Bryant 355AAV User Manual
355AAV
4--WAY MULTIPOISE
VARIABLE--CAPACITY CONDENSING GAS FURNACE
FOR SIZES 040--120, SERIES C
Installation Instructions
Visit www.bryant.com
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.
1
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.
2
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
!
CAUTION
.
3
355A
1 1 ⁄4 "
14 1 ⁄2 "
TYP
(368 mm)
(32 mm)
1 "
(25mm)
15
(684 mm)
26
⁄
16
"
(667 mm)
26 1 ⁄4 "
1
(622 mm)
24
⁄2 "
5
(567 mm)
⁄
16
"
22
2-IN . (51 mm) COMBUSTIONAIR CONN
1
⁄2 -IN . (13mm) DI A
GAS CONN
2-IN (51mm)
.
VENT CONN
1
⁄2 -IN . DIA (13mm)
THERMOST AT ENT RY
11
22
⁄
16
"
(576 mm)
SIDE INLE T
(591 mm)
23 1 ⁄4 " TYP
SIDE INLE T
15
26
⁄
16
" TYP
(684 mm)
AIRFL OW
13
/
16
"
CONDENSA TE DRAI N
TRAP LOCA TION
(DO WNFLO W &
HORIZONT AL LEF T )
7
⁄8 -IN . DI A (22mm)
PO WER CONN
11
7
⁄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 ⁄
16
"
17 5 ⁄
TYP
(439 mm)
CONDENSA TE
DRAIN LOCA TIO N
(UPFLO W)
(622 mm)
16
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:
29
TYP
(754 mm)
5
⁄8 "
27
(702 mm)
9
⁄
16
"
27
TYP
(700 mm)
1
⁄2 "
24
"
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)
1
13
⁄4 "
33
30
⁄
16
"
TYP
(783 mm)
(845 mm)
⁄
16
"
5
32
⁄8 "
TYP
(829 mm)
11
/
16
"
(17 mm) (17 mm)
A
D
OUTLET
INLE T
E
1
/
2 (368 mm)x 12-in. (305 mm) rectangle .
2 (368mm)x 19
2 (368mm)x 23
13
/
16
"
(21 mm)
CONDENSA TE DRAI N
TRAP LOCA TION
(DO WNFL OW &
HORIZONT AL RIGHT)
OR AL TERNA TE
1
⁄2 -IN . DIA GAS CONN
DRAIN LOCA TION
11
/
16
"
DIMPLE LOCA T ORS
FOR HORIZONT AL
1
/
2 -in. (495mm) rectangle .
1
/
4 -in. (591mm) rectangle .
(14 mm)
30 1 ⁄2 "
(775 mm)
18 1 ⁄4 "
(464 mm)
CONDENSA TE
(UPFL OW )
HANGING
9
TYP
1
(724 mm)
⁄2 "
28
15
(684 mm)
26
⁄
16
"
(667 mm)
26 1 ⁄4 "
5
(567 mm)
22
⁄
16
⁄
16
"
"
(483 mm)
19 "
OUTLET
2-IN . (51mm)
COMBUSTION-AIR CONN
1
⁄2 -IN . DI A (13mm)
GAS CONN
7
⁄8 -IN . DI A (22mm)
PO WER CONN
1
⁄2 -IN . DI A (13 mm)
THERMOS TA T ENTR Y
2-IN . (51 mm)
VENT CONN
11
22
⁄
16
"
(576 mm)
SIDE INLE T
22 1 ⁄4 " TYP
(565 mm)
24 3 ⁄
16
"
BO TT OM INLE T
(614 mm)
13
⁄
16
5
⁄8 "
(16 mm)
(25 mm)
1 "
7
⁄
16
11
⁄
16
(21 mm)
"
(16 mm)
5
⁄
16
"
7
⁄8 "
39
(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.
4
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
5
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
60
/ 16 C
A06745
Fig. 4 -- Return--Air Temperature
6
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.
7
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
1
26
4
(667mm)
SIDE VIEW FRONT VIEW END VIEW FRONT VIEW
DOWNFLOW AND ALTERNATE
EXTERNAL UPFLOW APPLICATIONS
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
1
(88mm)
1
2
3
4
1
8
7
7
8
WIRE TIE
GUIDES
(WHEN USED)
1
3
4
(181mm)
(44mm)
(3mm)
FRONT VIEW SIDE VIEW
1
(38mm)
1
2
(57mm)
7
(124mm)
4
8
1
2
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)
4
1/2 IN. (13mm) PVC OR CPV
(102mm)
FIELD
DRAIN
CONN
4
(667mm)
APPLICATIONS
3
(146mm) (146mm)
5
4
1
26
4
4
(102mm)
(19mm)
3
4
HORIZONTAL
3
5
4
Fig. 6 -- Condensate Trap
8
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
1
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
9
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.
10
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
11
355A
MANUAL
SHUTOFF
GAS VALVE
COMBUSTION - AIR
SEDIMENT
TRAP
INTAKE
3
5
/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.
12
A 3-IN.(76mm) MINIMUM CLEARANCE
TO COMBUSTION-AIR INTAKE
IS REQUIRED.
VENT
COMBUSTION AIR
GAS VALVE
INTAKE
MANUAL
SHUTOFF
30-IN. (762mm) MIN
3
5
/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.)
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.
14
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″
TO
1
⁄2″ MAX
(0 to 13 mm)
UPFLOW OR DOWNFLOW HORIZONTAL
FRONT
Fig. 15 -- Proper Condensate Drainage
1
⁄4″
MIN
TO
1
⁄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.
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
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
15
!
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.
16
!
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
17
355A
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
355A
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
2
/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
2
/kW) of combined
2
/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
I
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
3
3
I
other
1000 Btu/hr
I
fan
1000 Btu/hr
A04002
A04003
18
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