Bryant 355CAV User Manual

PLUS 95S -- MODEL 355CAV
DIRECT--VENT 4--W AY MULTIPOISE
CONDENSING GAS FURNACE
WITH PERFECT SENSET PERFECT HUMIDITYT
SERIES A

Installation Instructions

NOTE: Read the entire instruction manual before starting the

installation.
This furnace can be vented as a direct vent (2--pipe) or as an
optional ventilated combustion air application.

Furnaces installed in Canada must use Vent Systems that are
certified to the Standard for Type BH Gas Venting Systems,
ULC-- S636.
ULC--S636 certified plastic vent system material or the
components of ULC --S636 certified vent systems must not be
interchanged with other vent systems or unlisted pipe/fittings.
Vent components supplied with the furnace and components in
factory authorized vent kits may be used with ULC--S636
certified vent systems.
The ULC --S636 certified plastic components, and specified
primers and glues of the certified system must be from a
single--system manufacturer and not mixed with other system
manufacturer’s vent system parts.
The first 3 ft. (.91 M) of the venting system must be readily
accessible for inspection.
Some Provinces may require the combustion air system to be
ULC--S636 certified.

NOTE: Please retain these instructions with the furnace after
installation for future reference.

TABLE OF CONTENTS

PAGE

IMPORTANT INFORMATION 2........................

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 7..

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

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

Upflow 7........................................

Downflow 10.....................................

Horizontal Left 11..................................

Horizontal Right 13................................

LOCATION 14......................................

INSTALLATION 16..................................

Air Ducts 19.......................................

Air for Combustion and Ve ntilation 26..................

Combustion Air Pipe 32..............................

Vent Pipe 34......................................

Vent Termination 37................................

Condensate Drain 42................................

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

CHECKLIST 59.....................................

As an ENERGY STAR® Partne r,
Bryant Heating & Cooling has
determined that this product
meets the ENERGY STAR®
guidelines for energy efficiency.

AIRFLOW

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit damage.

Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure. This furnace can be vented as either a direct vent
(2--pipe) furnace or as an optional ventilated combustion air
application.
A direct vent system shall be installed in accordance with
the direct vent (2-- pipe) procedures in the Combustion Air
and Vent Pipe Systems section within this instruction. For
optional ventilated combustion air applications, refer to the
ventilated combustion air option procedures in the same
section.

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.

ama

AIRFLOW

UPFLOW

HORIZONTAL

LEFT

Fig. 1 -- Furnace Orientation

!

DOWNFLOW

AIRFLOW

CAUTION

ISO 9001:2000

REGISTERED

HORIZONTAL

CERTIFIED

RIGHT

AIRFLOW

A93041

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

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

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

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

(1.) The equipment listed in Chapter 10 entitled ”Equipment Not Required T oBe 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

SAFETY CONSIDERATIONS

!

CAUTION

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 combustion air
requirements, gas input rate, air temperature rise, unit
leveling, and unit sizing.

!

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD

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

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

Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with unit and other safety
precautions that may apply.

These instructions cover the minimum requirements and conform
to existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as
a minimum for a safe installation.

Wear safety glasses and work gloves. Have a fire extinguisher
available during start--up and adjustment procedures and service
calls.

Recognize safety information. This is the safety--alert symbol

. When you see this symbol on the furnace 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 a hazard
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.

!

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing and gloves when
handling parts.

The 355CAV 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. (25.4 mm) clearance from combustible materials
to supply air ductwork for a distance of 36 inches 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.
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 db or intermittent operation down to 55_F
db such as when used with a night setback thermostat. Return--air
temperature must not exceed 80_F 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.

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.

