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355MAV C Series

Bryant 355MAV C Series Installation, Start-up, And Operating Instructions Manual

installation, start-up, and operating instructions
4-WAY MULTIPOISE VARIABLE-CAPACITY CONDENSING GAS FURNACE
Cancels: II 355M-40-2 II 355M-40-3
355MAV
Series C
6-95
A93040
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
Horizontal Left (Supply-Air Discharge) Applications.........8-9
Horizontal Right (Supply-Air Discharge) Applications.....9-11
LOCATION ............................................................................11-12
General...............................................................................11-12
Low-Fire Only Installation.....................................................12
Furnace Location Relative to Cooling Equipment................12
INSTALLATION....................................................................13-16
Leveling Legs (If Desired).....................................................13
Installation On a Concrete Slab .............................................13
Installation On a Combustible Floor (Downflow
Applications)......................................................................13
Installation In Horizontal Applications..................................14
Filter Arrangement..................................................................14
Gas Piping..........................................................................14-16
ELECTRICAL CONNECTIONS...........................................16-19
115-v Wiring......................................................................17-19
24-v Wiring.............................................................................19
Accessories..............................................................................19
DIRECT VENTING ...............................................................19-29
Removal of Existing Furnaces from
Common Vent Systems................................................19-20
Combustion-Air and Vent Piping .....................................20-25
Concentric Vent and Combustion-Air Termination
Kit Installation..............................................................25-27
Multiventing and Vent Terminations................................27-29
CONDENSATE DRAIN..............................................................29
General....................................................................................29
Application..............................................................................29
Condensate Drain Protection..................................................29
®
HORIZONTAL
LEFT
AIRFLOW
Fig. 1—Multipoise Orientations
SEQUENCE OF OPERATION..............................................30-32
Self-Test Mode........................................................................30
Heating Mode..........................................................................30
Emergency Heat Mode......................................................30-31
Cooling Mode .........................................................................31
Continuous Fan Mode ............................................................32
Component Test......................................................................32
Bypass Humidifier Mode........................................................32
Zone Mode..............................................................................32
START-UP PROCEDURES ..................................................32-37
General...............................................................................32-33
Select Setup Switch Positions................................................33
Prime Condensate Trap With Water......................................33
Adjustments .......................................................................34-37
Set Gas Input Rate ............................................................34-36
Set Temperature Rise..............................................................36
Set Thermostat Heat Anticipator............................................37
CHECK SAFETY CONTROLS ............................................37-38
Check Primary Limit Control.................................................37
Check Pressure Switch......................................................37-38
CHECKLIST...........................................................................38-39
ama
As an ENERGY STAR Partner, BDP Company has deter­mined that this product meets the ENERGY STAR guidelines for energy efficiency.
AIRFLOW
UPFLOW
DOWNFLOW
AIRFLOW
CANADIAN GAS ASSOCIATION
HORIZONTAL
RIGHT
AIRFLOW
APPROVED
R
A93041
—1—
⁄2"
1
28
1
⁄16"
15
26
AIRFLOW
⁄4" 26
⁄8"
7
⁄16"
⁄8"
5
OUTLET
2-IN. COMBUSTION-
TYP
5
⁄2-IN. DIA
1
GAS CONN
AIR CONN
⁄8-IN. DIA
7
⁄16"
13
⁄16"
5
19"
22
⁄16"
9
39
POWER CONN
2-IN. VENT CONN
⁄2-IN. DIA
THERMOSTAT ENTRY
1
⁄16"
⁄16"
7
1
⁄4" TYP 22
11
⁄16"
3
24
1"
⁄16"
11
22
SIDE INLET
A93023
BOTTOM INLET
⁄4"
1
18
⁄2"
1
30
(DOWNFLOW &
OR ALTERNATE
TRAP LOCATION
/16"
13
A
D
-IN. DIA GAS CONN
⁄2
1
HORIZONTAL RIGHT)
CONDENSATE DRAIN
OUTLET
CONDENSATE
INLET
HANGING
(UPFLOW)
DRAIN LOCATION
FOR HORIZONTAL
DIMPLE LOCATORS
/16"
11
E
/2-In. rectangle.
/4-In. rectangle.
1
1
/2 x 19
/2 x 23
1
1
/2 x 12-In. rectangle.
1
/16"
13
⁄4"
1
TYP
33
⁄8"
5
TYP
32
⁄16"
13
30
⁄16"
11
TYP
29
⁄8"
5
27
⁄16"
9
TYP
27
⁄2"
1
24
⁄16"
5
/16"
11
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.
4.
17
⁄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
1
2-IN. COMBUSTION-
AIR CONN
GAS CONN
2-IN. VENT CONN
⁄8-IN. DIA
ACCESSORY
7
ENTRY
⁄16"
11
22
⁄2-IN. DIA THERMOSTAT
1
LOCATION
POWER ENTRY
⁄16"
7
9
(ALTERNATE
UPFLOW)
SIDE INLET
⁄2"
1
TYP
14
TYP
CONDENSATE
DRAIN LOCATION
(UPFLOW)
⁄4" TYP
⁄16" TYP
1
15
23
SIDE INLET
26
⁄4"
1
1
1"
042060 17-1/2 15-7/8 16
042080 21 19-3/8 19-1/2
042040* 24-1/2* 22-7/8* 23*
UNIT SIZE A D E
060100 21 19-3/8 19-1/2
→060080 21 19-3/8 19-1/2
→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. 54-1992/ANSI Z223.1-1992. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1­and .2-M91 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 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 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.
This appliance is equipped only for altitudes 0 - 2,000 ft (0-610 m) for use with natural gas and propane. A conversion kit, supplied by the manufacturer, shall be used to convert to the alternate fuel or elevation.
This direct-vent, forced-air furnace is for indoor installation in a building constructed on site or in a manufactured (mobile) home when using factory authorized kit, see rating plate. For installation in alcove or closet at minimum clearances from combustible material as shown below.
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 CLEARANCE TO COMBUSTIBLE MATERIAL
TOP
BOTTOM
FRONTBACKSIDES
0 1 0030 1 1030
#
For Installation on combustible floors only when installed on special base
#
†
0
*
VENT
Ø
03001 Ø Ø
INCHES
UPFLOW DOWNFLOW HORIZONTAL
No. KGASB0201ALL.
Clearance shown is for air inlet and air outlet end.
*
Horizontal position: Line contact is permissible only between lines formed by intersections
of top and two sides of furnace jacket, and building joists, studs, or framing.
†
120,000 BTU Input Furnaces require 1 inch bottom clearance to combustible materials. Minimum front clearance for service is 30 inches. (762mm).
Ø
320611-101 REV. G
A93060
→ Fig. 3—Clearances to Combustibles
—3—
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. 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. 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 Instructions User’s Information Manual Warranty Certificate
Loose Parts Bag includes: Quantity
Pressure tube extension 1 Collector box or condensate trap extension tube 1 Inducer housing drain tube 1 1/2-in. 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. For further information, the NFGC is 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 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.
—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)
1
2
1
3
4
WIRE TIE GUIDES (WHEN USED)
CONDENSATE TRAP
FURNACE
SIDE
7
8
4
1
4
26
1
2
1
FURNACE DOOR
FIELD
DRAIN
CONN
FURNACE SIDE
4
3
4
5
1
4
26
4
3
5
3
4
SIDE VIEW FRONT VIEW END VIEW FRONT VIEW
DOWNFLOW AND ALTERNATE
1
8
7
3
4
1
7
8
1
4
2
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 DOWN- FLOW APPLICATIONS (OPTIONAL)
1
⁄2-IN. PVC OR CPVC
HORIZONTAL
APPLICATIONS
4
FRONT VIEW SIDE VIEW
Fig. 4—Condensate Trap
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.
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.
A93026
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.
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.
—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
1
⁄2 -IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD-INSTALLED
FACTORY-SUPPLIED
COUPLING (RIGHT
DRAIN OPTION)
CONDENSATE  TRAP
DRAIN TUBE
Fig. 5—Factory-Shipped Upflow Tube Configuration
(Shown With Blower Access Panel Removed)
A94213
COLLECTOR BOX
DRAIN TUBE (GREEN)
CONDENSATE
TRAP
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
A94214
Fig. 6—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 the con-
densate 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. Use small diameter tube (factory-supplied in loose parts
bag) to extend this tube if required.
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.
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.
—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)
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 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.
A94216
Fig. 8—Downflow Tube Configuration
(Right-Hand Trap Installation)
(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
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 be-
tween gas valve and inlet housing as shown in
Fig. 8. (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
—7—
(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)
between gas valve and inlet housing behind
collector box drain tube. (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. 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 to pressure switch.
2. Use small diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection.
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.
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.
PLUG
CAP
AUXILIARY "J" BOX RELOCATED HERE
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
COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)
Fig. 9—Horizontal Left Tube Configuration
COLLECTOR BOX TUBE (GREEN)
INDUCER HOUSING DRAIN TUBE (VIOLET)
COLLECTOR BOX DRAIN TUBE (BLUE)
A93353
—8—
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 the con-
densate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube a. Use small diameter tube (factory-supplied in loose parts
bag) to extend collector box tube (green label) which was previously connected to the condensate trap.
b. Route extended collector box pressure tube to relief port
connection on the 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 5.)
NOTE: A 12-in. minimum horizontal 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.)
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.
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.
—9—
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
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
A93031
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. 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. Use small diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection.
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 10.)
—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
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX TUBE (PINK)
CONDENSATE TRAP
A93354
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 5.)
NOTE: A 12-in. minimum horizontal 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.
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 5.
LEVEL (0″)
TO
1
⁄2″ MAX
UPFLOW OR DOWNFLOW HORIZONTAL
FRONT
LEVEL (0″)
TO
1
⁄2″ MAX
FRONT
A93025
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.
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 construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems.
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.
—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.
FRONT
B A C K
BACK
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.
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.
IV. HAZARDOUS LOCATIONS
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.
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 9. 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.
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.
A93044
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.
—12—
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