Bryant 355AAV User Manual

355AAV 4--WAY MULTIPOISE VARIABLE--CAPACITY CONDENSING GAS FURNACE FOR SIZES 040--120, SERIES C

Installation Instructions

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NOTE: Read the entire instruction manual before starting the installation. Please retain these instructions with the furnace after installation for future reference.

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 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.

(1)

t, PVC Cement for Flue Gas Venting, rated Class

condensing gas furnace.

(2-pipe) direct vent

ama

ISO 9001:2000

CERTIFIED

REGISTERED

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 évacuation des gaz, évalué CLASSE IIA, 65 deg. C. doit ëtre 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.

Les autoritées ayant juridiction (inspecteurs de gas, inspecteurs en bâtiments, département des incendies, etc) devraient être consultées avant l’installation afin de déterminer si un permis est requis.

t, ciment pour PVC pour conduit en

(1)

(1) System 636 is a trademark of IPEX Inc.

355A

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 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 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. E ach 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 PAGE.........................

CAUTION

IMPORTANT 2.....................................

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

CODES AND STANDARDS 6.........................

INTRODUCTION 7..................................

APPLICATIONS 7...................................

LOCATION 15......................................

INSTALLATION 20..................................

START--- UP, ADJUSTMENTS AND SAFETY CHECK 43...

AIRFLOW

UPFLOW

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure.

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, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

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 include 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

355A

AIRFLOW

HORIZONTAL

LEFT

Fig. 1 -- Multipoise Orientations

DOWNFLOW

AIRFLOW

HORIZONTAL

RIGHT

SAFETY CONSIDERATIONS

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation, serious injury, death, or property damage.

Improper installation, adjustment, alteration, service, maintenance, or use could cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory--authorized and listed kits or accessories when modifying this product.

AIRFLOW

A93041

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

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental polution.

Remove and recycle all components or materials (i.e., oil, refrigerant, control boards, etc.) before unit final disposal.

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, safety glasses and gloves when handling parts and servicing furnaces.

CAUTION

355A

1 1 ⁄4 "

14 1 ⁄2 "

TYP

(368 mm)

(32 mm)

1 "

(25mm)

(684 mm)

⁄

(667 mm)

26 1 ⁄4 "

(622 mm)

⁄2 "

(567 mm)

⁄

2-IN . (51 mm) COMBUSTIONAIR CONN

⁄2 -IN . (13mm) DI A

GAS CONN

2-IN (51mm)

VENT CONN

⁄2 -IN . DIA (13mm)

THERMOST AT ENT RY

⁄

(576 mm)

SIDE INLE T

(591 mm)

23 1 ⁄4 " TYP

SIDE INLE T

⁄

" TYP

(684 mm)

AIRFL OW

CONDENSA TE DRAI N TRAP LOCA TION (DO WNFLO W & HORIZONT AL LEF T )

⁄8 -IN . DI A (22mm)

PO WER CONN

⁄8 -IN . DI A (22mm)

A CCESSOR Y PO WER ENT RY

CONDENSA TE DRAIN TRAP LOCA TION (AL TERNA TE UPFL OW )

(240 mm)

9 7 ⁄

17 5 ⁄

TYP

(439 mm)

CONDENSA TE DRAIN LOCA TIO N (UPFLO W)

(622 mm)

NO TES: 1. Minimum retur n-air openings at fur nace , based on metal duct. If fle x duct is used,

2. Minimum retur n-air opening at fur nace:

TYP

(754 mm)

⁄8 "

(702 mm)

⁄

TYP

(700 mm)

⁄2 "

see fle x duct manuf acturerí s recommendations f or equiv alent diameters .

a. F or 800 CFM–16-in. (406mm) round or 14 b. F or 1200 CFM–20-in. (508mm) round or 14 1 / c. F or 1600 CFM–22-in. (559mm) round or 14 1 / d. F or airflo w requirements abo v e 1800 CFM, see Air Deliv er y tab le in Product Data

literature f or specific use of single side inlets . The use of both side inlets , a combination of 1 side and the bottom, or the bottom only will ensure adequate retur n air openings f or airflo w requirements abo v e 1800 CFM .