355CAV

3

14 1⁄2"

TYP

1

26 15⁄16"

26 1⁄4"

1

24

⁄2"

5

⁄16"

22

2-IN. COMBUSTION­AIR CONN

1

⁄2-IN. DIA

GAS CONN

2-IN. VENT CONN

⁄2-IN. DIA THERMOSTAT

ENTRY

22 11⁄16"

SIDE INLET

CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL LEFT)

7

⁄8-IN. DIA

POWER CONN

7

⁄8-IN. DIA

ACCESSORY
POWER ENTRY

CONDENSATE
DRAIN TRAP
LOCATION
(ALTERNATE
UPFLOW)

17 5⁄16"

9 7⁄16"

TYP

1

⁄2"

28

AIRFLOW

13

/16"

1

⁄4"

33

TYP

5

⁄8"

32

TYP

13

⁄16"

30

11

⁄16"

29

TYP

5

⁄8"

27

9

⁄16"

27

TYP

1

⁄2"

24

A

D

OUTLET

13

/16"

CONDENSATE DRAIN

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL RIGHT)

OR ALTERNATE

1

⁄2-IN. DIA GAS CONN

30 1⁄2"

18 1⁄4"

TYP

9

⁄16"

26 15⁄16"

26 1⁄4"

5

22

⁄16"

19"

OUTLET

2-IN. COMBUSTION­AIR CONN

1

⁄2-IN. DIA

GAS CONN

7

⁄8-IN. DIA

POWER CONN

1

⁄2-IN. DIA

THERMOSTAT ENTRY

2-IN. VENT CONN

22 11⁄16"

SIDE INLET

13

⁄16"

5

⁄8"

5

⁄16"

7

⁄8"

39

1"

355CAV

11⁄4"

1"

23 1⁄4" TYP

SIDE INLET

26 15⁄16" TYP

CONDENSATE
DRAIN LOCATION
(UPFLOW)

NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,

see flex duct manufacturer’s recommendations for equivalent diameters.

2. Minimum return-air opening at furnace:
a. For 800 CFM–16-in. round or 14
b. For 1200 CFM–20-in. round or 141/2
c. For 1600 CFM–22-in. round or 141/2
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data

literature for 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
return air openings for airflow requirements above 1800 CFM.

11

/16"

INLET

E

1

/2

x 12-in. rectangle.

x 191/2

-in. rectangle.

x 231/4

-in. rectangle.

11

/16"

CONDENSATE

DRAIN LOCATION

(UPFLOW)

DIMPLE LOCATORS

FOR HORIZONTAL

HANGING

22 1⁄4" TYP

24 3⁄16"

BOTTOM INLET

7

⁄16"

11

⁄16"

A05124

Dimensio ns (In. / mm)

UNIT SIZE A D E

042060 17--- 1/2 / 444.5 15--- 7/8 / 403.2 16 / 406.4

042080 21 / 533.4 19--- 3/8 / 492.1 19--- 1/2 / 495.3

060080 21 / 533.4 19--- 3/8 / 492.1 19--- 1/2 / 495.3

060100 21 / 533.4 19--- 3/8 / 492.1 19--- 1/2 / 495.3

060120 24--- 1/2 / 622.3 22--- 7/8 / 581.0 23 / 584.2

Fig. 2 -- Dimensional Drawing

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

4

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 and all flue products are discharged
to the outside atmosphere. See furnace and factory accessory
termination kit instructions for proper installation.

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

This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft.

INSTALLATION

(0 - 2,135m).
An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications.
This furnace is for indoor installation in a building constructed on site. This furnace may be installed in a manufactured (mobile) home when stated on rating plate and
using factory authorized kit..
This furnace may be installed on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below.
This furnace requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC,
PVC-DWV, CPVC, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be
installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),excepté queles fournaises de 140 taille
sont pour altitudes comprises entre 0 - 2,135m (0 - 7,000pi).
Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel.
Cette fournaise à air pulsé est pour installation à l´intérieur dans un bâtiment construit sur place. Cette fournaise à air pulse peut être installée dans une maison
préfabriquée (maison mobile) si prescrit par la plaque signalétique et si l' on utilise une trousse specifiée par le fabricant.
Cette fournaise peut être installée sur un plancher combustible dans un enfoncement ou un placard en observant les Dégagement Minimum En Pouces Avec

Éléments De Construction Combustibles.

Cette fournaise nécessite un système d´évacuation spécial. La méthode d´installation et la liste des pièces nécessaires figurent dans les instructions d´installation. Cette
fournaise doit s´utiliser avec la tuyauterie des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ABS-DWV et elle ne peut pas être ventilée conjointment avec d´autres
appareils à gaz. Épaisseur de la construction au travers de laquelle il est possible de faire passer les tuyaux d'aération (admission/évacuation): 24 po (600 mm)
maximum, 3/4 po (19mm) minimum (y compris la toiture).

For upflow and downflow applications, furnace must be installed level, or pitched within 1/2" of level. For a
horizontal application, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper
drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.

Pour des applications de flux ascendant et descendant, la fournaise doit être installée de niveau ou inclinée à
pas plus de 1/2" du niveau. Pour une application horizontale, la fournaise doit être inclinée entre minimum
1/4" et maximum 1/2" du niveau pour le drainage approprié. En cas d´installation en position horizontale,
consulter les renseignements IMPORTANTS sur le support dans le manuel d´installation.

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

Minimum front clearance for service 24 inches (610mm).

*

DOWNFLOW POSITIONS:

For installation on combustible floors only when installed on special base No. KGASB0201ALL,

†

Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

HORIZONTAL POSITIONS:

Line contact is permissible only between lines formed by intersections of top and two sides
of furnace jacket, and building joists, studs, or framing.

§

Clearance shown is for air inlet and air outlet ends.

Ø

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

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS DE

CONSTRUCTION COMBUSTIBLES

POUR TOUS LES POSITIONS:

Dégagement avant minimum de 610mm (24 po) pour l'entretien.

*

POUR LA POSITION COURANT DESCENDANT:

Pour l´installation sur le plancher combustible seulement quand on utilise la base spéciale,

†

pièce nº KGASB0201ALL, l
serpentin, pièce nº KCAKC.

POUR LA POSITION HORIZONTALE:

Le contact n
deuxcôtés de la chemise de la fournaise, et des solives, des montants ou de la charpente du
bátiment.

§

La distance indiquée concerne l
sortie d

Ø

Pour les fournaises de 120 et 140 taille, 1 po (25mm) dégagement des matériaux combusitbles
est requis au-dessous.

´

est permis qúentre les lignes formées par les intersections du dessus et des

´

air.

´

ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de

´

extrémité du tuyau d´arrivée d´air et l´extrémité du tuyau de

LEVEL (0")

1/2" MAX

UPFLOW OR
DOWNFLOW

TO

FRONT

MIN 1/4" TO 1/2" MAX

FRONT

HORIZONTAL

This furnace is approved for UPFLOW, DOWNFLOW and
HORIZONTAL installations.

Cette fournaise est approuvée pour l´installation HORIZONTALE
et la circulation d´air VERS LE HAUT et VERS LE BAS.

0"
†

1"

Les fléches de dégagement

ne change pas avec

´

orientation de la

l

générateur d´air chaud.

TOP/PLENUM

DESSUS/CHAMBRE D´AI R

C

A

N

R

U

N

F

R

U

FO

R

F

A

F

R

A

V

A

BOTTOM

DESSOUS

Ø

d´évent avec combustibles.

I

S

O

E

C

E

S

I

A

T

N

O

T

N

A

V

S

E

L

È

N

T

O

N

T

N

T

3"

Vent clearance to
combustibles 0".

0 (po) Dégagement

D

T

R

EV. B (LIT TOP

E

S

E

R

V

I

E

T

I

Clearance arrows
do not change with
furnace orientation.

0"

B

A

A

C

R

K

R

I

E

R

E

E

D

I

S

E

T

O

C

0"

§

Clearance in inches
Dégagement (po).

328068-201 R

S

355CAV

§

0"

C

E

E

*

N

24

MIN

)

Fig. 3 -- Clearances to Combustibles

5

A04116

Installer Packet Includes:

Installation, Start--- up, and Operating Instructions

Service and Maintenance Instructions

User’s Information Manual

Warranty Certificate

Loose Parts Bag includes: Quantity

Collector Box or Condensate trap extension tube 1

Inducer housing drain tube 1

1/2--- in CPVC street elbow 2

Drain tube coupling 1

Drain tube coupling grommet 1

Gas line grommet 1

Vent pipe grommet 1

Combustion --- air pipe grommet 1

Gas line entry hole filler plug 1

Power entry hole filler plug 2

Condensate trap hole filler plug 3

355CAV

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

Combustion ---air pipe perforated disk assembly 1

Fig. 4 -- Return-- Air Temperature

18-IN. MINIMUM

TO BURNERS

Fig. 5 -- Installation in a Garage

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

For accessory installation details, refer to applicable installation
literature.

