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Permit M98-0197 - RUFFING RON
c?7 City of Tukwila ( Permit No: M98 -0197 Type: B -MECH Category: RES Address: 14243 58 AV S Location: Parcel #: 336590 -0745 Contractor License No: NORTHWH103R2 INSTALL FURNACE WITH GAS PIPING. Permit Center Authorized Signature The granting of this permit or cancel the provisions construction or the per obtain this' building p Signature: Print Name: MECHANICAL PERMIT Date UMC Edition: 1997 Valuation:_ Total Permit Fee: 1rrz1 -� is? (206) 431 -3670 Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188 Status: ISSUED Issued: 10/21/1998 Expires: 04/19/1999 TENANT RON RUFFING 14243 58 AV S, TUKWILA WA 98168 OWNER RUFFING RONALD R Phone: (206) 965 -7628 14243 58TH AVE S, TUKWILA WA 981684526 CONTRACTOR NORTHWEST WATER HEATER, INC. Phone: 206 282 -4700 2800 THORNDYKE AVENUE WEST, SEATTLE, WA 98199 CONTACT MOLLY Phone: 206 -282 -4700 NORTHWEST WATER HEATER, 2800 THORNDYKE AV W, SEATTLE WA 98199 ************************* k****************** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * ** Permit Description: 500.00 47.88 **********************.************** * * * * * * * * * * * * * * * * * * ** * * * * * * * * * ** I hereby certify that I have read and examined this permit and know the same to be true and correct. All provisions of 'Iaw and ordinances governing this work will-be complied with, whether specified herein or not. not sume to give authority to violate ate or local laws regulating I am authorized to sign for and KED 240 Date: L Title: This permit shall become null and void if the work:is' not commenced within 180 days from the date of issuance, or if the work is suspended or abandoned for a period of 180 days from the. :Last inspection. Project Name/Tenant: r—"Af6'---- Will there be storage of flammable /combustible hazardous material in the building? ❑ yes ❑ no Attach list of materials and storage location on se•arate 8 1/2 X 11 •a•erindicatin. • uantities & Material Safet Data Sheets Value of Construction / J_ Site Address: Cit St.te/ ip: Tax Pargel N r;•er: -- Address: Property Owner: d PhT °,� oe -c,2, X _ / V �_" Street Address 0 Standby City State /Zip: Fax #: Contact Person: UL ( r 2s7.2._ �� Street Address: City State /Zip: Fax #: Contractor: / P g2e;� �,���� Street d dress: _. , _ ■ Aitgye3Zip: Fax #: Architect: Phone: Street Address: City State /Zip: Fax #: Engineer: Phone: Street Address: City State /Zip: Fax #: MISCELLANEOUS PERMIT REVIE AN ' APPROVAL REQUES, EDt (TO BE FILLED OUT BY APPLICANT) Description of work to be done: ii rim_ l/ l lI t ,. Will there be storage of flammable /combustible hazardous material in the building? ❑ yes ❑ no Attach list of materials and storage location on se•arate 8 1/2 X 11 •a•erindicatin. • uantities & Material Safet Data Sheets ■ Above Ground Tanks ■ Antennas /Satellite Dishes ■ Bulkhead /Docks ■ Commercial Reroof ❑ Demolition ❑ Fence ❑ Mechanical ❑ Manufactured Housing - Replacement only ❑ Parking Lots ❑ Retaining Walls ❑ Temporary Pedestrian Protection /Exit Systems ❑ Temporary Facilities ❑ Tree Cutting MONTHLY SERVICE. BILLINGS TO: Name: Phone: Address: I City /State /Zip: r 0 Water 0 Sewer 0 Metro 0 Standby CITY OF rUKWILA Permit Cent& 6300 Southcenter Boulevard, Suite 100 Tukwila, WA 98188 (206) 431 -3670 FIR STAFF USE ONLY Project Number: Permit Number: teltiditi Miscellaneous Permit Application Application and plans must be complete in order to be accepted for plan review. Applications will not be accepted through the mail or facsimile. APPLICANT REQUEST FOR MISCELLANEOUS PUBLIC WORKS PERMITS ❑ Channelization /Striping ❑ Flood Control Zone ❑ Landscape Irrigation ❑ Storm Drainage ❑ Water Meter /Exempt # ❑ Water Meter /Permanent # ❑ Water Meter Temp # ❑ Curb cut /Access /Sidewalk ❑ Fire Loop /Hydrant (main to vault) #: Size(s): ❑ Land Altering: 0 Cut cubic yards 0 Fill cubic yards 0 sq. ft.grading /clearing ❑ Sanitary Side Sewer It: ❑ Sewer Main Extension 0 Private 0 Public ❑ Street Use ❑ Water Main Extension 0 Private 0 Public Size(s): 0 Deduct 0 Water Only Size(s): Size(s): Est. quantity: gal Schedule: ❑ Miscellaneous ❑ Moving Oversized Load /Hauling WATER METER DEPOSIT /REFUND BILLING: Name: Address: City /State /Zip: Phone: Value of Construction - In all cases, a value of construction amount should be entered by the applicant. This figure will be reviewed and is subject to possible revision by the Permit Center to comply with current fee schedules. Expiration of Plan Review - Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The building official may extend the time for action by the applicant for a period not exceeding 180 clays upon written request by the applicant as defined in Section 107.4 of the Uniforrn Building Code (current edition). No application shall be extended more than once. Dale applic tt accepted: - C37912 MISCPMT.DOC 7/11/96 Date applpa on 2KOres9 L i Appllc�fle by: (Initials) BUILDING OWNER OR AUT.i• MS:1=111111EW , ❑ Above Ground Tanks/Water:Tanks - Supported directly 'upon grade exceeding 5,000 gallons and a ratio of height to diameter or width which exceeds 2:1 Signature: ❑ Antennas /Satellite Dishes Alirdta_ / /�� M Dat ! ∎∎• c i n IND ,Fax #: d 4 f , Print name: i n Commercial Reroof Submit checklist No M =6 . �� ����'� - Address: �--, 10, Fences - Over 6 feet in Height AMIN - i ' 1` t'11�e.�ir.V1�✓ r •iI • r APPLICATIONS MUST BE SUBMITTED WITH THE FOLLOWING: ➢ ALL DRAWINGS SHALL (. AT A LEGIBLE SCALE AND NEATL DRAWN ➢ 11(flt:DING NL4NS AND UTILITY PLANS ARE TO BE COMBINED ➢ 'AI1CWIY CTURAC'DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED ARCHITECT ➢ STRUCTURAL CALCULATIONS AND DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED STRUCTURAL ENGINEER ➢ CIVIL/SiTE PLAN DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED CIVIL ENGINEER (P.E.) ❑ 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, unless the homeowner will be the builder OR submit Form H -4, "Affidavit in Lieu of Contractor Registration ". Building Owner /Authorized Agent if the applicant is other than the owner, registered, arctlitecbengineer, 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. MISCPMT.DOC 7/11/96 r SUBMIT APPLICATION AND REQUIRED CHECKLISTS FOR PERMIT REVIEW ❑ Above Ground Tanks/Water:Tanks - Supported directly 'upon grade exceeding 5,000 gallons and a ratio of height to diameter or width which exceeds 2:1 Submit checklist Nq: M=9 ❑ Antennas /Satellite Dishes Submit checklist ' No M -1 ' in Awnings /Canopies - No signage Commercial Tenant Improvement Permit i n Bulkhead/Dock Submit checklist No M =10 i n Commercial Reroof Submit checklist No M =6 . ❑ Demolition Submit checklist No 'M'- 3, M 3a . ❑ Fences - Over 6 feet in Height Submit checklist No: M -9 i n Land Altering/Grading/Preloads Submit checklist No: M -2 ❑ Loading Docks Commercial Tenant Improvement Permit. Submit checklist No: H-17 ❑ Mechanical (Residential & Commercial) Submit checklist No ' M-8;' Residential only - H -6, H -16 Submit checklist' No H =9 El Miscellaneous Public Works Permits 21 Manufactured Housing' (RED INSIGNIA ONLY) Submit checklist No M -5' in Moving Oversized Load/Hauling Submit checklist . No: M -5 ❑ Parking Lots Submit checklist No: M-4 ❑ Flesidential Reroof - Exempt with following exception: If roof structure to be repaired or replaced Residential Building Permit Submit checklist No:. M - ❑ Retaining Walls - Over 4 feet in height Submit checklist No: M -1" ❑ Temporary Facilities Submit checklist No; M -7 ❑ Temporary Pedestrian Protection/Exit'Systems Submit checklist No M 4 ❑ Tree Cutting Submit checklist No: M -2 r •iI • r APPLICATIONS MUST BE SUBMITTED WITH THE FOLLOWING: ➢ ALL DRAWINGS SHALL (. AT A LEGIBLE SCALE AND NEATL DRAWN ➢ 11(flt:DING NL4NS AND UTILITY PLANS ARE TO BE COMBINED ➢ 'AI1CWIY CTURAC'DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED ARCHITECT ➢ STRUCTURAL CALCULATIONS AND DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED STRUCTURAL ENGINEER ➢ CIVIL/SiTE PLAN DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED CIVIL ENGINEER (P.E.) ❑ 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, unless the homeowner will be the builder OR submit Form H -4, "Affidavit in Lieu of Contractor Registration ". Building Owner /Authorized Agent if the applicant is other than the owner, registered, arctlitecbengineer, 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. MISCPMT.DOC 7/11/96 r Address: 14243 58 AV S Permit No: M98-0197 Suite: Tenant: RON RUFFING Status: ISSUED, type: ti-MECH Appl led: 10/07/1998 Parcel #: 336590-0745 Issued: 10/21/199,8 *******************A******k*.k******************************A**** Permit Conditions: 1. No changes will be made to the plans unless approved by the Architect or Engineer and theTukw414 Building Division. ' 2. All permits, inspecttonp*O*440240,roved plans shall be available at the .190*fepr'fbi to" '04 any con- 'struction. The6,46C6Mentvari,e tostbe'mainte3Odsand avail- :able until ftWO):.>tnspevttopaPyro41 is 0-apteii 3.. All construct to Iff- approved plans and the Uniform Bui140$.14odei0997 Edition),e,AaTand4d;'\Uniform ,Coaeo(1997,Edjon), and Wasfrijfit,0 State Enb'rgy:Coe 9997 E611:ioni 4. Electr,f permit shall be throughupie4a0Angt* State Division of, and alT:eleprical work/011,J'be insp'e'ct 4 edV,; agency (248-6636 of' '''.' 5. MANUFACTURERS INSTALLATION INSTRUCTIONS REOUIRECrOWSITE FOR/j0E, INSPECTORS REVIEW. ,) , 6. Va0OltiofPermit. The — 4.s0ance,Of a permit or aPpro,43. oI,A\ plans, spe'6ificatisarvs:; fcciMput*On'S not he 651i.7,: '..,) 'stOed to be '`a permtt'for',..;Orap',*pyoVal any vloOtiOnWA of4ny,:2f...,,thei:OrovistOnS d*f;the'4UllOngcOde or of le other oriffitaftei-,of-ile pre g140'at4POrly 't.O provisions oftliti G ,,,, ;; co CshaliG valid. / ; , i -- \ . -, i,,k, •. , , 4 , 1 ' 4 ■ , ' \ , . , t:: 4 4 0,1zOl v , i 0 , ) ; .; ,, \ '' /=;' S ' t• ' 4 4 , ".1 vz:10. CITY OF TUKWILA 4 9 6 4' *.1 V4t ittt " 't if e4 g e e e 7 C (� PL���IEW�OUI G SLIP ACTIVITY NUMBER: M9 -01 DATE:. 10 -5 -98 PROJECT NAME:. RON BUFFING 70t Original Plan'Submittal Response to Correction Letter# DEPARTMENTS: tIgn Division 2 ubl ic J DETERMINATION OF COMPLETENESS: (Tues, Thurs) DUE DATE: 10 -8 -98 Complete n Incomplete Comments: TUES /THURS ROUTING: Please Route Approved LI \PR•ROUTE.DOC 6/98 Fire Prevention Structural Approved ❑ Approved with Conditions Routed by Staff (if routed by staff, make copy to master file and enter into Sierra) Response to Incomplete Letter Revision'# After Permit Is Issued ❑ Plannin� ision ❑ Permit Coordinator Not Applicable n No further Review Required REVIEWERS INITIALS: DATE: APPROVALS OR CORRECTIONS: (ten days) DUE DATE: 11 -5 -98 Not Approved (attach comments) ❑ REVIEWERS INITIALS: DATE: CORRECTION DETERMINATION: DUE DATE. Approved with Conditions Not Approved (attach comments) LI REVIEWERS INITIALS: DATE: '01 +*A**+*****A************+*x*********+*+A*4v++++***a**.A*a*A**fA*+a CITY OF TUKNILA. NA TRANSMIT ' +wA°+*o+**+*a+*+;%+*4*a**a++*a*+**+*a++**********^+*A*a+*******^* lRANSNIT Number: R9700852 Amount: 47°88 10/21/9813t44 Payment Method: CHECK Notation: NORTHWEST WATER Init^ ' -..---~-_�~~~-^-�~~~--_----~-~--_-_-_-----~---~-�--~_-_�--_-.--- Permit No: M98-0197 .Type: 8~MECH MECHANICAL PERMIT Parcel No 33659O~0745 SiteAddreeg: 14243 58 AV S � � . ` Total Fees: 4748 . This Payment 47.B8 Total ALL Pmts.: � ` 47.88 Pmts.: `B�lancn: A**a*A**a^***«*t4**0+«k*a+4*11*a**A****+***++++*+**a*+a+aA*++a*** Account Code Description 00p/345.830 PLAN CHECK - gE OOO/321.10O MECHANICAL ~ RrS~^ Amount 9`��8� ° 38.30 ' • ` ' �� �� � P 6-(0.Q J ed116, Tye of-I. peCtion: ) / Ay ddress: ( Sec t-"71 A f. Dat called: ,31 Special instructions: . , Date wante,d: / .0 /If (g a.m. (Fiii) RequAster;, I V( n Phone: ( , r 3. . . (/) 4 INSPECTION NO. CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd, #100, Tukwila, WA. Inspector: pproved per applicable codes. COMM TS: INSPECTION REC9RD Retain a copy with A. .nit I '4 PERMIT NO. (206)431-3670 corrections-required priotkoapproval, Date: A O . . 4 . r - :O . f /.61 4 zji II J $47. REINSOECTION REQUIR ..Prior to inspection, fee must be paid r . ' at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. Receipt No: Date: • • .• • • • installation, start -up, and operating instructions DELUXE 4 -WAY MULTIPOISE FIXED - CAPACITY DIRECT -VENT CONDENSING GAS FURNACE 350MAV Series D .J C:. • - 1 ;A code j of app Dr.te FILE rn:�.ion� a n ci contrz ctor's 1011111► 'I �"/ /MI � L_ N t -Grmit No. II a NOTE: Read the entire instruction manual before starting the installation. This symbol —> indicates a change since the last issue. Index DIMENSIONAL DRAWING SAFETY CONSIDERATIONS Clearances to Combustibles ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS INTRODUCTION APPLICATIONS 4-1-1 '- -- General 4 Upflow Applications 4 -7 Downflow Applications 7 -8 Horizontal Left (Supply -Air Discharge) Applications 8 -9 Horizontal Right (Supply -Air Discharge) Applications 9 -11 LOCATION 11 -12 General 11 -12 Furnace Location Relative to Cooling Equipment 12 Hazardous Locations 12 INSTALLATION 13 -17 Leveling Legs (If Desired) 13 Installation In Upflow and Downflow Applications 13 -15 Installation In Horizontal Applications 15 Filter Arrangement 16 Bottom Closure Panel 16 Gas Piping 17 ELECTRICAL CONNECTIONS 17 -21 115 -v Wiring 17 -18 24 -v Wiring 18 Wiring Diagram 19 Accessories 20 -21 DIRECT VENTING 21 -29 Removal of Existing Furnaces from Common Vent Systems 21 Combustion -Air and Vent Piping 21 -27 Concentric Vent and Combustion -Air Termination Kit Installation 27 -29 Multiventing and Vent Termination 29 CONDENSATE DRAIN 29 -31 General 29 Application 29 Condensate Drain Protection 29 -31 4CT 161996 3 ....3 -4 GPI Saro'N Lynn Maas M an ENERGY STAR Partner, Bryant/Day & Night has determined that this product meets the EN. ER Y STAR guidelines for energy efficiency. CITY OF TUIMILA t , Page 1t;- OVER AIRFLOW Cancels: 11 350M-40-7 s GCER IFIED RATING CERTIFIED ama AV AIRFLOW • CERTIFICATE N0. FM 29852 AIRFLOW Fig. 1— Multipoise Orientations 11 350M -40 -8 12-96 APPROVALS ISO 9001 EN 29001 8S 5750 PART 1 ANSI/ASOC 091 CERTIFICATION OF MANUFACTURING SITE HORIZONTAL 0 RIGHT AIRFLOW A93041 SEQUENCE OF OPERATION 31 -33 Heating Mode 31 -32 Cooling Mode 32 Continuous Blower Mode 32 sr Heat Pump Mode 32 "I■si Component Test 32 -33 CZ START -UP PROCEDURES 33 -41 General 33 e t Prime Condensate Trap With Water 33 Purge Gas Lines 34 Adjustments 34 -41 Set Gas Input Rate NETUICVWIL.A 34 -40 Set Temperature Rise Adjust Blower Off Delay (Heat 11M 0 199B 40 -41 41 Set Thermostat Heat Anticipator 41 CHECK SAFETY CONTROLS Fli'1 OENTER 41 Check Primary Limit Control 41 Check Pressure Switch 41 CHECKLIST 41 - 42 UNIT SIZE A D E 024040 17-1/2 15 -7/8 16 036040 17-1/2 15 -7/8 16 024060 17 -1/2 15 -7/8 16 036060 17 -1/2 15 -7/8 16 048060 17 -1/2 15 -7/8 16 036080 17-1/2 15 -7/8 16 048080 17 -1/2 15 -7/8 16 060080 21 19 -3/8 19-1/2 048100 21 19 -3/8 19 -1/2 060100 21 19 -3/8 19 -1/2 060120 24 -1/2 22 -7/8 23 060140 24 -1/2 22 -7/8 23 26 26Y1 24 W 22 2-IN. COMBUSTION - AIR CONN 3 DIA GAS CONN 2 -IN. VENT CONN S4 IN. DIA THERMOSTAT ENTRY 22 '1/46 T 14 W ' SIDE INLET TYP 1 . 1 ' 1 — 23 '/1 TYP SIDE INLET 26 TYP • CONDENSATE DRAIN TRAP LOCATION (DOWNFLOW & HORIZONTAL LEFT) DIA POWER CONN itt-IN. DIA ACCESSORY POWER ENTRY CONDENSATE DRAIN TRAP LOCATION (ALTERNATE UPFLOW) 9'Ai TYP CONDENSATE DRAIN LOCATION (UPFLOW) 27 'Ai TYP 24 'h' 1 1731. 29"/» 27 %h' TYP L32 1�i: % 30 TYP AIRFLOW A "hi D 4 r OUTLET DIMENSIONS (IN.) Fig. 2— Dimensional Drawing O O =0 INLET "hi E "hi CONDENSATE DRAIN TRAP LOCATION (DOWNFLOW & HORIZONTAL RIGHT) OR ALTERNATE 1/2-IN. DIA GAS CONN NOTES: Minimum retum -air opening at fumace: 1. For 800 CFM- 16 -In. round or 14 x 12 -In. rectangle. 2. For 1200 CFM- 20 -In. round or 14 1 /2 X 19 1 /2 -In. rectangle. 3. For 1600 CFM- 22 -In. round or 14 1 /2 x 23 1 /4 -in. rectangle. 4. For airflow requirements above 1800 CFM, use both side inlets, a combination of 1 side inlet and the bottom, or the bottom only. 1 30 W 18 'A' CONDENSATE DRAIN LOCATION (UPFLOW) DIMPLE LOCATORS FOR HORIZONTAL HANGING °A6' TYP 28 1' 26 'she' 26'/1 22 Vie 19' OUTLET 2 -IN. COMBUSTION - AIR CONN SIDE INLET Si-IN. DIA GAS CONN b4-IN. DIA POWER CONN DIA THERMOSTAT ENTRY „air 2 -IN. VENT CONN 22 "Aa' .1. 4 1 1 I - 0 --- 22'A TYP i Ai 24 "Ai BOTTOM INLET • • 34, 391' A93023 J ' This forced air fumace is equipped for use with natural gas at altitudes 0 - 10,000 it (0 - 3,050m), except 140 size Fumaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m). An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications. This direct -vent, forced -air fumace is for Indoor installation in a building constructed on site or in a manufactured (mobile) home when using factory authorized kit, see rating plate. This furnace may be installed on combustible flooring in alcove or closet at minimum clearance from combustible material. This appliance requires a special venting system. Refer to the installation instructions for parts list and method of installation. This fumace is for use with schedule -40 PVC, PVC -DWV, or ABS -DWV pipe, and must not be vented in common with other gas -fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials). MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION TOP / PLENUM BOTTOM SIDES BACK FRONT VENT INSTALLATION 1 0 0 0 tt 3* 0 UPFLOW 1 t 0 0 tt 3* 0 DOWNFLOW 1 0 0 1§ 0 tt 3* 0 HORIZONTAL For Installation on combustible floors only when installed on special base No. KGASB0201ALL, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC. Clearance shown is for air inlet and air outlet end. Horizontal position: Line contact is permissible only between lines formed by intersections of top and two sides of fumace jacket, and building joists, studs, or framing. 0 120 and 140 size Furnaces require 1 inch bottom clearance to combustible materials. * Minimum front clearance for service 30 inches (762mm). tt 140 size Fumaces require 1 inch back clearance to combustible materials. . 323855 -101 REV. A (LIT) J SAFETY CONSIDERAT.4S 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. —3 Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54 -1996 /ANSI Z223.1 -1996 and the Installation Standards, War Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B. In Canada, refer to the current edition of the National Standard of Canada CAN /CGA- B149.1- and .2 -M95 Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls. Recognize safety information. This is the safety -alert symbols . When you see this symbol on unit or in instructions and manuals, be alert to potential for personal injury. Understand the signal words DANGER, WARNING, and CAU- TION. These words are used with the safety -alert symbol. DAN- GER identifies most serious hazards which will result in severe 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. — Fig. 3— Clearances to Combustibles ELECTROSTA(.. 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. 5. Use this procedure for installed and uninstalled (un- grounded) furnaces. (L. A96313 6. Before removing a new control from its container, dis- cha,rgp your body's electrostatic charge to ( .d to protect the control from damage. If the control is to DC 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 -4 The model 350MAV, Series D Furnaces are available in sizes 40,000 through 138,000 Btuh input capacities. —4 The 350MAV Multipoise Condensing Gas -Fired Furnaces are A.G.A. /C.G.A. certified for natural and propane gases and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The fuse is fact ory- shipp for use with n n An A.G.A. /C.G.A. listed gas conversion kit is required to convert furnace for use with propane gas. She_. - 350MAV 040 through 120 size units are A.G.A. /C.G.A. approved use or ___ en tactory accessory conversion kit is used. The 140 sib unit is NOT approved for use in manufactured (mobile) lioines. These furnaces are suitable for installation in a residence built on site or a manufactured residence completed at final site. The design of this furnace line is NOT A.G.A. /C.G.A. certified for installation in recreation vehicles or outdoors. —3 T furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be Used when installed on combustible matenaT wood'floonng`. Special base is not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGH'T, 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 Instructions User's Information Manual Warranty Certificate Loose Parts Bag includes: Quantity Pressure tube extension 1 Collector box or condensate trap extension tube 1 Inducer housing drain tube 1 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 Vent Pipe Extension 1* * ONLY supplied with some furnaces. Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B. For further information, the NFGC and the NFPA 90B are available from National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209; or from Literature Distribution. Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. Contact Standards Department of Canadian Gas Association, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. Installations must comply,with regulations of serving gas supplier and local building, heati( .)lumbing, or other codes in effect in area in which installation is made. In absence of local codes, installation must conform with NFGC. Canadian installations must be made in accordance with NSCNG- PIC and all authorities having jurisdiction. These instructions cover minimum requirements for a safe instal- lation and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept pace with changing residential construction practices. We require these instructions as a minimum for a safe installation. CAUTION: Application of this furnace should be in- doors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing. Improper installation or misapplication of furnace can require excessive servicing or cause prema- ture component failure. WARNING: Improper installation, adjustment, alter- ation, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory- authorized and listed kits or accessories when modifying this product. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. For accessory installation details, refer to applicable installation literature. APPLICATIONS I. GENERAL Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain and pressure tubes are connected as shown in Fig. 5. See appropriate application instructions for these procedures. 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 Orienta- tion) NOTE: See Fig. 5 or tube routing label on main furnace door to confirm location of these tubes. 1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These tubes can be identified by their connection location • • • • • • BLOWER SHELF Q FURNACE DOOR CONDENSATE TRAP (INSIDE) FIELD 28 1 /4 DRAIN ALTERNATE DRAIN \ CONN TUBE LOCATION CONDENSATE TRAP DRAIN TUBE LOCATION UPFLOW APPLICATIONS SLOT FOR SCREW HORIZONTAL APPLICATION (OPTIONAL) 11/2 SIDE VIEW FRONT VIEW DOWNFLOW AND ALTERNATE EXTERNAL UPFLOW APPLICATIONS 1 WIRE TIE GUIDES (WHEN USED) FRONT VIEW Fig. 4—C and also by a color label on each tube. These tubes are identified as follows: collector box drain tube (blue label), inducer housing drain tube (violet label or molded), relief port tube (green label), and pressure switch tube (pink label). 2. Condensate Trap Drain Tube The condensate trap drain connection must be extended for field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2 or 5.) NOTE: If internal filter is used, drain tube should be located to opposite side of casing of return duct attachment to assist in filter removal. b. Remove and discard casing drain hole plug button from desired side. c. Install drain tube coupling grommet (factory- supplied in loose parts bag) in selected casing hole. d. Slide drain tube coupling (factory- supplied in loose parts bag) through grommet ensuring long end of coupling faces blower. e. Cement 2 factory- supplied 1 /2 -in. street CPVC elbows to the rigid drain tube connection on the condensate trap. (See Fig. 5.) These elbows must be cemented together and cemented to condensate trap drain connection. NOTE: Failure to use CPVC elbows may allow drain to kink and prevent draining. CONDENSATE TRAP FURNACE SIDE 1 SIDE VIEW 4 7 /e FURNACE DOOR FURNACE SIDE V4 OD COLLECTOR BOX TO TRAP RELIEF PORT 1 OD INDUCER HOUSING DRAIN CONNECTION sift 00 COLLECTOR BOX DRAIN CONNECTION SCREW HOLE FOR UPFLOW OR DOWN - FLOW APPLICATIONS (OPTIONAL) 1/2-IN. PVC OR CPVC 26 FIELD DRAIN CONN END VIEW FRONT VIEW HORIZONTAL APPLICATIONS 3 /4 4 A93026 ondensate Trap f. Connect larger diameter drain tube and clamp (factory- supplied in loose parts bag) to condensate trap and clamp securely. g. Route tube to coupling and cut to appropriate length. h. Attach tube to coupling and clamp securely. C. Condensate Trap Location (Alternate Upflow Orientation) An alternate location for the condensate trap is the left -hand side of casing. (See Fig. 2 and 6.) NOTE: If the alternate left -hand side of casing location is used, the factory- connected drain and relief port tubes must be discon- nected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for tubing attachment. To relocate condensate trap to the left -hand side, perform the following: 1. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole, (See Fig. 2 or 6.) 4. Install casing hole filler cap into blower shelf hole where trap was removed, , 5. Install condensate trap into left -hand side casing hole by inserting tube connection .stubs through casing hole and rotating until tabs snap into locking position. PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) INDUCER HOUSING (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX DRAIN TUBE) COLLECTOR BOX DRAIN TUBE (BLUE) FIELD - INSTALLED FACTORY - SUPPLIED DRAIN TUBE COUPLING (LEFT DRAIN OPTION) FIELD- INSTALLED FACTORY-SUPPLIED DRAIN TUBE FIELD - INSTALLED FACTORY - SUPPLIED 1/2-IN. CPVC STREET ELBOWS (2) FOR LEFT DRAIN OPTION FIELD-INSTALLED FACTORY-SUPPLIED DRAIN TUBE COUPLING (RIGHT DRAIN OPTION) A96194 Fig. 5— Factory- Shipped Upflow Tube Configuration (Shown With Blower Access Panel Removed) D. Condensate Trap Tubing (Alternate Upflow Orientation) NOTE: See Fig. 6 or tube routing label on main furnace door to confirm location of these tubes. 1. Collector Box Drain Tube Connect collector box drain tube (blue label) to condensate trap. NOTE: On 17- 1 /2 -in. wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring. 2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing drain tube which was previously connected to conden- sate trap. b. Use inducer housing drain extension tube (violet label and factory- supplied in loose parts bag) to connect LOWER inducer housing drain connection to the con- densate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. 3. Relief Port Tube a. Connect relief port tube (green label) to condensate trap. a 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. PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (BLUE) CONDENSATE --so- TRAP INDUCER HOUSING DRAIN TUBE (VIOLET) O O , A96195 Fig. 6-- Alternate Upflow Tube Configuration acid Trap Location 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 sect for recommenda- tions and procedures. III. DOWNFLOW APPLICATIONS A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and conditioned air is discharged downwards. A. Condensate Trap Location The condensate trap must be removed from the factory- installed blower shelf location and relocated in selected application location as shown in Fig. 2, 7, or 8. To relocate condensate trap from the blower shelf to desired location, perform the following: 1. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole. (See Fig. 2, 7, or 8.) 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Install condensate trap into desired casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position. B. Condensate Trap Tubing NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections. 1. Collector Box Drain Tube a. Remove factory- installed plug from LOWER collector box drain tube (blue and white striped label). b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was connected to condensate trap. COLLECTOR BOX DRAIN TUBE (BLUE) CAP PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) COLLECTOR BOX —4 DRAIN TUBE (BLUE & WHITE STRIPED) a COLLECTOR BOX ^ EXTENSION TUBE CONDENSATE -- -► TRAP 0 INDUCER HOUSING DRAIN TUBE (VIOLET) Fig. 7— Downflow Tube Configuration (Left -Hand Trap Installation) A96198 —7— c. Connect t ()WER collector box drain connection to condens.f ap. (1.) Condensate Trap Located on Left Side of Casing (a.) Connect LOWER collector box drain tube (blue and white striped label) to condensate trap. Tube does not need to be cut. (b.) Clamp tube to prevent any condensate leakage. (2.) Condensate Trap Located on Right Side of Casing (a.) Install drain tube coupling (factory- supplied in loose parts bag) into collector box drain tube (blue and white striped label) which was pre- viously plugged. (b.) Connect larger diameter drain tube (factory- supplied in loose parts bag) to drain tube coupling, extending collector box drain tube for connection to condensate trap. —� (c.) Route extended collector box drain tube di- rectly from collector box drain to condensate trap as shown in Fig. 8. (d.) Determine appropriate length and cut. (e.) Connect to condensate trap. (f.) Clamp tube to prevent any condensate leakage. 2. Inducer Housing Drain Tube a. Remove factory- installed cap and clamp from LOWER inducer housing drain connection. b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to conden- sate trap. c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed. DRAIN TUBE Apr COUPLING 0 0 PLUG CAP Fig. 8— Downflow Tube Configuration (Right -Hand Trap Installation) COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX EXTENSION TUBE INDUCER HOUSING DRAIN TUBE (VIOLET) CONDENSATE TRAP COLLECTOR BOX EXTENSION DRAIN TUBE A98197 d. Use , housing drain tube (violet and factory- suppl,^'1 in loose parts bag) to connectLvWER inducer heevin>t drain connection to the condensate trap. e. Conn'' inducer housing drain connection to condensate trap. wrdensate Trap Located on Left Side of Casing Determine appropriate length and cut. 0, I Connect tube to condensate trap. Clamp tube to prevent any condensate leakage. t „ ,rdensate Trap Located on Right Side of Casing t „ Route inducer housing drain tube (violet label) directly from inducer housing to condensate trap as shown in Fig. 8. ( 1, I Determine appropriate length and cut. t ,. Connect tube to condensate trap. o f t Clamp tube to prevent any condensate leakage. 3. Relief VIII t 'l'ube Refer to l' Switch Tubing section for connection procedtul C. CondenAa Trap Field Drain Attachment Refer to Corttivtj4 +ite Drain section for recommendations and procedures. D. Pressure (*witch Tubing (1.) ( One collector hog the pressure swill applications. T111.1 condensate trail tube (green lahrl t trap relief port switch in DOWN Iressure tube (pink label) is factory connected to II for use when furnace is installed in UPFLOW tube MUST be disconnected and used for the .lief port tube. The other collector box pressure which was factory connected to the condensate ifinection MUST be connected to the pressure I LOW or HORIZONTAL RIGHT applications. PLUG — AUXILIARY "J" BOX RELOCATED HERE CONDENSATE TRAP CAP COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) COLLECTOR BOX EXTENSION DRAIN TUBE COLLECTOR BOX EXTENSION TUBE DRAIN TUBE COUPLING COLLECTOR BOX TUBE (PINK) Fig. 9— Horizontal Left Tube Configuration —8— NOTE: See Fig. 7 or 8( ibe 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. —3 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. —3 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. COLLECTOR BOX TUBE (GREEN) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX DRAIN TUBE (BLUE) A98198 • ,CAUTION: Local codes may reqt( . drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling. NOTE: In Canada, installations shall be in accordance with current NSCNGPIC and/or local codes. NOTE: The auxiliary junction box (J -Box) MUST be relocated to opposite side of furnace casing. (See Fig. 9.) See Electrical Connection section for J -Box relocation. A. Condensate Trap Location The condensate trap must be removed from the factory- installed blower shelf location and relocated in selected application location as shown in Fig. 2 or 9. To relocate condensate trap from the blower shelf to desired location, perform the following: l. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 9.) 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position. B. Condensate Trap Tubing NOTE: See Fig. 9 or tube routing label on main furnace door to check for proper connections. 1. Collector Box Drain Tube a. Install drain tube coupling (factory- supplied in loose parts bag) into collector box drain tube (blue label) which was previously connected to condensate trap. b. Connect large diameter drain tube and clamp (factory- supplied in loose parts bag) to drain tube coupling, extending collector box drain tube. c. Route extended tube (blue label) to condensate trap and cut to appropriate length. d. Clamp tube to prevent any condensate leakage. 2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing drain tube which was previously connected to conden- sate trap. b. Use inducer housing drain extension tube (violet label and factory- supplied in loose parts bag) to connect LOWER inducer housing drain connection to the con- densate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. 3. Relief Port Tube —4 a. Extend collector box tube (green label) which was previously connected to the condensate trap by splicing to small diameter tube (factory- supplied in loose parts bag). b. Route extended collector box pressure tube to relief port connection on the condensate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage. —9— C. Condensaf Trap Field Drain Attachment Refer to Conded. ace Drain section for recommendations and procedures. D. Pressure Switch Tubing The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected, extended, rerouted, and then reconnected to the pressure switch in HORIZONTAL LEFT applications. NOTE: See Fig. 9 or tube routing label on main furnace door to check for proper connections. Modify tube as described below. 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. 2. Use smaller diameter tube (factory- supplied in loose parts bag) to extend tube disconnected in item 1. 3. Route extended tube: a. Behind inducer housing. b. Between blower shelf and inducer housing. c. Behind inducer motor bracket. d. Between inducer motor and pressure switch. 4. Determine appropriate length, cut, and reconnect tube to pressure switch connection labeled COLLECTOR BOX, E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. F. Construct a Working Platform Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.) CAUTION: The condensate trap MUST be installed below furnace. See Fig. 4 for dimensions. The drain connection to condensate trap must also i 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. CAUTION: Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling. NOTE: In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes. 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: MANUAL SHUTOFF GAS VALVE SEDIMENT TRAP COMBUSTION — AIR INTAKE -- CONDENSATE TRAP Fig. 10 —Attic Location and 1. Remove 3 tubes connected to condensate trap. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 11.) 4. Install casing hole filler cap into blower shelf hole where trap was removed. 5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position. B. Condensate Trap Tubing NOTE: See Fig. 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. VENT 4---- A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM 30" MIN EXITING THE VENT PIPE. WORK AREA DRAIN NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS. ACCESS OPENING FOR TRAP A93031 Working Platform c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed, d. Use inducer housing drain extension tube (violet label and factory- supplied in loose parts bag) to connect LOWER inducer housing drain connection to conden- sate trap. e. Determine appropriate length, cut, and connect tube to condensate trap. f. Clamp tube to prevent any condensate leakage. 3. Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure. C. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. D. Pressure Switch Tubing One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications, NOTE: See Fig. 11 or tube routing label on main furnace door to check for projerconnections. Relocate tubes as described below. 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. COLLECTOR BOX DRAT . (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE Fig. 11— Horizontal Right Tube Configuration —3 2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connec- tion by splicing to small diameter tube (factory- supplied in loose parts bag). 3. Route extended collector box pressure tube behind inducer motor bracket then between inducer motor and pressure switch. 4. Connect collector box pressure tube (green label) to pres- sure switch connection labeled COLLECTOR BOX. 5. Use remaining smaller diameter tube (factory- supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch. 6. Route this extended tube (pink label) to condensate trap relief port connection. 7. Determine appropriate length, cut, and connect tube. 8. Clamp tube to relief port connection. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda- tions and procedures. F. Construct a Working Platform 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.) 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 4ucts 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. UPFLOW OR DOWNFLOW CONDENSATE TRAP LOCATION LEVEL (0") 1 /z" MAX HORIZONTAL A96199 FRONT 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. Locate furnace as close to center of air distribution system as possible. Locate furnace so combustion -air pipe maximum lengths are not exceeded. Refer to Table 6. 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. A93043 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. CAUTION: If these furnaces are used during construc- tion when adhesives, sealers, and/or new carpets are being installed, make sure all combustion and circulating air requirements are followed. If operation of furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine, when burned with combustion air, form acids which will cause corrosion of heat exchangers. Some of these compounds are found in paneling, dry wall adhe- sives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems. 32 °F M NIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED A93058 CAUTION: If these furnaces are installed in an uncon- ditioned space where ambient temperatures may be 32 °F or lower, freeze protection measures must be taken. Provide ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on unit's clear- ance to combustibles label. (See Fig. 3.) Locate furnace where available electric power and gas supplies meet specifications on furnace rating plate. H. FURNACE LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on downstream side of furnace to avoid condensation in heat exchanger. When installed parallel with a furnace, dampers or other means used to control flow of air must prevent chilled air from entering furnace. If dampers are manually operated, they must be equipped with a means to prevent operation of either unit unless damper is in full -heat or full -cool position. III. HAZARDOUS LOCATIONS 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. • INSTALLATIO'i. I. LEVELING LEGS (IF DESIRED) When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 12.) Install field- supplied, corrosion - resistant 5 /16 -in. machine bolts and nuts. A89014 Fig. 12-- Leveling Legs NOTE: The maximum length of bolt should not exceed 1 -1/2 in. 1. Position furnace on its back. Locate and drill a 5 /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.) 1 Install another nut on other side of furnace base. (Install flat washer if desired.) 4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement. NOTE: Bottom closure must be used when leveling legs are used. See Bottom Closure Panel section. —4 II. INSTALL'' ON IN UPFLOW OR DOWNFLOW APPLICATIONS NOTE: For downflow applications, this furnace is approved for use on combustible flooring when special base (available from manufacturer) Part No. KGASB0201ALL is used. Special base in not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is used. 1. Determine application being installed from Table 1. 2. Construct hole in floor per dimensions specified in Table 1 and Fig. 13. 3. Construct plenum to dimensions specified in Table 1 and Fig. 13. 4. If downflow subbase (KGASB) is used, install as shown in Fig. 14. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 15. NOTE: Remove furnace perforated, discharge duct flanges when they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.) a WARNING: Do not bend duct flanges inward as shown in Fig. 16. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 16. NOTE: For 140 size unit when installed in downflow orientation, cut the white jumper wire off between terminals PL1 -6 and PL1 -9. Refer to Fig. 24 for location of jumper. Cut jumper close to connector and remove wire to avoid a short circuit. 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 Furnace with or without CD5 or CK5 Coll Assembly or KCAKC Coil Box 15 -1/8 19 16 -3/4 20-3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace 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 Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coll 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 Coil Box 19 19 20 20 24-1/2 Upflow Applications 23 24-1/8 23 -5/8 24 -3/4 Downflow Applications on Non - Combustible Flooring 22 -7/8 •• 19 23-1/2 19-5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 -1/8 19 23-3/4 20 -3/8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 22-1/2 19 23-1/2 20 t' FURNACE (OR COIL CASING WHEN USED) COMBUSTIBLE FLOORING \\\\\) D S BBA SE SHEET METAL FLOOR -..J OPENING A96285 Fig. 14— Furnace, Plenum, end Subbase Installed on a Combustible Floor A96283 Fig. 13 —Floor and Plenum Opening Dimensions TABLE 1— OPENING DIMENSIONS (IN ) FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM OPEN R ti A96284 Fig. 15— Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor • r PERFORATED DISCHARGE DUCT FLANGE (B) 210° MIN Fig. 16 —Duct Flanges L - - I I ANGLE --� IRON OR EQUIVALENT r (B) ALTERNATE ROD LOCATION III. INSTALLATION IN HORIZONTAL APPLICATIONS --3 These furnaces can be installed horizontally in either horizontal left or right discharge position. In a crawlspace, furnace can either NO 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.) YES YES A93029 (A) ROD LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL 3 /a -IN. HEX NUT–/ (A) DWG FOR & WASHER (4) LOCATIONS) REQD PER ROD 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. 1 (A) (B) 2 Fig. 17— Crawlspace Horizontal Application sib -IN. ROD 13 /18-IN. MAX (B) ALTERNATE SUPPORT LOCATION FROM BACK (A) PREFERRED ROD LOCATION 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. ALTERNATE SUPPORT LOCATION 4 -IN. MIN 8 -IN. MAX A93304 FURNACE CASING WIDTH (IN.) FILTER SIZE (IN.)* FILTER TYPE FRAMED Side Return Bottom Return 17-1/2 (1) 16 X 25 X 1t (1) 16 X 25 X 1 Cleanable 21 (1) 16 X 25 X 1 (1) 20 X 25 X if Cleanable 24 - 1/2 (2) 16 X 25 X if (1) 24 X 25 X 1 Cleanable t' , IV. FILTER ARRANGEMENT 0 CAUTION: Never operate unit without a filter or with blower access panel removed. Factory- supplied washable framed filters arc shipped in blower compartment. Determine location for filter and relocate filter retaining wire if necessary. See Table 2 to determine correct filter size for desired filter location. Table 2 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings. TABLE 2— FILTER INFORMATION Filters can be field modified by cutting frame as marked and folding to desired size. Alternate sizes can be ordered from your distributor or dealer. t Factory-provided with furnace. CAUTION: Air delivery above 1800 CFM requires that both sides, a combination of 1 side and bottom, or bottom only of furnace be used for return air. NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 18. WASHABLE FILTER FILTER RETAINER A93045 Fig. 18— Filter Installed for Side Inlet Bottom return-air opening may be used with all 4 orientations. Filter may need to be cut to fit some furnace widths. Install filter as shown in Fig. 19. NOTE: Remove and discard bottom closure panel when bottom inlet is used. V. BOTTOM CLOSURE PANEL These furnaces are shipped with bottom enclosure panel installed in bottom return-air opening. This panel MUST be in place when side return air is used. 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. 171/2-IN. WIDE CASINGS ONLY: INSTALL FIELD - SUPPLIED FILTER FILLER STRIP UNDER FILTER. 24 I/2" FRONT FILLER PANEL FILTER SUPPORT Fig. 19— Bottom Filter Arrangement 24 -IN. WIDE CASINGS ONLY: CUT AND FOLD FACTORY - PROVIDED FILTERS AS SHOWN TO DESIRED SIZE. FILTER RETAINER WASHABLE FILTER BOTTOM CLOSURE PANEL Fig. 20— Removing Bottom Closure Panel A96030 A93047 • • NOMINAL IRON PIPE INTERNAL DIAMETER LENGTH OF PIPE (FT) SIZE (IN.) 10 20 30 40 50 (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 VI. LUAS YtY%P4U Gds 'piping must be installed in accordanL .vith national and local codes. Refer to current edition of NFGC. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 3 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas. CAUTION: Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls. 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 tire, explosion, personal injury, or death. 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 -1996. 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.) CAUTION: If a flexible connector is required or al- lowed by authority having jurisdiction, black iron pipe shall be installed at gas valve and extend a minimum of 2 in. outside furnace casing. An accessible manual shutoff valve MUST be installed upstream of furnace gas controls and within 6 ft of furnace, A 1 /8 -in, NPT —17— GAS SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION A93324 Fig. 21— Typical Gas Pipe Arrangement 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. 45.) Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace is attached. In Canada, refer to current edition of NSCNGPIC. If pressure exceeds 0.5 psig (14 -in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14 -in. wc), turn off electric shutoff switch located on gas valve before test. It is recommended that ground joint union be loosened before pressure testing. After all connections have been made, purge lines and check for leakage. 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. WARNING: Blower access panel door switch opens 115 -v power to control center. No component operation can occur. Do not bypass or close switch with panel removed. Failure to follow this warning could result in personal injury or death. CAUTION: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. I. 115 -V WIRING Before proceeding with electrical connections, make certain that voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 4 for equipment electrical specifications. Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70 -1996 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.1 or subauthorities having jurisdiction. Use a separate, fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace. See Table 4 for wire size and fuse specifications. A disconnecting means must be located within sight from and readily accessible to furnace. • BLK WH 115 -VOLT FUSED DISCONNECT SWITCH (WHEN REQUIRED) ELECTRIC DISCONNECT SWITCH FIVE WIRE THREE -WIRE HEATING - ONLY AUXILIARY J -BOX CONTROL BOX 24 -VOLT TERMINAL BLOCK FURNACE COPPER WIRE ONLY NOTE 2 —I I L NOTE 1 A93033 CAUTION: Do not connect aluminum wire between © disconnect switch and furnace. Use only copper wire, NOTE: Proper polarity must be maintained for 115 -v wiring. If polarity is incorrect, control center LED status indicator light will flash rapidly and furnace will NOT operate. WARNING: The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSUNFPA 70 -1996 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death. J -BOX RELOCATION 1. Remove 2 screws holding auxiliary J -box. (See Fig. 23.) 2. Rotate J -box 180° and attach box to right side, using holes nrnvirieri NOTES: 1. 2. 3. THERMOSTAT TERMINALS - - -- FIELD 24 -VOLT WIRING - --- FIELD 115 -, 208/230 -, 460 -VOLT WIRING - FACTORY 24 -VOLT WIRING - FACTORY 115 -VOLT WIRING FIELD - SUPPLIED FUSED DISCONNECT • 208/230 - OR -- 460 -VOLT -- THREE PHASE ( - 208/230- SOLI - - SINGLE PHASE Connect Y- terminal as shown for proper operation. Some thermostats require a "C" terminal connection as shown. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire. - a Fig. 22 Heating and Cooling Application Wiring Diagram FACTORY INSTALLED LOCATION 4e Fig. 23— Relocating J -Box A96415 ALTERNATE FIELD LOCATION A93051 CAUTION: If manual disconnect switch is to be 0 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. For proper cooling operation, Y wire from thermo- stat MUST be connected to Y terminal on control center, as shown in Fig. 22, The 24 -v terminal board is marked for easy connection of field wiring. (See Fig. 24.) The 24 -v circuit contains a 3 -amp, automotive -type fuse located on control center. (See Fig. 25.) Any electrical shorts of 24-v wiring during installation, service, or maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of identical size (3 amp). 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 wiry. • • • • Fig. 24— Wiring Diagram A95087 ( PCB sTaz SEE NOTE /10 OFF cm — G R Y W — HUM (WHEN USED) PRS LGPS I _ ORN TO I15VAC FIELD NOTE t4 a DISCONNECT SCHEMATIC DIAGRAM NEUTRAL (NATURAL GAS & PROPANE) EQUIPMENT GROUND (NOT ON ALL MODELS) BLOWER OFF DELAY SELECTION CHART ci 90 SEC .I 135 SEC I = 1 II 180 SEC cm SEC 0 SW1 TES aWIN NOTE 18 YEL iLK •� • I LO i l2 • II-1 MEO LO \ LI BLWR T 2 .� ME HI • /a ` ED I BLU • H� HI S . SPARE -1 BART NOTE S irEi. RED 1 -M 3-P COOL • CAP -/ PLt 3 2 1 0 RED LS FRS • GV .J 2-C ' COM EAGI ■CON C WHT __.. 6 54 9 7 WIlT 0- 0 pill 225 RED EAG II GRN I It • IOM 1 SEC-2 GVR I SEC-EC -2 NOTE 15 I I ) I PL2 2 PL5 a>• wpm BLU .-• BLIL HULO RELAY RED NYEL WHT TOR �)-I I • • I>R1 nsvAC •� • BAN 24 VAC -3A wRr(COMI TRAN -!. O (HI) / j PL3 3 GRN F1111 FUSE I gLI ) BRN (^' 24VAC BRN • I HSIR IDfl BLWR COOL SPARE -1 BLOWER SELECT HEAT SPARE -2 • . • Y NOr CAP •I ( - P1.4 CAP •2 2 2 NOTE +_� • • TESTliWW FUi NOTE #7 J ( J SEC-1 FRS SE G2 LS EAC-1 BLU • LO `` • i• J / BRN L2 & P� NOTE /12 RUM 0 GVR 2 I t• I 7 Ilk Ilik Pl2 '� 1 °f r MR= RED (LO) BLVNM �..) 120 VAC 0 LL7 PRI �— I NlO 1; ■ ■ L• 2 _ Q 2 3 I-- 3 3 EAC-2 pR2 Ca" I . �vHr 1 0 , LGPS : " 'o- (WHEN USE D) Nib m ¢ WHT W 0 I I 8LK CD r ® I p � TE 18 PLt I 0 CAP -2 SWITCH DISCONNECT (WHEN RECTO) 7 U III 2(3I PL4 8RN WHT 4 � BRN 1 2 J I - _ - • IDM GRN • ILK NEUTRAL WHi 11 �_ / r i ' FU2 � �' Lt � i — • • HSI OALUA BU C •�• GRN 4 • C� GVR-1 3- P • Gy 2 , a Ny1 __, y g NOTE 15 J. -EGEND PL1 9.ORCUITCONNECTOR c 2 r i s S Co• O FEE BLWR BLOWER MOTOR RELAY, SPST•(N.0.) P12 2 -ORCUT PCB CONNECTOR BLWM BLOWER MOTOR P13 3-CIRCUIT IDM CONNECTOR CAP CAPACITOR P1.4 3-CIRCUIT IDM EXTENSION CONNECTOR CPU MICROPROCESSOR AND CIRCUITRY PLS 2-CIRCUIT HSYPCB CONNECTOR EAC-1 ELECTRONIC AIR CLEATER CONNECTION (115 VAC 15 AMP MAX) PRS PRESSURE SNITOI. SPST•(N 0) EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON) SW1 S 2 BLOWER OFF DELAY FRS FLAME ROLLOUT SW. -MANUAL RESET, SPST- (N.C.) TEST/TWIN COMPONENTTEST& TWIN TERMINAL FSE FLAME PROVING ELECTRODE TRAN TRANSFORMER 115VA0224VAC FU1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED FU2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE --ill-- JUNCTION (FIELD INSTALLED & SUPPLIED) a UNMARKED TERMINAL GV GAS VALVE-REDUNDANT OPERATORS OVA GAS VALVE RELAY, DPST{N.O.) — PCB TERMINAL FACTORY WIRING (115VAC) 0--911.- NOTES: I J 9 1. IF ANY OF THE ORIGINAL EQUIPMENT WIRE IS REPLACED USE WIRE RATED FOR 105C. 2. INDUCER (IDM) AND BLOWER (BLWM) MOTORS CONTAIN INTERNAL AUTO - RESET THERMAL OVERLOAD SWITCHES (0L). 3. BLOWER MOTOR SPEED SELECTIONS ARE FOR AVERAGE CONDITIONS, SEE INSTALLATION INSTRUCTIONS FOR DETAILS ON OPTIMUM SPEED SELECTION. 4. USE ONLY COPPER WIRE BETWEEN THE DISCONNECT SWITCH AND THE FURNACE JUNCTION BOX (38). 5. THIS WIRE MUST BE CONNECTED TO FURNACE SHEETMETAL FOR CONTROL TO PROVE FLAME. 6. FACTORY CONNECTED WHEN LGPS NOT USED. 7. REPLACE ONLY WiTH A 3 AMP FUSE. 8. YELLOW LEAD NOT ON ALL MOTORS. 9. BLOWER -ON DELAY, GAS HEATING 60 SECONDS, COOLING OR HEAT PUMP 2 SECONDS. 10. BLOWER -OFF DELAY, GAS HEATING 90.135,180 OR 225 SECONDS, COOLING OR HEAT PUMP 90 SECONDS. (135 SECONDS ONLY ON SOME MODELS) 11. IGNITION-LOCKOUT WILL OCCUR AFTER FOUR CONSECUTIVE UNSUCCESSFUL TRIALS-FOR-IGNii ON. CONTROL WILL AUTO -RESET AFTER THREE HOURS. 12. SOME MODELS MAY HAVE SPADE QUICK CONNECT TERMINALS. 322854 -101 REV. C W&O BLOWER MOTOR SPEED CHANGE RELAY, SPOT SURFACE IGNITOR VAC) FACTORY WIRING (24VAC) I1SI HOT (115 115W HOT SURFACE IGNITOR RELAY, SP5T.( N.O.) --- FIELD HARING (I15YAC) HIM 24VAC INDUCED DR AFT MOTOR ---- HUMIDIFIER CONFECTION (5 AMP. MAX) FIELD WIRING (24VAC) IDM INDUCED DR OR INDUCED DRAFT RELAY. SPST- (N.0.1 CONDUCTOR ON PCB ILK BLOWER ACCESS PANEL INTERLOCK SWITCH. SPST -(N.0) 0 FIELD YARNS TERMINAL JB JUNCTION BOX LED LIGHT EMITTING DIODE FOR STATUS CODES FIELD GROUND LGPS LOW GAS PRESSURE SWITCH. SPST - (N .O.) EQUIP/EN: GROUND LS LIMIT SWITCH, AUTO RESET, SPST(N.C.) - Q - FELD SPLICE OL AUTO -RESET INTERNAL MOTOR OVERLOAD TEMP. SW. PIS PRINTED CIRCUIT BOARD PLUG �` • Fig. 24— Wiring Diagram A95087 UNIT SIZE VOLTS- HERTZ- PHASE OPERATING VOLTAGE RANGE MAX UNIT AMPS UNIT AMPACITYt MIN WIRE SIZE MAX WIRE LENGTH (FT)$ MAX FUSE OR CKT BKR AMPS** Max' Min* 024040 115 -60-1 127 104 6.1 8.4 14 44 15 036040 115 -60-1 127 104 7.3 10.0 14 37 15 024060 115 -60-1 127 104 6.1 8.4 14 44 15 036060 115 -60-1 127 104 7.1 9.8 14 38 15 048060 115 --60 -1 127 104 9.5 12.8 14 29 15 036080 115 -60-1 127 104 7.6 10.4 14 36 15 048080 115 -60-1 127 104 10.0 13.4 14 28 15 060080 115 -60-1 127 104 14.1 18.4 12 31 20 048100 115 -60-1 127 104 10.2 13.5 14 27 15 060100 115 -60-1 127 104 14.8 19.3 12 30 20 060120 115 -60-1 127 104 14.6 19.1 12 30 20 - *080140 115 -60-1 127 104 14.3 18.8 12 30 20 • Permissible limits of voltage range at which unit will operate satisfactorily. t Unit ampacity = 25 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 fuse Is recommended. HI. ACCESSORIES 1. Electronic Air Cleaner (EAC) Two spring clamp terminals (for 12 gage maximum, solid or stranded wire), marked EAC -1 and EAC -2, are provided for EAC connection. (See Fig. 25.) These terminals are energized with 115v (1.5 -amp maximum) during blower motor operation. To connect EAC power leads to furnace control center, strip approximately 1/8 in. of insulation from wire. Open terminal by depressing switch arm with a screwdriver or finger, and insert wire as shown in Fig. 26. SEC -1 3 -AMP FUSE COOL -----„Z HEAT 1 ® { TEST/TWIN 115 -VAC (L1) POWER SUPPLY HOT SURFACE IGNITOR CONNECTOR TABLE 4 ELECTRICAL DATA i---- BLOWER OFF DELAY ADJUSTMENT SWITCH Q l 0 l n R �0� 000 000 a a rl EAC 1 (BLACK) EAC - ELECTRONIC AIR CLEANER TERMINALS (115 -VAC 1.5 AMP MAX) EAC 2 (WHITE) � - 115 -VAC (12) NEUTRAL CONNECTION INDUCER MOTOR CONNECTOR L Fig. 25- Control Center 1 - �-- 24V THERMOSTAT TERMINALS SPARE 1 SPARE 2 2. Humidifier (HUM) 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 inducer motor prepurge period. NOTE: A field supplied, 115 - v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation. HUMIDIFIER TERMINAL (24 -VAC 0.5 AMP MAX) J .. - LED OPERATION & STATUS LIGHT HARNESS CONNECTOR 24V TRANSFORMER SEC -2 BLOWER SPEED SELECTION TERMINALS A93052 • t LOCATION CLEARANCE (FT) U.S.A. Canada Above grade level or above antics- pated snow depth 1 1t Dryer vent 3 3 From plumbing vent stack 3 3 From any mechanical fresh air intake 1 6 For furnaces with an input capacity less than 100,000 Btuh —from any non - mechanical air supply (windows or doors which can be opened) or combustion -air opening 1 1 For furnaces with an input capacity greater than 100,000 Btuh —from any non - mechanical air supply (windows or doors which can be opened) or combustion -air opening 1 3 From service regulator vent, electric and gas meters, and relief equipment 4' 6$ Above grade when adjacent to public walkway 7 7 • • EAC2 A93053 Fig. 26 —EAC Terminals on Control Center DIRECT VENTING The 350MAV Furnaces require a dedicated (one 350MAV furnace only) direct -vent system. In a direct -vent system, all air for combustion is taken directly from outside atmosphere, and all flue products are discharged to outside atmosphere. I. REMOVAL OF EXISTING FURNACES FROM 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, ANSI Z223.I or the CAN /CGA B 149 Installation Codes and these instructions. Determine that there is no blockage or restric- tion, leakage, corrosion, and other deficiencies which could cause an unsafe condition. 3. In so far as is practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 5. Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner opera- tion. Use the flame of a match or candle. 6. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace damp- ers, and any other gas - burning appliance to their previous conditions of use. 7. If improper venting is observed during any of above tests, the venting system must be corrected. Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSC- NGPIC. II. COMBUSTION -AIR AND VENT PIPING A. General Combustion -air and vent pipe fittings must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785 (schedule -40 PVt,, D2665 (PVC -DWV), D2241 (SDR -21 and SDR -26 PVC), D2661 (ABS -DWV), F628 (schedule -40 ABS), or F891 (PVC -DWV cellular core). Pipe cement and primer must conform to ASTM standards D2564 (PVC) or D2235 (ABS). See Table 6 for maximum pipe lengths and Fig. 31, 32, 33, 34, and 35 for exterior piping arrangements. In Canada construct all combustion -air and vent pipes for this unit of CSA or ULC certified schedule -40 PVC, PVC -DWV or ABS -DWV pipe and pipe cement. SDR pipe is NOT approved in Canada. NOTE: Furnace combustion -air and vent pipe connections are sized for 2 -in, pipe. Any pipe size change should be made outside furnace casing in vertical pipe. (See Fig. 27.) This allows proper drainage of vent condensate. FURNACE NOT IN HORIZONTAL SECTION PIPE DIAMETER TRANSITION IN VERTICAL SECTION A93034 Fig. 27— Combustion -Air and Vent Pipe Diameter Transition Location and Elbow Configuration 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. 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 350MAV Furnaces, 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, Furnace cOmliustion -air and vent pipe connectiok .nust be at- tached as shown in Fig. 28. Combustion -air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications. NOTE: Slope combustion -air and vent pipes a minimum of 1/4 in, per linear ft with no sags between hangers. NOTE: Select 1 vont pipe connection and 1 combustion -air pipe connection. AIR COMBUSTION- FLOW COMBUSTION - A R 5 T AIR UPFLOW COMBUSTION - AIR VENT HORIZONTAL -LEFT DISCHARGE VENT NOTE: Select 1 vent pipe connection and 1 combustion -air pipe connection. VENT J 1 COMBUSTION - t' y COMBUSTION- VENT AIR AIR FLOW DOWNFLOW COMBUSTION - AR VENT 1 AIR FLOW HORIZONTAL -RIGHT DISCHARGE A98187 Fig. 28— 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 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 Annaflex -type insulation. CAUTION: Combustion air must not be taken from inside structure because inside air is frequently contami- nated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household prod- ucts. Locate combustion -air inlet as far as possible from swimming pool and swimming pool pump house. Excessive exposure to contaminated combustion air will result in safety and performance related problems. WARNING: Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well - ventilated areas. Avoid breathing in vapor or allow- ing contact with skin or eyes. Failure to follow this warning could result in fire, property damage, personal injury, or death. WARNING: All combustion -air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 31, 32, 33, 34, or 35. Failure to follow this warning could result in property damage, personal injury, or death. NOTE: The minimum combustion -air and vent pipe length (each) for these furnaces is 5 ft. Short pipe lengths (5 -8 ft) may discharge water droplets. These droplets may be undesirable, and a 12 -in. minimum offset pipe section is recommended, as shown in Fig. 29, to reduce excessive droplets from exiting vent pipe outlet. B. Combustion -Air and Vent Pipe Diameter Determine combustion -air and vent pipe diameter. I. Using Table 6, individually determine the combustion -air and vent pipe diameters. Pick the larger of these 2 pipe diameters and use this diameter for both combustion -air and vent pipes. 2. When installing vent systems of short pipe length, use the smallest allowable pipe diameter. Do not use pipe size greater than required or incomplete combustion, flame disturbance, or flame sense lockout may occur. NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 31, 32, 33, 34, and 35. EXAMPLE: An 036080 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed in an application requiring 3 elbows and 32 ft of vent pipe, along with 5 elbows and 34 ft of combustion -air pipe. Table 6 indicates this application would allow a 2 -in. diameter vent pipe, but require a 2 -1/2 in. diameter combustion air pipe (2 -in. pipe is good for 35 ft with 3 elbows, but only 30 ft with 5 elbows). Therefore, 2 -1/2 in. diameter pipe must be used for both vent and combustion -air pipes since larger required diameter must always be used for both pipes. If same installation were in Albuquerque, elevation 5250 ft above sea level, installation would require 2 -1/2 in. vent pipe and combustion -air pipe. At 5001- to 6000 -ft elevation, 2 -in. pipe is only good for 17 ft with 5 elbows, and 2 -1/2 in. pipe is good for 70 ft with 5 elbows. C. Combustion -Air and Vent Pipe Attachment NOTE: All pipe joints must be watertight except attachment of combustion -air pipe to inlet housing connection, since it may be necessary to remove pipe for servicing. 1. Attach combustion -air pipe as follows: a. Determine location of combustion -air intake pipe con- nection to combustion -air intake housing as shown in Fig. 28 for application. b. Reposition combustion -air intake housing plug fitting in appropriate unused intake housing connection. --3 c. If required, insert perforated disk assembly. (factory- supplied in loose parts bag) in intake housing where combustion -air intake pipe will be connected. If half disk set is required, install with shoulder of disk against stop in combustion -air inlet. • • 411ki • • VENT PIPE 12" MIN HORIZONTAL TO ROOF COMBUSTION -AIR PIPE 12" MIN COMBUSTION -AIR PIPE VERTICAL TO ROOF d. Install pipe support (factory- supplied in loose parts bag) into selected furnace casing combustion -air pipe hole. Pipe support should be positioned at bottom of casing hole, e. Insert 2 -in. diameter pipe into intake housing. NOTE: A 2 -in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing. f. Drill a 1 /8 -in. hole in 2 -in. combustion -air pipe using hole in intake housing as a guide. g. Install a field- supplied No. 6 or No. 8 sheet metal screw into combustion -air pipe. NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur. NOTE: Do not attach combustion -air intake pipe permanently to combustion -air intake housing since it may be necessary to remove pipe for service of ignitor or flame sensor. COMBUSTION -AIR INTAKE HOUSING PLUG 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. VENT PIPE VENT PIPE HORIZONTAL TO SIDEWALL COMBUSTION -AIR PIPE VERTICAL TO SIDEWALL NOTE: A 12 In. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. Fig. 29 —Short Vent (5 to 8 Ft) System 12" MIN COMBUSTION -AIR PIPE VENT PIPE A96230 A plugged drain connection has been provided on this fitting for use when moisture is found in combustion -air intake pipe and combustion box. NOTE: Moisture in combustion -air intake may be result of improper termination. Ensure combustion -air intake pipe is similar to that shown in Fig. 31, 32, 33, 34, or 35 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. 30.) 2. Attach vent pipe as follows: a. Determine location of vent pipe connection to inducer housing as shown in Fig. 28 for application. b. Reposition neoprene inducer housing outlet cap and clamp to appropriate unused inducer housing connec- tion. Tighten clamp. ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 0 to 2000 024040 036040 2 Pipe or 2 -In. Concentric 1 5 NA NA NA NA NA 1 -1/2 70 70 65 60 60 55 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2-1n. Concentric 1-1/2 20 15 10 5 NA NA 2 70 70 70 70 70 70 036080 048080 060080 2 Pipe or 2•In. Concentric 1-1/2 10 NA NA NA NA NA 2 55 50 35 30 30 20 2-1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 5 NA NA NA NA NA 2 -1/2 40 30 20 20 10 NA 3 70 70 70 70 70 70 - *060120 2 Pipe or 3 -In. Concentric 2 -1/2 one disk 10 NA NA NA NA NA 3t 45 40 35 30 25 20 3t no disk 70 70 70 70 70 70 4t no disk 70 70 70 70 70 70 - X060140 2 Pipe or 3 -in, Concentric 2 -1/2 one disk 5 NA NA NA NA NA 3t one disk 40 35 30 25 20 15 3t no disk 60 56 52 48 44 40 4t no disk 70 70 70 70 70 70 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 2001 to 3000 024040 036040 2 Pipe or 2 -1n. Concentric 1 -1/2 67 62 57 52 52 47 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2 -In. Concentric 1 -1/2 17 12 7 NA NA NA 2 70 67 66 61 61 61 036080 048080 060080 2 Pipe or 2 -1n, Concentric 2 49 44 30 25 25 15 2 -1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2-1/2 35 26 16 16 6 NA 3 70 70 70 70 66 61 - ►060120 2 Pipe or 3 -In. Concentric 3 14 9 NA NA NA NA 3t no disk 70 70 63 56 50 43 4t no disk 70 70 70 70 70 70 - 3060140 2 Pipe or 3 -In. Concentric 3t one disk 20 15 10 5 NA NA 31* no disk 39 35 31 27 23 19 41 no disk 70 70 70 70 70 70 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 3001 to 4000 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 64 59 _ 54 49 48 43 2 70 70 70 70 70 70 024060 036060 048060 2 pipe or 2 -In. Concentric 1 -1/2 16 11 6 NA NA NA 2 68 63 62 57 57 56 036080 048080 060080 2 Pipe or 2-1n. Concentric 2 46 41 28 23 22 13 2-1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 33 24 15 14 5 NA 3 70 70 70 66 61 56 - ,060120 2 Pipe or 3 -In. Concentric 3t no disk 65 58 51 44 38 31 4t no disk 70 70 70 70 70 70 - 3060140 2 Pipe or 3 -In. Concentric 3t one disk 11 6 NA NA NA NA 3t no disk 30 26 22 18 14 10 4t no disk 70 70 70 70 70 70 See notes on page 26. ( TABLE 6— MAXIMUM ALLOWABLE PIPE LENGTH (FT) It ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (iN.)• NUMBER OF 90° ELBOWS 1 2 3 4 5 6 4001 to 5000$ 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 60 55 50 45 44 39 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2-In. Concentric 1-1/2 15 10 5 NA NA NA 2 64 59 58 53 52 52 036080 048080 060080 2 Pipe or 2-In. Concentric 2 44 39 26 21 20 11 2 -1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 31 22 13 12 NA NA 3 70 70 67 62 57 52 - >060120 2 Pipe or 3 -In. Concentric 3t no disk 53 46 40 33 26 20 4t no disk 70 70 70 70 70 70 - *060140 2 Pipe or 3 -In. Concentric 3t no disk 21 17 13 9 5 NA 4t no disk 69 64 59 54 49 44 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)' NUMBER OF 90° ELBOWS 1 2 3 4 5 6 5001 to 6000$ 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 57 52 47 42 40 35 2 70 70 70 70 70 70 024060 036060 048060 2 Pipe or 2-In. Concentric 1 -1/2 14 9 NA NA NA NA 2 60 55 54 49 48 47 036080 048080 060080 2 Pipe or 2-In. Concentric 2 41 36 23 18 17 8 2-1/2 70 70 70 70 70 70 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 29 21 12 11 NA NA 3 70 67 62 57 52 47 - 4060120 2 Pipe or 3 -In. Concentric 3t no disk 42 35 29 22 15 9 4t no disk 70 70 70 70 70 70 - 3060140 2 Pipe or 3 -In. Concentric 3t no disk 12 8 NA NA NA NA 4t no disk 42 37 32 27 22 17 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)* NUMBER OF 90° ELBOWS 1 2 3 4 5 6 6001 to 7000$ $ 024040 036040 2 Pipe or 2 -In. Concentric 1 -1/2 53 48 43 38 37 32 2 70 70 68 67 66 64 024060 036060 048060 2 Pipe or 2-In. Concentric 1-1/2 13 8 NA NA NA NA 2 57 52 50 45 44 43 036080 048080 060080 2 Pipe or 2-In. Concentric 2 38 33 21 16 15 6 2 -1/2 70 70 68 67 66 64 048100 060100 2 Pipe or .3-In. Concentric 2 -1/2 27 19 10 9 NA NA 3 68 63 58 53 48 43 - 3060120 2 Pipe or 3 -In. Concentric 3t no disk 31 24 18 11 NA NA 4t no disk 70 70 70 70 67 62 - *060140 2 Pipe or 3-In. Concentric 4t no disk 17 12 7 NA NA NA ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (IN,)• NUMBER OF 90° ELBOWS 1 2 3 4 5 6 7001 to 8000$ 024040 036040 2 Pipe or 2 -In. Concentric 1-1/2 49 44 39 34 33 28 2 66 65 63 62 60 59 024060 036060 048060 2 Pipe or 2-In. Concentric 1-1/2 12 7 NA NA NA NA 2 53 48 46 41 40 38 036080 048080 060080 2 Pipe or 2 -In. Concentric 2 36 31 19 14 12 NA 2 -1/2 66 65 63 62 60 59 048100 060100 2 Pipe or 3 In. Concentric 2-1/2 25 17 8 7 NA NA 3 63 58 53 48 43 38 - X060120 2 Pipe or 3 -In. Concentric 3t no disk 20 13 7 NA NA NA 4t no disk 61 56 51 46 41 36 3060140 NA • • TABLE d, AAXIMUM ALLOWABLE PIPE LENGTH (F1 Continued See notes on page 26. ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (iN.)" NUMBER OF 90° ELBOWS 1 2 3 4 5 6 8001 to 9000* 024040 036040 2 Pipe or 2-In. Concentric 1 -1/2 46 41 36 31 29 24 2 62 60 58 56 55 53 024060 036060 048060 2 Pipe or 2 -In. Concentric 1-1/2 11 6 NA NA NA NA 2 49 44 42 37 35 34 036080 048080 060080 2 Pipe or 2-In. Concentric 2 33 28 17 12 10 NA 2 -1/2 62 60 58 56 55 53 048100 060100 2 Pipe or 3 -In. Concentric 2-1/2 23 15 7 5 NA NA 3 59 54 49 44 39 34 -A360120 2 Pipe or 3 -In. Concentric 3t no disk 10 NA NA NA NA NA 4t no disk 35 30 25 20 15 10 - 0060140 NA ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIA (IN.)" NUMBER OF 90° ELBOWS 1 2 3 4 5 6 9001 to 10,000* 024040 036040 2 Pipe or 2 -In. Concentric 1-1/2 42 , 37 32 27 25 20 2 57 55 53 51 49 47 024060 036060 048060 2 Pipe or 2 -In. Concentric 2 45 40 38 33 31 29 036080 048080 060080 2 pipe or 2 -In. Concentric 2 30 25 14 9 7 NA 2 -1/2 57 55 53 51 49 47 048100 060100 2 Pipe or 3 -In. Concentric 2 -1/2 21 13 5 NA NA NA 3 54 49 44 39 34 29 - X060120 2 Pipe or 3 -In. Concentric 4t no disk 10 5 NA NA NA NA - X060140 NA 3/18' DRILL t' TRAP TO OPEN DRAIN TABLE 6— MAXIMUM ALLOWABLE PIPE LENGTH (Fr) Continueu' • Disk usage — Unless otherwise specified, use perforated disk assembly (factory- supplied in loose parts bag). If one disk is stated, separate 2 halves of perforated disk assembly and use shouldered disk half. When using shouldered disk half, Install screen side toward inlet box. t Wide radius elbow. $ Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction. NA —Not Allowed; pressure switch will not make. NOTES: 1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur. 2. Size both the combustion -air and vent pipe independently, then use the larger diameter for both pipes. 3. Assume two 45° elbows equal one 90° elbow. Long radius elbows are desirable and may be required in some cases. 4. Elbows and pipe sections within the 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. 6. Use 3 -in. diameter vent termination kit for installations requiring 4 -in diameter pipe. COMBUSTION - AIR INTAKE HOUSING 3 /13' ID TUBE BURNER BOX .0 0 COMBUSTION - AIR PIPE Fig. 30— Intake Housing Plug Fitting Drain A93035 WARNING: Inducer housing outlet cap must be in- stalled and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. c. Install pipe support (factory- supplied in loose parts bag) into selected furnace casing vent pipe hole. Pipe support d. Insert 2 -in. diameter pipe into inducer housing through neoprene coupling and clamp in inducer housing. Tighten clamp. WARNING: Vent pipe must be installed 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. NOTE: A 2 -in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing. VENT EXTENSION PIPE -* Furnaces with 100,000 Btuh and larger inputs are supplied with a PVC vent extension pipe (2 -in. diameter by 12 -in. long). This pipe has a built -in channel to assist vent condensate disposal. When this vent extension pipe is supplied, it must be used to connect the field vent pipe to furnace inducer housing on ALL upflow and downflow applications. NOTE: See label on vent extension pipe for proper installation. This pipe may be shortened if an elbow is used to connect vent extension tube to field- installed vent pipe. 3. Working from furnace to outside, cut pipe to required length(s). 4. Deburr inside and outside of pipe. UNIT SIZE WINTER DESIGN TEMPERATURE ( °F) MAX PIPE DIAMETER (IN.) WITHOUT INSULATION WITH 3/8-IN. OR THICKER INSULATIONt 040 20 1.-1/2 51 70 0 ____ 1.1/2 28 70 -20 1-1/2 16 70 060 080 20 2 65 70 0 2 35 70 -20 2 20 70 20 2-1/2 70 70 0 2-1/2 47 70 -20 2-1/2 28 70 100 20 3 70 70 0 3 50 70 -20 3 28 70 120 . 140 20 4 70 70 0 4 48 70 -20 4 23 70 20 4 70 70 0 4 57 70 -20 4 30 70 '' '5: Chamfer outside edge of pipe for ...cter 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 side wall. III. CONCENTRIC VENT AND COMBUSTION -AIR TERMINATION KIT INSTALLATION NOTE: If these instructions differ from those packaged with termination kit, follow kit instructions. 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. 31, 32, 33, 34, or 35. Four termination kits are available. 1, The 2 -in. termination bracket kit is for 1 -in., 1 -1/2 in., and 2 -in. diameter 2 -pipe termination systems. -a TABLE 7— MAXIMUM ALLOWABLE EXPOSED V IN WINTER DESIGN --> 2. The 3 -in. Lt, .,nation bracket kit is for 2 -1/2 in., 3 -in., and 4 -in. diameter 2 -pipe termination systems. 3. The 2 -in. concentric vent/air termination kit is for 1 -in., 1 -1/2 in., 2 -in., and 2 -1/2 in. diameter pipe systems when single penetration of wall or roof is desired. --* 4. The 3 -in. concentric vent/air termination kit is for 2 -1/2 in., 3 -in., and 4 -in. diameter pipe systems when single penetra- tion of wall or roof is desired. NOTE: Shaded parts in Fig. 31, 32, 33, 34, and 35 are considered to be termination. These components should NOT be counted when determining pipe diameter. Roof termination is preferred since it is less susceptible to damage, has reduced chances to take in contaminants, and has less visible vent vapors. (See Fig. 31 or 32.) 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. 34 or 35 in outside ambient by insulating pipes as indicated in Table 7. 1. Determine combustion -air and vent pipe diameters, as stated above, using total pipe length and number of elbows. 2. Using winter design temperature (used in load calculations), find appropriate temperature for your application and fur- nace model. 3. Determine required insulation thickness for exposed pipe lengths. NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 6. B. Two -Pipe Termination Kit 1. Determine location for termination. Consideration of the following should be made when determining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table 5. b. Termination kit should be positioned where vent vapors will not damage plants /shrubs or air conditioning equip- ment. ENT PIPE LENGTH (FT) WITH AND WITHOUT INSULATION TEMPERATURE AMBIENT* ri pe l ength (ft) specif ed for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified In Table 8. t Insulation thickness based on R value of 3.5 per in. MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. VERTICAL SEPARATION BETWEEN COMBUSTION AIR AND VENT 8 3 /4" FOR 3" KIT 6 3 /4" FOR 2" KIT MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. 101 vet I L '*`.- COMBUSTION IOW AIR A93054 Fig. 32— Concentric Vent and Combustion -Air Roof Termination (Preferred) l 90 BRACKET L ••" OVERHANG OR ROOF VENT 12" MINIMUM COMBUSTION-AIR Fig. 34— Sidewall Termination of 12 In. or More Fig. 31—Roof Termination (Preferred) 12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. COMBUSTION AIR OVERHANG OR ROOF A87224 12" MINIMUM �`- MAINTA N 12 IN. CLEARANCE \ ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER, A93055 Fig. 33—Concentric Vent and Combustion -Air Side Termination OVERHANG OR ROOF 12" MINIMUM VENT W _ 90° � COUPLING il 0 BRACKET V. COMBUSTION-AIR (ELBOW PARALLEL TO WALL) 12 IN. SEPARATION . BETWEEN BOTTOM OF COMBUSTION AIR AND -'BOTTOM OF VENT MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. A87225 A87226 Fig. 35— Sidewall Termination of Less than 12 in. i , c. Termination kit should be positi( ' so that it will not be affected by wind eddy (such as 1,.,,ide building corners) or allow recirculation of flue gases, airborne leaves, or light snow. d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc. e. Termination kit should be positioned where vent vapors are not objectionable. 2. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size being used. 3. Loosely install elbow in bracket and place assembly on combustion -air pipe. Roof terminations — Loosely install pipe coupling on prop- erly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 31. For applications using combustion -air pipe option, indi- cated by dashed lines in Fig. 31, 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. 34 or 35. For applications using vent pipe option indicated by dashed lines in Fig. 34, rotate vent elbow 90° from position shown in Fig. 34. 4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. 5. Check required dimensions as shown in Fig. 31, 34, or 35. C. Concentric Vent/Air Termination Kit 1. Determine location for termination. Consideration of the following should be made when determining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table 5. b. Termination kit should be positioned where vent vapors will not damage plants /shrubs or air conditioning equip- ment. c. Termination kit should be positioned so it will not be affected by wind eddy (such as inside building corners) or that may allow recirculation of flue gases, airborne leaves, or light snow. d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc. e. Termination kit should be positioned where vent vapors are not objectionable. 2. Cut one 4 -in. diameter hole for 2 -in. kit, or one 5 -in. diameter hole for 3 -in. kit. 3. Loosely assemble concentric vent/air termination compo- nents together using instructions in kit. 4. Slide assembled kit with rain shield REMOVED through hole. NOTE: Do not allow insulation or other materials to accumulate • inside of pipe assembly when installing it through hole. Roof terminations — Locate assembly through roof to ap- propriate height as shown in Fig. 32, Sidewall terminations— Locate assembly through sidewall with rain shield positioned no more than 1 -in. from wall as shown in Fig. 33. 5. Disassem 'oose pipe fittings. Clean and cement using same proc cures as used for system piping. 6. Check required dimensions as shown in Fig. 32 or 33. IV. MULTIVENTING AND VENT TERMINATIONS When 2 or more 350MAV Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 350MAV furnaces. When 2 or more 350MAV furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 36, 37, 38, 39, or 40, 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. 36, 37, 38, 39, and 40 represents distance between pipes or rain shields, as touching or 2 -in. maximum separation. CONDENSATE DRAIN I. GENERAL Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications. Condensate trap MUST be used for all applications. An external trap is not required when connecting the field drain to this condensate trap. The field drain connection (condensate trap or drain tube coupling) is sized for 1 /2 -in. CPVC, 1 /2 -in. PVC, or 5 /8 -in. ID tube connection. Drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certified schedule 40 CPVC or PVC drain pipe, fittings, and cement. When a condensate pump is required, select a pump which is approved for condensing furnace applications. To avoid conden- sate spillage, select a pump with an overflow switch. Furnace condensate is mildly acidic, typically in the pH range of 3.2 to 4.5. Due to corrosive nature of this condensate, a condensate pH neutralizing filter may be desired. Check with local authorities to determine if a pH neutralizer is required, II. APPLICATION The furnace, A/C, and humidifier drains may be combined and drained together. The AJC 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. 41 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. , Fig. 36 Rooftop Termination (Dimension "A" is Touching or 2 - In. Maximum Separation) COMBUSTION AIR A93056 Fig. 37—Concentric Vent and Combustion -Air Roof Termination (Dimension "A" is Touching or 2 -In. Maximum Separation) VEN mfr � of 12 in. or Less COMBUSTION AIR • Fig. 38_ Concentric Vent and Combustion -Air Side Termination (Dimension "A" is Touching or 2 -In. Maximum Separation) __ -- COMBUSTION AIR 1" MAXIMUM (TYP) A VENT A96128 A93057 COMBUSTION AIR. A96130 A96129 Fig. 40— Sidewall Termination of More Than 12 in. ....___..�.... " en Ira Touching or 2 -in. Maximum separation) • OPEN STAND PIPE FOR NC OR HUMIDIFIER DRAIN TEE u n TO OPEN DRAIN Fig. 41— 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 off and left in an unoccupied structure during cold weather when temperature drops to 32 °F and below unless drain trap and drain line have adequate freeze protection. See Service and Maintenance Instructions for winterizing procedure. 1. Fold heat tape in half and wrap on itself 3 times. 2. Locate heat tape between sides of condensate trap back. (See Fig. 42.) 3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig. 42.) 4. Wrap field drain pipe with remaining heat tape, approxi- mately 1 wrap per ft. 5. When using .,cld- supplied heat tape, follow heat tape manufacturer's instructions for all other installation guide- lines. CONDENSATE TRAP WIRE TIE(S) HEAT TAPE (3 WRAPS MINIMUM) Fig. 42— Condensate Trap Heat Tape SEQUENCE OF OPERATION A93038 CAUTION: Furnace control must be grounded for proper operation, or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. Using schematic diagram, follow sequence of operation through different modes. (See Fig. 24.) Read and follow wiring diagram carefully. NOTE: If 115 -v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates for 90 sec when power is restored before heating cycle is resumed. I. HEATING MODE When wall thermostat calls for heat, R -W circuit closes. Furnace control performs a self - check, verifies pressure switch contacts are open, and starts inducer motor. 1. Prepurge period —As inducer motor comes up to speed, pressure switch contacts close to begin a 15 -sec prepurge period. 2. Ignitor warm up—At end of prepurge period, ignitor is energized for a 17 -sec ignitor warm -up period. 3. Ignition sequence —When ignitor warm -up period is com- pleted, gas valve opens, permitting gas flow to burners where it is ignited. After 5 sec, ignitor is de- energized and a 2 -sec flame - sensing period begins. HUM terminal on control center is energized with gas valve. See Accessories — Humidifier section. 4. Flame sensing —When burner flame is sensed, control begins blower on delay period and continues holding gas valve open. If burner flame is not sensed, control center de- energizes gas valve and ignition sequence is repeated. NOTE: Ignition sequence repeats 3 additional times before a lockout occurs. Lockout automatically resets after 3 hr or can be manually reset by turning off 115v (not at thermostat) for 3 sec minimum, then turning it on again. —4 5. Blower on delay —Sixty sec after burner flame is proven (40 sec if jumper has been cut for 140 size unit in downflow orientation), blower motor is energized on heating speed. Simultaneously, electronic air cleaner terminal EAC -1 is energized. 6. Alo1ver qff delay —When thermostat is satj' "'d, circuit between R -W is opened, de- energizing gas v. (stopping gas flow to burners) and humidifier. Blower motor and electronic air cleaner remains energized 90, 135, 180, or 225 sec (depending on blower off time selection). Furnace is factory shipped set for a 135 -sec blower off delay. 7. Post purge — Inducer motor remains energized 15 sec after burners are extinguished (5 sec if jumper has been cut for 140 size unit in downflow orientation). II. COOLING MODE When thermostat calls for cooling, R -G and R -Y circuits close. R -Y circuit starts outdoor condensing unit, and combined R -Y and R -G circuit starts furnace blower motor on cooling speed. Elec- tronic air cleaner EAC -1 terminal is energized with 115v whenever blower is operating. When thermostat is satisfied, R -G and R -Y circuits are opened, furnace blower continues operating on cooling speed for an additional 90 sec. III. CONTINUOUS BLOWER MODE When R -G circuit is made, blower motor operates on heating speed. NOTE: Electronic air cleaner EAC -I terminal is energized with 115v whenever blower is operating. 4 If a call for heat (R -W) occurs while thermostat is in continuous blower mode, blower stops to allow furnace heat exchangers to heat up more quickly, then restarts at end of blower on delay period of 60 sec (40 sec if jumper has been cut for 140 size unit in downflow orientation). Blower reverts to continuous operation after heating cycle is completed. If a call for cooling (R -Y) occurs while thermostat is in continuous blower mode, blower changes from continuous blower speed (heating speed) to cooling speed. When thermostat cooling call is satisfied, R -Y opens and blower operates an additional 90 sec at cooling speed before reverting back to continuous operation (heating speed). IV. HEAT PUMP MODE When installed with a heat pump, furnace control automatically changes blower on delay timing sequence to avoid no blower operation time during demand defrost cycles. When R -W and R -Y or R -W, R -Y, and R -G thermostat inputs are received at the same time at furnace control center, control starts blower in heating speed. Then a gas heat mode begins. Blower remains operating at heating speed for 15 sec or until end of prepurge period, then blower shuts off until end of ignitor warm up and trial for ignition periods (a total of 24 sec). Blower restarts at heating speed. —4 When R -W thermostat call disappears, control completes inducer post -purge period of 15 sec (5 sec if jumper has been cut for 140 size unit in downflow orientation) and changes to cooling speed after a 2 -sec delay. —4 If R -W, R -Y, and R -G thermostat signals should disappear simultaneously, blower remains on for selected heating blower off delay period (90, 135, 180, or 225 sec), and the inducer goes through 15 sec post -purge period (5 sec if jumper has been cut for 140 size unit in downflow orientation). If R -W and R -Y thermostat signals should disappear, leaving R -G thermostat signal, blower remains on in heating speed and inducer remains on for 15 sec (5 sec if jumper has been cut for 140 size unit in downflow orientation) to complete post -purge period. Control initiates a 90 -sec blower only on period before starting another heat pump cycle if there is a power interruption. Anytime control senses false flame, control locks out of heating mode. This reaction occurs because control ignores W input due to false flame signal and, as a result, sees only Y input and goes into cooling mode blower off delay. All other control functions remain in standard format. --32— NU It: tMl - i w .... _.._. HUM terminal is only ene( •d when gas valve is energized. V. COMPONENT TEST A. Component Test Sequence NOTE: All components are functionally operated except the gas valve. When component test is initiated, the following sequence of events occurs: I. LED flashes a status code 4 times. 2. Inducer motor starts and continues to run for remainder of component test. 3. Hot surface ignitor is energized for 15 sec, then de- energized. 4. Main blower operates at cooling speed for 10 sec, then turns off. 5. Main blower operates at heating speed for 10 sec, then turns off. 6. Inducer motor stops. Component test can be initiated by one of the following proce- dures. B. Initiating Component Test By Removing Main Limit Switch Wire NOTE: NO thermostat signal may be present at control center and all blower time delay off periods must be completed. 1. Leave 115 -v power to furnace turned on. 2. Remove main furnace door. 3. Look into blower access panel sight glass for current LED status. NOTE: Leave blower access panel installed to maintain power to control center to view current LED status. 4. BRIEFLY remove either wire from the main limit switch until the LED goes out, then reconnect it. CAUTION: Make sure limit switch wire does not con- tact any metallic component such as the gas valve. If wire is shorted, 3 -amp fuse on control center will blow. NOTE: If wire to main limit is disconnected longer than 4 sec, the control senses limit circuit is open. Main blower will start and status retrieval request will be ignored. 5. When above items have been completed, the component test sequence will occur as described in the Component Test Sequence section above. NOTE: Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting. 6. After component test is completed and LED is ON continu- ously indicating the furnace is ready to operate when a signal from the thermostat is received, replace main furnace door. C. Initiating Component Test By Jumpering Control TEST Terminal 1. Remove main furnace door. 2. Remove blower access panel. 3. Manually close blower access panel door switch. Use a piece of tape to hold switch closed. • • WARNING: Blower access panel door switch opens 115 -v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death. 4. BRIEFLY short (jumper) TEST, 1 /4 -in. quick- connect terminal on control center (adjacent to the LED diagnostic light) and the CoM terminal on thermostat connection block. (See Fig. 25.) NOTE: If TEST to CoM terminals are jumpered longer than 2 sec, LED will flash rapidly, and retrieval request will be ignored. 5. When above items have been completed, the component test sequence will occur as described in the Component Test Sequence section above. NOTE: Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting. 6. After component test is completed and furnace is operating properly, release blower access panel door switch, replace blower access panel, and replace main furnace door. START -UP PROCEDURES I. GENERAL 1. Furnace must have a 115 -v power supply properly con- nected and grounded. Proper polarity must be maintained for correct operation. NOTE: Proper polarity must be maintained for 115 -v wiring. If polarity is incorrect, control center LED status indicator light will • flash rapidly and furnace will not operate. 2. Thermostat wire connections at terminals R, W, G, and Y must be made at 24 -v terminal block on control center. 3. Natural gas service pressure must not exceed 0.5 psig (14 -in. wc), but must be no less than 0.16 psig (4.5 -in. wc). 4. Blower access panel must be in place to complete 24 -v electrical circuit to furnace, CAUTION: These furnaces are equipped with a manual reset limit switch in burner box. This switch will open if an overheat condition (rollout) occurs in burner enclo- sure. Correct inadequate combustion -air supply or im- proper venting condition and reset switch. DO NOT jumper this switch. Before operating furnace, check each manual reset switch for continuity. If necessary, press button to reset switch. II PRIME CONDENSATE TRAP WITH WATER 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. 43.) 2. Connect field- supplied 1 /2 -in. ID tube to upper inducer housing drain connection. 3. Insert field - supplied funnel into tube. 4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 44.) 5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp. Fig. 43— Inducer Housing Drain Tube Fig. 44— Filling Condensate Trap A94206 A94209 4 III. PURGE GAS LINES If not previously done, purge lines after all connections have been made and check for leaks. z WARNING: Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap - and -water solution to check for leakage. Failure to follow this warning could result in fire, explosion, per- sonal injury, or death. IV. ADJUSTMENTS A. Set Gas Input Rate Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. -3 In the U.S.A., the input ratings for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level. —3 In Canada, the input ratings must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level. -3 Furnace input rate must be within ±2 percent of input on furnace rating plate adjusted for altitude. I. Determine natural gas orifice size and manifold pressure for correct input. a. Obtain average yearly heat value (at installed altitude) from local gas supplier. b. Obtain average yearly specific gravity from local gas supplier. —3 c. Verify furnace model and size. Table 8 can only be used for model 350MAV furnaces with heating sizes of 040 through 120. Table 9 can only be used for model 3S0MAV furnaces with a 140 heating size. d. Find installation altitude in Table 8 or 9. —� NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 8 or 9. —3 e. Find closest natural gas heat value and specific gravity on Table 8 or 9. f. Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation. EXAMPLE: (0 -2000 ft altitude using Table 8) Heating value = 1050 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 45 Manifold pressure 3.6 -in. wc * Furnace is shipped with No. 45 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate. Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY. 2. Adjust manifold pressure to obtain input rate. NOTE: Manifold pressure must always be measured with burner enclosure front REMOVED. Gas meter must always be clocked with burner enclosure front INSTALLED. a. Remove burner enclosure front. b. Remove cap that conceals adjustment screw for gas valve regulator. (See Fig. 45.) c. Turn adjusting screw, counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure. NOTE: This furnace ,ss been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft. For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc. CAUTION: DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures. —INLET PRESSURE TAP ON AND OFF SWITCH MANIFOLD PRESSURE TAP BURNER ORIFICE GAS PRESSURE REGULATOR ADJUSTMENT BURNER ENCLOSURE REFERENCE PRESSURE TAP A95822 Fig. 45— Redundant Automatic Gas Valve 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. A93059 CAUTION: DO NOT redrill orifices. Improper drilling (burrs, out -of -round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of burners and heat exchang- ers causing failures. d. Replace gas valve regulator adjustment screw cap. e. Replace burner enclosure front and verify adjusted gas input rate using method outlined in item 3. ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT AT ALTITUDE (BTU /CU I SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.80 0.82 _ 0.84 0.88 Manifold Pressure Orifice Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. and Canada 0 to 2000 850 875 900 925 950 975 1000 1025 1050 1075 1100 C) C) w w w w w w N A CD V in V 43 43 43 44 CD CO d C7 CO co co CO CO CO c 4 4 4 4 CJ CJ W W CJ CJ W N A CD CD CJ) V N .. .,. 4 4 44 cocDmanu ( r) CO r) CO r) CO r ) r) N N C3C9 4444 � et V V: N f` to CD CO UY M CO CO C') C') C') C') CO CO 45 45 45 45 t. 11) C') N C) C) C') C) 45 45 45 45 3.8 3.6 3.4 3.3 45 45 45 45 3. 3.6 3.4 3.2 45 45 45 3.7 3.5 3.4 45 45 45 3.8 3.8 3.5 47 3.6 47 3.7 ALTITUDE RANGE ((FT) AVG GAS HEAT VALUE AT LTITI A AL (BTU/CU SPECIFIC GRAVITY OF NATURAL GA_ 0.58 0.80 0.82 0.64 0.66 Mani Pressure a Manil Pressure a No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure 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 C') C') CO 1A CO CO N CO CO C') CO CO C) 42 43 43 44 44 44 CO CO CO CO CO CD fJ in V D V N .. . . 4 4 4 4 C) CD CO CO CD d N C) CO r) t) .'t. . V. N CD r) r) C) C7 CO CO CO C') 42 42 43 43 43 44 44 44 CJ G ) W W CJ p W W CO A CO A CO CO W in 45 45 45 45 45 h WI C ) e- 0 N C) C') 45 45 45 45 45 m m Q N e- CO C) C C) CO 45 45 45 45 3.7 3.5 3.4 3.2 45 45 45 45 3.8 3.6 3.5 3.3 45 45 45 3.8 3.8 3.4 ALTITUDE RANGE (Fr) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.84 0.88 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. Only 3001 to 4000 • 750 775 800 825 850 875 900 925 950 975 1000 43 43 44 44 44 n Cn n 1n CO Cr; CO r) C) r) 43 43 43 44 44 44 CD tD � tp '7 N C7 CO C) CO CO CO V . CO 7 W W CJ P W CJ CJ CJI CD CJI V Ca 42 43 43 43 44 44 44 ✓ T CO CD n 111 C7 C) 07 C) C) C') C) M ▪ V CO <f N f` Ip CO CO N C) C) CO C) CO CO CO CO 45 45 45 45 45 45 CO CO " N O Ca C) C) C! C) C) N 45 45 45 45 45 N C) N O CO C) C) M CO 45 45 45 45 45 m CO Q C) r CI CO CO CI 45 45 45 45 3.7 3.5 3.4 3.2 45 45 45 3.7 3.5 3.3 • • • • -, TI 50MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT FOR USE WITH (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE AT FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 No. Manifold Pressure No. Manifold Pressure No. Manifold Pressure No. Manifold Pressure No. Manifold Pressure 'v s - n 4001 to 5000 725 750 775 800 825 850 875 900 925 950 ✓ v344 W W W W N A -) 43 44 44 44 CO LO CD CD 't7 C3 C') r) C) CO • �� 444 I I '. W W CO W W W CJ CA V A V I') W W W W W W m N A CA W in in W N N C') r) 4 4 ✓ V et et et 99 W Ui V ? -.7 N A 45 45 45 45 45 ▪ 'q r) — O N r) O r) r) 45 45 45 45 45 O W Q N r- CO r) P) P) t%) 45 45 45 45 3.7 3.5 3.3 3.2 45 45 45 3.6 3.4 3.3 45 45 45 3.8 3.6 3.4 ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE AT ( FT) SPECIFIC 0.58 0.60 0. 64 0.86 Orifice Manifold Pressure No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Ajuo - v - s - n 5001 to 6000 700 725 750 775 800 825 850 875 900 925 950 975 1000 43 43 44 44 44 9999 N A IA A O) vv444 n)nr) ri 42 43 43 44 44 44 N CD CD V N Cr) P 0) F CO C') C') r) C') 03 C') Ncotgc7 Q � Ts- V' CO CD V CO V N r) r) C') r) r) r) r) 45 45 45 45 45 45 45 45 CO O Q) ti CD r) C7 r) rf N N N N 45 45 45 45 45 45 45 45 C` 117 r O m P ID 03 C') r) CO C'') N Cl N 45 45 45 45 45 45 45 CO 't C7 •- Cf @ tD r) r) r) r) Cl N N 45 45 45 45 45 45 45 O CO et N O O P• r) 03 r) O Ci N 45 45 45 45 45 45 P O C9 r CA CD rf r) M N N N ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.82 0.84 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Aiuo vsn 6001 to 7000 650 675 700 725 750 775 800 825 850 875 42 43 44 44 44 N CO CO CD CO r) r) r) r) M I I V V V 4 V t r) f\ V h V N 07 C') C') r) C) r) 42 43 43 44 44 44 'Cr CO CO CO CD 01 C7 r) r) r) C') r) 03 4 V N 0.1 d �f V U) N h V V r) r) r) r) r) 42 42 43 43 44 44 44 G) C.) CJ C) W W CJ • D) Cn CO W In 45 45 45 45 45 m N O O r) r) 45 45 45 45 P a N r) C) r) r) 45 45 45 45 3.8 3.6 3.4 3.2 45 45 45 3.7 3.5 3.3 45 45 45 3.8 3.6 3.4 '1 '. --4 TABLE 8 -MODEL 350MAV OICtiriCE SIZE AND MANIFOLD Continued FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, D :% FOR EACH 1000 FT ABOVE SEA LEVEL) 41 ALTITUDE RANGE (� AVG GAS HEAT VALUE AT ALTITUDE ( BTU /CU SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.88 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. Only 7001 to 8000 825 650 675 700 725 750 775 800 825 850 I , . w w C.' w w W 01 CO 01 C) 42 of C) C) C) C) �^ - . - w w w w w w is in m 01 01 v C . J C ) Ca w w G) w w A CA ? C) R) in N N C7 C7 7 4 4 CD CO N Ul N C) C) C') CO 0)COC7C) P N M '7 C) C? P) C) Pi CV 45 45 45 45 CO CO R N O C') CO C) C7 C7 P >n C') n CO C7 C) 03 { 45 45 45 3 3.6 3.4 3.2 45 45 45 3.7 3.5 3.3 A LTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE AT ALTILTI (BTU/CU � SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.84 0.86 Orifice No. Manifold Pressure Orifice No, Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure i AiuO 'V'SYI 8001 to 9000 600 625 650 875 700 725 750 775 800 av 444 CO 1A C` to N ri of C') Ci oi 42 43 43 44 44 wwww co in A C) C.) st - 7 C CD 1A r d; N CO CO 07 CO C) C) 42 42 43 44 44 44 w CA Ca w w w N N C7 CO . et V a CO CO N C f+ V t7 Ci C7 C) CO C7 Ci 45 45 45 45 3.6 3.4 3.2 3.0 45 45 45 45 CO In C9 07 !7 O C') 45 45 45 3.6 3.4 3.2 45 45 45 3.8 3.5 3.3 45 45 3.8 3.4 ALTITUDE RANGE (FT) - AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.68 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Orifice Pressure No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. Only 9001 to 10,000 575 600 625 650 675 700 725 750 775 43 43 44 44 3.8 3,5 3.7 3.4 v. N tD m 1n C) CO CO CO C) C') 42 43 43 44 44 w w w w w ' via ' - - CO N CD CO to C) CO CO CO CO CO CO 42 42 43 43 44 44 CD CO C: • CD • Ci C) Ci C) Ci C7 45 45 45 45 45 CO CO CO CA C'! C') C) C) N 45 45 45 45 3.7 3.4 3.2 3.0 45 45 45 45 03 03 03 r- C) l7 C) l7 45 45 45 3.7 3.4 3.2 45 45 45 3.8 3.5 3.3 -> TABLE 8 -MODEL 350MA(ORIFICE SIZE AND MANIFOLD __. ___ ...ESSURE FOR CORRECT INPUT Continued FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) • 111 • ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 58 0.66 orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No, Manifold Pressure Orifice No. Manifold Pressure U.S.A. and Canada 0 to 2000 850 875 900 925 950 975 1000 1025 1050 1075 1100 41 42 42 42 42 CO CO M ‘t N C) M M C) 41 41 "" 42 42 t-. C1) N to C) M C) C) c ) 41 41 2 42 42 42 CO CO M 41:.! C7 M CO CO CO CO 40 41 41 42 42 42 42 CO n M n M N t0 M CO CO CO CO CO 40 41 41 42 42 42 42 Cri c0 tO CO CO v N M M M M M C) 4 4 4 My IA C) N C7 CO e) C') 4 4 `. ' . 3.8 3.8 3.4 3.3 43 43 43 43 3.7 3.8 3.4 3.2 It) C9 N M N C7 M 43 43 43 43 3.8 3.6 3.4 3.3 44 44 3.5 3.3 44 44 3.6 3.4 3.5 ALTITUDE RANGE (FT) AVG GAS HEAT ALTITUDE AT '_... ___ AT (BTU/CU FT) SPECIFIC GRAVITY OF NATURAL GAS i8 0.60 0.62 0.64 0.86 OrifiOrifice rce No. Manifold Pressure Orifice No, Manifold Pressure Orifice No, Manifold Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. and Canada U.S.A. Altitudes 2001 to 3000 or Canada Altitudes 2001 to 4500 775 800 825 850 875 900 925 950 975 1000 1025 41 42 42 42 42 M CO a N CO C) CO CO C`) 41 41 42 42 42 W W W W W W UI V 01 OD 40 41 41 42 42 42 CO r U) CO V N 1 40 41 41 42 42 42 42 I` CO CO Cr! M N M CO CO C`) CO CO el 39 40 41 41 42 42 42 CC! CO "?. CD V: CO CO CO C) CO M CO ".. . "v `' In r O CCI M e7 M C9 t7 N 43 43 43 43 43 43 CO. CO e M r fA CO. C') C7 C) C') N 444 In tt N 4 C ) C 7 O) M 07 Pt IC) M r CO CI M r) Q4 3.8 3.6 3.4 3.2 ALTITUDE RANGE (Fr) AVG GAS HEAT VALUE AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.82 0.84 0.66 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure U.S.A. Only 3001 to 4000 750 775 800 825 850 875 900 925 950 975 1000 41 42 42 42 3.6 3.8 3.5 3.3 41 41 42 42 42 CO M 1- V M 40 41 42 42 42 42 W W W W W W . 1%) 0) 0) 0) 0 40 41 41 42 42 42 I` 1` LP. IC) Cl CO C.) CO CO CO CO 40 40 41 42 42 42 42 M cc? ca C CO N CO CO CO CO C) CO CO CD CO N r CI) CR C7 C) C) C') C) N N 43 43 43 43 43 43 O CA C) C) M C) M N 43 43 43 43 43 CO 41 M r O C9 M C) C) M W W W W W O )J ? a) in 43 43 43 43 P K) C) C) C) l7 C) --4 TABU IAV ORIFICE MANIFOLD PRESSURE CORRECT INPUT FOR USE ONLY (TABULATED DATA J0 BTUH PER BURNER, DERATED 2cYa FOR EACH 1000 Fr ABOVE SEA LEVEL) RANGE (FT) AVG GAS HEAT VALUE AT A i SPECIFIC 0.58 0.60 0.62 0.84 0.66 Manifold Pressure Orifice Manifold Orifice Manifold Orifice Manifold Pressure A uo •v 4001 to 5000 725 750 775 800 825 850 875 900 925 950 41 42 42 42 16 3.7 3.5 3.3 41 42 42 42 42 P WwWw r)AC)C) 41 41 42 42 42 Co ccn)nco C) C) C) C) C) 40 41 42 42 42 42 CaCatawPw IV A C) C) -7 C) 40 41 41 42 42 42 W CA CA CA CJ W 4) in -4 C) m ao 43 43 43 43 43 43 tt U) C7 r O CO M l7 e3 N N 43 43 43 43 43 CO t1 N r CA O C7 C7 M N 43 43 43 43 43 CO CO Q N O C9 C7 r e3 09 4444 W 1!) C7 C7 e3 O C4 4 v `4' 3.8 3.6 3.4 3.2 ALTITUDE RANGE (FT) AVG GAS AT ALTITUDE (BTU/CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.82 0.64 0,86 Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold sure Orifice No. Manifold Pressure C d vi m 5001 to 6000 750 775 800 825 850 875 900 925 950 975 1000 42 42 3.4 3.2 42 42 15 3.3 42 42 42 CO O V C7 C') C') C ) C ) 42 42 42 CO CO CA 1n C7 C') C') Cfl C') N 40 41 41 42 42 42 W CJ CJ CJ CJ CJ N A V Cft CO V N N N N N C.) CJ co CO W N C) V CO -• CAD C71 V 44'444444 CO CO 'It N O e3 C7 C) C9 e3 N N N N 43 43 43 43 43 43 43 43 N N N N CO W CJ C) C) CO CO CO - 44) U) V 44444'444 !.%) N IV CJ W W W W CA V CO O 10 a CA CO 4 44 `4444 N N W CA W co to ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT AT ALTITUDE (BTU /CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.80 0,82 0,64 0.66 No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure Orifice No. Manifold Pressure O a N 6001 to 7000 650 675 700 725 750 775 800 825 350 375 41 41 42 42 3.8 3.5 3.6 3.4 40 41 42 42 CJ W CJ C) C i V C) CA 40 41 41 42 n n «) tO C') C') C') C) 40 40 41 42 • CO CO f` C') C) C') C') 39 40 41 42 n n CA t7 C) C) P) 42 42 42 42 42 42 4 444 P .3 9 9 9 OD O N A. 4444 CC) t7 r Of C) co, C) N 4444 O 099 O N A O) Q V Ul O r • C9 C7 CO 4444 3.8 3.6 3.4 3.2 .ti —> TABLE AND MANIFOLD PRESSURE CORRECT INPUT Continued FOR USE WITH 140SIZE (TABULATED DATA BURNER, EA LEVEL) • 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 1838 51 71 141 355 12 300 800 1500 52 69 138 348 13 277 555 1385 53 88 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 58 84 129 321 17 212 424 1059 57 63 126 318 18 200 400 1000 58 62 124 310 19 189 379 947 59 81 122 305 20 180 360 900 60 120 300 21 171 343 857 82 118 290 22 164 327 810 64 CD ID 112 281 23 157 313 783 86 109 273 24 150 300 750 88 106 265 25 144 288 720 70 51 103 257 28 138 277 692 72 50 100 250 27 133 287 667 74 48 97 243 26 129 257 643 76 47 95 237 29 124 248 821 78 46 92 231 30 120 240 800 80 45 O co co ' N ICI mm CD CO 225 31 116 232 581 82 44 220 32 113 225 563 84 43 214 33 109 218 545 86 42 209 34 106 212 529 88 41 205 35 103 206 514 90 40 80 200 38 100 200 500 92 39 78 196 37 97 195 468 94 38 78 192 38 95 189 474 96 38 75 188 39 92 185 482 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 64 167 419 106 34 88 170 44 82 184 409 108 33 67 167 45 80 160 400 110 33 85 184 46 78 157 391 112 32 64 161 47 76 153 383 116 31 82 155 48 49 75 73 150 147 375 387 120 30 80 150 ALTITUDE (FT) % OF DEBATE 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 f. Look through sight glass in burner enclosure and check burner flame. Burner flame should be clear blue, almost transparent. (See Fig. 46.) BURNER FLAME —\ Or% o MANIFOLD 2 BURNER • Derate multiplier factor is based on midpoint altitude for altitude range. A89020 Fig. 46— Burner Flame 3. Verify natural gas input rate by clocking gas meter. NOTE: Be sure all pressure tubing, combustion -air and vent pipes, and burner enclosure front are in place when checking input by clocking gas meter. a. Calculate high - altitude adjustment (if required). UNITED STATES At altitudes above 2000 ft, this furnace has been ap- proved for a 2% derate for each 1000 ft above sea level. See Table 10 for derate multiplier factor. TABLE 10—ALTITUDE DEBATE MULTIPLIER FOR U.S.A. EXAMPLE: 100,000 Btuh input furnace installed at 4300 ft. Furnace Input Derate Furnace Input Rate Rate at X Multiplier = at Installation Sea Level Factor Altitude 100,000 X 0.91 91,000 CANADA -3 At installation altitudes from 2000 to 4500 ft, this furnace must be derated 5% by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.95 as derate multiplier factor. b. Turn off all other gas appliances and pilots. c. Start furnace and let operate for 3 minutes. d. Measure time (in sec) for gas meter test dial to complete e. Refer to Table 11 for cu ft of gas per hr. TABLE 11 —GAS RATE (CU FT /HR) f. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using natural gas heating value from local gas utility /supplier. EXAMPLE: (0 -2000 ft altitude) Furnace input from rating plate is 100,000 Btuh. Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for 1 revolution of 2 -cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 11) Btu heating input = 103 X 975 = 100,425 Btuh In this example, the orifice size and manifold pressure adjustment is within ±2 percent of the furnace input rate. B. Set Temperature Rise CAUTION: Temperature rise must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or above. Failure to follow this caution may result in condensing or overheating the heat ex- changers. Determine and adjust air temperature rise as follows: 1. Place thermometers in return and supply ducts as close to furnace as possible, Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight -run ducts. 2. When thermometer readings stabilize, subtract return -air temperature from supply -air temperature to determine air temperature rise. • COLOR SPEED FACTORY - SHIPPED CONNECTION Black High Cool Yellow (When Present) Medium High Spare Blue Medium Low Heat Red Low Spare White Common Corn DESIRED HEATING MODE BLOWER OFF DELAY (SEC) SETUP SWITCH POSITION SW - 1 SW - 2 90 OFF OFF 135 ON OFF 180 OFF ON 225 ON ON . , 111 . • • 3. Adjust temperature rise by adjusting °rower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. L, WARNING: Disconnect 115 -v electrical power before changing speed tap. Failure to follow this warning could result in personal injury. 4. To change blower motor speed selections for heating mode, remove blower motor lead from control center HEAT terminal. (See Fig. 25.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to HEAT terminal. See Table 12 for lead color identification. Recon- nect original lead on SPARE terminal. Follow this same procedure for proper selection of COOL speed selection. TABLE 12 —SPEED SELECTOR C. Adjust Blower Off Delay (Heat Mode) If desired, the main blower off time delay period may be lengthened or shortened when operating in the heating mode to provide greater comfort. See Table 13 for position of switches and • Fig. 24 or 25 for location of switches on control center. TABLE 13— BLOWER OFF DELAY SETUP SWITCH POSITION D. Set Thermostat Heat Anticipator Thermostat heat anticipator must be set to match amp draw of components in R -W circuit. Accurate amp draw measurements can be obtained at thermostat subbase terminals R and W. Fig. 47 illustrates an easy method of obtaining these measure- ments. Amp reading should be taken after blower motor has started. See thermostat manufacturer's instructions for adjusting heat anticipator and for varying heating cycle length. CHECK SAFETY CONTROLS I. CHECK PRIMARY LIMIT CONTROL This control shuts off combustion control system and energizes air - circulating blower motor if furnace overheats. Recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 46 5 minutes. As soon as limit control has shut off burners, return -air opening should be unblocked to permit normal air circulation. By THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED 10 TURNS HOOK - AROUND VOLT /AMMETER FROM UNIT 24 -VOLT TERMINAL BLOCK EXAMPLE: 5.0 AMPS ON AMMETER = 0.6 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS A80201 Fig. 47 —Amp Draw Check with Ammeter using this method to check limit control, it can be established that limit is functioning properly and operates if there is a restricted return-air supply or motor failure. If limit control does not function during this test, cause must be determined and corrected. II. CHECK PRESSURE SWITCH This control proves operation of draft inducer. Check switch operation as follows: 1. Turn off 115 -v power to furnace. 2. Remove main furnace door and disconnect inducer motor lead wires from wire harness. 3. Turn on 115 -v power to furnace. 4. Set thermostat to call for heat and wait 1 minute. When pressure switch is functioning properly, hot surface ignitor should NOT glow, and control center diagnostic light flashes a Status Code 31. If hot surface ignitor glows when inducer motor is disconnected, shut furnace down immedi- ately. Determine reason pressure switch did not function properly and correct condition. 5. Turn off 115 -v power to furnace. 6. Reconnect inducer motor leads, reinstall main furnace door, and turn on 115 -v power supply. CHECKLIST 1. Put away tools and instruments. Clean up debris. 2. Verify manual reset switch has continuity. 3. Verify that blower and control access doors are properly installed. 4. Cycle test furnace with room thermostat. 5. Check operation of accessories per manufacturer's instruc- tions. 6. Review User's Guide with owner. 7. Leave literature packet near furnace. LOAD CALCULATION Heating Load (Btuh) Cooling Load (Btuh) Furnace Model Selection COMBUSTION AND VENT PIPING Termination Location Roof or Sidewall Termination Kit — 2 Pipe or Concentric Combustion -Air Pipe Length Combustion -Air Pipe Elbow Quantity Vent Pipe Length Vent Pipe Elbow Quantity Pipe Diameter Determined from Sizing Table Pipe Sloped To Furnace Pipe Insulation Over Ceilings Low - Ambient Exposed Pipes CHECKLIST — INSTALLATION Condensate Drain Unit Level or Pitched Forward Internal Tubing Connections Free of Kinks and Traps External Drain Connection Leak Tight and Sloped Condensate Trap Primed before Start-Up Heat Tape Installed if Required CHECKLIST — START - UP Gas input Rate (Set Within 2 percent of Rating Plate) Temperature Rise Adjusted Thermostat Anticipator Anticipator Setting Adjusted or Cycle Rate (3 Cycles per Hr) Selected Safety Controls Check Operation Primary Limit Pressure Switch • SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book. Classroom Service Training plus "hands -on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog. CALL FOR FREE CATALOG 1 [ ] Packaged Service Training [ ] Classroom Service Training A94328 r-- -- Detach And Dish .l 'ertificate ----, DEPARTMENT OF LABOR AND INDUSTRIES REGISTERED AS PROVIDED BY LAW AS CONST CONT GENERAL REGIST:' .# EXP.. DATE:, CCO1 . NORTHWH103R2:'.o6 /24/1999: EFFECTIVE DATE 7:•12/2211990: NORTHWEST WTR HTR INC /DAVIS WH 2800 THORNDYKE AVE W SEATTLE WA 98199 Detach And Display Certificate REGISTERED AS PROVIDED BY LAW AS� CONST CONT GENERAL REGIST. # EXP. DATE CCO1 NORTHWH103R2 06/24/1999 EFFECTIVE DATE 12/22/1990 NORTHWEST WTR HTR INC /DAVIS WH 2800 THORNDYKE AVE W SEATTLE WA 98199 Signature Issued by DEPARTMENT OF LABOR AND INDUSTRIES State of Washington County of King I'certify that this isa true ante correct copy'ofthe origi Lynh Rowe of Washington Energy Services on Mo d Please Remove And Sign Identification Card Before Placing In Billfold adocument as presented o me by , July 06, 1998, (Signs ure of Nota Marla Shea Notary Public in and for the State of Washington My comrnission 09/09/99: