Bryant 355M-40-4, 355M-40-5 User Manual

UPFLOW

DOWNFLOW

HORIZONTAL

LEFT

AIRFLOW

HORIZONTAL

RIGHT

installation, start-up, and operating instructions

DELUXE 4-WAY MULTIPOISE VARIABLE-CAPACITY DIRECT-VENT CONDENSING GAS FURNACE

Cancels: II 355M-40-4 II 355M-40-5

355MAV

Series D

7-97

NOTE: Read the entire instruction manual before starting the installation.

This symbol → indicates a change since the last issue. Index Page

DIMENSIONAL DRAWING........................................................2

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

Clearances to Combustibles......................................................3

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS....3-4

INTRODUCTION..........................................................................4

APPLICATIONS ......................................................................4-11

General......................................................................................4

Upflow Applications..............................................................4-6

Downflow Applications.........................................................7-8

Horizontal Left (Supply-Air Discharge) Applications.........8-9

Horizontal Right (Supply-Air Discharge) Applications.....9-11

LOCATION ............................................................................11-13

General...............................................................................11-12

Low-Fire Only Installation.....................................................12

Furnace Location Relative to Cooling Equipment................12

Hazardous Locations...............................................................13

INSTALLATION....................................................................13-17

Leveling Legs (If Desired).....................................................13

Installation In Upflow or Downflow Applications ..........13-15

Installation In Horizontal Applications..................................15

Filter Arrangement..................................................................16

Bottom Closure Panel.............................................................16

Gas Piping...............................................................................17

ELECTRICAL CONNECTIONS...........................................17-21

115-v Wiring......................................................................17-18

24-v Wiring........................................................................18-20

Accessories ........................................................................20-21

DIRECT VENTING ...............................................................21-29

Removal of Existing Furnaces from

Common Vent Systems.....................................................21

Combustion-Air and Vent Piping .....................................21-26

Concentric Vent and Combustion-Air Termination

Kit Installation..............................................................26-29

Multiventing and Vent Terminations.....................................29

CONDENSATE DRAIN..............................................................29

General....................................................................................29

Application..............................................................................29

Condensate Drain Protection..................................................29

SEQUENCE OF OPERATION..............................................31-34

Self-Test Mode........................................................................31

Heating Mode....................................................................31-32

A93040

CANADIAN GAS ASSOCIATION

APPROVED

A93041

As an ENERGY STAR Partner, Bryant Heating & Cooling Systems Company has determined that this product meets the ENERGY STAR guidelines for energy efficiency.

Fig. 1—Multipoise Orientations

ama

CERTIFICATION OF MANUFACTURING SITE

Heating Mode—Two Stage....................................................32

Emergency Heat Mode...........................................................32

Cooling Mode .........................................................................32

Heat Pump Mode...............................................................32-33

Continuous Fan Mode ............................................................33

Component Test......................................................................34

Bypass Humidifier Mode........................................................34

Dehumidification Mode..........................................................34

Zone Mode..............................................................................34

START-UP PROCEDURES ..................................................34-42

General....................................................................................34

Select Setup Switch Positions...........................................34-35

Prime Condensate Trap With Water.................................35-36

Purge Gas Lines......................................................................37

Adjustments .......................................................................37-42

Set Gas Input Rate ............................................................37-41

Set Temperature Rise........................................................41-42

Set Thermostat Heat Anticipator............................................42

CHECK SAFETY CONTROLS ............................................42-43

Check Primary Limit Control.................................................42

Check Pressure Switch......................................................42-43

CHECKLIST...........................................................................43-44

—1—

⁄2"

⁄16"

AIRFLOW

⁄4" 26

⁄8"

⁄16"

⁄8"

OUTLET

2-IN. COMBUSTION-

TYP

⁄2-IN. DIA

GAS CONN

AIR CONN

⁄8-IN. DIA

⁄16"

19"

⁄16"

POWER CONN

2-IN. VENT CONN

⁄2-IN. DIA

THERMOSTAT ENTRY

⁄16"

⁄4" TYP 22

⁄16"

SIDE INLET

A93023

BOTTOM INLET

⁄4"

⁄2"

(DOWNFLOW &

OR ALTERNATE

TRAP LOCATION

/16"

-IN. DIA GAS CONN

⁄2

HORIZONTAL RIGHT)

CONDENSATE DRAIN

OUTLET

CONDENSATE

INLET

HANGING

(UPFLOW)

DRAIN LOCATION

FOR HORIZONTAL

DIMPLE LOCATORS

/16"

/2-In. rectangle.

/4-In. rectangle.

/2 x 19

/2 x 23

/2 x 12-In. rectangle.

/16"

⁄4"

TYP

⁄8"

TYP

⁄16"

⁄16"

TYP

⁄8"

⁄16"

TYP

⁄2"

⁄16"

/16"

DIMENSIONS (IN.)

Fig. 2—Dimensional Drawing

For 800 CFM--16-In. round or 14

For 1200 CFM--20-In. round or 14

For 1600 CFM--22-In. round or 14

For airflow requirements above 1800 CFM, use both side inlets, a

combination of 1 side inlet and the bottom, or the bottom only.

NOTES: Minimum return-air opening at furnace:

1.

2.

3.

⁄8-IN. DIA

POWER CONN

CONDENSATE

DRAIN TRAP

CONDENSATE DRAIN

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL LEFT)

⁄16"

⁄4"

⁄2"

⁄16"

⁄2-IN. DIA

2-IN. COMBUSTION-

AIR CONN

GAS CONN

2-IN. VENT CONN

⁄8-IN. DIA

ACCESSORY

ENTRY

⁄16"

⁄2-IN. DIA THERMOSTAT

LOCATION

POWER ENTRY

⁄16"

(ALTERNATE

UPFLOW)

SIDE INLET

⁄2"

TYP

CONDENSATE

DRAIN LOCATION

(UPFLOW)

⁄4" TYP

⁄16" TYP

SIDE INLET

⁄4"

042060 17-1/2 15-7/8 16

042080 21 19-3/8 19-1/2

060080 21 19-3/8 19-1/2

060100 21 19-3/8 19-1/2

042040* 24-1/2* 22-7/8* 23*

UNIT SIZE A D E

060120 24-1/2 22-7/8 23

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

—2—

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

→

Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54-1996/ANSI Z223.1-1996 and the Installation Standards, Warm Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1- and .2-M95 Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.

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

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with 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 would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

CAUTION: Electrostatic discharge can affect electronic

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

1. Disconnect all power to the furnace. DO NOT TOUCH

THE CONTROL OR ANY WIRE CONNECTED TO THE

CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that

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

Furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m).

An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for

some natural gas applications.

This 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 clearance from combustible

material.

This appliance requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC, PVC-DWV, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

MINIMUM INCHES CLEARANCE

TO COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

Mimimum front clearance for service 30

inches (762mm).

140 size furnaces require 1 inch back

††

clearance to combustible materials.

Clearance arrows do not change with furnace orientation.

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:

Clearance shown is for air inlet and air

outlet end.

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

120 and 140 size Furnaces require 1 inch

bottom clearance to combustible materials.

323857-101 REV. B (LIT)

††

Clearance in inches

TOP/PLENUM

DESSUS/CHAMBRE D´AIR

BOTTOM

DESSOUS

MIN

†

Vent clearance to

combustibles 0".

→ Fig. 3—Clearances to Combustibles

—3—

A97378

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.

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

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

INTRODUCTION

The 355MAV Multipoise Condensing Gas-Fired Furnaces are A.G.A./C.G.A. certified for natural and propane gases and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. An A.G.A./C.G.A. listed gas conversion kit is required to convert furnace for use with propane gas.

These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. The design of this furnace line is not A.G.A./C.G.A. certified for installation in mobile homes, recreation vehicles, or outdoors. These furnaces are suitable for installation in a residence built on site or a manufactured residence completed at final site. These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 1. See details in Applications section. These furnaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment.

Installer Packet includes:

Installation, Start-Up, and Operating Instructions Service and Maintenance Procedures User’s Information Manual Warranty Certificate

Loose Parts Bag includes: Quantity

Pressure tube extension 1 Collector box or condensate trap extension tube 1 Inducer housing drain tube 1 1/2-in. CPVC street elbow 2 Drain tube coupling 1 Drain tube coupling grommet 1 Vent and combustion-air pipe support 2 Combustion-air pipe perforated disk assembly 1

→

Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B. For further information, the NFGC and the NFPA 90B are available from National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209; or from Literature Distribution. Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. Contact Standards Department of Canadian Gas Association, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3.

Installations must comply with regulations of serving gas supplier and local building, heating, plumbing, or other codes in effect in area in which installation is made. In absence of local codes, installation must conform with NFGC.

Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction.

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

CAUTION: Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing. Improper installation or misapplication of furnace can require excessive servicing or cause premature component failure.

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

For accessory installation details, refer to applicable installation literature.

APPLICATIONS

I. GENERAL

Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain and pressure tubes are connected as shown in Fig. 5. See appropriate application instructions for these procedures.

II. UPFLOW APPLICATIONS

An upflow furnace application is where furnace blower is located below combustion and controls section of furnace, and conditioned air is discharged upwards.

A. Condensate Trap Location (Factory-Shipped Orientation)

The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications. A factory-supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment. See Condensate Trap Tubing (Factory-Shipped Orientation) section for drain tube extension details.

B. Condensate Trap Tubing (Factory-Shipped Orientation)

NOTE: See Fig. 5 or tube routing label on main furnace door to

confirm location of these tubes.

1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes

These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These tubes can be identified by their connection location

—4—

BLOWER SHELF

CONDENSATE TRAP (INSIDE)

ALTERNATE DRAIN TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FURNACE DOOR

FIELD

DRAIN

CONN

EXTERNAL UPFLOW APPLICATIONS

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

WIRE TIE GUIDES (WHEN USED)

CONDENSATE TRAP

FURNACE

SIDE

FURNACE DOOR

FIELD

DRAIN

CONN

FURNACE SIDE

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

⁄4 OD COLLECTOR BOX TO TRAP RELIEF PORT

⁄2 OD INDUCER HOUSING DRAIN CONNECTION

⁄8 OD COLLECTOR BOX DRAIN CONNECTION

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

⁄2-IN. PVC OR CPVC

HORIZONTAL

APPLICATIONS

FRONT VIEW SIDE VIEW

Fig. 4—Condensate Trap

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

2. Condensate Trap Drain Tube The condensate trap drain connection must be extended for

field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2

or 5.)

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

b. Remove and discard casing drain hole plug button from

desired side.

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

loose parts bag) in selected casing hole.

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

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

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

rigid drain tube connection on condensate trap. (See Fig.

5.) These elbows must be cemented together and cemented to condensate trap drain connection.

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

A93026

f. Connect larger diameter drain tube and clamp (factory-

supplied in loose parts bag) to condensate trap and clamp

securely. g. Route tube to coupling and cut to appropriate length. h. Attach tube to coupling and clamp securely.

C. Condensate Trap Location (Alternate Upflow Orientation)

An alternate location for the condensate trap is the left-hand side of casing. (See Fig. 2 and 6.)

NOTE: If the alternate left-hand side of casing location is used, the factory-connected drain and relief port tubes must be disconnected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for tubing attachment.

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

1. Remove 3 tubes connected to condensate trap.

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

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 6.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

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

—5—

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)

COLLECTOR BOX

TUBE (GREEN)

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

⁄2 -IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE  TRAP

DRAIN TUBE

DRAIN OPTION)

A94213

Fig. 5—Factory-Shipped Upflow Tube Configuration

(Shown With Blower Access Panel Removed)

D. Condensate Trap Tubing (Alternate Upflow Orientation)

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

confirm location of these tubes.

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

trap.

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

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 conden-

sate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube a. Connect relief port tube (green label) to condensate trap.

b. Extend this tube (if required) by splicing to small

diameter tube (factory-supplied in loose parts bag).

COLLECTOR BOX

DRAIN TUBE (GREEN)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A94214

Fig. 6—Alternate Upflow Tube Configuration and

Trap Location

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

E. Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and procedures.

F. Pressure Switch Tubing

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

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

G. Upper Collector Box and Inducer Housing (Unused) Drain Connections

UPPER COLLECTOR BOX DRAIN CONNECTION

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

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

UPPER INDUCER HOUSING DRAIN CONNECTION

Attached to the UPPER (unused) inducer housing drain connection is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped.

—6—

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX 

EXTENSION TUBE

CONDENSATE

TRAP

INDUCER HOUSING 

DRAIN TUBE (VIOLET)

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

INDUCER HOUSING  DRAIN TUBE  (VIOLET)

CONDENSATE TRAP

COLLECTOR BOX  EXTENSION  DRAIN TUBE

DRAIN TUBE COUPLING

A94215

Fig. 7—Downflow Tube Configuration

(Left-Hand Trap Installation)

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door

to check for proper connections.

H. Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations and procedures.

III. DOWNFLOW APPLICATIONS

A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and conditioned air is discharged downwards.

A. Condensate Trap Location

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application location as shown in Fig. 2, 7, or 8.

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

1. Remove 3 tubes connected to condensate trap.

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

3. Remove casing hole filler cap from casing hole. (See Fig. 2, 7, or 8.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into desired casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

B. Condensate Trap Tubing NOTE: See Fig. 7 or 8 or tube routing label on main furnace door

to check for proper connections.

1. Collector Box Drain Tube

Fig. 8—Downflow Tube Configuration

(Right-Hand Trap Installation)

a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

box drain tube (blue label) which was connected to condensate trap.

c. Connect LOWER collector box drain connection to

condensate trap. (1.) Condensate Trap Located on Left Side of Casing

(a.) Connect LOWER collector box drain tube

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

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

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

(b.) Connect larger diameter drain tube (factory-

→

(c.) Route extended collector box drain tube di-

(d.) Determine appropriate length and cut. (e.) Connect to condensate trap. (f.) Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER

inducer housing drain connection.

A94216

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

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

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

rectly from collector box drain to condensate trap as shown in Fig. 8.

—7—

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain tube (violet label and factory-

supplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate

trap. (1.) Condensate Trap Located on Left Side of Casing

(a.) Determine appropriate length and cut. (b.) Connect tube to condensate trap. (c.) Clamp tube to prevent any condensate leakage.

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

→

3. Relief Port Tube

C. Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and procedures.

D. Pressure Switch Tubing

One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW 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. 7 or 8 or tube routing label on main furnace door to check for proper connections.

Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) attached

2. Extend collector box pressure tube (green label) which was

3. Connect collector box pressure tube (green label) to pres-

4. Extend collector box pressure tube (pink label) which was

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

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

7. Clamp tube to relief port connection.

E. Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations and procedures.

(a.) Route inducer housing drain tube (violet label)

directly from inducer housing drain to conden-

sate trap as shown in Fig. 8. (b.) Determine appropriate length and cut. (c.) Connect tube to condensate trap. (d.) Clamp tube to prevent any condensate leakage.

Refer to Pressure Switch Tubing section for connection procedure.

to pressure switch.

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

sure switch connection labeled COLLECTOR BOX.

previously connected to pressure switch by splicing to remaining small diameter tube (factory-supplied in loose parts bag).

relief port connection.

IV. HORIZONTAL LEFT (SUPPLY-AIR DISCHARGE) APPLICATIONS

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

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

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

NOTE: The auxiliary junction box (J-box) MUST be relocated to opposite side of furnace casing. (See Fig. 9.) See Electrical Connection section for J-box relocation.

A. Condensate Trap Location

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

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

1. Remove 3 tubes connected to condensate trap.

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

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or 9.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

B. Condensate Trap Tubing NOTE: See Fig. 9 or tube routing label on main furnace door to

check for proper connections.

1. Collector Box Drain Tube a. Install drain tube coupling (factory-supplied in loose

parts bag) into collector box drain tube (blue label) which was previously connected to condensate trap.

b. Connect large diameter drain tube and clamp (factory-

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

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

cut to appropriate length.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing

drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to conden-

sate 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).

—8—

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.

C. Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and procedures.

D. Pressure Switch Tubing

The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch and should not require any modification. NOTE: See Fig. 9 or tube routing label on main furnace door to check for proper connections.

E. Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations and procedures.

F. Construct a Working Platform

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.)

CAUTION: The condensate trap MUST be installed below furnace. See Fig. 4 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.) NOTE: A 12-in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 29.)

PLUG

AUXILIARY "J" BOX RELOCATED HERE

V. HORIZONTAL RIGHT (SUPPLY-AIR DISCHARGE) APPLICATIONS

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

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

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

A. Condensate Trap Location

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

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

1. Remove 3 tubes connected to condensate trap.

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

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

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

CAP

COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)



CONDENSATE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

TRAP

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR

BOX EXTENSION

DRAIN TUBE

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

040, 060, AND 080 HEATING INPUT FURNACES

Fig. 9—Horizontal Left Tube Configuration

—9—

COLLECTOR BOX TUBE (GREEN)

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX DRAIN TUBE (BLUE)

A93353

MANUAL

SHUTOFF

GAS VALVE

COMBUSTION – AIR

SEDIMENT TRAP

INTAKE

5 3⁄4″

CONDENSATE TRAP

VENT



30″ MIN WORK AREA

DRAIN

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

ACCESS OPENING FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

Fig. 10—Attic Location and Working Platform

B. Condensate Trap Tubing NOTE: See Fig. 11 or tube routing label on main furnace door to

check for proper connections.

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

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

box drain tube (blue label) which was previously connected to condensate trap.

c. Connect LOWER collector box drain tube (blue and

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

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

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.

A93031

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

procedure.

C. Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and procedures.

D. Pressure Switch Tubing

NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections.

Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) attached to pressure switch.

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.

—10—

CAP

PLUG

COLLECTOR BOX DRAIN TUBE 

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 11—Horizontal Right Tube Configuration

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

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

7. Clamp tube to relief port connection.

E. Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations and procedures.

F. Construct a Working Platform

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.)

CAUTION: The condensate trap MUST be installed below furnace. See Fig. 4 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

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

NOTE: A 12-in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 29.)

LOCATION

I. GENERAL

When a furnace is installed so that supply ducts carry air to areas outside the space containing the furnace, return air must also be handled by ducts sealed to furnace casing. The ducts terminate outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space. Furnace may be located in a confined space without special provisions for dilution or ventilation air. This furnace must be installed so electrical components are protected from water.

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX TUBE (PINK)

CONDENSATE TRAP

LEVEL (0″)

TO

⁄2″ MAX

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

NOTE: For proper furnace operation, install furnace so that it is level or pitched forward within 1/2 in. to ensure proper condensate drainage from secondary heat exchangers.

Locate furnace as close to center of air distribution system as possible.

Locate furnace so combustion-air pipe lengths are not exceeded. Refer to Table 6.

CAUTION: If these furnaces are used during construction when adhesives, sealers, and/or new carpets are being installed, make sure all combustion and circulating air requirements are followed. If operation of furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine, when burned with combustion air, form acids which will cause corrosion of heat exchangers. Some of these compounds are found in paneling, dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems.

LEVEL (0″)

TO

⁄2″ MAX

A93354

FRONT

A93025

—11—

FRONT

°F °F

RETURN AIR

MAX 85°F MIN 55°F

A93042

NOTE: These furnaces are designed for a minimum continuous return-air temperature of 60°F or intermittent operation down to 55°F such as when used with a night setback thermostat. Return-air temperature must not exceed a maximum of 85°F. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls.

Provide ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on unit’s clearance to combustibles label. (See Fig. 3.) Locate furnace where available electric power and gas supplies meet specifications on furnace rating plate.

FRONT

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

A93058

CAUTION: If these furnaces are installed in an unconditioned space where ambient temperatures may be 32°F or lower, freeze protection measures must be taken.

II. LOW-FIRE ONLY INSTALLATION

This 355MAV furnace can be installed to operate in the low-fire only heating mode when sized using the low-fire heating capacity. This is accomplished by placing setup switch SW-2 in the ON position to provide only low-fire-heat operation. See Fig. 25 and Table 10. With this setup, high-fire operation will not occur.

When the model no. on the furnace rating plate is followed by an asterisk (*), the furnace has an alternate low-fire only efficiency rating as listed in the GAMA and CEC directories. This alternate rating will be listed as the furnace model number followed by an (-L) suffix.

B A C K

BACK

FRONT

A93043

WARNING: Do not install furnace on its back. Safety control operation will be adversely affected. Never connect return-air ducts to back of furnace. Failure to follow this warning could result in fire, personal injury, or death.

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

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

2. Check the high-fire input and adjust it per the main literature instructions.

NEVER assume the high-fire input rate is not important for low-fire-only installation.

III. FURNACE LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with or on downstream side of furnace to avoid condensation in heat exchanger. When installed parallel with a furnace, dampers or other means used to control flow of air must prevent chilled air from entering furnace. If dampers are manually operated, they must be equipped with a means to prevent operation of either unit unless damper is in full-heat or full-cool position.

—12—

IV. HAZARDOUS LOCATIONS

18-IN. MINIMUM

TO BURNERS

WARNING: When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, unit must be installed in accordance with requirements of National Fire Protection Association, Inc.

A93044

⁄16″

1 3⁄4″

⁄4″

⁄16″

1 3⁄4″

Fig. 12—Leveling Legs

1. Determine application being installed from Table 1.

A89014

I. LEVELING LEGS (IF DESIRED)

INSTALLATION

When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 12.) Install field-supplied, corrosion-resistant 5/16-in. machine bolts and nuts. NOTE: The maximum length of bolt should not exceed 1-1/2 in.

1. Position furnace on its back. Locate and drill a 5/16-in. diameter hole in each bottom corner of furnace. (See Fig.

12.) Holes in bottom closure panel may be used as guide locations.

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

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

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

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

II. INSTALLATION IN UPFLOW OR DOWNFLOW APPLICATIONS

NOTE: This furnace is approved for use on combustible flooring

when special base (available from manufacturer) Part No. KGASB0201ALL is used. Special base in not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is used.

2. Construct hole in floor per dimensions specified in Table 1 and Fig. 13.

3. Construct plenum to dimensions specified in Table 1 and Fig. 13.

4. If downflow subbase (KGASB) is used, install as shown in Fig. 14.

If coil assembly CD5 or CK5 or Coil Box KCAKC is used, install as shown in Fig. 15.

NOTE: Remove furnace perforated, discharge duct flanges when they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.)

WARNING: Do not bend duct flanges inward as shown in Fig. 16. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 16.

—13—

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

FURNACE

SHEET METAL

PLENUM

FLOOR

OPENING

COMBUSTIBLE

FLOORING

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

PLENUM

OPENING

FLOOR

OPENING

A96283

Fig. 13—Floor and Plenum Opening Dimensions

A96285

Fig. 14—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

FURNACE

CASING

WIDTH

Upflow Applications 16 24-1/8 16-5/8 24-3/4

17-1/2

24-1/2

Downflow Applications on Combustible Flooring Using KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Downflow Applications on Combustible Flooring Using KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Downflow Applications on Combustible Flooring Using KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Downflow Applications on Non-Combustible Flooring 15-7/8 19 16-1/2 19-5/8

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

Upflow Applications 19-1/2 24-1/8 20-1/8 24-3/4

Downflow Applications on Non-Combustible Flooring 19-3/8 19 20 19-5/8

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

Upflow Applications 23 24-1/8 23-5/8 24-3/4

Downflow Applications on Non-Combustible Flooring 22-7/8 19 23-1/2 19-5/8

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

TABLE 1—OPENING DIMENSIONS (IN.)

APPLICATION

—14—

A96284

Fig. 15—Furnace, Plenum, and Coil

Assembly or Coil Box Installed

on a Combustible Floor

PLENUM OPENING FLOOR OPENING

ABCD

15-1/8 19 16-3/4 20-3/8

15-1/2 19 16-1/2 20

18-5/8 19 20-1/4 20-3/8

19 19 20 20

22-1/8 19 23-3/4 20-3/8

22-1/2 19 23-1/2 20

+ 30 hidden pages

Bryant 355M-40-4, 355M-40-5 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual