Bryant 353BAV Installation, Start-up & Operating Instructions

353BAV DELUXE 4--WAY MULTIPOISE 2--STAGE CONDENSING GAS FURNACE SIZES 060--120

Installation, Start--up and

Operating Instructions

NOTE: Read the entire instruction manual before starting

the installation.

NOTE: This furnace can be installed as a

or (1-pipe) non-direct vent

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC S636. The special vent fittings and accessory concentric vent termination kits and accessory external drain trap have been certified to ULC S636 for use with those IPEX PVC vent components which have been certified to this standard. In Canada, the primer and cement must be of the same manufacturer as the vent system -- IPEX System 636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and IPEX System 636, PVC Cement for Flue Gas Venting, rated Class IIA, 65 deg C. must be used with this venting system -- do not mix primers and cements from one manufacturer with a vent system from a different manufacturer. Follow the manufacturer’s instructions in the use of primer and cement and never use primer or cement beyond its expiration date.

The safe operation, as defined by ULC S636, of the vent system is based on following these installation instructions, the vent system manufacturer’s installation instructions, and proper use of primer and cement. All fire stop and roof flashing used with this system must be UL listed material. Acceptability under Canadian standard CSA B149 is dependent upon full compliance with all installation instructions. Under this standard, it is recommended that the vent system be checked once a year by qualified service personnel.

The authority having jurisdiction (gas inspection authority, municipal building department, fire department, etc) should be consulted before installation to determine the need to obtain a permit.

condensing gas furnace.

(2-pipe) direct vent

Consignes spéciales pour l’installation de ventillation au Canada

L’installation faite au Canada doit se conformer aux exigences du code CSA B149. Ce systême de ventillation doit se composer de tuyaux, raccords, ciments et apprêts conformes au ULC S636. La tuyauterie de ventillation des gaz, ses accessoires, le terminal concentrique mural ainsi que l’ensemble du drain de condensat extérieur ont été certifiés ULCS 636 pour l’application des composantes IPEX PVC qui sont certifiées à ce standard. Au Canada l’apprêt et le ciment doivent être du même manufacturier que le systême de ventillation -- IPEX Système 636, Apprêt PVC/CPVC. Mauve Violette pour conduit en évacuation des gaz et IPEX Système 636, ciment pour PVC pour conduit en évacuation des gaz, évalué CLASSEIIA,65deg.C.doitëtre utilisé avec ce systèeme d’évacuation -- ne pas mélanger l’apprêt et le ciment d’un manufacturier avec le systême de ventillation d’un autre manufacturier. Bien suivre les indications du manufacturier lors de l’utilisation de l’apprêt et du ciment et ne pas utiliser ceux--ci si la date d’expiration est atteinte.

L’opération sécuritaire, tel que définit par ULC S636, du système de ventilation est basé sur les instructions d’installation suivantes, ainsi que l’usage approprié de l’apprêt et ciment. Tout arrët feu et solin de toit utilisés avec ce système doivent être des matériaux listés UL. L’acceptation du standard Canadien CSA B419 est directement relié à l’installation conforme aux instructions ci-haut mentionnées. Le standard Canadien recommande l’ inspection par un personel qualifié et ce, une fois par année.

Some Provinces may require the combustion air system to be ULC--S636 certified.

Required Notice for Massachusetts Installations

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:

5.08: Modifications to NFPA--54, Chapter 10

2) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used

in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet (2.1 M) above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back--up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard

353BAV

wired carbon monoxide detector with alarm and battery back--up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner

shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one--half (1/2) inch in size, ”GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

(1.) The equipment listed in Chapter 10 entitled ”Equipment Not Required To Be Vented” in the most current edition of

NFPA 54 as adopted by the Board; and

(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from

the dwelling, building or structure used in whole or in part for residential purposes.

c. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

d. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When

the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled

equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers

and Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617--727--9952.

TABLE OF CONTENTS

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

CODES AND STANDARDS 5...........................

Safety 5............................................

General Installation 5..................................

Combustion and Ventilation Air 5........................

Duct Systems 5......................................

Acoustical Lining and Fibrous Glass Duct 5................

Gas Piping and Gas Pipe Pressure Testing 5................

Electrical Connections 5...............................

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 7...

INTRODUCTION 8....................................

APPLICATIONS 8.....................................

General 8...........................................

Upflow Applications 8.................................

Downflow Applications 10.............................

Horizontal Left (Supply-Air Discharge) Applications 12......

Horizontal Right (Supply-Air Discharge) Applications 13.....

LOCATION 16........................................

General 16..........................................

Furnace Location Relative to Cooling Equipment 17.........

Hazardous Locations 17...............................

Furnace Location and Application 17.....................

AIR FOR COMBUSTION AND VENTILATION 18..........

INSTALLATION 21....................................

Leveling Legs (If Desired) 21...........................

Installation in Upflow and Downflow Applications 21.......

Installation in Horizontal Applications 21.................

Air Ducts 22.........................................

Filter Arrangement 25.................................

Bottom Closure Panel 26...............................

Gas Piping 26........................................

Electrical Connections 28..............................

Removal of Existing Furnaces from

Common Vent Systems 30..............................

Combustion Air and Vent Pipe Systems 31.................

Condensate Drain 46..................................

START-UP, ADJUSTMENTS, AND SAFETY CHECK 47.....

General 47..........................................

Prime Condensate Trap With Water 48....................

Purge Gas Lines 48...................................

Sequence of Operation 48..............................

Check Safety Controls 60..............................

Checklist 61.........................................

SAFETY CONSIDERATIONS

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

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.

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death or property damage.

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.

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.

These instructions cover the minimum requirements 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 up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

Wear safety glasses and work gloves.

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing and gloves when handling parts.

Follow all safety codes. Wear safety glasses, protective clothing and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC) NFPA 70.

In Canada, refer to the current editions of the National Standards of Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane Installation Codes, and Canadian Electrical Code CSA C22.1.

Recognize safety information. This is the safety-alert symbol When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand these signal words: DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to

CAUTION

353BAV

highlight suggestions which will result in enhanced installation, reliability, or operation.

AIRFLOW

UPFLOW

HORIZONTAL

LEFT

AIRFLOW

353BAV

Fig. 1 -- Multipoise Orientations

DOWNFLOW

AIRFLOW

HORIZONTAL

RIGHT

The model 353BAV, 2-Stage, 4-way Multipoise, Gas-Fired, Category IV, condensing furnace is available in model sizes ranging in high-stage gas input rates of 60,000 to 120,000 Btuh. This furnace is CSA (formerly AGA and CGA) design-certified for natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. This furnace is factory-shipped for use with natural gas. A CSA listed gas conversion kit is required to convert furnace for use with propane gas.

See Fig. 3 for required clearances to combustibles. This furnace SHALL NOT be installed directly on carpeting, tile,

or any other combustible material other than wood flooring. For downflow installations, a 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 the manufacturer’s coil assembly or when the manufacturer’s coil box is used. The design of the 353BAV furnace is not CSA certified for installation in mobile homes, recreational vehicles, or outdoors. This furnace is suitable for installation in a structure built on site or a manufactured building completed at final site.

This furnace is designed for continuous return-air minimum temperature of 60°F(15°C) db or intermittent operation down to 55°F(13°C) db such as when used with a night setback thermostat. Return-air temperature must not exceed 80°F(27°C) db. Failure to follow these return air limits may affect reliability of heat exchangers, motors and controls. (See Fig. 4.)

This furnace is shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are requiredwhenusedinDOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 1. See details in Applications section.

Install this furnace only in a location and position as specified in LOCATION and INSTALLATION sections of these instructions.

Always provide adequate combustion and ventilation air as specified in section Combustion Air and Vent Pipe Systems of these instructions to furnace.

AIRFLOW

A93041

Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the Combustion Air and Vent Piping sections of these instructions.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the GAS PIPING section of these instructions.

Always install furnace to operate within the furnace’s intended rise range with a duct system which has an external static pressure within the allowable range, as specified in the SET TEMPERATURE RISE section of these instructions and furnace rating plate.

When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

A gas-fired furnace for installation in a residential garage must be installed as specified in the Hazardous Locations section of these instructions.

The furnace may be used for construction heat provided that the furnace installation and operation complies with:

S The furnace is permanently installed with all electrical wiring,

piping, air filters, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

S The furnace is controlled by a thermostat. It may not be “hot

wired” to provide heat continuously to the structure without thermostatic control.

S Clean outside air is provided for combustion. This is to

minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

The temperature of the return air to the furnace is maintained between 55°F(13°C) and 80°F(27°C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

S The air temperature rise is within the rated rise range on the

furnace rating plate, and the firing rate has been set to the nameplate value.

S The filters used to clean the circulating air during the

construction process must be either changed or thoroughly cleaned prior to occupancy.

S The furnace, ductwork and filters are cleaned as necessary to

remove drywall dust and construction debris from all HVAC system components after construction is completed.

This furnace is shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment.

The furnace shall be installed so that the electrical components are protected from water.

For accessory installation detail, refer to the accessory installation instruction.

NOTE: Remove all shipping materials before operating furnace.

Installer Packet includes:

Installation, Startup, 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 Condensate trap hole filler plug 3 Vent and combustion-air intake hole filler plug 2 Combustion--air intake pipe perforated disk assembly 1 Gas line grommet 1 Vent pipe grommet 1 Combustion--air pipe grommet 1 Power entry hole filler plug 2 Vent Pipe Extension 1*

*100,000 Btuh and larger.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with

regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for the following:

Step 1 -- Safety

S US: National Fuel Gas Code (NFGC) NFPA 54--2009/ANSI

Z223.1--2009 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

S CANADA: National Standard of Canada, Natural Gas and

Propane Installation Code (NSCNGPIC) CSA B149.1--05

Step 2 -- General Installation

S US: NFGC and the NFPA 90B. For copies, contact the

National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American Gas Association, 400 N. Capitol, N.W., Washington DC 20001

S CANADA: NSCNGPIC. For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada.

Step 3 -- Combustion and Ventilation Air

S US: Section 9.3 of the NFGC, Air for Combustion

and Ventilation

S CANADA: Part 8 of the NSCNGPIC, Venting Systems and Air

Supply for Appliances

Step 4 -- Duct Systems

S US and CANADA: Air Conditioning Contractors Association

(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2005 Fundamentals Handbook Chapter 35.

Step 5 -- Acoustical Lining and Fibrous Glass Duct

S US and CANADA: current edition of SMACNA, NFPA 90B as

tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6 -- Gas Piping and Gas Pipe Pressure Testing

S US: Section 9.3 NFPA 54/ANSI Z223.1--2009 NFGC; Chapters 5,

6, 7, and 8 and national plumbing codes. CANADA: CAN/CSA----B149.1----05, Parts 4, 5, 6, and 9.

In the state of Massachusetts:

S This product must be installed by a licensed plumber or gas fitter. S When flexible connectors are used, the maximum length shall

not exceed 36 in. (914 mm).

S When lever type gas shutoffs are used they shall be T--handle type. S The use of copper tubing for gas piping is not approved by the

state of Massachusetts.

Step 7 -- Electrical Connections

S US: National Electrical Code (NEC) ANSI/NFPA 70--2008 S CANADA: Canadian Electrical Code CSA C22.1

(27º C)

(16º C)

A05004

Fig. 2 -- Return--Air Temperature

353BAV

(694mm)

(724mm)

⁄

(667mm)

⁄

(567mm)

⁄

(21mm)

(16mm)

⁄

(483mm) 19"

OUTLET

⁄

AIR CONN

2-IN. COMBUSTION-

(8mm)

-IN. DIA

⁄

GAS CONN

DIA

-IN.

⁄

POWER CONN

. DIA

-IN

⁄

(1013mm)

T ENTRY A

THERMOST

. VENT CONN

2-IN

⁄

1 1

(25mm)

SIDE INLET

(11mm)

⁄

TYP

⁄

1 1

(565mm)

(17mm)

⁄

BOTTOM INLET

(614mm)

⁄

TYP

(14mm)

⁄

TYP

(845mm)

⁄

(783mm)

⁄

1 1

TYP

(775mm)

⁄

TYP

(754mm)

⁄

(702mm)

353BAV

(DOWNFLOW &

TRAP LOCATION

HORIZONTAL RIGHT)