80 / 27 C

60

/ 16 C

A06745

A93044

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:

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

S CANADA: National Standard of Canada, Natural Gas

and Propane Installation Code
(CAN/CSA--B149.1--05) CSA B149.1--05

General

Combustion and Ventilation Air

Duct

Acoustical Lining and Fibrous Glass

Gas Piping and Gas Pipe Pressure T

In the state of Massachusetts:

6

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 A manufactured (Mobile) home installation must

conform with the Manufactured Home Construction
and Safety Standard, Title 24 CFR, Part 3280, or when

this standard is not applicable, the Standard for

Manufactured Home Instllation (Manufactured Home
Suites, Communities, and Set--Ups), ANSI/NCS A225.1,
and/or CAN/CSA--z240, MH Series Mobile Homes.

S CANADA: CAN/CSA --B149.1--05. For a copy,

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

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

Ventilation.

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

Venting Systems and Air Supply for Appliances.

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.

Duct

S US and CANADA: current edition of SMACNA,

NFPA 90B as tested by UL Standard 181 for Class I
Rigid Air Ducts.

esting

S US: NFGC; chapters 5, 6, 7, and 8 and national

plumbing codes.

S CANADA: CAN/CSA --B149.1--05 Parts 4, 5, 6, and 9.

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 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.

Electrical

Connections

S US: National Electrical Code (NEC) ANSI/NFPA

70--2005.

S CANADA: Canadian Electrical Code CSA C22.1.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

!

CAUTION

drain and pressure tubes are connected as shown in Fig. 7. See
appropriate application instructions for these procedures.

!

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property
damage.

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

UNIT DAMAGE HAZARD

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

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

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

4. Firmly touch 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.

5. 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.).

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

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

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

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

INTRODUCTION

The model 355CAV Direct Vent, Upflow, Gas--Fired, Category
IV, condensing furnace is available in model sizes ranging in
input capacities of 60,000 to 120,000 Btuh.

APPLICATIONS

General

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

NOTE: In Canada, installations shall be in accordance with
current CAN/CSA--B149.1--05 and/or local codes.

UPFLOW APPLICATION

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 (Factory-- Shipped

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 section for drain tube extension details. (See Fig. 6.)

Condensate Trap Tubing (Factory--Shipped

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
andpressureswitchreadyforuseinUPFLOW
applications. These tubes can be identified by their
connection location and also by a color label on each tube.
These tubes are identifed as follows: collector box drain
tube (blue label), inducer housing drain tube (violet label
or molded), relief port tube (green label), and pressure
switch tube (pink label).

2. Condensate Trap Drain Tube
The condensate trap drain connection must be extended
for field attachment by doing the following:

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

2or7.)

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

g. Remove and discard casing drain hole plug button from

desired side.

h. Install drain tube coupling grommet (factory--suppliedin

loose parts bag) in selected casing hole.

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

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

j. Cement 2 factory--supplied 1/2--in. (12.7mm) street

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

Orientation)

Orientation)

355CAV

7

BLOWER SHELF

CONDENSATE
TRAP (INSIDE)

ALTERNATE DRAIN
TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FURNACE
DOOR

FIELD

DRAIN

CONN

CONDENSATE
TRAP

FURNACE

1

26

4

(667mm) (38mm)

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

SIDE

1

1

FURNACE
DOOR

7

(124mm)

8

4

2

FIELD

DRAIN

CONN

4

3

(146mm) (146mm)

4

5

1

26

4

(667mm) (19mm)

HORIZONTAL

APPLICATIONS

FURNACE
SIDE

4

3

3

4

5

4

355CAV

(19mm)

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

1

1

2

3

4

WIRE TIE
GUIDES
(WHEN USED)

(88mm)

3

1

4

(181mm)

(44mm)

(3mm)

FRONT VIEW SIDE VIEW

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

k. Connect larger diameter drain tube and clamp

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

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

m. Attach tube to coupling and clamp securely.

Condensate Trap (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
Tubing (Alternate Upflow Orientation) section for tubing
attachment.

To relocate condensate trap to the left--hand side, perform the
following:

1. Remove three 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.

1

8

7

7

8

1

4

2

(57mm)

Fig. 6 -- Condensate Trap

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 casing hole by

5. Fill unused condensate trap casing holes with plastic filler

Condensate Trap Tubing (Alternate Upflow

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

confirm location of these tubes.

1/4 OD
COLLECTOR BOX TO
TRAP RELIEF PORT

1/2 OD
INDUCER HOUSING
DRAIN CONNECTION

5/8 OD
COLLECTOR BOX
DRAIN CONNECTION

SCREW HOLE FOR
UPFLOW OR DOWN­FLOW APPLICATIONS
(OPTIONAL)

1/2 IN. PVC OR CPVC

!

WARNING

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

caps (factory--supplied in loose parts bag).

Orientation)

A07459

8

PLUG

T

COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

CAP

COLLECTOR BOX

TUBE (PINK)

INDUCER HOUSING

(MOLDED) DRAIN

UBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (GREEN

ROUTES BEHIND

INDUCER)

CONDENSATE

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-

SUPPLIED

DRAIN TUBE

FIELD-INSTALLED
FACTORY­½ - IN. CPVC STREET

LEFT DRAIN OPTION

SUPPLIED

ELBOWS (2) FOR

FIELD- INSTALLED

FACTORY-

SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

A07274

Fig. 7 -- Factory--Shipped Trap Location

(Shown with Blower Access Panel Removed)

1. Collector Box Drain Tube
Connect collector box drain tube (blue label) to
condensate trap.

NOTE: On 17-- 1/2 --in. (444.5mm) wide furnaces ONLY, cut
tube between corrugated sections to prevent kinks.

2. Inducer Housing Drain Tube

a. Remove and discard LOWER (molded) inducer housing

draintube which was previously connectedto 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. Determineappropriate 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).

c. Determineappropriate length, then cut and connect tube.

Condensate Trap Field Drain

Attachment

Refer to Condensate Drain section for recommendations and
procedures.

PLUG

COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

CAP

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (GREEN)

CONDENSATE

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (VIOLET)

A07281

Fig. 8 -- Alternate Trap Location

Pressure Switch T

ubing

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)

Drain

Connections

Upper Collector Box Drain

Connection

Attached to the UPPER collector box drain connection is a
factory--installed corrugated, plugged tube (blue and white
striped label). This tube is plugged to prevent condensate leakage
in this application. Ensure this tube is plugged.

NOTE: See Fig. 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 Pr

otection

Refer to Condensate Drain Protection section for
recommendations and procedures.

355CAV

9

DRAIN TUBE (BLUE)

COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

CONDENSATE

355CAV

INDUCER HOUSING

COLLECTOR BOX

PLUG

CAP

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE EXTENSION

(MOLDED) DRAIN

TUBE (VIOLET)

DRAIN TUBE
COUPLING

COLLECTOR BOX
TUBE (GREEN)

CAP

COLLECTOR BOX
DRAIN TUBE (BLUE)

COLLECTOR BOX
TUBE (PINK)

PLUG

COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)

COLLECTOR BOX
TUBE EXTENSION

INDUCER HOUSING
(MOLDED) DRAIN
TUBE (VIOLET)

CONDENSATE

COLLECTOR BOX
EXTENSION
DRAIN TUBE

A07276

Fig. 9 -- Condensate Trap

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.

Condensate Trap

The condensate trap must be removed from the factory--installed
blower shelf location and relocated in selected application
location as shown in Fig. 2, 9, or 10.

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

1. Remove three tubes connected to condensate trap.

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

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.

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 tabls snap into locking position.

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

Location

!

WARNING

A07277

Fig. 10 -- Factory--Shipped Trap Location

(Shown with Blower Access Panel Removed)

Condensate Trap T

ubing

NOTE: See Fig. 9 or 10 or tube routing label on main furnace

door to check for proper connections.

1. Collector Box DrainTube

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.

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

(a.)Connect LOWER collector box drain tube (blue

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

(b.)Clamp tube to prevent any condensate leakage.

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

(a.)Install drain tube coupling (factory-- supplied in

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

(b.)Connect larger diameter drain tube

(factory--supplied in loose parts bag) to drain
tube coupling, extending collecor 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.

2. Inducer Housing Drain Tube

a. Remove factory-- installed cap and clamp from LOWER

inducer housing drain connection.

10

b. Remove and discard UPPER (molded) inducer housing

draintube which was previously connectedto condensate
trap.

PLUG

AUXILIARY “J” BOX

CONDENSATE

CAP

COLLECTOR BOX

TUBE EXTENSION

COLLECTOR BOX

EXTENSION

DRAIN TUBE

DRAIN TUBE

COUPLING

Fig. 11 -- Horizontal Left Tube Configuration

COLLECTOR BOX
DRAIN TUBE (BLUE &
WHITE STRIPED)

355CAV

COLLECTOR BOX
TUBE (GREEN)

INDUCER HOUSING
(MOLDED) DRAIN
TUBE (VIOLET)

COLLECTOR BOX
DRAIN TUBE (BLUE)

COLLECTOR BOX
TUBE (PINK)

A07278

c. Install cap and clamp on UPPER inducer housing drain

conection where molded drain tube was removed.

d. Use inducer housing drain tube (violet label and

factory--supplied in loose parts bag) to connect LOWER
inducerhousing drain connection to the condensate trap.

e. Connectinducerhousing 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 yhousing drain tube (violet label)

directly from inducer housing to condensate
trap.

(b.)Determine apprpriate 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 T

ubing

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. The tube
MUST be disconnected and used or 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 o r HORIZONTAL RIGHT applications.

NOTE: See Fig. 9 or 10 or tube routing label on man 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
pressu re 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.

Condensate Trap Freeze Pr

otection

Refer to Condensate Drain Protection section for
recommendations and procedures.

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.

11

COMBUSTION – AIR




INTAKE

3

5

⁄4″

VENT



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

30″ MIN
WORK AREA

COMBUSTION–AIR

INTAKE

A 3-IN. MINIMUM CLEARANCE
TO COMBUSTION-AIR INTAKE
IS REQUIRED.

3

5

⁄4″

VENT



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

30-IN. MIN
WORK AREA

MANUAL

SHUTOFF

GAS VALVE

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

DRAIN

ACCESS OPENING
FOR TRAP

Fig. 12 -- Attic Location and Working Platform for Direct

Vent (2--Pipe) Application

355CAV

!

CAUTION

PROPERTY DAMAGE

Failure to follow this caution may result in property
damage.

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

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

Condensate Trap

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 three tubes connected to condensate trap.

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

3. Remove casing hole filler cap from casing hole. (See Fig.
2or11.)

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

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 an
rotating until tabls snap into locking position.

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

Location

!

WARNING

A93031

MANUAL

SHUTOFF

GAS VALVE

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

DRAIN

ACCESS OPENING
FOR TRAP

Fig. 13 -- Attic Location and Working Platform for

Ventilated Combustion Air Applications

Condensate Trap T

ubing

NOTE: See Fig. 11 or tube routing label on main furnace door

to check for proper connections.

1. Collector Box DrainTube

a. Install drain tube coupling (factory-- supplied in loose

partsbag) into collector box draintube (bluelabel) which
was previously connected to condensate trap.

b. Connect large diameter drain tube and clamp

(factory--supplied in loose parts bag) to drain tube
coupling, extending collecor box drain tube.

c. Route extended tube (blue label) to condensate trap and

cut to appropriate length.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube

(a.)Remove and discard LOWER (molded) inducer

housing drain tube which was previously
connected to condensate trap.

(b.)Use inducer housing drain extension tube (violet

label and factory--supplied in loose parts bag) to
connect LOWER inducer housing drain
connection to 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--suppled in loose partsbag).

b. Route extended collector box pressur tube to relief port

connectio 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 T

ubing

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.

12

A96184

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

2. Use smaller diameter tube (factory--suppled in loose pars
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 lenght, cut, and reconnect tube to
High Pressure Switch connections labeled COLLECTOR
BOX.

Condensate Trap Freeze Pr

otection

Refer to Condensate Drain Protection section for
recommendations and procedures.

Construct a Wo rking

Platform

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

!

CAUTION

UNIT OPERATION HAZARD

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

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

NOTE: A 12 --in. (304.8mm) minimum offset pipe section is
recommended with short (5 to 8 ft or 1.5 M to 2.4 M) vent
systems. This recommendation is to reduce excessive condensate
droplets from exiting the vent pipe. (See Fig. 12, 13, or 44.)

HORIZONTAL RIGHT
(SUPPLY-- AIR DISCHARGE) APPLICATIONS

A horizontal right furnace application is where furnace blower is
located to the left of combustion and controls section of furnace,
and conditioned air is discharged to the right.

!

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property
damage.

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

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

NOTE: The auxiliary junction box (J--box ) MUST be relocated
to opposite side of furnace casing. (See Fig. 14.) See Electrical
Connection section for J--box relocation.

Condensate Trap

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (VIOLET)

Location

COLLECTOR BOX

EXTENSION TUBE

PLUG

COLLECTOR BOX
TUBE (GREEN)

COLLECTOR BOX TUBE (PINK)

AUXILIARY “J” BOX RELOCATED HERE

CONDENSATE

A07279

Fig. 14 -- Horizontal Right Tube Configuratio n

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 three tubes connected to condensate trap.

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

!

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.

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

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

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

355CAV

LEVEL (0″)

TO

1

⁄2″ MAX

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

MIN

TO

1

⁄2″ MAX

1

⁄4″

Fig. 15 -- Proper Condensate Drainage

13

FRONT

A02146

Condensate Trap T

NOTE: See Fig. 14 or tube routing label on main furnace door

to check for proper connections.

1. Collector Box DrainTube

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

355CAV

3. Relief Port Tube
Refer to Pressure Switch Tubing section for
recommendations and procedures.

Condenste Trap Field Drain

Refer to Condensate Drain section for recommendations and
procedures.

Pressure Switch T

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 connect to the pressure switch in
DOWNFLOW o r 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--suppled in loose parts bag.)

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

4. Use remaining small diameter tube (factory--suppled in
loose parts bag) to extend collector box pressure tube
(pink label) which was previously connected to pressure
switch.

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

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

7. Clamp tube to relief port connection.

ubing

(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--suppled 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.

Attachment

ubing

Condensate Trap Freeze Pr

Refer to condensate Drain Protection section for
recommendations and procedures.

Construct a Wo rking

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

!

UNIT OPERATION HAZARD

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. (304.8mm) minimum offset pipe section is
recommended with short (5 to 8 ft or 1.5 m to 2.4 m) vent
systems. This recommendation is to reduce excessive condensate
droplets from exiting the vent pipe. (See Fig. 12, 13, or 44.)

otection

Platform

CAUTION

LOCATION

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 7.

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 and forward within 1/2--in. (12.7mm) for
proper furnace operation. For horizontal applications pitch
1/4--in. (6mm) minimum to 1/2--in. (12.7mm) 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.

14

FRONT

B
A
C
K

BACK

FRONT

A93043

Fig. 16 -- Prohibit Installation on Back

!

CAUTION

UNIT DAMAGE HAZARD

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

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

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

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

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

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

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

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

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

!

WARNING

FIRE OR DEATH HAZARD

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

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

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.

!

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 Condensate
Drain Protection section and Fig. 17.

32oF MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED

A93058

Fig. 17 -- Freeze Protection

Furnace Location Relative to Cooling

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.

Equipment

355CAV

15

Hazardous

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. (457.2mm) 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. 5.)

355CAV

Locations

!

5

⁄16″

1 3⁄4″

WARNING

5

⁄16″

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

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

Installation in Upflow or Downflow

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when special base (available from
Manufacturer) Part No. KGASB is used. Special base is not
required when this furnace is installed on Manufacturer’s Cased
Coil Assembly or when Manufacturer’s Coil Box is used.

1. Determine application being installed from Table 1.

2. Construct hole in floor per dimensions specified in Table 1
and Fig. 19.

3. Construct plenum to dimensions specified in Table 2 and
Fig. 19.

4. If special b ase (KGASB) is used, install as shown in Fig.

20.

5. If Manuracturer’s Cased Coil Assembly or Manufacturer’s
Coil Box is used, install as shown in Fig. 21.

NOTE: Remove furnace perforated discharge duct flanges when
they interfere with mating flanges on coil on downflow subbase.
To remove furnace perforated discharge duct flange, use hand
scanners, wide duct pliers or duct flange tool to bend flange back
and forth until it breaks off. Be careful of sharp edges. (See Fig.

22.)

Applications

3

⁄4″

1

5

⁄16″

5

⁄16″

3

⁄4″

1

3

1

⁄4″

A89014

Fig. 18 -- Leveling Legs

INSTALLATION

Leveling Legs (If Desired)

When furnace is used in upflow position with side inlet(s),
leveling legs may be desired. (See Fig. 18.) Install field--supplied,
corrosion--resistant 5/16--in.(7.9mm) machine bolts and nuts.

NOTE: The maximum length of bolt should not exceed 1 --1/2
in. (38.1mm).

1. Position furnace on its back. Locate and drill a 5/16--in.
(7.9mm) diameter hole in each bottom corner of furnace.
(See Fig. 18.) Holes in bottom closure panel may be used
as guide locations.

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

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

!

CAUTION

UNIT MAY NOT OPERATE HAZARD

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

Do not bend duct flanges inward as shown in Fig. 22. This
will affect airflow across heat exchangers and may cause
limit cycling or premature heat exchanger failure. Remove
duct flange completely or bend it inward a minimum of
210_F(99_C) as shown in Fig. 22.

Installation in Horizontal Applications

These furnaces can be installed in either horizontal left or right
discharge position. In a crawlspace, furnace can either be hung
from floor joist or installed on suitable blocks or pad. Furnace
can be suspended from each corner by hanger bolts and angle
iron supports. (See Fig. 23.) Cut hanger bolts (4 each 3/8-- in.
all--thread rod) to desired length. Use 1 X 3/8--in. flat washers,
3/8--in. lock washers, and 3/8--in. nuts on hanger rods as shown
in Fig. 23. Dimples are provided for hole locations. (See Fig. 2.)

!

CAUTION

UNIT MAY NOT OPERATE HAZARD

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

The entire length of furnace MUST be supported when
furnace is used in a horizontal position to ensure proper
draining. When suspended, bottom brace supports sides
and center blower shelf. When unit is supported from the
ground, blocks or pad should support sides and center
blower shelf area.

16

FURNACE

FACTORY SUPPLIED

CASED COIL OR COIL BOX

A

PLENUM

OPENING

B D

FLOOR

OPENING

C

Fig. 19 -- Floor and Plenum Opening Dimensions

FURNACE

(OR OTHER MANUFACTURERS
COIL CASING WHEN USED)

A96283

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

355CAV

A07586

Fig. 21 -- Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

PERFORATED
DISCHARGE DUCT
FLANGE

NO

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Fig. 20 -- Furnace, Plenum, and Subbase Installed on a

Combustible Floor

A07585

YES

210¡
MIN

YES

A93029

Fig. 22 -- Duct Flanges

17

3

/8-IN. ROD

ANGLE
IRON OR
EQUIVALENT

355CAV

(B)

(A)

(B)

3

5

DRAIN

/4″

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

(A)

(A) ROD LOCATION

USING DIMPLE
LOCATORS
(SEE DIMENSIONAL
DWG FOR
LOCATIONS)

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

3

/8-IN. HEX NUT

& WASHER (4)

REQD PER ROD

NOTES:

(A)

1. A 1 In. clearance minimum between top of
furnace and combustible material.

2. The entire length of furnace must be
supported when furnace is used in horizontal
position to ensure proper drainage.

(B)

(B)

13

/16-IN. MAX
ALTERNATE SUPPORT
LOCATION FROM BACK

Fig. 23 -- Crawlspace Horizontal Application for Direct Vent/2--Pipe Installation and for Ventilated Combustion Air Installation

A93304

18