(21 mm)

⁄4 "

⁄

TYP

(783 mm)

(845 mm)

⁄

⁄8 "

TYP

(829 mm)

(17 mm) (17 mm)

OUTLET

INLE T

2 (368 mm)x 12-in. (305 mm) rectangle .

2 (368mm)x 19

2 (368mm)x 23

(21 mm)

CONDENSA TE DRAI N

TRAP LOCA TION

(DO WNFL OW &

HORIZONT AL RIGHT)

OR AL TERNA TE

⁄2 -IN . DIA GAS CONN

DRAIN LOCA TION

DIMPLE LOCA T ORS

FOR HORIZONT AL

2 -in. (495mm) rectangle .

4 -in. (591mm) rectangle .

(14 mm)

30 1 ⁄2 "

(775 mm)

18 1 ⁄4 "

(464 mm)

CONDENSA TE

(UPFL OW )

HANGING

TYP

(724 mm)

⁄2 "

(684 mm)

⁄

(667 mm)

26 1 ⁄4 "

(567 mm)

⁄

(483 mm)

19 "

OUTLET

2-IN . (51mm) COMBUSTION-AIR CONN

⁄2 -IN . DI A (13mm)

GAS CONN

⁄8 -IN . DI A (22mm)

PO WER CONN

⁄2 -IN . DI A (13 mm)

THERMOS TA T ENTR Y

2-IN . (51 mm)

VENT CONN

⁄

(576 mm)

SIDE INLE T

22 1 ⁄4 " TYP

(565 mm)

24 3 ⁄

BO TT OM INLE T

(614 mm)

⁄

⁄8 "

(16 mm)

(25 mm) 1 "

⁄

(21 mm)

(16 mm)

⁄

⁄8 "

(1013 mm)

(11 mm)

(25 mm)

A05124

Dimensions -- In. (mm)

UNIT SIZE A D E

040 --- 14 / 042040 24--- 1/2 (622)* 22--- 7/8 (581)* 23 (584)*

060 --- 14 / 042060 17--- 1/2 (445) 15--- 7/8 (403) 16 (406)

080 --- 14 / 042080 21 (533) 19--- 3/8 (492) 19--- 1/2 (495)

080 --- 20 / 060080 21 (533) 19--- 3/8 (492) 19--- 1/2 (495)

100 --- 20 / 060100 21 (533) 19--- 3/8 (492) 19--- 1/2 (495)

120 --- 20 / 060120 24--- 1/2 (622) 22--- 7/8 (581) 23 (584)

*These dimensions reflect the wider casing for the Trophy (96.6% AFUE) furnace.

Fig. 2 -- Dimensional Drawing

The 355AAV Multipoise Condensing Gas--Fired Furnaces are 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. The 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.

Maintain a 1-- in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 inches (914.4 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

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 or when Manufacturer’s Coil Box is used. These furnaces are suitable for installation in a structure built on site or a manufactured building completed at final site. The design of this furnace line is NOT CSA design--certified for installation in recreation vehicles, manufactured (mobile) homes or outdoors.

This furnace is designed for continuous return-- air minimum temperature of 60_F(16_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.)

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. Install this furnace only in a location and position as specified in LOCATION and INSTALLATION sections of these instructions. 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 detection of leaks to check all connections as specified in the GAS PIPING section of these instructions.

Always install the 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.

335122-201 REV. B LIT TOP

Fig. 3 -- Clearances to Combustibles

355A

A08435

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 ducts 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 and Fig. 5.

The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

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

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.

S 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.

S After construction is complete, verify furnace operating

conditions including ignition, input rate, temperature rise and

venting, according to the manufacturer’s instructions. If this

furnace is installed with a direct--vent (combustion air and flue)

system, a factory accessory termination kit must be installed. In a

direct--vent system, all air for combustion is taken directly from

the outside atmosphere. See furnace and factory accessory

termination kit instructions for proper installation.

S These furnaces are shipped with the following materials to assist

in proper furnace installation. These materials are shipped in the

main blower compartment.

