -in. Maximum Separation) COMBUSTION AIR VENT A COMBUSTION AIR A96129 Fig. 41— Sidewall Termination of 12 in. or Less (Dimension "A" Is Touching or 2 -In. Maximum Separation) —31— COMBUSTION AIR COMBUSTION AIR VENT A 1" MAXIMUM (NP) VENT A A93057 Fig. 40— Concentric Vent and Combustion -Air Side Termination (Dimension "A" is Touching or 2 -In. Maximum Separation) k J - 6r VENT-- COMBUSTION AIR.- A96130 Fig. 42— Sidewall Termination of More Than 12 in. (Dimension "A" is Touching or 2 -In. Maximum Separation) OPEN STAND PIPE FOR A/C OR HUMIDIFIER DRAIN TEE —N f= TO OPEN DRAIN Fig. 43 Example of Field Drain Attachment 32 °F M NIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED A94054 A93058 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 ft. —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 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. I. 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 I 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 fora I7 -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 1 1 5-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- I terminal is energized whenever the blower operates. 9. Blower off delay —When thermostat is satisfied, the R -W/W I 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 I 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 I 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.) 1 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. 1 Electronic Air Cleaner —The EAC -1 terminal is energized whenever blower operates. 4. Cooling unit —The cooling unit stops when thermostat R -Y signal is terminated. 5. Blower off delay —When thermostat is satisfied, the R -Y/Y2 and R -G signals are terminated, and blower 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 THERMOSTAT THERMOSTAT 0 2 -SPEED AIR CONDITIONER 0 Ea Fig. 45— Wiring Schematic for 2 -Speed Cooling Applications VI. HEAT PUMP MODE A94302 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/W 1 circuits close starting gas heat cycle, and blower adjusts to low -heat speed. I. 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. —34— 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 /W I 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 For details on 2 - speed heat pump applications, refer to Fig. 46. VII. CONTINUOUS FAN MODE 1. Operating with continuous fan only — a. CaII 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 I /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. 2. Operating with continuous fan (R -G) and call for heat (R -W /W1) is received —Same as heat pump mode except blower on delay is 10 sec less than heat mode. After call for heat (R -W /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 13 W2 - m rn- u ra YIY2 2 -SPEED HEAT PUMP AL u ta AIL 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 furnace 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 I sec, followed by I sec where both green and yellow LEDs are on. During this tine, 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, 1 or more fault codes (I I, 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, perform the following: 1. Release blower panel access door switch and turn setup switch SW -6 to OFF position. 2. If applicable, replace blower access panel and check LED status by removing plug in blower access panel. 3. Reinstall main furnace door if all LEDs are off, indicating furnace is ready to operate when a signal from thermostat is received. 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 turned ON when no dehumidify demand exists and is turned OFF when demand exists. This logic reversal has come about from historical use of a standard humidistat to do dehumidification since the contacts open on high humidity, thus removing the 24 vac signal to initiate dehumidification. The DHUM output on the thermidistat control or the humidi 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 Thermidistatml control Installation, Start-Up, and Op- erating Instructions for further details. Xl. 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* 800 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 1, 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. m 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: I. 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 Tum 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 Tum 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 Tum switch to ON to bypass microprocessor control. Fumace will oper- ate at high heat only with main blower and inducer motor operating at maximum RPM. NO safeties are bypassed. S W- 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 furnace is in low -heat or continuous fan mode. , SW -6 (COMP TEST) OFF Tum 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 l /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. —37— 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 ft above sea level. Furnace input rate must be within t2 percent of input on furnace rating plate. 1. Determine natural gas orifice size and manifold pressure for correct input. a. Obtain yearly heat value average (at installed altitude) from local gas supplier. b. Obtain yearly specific gravity average from local gas supplier. c. Verify furnace model. Table 12 can only be used for model 355MAV Furnaces. d. Find installation altitude in Table 12. NOTE: For Canada altitudes of 2000 to 4500 11, use U.S.A. altitudes of 2001 to 3000 fl in Table 12. e. Find closest natural gas heat value and specific gravity in Table 12. 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 1.5 -in. we 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 bumer 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. Fig. 48 Inducer Housing Drain Tube —38— NOTE: DO NOT set low -heat manifold pressure less than 1.3 -in. wc or more than 1.7 -in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices. CAUTION: DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures. NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. f. 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 fumace 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 ALTIE AT TUUDDE E T A (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 A (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 HEAT VALUE AT ALTITUDE (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 Au° vs•n 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 3.2/1.4 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 3.7/1.1 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 0.82 0.64 0.66 Orifice No Manifold Pressure High /Low Orifice No. Manifold Pressure High /Low Orifice N o Manifold Pressure High /Low Orifice N o Manifold Pressure High /Low Orifice No Manifold Pressure High /Low ' Aiuo vs n 4001 to 5000 725 750 775 800 825 850 875 900 925 950 43 43 44 44 44 3.7/1.5 3.4/1.4 3.7/1.6 3.5/1.5 3.2/1.4 43 43 44 44 44 3.8/1.6 3.5/1.5 3.8/1.6 3.6/1.5 3.4/1.4 42 43 43 44 44 44 3.2/1.4 3.7/1.5 3.4/1.4 3.7/1.6 3.5/1.5 3.3/1.4 42 43 43 44 44 44 44 3.3/1.4 3.8/1.6 3.511.5 3.8/1.6 3.6/1.5 3.4/1.4 3.2/1.3 42 42 43 43 44 44 44 3.4/1.4 3.2/1.4 3.7/1.5 3.4/1.4 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 3.2/1.4 45 45 45 45 3.7/1.6 3.5/1.5 3.3/1.4 3.2/1.3 45 45 45 3.6/1.5 3.411.5 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 3.5/1.5 47 3.6/1.5 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice 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 (wo - vrs•n 5001 to 6000 700 725 750 775 800 825 850 875 900 925 950 975 1000 43 43 44 44 44 3.6/1.5 3.4/1.4 3.6/1.5 3.4/1.4 3.2/1.3 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 42 43 43 44 44 44 3.2/1.3 3.6/1.5 3.4/1.4 3.6/1.5 3.4/1.4 3.2/1.4 42 43 43 44 44 44 3.3/1.4 3.7/1.6 3.5/1.5 3.7/1.6 3.5/1.5 3.3/1.4 42 43 43 43 44 44 44 3.4/1.4 3.8/1.6 3.6/1.5 3.4/1.4 3.6/1.5 3.4/1.4 3.2/1.4 45 45 45 3.611.5 3.4/1.4 3.2/1.4 45 45 45 3.711.6 3.5/1.5 3.3/1.4 45 45 45 3.6/1.5 3.4/1.5 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 3.7/1.5 3.5/1.5 3.3/1.4 47 47 48 48 48 3.6/1.5 3.4/1.4 3.7/1.6 3.5/1.5 3.3/1.4 47 47 48 48 48 3.7/1.6 3.5/1.5 3.8/1.6 3.6/1.5 3.5/1.5 47 47 48 48 3.7/1.5 3.5/1.5 3.8/1.6 3.6/1.5 47 47 48 3.6/1.5 3.4/1.4 3.7/1.6 47 47 48 3.7/1.6 3.5/1.5 3.8/1.6 ALTITUDE RANGE 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 High /Low AWO 'M's'n 1 8001 to 7000 650 675 700 725 750 775 800 825 850 875 42 43 44 44 44 3.2/1.3 3.6/1.5 3.8/1.6 3.6/1.5 3.3/1.4 42 43 43 44 44 44 3.3/1.4 3.7/1.6 3.4/1.5 3.7/1.6 3.4/1.5 3.2/1.4 42 43 43 44 44 44 3.4/1.4 3.8/1.6 3.6/1.5 3.8/1.6 3.6/1.5 3.3/1.4 42 42 43 43 44 44 44 3.5/1.5 3.2/1.4 3.7/1.6 3.4/1.4 3.7/1.6 3.4/1.5 3.2/1.4 42 42 43 43 44 44 44 3.6/1.5 3.3/1.4 3.8/1.6 3.5/1.5 3.8/1.6 3.5/1.5 3.3/1.4 45 45 45 3.8/1.6 3.5/1.5 3.3/1.4 45 45 45 3.7/1.5 3.4/1.5 3.2/1.4 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 3.8/1.6 3.6/1.5 3.4/1.4 47 47 3.7/1.6 3.5/1.5 47 3.6/1.5 di 1 • Orifice numbers shown in BOLO are factory installed. —40— 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) " 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 /IuO 'v s 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 3.711.6 3.5/1.5 3.3/1.4 45 45 45 45 3.8/1.6 3.6/1.5 3.411.4 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) 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 AJuO •vs•n I 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 3.4/1.4 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 (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 AIuO •irS'n 1 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 3.3/1.4 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 3.3/1.4 45 3.4/1.5 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 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 I * • Orifice numbers shown In BOLD are factory installed. ALTITUDE (FT) • OF DERATE DERATE MULTIPLIER FACTOR FOR U.S.A.` 0-2000 0 1.00 2001 -3000 4-6 0.95 3001 -4000 6-8 0.93 4001 -5000 8 -10 0.91 5001 -6000 10-12 0.89 6001 -7000 12 -14 0.87 7001 -8000 14 -16 0.85 8001 -9000 16-18 0.83 9001 - 10,000 18-20 0.81 ON /OFF SWITCH LOW -FIRE ADJUSTMENT ALLEN SCREW (UNDER CAP) HIGH -FIRE ADJUSTMENT INLET !�� �'� L NDER CAP) (UNDER PRESSURE TAP BURNER ENCLOSURE REFERENCE PRESSURE TAP MANIFOLD PRESSURE TAP Fig. 50 Redundant Automatic Gas Valve BURNER ORIFICE A97386 A93059 CAUTION: DO NOT redrill orifices. Improper drilling (burrs, out -of -round holes, etc.) can cause excessive burner noise and misdirection of bumer flames. This can result in flame impingement of burners and heat exchang- ers, causing failures. j. Remove jumpers R- to -W/W 1 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. Fig. 51— Burner Flame TABLE 13— ALTITUDE DERATE MULTIPLIER FOR U.S.A. Derate multiplier factor is based on midpoint altitude for altitude range. A89020 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 for proper input to be clocked. d. Obtain yearly heat value average for local gas supply. NOTE: Be sure heating value of gas used for calculations is correct for your altitude. Consult local gas utility for altitude adjustment of gas heating value. 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 1 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 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 120 300 21 171 343 857 62 116 290 22 164 327 818 64 I0 co 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 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 200 36 100 200 500 92 39 196 37 97 195 486 94 38 192 38 95 189 474 96 38 188 39 92 185 462 98 37 184 40 0 CO fD N W CO C CO CO 180 450 100 36 72 180 41 176 439 102 35 71 178 42 172 429 104 35 69 173 43 167 419 106 34 68 170 44 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 • j. Measure time (in sec) for gas meter to complete I revolution. Note reading. k. Refer to Table 14 for cubic ft of gas per hr, 1. Multiply gas rate cu Mir by heating value (Btu /cu ft). m. Turn setup switch SW -2 to OFF position and jumper 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 ft X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for 1 revolution of 2 -cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 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 f2 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 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 return 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 dente 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 Fumaces. C. Set Thermostat Heat Anticipator The thermostat heat anticipator must be set to match the amp draw of components in the R-W/W1 circuit. Accurate amp draw measurements can be obtained at the thermostat subbase terminals R and W. Fig. 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. I. To operate furnace in low heat, turn setup switch SW -2 to ON position (See Fig. 25) and connect ammeter leads across thermostat subbase R -W. 2. See thermostat manufacturer's instructions for adjusting,the heat anticipator and for varying heating cycle length. 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. EXAMPLE: 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 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— oia 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 12 -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 I. Put away tools and instruments. Clean up debris. 2. Verify manual reset switch has continuity. 3. Verify that blower and control access doors are properly, installed. 4. Cycle test furnace with room thermostat. 5. Check operation of accessories per manufacturer's instruc- tions. 6. Review User's Manual with owner. 7. Leave literature packet near furnace. 4 r ) 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 ~ , THIS ,______LESS CLEAR THIS NOTICE IT IS DUE TO THE QUALITY OF THE DOCUMENT. r 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 desaiptions 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. Monis St. Indianapolis. IN 46231 -48- A94328 Printed in U.S.A. 355m409 Catalog No. 5335 -515 alance Due: Need 'Current Contractor Registration Card: Need to Enter Contractor Information in Sierra: (]Yes 'No i.�a_s1�s;YSi?,a�3dca�4 `s ?l�V2i,•':.�wi� :�.+- �5'- ,t4:�r..