Bryant 355MAV User Manual
installation, start-up,
355MAV
and operating instructions
DELUXE 4-WAY MULTIPOISE
VARIABLE-CAPACITY DIRECT-VENT
CONDENSING GAS FURNACE
A93040
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index Page
DIMENSIONAL DRAWING........................................................3
SAFETY CONSIDERATIONS..................................................2-5
Clearances to Combustibles......................................................4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........5
INTRODUCTION..........................................................................5
APPLICATIONS ......................................................................5-12
General......................................................................................5
Upflow Applications..............................................................5-8
Downflow Applications.........................................................8-9
Horizontal Left (Supply-Air Discharge) Applications.......9-11
Horizontal Right (Supply-Air Discharge) Applications...11-12
LOCATION ............................................................................13-14
General....................................................................................13
Low-Heat Only Installation....................................................13
Furnace Location Relative to Cooling Equipment................14
Hazardous Locations...............................................................14
INSTALLATION....................................................................14-16
Leveling Legs (If Desired).....................................................14
Installation In Upflow or Downflow Applications................14
Installation In Horizontal Applications.............................14-16
AIR DUCTS............................................................................16-19
General Requirements .......................................................16-17
Ductwork Acoustical Treatment.............................................17
Supply Air Connections..........................................................17
Return Air Connections..........................................................17
Filter Arrangement..................................................................17
Bottom Closure Panel........................................................17-18
Gas Piping..........................................................................18-19
ELECTRICAL CONNECTIONS...........................................19-21
115-v Wiring...........................................................................19
24-v Wiring.............................................................................20
Accessories ........................................................................20-21
DIRECT VENTING ...............................................................21-31
Removal of Existing Furnaces from
Common Vent Systems.....................................................21
Combustion-Air and Vent Piping .....................................21-29
Concentric Vent and Combustion-Air Termination
Kit Installation...................................................................29
Multiventing and Vent Terminations................................29-31
CONDENSATE DRAIN..............................................................31
General....................................................................................31
Series H
Cancels: II 355M-40-9 II 355M-40-10
12-02
ama
CERTIFIED
As an ENERGY STAR®
Partner, Bryant Heating &
Cooling Systems has determined that this product
meets the ENERGY
STAR® guidelines for energy efficiency.
AIRFLOW
Application..............................................................................31
Condensate Drain Protection..................................................31
SEQUENCE OF OPERATION..............................................31-36
Single-Stage Thermostat and Two-Stage Heating
(Adaptive Mode)................................................................33-34
Two-Stage Thermostat and Two-Stage Heating....................34
Cooling Mode....................................................................34-35
Thermidistat Mode..................................................................35
Super-Dehumidify Mode...................................................35-36
Continuous Blower Mode.......................................................36
Heat Pump...............................................................................36
Component Test......................................................................36
START-UP PROCEDURES ..................................................36-45
General....................................................................................36
Select Setup Switch Positions...........................................36-39
Prime Condensate Trap With Water......................................39
Purge Gas Lines......................................................................39
Adjustments .......................................................................39-45
Set Gas Input Rate ............................................................39-42
Set Temperature Rise..............................................................42
Set Thermostat Heat Anticipator ......................................42-45
CHECK SAFETY CONTROLS ............................................45-46
REGISTERED QUALITY SYSTEM
AIRFLOW
UPFLOW
HORIZONTAL
LEFT
Fig. 1—Multipoise Orientations
DOWNFLOW
AIRFLOW
HORIZONTAL
RIGHT
AIRFLOW
A93041
—1—
Check Primary Limit Control.................................................45
Check Pressure Switch......................................................45-46
CHECKLIST................................................................................46
SAFETY CONSIDERATIONS
CAUTION: Application of this furnace should be in-
doors 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, tire, 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.
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 unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand these signal words: DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert
symbol. DANGER identifies the most serious hazards which will
result in severe personal injury or death. WARNING signifies
hazards which could result in personal injury or death. CAUTION
is used to identify unsafe practices which 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.
closets, utility rooms, crawlspaces, and garages. The furnace is
factory-shipped for use with natural gas. A C.S.A. 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. 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. In
downflow installations, factory accessory floor base MUST be
used when installed on combustible materials and wood flooring.
Special base is not required when this furnace is installed on
manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil
Box Part No. KCAKC is used. These furnaces are suitable for
installation in a structure built on site or a manufactured building
completed at final site. The design of this furnace line is NOT
C.S.A. design-certified for installation in recreation vehicles or
outdoors.
→
This furnace is designed for continuous return-air minimum
temperature of 60 °F db or intermittent operation down to 55°Fdb
such as when used with a night setback thermometer. Return-air
temperature must not exceed 85°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.
This furnace must be installed with a direct-vent (combustion air
and flue) system and a factory accessory termination kit. 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.
→
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of leaks
to check all connections as specified in the GAS PIPING section
of these instructions.
→
Always install furnace to operate within the furnace’s intended
temperature-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 the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air must also be handled by a duct(s) sealed to
the furnace casing and terminating outside the space containing the
furnace.
→
A gas-fired furnace for installation in a residential garage must be
installed as specified in the Hazardous Locations section and Fig.
5.
→
The furnace is not to be used for temporary heating of buildings or
structures under construction unless the furnace installation and
operation complies with first CAUTION in the LOCATION
section of these instructions.
CAUTION: Sheet metal parts may have sharp edges or
burrs. Use care and wear appropriate protective clothing
and gloves when handling parts. Failure to follow this
caution could result in personal injury.
The 355MAV Multipoise Condensing Gas-Fired Furnaces are
C.S.A. design-certified for natural and propane gases (see furnace
rating plate) and for installation in alcoves, attics, basements,
—2—
"
8
⁄
"
16
"
16
⁄
13
⁄
5
"
8
⁄
5
7
39
1"
"
"
16
⁄
16
⁄
7
11
A99112
"
16
⁄
5
19"
"
22
4
⁄
1
"
16
⁄
26
15
"
2
⁄
26
1
OUTLET
2-IN. COMBUSTION-
AIR CONN
⁄2-IN. DIA
1
GAS CONN
⁄8-IN. DIA
POWER CONN
7
⁄2-IN. DIA
1
THERMOSTAT ENTRY
2-IN. VENT CONN
"
16
⁄
11
22
SIDE INLET
1
" TYP
4
⁄
22
"
16
⁄
3
24
BOTTOM INLET
28
"
16
⁄
9
TYP
"
4
⁄
1
18
"
2
⁄
1
30
(DOWNFLOW &
OR ALTERNATE
TRAP LOCATION
"
16
/
13
A
D
"
16
/
13
OUTLET
AIRFLOW
HORIZONTAL RIGHT)
CONDENSATE DRAIN
-IN. DIA GAS CONN
2
⁄
1
"
4
⁄
1
TYP
33
"
8
⁄
5
32
TYP
13
"
16
⁄
30
"
16
⁄
11
TYP
29
"
8
⁄
5
27
"
16
⁄
9
TYP
"
27
2
⁄
1
24
"
16
⁄
5
CONDENSATE
INLET
17
(UPFLOW)
DRAIN LOCATION
"
16
/
11
E
"
16
/
11
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
x 12-in. rectangle.
/2
1
see flex duct manufacturer’s recommendations for equivalent diameters.
a. For 800 CFM–16-in. round or 14
2. Minimum return-air opening at furnace:
-in. rectangle.
-in. rectangle.
/2
/4
1
1
x 19
x 23
/2
/2
1
1
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
c. For 1600 CFM–22-in. round or 14
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data
b. For 1200 CFM–20-in. round or 14
DIMENSIONS (IN.)
Fig. 2—Dimensional Drawing
return air openings for airflow requirements above 1800 CFM.
"
16
(ALTERNATE
UPFLOW)
SIDE INLET
"
2
⁄
1
14
TYP
⁄
7
TYP
9
CONDENSATE
1
"
4
⁄
1
1
DRAIN LOCATION
(UPFLOW)
" TYP
" TYP
16
4
⁄
⁄
15
23
SIDE INLET
26
1"
NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
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.
⁄8-IN. DIA
POWER CONN
7
CONDENSATE
DRAIN TRAP
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL LEFT)
"
16
⁄
"
15
4
⁄
1
"
26
2
⁄
1
26
"
16
⁄
24
5
22
⁄2-IN. DIA
2-IN. COMBUSTION-
AIR CONN
1
GAS CONN
2-IN. VENT CONN
⁄8-IN. DIA
ACCESSORY
7
ENTRY
"
16
⁄
11
22
⁄2-IN. DIA THERMOSTAT
1
LOCATION
POWER ENTRY
—3—
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
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).
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.
Minimum Inches Clearance To Combustible Construction
LEVEL (0")
TO
1/2" MAX
UPFLOW OR
DOWNFLOW
FRONT
as described below.
MIN 1/4" TO 1/2" MAX
FRONT
HORIZONTAL
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
ALL POSITIONS:
Mimimum front clearance for service 30 inches (762mm).
*
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.
120 size furnace requires 1 inch bottom clearance to combustible materials.
Ø
→ Fig. 3—Clearances to Combustibles
M
328068-201 REV. A
LIT - TOP
This furnace is approved for UPFLOW, DOWNFLO W and
HORIZONTAL installations.
Clearance arrows
do not change with
furnace orientation.
0"
B
A
C
K
D
I
S
0"
§
Clearance in inches.
E
1"
TOP/PLENU
E
C
A
N
R
U
F
N
O
R
F
F
R
O
N
BOTTOM
0"
Ø
†
I
S
T
S
E
R
V
T
3"
Vent clearance to
combustibles 0".
E
D
I
§
0"
C
E
*
30
MIN
A02250
A93042
Fig. 4—Return-Air Temperature
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
—4—
18-IN. MINIMUM
TO BURNERS
A93044
Fig. 5—Installation in a Garage
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
Condensate trap hole filler plug 3
Vent and combustion-air intake hole filler plug 2
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:
I. SAFETY
→
• US: National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI
Z223.1-2002 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
→
• CANADA: National Standard of Canada, Natural Gas and
Propane Installation Code (NSCNGPIC) CSA B149.1-00
II. GENERAL INSTALLATION
• 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 2001
• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada.
III. COMBUSTION AND VENTILATION AIR
• US: Section 8.3 of the NFGC, Air for Combustion and
Ventilation
• CANADA: Part 7 of the NSCNGPIC, Venting Systems and Air
Supply for Appliances
IV. DUCT SYSTEMS
• 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) 2001 Fundamentals Handbook Chapter 34.
V. ACOUSTICAL LINING AND FIBROUS GLASS DUCT
• US and CANADA: current edition of SMACNA, NFPA 90B as
tested by UL Standard 181 for Class I Rigid Air Ducts
VI. GAS PIPING AND GAS PIPE PRESSURE TESTING
→
• US: NFGC; chapters 5, 6, 7, and 12 and national plumbing
codes
→
• CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E, G, and H
VII. ELECTRICAL CONNECTIONS
• US: National Electrical Code (NEC) ANSI/NFPA 70-2002
• CANADA: Canadian Electrical Code CSA C22.1
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. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S ELECTROSTATIC
CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
a person’s hand during grounding will be satisfactorily
discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching control or wires.
5. Use this procedure for installed and uninstalled (ungrounded) furnaces.
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 model 355MAV 4-way multipoise, Gas-Fired, Category IV,
direct-vent condensing furnace is available in model sizes ranging
in input capacities of 40,000 to 120,000 Btuh.
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. 7. See appropriate
application instructions for these procedures.
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.
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. (See Fig. 6.)
B. Condensate Trap Tubing (Factory-Shipped
Orientation)
NOTE: See Fig. 7 or tube routing label on main furnace door to
confirm location of these tubes.
—5—
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)
1
1
2
3
4
WIRE TIE
GUIDES
(WHEN USED)
CONDENSATE
TRAP
FURNACE
SIDE
7
4
8
1
26
4
1
1
2
FURNACE
DOOR
FIELD
DRAIN
CONN
FURNACE
SIDE
4
3
5
4
4
1
26
4
3
5
3
4
SIDE VIEW FRONT VIEW END VIEW FRONT VIEW
DOWNFLOW AND ALTERNATE
1
7
8
3
1
4
7
8
1
42
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
HORIZONTAL
APPLICATIONS
4
FRONT VIEW SIDE VIEW
Fig. 6—Condensate Trap
1. Collector Box Drain, Inducer Housing Drain, Relief Port,
and Pressure Switch Tubes
These tubes should be factory attached to condensate trap
and pressure switch ready for use in UPFLOW applications.
These tubes can be identified by their connection location
and also by a color label on each tube. These tubes are
identified as follows: collector box drain tube (blue label),
inducer housing drain tube (violet label or molded), relief
port tube (green label), and pressure switch tube (pink
label).
2. Condensate Trap Drain Tube
The condensate trap drain connection must be extended for
field attachment by doing the following:
a. Determine location of field drain connection. (See Fig. 2
or 7.)
NOTE: If internal filter or side filter/media cabinet is used, drain
tube should be located to opposite side of casing from return duct
attachment to assist in filter removal.
b. Remove and discard casing drain hole plug button from
desired side.
c. Install drain tube coupling grommet (factory-supplied in
loose parts bag) in selected casing hole.
d. Slide drain tube coupling (factory-supplied in loose parts
bag) through grommet so long end of coupling faces
blower.
A93026
e. Cement 2 factory-supplied 1/2-in. street CPVC elbows to
rigid drain tube connection on condensate trap. (See Fig.
7.) These elbows must be cemented together and cemented to condensate trap drain connection.
NOTE: Failure to use CPVC elbows may allow drain to kink,
preventing draining.
f. Connect larger diameter drain tube and clamp (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 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 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
—6—
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
1
⁄2 -IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD-INSTALLED
FACTORY-SUPPLIED
COUPLING (RIGHT
CONDENSATE
TRAP
DRAIN TUBE
DRAIN OPTION)
Fig. 7—Factory-Shipped Upflow Tube Configuration
(Shown With Blower Access Panel Removed)
→
WARNING: Casing hole filler cap must be installed in
blower shelf hole when condensate trap is relocated.
Failure to follow this warning could result in electrical
shock, fire, personal injury or death.
4. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condenstate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
D. Condensate Trap Tubing (Alternate Upflow
Orientation)
NOTE: See Fig. 8 or tube routing label on main furnace door to
confirm location of these tubes.
1. Collector Box Drain Tube
Connect collector box drain tube (blue label) to condensate
trap.
NOTE: On 17-1/2-in. 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.
A94213
COLLECTOR BOX
DRAIN TUBE (GREEN)
CONDENSATE
TRAP
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
A94214
Fig. 8—Alternate Upflow Tube Configuration and
Trap Location
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).
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. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
—7—
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. 9—Downflow Tube Configuration
(Left-Hand Trap Installation)
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. 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.
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, 9, or 10.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
Fig. 10—Downflow Tube Configuration
(Right-Hand Trap Installation)
→
3. Remove casing hole filler cap from casing hole. (See Fig. 2
and 10.)
4. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
→
WARNING: Casing hole filler cap must be installed in
blower shelf hole when condensate trap is relocated.
Failure to follow this warning could result in electrical
shock, fire, personal injury or death.
→
5. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
6. Fill unused condenstate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
B. Condensate Trap Tubing
NOTE: See Fig. 9 or 10 or tube routing label on main furnace
door to check for proper connections.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was connected to
condensate trap.
c. Connect LOWER collector box drain connection to
condensate trap.
(1.) 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.
A94216
—8—
(2.) Condensate Trap Located on Right Side of Casing
(a.) Install drain tube coupling (factory-supplied in
loose parts bag) into collector box drain tube
(blue and white striped label) which was previously plugged.
(b.) Connect larger diameter drain tube (factory-
supplied in loose parts bag) to drain tube
coupling, extending collector box drain tube
for connection to condensate trap.
(c.) Route extended collector box drain tube di-
rectly from collector box drain to condensate
trap as shown in Fig. 10.
(d.) Determine appropriate length and cut.
(e.) Connect to condensate trap.
(f.) Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain tube (violet label and factory-
supplied in loose parts bag) to connect LOWER inducer
housing drain connection to the condensate trap.
e. Connect inducer housing drain connection to condensate
trap.
(1.) Condensate Trap Located on Left Side of Casing
(a.) Determine appropriate length and cut.
(b.) Connect tube to condensate trap.
(c.) Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
(a.) Route inducer housing drain tube (violet label)
directly from inducer housing 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.
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
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. 9 or 10 or tube routing label on main furnace
door to check for proper connections.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in
loose parts bag).
3. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.
4. Extend collector box pressure tube (pink label) which was
previously connected to pressure switch by splicing to
remaining small diameter tube (factory-supplied in loose
parts bag).
5. Route this extended tube (pink label) to condensate trap
relief port connection.
6. Determine appropriate length, cut, and connect tube.
7. Clamp tube to relief port connection.
E. Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations and procedures.
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.
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 (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
→
→
WARNING: Casing hole filler cap must be installed in
blower shelf hole when condensate trap is relocated.
Failure to follow this warning could result in electrical
shock, fire, personal injury or death.
5. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
6. Fill unused condenstate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
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
—9—
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).
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 High Pressure Switch for use when furnace is
installed in UPFLOW applications. This tube MUST be disconnected, extended, rerouted, and then reconnected to the pressure
switch in HORIZONTAL LEFT applications for 060 and 080
heating input furnaces.
NOTE: See Fig. 11 or tube routing label on main furnace door to
check for proper connections.
→
Modify tube as described below.
1. Disconnect collector box pressure tube (pink label) attached
to High Pressure Switch.
2. Use smaller diameter tube (factory-supplied in loose parts
bag) to extend tube disconnected in item 1.
3. Route extended tube:
a. Behind inducer housing.
b. Between blower shelf and inducer housing.
4. Determine appropriate length, cut, and reconnect tube to
High Pressure Switch connection labeled COLLECTOR
BOX.
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 12.)
PLUG
CAP
AUXILIARY "J" BOX
CONDENSATE
TRAP
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR
BOX EXTENSION
DRAIN TUBE
DRAIN TUBE COUPLING
COLLECTOR BOX TUBE (PINK)
RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR
060, AND 080 HEATING INPUT FURNACES
COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)
→ Fig. 11—Horizontal Left Tube Configuration
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
DRAIN TUBE (BLUE)
A02288
—10—
MANUAL
SHUTOFF
GAS VALVE
COMBUSTION – AIR
SEDIMENT
TRAP
INTAKE
3
5
⁄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. 12—Attic Location and Working Platform
CAUTION: 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: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 7.)
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. 12 or 35.)
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.
NOTE: The auxiliary junction box (J-box) MUST be relocated to
opposite side of furnace casing. (See Fig. 13.) See Electrical
Connection section for J-box relocation.
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 13.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
→
WARNING: Casing hole filler cap must be installed in
blower shelf hole when condensate trap is relocated.
Failure to follow this warning could result in electrical
shock, fire, personal injury or death.
4. Install condensate trap into right-hand side casing hole by
→
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condenstate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
B. Condensate Trap Tubing
NOTE: See Fig. 13 or tube routing label on main furnace door to
check for proper connections.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was previously connected to condensate trap.
c. Connect LOWER collector box drain tube (blue and
white striped label) to condensate trap. Tube does not
need to be cut.
A93031
—11—
CAP
PLUG
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
→ Fig. 13—Horizontal Right Tube Configuration
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain extension tube (violet label
and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to condensate trap.
e. Determine appropriate length, cut, and connect tube to
condensate trap.
f. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection
procedure.
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. 13 or tube routing label on main furnace door to
check for proper connections.
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX TUBE (PINK)
AUXILIARY "J" BOX RELOCATED HERE
CONDENSATE
TRAP
A02289
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in
loose parts bag).
3. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.
4. Use remaining small diameter tube (factory-supplied in
loose parts bag) to extend collector box pressure tube (pink
label) which was previously connected to pressure switch.
5. Route this extended tube (pink label) to condensate trap
relief port connection.
6. Determine appropriate length, cut, and connect tube.
7. Clamp tube to relief port connection.
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 12.)
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 7.)
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. 12 or 35.)
—12—
LOCATION
I. GENERAL
→
This furnace must
• be installed so the electrical components are protected from
water.
• not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).
• be located so combustion-air and vent pipe maximum lengths
are not exceeded. Refer to Table 7.
• be located where available electric power and gas supplies meet
specifications on the furnace rating plate.
• 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.
• be provided with ample space for servicing and cleaning.
Always comply with minimum fire protection clearances
shown on the furnace clearance-to-combustibles label. (See
Fig. 3.)
This furnace may be located in a confined space without special
provisions for dilution or ventilation air.
→
NOTE: For upflow/downflow applications install furnace so that
it is level or pitched forward within 1/2-in. for proper furnace
operation. For horizontal applications pitch 1/4-in. minimum to
1/2-in. maximum forward to ensure proper condensate drainage
from secondary heat exchangers. (See Fig. 14.)
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.
(See Fig. 15.)
FRONT
B
A
C
K
BACK
FRONT
A93043
Fig. 15—Prohibit Installation on Back
CAUTION: If these furnaces are installed in an uncon-
ditioned space where ambient temperatures may be 32°F
or lower, freeze protection measures must be taken. (See
Fig. 16.)
LEVEL (0″)
TO
1
⁄2″ MAX
UPFLOW OR DOWNFLOW HORIZONTAL
FRONT
MIN
TO
1
⁄2″ MAX
1
⁄4″
FRONT
Fig. 14—Proper Condensate Drainage
→
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.
CAUTION: Do not operate this furnace during con-
struction. If the furnace is required for temporary heating
of buildings or structures under construction, use clean
outside air free of chlorine and fluorine compounds for
combustion and ventilation. These compounds form acids
that corrode the heat exchangers. These compounds are
found in paneling and dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents.
→
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.
A02146
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
A93058
Fig. 16—Freeze Protection
II. LOW-HEAT ONLY INSTALLATION
This 355MAV furnace can be installed to operate in the low-heat
only heating mode when sized using the low-heat heating capacity.
This is accomplished by placing setup switch SW1-2 in the ON
position to provide only low-heat operation. See Fig. 32 and Table
9. With this setup, high-heat operation will not occur.
When the model no. on the furnace rating plate is followed by an
asterisk (*), the furnace has an alternate low-heat 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.
—13—
CAUTION: The furnace can operate in the high-heat
mode when certain fault conditions occur. The following
precautions should be taken:
1. Size gas piping based on the high-heat input.
2. Check the high-heat input and adjust it per the main
literature instructions.
NEVER assume the high-heat input rate is not important
for low-heat-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 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.
IV. HAZARDOUS LOCATIONS
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.
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 1 and
Fig. 19.
4. If downflow subbase (KGASB) is used, install as shown in
Fig. 20.
If coil assembly CD5 or CK5 or Coil Box KCAKC 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
seamers, 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.)
18-IN. MINIMUM
TO BURNERS
A93044
Fig. 17—Installation in a Garage
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. (See Fig. 17.)
INSTALLATION
I. 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. 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.
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.)
WARNING: 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° as shown in Fig. 22.
III. 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
5
⁄16″
5
⁄16″
1 3⁄4″
3
⁄4″
1
5
⁄16″
5
⁄16″
1 3⁄4″
3
⁄4″
1
A89014
Fig. 18—Leveling Legs
—14—
A
PLENUM
OPENING
B
C
FLOOR
OPENING
D
A96283
Fig. 19—Floor and Plenum Opening Dimensions
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
A96285
Fig. 20—Furnace, Plenum, and Subbase
Installed on a Combustible Floor
FURNACE
CASING
WIDTH
Upflow Applications 16 24-1/8 16-5/8 24-3/4
Downflow Applications on Non-Combustible Flooring 15-7/8 19 16-1/2 19-5/8
17-1/2
21
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
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
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
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
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
Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box
TABLE 1—OPENING DIMENSIONS (IN.)
APPLICATION
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
A96284
Fig. 21—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
—15—
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