Bryant 350MAV User Manual

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Page 1

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

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

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

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Page 2

⁄2"

⁄16"

AIRFLOW

⁄4" 26

⁄8"

⁄16"

⁄8"

OUTLET

2-IN. COMBUSTION-

TYP

⁄2-IN. DIA

GAS CONN

AIR CONN

⁄8-IN. DIA

⁄16"

19"

⁄16"

POWER CONN

2-IN. VENT CONN

⁄2-IN. DIA

THERMOSTAT ENTRY

⁄16"

⁄4" TYP 22

⁄16"

SIDE INLET

A93023

BOTTOM INLET

⁄4"

⁄2"

(DOWNFLOW &

OR ALTERNATE

TRAP LOCATION

/16"

-IN. DIA GAS CONN

⁄2

HORIZONTAL RIGHT)

CONDENSATE DRAIN

OUTLET

CONDENSATE

INLET

HANGING

(UPFLOW)

DRAIN LOCATION

FOR HORIZONTAL

DIMPLE LOCATORS

/16"

/2-In. rectangle.

/4-In. rectangle.

/2 x 19

/2 x 23

/2 x 12-In. rectangle.

/16"

⁄4"

TYP

⁄8"

TYP

⁄16"

⁄16"

TYP

⁄8"

⁄16"

TYP

⁄2"

⁄16"

/16"

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.

⁄8-IN. DIA

POWER CONN

CONDENSATE

DRAIN TRAP

CONDENSATE DRAIN

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL LEFT)

⁄16"

⁄4"

⁄2"

⁄16"

⁄2-IN. DIA

2-IN. COMBUSTION-

AIR CONN

GAS CONN

2-IN. VENT CONN

⁄8-IN. DIA

ACCESSORY

ENTRY

⁄16"

⁄2-IN. DIA THERMOSTAT

LOCATION

POWER ENTRY

⁄16"

(ALTERNATE

UPFLOW)

SIDE INLET

⁄2"

TYP

CONDENSATE

DRAIN LOCATION

(UPFLOW)

⁄4" TYP

⁄16" TYP

SIDE INLET

⁄4"

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—

Page 3

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

†

††

VENTFRONTBACKSIDES

03001

* *

INSTALLATION

UPFLOW

DOWNFLOW

HORIZONTAL

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

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

Page 4

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—

Page 5

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)

WIRE TIE GUIDES (WHEN USED)

CONDENSATE TRAP

FURNACE

SIDE

FURNACE DOOR

FIELD

DRAIN

CONN

FURNACE SIDE

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

⁄4 OD COLLECTOR BOX TO TRAP RELIEF PORT

⁄2 OD INDUCER HOUSING DRAIN CONNECTION

⁄8 OD COLLECTOR BOX DRAIN CONNECTION

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

⁄2-IN. PVC OR CPVC

HORIZONTAL

APPLICATIONS

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—

Page 6

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

⁄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—

Page 7

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—

Page 8

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

Page 9

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—

Page 10

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

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—

Page 11

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

⁄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

⁄2″ MAX

A96199

FRONT

A93025

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.)

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—

Page 12

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.

Page 13

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.

⁄16″

1 3⁄4″

⁄4″

⁄16″

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—

Page 14

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

PLENUM

OPENING

FLOOR

OPENING

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

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

Page 15

PERFORATED DISCHARGE DUCT FLANGE

III. INSTALLATION IN HORIZONTAL APPLICATIONS

These furnaces can be installed horizontally in either horizontal

→

left or right discharge position. In a crawlspace, furnace can either be hung from floor joist or installed on suitable blocks or pad. Furnace can be suspended from each corner by hanger bolts and angle iron supports. (See Fig. 17.) Cut hanger bolts (4 each 3/8-in. all-thread rod) to desired length. Use 1 X 3/8-in. flat washers, 3/8-in. lockwashers, and 3/8-in. nuts on hanger rods as shown in Fig. 17. Dimples are provided for hole locations. (See Fig. 2.)

210°

MIN

Fig. 16—Duct Flanges

YES

A93029

→

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.

ANGLE IRON OR EQUIVALENT

(B)

(A) ROD LOCATION

USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS)

(A) PREFERRED ROD LOCATION  (B) ALTERNATE ROD LOCATION

5 3⁄4″

(B)

(A)

DRAIN

(A)

(B)

/8-IN. HEX NUT

& WASHER (4)

REQD PER ROD

NOTES:

(A)

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.

(B)

ALTERNATE SUPPORT LOCATION FROM BACK

Fig. 17—Crawlspace Horizontal Application

/16-IN. MAX

⁄8-IN. ROD

ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX

A93304

—15—

Page 16

IV. FILTER ARRANGEMENT

BOTTOM CLOSURE PANEL

FRONT FILLER PANEL

CAUTION: Never operate unit without a filter or with blower access panel removed.

Factory-supplied washable framed filters are 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

FURNACE

CASING

WIDTH (IN.)

17-1/2 (1) 16 X 25 X 1† (1) 16 X 25 X 1 Cleanable

21 (1) 16 X 25 X 1 (1) 20 X 25 X 1† Cleanable

24-1/2 (2) 16 X 25 X 1† (1) 24 X 25 X 1 Cleanable

* 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.

† Factory-provided with furnace.

FILTER SIZE (IN.)*

Side Return Bottom Return

FILTER TYPE

FRAMED

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.

171⁄2-IN. WIDE  CASINGS ONLY:

INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER.

3″

/2″

1″

241⁄2-IN. WIDE  CASINGS ONLY:

CUT AND FOLD FACTORY-PROVIDED FILTERS AS SHOWN TO DESIRED SIZE.

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.

—16—

WASHABLE FILTER

FILTER SUPPORT

FILTER RETAINER

Fig. 19—Bottom Filter Arrangement

Fig. 20—Removing Bottom Closure Panel

A96030

A93047

Page 17

VI. GAS PIPING

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 3 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

CAUTION: Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls.

WARNING: Gas valve shutoff switch MUST be facing forward or tilted upward. Failure to follow this warning could result in property damage or death.

WARNING: Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap-and-water solution to check for leakage. A failure to follow this warning could result in fire, explosion, personal injury, or death.

WARNING: Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death.

TABLE 3—MAXIMUM CAPACITY OF PIPE*

NOMINAL

IRON

PIPE SIZE

(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

→ * 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.

INTERNAL

DIAMETER

(IN.)

LENGTH OF PIPE (FT)

10 20 30 40 50

GAS SUPPLY

MANUAL SHUTOFF VALVE (REQUIRED)

SEDIMENT TRAP

plugged tapping, accessible for test gage connection, MUST be

Fig. 21—Typical Gas Pipe Arrangement

UNION

A93324

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.

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 allowed 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

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.

—17—

Page 18

BLK

ALTERNATE FIELD LOCATION

FACTORY

INSTALLED

LOCATION

WHT

BLK

WHT

GND

115-VOLT FUSED

DISCONNECT

SWITCH

(WHEN

REQUIRED)

FIVE

WIRE

THREE-WIRE

NOTE 2

WCR GY

THERMOSTAT TERMINALS

HEATING-

ONLY

GND

AUXILIARY J-BOX

CONTROL

BOX

FURNACE

C Y

24-VOLT

TERMINAL

BLOCK

NOTE 1

CONDENSING UNIT

TWO WIRE

NOTES: Connect Y-terminal as shown for proper operation.

1.

2.

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.

→ Fig. 22—Heating and Cooling Application Wiring Diagram

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- VOLT SINGLE

GND

PHASE

A96415

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

ALUMINUM

WIRE

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 ANSI/NFPA 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 provided.

A93051

Fig. 23—Relocating J-Box

CAUTION: If manual disconnect switch is to be

mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components.

II. 24-V WIRING

Make field 24-v thermostat connections at 24-v terminal block on control center. For proper cooling operation, Y wire from thermostat 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 wire.

—18—

Page 19

TO 115VAC FIELD DISCONNECT

CAP-1

START

SCHEMATIC DIAGRAM

(NATURAL GAS & PROPANE)

EQUIPMENT GROUND

NEUTRAL

NOTE #4

LGPS

(WHEN USED)

PRS

MED LO

MED HI

COM

NOTE #8

COM

COOL

SPARE-1

HI/LO

BLWR

3-P

1-M

BLU

FRS

RED

ILK

HEAT

SPARE-2

YEL

NOTE #6

IDM

BLWM

HSI

EAC-2

EAC-1

HSIR

NOTE #5

2-C

GRN

RED

FSE

BRN

AUX

PL52

PL2

IDR

WHT

BLK

BLU

CAP -2

BRN

PL4

PL3

PR2

115VAC

TRAN

PR1

GRN

WHT (COM)

BRN

TRAN

RED

2-C

(WHEN USED)

FRS

CAP -1

START

NOTE #7

FU1

TEST/TWIN

SEC-2

SEC-1

GVR-2

HUM

NOTE #12

BRN

BLWM

24VAC

NOTE #6

LGPS

PL1

HI/LO

BLWR

HSIR

FUSED DISCONNECT

BLK

WHT

PRS

3-P

1-M

GVR

IDR

SWITCH (WHEN REQ’D)

GVR-1

CPU

NEUTRAL

NOTE #4

FU2

BLK

GRN

WHT

GRN

ILK

FSE

NOTE #5

PL1 9-CIRCUIT CONNECTOR

PL2 2-CIRCUIT PCB CONNE CT OR

PL3 3-CIRCUIT IDM CONNECTOR

PL4 3-CIRCUIT IDM EXTENSION CONN ECTOR

PL5 2-CIRCUIT HSI/PCB CONNECTOR

AUTO-RESET THERMAL OVERLOAD SWITCHES (OL).

INSTRUCTIONS FOR DETAILS ON OPTIMUM SPEED SELECTION.

FURNACE JUNCTION BOX (JB).

1. IF ANY OF THE ORIGINAL EQUIPMENT WIRE IS REPLACED USE WIRE RATED FOR 105°C.

FLAME.

2. INDUCER (IDM) AND BLOWER (BLWM) MOTORS CONTAIN INTERNAL

3. BLOWER MOTOR SPEED SELECTIONS ARE FOR AVERAGE CONDITIONS, SEE INSTALLATION

4. USE ONLY COPPER WIRE BETWEEN THE DISCONNECT SWITCH AND THE

5. THIS WIRE MUST BE CONNECTED TO FURNACE SHEETMETAL FOR CONTROL TO PROVE

NOTES:

JUNCTION

UNMARKED TERMINAL

PRS PRESSURE SWITCH, SPST-(N.O.)

SW1 & 2 BLOWER OFF DELAY

TEST/TWIN COMPONENT TEST & TWIN TERMINAL

TRAN TRANSFORMER-115VAC/24VAC

6. FACTORY CONNECTED WHEN LGPS NOT USED.

PCB TERMINAL

FACTORY WIRING (115VAC)

FACTORY WIRING (24VAC)

FIELD WIRING (115VAC)

HEAT PUMP 90 SECONDS. (135 SECONDS ONLY ON SOME MODELS)

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

11. IGNITION-LOCKOUT WILL OCCUR AFTER FOUR CONSECUTIVE UNSUCCESSFUL

FIELD WIRING (24VAC)

CONDUCTOR ON PCB

FIELD WIRING TERMINAL

FIELD GROUND

EQUIPMENT GROUND

A95087

322854-101 REV. C

TRIALS-FOR-IGNITION. CONTROL WILL AUTO-RESET AFTER THREE HOURS.

12. SOME MODELS MAY HAVE SPADE QUICK CONNECT TERMINALS.

PLUG RECEPTACLE

Fig. 24—Wiring Diagram

FIELD SPLICE

GRY

SW2

OFF

BLOWER

SEE NOTE #10

PCB

RED

ORN

LED

HUM

SW1

TEST/TWIN

DELAY

WHT

1 2 3

PL1

5 6

87 9

WHT

SEC-2

SEC-1

HI/LO

YEL (MED HI)

BLK (HI)

SPARE-1

FUSE

24 VAC-3A

COOL

FU1

SPEED

BLOWER

RELAY

GVR

90 SEC

135 SEC

180 SEC

225 SEC

SELECTION CHART

BLOWER OFF DELAY

(NOT ON ALL MODELS)

HSIR IDR BLWR

RED (LO)

NOTE #8

BLU (MED LO)

SPARE-2

EAC-1

HEAT

SELECT

PL3

123

PL2

WHT (COM)

1.5 AMP

EAC-2

PR2

WHT

GRN

BLK

PR1

VAC

120

CAP -2

PL4 3 2

WHT

BLK BLK

BLK

BRN

WHT

PL5

IDM

AUX

BLK

GRN

HSI

(FIELD INSTALLED & SUPPLIED)

BLWR BLOWER MOTOR RELAY, SPST-(N.O.)

BLWM BLOWER MOTOR

CAP CAPACITOR

CPU MICROPROCESSOR AND CIRCUITRY

EAC-1 ELECTRONIC AIR CLEANER CONNE CTION (115 VAC 1.5 AMP MAX.)

EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)

FRS FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)

FSE FLAME PROVING ELECTRODE

FU1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED

FU2 FUSE OR CIRCUIT BREAKER CURR E NT INT E RR UP T DE VICE

GV GAS VALVE-REDUNDANT OPERATORS

GVR GAS VALVE RELAY, DPST-(N.O.)

HI/LO BLOWER MOTOR SPEED CHANGE RELAY, SPDT

HSI HOT SURFACE IGNITOR (115 VAC)

HSIR HOT SURFACE IGNITOR RELAY, SPST-(N.O .)

HUM 24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)

IDM INDUCED DRAFT MOTOR

IDR INDUCED DRAFT RELAY, SPST-(N.O.)

ILK BLOWER ACCESS PA N EL IN TERLOCK SWITCH, SPST- (N .O. )

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES

LGPS LOW GAS PRESSURE SWITCH, SPST-(N.O.)

LS LIMIT SWITCH, AUTO RESET, SPST(N.C.)

OL AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.

LEGEND

PCB PRINTED CIRCUIT BOARD

—19—

Page 20

TABLE 4—ELECTRICAL DATA

UNIT

SIZE

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

→060140 115—60—1 127 104 14.3 18.8 12 30 20

* Permissible limits of voltage range at which unit will operate satisfactorily. † Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load

amps. ‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. ** Time-delay fuse is recommended.

VOLTS— HERTZ—

PHASE

OPERATING

VOLTAGE RANGE

Max* Min*

MAX UNIT

AMPS

UNIT

AMPACITY†

MIN

WIRE

SIZE

MAX WIRE

LENGTH

(FT)‡

MAX FUSE

OR CKT BKR

AMPS**

III. 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.

TEST/TWIN

2. Humidifier (HUM)

NOTE: A field-supplied, 115-v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation.

BLOWER OFF DELAY ADJUSTMENT SWITCH

G

R Y

Com

24V 

HUM

24V THERMOSTAT TERMINALS

HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX)

LED OPERATION & STATUS LIGHT

HARNESS CONNECTOR

Screw terminals (HUM and C

OM) 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.

115-VAC (L1)

POWER

SUPPLY

HOT SURFACE

CONNECTOR

SEC-1

3-AMP FUSE

COOL

HEAT

IGNITOR

24V TRANSFORMER SEC-2 SPARE 1 BLOWER SPEED

SELECTION TERMINALS SPARE 2

EAC 1 (BLACK) EAC-ELECTRONIC AIR CLEANER

TERMINALS (115-VAC 1.5 AMP MAX) EAC 2 (WHITE)

115-VAC (L2) NEUTRAL CONNECTION

INDUCER MOTOR CONNECTOR

A93052

Fig. 25—Control Center

—20—

Page 21

EAC1

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 operation, 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 Z223.1 or the CAN/CGA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition.

3. In so far as is practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

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 operation. 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 dampers, 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 NSCNGPIC.

II. COMBUSTION-AIR AND VENT PIPING A. General

Combustion-air and vent pipe fittings must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785

(schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661 (ABS-DWV), F628 (schedule-40 ABS), 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

LOCATION

Above grade level or above anticipated snow depth

Dryer vent 33 From plumbing vent stack 33 From any mechanical fresh air intake 16 For furnaces with an input capacity

less than 100,000 Btuh—from any nonmechanical air supply (windows or doors which can be opened) or combustion-air opening

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

From service regulator vent, electric and gas meters, and relief equipment

Above grade when adjacent to public walkway

* Horizontal distance. † 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.

CLEARANCE (FT)

U.S.A. Canada

11†

4* 6‡

—21—

Page 22

Furnace combustion-air and vent pipe connections must be attached 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.

Select 1 vent pipe connection and

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

AIR

COMBUSTION-

AIR

VENT

COMBUSTION-

AIR

FLOW

COMBUSTION-

UPFLOW DOWNFLOW

AIR

VENT

AIR

VENT

NOTE:

1 combustion-air pipe connection.

VENT

COMBUSTION-

AIR

AIR

FLOW

COMBUSTION-

VENT

COMBUSTION-

AIR

AIR

FLOW

WARNING: Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well-ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes. Failure to follow this warning could result in fire, property damage, personal injury, or death.

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.

1. Using Table 6, individually determine the combustion-air and vent pipe diameters. Pick the larger of these 2 pipe diameters and use this diameter for both combustion-air and vent pipes.

2. When installing vent systems of short pipe length, use the smallest allowable pipe diameter. Do not use pipe size greater than required or incomplete combustion, flame disturbance, or flame sense lockout may occur.

NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 31, 32, 33, 34, and 35.

HORIZONTAL-LEFT DISCHARGE HORIZONTAL-RIGHT DISCHARGE

A96187

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 Armaflex-type insulation.

CAUTION: Combustion air must not be taken from inside structure because inside air is frequently contaminated 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 products. 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.

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.

→

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.

—22—

Page 23

12″ MIN

VENT PIPE

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

COMBUSTION-AIR PIPE

VENT PIPE

COMBUSTION-AIR PIPE COMBUSTION-AIR PIPE

COMBUSTION-AIR PIPE

VENT PIPE

12″ MIN

VERTICAL TO SIDEWALLVERTICAL TO ROOF

VENT PIPE

NOTE: A 12 In. minimum offset pipe section is recommended with

short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe.

Fig. 29—Short Vent (5 to 8 Ft) System

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.

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 connection. Tighten clamp.

—23—

Page 24

ALTITUDE UNIT SIZE

0 to 2000

ALTITUDE UNIT SIZE

2001 to 3000

ALTITUDE UNIT SIZE

3001 to 4000

See notes on page 26.

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120

→060140

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120

→060140

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120

→060140

TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT)

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIA

(IN.)*

1 5 NA NA NA NA NA

1-1/2 70 70 65 60 60 55

2 707070707070

1-1/2 20 15 10 5 NA NA

2 707070707070

1-1/2 10 NA NA NA NA NA

2 555035303020

2-1/2 70 70 70 70 70 70

2 5 NA NA NA NA NA

2-1/2 40 30 20 20 10 NA

3 707070707070

2-1/2 one disk 10 NA NA NA NA NA

3† 45 40 35 30 25 20 3† no disk 70 70 70 70 70 70 4† no disk 70 70 70 70 70 70

2-1/2 one disk 5 NA NA NA NA NA

3† one disk 40 35 30 25 20 15

3† no disk 60 56 52 48 44 40 4† no disk 70 70 70 70 70 70

PIPE DIA

(IN.)*

1-1/2 67 62 57 52 52 47

2 707070707070

1-1/2 17 12 7 NA NA NA

2 706766616161 2 494430252515

2-1/2 70 70 70 70 70 70 2-1/2 35 26 16 16 6 NA

3 707070706661

3 14 9 NANANANA 3† no disk 70 70 63 56 50 43 4† no disk 70 70 70 70 70 70

3† one disk 20 15 10 5 NA NA

3† no disk 39 35 31 27 23 19 4† no disk 70 70 70 70 70 70

PIPE DIA

(IN.)*

1-1/2 64 59 54 49 48 43

2 707070707070

1-1/2 16 11 6 NA NA NA

2 686362575756

2 464128232213

2-1/2 70 70 70 70 70 70 2-1/2 33 24 15 14 5 NA

3 707070666156 3† no disk 65 58 51 44 38 31 4† no disk 70 70 70 70 70 70

3† one disk 11 6 NA NA NA NA

3† no disk 30 26 22 18 14 10 4† no disk 70 70 70 70 70 70

123456

NUMBER OF 90° ELBOWS

—24—

Page 25

ALTITUDE UNIT SIZE

4001 to 5000‡

ALTITUDE UNIT SIZE

5001 to 6000‡

ALTITUDE UNIT SIZE

6001 to 7000‡

ALTITUDE UNIT SIZE

7001 to 8000‡

See notes on page 26.

TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT) Continued

TERMINATION

TYPE

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120

→060140

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120

→060140

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120

→060140

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120 →060140 NA

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3 In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIA

(IN.)*

1-1/2 60 55 50 45 44 39

2 70707070 70 70

1-1/2 15 10 5 NA NA NA

2 64595853 52 52 2 44392621 20 11

2-1/2 70 70 70 70 70 70 2-1/2 31 22 13 12 NA NA

3 70706762 57 52 3† no disk 53 46 40 33 26 20 4† no disk 70 70 70 70 70 70 3† no disk 21 17 13 9 5 NA 4† no disk 69 64 59 54 49 44

PIPE DIA

(IN.)*

1-1/2 57 52 47 42 40 35

2 707070707070

1-1/2 14 9 NA NA NA NA

2 605554494847

2 4136231817 8

2-1/2 70 70 70 70 70 70 2-1/2 29 21 12 11 NA NA

3 706762575247 3† no disk 42 35 29 22 15 9 4† no disk 70 70 70 70 70 70 3† no disk 12 8 NA NA NA NA 4† no disk 42 37 32 27 22 17

PIPE DIA

(IN.)*

1-1/2 53 48 43 38 37 32

2 707068676664

1-1/2 13 8 NA NA NA NA

2 575250454443

2 3833211615 6

2-1/2 70 70 68 67 66 64 2-1/2 27 19 10 9 NA NA

3 686358534843 3† no disk 31 24 18 11 NA NA 4† no disk 70 70 70 70 67 62

4† no disk 17 12 7 NA NA NA

PIPE DIA

(IN.)*

1-1/2 49 44 39 34 33 28

2 666563626059

1-1/2 12 7 NA NA NA NA

2 534846414038

2 3631191412NA

2-1/2 66 65 63 62 60 59 2-1/2 25 17 8 7 NA NA

3 635853484338 3† no disk 20 13 7 NA NA NA 4† no disk 61 56 51 46 41 36

1234 5 6

123456

NUMBER OF 90° ELBOWS

—25—

Page 26

TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT) Continued

ALTITUDE UNIT SIZE

024040 036040

024060 036060 048060

036080

8001 to 9000‡

ALTITUDE UNIT SIZE

9001 to 10,000‡

* Disk usage—Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag). If one disk is stated, separate 2 halves of perforated disk

assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box. † Wide radius elbow. ‡ Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction. NA—Not Allowed; pressure switch will not make.

NOTES:

1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.

2. Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes.

3. Assume two 45° elbows equal one 90° elbow. Long radius elbows are desirable and may be required in some cases.

4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.

5. The minimum pipe length is 5 ft for all applications.

6. Use 3-in. diameter vent termination kit for installations requiring 4-in diameter pipe.

048080 060080

048100 060100

→060120 →060140 NA

024040 036040

024060 036060 048060

036080 048080 060080

048100 060100

→060120 →060140 NA

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIA

(IN.)*

1-1/2 46 41 36 31 29 24

2 626058565553

1-1/2 11 6 NA NA NA NA

2 494442373534 2 3328171210NA

2-1/2 62 60 58 56 55 53 2-1/2 23 15 7 5 NA NA

3 595449443934 3† no disk 10 NA NA NA NA NA 4† no disk 35 30 25 20 15 10

PIPE DIA

(IN.)*

1-1/2 42 37 32 27 25 20

2 575553514947

2 454038333129

230251497NA

2-1/2 57 55 53 51 49 47 2-1/2 21 13 5 NA NA NA

3 544944393429 4† no disk 10 5 NA NA NA NA

123456

NUMBER OF 90° ELBOWS

COMBUSTION – AIR

3/8" ID TUBE

3/16"

DRILL

TRAP

TO OPEN

DRAIN

4″

MIN

INTAKE HOUSING

BURNER BOX

COMBUSTION – AIR PIPE 

Fig. 30—Intake Housing Plug Fitting Drain

WARNING: Inducer housing outlet cap must be in-

stalled and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

c. Install pipe support (factory-supplied in loose parts bag)

into selected furnace casing vent pipe hole. Pipe support should be positioned at bottom of casing hole.

A93035

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.

—26—

Page 27

5. Chamfer outside edge of pipe for better distribution of primer and cement.

6. Clean and dry all surfaces to be joined.

7. Check dry fit of pipe and mark insertion depth on pipe.

NOTE: It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint.

8. After pipes have been cut and preassembled, apply generous 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.

→

2. The 3-in. termination 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 penetration 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 furnace 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 equipment.