CONDENSATE DRAIN

OR ALTERNATE

-IN. DIA GAS CONN

⁄

OUTLET

AIRFLOW

(22mm)

-IN. DIA

CCESSOR

⁄

CONDENSAT E

POWER ENTRY

HORIZONTAL LEFT)

(DOWNFLOW &

TRAP LOCATION

CONDENSATE DRAIN

-IN. DIA

⁄

POWER CONN

(829mm)

⁄

TYP

(700mm)

ALTERNATE

(

LOCATION

DRAIN TRAP

UPFLOW)

⁄

(464mm)

(622mm)

⁄

. P

ate

. ES

, a

5“ W

CFM at 00

ve 18

. The use of both side inlets s

CFM, see Air Delivery table in Product Data

ove 1800 ab

return air openings for airflow requirements abo

combination of 1 side and the bottom, or the bottom only will ensure adequ

literature for specific use of single side inlet

d. For airflow requirements

DIMENSIONS --- IN. (MM)

ADE

21 (533) 19---3/8 (492) 19---1/2 (495)

7---1/2 (445) 15---7/8 (403) 16 (406)

17---1/2 (445) 15---7/8 (403) 16 (406)

24---1/2 (622) 22---7/8 (581) 23 (584)

CONDENSAT E

DRAIN LOCATION

INLET

ORS

(UPFLOW)

DIMPLE LOCAT

HANGING

FOR HORIZONTA L

ed,

-in. (495mm) rectangle.

-in.(591mm) rectangle.

x 23

valent diameters.

(368mm) x 19

(368mm)

(368mm) x 12-in. (305mm) rectangle.

, based on metal duct. If flex duct is us

round or 14

)

round or 14

at furnace

s recommendations for equi

ufacturerÕ n a

see flex duct m

)

08mm

n .(559mm)

n . (5

n . (406mm

0-i

6-i

00 CFM 2

600 CFM 22-i

c. For 1

b. For 12

a. For 800 CFM 1

2. Minimum return-air opening at furnace:

(440mm)

036060

036080

048080

060100

⁄

TYP

(240mm)

(UPFLOW)

DRAIN LOCATION

CONDENSAT E

NOTES: 1. Minimum return-air openings

UNIT SIZE

060120

(684mm)

⁄

(667mm)

⁄

(51mm)

(666mm)

(567mm)

⁄

-IN. COMBUSTION2

AIR CONN

(13mm)

-IN. DIA

⁄

GAS CONN

-IN. VENT CONN

(51mm)

T TA

ENTRY

⁄

1 1

THERMOS

(13mm)

-IN. DIA

⁄

(576mm)

(32mm)

⁄

T E

(591mm) P

SIDE INL

⁄

(25mm)

(684mm) P

⁄

SIDE INLE

⁄

(368mm)

Fig. 3 -- Dimensional Drawing

A08323

335122-201 REV. B LIT TOP

Fig. 4 -- Clearances to Combustibles

353BAV

A08435

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit components.

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.

3. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

4. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in hand during grounding will be discharged.

5. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body (moving or shuffling feet, touching ungrounded objects, etc.).

6. If you touch ungrounded objects, firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

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

8. 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 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

9. An ESD service kit (available from commercial sources) mayalsobeusedtopreventESDdamage.

INTRODUCTION

The model 353BAV 4-way multipoise, Gas-Fired, Category IV, condensing furnace is available in model sizes ranging from input capacity of 60,000 to 120,000 Btuh as a direct vent (2-pipe) application as well as a non-direct vent (1-pipe) application.

APPLICATIONS

CAUTION

PROPERTY DAMAGE

Failure to follow this caution may result in property damage. 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.

Step 1 -- General

Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain

353BAV

and pressure tubes are connected as shown in Fig. 6. See appropriate application instructions for these procedures.

Step 2 -- Upflow Applications

In an upflow application, the blower is located below the burner section, and conditioned air is discharged upwards.

CONDENSATE TRAP LOCATION (FACTORY-SHIPPED ORIENTA

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. (See Fig. 5.)

TION)

CONDENSATE TRAP TUBING (FACTORY-SHIPPED ORIENTA

NOTE: See Fig. 6 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 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:

f. Determine location of field drain connection. (See Fig.

2or6)

NOTE: If internal filter or side Filter/Media Cabinet is used, drain tube should be located to opposite side of casing from return duct attachment to assist in filter removal.

g. Remove and discard casing drain hole plug button

from desired side.

h. Install drain tube coupling grommet (factory-supplied

in loose parts bag) in selected casing hole.

i. Slide drain tube coupling (factory-supplied in loose

parts bag) through grommet ensuring long end of coupling faces blower.

j. Cement 2 factory-supplied 1/2-in. street CPVC elbows to

the rigid drain tube connection on the condensate trap. (See Fig. 6.) These elbows must be cemented together and cemented to condensate trap drain connection.

TION)

Fig. 5 -- Condensate Trap

NOTE: Failure to use CPVC elbows may allow drain to kink

and prevent draining.

k. Connect larger diameter drain tube and clamp (factory

supplied in loose parts bag) to condensate trap and clamp securely.

l. Route tube to coupling and cut to appropriate length.

m. Attach tube to coupling and clamp securely.

CONDENSATE TRAP LOCATION (ALTERNATE UPFLOW ORIENTA

An alternate location for the condensate trap is the left-hand side of casing. (See Fig. 2 and 7.)

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. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

TION)

A93026

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

4. 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. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING (ALTERNATE UPFLOW ORIENTA

NOTE: See Fig. 7 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. (445 mm) wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring.

TION)

353BAV

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

353BAV

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE TRAP

FIELD-INSTALLED

DRAIN TUBE

DRAIN OPTION)

Fig. 6 -- Factory-Shipped Upflow Tube Configuration

(Shown with Blower Access Panel Removed)

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

condensate 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.

CONDENSATE TRAP FIELD DRAIN ATT

ACHMENT

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING

The LOWER collector box pressure tube (pink label) is factory connected to the High Pressure Switch and should not require any modification.

A01030

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A01031

Fig. 7 -- Alternate Upflow Configuration and Trap Location

NOTE: See Fig. 6 or 7 or tube routing label on main furnace

door to check for proper connections.

UPPER COLLECTOR BOX AND INDUCER HOUSING (UNUSED) DRAIN

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. 6 or 7 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. 6 or 7 or tube routing label on main furnace door to check for proper connections.

CONNECTIONS

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 3 -- Downflow Applications

In a downflow furnace application, the blower is located above the burner section, and conditioned air is discharged downwards.

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, 8 or 9.

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)

DRAIN TUBE COUPLING

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

353BAV

A01023

Fig. 8 -- Downflow Tube Configuration

(Left-Hand Trap Installation)

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, 8 or 9.)

4. Install casing hole filler cap into blower shelf hole where

trap was removed.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

5. Install condensate trap into desired casing hole by

inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

CONDENSATE TRAP TUBING

NOTE: See Fig. 8 or 9 or tube routing label on main furnace

door to check for proper connections. Relocate tubes as described below.

1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

A01024

Fig. 9 -- Downflow Tube Configuration

(Right-Hand Trap Installation)

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.

(3.) Condensate Trap Located on Left Side of Casing

a. Connect LOWER collector box drain tube (blue

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

b. Clamp tube to prevent any condensate leakage.

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

a. Install drain tube coupling (factory-supplied in

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

b. Connect larger diameter drain tube

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

c. Route extended collector box drain tube

directly from collector box drain to condensate

trap as shown in Fig. 9. 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.

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

353BAV

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

trap as shown in Fig. 9. b. Determine appropriate length and cut. c. Connect tube to condensate trap. d. Clamp tube to prevent any condensate leakage.

CONDENSATE TRAP FIELD DRAIN ATT

ACHMENT

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the High 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 High Pressure Switch in DOWNFLOW or HORIZONTAL RIGHT applications

NOTE: See Fig. 8 or 9 or tube routing label on main furnace door to check for proper connections.

1. Disconnect collector box pressure tube (pink label) attached to High 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 High Pressure Switch connection labeled COLLECTOR BOX.

4. Extend collector box pressure tube (pink label) which was previously connected to High 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.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 4 -- Horizontal Left (Supply-Air Discharge) Applications

In a horizontal left furnace application, the blower is located to the right of the burner section, and conditioned air is discharged to the left.

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 10.

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

1. Remove 3 tubes connected to condensate trap.

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

3. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

4. 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. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING

NOTE: See Fig. 10 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 condensate trap.

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

d. Clamp tube to prevent any condensate leakage.

AUXILIARY "J" BOX

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)

CONDENSATE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

TRAP

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

040, 060, AND 080 HEATING INPUT FURNACES

Fig. 10 -- Horizontal Left Tube Configuration

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.

CONDENSATE TRAP FIELD DRAIN ATT

ACHMENTS

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING

The LOWER collector box pressure tube (pink label) is factory connected to the High 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 for 060 and 080 heating input furnaces.

NOTE: See Fig. 10 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 High 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.

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

4. Determine appropriate length, cut, and reconnect tube to High Pressure Switch connection labeled COLLECTOR BOX.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 11 or 12.)

UNIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit operation.

The condensate trap MUST be installed below furnace. See Fig. 5 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. (1.5 M). (See Table 14.)

NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with short (5 to 8 ft (1.5 to 2.4 M)) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12 or 43.)

Step 5 -- Horizontal Right (Supply-Air Discharge) Applications

In a horizontal right furnace application, the blower is located to the left of the burner section, and conditioned air is discharged to the right.

COLLECTOR BOX TUBE (GREEN)

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX DRAIN TUBE (BLUE)

CAUTION

353BAV

A01029

COMBUSTION - AIR

/4″

INTAKE

(146 mm)

VENT

A 12-IN. (305 mm) MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT / 1.5 TO 2.4 M) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE.

30″ (762 mm)MIN WORK AREA

353BAV

MANUAL

SHUTOFF

GAS VALVE

SEDIMENT TRAP

CONDENSATE TRAP

DRAIN

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. 11 -- Attic Location and Working Platform for Direct Vent (2-Pipe) Applications

CAUTION

PROPERTY DAMAGE

Failure to follow this caution may result in property damage. 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: The auxiliary junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 13.) See Electrical Connection section for J-Box relocation.

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 13.

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

1. Remove 3 tubes connected to condensate trap.

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

3. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

A93031

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

4. Install condensate trap into right-hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING

NOTE: See Fig. 13 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.

A 3-IN.(76mm) MINIMUM CLEARANCE TO COMBUSTION-AIR INTAKE IS REQUIRED.

VENT

COMBUSTION AIR

GAS VALVE

INTAKE

MANUAL

SHUTOFF

30-IN. (762mm) MIN

/4 IN. (146mm)

SEDIMENT TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

CONDENSATE TRAP

WORK AREA

DRAIN

A 12-IN. (305mm) MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT / 1.5 TO 2.4M) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE.

ACCESS OPENING FOR TRAP

Fig. 12 -- Attic Location and Working Platform for Non-Direct Vent (1-pipe) Applications

353BAV

A96184

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.

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.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the High 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 High Pressure Switch in DOWNFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 12 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 High 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 High Pressure Switch connection labeled COLLECTOR BOX.

4. Use remaining smaller diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to High Pressure Switch. Route this extended tube (pink label) to condensate trap relief port connection.

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

6. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 11 or 12.)

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

AUXILARY “J” BOX RELOCATED HERE

353BAV

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 13 -- Horizontal Right Tube Configuration

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit operation.

The condensate trap MUST be installed below furnace. See Fig. 5 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air pipe (when applicable) and vent pipe(s) are restricted to a minimum length of 5 ft (1.5 M). (See Table 11.)

LOCATION

Step 1 -- General

This furnace must

S be installed so the electrical components are protected from water. S not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS).

S be located so combustion-air and vent pipe maximum lengths

are not exceeded. Refer to Table 11.

S be located where available electric power and gas supplies

meet specifications on the furnace rating plate.

S be attached to an air distribution system and be located as close

to the center of the distribution system as possible. Refer to Air Ducts section.

S be provided with ample space for servicing and cleaning.

Always comply with minimum fire protection clearances

CONDENSATE TRAP

A01028

shown on the furnace clearance to combustibles label.

NOTE: For upflow/downflow applications install furnace so that it is level or pitched forward within 1/2-in. (13 mm) for proper furnace operation. For horizontal applications pitch 1/4-in. (6 mm) minimum to 1/2-in. (13 mm) maximum forward to ensure proper condensate drainage from secondary heat exchangers. (See Fig. 14.)

When a furnace is installed so that supply ducts carry air circulated by the furnace 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 a negative pressure condition will not occur within equipment room or space.

WARNING

FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in property damage, personal injury, or death.

Do not install furnace on its back. (See Fig. 15.) Safety control operation will be adversely affected. Never connect return-air ducts to back of furnace.

LEVEL (0”)

TO 1/2” (13mm)

MAX

UPFLOW OR DOWNFLOW

FRONT FRONT

MIN 1/4” (7mm) TO 1/2” (13mm)

MAX

Fig. 14 -- Proper Condensate Drainage

HORIZONTAL

A02146

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in property or unit damage.

This gas furnace may be used for construction heat provided that:

--The furnace is permanently installed with all electrical wiring, piping, air filters, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/ or drawing combustion products into the structure.

--The furnace is controlled by a thermostat. It may not be “hot wired” to provide heat continuously to the structure without thermostatic control.

--Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

--The temperature of the return air to the furnace is maintained between 55°F(13°C) and 80°F(27°C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

--The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the nameplate value.

--The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

--The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

-- After construction is complete, verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer’s instructions.

CAUTION

FRONT

B A C K

BACK

FRONT

A93043

Fig. 15 -- Prohibit Installation on Back

Step 3 -- Hazardous Locations

WARNING

FIRE, EXPLOSION, INJURY OR DEATH HAZARD

Failure to follow this warning could result in personal injury, or death or property damage.

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 in. (457 mm) above the floor. The furnace must be located or protected to avoid physical damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC or NSCNGPIC. (See Fig. 17.)

Step 4—Furnace Location and Application

DIRECT VENT (2-PIPE) APPLICATION

Furnace may be located in a confined space without special provisions for dilution or ventilation air.

353BAV

UNIT DAMAGE HAZARD

Failure to follow this caution may result in property or unit damage.

If this furnace is installed in an unconditioned space where the ambient temperatures may be 32°F(0°C) or lower, freeze protection measures must be taken. (See Fig. 16.)

Step 2 -- 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 shall be adequate to 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 the damper is in full-heat or full-cool position.

A07911

Fig. 16 -- Freeze Protection

18-IN. (457.2 mm)

MINIMUM TO BURNERS

Fig. 17 -- Installation in a Garage

NON-DIRECT VENT (1-PIPE) APPLICATION

CAUTION

353BAV

UNIT DAMAGE HAZARD

Failure to follow this caution may result in intermittent unit operation.

Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met.

Refer to the AIR FOR COMBUSTION AND VENTILATION section for details.

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

S U.S. Installations: Section 9.3 NFPA 54/ANSI Z223.1--2009,

Air for Combustion and Ventilation and applicable provisions of the local building codes.

S Canadian Installations: Part 8 of CAN/CS----B149.1--05.

Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.

WARNING

FURNACE CORROSION HAZARD

Failure to follow this warning could result in reduced furnace component life.

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements could corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms, and S Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for combustion:

S Permanent wave solutions S Chlorinated waxes and cleaners

A93044

S Chlorine based swimming pool chemicals S Water softening chemicals S De-icing salts or chemicals S Carbon tetrachloride S Halogen type refrigerants S Cleaning solvents (such as perchloroethylene) S Printing inks, paint removers, varnishes, etc. S Hydrochloric acid S Cements and glues S Antistatic fabric softeners for clothes dryers S Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and from draft safeguard opening.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount of make-up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

S Spaces having less than 50 cubic feet per 1,000 Btuh require

the OUTDOOR COMBUSTION AIR METHOD.

S Spaces having at least 50 cubic feet per 1,000 Btuh may use

the INDOOR COMBUSTION AIR, STANDARD or

KNOWN AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 18 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air openings to the outdoors.

a. One opening MUST commence within 12 in. (305

mm) of the ceiling and the second opening MUST commence within 12 in. (305 mm) of the floor.

b. Size openings and ducts per Fig. 18 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm input for all gas appliances in the space per Fig. 18 and Tab le 1 .

d. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of free area per 4,000 Btuh (550 mm for combined input of all gas appliances in the space per Fig. 18 and Table 1.

3. ONE OUTDOOR OPENING requires:

a. 1 square inch of free area per 3,000 Btuh (734 mm

for combined input of all gas appliances in the space per Table 1 and 11.

/kW) of combined

/kW)

Ta bl e 1 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

TWO HORIZONTAL DUCTS

(1 SQ. IN./2,000 BTUH)

D u c t ---

(1,100 SQ.

MM/KW)

Round Duct

In. (mm) Dia

FURNACE

INPUT

(BTUH)

40,000 20 (12903) 6 (152) 13.4 (8645) 5 (127) 10 (6451) 4 (102) 60,000 30 (19354) 7 (178) 20 (12903) 6 (152) 15 (9677) 5 (127)

80,000 40 (25806) 8 (203) 26.7 (17225) 6 (152) 20 (12903) 6 (152) 100,000 50 (32258) 8 (203) 33.4 (21548) 7 (178) 25 (16129) 6 (152) 120,000 60 (38709) 9 (229) 40 (25806) 8 (203) 30 (19354) 7 (178)

Free Area of

Opening and

Sq. In (Sq. mm)

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH)

(734 SQ. MM/KW)

Free Area of

Opening and

D u c t ---

Sq. In (Sq. mm)

Round Duct ---

In. (mm) Dia

TWO OPENINGS OR

VERTICAL DUCTS

(1 SQ. IN./4,000 BTUH)

(550 SQ. MM/KW)

Free Area of

Opening and

D u c t ---

Sq. In (mm)

Round Duct ---

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

100,000 + 40,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

60,000 + 40,000 = (100,000 divided by 3,000) = 33.4 Sq. In. for a Single Duct or Opening 80,000 + 30,000 = (110,000 divided by 2,000) = 55.0 Sq. In. for each of two Horizontal Ducts

Ta bl e 2 – Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors

In. (mm) Dia

353BAV

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

ACH

0.60

0.50

0.40

0.30

0.20

0.10

0.00 NP NP NP NP NP NP NP NP NP

b. Not less than the sum of the areas of all vent

connectors in the space.

30 40 50 44 66 88 110 132 154

SpaceVolumeFt3(M3)

1,050

(29.7)

1,260

(35.6)

1,575

(44.5)

2,100

(59.4)

3,150

(89.1)

6,300

(178.3)

1,400 (39.6)

1,680 (47.5)

2,100 (59.4)

2,800 (79.2)

4,200

(118.9)

8,400

(237.8)

1,750 (49.5)

2,100

(59.4)

2,625

(74.3)

3,500

(99.1)

5,250

(148.6)

10,500 (297.3)

1,100

(31.1)

1,320

(37.3)

1,650

(46.7)

2,200

(62.2)

3,300

(93.4)

6,600

(186.8)

1,650

(46.7)

1,980

(56.0)

2,475

(70.0)

3,300

(93.4)

4,950

(140.1)

9,900

(280.3)

The Standard Method:

1. The space has no less volume than 50

The opening shall commence within 12 in. (305 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (153 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion AirE NFPA & AGA Standard and Known-Air-Infiltration Rate Methods Indoor combustion air is permitted for combustion, ventilation,

and dilution, if the Standard or Known-Air-Infiltration Rate Method is used.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in death and/or

2. The air infiltration rate is not known to be less than 0.40

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 2 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

Table 2 -- Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI

Z223.1--2009/NFPA 54--2009,9.3.2.2:

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

2,200 (62.2)

2,640 (74.7)

3,300 (93.4)

4,400

(124.5)

6,600

(186.8)

13,200 (373.7)

2,750 (77.8)

3,300 (93.4)

4,125

(116.8)

5,500

(155.7)

8,250

(233.6)

16,500 (467.2)

3,300 (93.4)

3,960

(112.1)

4,950

(140.1)

6,600

(186.8)

9,900

(280.3)

19,800 (560.6)

ft. (1.43M) (per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

air changes per hour (ACH).

personal injury. Many homes require air to be supplied from outdoors for

furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in accordance with this instruction manual.

3,850

(109.0)

4,620

(130.8)

5,775

(163.5)

7,700

(218.0)

11,550 (327.0)

23,100 (654.1)

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