355A

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. (13 mm) CPVC street elbow 2

Drain tube coupling 1

Drain tube coupling grommet 1

Gas line grommet 1

Vent pipe grommet 1

Combustion --- air pipe grommet 2

Gas line entry hole filler plug 1

Power entry hole filler plug 2

Condensate trap hole filler plug 3

Vent and combustion---air intake hole filler plug 2

Combustion --- air pipe perforated disk assembly 1

S CANADA: National Standard of Canada, Natural Gas and

Propane Installation Code (NSCNGPIC) CAN/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,

Step 3 — Combustion and Ventilation Air

S NFPA 54--2006/ANSI Z223.1--2006, Air for Combustion and

Ventilation

S CANADA: Part 8 of the NSCNGPIC CAN/CSA B149.1--05,

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 Testi n g

S US: NFGC; chapters 5, 6, 7, and 8 and national plumbing codes S CANADA: NSCNGPIC 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 inches.

S The furnace shall be installed so that the electrical components

are protected from water.

S For accessory installation details, refer to applicable installation

literature.

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 Canada.

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--2006/ANSI

Z223.1--2006 and the Installation Standards, Warm Air Heating

and Air Conditioning Systems ANSI/NFPA 90B

80 / 27 C

/ 16 C

A06745

Fig. 4 -- Return--Air Temperature

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5 -- Installation in a Garage

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

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

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) mayalsobeusedtopreventESDdamage.

INTRODUCTION

The model 355AAV 4 --way multipoise, Gas--Fired, Category IV, direct vent and non--direct vent condensing furnace is available in model sizes ranging in input capacities of 40,000 to 120,000 Btuh.

APPLICATIONS

Step 1 — 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. 7. See appropriate application instructions for these procedures.

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor 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.

CAUTION

355A

UNIT DAMAGE HAZARD

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

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.

CAUTION

NOTE: In Canada, installations shall be in accordance with

current NSCNGPIC and/or local codes.

Step 2 — 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.

Condensate Trap Tubing (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. (See Fig. 7.)

NOTE: See Fig. 7 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:

a. Determine location of field drain connection. (See Fig. 2

or 7.)

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.

b. Remove and discard casing drain hole plug button from

desired side.

c. Install drain tube coupling grommet (factory--supplied

in loose parts bag) in selected casing hole.

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

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

e. Cement 2 factory--supplied 1/2-- in. (13 mm)street CPVC

elbows to rigid drain tube connection on condensate trap. (See Fig. 7.) These elbows must be cemented together and cemented to condensate trap drain connection.

NOTE: Failure to use CPVC elbows may allow drain to kink, preventing draining.

f. Connect larger diameter drain tube and clamp

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

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

355A

h. Attach tube to coupling and clamp securely.

Condensate Trap Tubing (Alternate Upflow Orientation)

An alternate location for the condensate trap is the left--hand side of casing. (See Fig. 2 and 8.)

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

BLOWER SHELF

CONDENSATE TRAP (INSIDE)

FURNACE DOOR

CONDENSATE TRAP

FURNACE

SIDE

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.

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).

FURNACE DOOR

FURNACE SIDE

ALTERNATE DRAIN TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

(19mm)

FIELD

DRAIN

CONN

(667mm)

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

(88mm)

WIRE TIE GUIDES (WHEN USED)

(181mm)

(44mm)

(3mm)

FRONT VIEW SIDE VIEW

(38mm)

(57mm)

(124mm)

1/4” (6mm) COLLECTOR BOX TO TRAP RELIEF PORT

1/2 (13mm) INDUCER HOUSING DRAIN CONNECTION

5/8 (16mm) COLLECTOR BOX DRAIN CONNECTION

SCREW HOLE FOR UPFLOW OR DOWNFLOW APPLICATIONS (OPTIONAL)

1/2 IN. (13mm) PVC OR CPV

(102mm)

FIELD

DRAIN

CONN

(667mm)

APPLICATIONS

(146mm) (146mm)

(102mm)

(19mm)

HORIZONTAL

Fig. 6 -- Condensate Trap

A07459

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

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)

COLLECTOR BOX

TUBE (GREEN)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

Ú2 -IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE TRAP

FIELD-INSTALLED

DRAIN TUBE

DRAIN OPTION)

A94213

Fig. 7 -- Factory--Shipped Upflow Tube Configuration

(Shown with Blower Access Panel Removed)

Condensate Trap Tubing (alternate Upflow Orientation)

NOTE: See Fig. 8 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.

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 condensate trap.

c. Determine appropriate length, then 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).

Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and procedures.

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (GREEN)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A94214

Fig. 8 -- Alternate Upflow Tube Configuration and Trap

Location

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

Upper Collector Box and Inducer Housing (Unused)

Connections

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

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 3 — 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.

355A

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX TUBE (GREEN)

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX EXTENSION TUBE

355A

CONDENSATE

TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

Fig. 9 -- Downflow Tube Configuration

(Left--Hand Trap Installation)

Condensate Trap Location

The condensate trap must be removed from the factory--installed blower shelf location and relocated in selected application location asshowninFig.2,9,or10.

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 inwardandrotatingtrap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2 and 10.)

4. 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

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.

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

A94215

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

A94216

Fig. 10 -- Downflow Tube Configuration

(Right--Hand Trap Installation)

Condensate Trap Tubing

NOTE: See Fig. 9 or 10 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.

S 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.

S 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 (factorysupplied 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 between gas valve

and inlet housing as shown in Fig. 10.

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.

AUXILIARY "J" BOX

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR

BOX EXTENSION

DRAIN TUBE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

060, AND 080 HEATING INPUT FURNACES

Fig. 11 -- Horizontal Left Tube Configuration

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

factorysupplied 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.

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.

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 pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications. This tube MUST be

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 9 or 10 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.

COLLECTOR BOX TUBE (GREEN)

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX DRAIN TUBE (BLUE)

355A

A02288

355A

MANUAL

SHUTOFF

GAS VALVE

COMBUSTION - AIR

SEDIMENT TRAP

INTAKE

/4″ (146 mm)

CONDENSATE TRAP

VENT

30″ (762 mm)MIN WORK AREA

ACCESS OPENING

DRAIN

FOR TRAP

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.

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

Fig. 12 -- Attic Location and Working Platform for Direct Vent (2--Pipe) Application -- All Sizes

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 4 — 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.

MINOR PROPERTY HAZARD

Failure to follow this caution may result in minor 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: In Canada, installations shall be in accordance with current NSCNGPIC and/or local codes.

Condensate Trap Location

The condensate trap must be removed from the factory--installed blower shelf location and relocated in selected application location as shown in Fig. 2 or 11.

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

1. Remove 3 tubes connected to condensate trap.

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

CAUTION

A93031

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 11.)

4. 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.

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.

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

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. 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

(factorysupplied in loose parts bag) to drain tube coupling, extending collector box drain tube.

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. 13 -- Attic Location and Working Platform for Non--Direct Vent (1-- Pipe) Applications -- Sizes 040 through 120 Only

355A

A96184

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 condensate trap.

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

d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

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

previously connected to condensate trap by splicing to small diameter tube (factory--supplied in loose parts bag).

b. Route extended collector box pressure tube to relief port

connection on condensate trap.

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

d. Clamp tube to prevent any condensate leakage.

Condensate Trap Field Drain Attachment

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. 11 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.

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 Platfor m

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 12 or 13.)

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX TUBE (PINK) AUXILIARY "J" BOX RELOCATED HERE

355A

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 14 -- Horizontal Right Tube Configuration

UNIT MAY NOT OPERATE

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

The condensate trap MUST be installed below furnace. See Fig. 6 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: A 12--in. (305 mm) minimum offset pipe section is recommended with short (5 to 8 ft./ 1.5 -- 2.4 M) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 12, 13 or 42.)

CAUTION

Step 5 — 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.

MINOR PROPERTY DAMAGE

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

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.

CAUTION

CONDENSATE TRAP

A02289

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 14.

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 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. 14 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.

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.

LEVEL 0″

⁄2″ MAX

(0 to 13 mm)

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

Fig. 15 -- Proper Condensate Drainage

⁄4″

MIN

⁄2″ MAX

(6 to 13 mm)

FRONT

A02146

Pressure Switch Tubing

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

NOTE: See Fig. 14 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. Use remaining small diameter tube (factory--supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch.

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

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.

Construct a Working Platfor m

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 12 or 13.)

UNIT MAY NOT OPERATE

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

The condensate trap MUST be installed below furnace. See Fig. 6 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

CAUTION

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 shown

on the furnace clearance--to--combustibles label. (See Fig. 3.)

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

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. 15.)

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 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.

355A

WARNING

CAUTION

FIRE, INJURY OR DEATH HAZARD

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

Do NOT install furnace on its back. (See Fig. 16.) Safety control operation will be adversely affected. Never connect return--air ducts to back of furnace.

UNIT DAMAGE HAZARD

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

--The furnace is permanently installed with all electrical

355A

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

UNIT DAMAGE HAZARD

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

If these furnaces are installed in an unconditioned space where ambient temperatures may be 32_F(0_C) or lower, freeze protection measures must be taken. (See Fig. 17.)

FRONT

B A C K

BACK

FRONT

A93043

Fig. 16 -- Prohibit Installation on Back

The furnace and its return air system shall be designed and installed so that negative pressure created by the air circulating fan cannot affect another appliance’s combustion air supply or act to mix products of combustion with circulating air, and that the air circulating fan of the furnace, if installed in an enclosure communicating with another fuel--burning appliance not of the direct --vent type, shall be operable only when any door or panel covering an opening in the furnace fan compartment or in a return air plenum on ducts is in the closed position.

A07911

Fig. 17 -- Freeze Protection

Step 2 — Low --Heat Only Installation

This 355AAV furnace can be installed to operate in the low--heat only heating mode when sized using the low--heat heating capacity. This is accomplished by placing setup switch SW1--2 in the ON position to provide only low--heat operation. See Fig. 37 and Table

13. With this setup, high--heat operation will not occur.

UNIT DAMAGE HAZARD

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

The furnace can operate in the high--heat mode when certain fault conditions occur. The following precautions should be taken:

1. Size gas piping based on the high--heat input

2. Check the high--heat input and adjust it per the main literature instruction.

CAUTION

Step 3 — Furnace L ocation 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 damper is in full-- heat or full--cool position.

Step 4 — Hazardous Locations

WARNING

FIRE, EXPLOSION, INJURY OR DEATH HAZARD

Improper location or inadequate protection could result in fire or explosion.

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. (457 mm) 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. (See Fig. 18.)

Step 5 — 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.

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 18 -- Installation in a Garage

NON--DIRECT VENT (1--PIPE) APPLICATION

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.

CAUTION

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 of the NFGC, Air for Combustion

and Ventilation and applicable provisions of the local building

codes.

S Canadian Installations: Part 8 of the NFPA54/ANSI

Z223.1--2006 CAN/CSA--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 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

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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.

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 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

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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” (300 mm)

of the ceiling and the second opening MUST commence within 12” (300 mm) of the floor.

b. Size openings and ducts per Fig. 19 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 square inch o f

free area per 2,000 Btuh (1,100 mm input for all gas appliances in the space per Fig. 19 and Tab l e 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. 19 and Table 1.

3. ONE OUTDOOR OPENING requires:

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

/kW) for combined input of all gas appliances in

mm the space per Table 1 and Fig. 19.

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

in the space. The opening shall commence within 12” (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1” (25 mm) from the sides and back and 6” (150 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

/kW) of combined

/kW)

WARNING

CARBON MONOXIDE POISONING HAZARD

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

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.

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

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--2006/NFPA 54--2006, 9.3.2.2:

1. For other than fan-- assisted appliances, such as a draft hood-- equipped water heater:

Volume

2. For fan--assisted appliances such as this furnace:

Volume

IfIother = combined input of all other than fan--assisted appliances in Btu/hr

fan = combined input of all fan--assisted appliances in Btu/hr ACH = air changes per hour (ACH shall not exceed 0.60.) The following requirements apply to the Standard Method and to

the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if:

a. There are no closable doors between rooms.

Other

Fan

21ft ACH

15ft ACH

other

1000 Btu/hr

fan

1000 Btu/hr

A04002

A04003

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