→ TABLE 7—MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH (FT) WITH AND WITHOUT INSULATION

IN WINTER DESIGN TEMPERATURE AMBIENT*

UNIT

SIZE

040

060

080

100

120

140

* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as

specified in Table 6.

† Insulation thickness based on R value of 3.5 per in.

WINTER DESIGN

TEMPERATURE

(°F)

20 1-1/2 51 70

0 1-1/2 28 70

-20 1-1/2 16 70 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 20 3 70 70

0 3 50 70

-20 3 28 70 20 4 70 70

0 4 48 70

-20 4 23 70 20 4 70 70

0 4 57 70

-20 4 30 70

MAX PIPE

DIAMETER

(IN.)

WITHOUT

INSULATION

WITH 3/8-IN. OR

THICKER INSULATION†

—27—

Page 28

VERTICAL SEPARATION

MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.

90°

VENT

12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT

BRACKET

COUPLING

12″ MINIMUM

OVERHANG OR ROOF

COMBUSTION-AIR (ELBOW PARALLEL TO WALL)

MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.

COMBUSTION-AIR

VENT

1″ MAXIMUM

12″ MINIMUM

OVERHANG OR ROOF

BETWEEN COMBUSTION

MAXIMUM OF 24 IN. ABOVE ROOF.

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.

COUPLING

VENT

ROOF

18″ MAXIMUM

BRACKET

COMBUSTION AIR

Fig. 31—Roof Termination (Preferred)

VENT

COMBUSTION AIR

MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

Fig. 32—Concentric Vent and Combustion-Air Roof

Termination (Preferred)

OVERHANG OR ROOF

A93054

A87224

A93055

Fig. 33—Concentric Vent and Combustion-Air Side

Termination

12″ MINIMUM

VENT

90°

COMBUSTION-AIR

12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT

MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.

BRACKET

Fig. 34—Sidewall Termination of 12 in. or More

A87225

A87226

Fig. 35—Sidewall Termination of Less than 12 in.

—28—

Page 29

c. Termination kit should be positioned so that it will not be

affected by wind eddy (such as inside building corners) or allow recirculation of flue gases, airborne leaves, or light snow.

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 properly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 31.

For applications using combustion-air pipe option, indicated 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 equipment.

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 components together using instructions in kit.

4. Slide assembled kit with rain shield REMOVED through hole.

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

Roof terminations—Locate assembly through roof to appropriate height as shown in Fig. 32.

Sidewall terminations—Locate assembly through sidewall with rain shield positioned no more than 1-in. from wall as shown in Fig. 33.

5. Disassemble loose pipe fittings. Clean and cement using same procedures 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 condensate spillage, select a pump with an overflow switch. Furnace condensate is mildly acidic, typically in the pH range of

3.2 to 4.5. Due to corrosive nature of this condensate, a condensate pH neutralizing filter may be desired. Check with local authorities to determine if a pH neutralizer is required.

II. APPLICATION

The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, fieldsupplied 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 draining where slippery conditions may cause personal injuries. 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 recommendations.

—29—

Page 30

Fig. 36—Rooftop Termination (Dimension "A" is Touching or 2-In. Maximum Separation)

A96128

VENT

COMBUSTION AIR

A93056

Fig. 37—Concentric Vent and Combustion-Air

Roof Termination

(Dimension "A" is Touching or 2-In. Maximum Separation)

VENT

1″ MAXIMUM (TYP)

COMBUSTION AIR

VENT

A93057

Fig. 38—Concentric Vent and Combustion-Air

Side Termination

(Dimension "A" is Touching or 2-In. Maximum Separation)

VENT

COMBUSTION AIR

A96129

Fig. 39—Sidewall Termination of 12 in. or Less

(Dimension "A" is Touching or 2-In. Maximum Separation)

—30—

COMBUSTION AIR

A96130

Fig. 40—Sidewall Termination of More Than 12 in.

(Dimension "A" is Touching or 2-In. Maximum Separation)

Page 31

OPEN STAND

CONDENSATE TRAP

WIRE TIE(S)

HEAT TAPE

(3 WRAPS MINIMUM)

PIPE FOR

A/C OR

HUMIDIFIER

DRAIN

TEE

TO OPEN DRAIN

5. When using field-supplied heat tape, follow heat tape manufacturer’s instructions for all other installation guidelines.

Fig. 41—Example of Field Drain Attachment

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, approximately 1 wrap per ft.

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

A94054

A93058

Fig. 42—Condensate Trap Heat Tape

SEQUENCE OF OPERATION

CAUTION: Furnace control must be grounded for

proper operation, or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw.

Using schematic diagram, follow sequence of operation through different modes. (See Fig. 24.) Read and follow wiring diagram carefully. 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.

→

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.

A93036

—31—

Page 32

6. Blower off delay—When thermostat is satisfied, circuit

between R-W is opened, de-energizing gas valve (stopping gas flow to burners) and humidifier. Blower motor and electronic air cleaner remains energized 90, 135, 180, or 225 sec (depending on blower off time selection). Furnace is factory shipped set for a 135-sec blower off delay.

→

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. Electronic 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-1 terminal is energized with 115v whenever blower is operating.

→

If a call for heat (R-W) occurs while thermostat is in continuous blower mode, blower stops to allow furnace heat exchangers to heat up more quickly, then restarts at end of blower on delay period of 60 sec (40 sec if jumper has been cut for 140 size unit in downflow orientation).

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.

→

When R-W thermostat call disappears, control completes inducer post-purge period of 15 sec (5 sec if jumper has been cut for 140 size unit in downflow orientation) and changes to cooling speed after a 2-sec delay.

→

If R-W, R-Y, and R-G thermostat signals should disappear simultaneously, blower remains on for selected heating blower off delay period (90, 135, 180, or 225 sec), and the inducer goes through 15 sec post-purge period (5 sec if jumper has been cut for 140 size unit in downflow orientation). If R-W and R-Y thermostat signals should disappear, leaving R-G thermostat signal, blower remains on in heating speed and inducer remains on for 15 sec (5 sec if jumper has been cut for 140 size unit in downflow orientation) to complete post-purge period. Control initiates a 90-sec blower only on period before starting another heat pump cycle if there is a power interruption. Anytime control senses false flame, control locks out of heating mode. This reaction occurs because control ignores W input due to false flame signal and, as a result, sees only Y input and goes into cooling mode blower off delay. All other control functions remain in standard format.

