Bryant 350MAV User Manual

installation, start-up,
and operating instructions

DELUXE 4-WAY MULTIPOISE
FIXED-CAPACITY DIRECT-VENT
CONDENSING GAS FURNACE

Cancels: II 350M-40-7 II 350M-40-8

350MAV

Series D

12-96

A93040

NOTE: Read the entire instruction manual before starting the
installation.

This symbol → indicates a change since the last issue.
Index Page

DIMENSIONAL DRAWING........................................................2

SAFETY CONSIDERATIONS.....................................................3

Clearances to Combustibles......................................................3

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS....3-4

INTRODUCTION..........................................................................4

APPLICATIONS ......................................................................4-11

General......................................................................................4

Upflow Applications..............................................................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

CANADIAN GAS ASSOCIATION

APPROVED

R

HORIZONTAL

RIGHT

AIRFLOW

A93041

®

As an ENERGY STAR
Partner, Bryant/Day &
Night has determined that
this product meets the EN­ERGY STAR guidelines
for energy efficiency.

HORIZONTAL

LEFT

AIRFLOW

Fig. 1—Multipoise Orientations

ama

SM

CERTIFICATION OF MANUFACTURING SITE

AIRFLOW

UPFLOW

DOWNFLOW

AIRFLOW

SEQUENCE OF OPERATION..............................................31-33

Heating Mode....................................................................31-32

Cooling Mode .........................................................................32

Continuous Blower Mode.......................................................32

Heat Pump Mode....................................................................32

Component Test.................................................................32-33

START-UP PROCEDURES ..................................................33-41

General....................................................................................33

Prime Condensate Trap With Water......................................33

Purge Gas Lines......................................................................34

Adjustments .......................................................................34-41

Set Gas Input Rate ............................................................34-40

Set Temperature Rise........................................................40-41

Adjust Blower Off Delay (Heat Mode).................................41

Set Thermostat Heat Anticipator............................................41

CHECK SAFETY CONTROLS..................................................41

Check Primary Limit Control.................................................41

Check Pressure Switch ...........................................................41

CHECKLIST...........................................................................41-42

—1—

⁄2"

1

28

1

⁄16"

15

26

AIRFLOW

⁄4"
26

⁄8"

7

⁄16"

⁄8"

5

OUTLET

2-IN. COMBUSTION-

TYP

5

⁄2-IN. DIA

1

GAS CONN

AIR CONN

⁄8-IN. DIA

7

⁄16"

13

⁄16"

5

19"

22

⁄16"

9

39

POWER CONN

2-IN. VENT CONN

⁄2-IN. DIA

THERMOSTAT ENTRY

1

⁄16"

⁄16"

7

1

⁄4" TYP
22

11

⁄16"

3

24

1"

⁄16"

11

22

SIDE INLET

A93023

BOTTOM INLET

⁄4"

1

18

⁄2"

1

30

(DOWNFLOW &

OR ALTERNATE

TRAP LOCATION

/16"

13

A

D

-IN. DIA GAS CONN

⁄2

1

HORIZONTAL RIGHT)

CONDENSATE DRAIN

OUTLET

CONDENSATE

INLET

HANGING

(UPFLOW)

DRAIN LOCATION

FOR HORIZONTAL

DIMPLE LOCATORS

/16"

11

E

/2-In. rectangle.

/4-In. rectangle.

1

1

/2 x 19

/2 x 23

1

1

/2 x 12-In. rectangle.

1

/16"

13

⁄4"

1

TYP

33

⁄8"

5

TYP

32

⁄16"

13

30

⁄16"

11

TYP

29

⁄8"

5

27

⁄16"

9

TYP

27

⁄2"

1

24

⁄16"

5

/16"

11

DIMENSIONS (IN.)

Fig. 2—Dimensional Drawing

For 800 CFM--16-In. round or 14

For 1200 CFM--20-In. round or 14

For 1600 CFM--22-In. round or 14

For airflow requirements above 1800 CFM, use both side inlets, a

combination of 1 side inlet and the bottom, or the bottom only.

NOTES: Minimum return-air opening at furnace:

1.

2.

3.

4.

17

⁄8-IN. DIA

POWER CONN

7

CONDENSATE

DRAIN TRAP

CONDENSATE DRAIN

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL LEFT)

⁄16"

15

⁄4"

1

26

⁄2"

1

26

⁄16"

24

5

22

⁄2-IN. DIA

1

2-IN. COMBUSTION-

AIR CONN

GAS CONN

2-IN. VENT CONN

⁄8-IN. DIA

ACCESSORY

7

ENTRY

⁄16"

11

22

⁄2-IN. DIA THERMOSTAT

1

LOCATION

POWER ENTRY

⁄16"

7

9

(ALTERNATE

UPFLOW)

SIDE INLET

⁄2"

1

TYP

14

TYP

CONDENSATE

DRAIN LOCATION

(UPFLOW)

⁄4" TYP

⁄16" TYP

1

15

23

SIDE INLET

26

⁄4"

1

1

1"

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

UNIT SIZE A D E

060140 24-1/2 22-7/8 23

—2—

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified person­nel should install, repair, or service heating equipment. Untrained
personnel can perform basic maintenance functions such as clean­ing and replacing air filters. All other operations must be per­formed by trained service personnel. When working on heating
equipment, observe precautions in literature, on tags, and on labels
attached to or shipped with unit and other safety precautions that
may apply.

→

Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA No.
54-1996/ANSI Z223.1-1996 and the Installation Standards, Warm
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 90B. In Canada, refer to the current edition of the
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 symbol
When you see this symbol on unit or in instructions and manuals,
be alert to potential for personal injury.

Understand the signal words DANGER, WARNING, and CAU­TION. These words are used with the safety-alert symbol. DAN­GER 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.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

CAUTION: Electrostatic discharge can affect electronic

components. Take precautions during furnace installation
and servicing to protect the furnace electronic control.
Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the
procedure. These precautions will help to avoid exposing
the control to electrostatic discharge by putting the
furnace, the control, and the person at the same electro­static 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 un­grounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touch­ing control or wires.

5. Use this procedure for installed and uninstalled (un­grounded) furnaces.

This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m),

except 140 size Furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m).

An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be

required for some natural gas applications.

This direct-vent, forced-air furnace 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 furnace 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 COM BUSTIBLE CONSTRUCTION

TOP / PLENUM

10030
11030

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 furnace jacket, and building joists, studs, or framing.

BOTTOM

0

†

Ø

0

††

††

§

††

VENTFRONTBACKSIDES

*

03001

*
*

INSTALLATION

UPFLOW

DOWNFLOW

HORIZONTAL

120 and 140 size Furnaces require 1 inch bottom clearance to combustible materials.

Ø

Minimum front clearance for service 30 inches (762mm).

*

140 size Furnaces require 1 inch back clearance to combustible materials.

††

→ Fig. 3—Clearances to Combustibles

—3—

323855-101 REV. A (LIT)

A96313

6. Before removing a new control from its container, dis­charge your body’s electrostatic charge to ground to protect
the control from damage. If the control is to be installed in
a furnace, follow items 1 through 5 before bringing the
control or yourself into contact with the furnace. Put all
used AND new controls into containers before touching
ungrounded objects.

7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.

INTRODUCTION

→

The model 350MAV, Series D Furnaces are available in sizes
40,000 through 138,000 Btuh input capacities.

→

The 350MAV Multipoise Condensing Gas-Fired Furnaces are
A.G.A./C.G.A. certified for natural and propane gases and for
installation in alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory-shipped for use
with natural gas. An A.G.A./C.G.A. listed gas conversion kit is
required to convert furnace for use with propane gas. The
350MAV 040 through 120 size units are A.G.A./C.G.A. approved
for use in manufactured (mobile) homes when factory accessory
conversion kit is used. The 140 size unit is NOT approved for use
in manufactured (mobile) homes. These furnaces are suitable for
installation in a residence built on site or a manufactured residence
completed at final site. The design of this furnace line is NOT
A.G.A./C.G.A. certified for installation in recreation vehicles or
outdoors.

→

These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring. In
downflow installations, factory accessory floor base MUST be
used when installed on combustible materials and wood flooring.
Special base is not required when this furnace is installed on
manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil
Box Part No. KCAKC is used.

These furnaces are shipped with the drain and pressure tubes
connected for UPFLOW applications. Minor modifications are
required when used in DOWNFLOW, HORIZONTAL RIGHT, or
HORIZONTAL LEFT (supply-air discharge direction) applica­tions 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, heating, plumbing, 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 NSCNG­PIC and all authorities having jurisdiction.

These instructions cover minimum requirements for a safe instal­lation 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 in­doors 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 prema­ture component failure.

WARNING: Improper installation, adjustment, alter­ation, 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 Orienta­tion)

NOTE: See Fig. 5 or tube routing label on main furnace door to

confirm location of these tubes.

1. Collector Box Drain, Inducer Housing Drain, Relief Port,
and Pressure Switch Tubes

These tubes should be factory attached to condensate trap
and pressure switch ready for use in UPFLOW applications.
These tubes can be identified by their connection location

—4—

BLOWER SHELF

CONDENSATE
TRAP (INSIDE)

ALTERNATE DRAIN
TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FURNACE
DOOR

FIELD

DRAIN

CONN

EXTERNAL UPFLOW APPLICATIONS

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

1

2

1

3

4

WIRE TIE
GUIDES
(WHEN USED)

CONDENSATE
TRAP

FURNACE

SIDE

7

8

4

1

4

26

1

2

1

FURNACE
DOOR

FIELD

DRAIN

CONN

FURNACE
SIDE

4

3

4

5

1

4

26

4

5

3

4

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

1

8

7

3

4

1

7

8

1

4

2

1

⁄4 OD
COLLECTOR BOX TO
TRAP RELIEF PORT

1

⁄2 OD
INDUCER HOUSING
DRAIN CONNECTION

5

⁄8 OD
COLLECTOR BOX
DRAIN CONNECTION

SCREW HOLE FOR
UPFLOW OR DOWN-
FLOW APPLICATIONS
(OPTIONAL)

1

⁄2-IN. PVC OR CPVC

HORIZONTAL

APPLICATIONS

3

4

FRONT VIEW SIDE VIEW

Fig. 4—Condensate Trap

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.

A93026

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 discon­nected 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.

—5—

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)

CONDENSATE 
TRAP

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

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)

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 conden­sate trap.

b. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to the con-

densate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube
a. Connect relief port tube (green label) to condensate trap.

→

b. Extend this tube (if required) by splicing to small

diameter tube (factory-supplied in loose parts bag).

c. Determine appropriate length, cut, and connect tube.

A96194

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A96195

Fig. 6—Alternate Upflow Tube Configuration and

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.

—6—

H. Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommenda­tions 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.

c. Connect LOWER collector box drain connection to

condensate trap.
(1.) Condensate Trap Located on Left Side of Casing

(a.) Connect LOWER collector box drain tube

(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

(b.) Connect larger diameter drain tube (factory-

→

(c.) Route extended collector box drain tube di-

(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 conden­sate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

(blue and white striped label) to condensate
trap. Tube does not need to be cut.

loose parts bag) into collector box drain tube
(blue and white striped label) which was pre­viously plugged.

supplied in loose parts bag) to drain tube
coupling, extending collector box drain tube
for connection to condensate trap.

rectly from collector box drain to condensate
trap as shown in Fig. 8.

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX 

EXTENSION TUBE

CONDENSATE

TRAP

INDUCER HOUSING 

DRAIN TUBE (VIOLET)

Fig. 7—Downflow Tube Configuration

(Left-Hand Trap Installation)

A96196

PLUG
CAP

COLLECTOR BOX
DRAIN TUBE (BLUE)

COLLECTOR BOX
TUBE (PINK)

COLLECTOR BOX
TUBE (GREEN)

COLLECTOR BOX
EXTENSION TUBE

COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)

COLLECTOR BOX 
EXTENSION TUBE

INDUCER HOUSING 
DRAIN TUBE 
(VIOLET)

CONDENSATE
TRAP

COLLECTOR BOX 
EXTENSION 
DRAIN TUBE

DRAIN TUBE
COUPLING

A96197

Fig. 8—Downflow Tube Configuration

(Right-Hand Trap Installation)

—7—

d. Use inducer housing drain tube (violet label and factory-

supplied in loose parts bag) to connect LOWER inducer
housing drain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate

trap.
(1.) Condensate Trap Located on Left Side of Casing

(a.) Determine appropriate length and cut.
(b.) Connect tube to condensate trap.
(c.) Clamp tube to prevent any condensate leakage.

(2.) Condensate Trap Located on Right Side of Casing

→

(a.) Route inducer housing drain tube (violet label)

directly from inducer housing to condensate

trap as shown in Fig. 8.
(b.) Determine appropriate length and cut.
(c.) Connect tube to condensate trap.
(d.) Clamp tube to prevent any condensate leakage.

3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection

procedure.

C. Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and
procedures.

D. Pressure Switch Tubing

One collector box pressure tube (pink label) is factory connected to
the pressure switch for use when furnace is installed in UPFLOW
applications. This tube MUST be disconnected and used for the
condensate trap relief port tube. The other collector box pressure
tube (green label) which was factory connected to the condensate
trap relief port connection MUST be connected to the pressure
switch in DOWNFLOW or HORIZONTAL RIGHT applications.

PLUG

AUXILIARY "J" BOX
RELOCATED HERE

NOTE: See Fig. 7 or 8 or tube routing label on main furnace door
to check for proper connections.

Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.

→

2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connec­tion by splicing to small diameter tube (factory-supplied in
loose parts bag).

3. Connect collector box pressure tube (green label) to pres­sure switch connection labeled COLLECTOR BOX.

→

4. Extend collector box pressure tube (pink label) which was
previously connected to pressure switch by splicing to
remaining small diameter tube (factory-supplied in loose
parts bag).

5. Route this extended tube (pink label) to condensate trap
relief port connection.

6. Determine appropriate length, cut, and connect tube.

7. Clamp tube to relief port connection.

E. Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommenda­tions 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.

CAP

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

Fig. 9—Horizontal Left Tube Configuration

—8—

COLLECTOR BOX
TUBE (GREEN)

INDUCER HOUSING
DRAIN TUBE (VIOLET)

COLLECTOR BOX
DRAIN TUBE (BLUE)

A96198

CAUTION: Local codes may require a drain pan under
entire furnace and condensate trap when a condensing
furnace is used in an attic application or over a finished
ceiling.

NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.

NOTE: The auxiliary junction box (J-Box) MUST be relocated to
opposite side of furnace casing. (See Fig. 9.) See Electrical
Connection section for J-Box relocation.

A. Condensate Trap Location

The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2 or 9.

To relocate condensate trap from the blower shelf to desired
location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2
or 9.)

4. Install casing hole filler cap into blower shelf hole where
trap was removed.

5. Install condensate trap into casing hole by inserting tube
connection stubs through casing hole and rotating until tabs
snap into locking position.

B. Condensate Trap Tubing
NOTE: See Fig. 9 or tube routing label on main furnace door to

check for proper connections.

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 conden­sate trap.

b. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to the con-

densate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

→

a. Extend collector box tube (green label) which was

previously connected to the condensate trap by splicing

to small diameter tube (factory-supplied in loose parts

bag).
b. Route extended collector box pressure tube to relief port

connection on the condensate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.

C. Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and
procedures.

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 recommenda­tions 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 mini­mum 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:

—9—

MANUAL

SHUTOFF

GAS VALVE

COMBUSTION – AIR

SEDIMENT
TRAP

INTAKE

5 3⁄4″

CONDENSATE
TRAP

VENT



30″ MIN
WORK AREA

DRAIN

A 12-IN. MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT) VENT SYSTEMS
TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.

ACCESS OPENING
FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

Fig. 10—Attic Location and Working Platform

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 con­nected 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 conden­sate trap.

A93031

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 conden­sate trap.

e. Determine appropriate length, cut, and connect tube to

condensate trap.

f. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection

procedure.

C. Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and
procedures.

D. Pressure Switch Tubing

One collector box pressure tube (pink label) is factory connected to
the pressure switch for use when furnace is installed in UPFLOW
applications. This tube MUST be disconnected and used for the
condensate trap relief port tube. The other collector box pressure
tube (green label) which was factory connected to the condensate
trap relief port connection MUST be connected to the pressure
switch in DOWNFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 11 or tube routing label on main furnace door to
check for proper connections.

Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.

—10—

CAP

PLUG

COLLECTOR BOX DRAIN TUBE 

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 11—Horizontal Right Tube Configuration

2. Extend collector box pressure tube (green label) which was

→

previously connected to condensate trap relief port connec­tion 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 pres­sure 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 recommenda­tions 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.

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

CONDENSATE
TRAP

LOCATION

I. GENERAL

When a furnace is installed so that supply ducts carry air to areas
outside the space containing the furnace, return air must also be
handled by ducts sealed to furnace casing. The ducts terminate
outside the space containing the furnace to ensure there will not be
a negative pressure condition within equipment room or space.
Furnace may be located in a confined space without special
provisions for dilution or ventilation air. This furnace must be
installed so electrical components are protected from water.

LEVEL (0″)

TO

1

⁄2″ MAX

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

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.

LEVEL (0″)

TO

1

⁄2″ MAX

A96199

FRONT

A93025

NOTE: Combustion-air and vent pipes are restricted to a mini­mum 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.)

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.

—11—

FRONT

°F °F

RETURN
AIR

MAX 85°F MIN 55°F

A93042

NOTE: These furnaces are designed for a minimum continuous
return-air temperature of 60°F or intermittent operation down to 55°F
such as when used with a night setback thermostat. Return-air
temperature must not exceed a maximum of 85°F. Failure to follow
these return-air temperature limits may affect reliability of heat
exchangers, motors, and controls.

FRONT

B
A
C
K

BACK

FRONT

32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED

A93058

CAUTION: If these furnaces are installed in an uncon­ditioned 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 clear­ance to combustibles label. (See Fig. 3.) Locate furnace where
available electric power and gas supplies meet specifications on
furnace rating plate.

II. FURNACE LOCATION RELATIVE TO COOLING
EQUIPMENT

The cooling coil must be installed parallel with or on downstream
side of furnace to avoid condensation in heat exchanger. When
installed parallel with a furnace, dampers or other means used to
control flow of air must prevent chilled air from entering furnace.
If dampers are manually operated, they must be equipped with a
means to prevent operation of either unit unless damper is in
full-heat or full-cool position.

III. HAZARDOUS LOCATIONS

A93043

WARNING: Do not install furnace on its back. Safety
control operation will be adversely affected. Never con­nect 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 construc­tion 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 adhe­sives, paints, thinners, masonry cleaning materials, and
many other solvents commonly used in construction
process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.

—12—

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 accor­dance with requirements of National Fire Protection
Association, Inc.

INSTALLATION

I. LEVELING LEGS (IF DESIRED)

When furnace is used in upflow position with side inlet(s), leveling
legs may be desired. (See Fig. 12.) Install field-supplied,
corrosion-resistant 5/16-in. machine bolts and nuts.

5

⁄16″

5

⁄16″

1 3⁄4″

3

⁄4″

1

5

⁄16″

5

⁄16″

1 3⁄4″

1 3⁄4″

A89014

Fig. 12—Leveling Legs

→

II. INSTALLATION IN UPFLOW OR DOWNFLOW
APPLICATIONS

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when special base (available from
manufacturer) Part No. 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.)

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: The maximum length of bolt should not exceed 1-1/2 in.

1. Position furnace on its back. Locate and drill a 5/16-in.
diameter hole in each bottom corner of furnace. (See Fig.

12.) Holes in bottom closure panel may be used as guide
locations.

2. For each hole, install nut on bolt and then install bolt and
nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat
washer if desired.)

4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.

NOTE: Bottom closure must be used when leveling legs are used.
See Bottom Closure Panel section.

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.

—13—

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

FURNACE

SHEET METAL

PLENUM

FLOOR

OPENING

COMBUSTIBLE

FLOORING

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A

PLENUM

OPENING

B

FLOOR

OPENING

C

D

A96283

Fig. 13—Floor and Plenum Opening Dimensions

A96285

Fig. 14—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

FURNACE

CASING

WIDTH

Upflow Applications 16 24-1/8 16-5/8 24-3/4

17-1/2

21

24-1/2

Downflow Applications on Combustible Flooring Using KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Downflow Applications on Combustible Flooring Using KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Downflow Applications on Combustible Flooring Using KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Downflow Applications on Non-Combustible Flooring 15-7/8 19 16-1/2 19-5/8

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

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

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

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

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

TABLE 1—OPENING DIMENSIONS (IN.)

APPLICATION

—14—

A96284

Fig. 15—Furnace, Plenum, and Coil

Assembly or Coil Box Installed

on a Combustible Floor

PLENUM OPENING FLOOR OPENING

ABCD

15-1/8 19 16-3/4 20-3/8

15-1/2 19 16-1/2 20

18-5/8 19 20-1/4 20-3/8

19 19 20 20

22-1/8 19 23-3/4 20-3/8

22-1/2 19 23-1/2 20