NOTE: EAC-1 terminal is energized whenever blower operates. HUM terminal is only energized when gas valve is energized.

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:

1. LED flashes a status code 4 times.

2. Inducer motor starts and continues to run for remainder of component test.

3. Hot surface ignitor is energized for 15 sec, then deenergized.

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 procedures.

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 contact 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 continuously 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.

—32—

Page 33

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 C

OM terminal on thermostat connection block.

(See Fig. 25.)

NOTE: If TEST to C

OM 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 connected 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.

5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp.

A94208

Fig. 43—Inducer Housing Drain Tube

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 enclosure. Correct inadequate combustion-air supply or improper venting condition and reset switch. DO NOT jumper this switch.

Before operating furnace, check each manual reset switch for continuity. If necessary, press button to reset switch.

II. 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 pouring 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.)

A94209

Fig. 44—Filling Condensate Trap

—33—

Page 34

III. PURGE GAS LINES

If not previously done, purge lines after all connections have been made and check for leaks.

WARNING: Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning could result in fire, explosion, personal injury, or death.

IV. ADJUSTMENTS A. Set Gas Input Rate

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft.

In the U.S.A., the input ratings for altitudes above 2000 ft must be

→

reduced by 2 percent for each 1000 ft above sea level. In Canada, the input ratings must be derated by 5 percent for

→

altitudes of 2000 ft to 4500 ft above sea level. Furnace input rate must be within ±2 percent of input on furnace

→

rating plate adjusted for altitude.

1. Determine natural gas orifice size and manifold pressure for correct input.

a. Obtain average yearly heat value (at installed altitude)

from local gas supplier.

b. Obtain average yearly specific gravity from local gas

supplier.

→

→ →

→

c. Verify furnace model and size. Table 8 can only be used

for model 350MAV furnaces with heating sizes of 040 through 120. Table 9 can only be used for model 350MAV furnaces with a 140 heating size.

d. Find installation altitude in Table 8 or 9.

NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 8 or 9.

e. Find closest natural gas heat value and specific gravity

on Table 8 or 9.

f. Follow heat value and specific gravity lines to point of

intersection to find orifice size and manifold pressure settings for proper operation.

NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft. For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc.

CAUTION: DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

ON AND OFF SWITCH

GAS PRESSURE REGULATOR ADJUSTMENT

BURNER ENCLOSURE REFERENCE PRESSURE TAP

INLET PRESSURE TAP

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.

MANIFOLD PRESSURE TAP

A95622

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.

BURNER 

ORIFICE

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 exchangers 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.

—34—

Page 35

→ TABLE 8—MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT

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)

ALTITUDE

RANGE

(FT)

0 925 44 3.5 44 3.7 44 3.8 43 3.4 43 3.5

to 975 44 3.2 44 3.3 44 3.4 44 3.5 44 3.6

2000 1025 45 3.5 45 3.6 45 3.7 44 3.2 44 3.3

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. 775 43 3.8 42 3.2 42 3.3 42 3.4 42 3.5

Altitudes 800 43 3.5 43 3.7 43 3.8 42 3.2 42 3.3

2001 825 44 3.8 43 3.4 43 3.6 43 3.7 43 3.8

to 850 44 3.6 44 3.7 44 3.8 43 3.5 43 3.6

3000 875 44 3.4 44 3.5 44 3.6 44 3.7 43 3.4

or 900 44 3.2 44 3.3 44 3.4 44 3.5 44 3.6

Canada 925 45 3.7 45 3.8 44 3.2 44 3.3 44 3.4

Altitudes 950 45 3.5 45 3.6 45 3.7 45 3.8 44 3.3

U.S.A. and Canada

2000 975 45 3.3 45 3.4 45 3.5 45 3.6 45 3.8

to 1000 45 3.1 45 3.2 45 3.4 45 3.5 45 3.6

4500 1025 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

ALTITUDE

RANGE

(FT)

3001 825 44 3.5 44 3.6 44 3.8 43 3.4 43 3.5

to 875 45 3.8 44 3.2 44 3.3 44 3.5 44 3.6

U.S.A. Only

4000 925 45 3.4 45 3.5 45 3.6 45 3.7 44 3.2

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

850 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4 875 43 3.5 43 3.6 43 3.7 43 3.8 42 3.2 900 44 3.7 43 3.4 43 3.5 43 3.6 43 3.7

950 44 3.4 44 3.5 44 3.6 44 3.7 44 3.8

1000 45 3.7 45 3.8 44 3.2 44 3.4 44 3.5

1050 45 3.3 45 3.4 45 3.6 45 3.7 45 3.8 1075 45 3.2 45 3.3 45 3.4 45 3.5 45 3.6 1100 47 3.6 47 3.7 45 3.2 45 3.4 45 3.5

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

750 43 3.7 43 3.8 42 3.3 42 3.4 42 3.5 775 43 3.5 43 3.6 43 3.7 43 3.8 42 3.2 800 44 3.7 43 3.4 43 3.5 43 3.6 43 3.7

850 44 3.3 44 3.4 44 3.5 44 3.7 44 3.8

900 45 3.6 45 3.7 45 3.8 44 3.3 44 3.4

950 45 3.2 45 3.3 45 3.4 45 3.5 45 3.7 975 45 3.0 45 3.2 45 3.3 45 3.4 45 3.5

1000 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

—35—

Page 36

→ TABLE 8—MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued

FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY

(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)

ALTITUDE

RANGE

(FT)

4001 800 44 3.5 44 3.6 44 3.7 44 3.8 43 3.4

to 850 45 3.7 45 3.8 44 3.3 44 3.4 44 3.5

U.S.A. Only

5000 900 45 3.3 45 3.4 45 3.5 45 3.6 45 3.8

ALTITUDE

RANGE

(FT)

5001 800 44 3.2 44 3.3 44 3.4 44 3.5 44 3.6

to 850 45 3.4 45 3.5 45 3.6 45 3.8 44 3.2

U.S.A. Only

6000 900 45 3.0 45 3.1 45 3.3 45 3.4 45 3.5

ALTITUDE

RANGE

(FT)

6001 725 44 3.6 44 3.7 44 3.8 43 3.4 43 3.5

to 775 45 3.8 44 3.2 44 3.3 44 3.4 44 3.5

U.S.A. Only

7000 825 45 3.3 45 3.4 45 3.6 45 3.7 45 3.8

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4

750 43 3.4 43 3.5 43 3.7 43 3.8 42 3.2

775 44 3.7 44 3.8 43 3.4 43 3.5 43 3.7

825 44 3.2 44 3.4 44 3.5 44 3.6 44 3.7

875 45 3.5 45 3.6 45 3.7 44 3.2 44 3.3

925 45 3.1 45 3.2 45 3.3 45 3.4 45 3.6

950 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

700 43 3.6 43 3.7 42 3.2 42 3.3 42 3.4

725 43 3.4 43 3.5 43 3.6 43 3.7 43 3.8

750 44 3.6 44 3.7 43 3.4 43 3.5 43 3.6

775 44 3.4 44 3.5 44 3.6 44 3.7 43 3.4

825 45 3.6 45 3.7 44 3.2 44 3.3 44 3.4

875 45 3.2 45 3.3 45 3.4 45 3.6 45 3.7

925 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

950 45 2.7 45 2.8 45 2.9 45 3.0 45 3.1

975 45 2.6 45 2.7 45 2.8 45 2.9 45 2.9

1000 45 2.5 45 2.5 45 2.6 45 2.7 45 2.8

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6

675 43 3.6 43 3.7 43 3.8 42 3.2 42 3.3

700 44 3.8 43 3.4 43 3.6 43 3.7 43 3.8

750 44 3.3 44 3.4 44 3.6 44 3.7 44 3.8

800 45 3.5 45 3.7 45 3.8 44 3.2 44 3.3

850 45 3.1 45 3.2 45 3.4 45 3.5 45 3.6

875 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

—36—

Page 37

→ TABLE 8—MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued

FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY

(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)

ALTITUDE

RANGE

(FT)

7001 700 44 3.5 44 3.6 44 3.8 43 3.4 43 3.5

to 750 45 3.7 45 3.8 44 3.3 44 3.4 44 3.5

U.S.A. Only

8000 800 45 3.3 45 3.4 45 3.5 45 3.6 45 3.7

ALTITUDE

RANGE

(FT)

8001 650 44 3.7 43 3.4 43 3.5 43 3.6 43 3.7

to 700 44 3.2 44 3.3 44 3.4 44 3.6 44 3.7

U.S.A. Only

9000 750 45 3.4 45 3.5 45 3.6 45 3.8 44 3.2

ALTITUDE

RANGE

(FT)

9001 625 44 3.7 44 3.8 43 3.5 43 3.6 43 3.7

to 675 45 3.8 44 3.3 44 3.4 44 3.5 44 3.6

U.S.A. Only

10,000 725 45 3.3 45 3.4 45 3.6 45 3.7 45 3.8

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

625 43 3.8 42 3.3 42 3.4 42 3.5 42 3.6 650 43 3.5 43 3.7 43 3.8 42 3.2 42 3.3 675 44 3.8 43 3.4 43 3.5 43 3.6 43 3.7

725 44 3.3 44 3.4 44 3.5 44 3.6 44 3.7

775 45 3.5 45 3.6 45 3.7 45 3.8 44 3.3

825 45 3.1 45 3.2 45 3.3 45 3.4 45 3.5 850 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

600 43 3.8 42 3.3 42 3.4 42 3.5 42 3.6 625 43 3.5 43 3.6 43 3.8 42 3.2 42 3.3

675 44 3.5 44 3.6 44 3.7 44 3.8 43 3.4

725 45 3.6 45 3.8 44 3.2 44 3.3 44 3.4

775 45 3.2 45 3.3 45 3.4 45 3.5 45 3.6 800 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

575 43 3.8 42 3.2 42 3.3 42 3.5 42 3.6 600 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

650 44 3.4 44 3.5 44 3.7 44 3.8 43 3.4

700 45 3.6 45 3.7 45 3.8 44 3.3 44 3.4

750 45 3.1 45 3.2 45 3.3 45 3.4 45 3.5 775 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

—37—

Page 38

→ TABLE 9—MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT

FOR USE WITH 140 SIZE FURNACES ONLY

(TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)

ALTITUDE

RANGE

(FT)

0 925 42 3.4 42 3.5 42 3.6 42 3.7 42 3.8

to 975 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4

2000 1025 43 3.3 43 3.4 43 3.6 43 3.7 43 3.8

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. 775 41 3.7 41 3.8 40 3.6 40 3.7 39 3.6

Altitudes 800 42 3.8 41 3.6 41 3.7 41 3.8 40 3.6

2001 825 42 3.6 42 3.7 41 3.5 41 3.6 41 3.7

to 850 42 3.4 42 3.5 42 3.6 42 3.7 41 3.5

3000 875 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6

or 900 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4

Canada 925 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

Altitudes 950 43 3.3 43 3.4 43 3.5 43 3.7 43 3.8

U.S.A. and Canada

2001 975 43 3.1 43 3.3 43 3.4 43 3.5 43 3.6

to 1000 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4

4500 1025 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

ALTITUDE

RANGE

(FT)

3001 825 42 3.3 42 3.4 42 3.6 42 3.7 42 3.8

to 875 43 3.6 43 3.7 42 3.2 42 3.3 42 3.4

U.S.A. Only

4000 925 43 3.2 43 3.3 43 3.5 43 3.6 43 3.7

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

850 41 3.6 41 3.7 41 3.8 40 3.6 40 3.8

875 42 3.8 41 3.5 41 3.6 41 3.7 41 3.8

900 42 3.5 42 3.7 42 3.8 41 3.5 41 3.6

950 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6

1000 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

1050 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6 1075 44 3.5 44 3.6 43 3.2 43 3.3 43 3.4 1100 44 3.3 44 3.4 44 3.5 43 3.2 43 3.3

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

750 41 3.6 41 3.8 40 3.6 40 3.7 40 3.8

775 42 3.8 41 3.5 41 3.6 41 3.7 40 3.6

800 42 3.5 42 3.7 42 3.8 41 3.5 41 3.6

850 43 3.8 42 3.2 42 3.4 42 3.5 42 3.6

900 43 3.4 43 3.5 43 3.6 43 3.8 42 3.2

950 43 3.1 43 3.2 43 3.3 43 3.4 43 3.5

975 43 2.9 43 3.0 43 3.1 43 3.2 43 3.3

1000 43 2.8 43 2.9 43 3.0 43 3.0 43 3.1

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

—38—

Page 39

→ TABLE 9—MODEL 350MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued

FOR USE WITH 140 SIZE FURNACES ONLY

(TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)

ALTITUDE

RANGE

(FT)

4001 775 42 3.5 42 3.6 42 3.7 42 3.8 41 3.6

to 825 43 3.7 42 3.2 42 3.3 42 3.4 42 3.5

5000 875 43 3.3 43 3.4 43 3.6 43 3.7 43 3.8

U.S.A. Only

ALTITUDE

RANGE

(FT)

5001 800 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4

to 850 43 3.3 43 3.4 43 3.5 43 3.6 43 3.7

U.S.A. Only

6000 900 43 2.9 43 3.0 43 3.1 43 3.2 43 3.3

ALTITUDE

RANGE

(FT)

6001 700 42 3.6 42 3.7 41 3.5 41 3.6 41 3.7

to 750 43 3.8 42 3.3 42 3.4 42 3.5 42 3.6

7000 800 43 3.4 43 3.5 43 3.6 43 3.7 43 3.8

U.S.A. Only

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

725 41 3.6 41 3.7 41 3.8 40 3.6 40 3.8 750 42 3.7 42 3.8 41 3.6 41 3.7 41 3.8

800 42 3.3 42 3.4 42 3.5 42 3.6 42 3.7

850 43 3.5 43 3.6 43 3.8 42 3.2 42 3.3

900 43 3.1 43 3.3 43 3.4 43 3.5 43 3.6 925 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4 950 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

700 41 3.5 41 3.7 41 3.8 40 3.6 40 3.7 725 42 3.7 42 3.8 41 3.5 41 3.6 41 3.8 750 42 3.4 42 3.5 42 3.7 42 3.8 41 3.5 775 42 3.2 42 3.3 42 3.4 42 3.5 42 3.7

825 43 3.5 43 3.6 43 3.7 43 3.8 42 3.2

875 43 3.1 43 3.2 43 3.3 43 3.4 43 3.5

925 43 2.7 43 2.8 43 2.9 43 3.0 43 3.1 950 43 2.6 43 2.7 43 2.8 43 2.9 43 3.0 975 43 2.5 43 2.6 43 2.6 43 2.7 43 2.8

1000 43 2.3 43 2.4 43 2.5 43 2.6 43 2.7

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

650 41 3.8 40 3.6 40 3.7 40 3.8 39 3.7 675 41 3.5 41 3.6 41 3.7 40 3.6 40 3.7

725 42 3.4 42 3.5 42 3.6 42 3.7 42 3.8

775 43 3.6 43 3.7 43 3.8 42 3.3 42 3.4

825 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6 850 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4 875 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

—39—

Page 40

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

BURNER

MANIFOLD

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 DERATE MULTIPLIER FOR U.S.A.

ALTITUDE

(FT)

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

* Derate multiplier factor is based on midpoint altitude for altitude range.

%OF

DERATE

DERATE MULTIPLIER FACTOR FOR U.S.A.*

EXAMPLE: 100,000 Btuh input furnace installed at 4300 ft.

Furnace Input

Rate at

Sea Level

100,000 X 0.91 = 91,000

Derate

Multiplier

Factor

Furnace Input Rate

at Installation

Altitude

CANADA

→

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

1 revolution.

A89020

e. Refer to Table 11 for cu ft of gas per hr.

TABLE 11—GAS RATE (CU FT/HR)

SECONDS

FOR 1

REVOLUTION

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

360

720

327

655

300

600

277

555

257

514

240

480

225

450

212

424

200

400

189

379

180

360

171

343

164

327

157

313

150

300

144

288

138

277

133

267

129

257

124

248

120

240

116

232

113

225

109

218

106

212

103

206

100

200

195

189

185

180

176

172

167

164

160

157

153

150

147

1800 1636 1500 1385 1286 1200 1125 1059 1000

947 900 857 818 783 750 720 692 667 643 621 600 581 563 545 529 514 500 486 474 462 450 439 429 419 409 400 391 383 375 367

SECONDS

FOR 1

REVOLUTION

50 51 52 53 54 55 56 57 58 59 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96

98 100 102 104 106 108

110 112 116 120

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

144

141

138

136

133

131

129

126

124

122

120

116

112

109

106

103

100

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 exchangers.

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.

360 355 346 340 333 327 321 316 310 305 300 290 281 273 265 257 250 243 237 231 225 220 214 209 205 200 196 192 188 184 180 178 173 170 167

164 161 155 150

—40—

Page 41

3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

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. Reconnect original lead on SPARE terminal.

Follow this same procedure for proper selection of COOL speed selection.

TABLE 12—SPEED SELECTOR

COLOR SPEED

Black High Cool

Yellow (When Present) Medium High Spare

Blue Medium Low Heat Red Low Spare

White Common Com

FACTORY-

SHIPPED

CONNECTION

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

DESIRED HEATING

MODE BLOWER OFF

DELAY (SEC)

90 OFF OFF 135 ON OFF 180 OFF ON 225 ON ON

SETUP SWITCH POSITION

SW-1 SW-2

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 measurements. 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 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

HOOK-AROUND

VOLT/AMMETER

R Y W G

10 TURNS

FROM UNIT 24-VOLT TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

= 0.5 AMPS FOR THERMOSTAT SETTING

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 immediately. 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 instructions.

6. Review User’s Guide with owner.

7. Leave literature packet near furnace.

—41—

Page 42

LOAD CALCULATION

____________ Heating Load (Btuh)

____________ Cooling Load (Btuh)

____________ Furnace Model Selection

CHECKLIST—INSTALLATION

________ Unit Level or Pitched Forward

________

Condensate Drain

Internal Tubing Connections Free of Kinks and Traps

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

________

________ Condensate Trap Primed before Start-Up

________ Heat Tape Installed if Required

________

________ Temperature Rise Adjusted

________ Anticipator Setting Adjusted or

________ Cycle Rate (3 Cycles per Hr) Selected

________ Primary Limit

________ Pressure Switch

External Drain Connection Leak Tight and Sloped

CHECKLIST—START-UP

Gas Input Rate (Set Within 2 percent of Rating Plate)

Thermostat Anticipator

Safety Controls Check Operation

—42—

Page 43

—43—

Page 44

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:  • Unit Familiarization • Maintenance  • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book.  Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog. 

CALL FOR FREE CATALOG 1-800-962-9212



[ ] Packaged Service Training [ ] Classroom Service Training

A94328

—44—

350m408 Catalog No. BDP-3335-014

Bryant 350MAV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual