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

Page 1
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—
Page 2
⁄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—
Page 3
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—
Page 4
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—
Page 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
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—
Page 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
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—
Page 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. 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—
Page 8
(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—
Page 9
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—
Page 10
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—
Page 11
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—
Page 12
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—
Page 13
INSTALLATION
FURNACE
PLENUM
I. LEVELING LEGS (IF DESIRED)
When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 12.) Install field-supplied, corrosion-resistant 5/16-in. machine bolts and nuts.
5
⁄16″
5
⁄16″
1 3⁄4″
3
⁄4″
1
5
⁄16″
5
⁄16″
1 3⁄4″
1 3⁄4″
A89014
Fig. 12—Leveling Legs
NOTE: The maximum length of bolt should not exceed 1-1/2 in.
1. Position furnace on its back. Locate and drill a 5/16-in. diameter hole in each bottom corner of furnace. (See Fig.
12.) Holes in bottom closure panel may be used as guide locations.
2. For each hole, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.
NOTE: Bottom closure must be used when leveling legs are used. See Bottom Closure Panel section.
A
HOLE IN
FLOOR
B
A73382
OPENING DIMENSIONS (IN.)
FURNACE
CASING WIDTH
17-1/2 16-7/16 19-5/8 19-7/16
21 19-7/8 19-5/8 19-7/16
24-1/2 23-7/16 19-5/8 19-7/16
* These dimensions apply when a model CB or CD Evaporator Coil casing is to be installed.
A
Heat Only Heat/Cool*
B
Fig. 13—Floor Opening in Concrete Slab
LEVEL (0″)
TO
1
⁄2″ MAX
UPFLOW OR DOWNFLOW HORIZONTAL
FRONT
LEVEL (0″)
TO
1
⁄2″ MAX
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.
II. INSTALLATION ON A CONCRETE SLAB
1. Construct hole in floor per dimensions in Fig. 13.
2. Place plenum and furnace as shown in Fig. 14.
III. INSTALLATION ON A COMBUSTIBLE FLOOR (DOWNFLOW APPLICATIONS)
1. Cut and frame hole in floor per dimensions in Installation Instructions packaged with downflow subbase kit.
FRONT
A93025
A73383
Fig. 14—Furnace on a Concrete Slab
(Non-Garage Installation)
NOTE: Remove furnace perforated, discharge duct flanges when
they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 15.)
WARNING: Do not bend duct flanges inward as shown in Fig. 15. This will affect airflow across heat exchangers and may cause limited cycling or premature heat ex­changer failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 15.
2. When complete, downflow subbase, plenum, and furnace (or coil casing when used) should be installed as shown in Fig. 16.
—13—
Page 14
PERFORATED DISCHARGE DUCT FLANGE
NO
Factory-supplied washable framed filters are shipped in blower compartment. Determine location for filter and relocate filter retaining wire if necessary. See Table 1 to determine correct filter size for desired filter location. Table 1 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings.
210° MIN
Fig. 15—Duct Flanges
FURNACE
(OR COIL CASING
WHEN USED)
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
YES
YES
A93029
TABLE 1—FILTER INFORMATION
FURNACE
CASING
WIDTH (IN.)
17-1/2 (1) 16 X 25 X 1† (1) 16 X 25 X 1 Cleanable
21 (1) 16 X 25 X 1 (1) 20 X 25 X 1† Cleanable
24-1/2 (2) 16 X 25 X 1† (1) 24 X 25 X 1 Cleanable
* Filters can be field modified by cutting frame as marked and folding to desired size. Alternate sizes can be ordered from your distributor or dealer. † Factory-provided with furnace.
FILTER SIZE (IN.)*
Side Return Bottom Return
FILTER TYPE
FRAMED
CAUTION: Air delivery above 1800 CFM requires that
both sides, a combination of 1 side and bottom, or bottom only of furnace be used for return air.
NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 18.
For bottom return-air applications, filter may need to be cut to fit some furnace widths. Install filter as shown in Fig. 19.
NOTE: Remove and discard bottom closure panel when bottom inlet is used.
VI. BOTTOM CLOSURE PANEL
These furnaces are shipped with bottom enclosure panel installed in bottom return-air opening. This panel MUST be in place when side return air is used.
To remove bottom closure panel, perform following:
Fig. 16—Furnace, Plenum, and Subbase Installed on a
Combustible Floor
IV. INSTALLATION IN HORIZONTAL APPLICATIONS
These furnaces can be installed horizontally in either horizontal left or right discharge position. In a crawlspace, furnace can either be hung from floor joist or installed on suitable blocks or pad. Furnace can be suspended from each corner by hanger bolts. (See Fig. 17.) Cut hanger bolts (4 each 3/8-in. all-thread rod) to desired length. Use 1 X 3/8-in. flat washers, 3/8-in. lockwashers, and 3/8-in. nuts on hanger rods as shown in Fig. 17. Dimples are provided for hole locations. (See Fig. 2.)
CAUTION: The entire length of furnace MUST be supported when furnace is used in a horizontal position to ensure proper draining.
V. FILTER ARRANGEMENT
CAUTION: Never operate unit without a filter or with
blower access panel removed.
A78651
1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 20.)
2. Rotate front filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall front filler panel and screws.
VII. GAS PIPING
Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 2 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.
—14—
Page 15
3
⁄8-IN. ROD
ANGLE IRON OR EQUIVALENT
(B)
(A) ROD LOCATION
USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS)
(A) PREFERRED ROD LOCATION  (B) ALTERNATE ROD LOCATION
WASHABLE
FILTER
5 3⁄4″
(B)
(A)
DRAIN
(A)
(B)
3
/8-IN. HEX NUT
& WASHER (4)
REQD PER ROD
NOTES:
(A)
(B)
1. A 1 In. clearance minimum between top of
13
ALTERNATE SUPPORT LOCATION FROM BACK
furnace and combustible material. 
2. The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage.
Fig. 17—Crawlspace Horizontal Application
TABLE 2—MAXIMUM CAPACITY OF PIPE*
NOMINAL
IRON
PIPE SIZE
(IN.)
1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151
1 1.049 680 465 375 320 285
1-1/4 1.380 1400 950 770 660 580
FILTER RETAINER
1-1/2 1.610 2100 1460 1180 990 900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 10-2 NFPA 54-1992.
/16-IN. MAX
INTERNAL DIAMETER
(IN.)
ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX
A93304
LENGTH OF PIPE (FT)
10 20 30 40 50
Fig. 18—Filter Installed for Side Inlet
A93045
CAUTION: Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls.
WARNING: Gas valve knob MUST be facing forward or tilted upward. Failure to follow this warning could result in property damage or death.
—15—
Page 16
WARNING: Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap-and-water solution to check for leakage. A failure to follow this warning could result in fire, explosion, personal injury, or death.
3″
1
24
/2″
WARNING: Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death.
Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight-through section of tee is vertical. Then connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and manual gas shutoff valve. (See Fig. 21.)
1″
FIELD-SUPPLIED FILTER FILLER STRIP FOR 
1
⁄2-IN. WIDE 
17 CASINGS ONLY. INSTALL UNDER FILTER.
WASHABLE FILTER
FILTER SUPPORT
FILTER RETAINER
Fig. 19—Bottom Filter Arrangement
BOTTOM CLOSURE PANEL
FRONT FILLER PANEL
Fig. 20—Removing Bottom Closure Panel
A93321
A93047
GAS SUPPLY
MANUAL SHUTOFF VALVE
SEDIMENT TRAP
UNION
A93324
Fig. 21—Typical Gas Pipe Arrangement
CAUTION: If a flexible connector is required or al-
lowed by authority having jurisdiction, black iron pipe shall be installed at gas valve and extend a minimum of 2 in. outside furnace casing.
An accessible manual shutoff valve MUST be installed upstream of furnace gas controls and within 6 ft of furnace. A 1/8-in. NPT plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve.
NOTE: The gas valve inlet press tap connection is suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 46.) Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace has been attached. In Canada, refer to current edition of NSCNGPIC. If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14-in. wc), close manual shutoff valve located on gas valve before test. It is recommended that ground joint union be loosened before pressure testing. After all connections have been made, purge lines and check for leakage.
ELECTRICAL CONNECTIONS
See Fig. 22 for field wiring diagram showing typical field 115-v and 24-v wiring. Check all factory and field electrical connections for tightness.
—16—
Page 17
115-VOLT
SINGLE
PHASE
115-VOLT FIELD-
SUPPLIED
FUSED
DISCONNECT
FIVE
WIRE
THREE-WIRE
NOTE 5
WCR GY
THERMOSTAT TERMINALS
HEATING
ONLY
AUXILIARY J-BOX
FURNACE
CONTROL
CENTER
W/W1
NOTE
W2
3
R
G
C
Y/Y2
24-VOLT TERMINAL BLOCK
NOTE 1
TWO WIRE
NOTES:
1.
Connect Y or Y/Y2 terminal as shown for proper cooling operation.
2.
Proper polarity must be maintained for 115-volt wiring.
3.
Use W2 with 2-stage thermostat when zoning.
4.
If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
5.
Some thermostats require a "C" terminal connection as shown.
GND
GND
CONDENSING
Fig. 22—Heating and Cooling Application Wiring Diagram
FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-, 208/230-, 460-VOLT WIRING
FIELD-SUPPLIED
FUSED DISCONNECT
208/230- OR 460-VOLT THREE PHASE
GND
208/230- VOLT SINGLE
GND
PHASE
UNIT
A95199
TABLE 3—ELECTRICAL DATA
UNIT SIZE
VOLTS— HERTZ—
PHASE
OPERATING
VOLTAGE RANGE
Maximum* Minimum*
MAXIMUM
UNIT
AMPS
UNIT
AMPACITY†
042040 115—60—1 127 104 8.9 12.0 14 31 15 042060 115—60—1 127 104 8.9 12.0 14 31 15 042080 115—60—1 127 104 8.9 12.0 14 31 15
→060080 115—60—1 127 104 13.8 17.9 12 32 20
060100 115—60—1 127 104 13.8 18.1 12 32 20
→060120 115—60—1 127 104 11.2 14.7 14 25 15
* Permissible limits of voltage range at which unit will operate satisfactorily. † Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load amps. ‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. ** Time-delay fuse is recommended.
apply. For Canadian installations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.1 or subauthorities having jurisdiction.
→
WARNING:
Blower access panel door switch opens 115-v power to control center. No component operation can occur. Do
MINIMUM
WIRE
SIZE
MAXIMUM WIRE
LENGTH (FT)‡
MAXIMUM FUSE OR
CKT BKR AMPS**
not bypass or close switch with panel removed. Failure to follow this warning could result in personal injury or death.
ELECTRIC
DISCONNECT
CAUTION: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green wire routed to gas valve and
SWITCH
COPPER
WIRE ONLY
burner box screw.
ALUMINUM
WIRE
I. 115-V WIRING
Before proceeding with electrical connections, make certain that voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility
CAUTION: Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.
is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 3 for equipment electrical specifications.
Make all electrical connections in accordance with NEC ANSI/NFPA 70-1993 and any local codes or ordinances that might
Use a separate, fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace. See Table 3 for wire
A93033
—17—
Page 18
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
MTR1
6
412
12
10
PL7
EQUIPMENT GROUND
T 1
T 2
L2
L2
NOTE #2
L1
654
PL1
L1
ILK
TO 115 VAC FIELD DISCONNECT
P2
SEC-2
HSI
TRAN
24VAC
115VAC
P1
PL9
2
PL12
1
PL4
2
1
B2
HSIR
EAC
MTR2
8
6
3
14
16
PL13
PCB
NOTE #5
1
2
3
5
4
PL11
D.C.
POWER
SUPPLY
CPU2
SW - 4
EMER. HEAT
IND
NOTE #7
PL11
12345
6
PL10
B1 7
CPU1
12345
SEC-1
FU1
PL1-11
NOTE #6
PL1-9
EAC-1 EAC-2
ALS
LS
FRS
PL3
PL1-7
NOTE #3HPS
C
C
NO
PL2-4
LPS
PL2-2
C
FSE
NO
PL1-1
PL2-1
GV
M
P
HI
PCB
NOTE #5
PL1-10
PL1-2
SUPPLY
D.C. POWER
EAC
GVR
HUMR
DH
R
HUM
CPU1
G
W2
OM
Y/Y2
C
W/W1
CPU2
GVR
HSIR
HUMR
1. If any of the original equipment wire is replaced use wire rated for 105°C.
2. Use only copper wire between the disconnect switch and the furnace junction box (JB).
3. This wire must be connected to furnace sheet metal for control to prove flame.
4. Symbols are electrical representation only.
5. Solid lines, inside circuit board PCB are printed circuit board traces and are not depicted as shown in the legend.
6. Replace only with a 3 AMP fuse.
7. Inductor used on all 060 or -20 airflow units.
8. Blower-on delay, gas heating 60 seconds low heat, 35 seconds high heat, cooling or heat pump 2 seconds..
9. Blower-off delay, gas heating 90, 135, 180 or 225 seconds, cooling or heat pump 90 seconds.
A95088
322296-101 REV. A
Control will auto-reset after three hours.
10. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition.
NOTES:
NOTE #2
FU2
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
BLK
GRN
WHT
JB
BLK
WHT
GRN
ILK
PL7
MTR1
12104 612
NO
RED
BLUE
C
TRAN HPS
BLK
WHT
WHT
BLK
BLK
HSI
12
WHT GRN
YEL
PL9
BRN
3
ORN
FSE
ALS
P
LS
GV
FRS
RED
BLK
BLU
C
RED
WHT
WHT BLK
EAC2 EAC1
BRN
NO
LPS
C
YEL
P1
P2
HUMGR
ORN
1234
YEL
L1
L2
PL2
B2
B1
10 11
T 1
T 2
RED
9 8 7
PL4
BRN
2
1
ORN YEL
456
123
1.5 AMP
PL1
WHT
WHT
3
BRN
GRN
HI
M
GRN
NOTE #3
WHT BLK
RED BRN
GRN
BLU
RED
Y/Y2
BLK
OM
W/W1CW2
5
WHT
BLUE
DH
SEC-1
SEC-2
5BLU 4YEL
3VIO
2ORN 1RED
RED
ORN VIO YEL BLU
WHT BLK
987654321
RED
PL3
RED ORN
VIO
YEL BLU
PL10
NOTE #6
FUSE
A/C AND CF
SWITCH
A/C AND CF
SWITCH
BLOWER
24VAC-3A
FU1
SELECTION CHART
POS.
SELECTION CHART
POS.
1
PL11
OFF-DELAY
SELECTION CHART
234
CF A/C
1
(1-4)
LEDS
1200
3
213
A/C CF A/C CF
213
5
90
78
DEFAULT
DEFAULT
SEC.
123 123
CFM
TON
OFF
OFF
NOTE #7
IND.
135
OFF
78
8 7 6
45 3
12
SW
(1-8)
CFM
1400
TON
3-1/2
213
OFF
600
CFM
TON2TON
1-1/2
213
OFF
1
PL11
SEC.
180
8
OFF
7
MZ
BPH FLT
CFM
1600
4
TON
213
OFF
800
CFM
213
OFF
RED
PL12
3168
GRN
WHT BLK
YEL
12543
SEC.
225
OFF
78
OFF-DELAY
BLOWER
COMP. TEST
32 1
EMER. HEAT
LOW HEAT
CFM
2000
5
TON
213
OFF
CFM
1000
TON
2-1/2
213
OFF
VIO
YEL
BLU
ORN
14
MTR2
SEC.
OFF
654
PL6
PL5
1
PL6 3-CIRCUIT COMM. CONNECTOR
PL7 12-CIRCUIT INDUCER MTR CONNECTOR
PL9 2-CIRCUIT HSI CONNECTOR
PL10 9-CIRCUIT BLOWER ADAPTER CONNECTOR
PL11 1-CIRCUIT INDUCTOR SPLICE CONNECTOR
PL12 5-CIRCUIT BLOWER POWER CONNECTOR
PL13 16-CIRCUIT BLOWER CTRL. CONNECTOR
SW1 MANUAL SWITCH, FAULT DISPLAY, SPST-(N.O.)
SW2 MANUAL SWITCH, LOW HEAT, SPST-(N.O.)
SW3 MANUAL SWITCH, BYPASS HUMIDIFIER, SPST-(N.O.)
JUNCTION
UNMARKED TERMINAL
PCB TERMINAL (FACTORY CONNECTED)
FACTORY WIRING (115 VAC)
FACTORY WIRING (24 VAC)
FIELD WIRING (115 VAC)
CONDUCTOR ON PCB
FIELD WIRING SCREW TERMINAL
TERMINAL BLOCK - MARKED TERMINAL
FIELD GROUND
EQUIPMENT GROUND
FIELD SPLICE
PCB TERMINAL (FIELD CONNECTION)
SW4 MANUAL SWITCH, EMERGENCY HEAT, SPST-(N.O.)
SW5 MANUAL SWITCH, MULTIPLE ZONE, SPST-(N.O.)
SW6 COMPONENT TEST, SPST-(N.O.)
SW7-8 MANUAL SWITCH, BLOWER OFF-DELAY, SPST-(N.O.)
TRAN TRANSFORMER - 115VAC/24VAC
→ Fig. 23—Wiring Diagram
PLUG RECEPTACLE
PCB
PL13
6
X
X
XX
JUMPERS
X
1-4 2-5 3-6
XX
XX
SIZE
042040
042060
042080
060100
060080
MODEL
060120
—18—
LEGEND
A/C AIR CONDITIONING (ADJUSTABLE TONNAGE)
ALS AUXILIARY LIMIT SWTICH OVERTEMP - MANUAL RESET SPST-(N.C)
CF CONTINUOUS FAN (ADJUSTABLE CFM)
CPU1 MAIN MICROPROCESSOR & CIRCUITRY
CPU2 IGNITION MICROPROCESSOR & CIRCUITRY
DH DEHUMIDIFICATION CONNECTION (24VAC .02 AMPS)
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FRS FLAME ROLLOUT SWITCH - MANUAL RESET, SPST-(N.C.)
FSE FLAME PROVING SENSOR ELECTRODE
FU1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FU2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE (FIELD INSTALLED & SUPPLIED)
GV GAS VALVE
GVR GAS VALVE RELAY, DPST-(N.O.)
HI GAS VALVE HIGH STAGE OPERATOR
HPS HIGH HEAT PRESSURE SWITCH, SPST-(N.O.)
HSI HOT SURFACE IGNITOR (115 VAC)
HSIR HOT SURFACE IGNITOR RELAY, SPST-(N.O.)
HUM 24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)
HUMR HUMIDIFIER RELAY, SPST-(N.O.)
ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
IND INDUCTOR (NOTE #7)
JB JUNCTION BOX
LEDS LIGHT EMITTING DIOES FOR STATUS CODES
LPS LOW HEAT PRESSSURE SWITCH, SPST-(N.O.)
LS LIMIT SWITCH, AUTO RESET, (N.C.)
MTR1 MOTOR (ICM) INDUCER
MTR2 MOTOR (ICM) BLOWER
PCB PRINTED CIRCUIT BOARD
PL1 11-CIRCUIT CONNECTOR
PL2 4-CIRCUIT PRESSURE SWITCH CONNECTOR
PL3 5-CIRCUIT BLOWER MTR CONNECTOR
PL4 2-CIRCUIT HSI CONNECTOR
PL5 6-CIRCUIT MODEL PLUG
Page 19
size and fuse specifications. A disconnecting means must be located within sight from and readily accessible to furnace.
NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control center fault code indicator light will flash rapidly and furnace will NOT operate.
WARNING: The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-1993 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electric shock, fire, or death.
J-BOX RELOCATION
1. Remove 2 screws holding auxiliary J-box. (See Fig. 24.)
2. Rotate J-box 180° and attach box to right side, using holes provided.
A93051
Fig. 24—Relocating J-Box
CAUTION: If manual disconnect switch is to be
mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components.
II. 24-V WIRING
Make field 24-v thermostat connections at 24-v terminal block on control center. Y wire from thermostat MUST be connected to Y terminal on control center, as shown in Fig. 22, for proper cooling operation. The 24-v terminal board is marked for easy connection of field wiring. (See Fig. 23.) The 24-v circuit contains a 3-amp, automotive-type fuse located on control center. (See Fig. 25.) Any electrical shorts of 24-v wiring during installation, service, or maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of identical size (3 amp).
NOTE: Use AWG No. 18 color-coded copper thermostat wire for lengths up to 100 ft. For wire lengths over 100 ft, use AWG No. 16 wire.
III. ACCESSORIES
1. Electronic Air Cleaner (EAC) The control center EAC terminals are energized with 115v
(1.5-amp maximum) during blower operation. a. Two extension leads are connected to the control center
EAC terminals to assist field installation of an EAC. (See Fig. 25.) To use these leads, proceed with the following:
(1.) Strip EAC power lead insulation approximately
1/4-in.
(2.) Insert stripped end into factory-supplied black
lead’s butt connector and crimp to secure.
(3.) Strip EAC neutral lead insulation approximately
1/4-in.
(4.) Insert stripped end into factory-supplied white
leads’s butt connector and crimp to secure.
NOTE: If desired, cut butt connectors off factory leads and strip insulation approximately 1/4-in and use field supplied wire nuts to connect.
b. An alternate method to attach EAC lead to control center
is the following procedure: (1.) Remove 2 screws securing the control box to
furnace blower shelf.
(2.) Remove and discard 2 factory-supplied leads from
control center EAC terminals.
(3.) Strip EAC power leads insulation approximately
1/8-in.
NOTE: The control center EAC terminals are sized for 12 gage maximum, solid or stranded wire.
(4.) Route EAC leads through right-hand wire grommet. (5.) Insert EAC stripped leads into control center EAC
terminals by depressing terminal’s arm with a screwdriver or finger. (See Fig. 26.)
(6.) Reinstall control box to furnace blower shelf using
2 screws removed earlier.
2. Humidifier (HUM) Screw terminals (HUM and Com) are provided for 24-v
humidifier connection. (See Fig. 23.) HUM terminal is energized with 24v (0.5-amp maximum) after inducer motor prepurge period.
NOTE: A field-supplied, 115-v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation.
3. Dehumidification (DH) A 1/4-in. male quick-connect terminal is provided on
control center to attach a normally open (N/O) humidistat contact when dehumidification is desired. (See Fig. 25.) Connect humidistat to thermostat R terminal and DH terminal on control center. A 15 percent reduction of cooling airflow or constant fan airflow will occur when DH terminal is energized and a single- or 2-speed "call for cooling" is received.
DIRECT VENTING
The 355MAV Furnaces require a dedicated (one 355MAV furnace only) direct vent system. In a direct vent system, all air for combustion is taken directly from outside atmosphere, and all flue products are discharged to outside atmosphere.
I. REMOVAL OF EXISTING FURNACES FROM COMMON VENT SYSTEMS
If furnace being replaced was connected to a common vent system with other appliances, these steps shall be followed with each appliance remaining connected to common vent system placed in operation, while other appliances remaining connected to common vent system are not in operation:
1. Seal any unused openings in common vent system.
2. Visually inspect vent system for proper size and horizontal pitch. Determine there is no blockage or restriction, leak­age, corrosion, and other deficiencies which could cause an unsafe condition.
—19—
Page 20
EAC-ELECTRONIC AIR CLEANER TERMINALS
(115-VAC 1 AMP MAX)
MAIN BLOWER
CONTROL WIRE
CONNECTOR
CONTINUOUS
FAN (CF) SETUP
SWITCHES
TRANSFORMER
24-V CONNECTORS
COMMUNICATION
CONNECTOR
Fig. 25—Control Center
HOT SURFACE IGNITOR CONNECTOR
HUM
RG
W/W1 Y/Y2
COM
W2
115-V CONNECTORS
PRESSURE SWITCH CONNECTOR
HUM-HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX)
24-V THERMOSTAT TERMINALS
24V
DEHUMIDIFIER (DH)  CONNECTOR 3-AMP FUSE
STATUS AND DIAGNOSTIC LED LIGHTS
AIR CONDITIONING (A/C) SETUP SWITCH SETUP SWITCHES (SW) AND BLOWER OFF DELAY SETUP SWITCHES
MODEL PLUG
A93062
A93053
Fig. 26—EAC Terminals on Control Center
3. Insofar as is practical, close all building doors and windows and all doors between space in which appliances remaining connected to common vent system are located and other spaces of building. Turn on clothes dryers and any appli­ance not connected to common vent system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Follow lighting instructions and place appliance in opera­tion. Adjust thermostat so appliance operates continuously.
5. Test for flue gas spillage at drafthood relief opening after 5 minutes of main burner operation. Use flame of a match or candle, etc.
6. After it has been determined that each appliance remaining connected to common vent system properly vents when tested as above, return doors, windows, exhaust fans, fireplace dampers, any other gas burning appliances to their previous condition of use.
7. If improper venting is observed during any of above tests, common vent system must be corrected. Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in Part 11 of NFGC or Section 5 of NSCNGPIC.
II. COMBUSTION-AIR AND VENT PIPING A. General
Combustion-air and vent pipe fittings must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785 (schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661 (ABS-DWV), F628 (schedule-40 ABS), or F891 (PVC-DWV cellular core). Pipe cement and primer must conform to ASTM standards D2564 (PVC) or D2235 (ABS). See Table 5 for maximum pipe lengths and Fig. 31, 32, 33, 34, and 35 for exterior piping arrangements.
In Canada construct all combustion-air and vent pipes for this unit of CSA or ULC certified schedule-40 PVC, PVC-DWV or ABS-DWV pipe and pipe cement. SDR pipe is NOT approved in Canada.
NOTE: Furnace combustion-air and vent pipe connections are sized for 2-in. pipe. Any pipe size change should be made outside furnace casing in vertical pipe. (See Fig. 27.) This allows proper drainage of vent condensate.
—20—
Page 21
Combustion-air and vent pipes must terminate together in same atmosphere pressure zone, either through roof or sidewall (roof termination preferred), using accessory termination kit. See Table 4 for required clearances.
TABLE 4—COMBUSTION-AIR AND VENT PIPE
TERMINATION CLEARANCES
LOCATION
Above grade level or above anticipated snow depth
Dryer vent 33 From plumbing vent stack 33 From any mechanical fresh
air intake For furnaces with an input
capacity less than 100,000 Btuh–from any non­mechanical air supply (win­dows or doors which can be opened) or combustion­air opening
For furnaces with an input capacity greater than 100,000 Btuh–from any non-mechanical air supply (windows or doors which can be opened) or combustion-air opening
From service regulator vent, electric and gas meters, and relief equip­ment
Above grade when adjacent to public walkway
* Horizontal distance. † 18 in. above roof surface in Canada. ‡ 36 in. to electric meter in Canada only.
NOTES:
1. If installing 2 adjacent 355MAV Furnaces, refer to Multiventing and Vent Terminations section for proper vent configurations.
2. When locating combustion-air and vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculation of the appliance’s own flue products or the flue products of adjacent vents. Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of heat exchangers.
CLEARANCE (FT)
U.S.A. Canada
11†
16
11
13
4* 6‡
77
Furnace combustion-air and vent pipe connections must be at­tached as shown in Fig. 28. Combustion-air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications.
FURNACE
A93083
Fig. 28—Combustion-Air and Vent Pipe Connections
CAUTION: When combustion-air pipe is installed
above a suspended ceiling, pipe must be insulated with 3/8-in. thick Armaflex-type insulation. Combustion-air pipe should also be insulated when it passes through warm, humid space.
CAUTION: When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as shown in Table 6 with Armaflex-type insulation.
CAUTION: Combustion air must not be taken from inside structure because that air is frequently contami­nated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household prod­ucts. Locate combustion-air inlet as far as possible from swimming pool and swimming pool pump house. Excessive exposure to contaminated combustion air will result in safety and performance related problems.
NOT IN HORIZONTAL SECTION
PIPE DIAMETER
TRANSITION IN
VERTICAL SECTION
Fig. 27—Combustion-Air and Vent Pipe Diameter
Transition Location and Elbow Configuration
A93034
WARNING: Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes. Failure to follow this warning could result in fire, property damage, personal injury, or death.
—21—
Page 22
WARNING: All combustion-air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 31, 32, 33, 34, or 35. Failure to follow this warning could result in property damage, personal injury, or death.
NOTE: The minimum combustion-air and vent pipe length (each) for these furnaces is 5 ft. Short pipe lengths (5-8 ft) may discharge water droplets. These droplets may be undesirable, and a 12-in. minimum horizontal pipe section is recommended, as shown in Fig. 29, to reduce excessive droplets from exiting vent pipe outlet.
B. Combustion-Air and Vent Pipe Diameter
Determine combustion-air and vent pipe diameter.
1. Using Table 5, determine preliminary combustion-air pipe diameter.
2. Using Table 5, determine preliminary vent pipe diameter.
3. Use largest diameter pipe determined in 1. and 2. above for both pipes.
NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 31, 32, 33, 34, and 35.
EXAMPLE:
An 042080 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed in an application requiring
3 elbows and 17 ft of vent pipe, along with 5 elbows and 16 ft of combustion-air pipe. Table 5 indicates this application would allow a 1-1/2-in. diameter vent pipe, but require a 2-in. diameter combustion air pipe (1-1/2-in. pipe is good for 20 ft with 3 elbows, but only 10 ft with 5 elbows). Therefore, 2-in. diameter pipe must be used for both vent and combustion-air pipes since larger required diameter must always be used for both pipes. If same installation were in Albuquerque, elevation 5250 ft above sea level, installation would require 2-in. vent pipe and combustion-air pipe. At 5001- to 6000-ft elevation, 1-1/2-in. pipe is not allowed with 5 elbows, and 2-in. pipe is good for 68 ft with 5 elbows.
C. Combustion-Air and Vent Pipe Attachment NOTE: All pipe joints must be watertight except attachment of
combustion-air pipe to inlet housing connection since it may be necessary to remove pipe for servicing.
1. Attach combustion-air pipe as follows: a. Determine location of combustion-air intake pipe con-
nection to combustion-air intake housing as shown in Fig. 28 for application.
b. Reposition combustion-air intake housing plug fitting in
appropriate unused intake housing connection.
c. Insert perforated disk assembly (factory supplied) in
intake housing where combustion-air intake pipe will be connected.
VENT PIPE
HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL
12″ MIN
COMBUSTION-AIR PIPE
12″ MIN
VENT PIPE
COMBUSTION-AIR PIPE COMBUSTION-AIR PIPE
COMBUSTION-AIR PIPE
VENT PIPE
12″ MIN
12″ MIN
VENT PIPE
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.
VERTICAL TO SIDEWALLVERTICAL TO ROOF
A93591
Fig. 29—Short Vent (5 to 8 Ft) System
—22—
Page 23
ALTITUDE UNIT SIZE
0 to 2000
2001 to 3000
3001 to 4000
4001 to 5000‡
5001 to 6000‡
See notes on following page.
042040
042060 042080
→060080
060100
→060120**
042040
042060 042080
→060080
060100
→060120**
042040
042060 042080
→060080
060100
→060120**
042040
042060 042080
→060080
060100
→060120**
042040
042060 042080
→060080
060100
→060120**
TABLE 5—MAXIMUM ALLOWABLE PIPE LENGTH (FT)
TERMINATION
TYPE
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
PIPE
DIAMETER
(IN.)*
1-1/2 50 45 40 35 30 25
2 707070707070
1-1/2 50 45 40 35 30 25
2 707070707070
1-1/2 30 25 20 15 10 5
2 707070707070 2 454035302520
2-1/2 70 70 70 70 70 70
2-1/2 one disk 10 NA NA NA NA NA
3 one disk 35 30 15 NA NA NA
3† one disk 35 35 35 30 30 30
3† no disk 70 70 70 70 70 70
1-1/2 45 40 35 30 25 20
2 707070707070
1-1/2 45 40 35 30 25 20
2 707070707070
1-1/2 26 21 16 11 6 NA
2 707070707070 2 403530252015
2-1/2 70 70 70 70 70 70
3 one disk 31 26 12 NA NA NA
3† one disk 31 30 30 25 25 24
3† no disk 63 62 62 61 61 61
1-1/2 42 37 32 27 22 17
2 707070707070
1-1/2 42 37 32 27 22 17
2 707070707070
1-1/2 25 20 15 10 5 NA
2 707070707070 2 383328231813
2-1/2 70 70 70 70 70 70
3 one disk 29 24 10 NA NA NA
3† one disk 29 28 28 23 22 21
3† no disk 59 59 58 57 57 56
1-1/2 40 35 30 25 20 15
2 707070707070
1-1/2 40 35 30 25 20 15
2 707070707070
1-1/2 23 18 13 8 NA NA
2 707070707068 2 363126211611
2-1/2 70 70 70 70 70 70
3† one disk 27 26 26 21 20 19
3† no disk 56 55 54 53 52 52
1-1/2 37 32 27 22 17 12
2 707070707070
1-1/2 37 32 27 22 17 12
2 707070707070
1-1/2 22 17 12 7 NA NA
2 707070706863 2 3328231813 8
2-1/2 70 70 70 70 70 70
3† one disk 26 24 23 18 17 16
3† no disk 53 52 50 49 48 47
123456
NUMBER OF 90° ELBOWS
—23—
Page 24
TABLE 5—MAXIMUM ALLOWABLE PIPE LENGTH (FT) Continued
ALTITUDE UNIT SIZE
042040
042060
6001 to 7000‡
7001 to 8000‡
8001 to 9000‡
9001 to 10000‡
* Disk usage—Unless otherwise stated, use perforated disk assembly (factory-supplied in loose parts bag). † Wide radius elbow. ‡ Vent sizing for Canadian installations over 4500 ft (1370m) above sea level are subject to acceptance by the local authorities having jurisdiction. ** Tentative data. NA—Not Allowed; pressure switch will not make.
NOTES:
1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.
2. Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes.
3. Assume two 45° elbows equal one 90° elbow. Long radius elbows are desirable and may be required in some cases.
4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.
5. The minimum pipe length is 5 ft for all applications.
d. Install pipe support (factory-supplied in loose parts bag)
042080
→060080
060100
→060120**
042040
042060 042080
→060080
060100
→060120**
042040
042060 042080
→060080
060100
→060120**
042040
042060 042080
→060080
060100
→060120**
TERMINATION
TYPE
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
2 Pipe or 3-In.
Concentric
into selected furnace casing combustion-air pipe hole. Pipe support should be positioned to bottom of casing hole.
e. Insert 2-in. diameter pipe into intake housing.
NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing.
f. Drill a 1/8-in. hole in 2-in. combustion-air pipe using
hole in intake housing as a guide.
g. Install a field-supplied No. 6 or No. 8 sheet metal screw
into combustion-air pipe.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur.
PIPE
DIAMETER
(IN.)*
1-1/2 35 30 25 20 15 10
2 70706867 66 64
1-1/2 35 30 25 20 15 10
2 70706867 66 64
1-1/2 20 15 10 5 NA NA
2 70706867 62 57 2 31262116 11 6
2-1/2 70 70 68 67 66 64
3† one disk 24 22 21 16 15 13
3† no disk 49 48 47 45 44 43
1-1/2 32 27 22 17 12 7
2 66656362 60 59
1-1/2 32 27 22 17 12 7
2 66656362 60 59
1-1/2 18 13 8 NA NA NA
2 66656362 57 52 2 29241914 9 NA
2-1/2 66 65 63 62 60 59
3† one disk 22 20 19 14 12 11
3† no disk 46 44 43 41 40 38
1-1/2 30 25 20 15 10 5
2 62605856 55 53
1-1/2 30 25 20 15 10 5
2 62605856 55 53
1-1/2 17 12 7 NA NA NA
2 62605856 51 46 2 27221712 7 NA
2-1/2 62 60 58 56 55 53
3† one disk 20 18 17 12 10 8
3† no disk 43 41 39 37 35 34
1-1/2 27 22 17 12 7 NA
2 57555351 49 47
1-1/2 27 22 17 12 7 NA
2 57555351 49 47
1-1/2 15 10 5 NA NA NA
2 57555351 46 41 2 241914 9 NANA
2-1/2 57 55 53 51 49 47
3† one disk 18 16 14 9 7 5
3† no disk 39 37 35 33 31 29
1234 5 6
NOTE: Do not attach combustion-air intake pipe permanently to combustion-air intake housing since it may be necessary to remove pipe for service of ignitor or flame sensor.
COMBUSTION-AIR INTAKE HOUSING PLUG FITTING
The combustion-air intake plug fitting must be installed in unused combustion-air intake housing. This fitting must be attached by using RTV sealant, or by drilling a 1/8-in. hole in fitting, using hole in intake housing as a guide. Install a field-supplied No. 6 or No. 8 sheet metal screw.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur.
NUMBER OF 90° ELBOWS
—24—
Page 25
A plugged drain connection has been provided on this fitting for use when moisture is found in combustion-air intake pipe and combustion box.
NOTE: Moisture in combustion-air intake may be result of improper termination. Ensure combustion-air intake pipe is similar to that shown in Fig. 31, 32, 33, 34, or 35 so it will not be susceptible to areas where light snow or other sources of moisture could be pulled in.
If use of this drain connection is desired, drill out fitting’s tap plug with a 3/16-in. drill and connect a field-supplied 3/8-in. tube. This tube should be routed to open condensate drain for furnace and A/C (if used), and should be trapped. (See Fig. 30.)
COMBUSTION – AIR
3/8" ID TUBE
3/16"
DRILL
4″
TRAP
TO OPEN
MIN
DRAIN
Fig. 30—Intake Housing Plug Fitting Drain
INTAKE HOUSING
BURNER BOX
COMBUSTION – AIR PIPE 
A93035
2. Attach vent pipe as follows: a. Determine location of vent pipe connection to inducer
housing as shown in Fig. 28 for application.
b. Reposition neoprene inducer housing outlet cap and
clamp to appropriate unused inducer housing connec­tion. Tighten clamp.
WARNING: Inducer housing outlet cap must be in­stalled and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.
c. Install pipe support (factory-supplied in loose parts bag)
into selected furnace casing vent pipe hole. Pipe support should be positioned to bottom of casing hole.
d. Insert 2-in. diameter pipe into inducer housing through
neoprene coupling and clamp in inducer housing. Tighten clamp.
WARNING: Vent pipe must be installed and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.
NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing.
3. Working from furnace to outside, cut pipe to required length(s).
4. Deburr inside and outside of pipe.
5. Chamfer outside edge of pipe for better distribution of primer and cement.
6. Clean and dry all surfaces to be joined.
7. Check dry fit of pipe and mark insertion depth on pipe.
NOTE: It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint.
8. After pipes have been cut and preassembled, apply gener­ous layer of cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat.
9. While cement is still wet, twist pipe into socket with 1/4 turn. Be sure pipe is fully inserted into fitting socket.
10. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint.
11. Handle pipe joints carefully until cement sets.
12. Support combustion-air and vent piping a minimum of every 5 ft (3 ft for SDR-21 or -26 PVC) using perforated metal hanging strap.
13. Slope combustion-air and vent pipes toward furnace a minimum of 1/4 in. per linear ft with no sags between hangers.
14. Use appropriate methods to seal openings where vent and combustion-air pipes pass through roof or side wall.
III. CONCENTRIC VENT AND COMBUSTION-AIR TERMINATION KIT INSTALLATION
NOTE: If these instructions differ from those packaged with
termination kit, follow kit instructions. Combustion-air and vent pipes must terminate outside structure. A
factory accessory termination kit must be installed in 1 of the installations shown in Fig. 31, 32, 33, 34, or 35. Four termination kits are available.
1. The 2-in. termination bracket kit is for 1-in., 1-1/2 in., and 2-in. diameter 2-pipe termination systems.
2. The 3-in. termination bracket kit is for 2-1/2 in. and 3-in. diameter 2-pipe termination systems.
3. The 2-in. concentric vent/air termination kit is for 1-in., 1-1/2 in., 2-in., and 2-1/2 in. diameter pipe systems when single penetration of wall or roof is desired.
4. The 3-in. concentric vent/air termination kit is for 2-1/2 in. and 3-in. diameter pipe systems when single penetration of wall or roof is desired.
NOTE: Shaded parts in Fig. 31, 32, 33, 34, and 35 are considered to be terminations. These components should NOT be counted when determining pipe diameter. Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and has less visible vent vapors. (See Fig. 31 or 32.) Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system.
A. Extended Exposed Sidewall Pipes
Sidewall combustion-air and vent pipe terminations may be extended beyond area shown in Fig. 34 or 35 in outside ambient by insulating pipes as indicated in Table 6.
1. Determine combustion-air and vent pipe diameters, as stated above, using total pipe length and number of elbows.
2. Using winter design temperature (used in load calculations), find appropriate temperature for your application and fur­nace model.
3. Determine required insulation thickness for exposed pipe lengths.
—25—
Page 26
MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.
90°
VENT
12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT
BRACKET
COUPLING
12″ MINIMUM
OVERHANG OR ROOF
COMBUSTION-AIR (ELBOW PARALLEL TO WALL)
VERTICAL SEPARATION
BETWEEN COMBUSTION
MAXIMUM OF 24 IN. ABOVE ROOF.
AIR AND VENT 8 3/4″ FOR 3″ KIT 6 3/4″ FOR 2″ KIT
MAINTAIN 12 IN. MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL.
COUPLING
VENT
ROOF
18″ MAXIMUM
BRACKET
COMBUSTION AIR
Fig. 31—Roof Termination (Preferred)
VENT
COMBUSTION AIR
MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.
Fig. 32—Concentric Vent and Combustion-Air Roof
Termination (Preferred)
OVERHANG OR ROOF
A93054
A87224
OVERHANG OR ROOF
12″ MINIMUM
1″ MAXIMUM
COMBUSTION-AIR
VENT
MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.
Fig. 33—Concentric Vent and Combustion-Air Side
Termination
A93055
BRACKET
90°
Fig. 34—Sidewall Termination of 12 in. or More
12″ MINIMUM
VENT
COMBUSTION-AIR
12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT
MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.
A87225
A87226
Fig. 35—Sidewall Termination of Less than 12 in.
—26—
Page 27
TABLE 6—MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH (FT) WITH INSULATION IN WINTER DESIGN
TEMPERATURE AMBIENT*
UNIT
SIZE
042040
042060
042080
→060080
060100
→060120
* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 5. † Insulation thickness based on R value of 3.5 per in.
NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 5.
B. Two-Pipe Termination Kit
WINTER
DESIGN TEMPERA-
TURE (°F)
20 2 2137425057
0 2 10 22 25 30 35
-20 2 5 14 17 21 25 20 2 3055617070
0 2 16 33 38 46 53
-20 2 9 23 26 33 38 20 2 3765707070
0 2 20 39 45 55 63
-20 2 1127313945 20 2-1/2 41 70 70 70 70
0 2-1/2 21 42 48 59 68
-20 2-1/2 11 28 33 41 49 20 3 4970707070
0 3 26 51 58 70 70
-20 3 1535405059
MAXIMUM PIPE
DIAMETER
0 3/8 1/2 3/4 1
5. Check required dimensions as shown in Fig. 31, 34, or 35.
C. Concentric Vent/Air Termination Kit
1. Determine location for termination.
1. Determine location for termination. Consideration of the following should be made when
determining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in
Table 4.
b. Termination kit should be positioned where vent vapors
will not damage plants/shrubs or air conditioning equip­ment.
c. Termination kit should be positioned so it will not be
affected by wind eddy (such as inside building corners) or accumulation of airborne leaves or light snow, or allow recirculation of flue gases.
d. Termination kit should be positioned where it will not be
damaged by or subjected to foreign objects, such as stones, balls, etc.
e. Termination kit should be positioned where vent vapors
2. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in.
are not objectionable.
2. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size
3. Loosely assemble concentric vent/air termination compo-
being used.
3. Loosely install elbow in bracket and place assembly on
4. Slide assembled kit with rain shield REMOVED through
combustion-air pipe. Roof terminations—Loosely install pipe coupling on prop-
erly cut vent pipe. Coupling must be positioned so bracket
NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.
will mount as shown in Fig. 31. For applications using combustion-air pipe option, indi-
cated by dashed lines in Fig. 31, install 90° street elbow into 90° elbow, making U-fitting. A 180° U-fitting may be used.
Sidewall terminations—Install bracket as shown in Fig. 34
5. Disassemble loose pipe fittings. Clean and cement using
or 35. For applications using vent pipe option indicated by dashed
lines in Fig. 34, rotate vent elbow 90° from position shown in Fig. 34.
4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping.
6. Check required dimensions as shown in Fig. 32 or 33.
IV. MULTIVENTING AND VENT TERMINATIONS
When 2 or more 355MAV Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 355MAV furnaces. When 2 or more 355MAV
INSULATION THICKNESS (IN.)†
Consideration of the following should be made when determining an appropriate location for termination kit.
a. Comply with all clearance requirements as stated in
Table 4.
b. Termination kit should be positioned where vent vapors
will not damage plants/shrubs or air conditioning equip­ment.
c. Termination kit should be positioned so it will not be
affected by wind eddy (such as inside building corners) or accumulation of airborne leaves or light snow, or allow recirculation of flue gases.
d. Termination kit should be positioned where it will not be
damaged by or subjected to foreign objects, such as stones, balls, etc.
e. Termination kit should be positioned where vent vapors
are not objectionable.
diameter hole for 3-in. kit.
nents together using instructions in kit.
hole.
Roof terminations—Locate assembly through roof to ap­propriate height as shown in Fig. 32.
Sidewall terminations—Locate assembly through sidewall with rain shield positioned no more than 1-in. from wall as shown in Fig. 33.
same procedures as used for system piping.
—27—
Page 28
A
A85182
Fig. 36—Rooftop Termination (Dimension "A" is Touching or 2-In. Maximum Separation)
VENT
VENT
A
COMBUSTION AIR
A93056
Fig. 37—Concentric Vent and Combustion-Air Roof
Termination (Dimension "A" is Touching or 2-In. Maximum
Separation)
VENT
1″ MAXIMUM (TYP)
COMBUSTION AIR
VENT
A
VENT
A93057
Fig. 38—Concentric Vent and Combustion-Air Side
Termination (Dimension "A" is Touching or
2-In. Maximum Separation)
VENT
COMBUSTION AIR
COMBUSTION AIR
A
Fig. 39—Sidewall Termination of 12 in. or Less
(Dimension "A" is Touching or 2-In.
Maximum Separation)
A85184
—28—
COMBUSTION AIR
A
COMBUSTION AIR
Fig. 40—Sidewall Termination of More Than 12 in.
(Dimension "A" is Touching or 2-In.
Maximum Separation)
A85183
Page 29
furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 36, 37, 38, 39, or 40, but next vent termination must be at least 36 in. away from first 2 terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension "A" in Fig. 36, 37, 38, 39, and 40 represents distance between pipes or rain shields, as touching or 2-in. maximum separation.
CONDENSATE DRAIN
I. GENERAL
Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications.
Condensate trap MUST be used for all applications. An external trap is not required when connecting the field drain to
this condensate trap. The field drain connection (condensate trap or drain tube coupling)
is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube connection.
Drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certified schedule 40 CPVC or PVC drain pipe, fittings, and cement.
When a condensate pump is required, select a pump which is approved for condensing furnace applications. To avoid conden­sate spillage, select a pump with an overflow switch.
II. APPLICATION
Outdoor draining of the furnace is permissible if allowed by local codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining.
WARNING: Caution should be taken to prevent drain­ing where slippery conditions may cause personal inju­ries. Excessive condensate draining may cause saturated soil conditions which may result in damage to plants.
III. CONDENSATE DRAIN PROTECTION
Freezing condensate left in condensate trap and drain line may cause cracks, and possible water damage may occur. If freeze protection is required, use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40°F self-regulating, shielded, and waterproof heat tape. See Installation Instructions supplied with accessory or heat tape manufacturer’s recommenda­tions.
OPEN STAND
PIPE FOR
A/C OR
HUMIDIFIER
DRAIN
TEE
TO OPEN DRAIN
A94054
Fig. 41—Example of Field Drain Attachment
The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, field­supplied trap prior to the furnace drain connection. All drain connections (furnace, A/C, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment’s drain.
See Fig. 41 for example of possible field drain attachment using 1/2-in. CPVC or PVC tee for vent and A/C or humidifier drain connection.
32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED
A93058
CAUTION: Unit must not be installed, operated, and then turned and left off in an unoccupied structure during cold weather when temperature drops to 32°F or below unless drain trap and drain line have adequate freeze protection. See Service and Maintenance Instructions for winterizing procedure.
1. Fold heat tape in half and wrap on itself 3 times.
2. Locate heat tape between sides of condensate trap back. (See Fig. 42.)
3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig.
42.)
4. Wrap field drain pipe with remaining heat tape, approxi­mately 1 wrap per ft.
5. When using field-supplied heat tape, follow heat tape manufacturer’s instructions for all other installation guide­lines.
—29—
Page 30
CONDENSATE TRAP
WIRE TIE(S)
(3 WRAPS MINIMUM)
Using schematic diagram (see Fig. 23), follow sequence of operation through different modes. This furnace has a new control system. Read and follow wiring diagram carefully.
→
NOTE: If 115-v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates at low-heat speed for 60 sec when power is restored before heating cycle is resumed.
I. SELF-TEST MODE
The control center goes through a brief self test whenever 115-v or 24-v power is interrupted. The self test takes approximately 2 sec to complete. After power is restored, red (microprocessor) LED briefly comes on. Then green LED comes on for 1 sec, followed by 1 sec where both yellow and green LEDs are on. During this time, the microprocessor is checking itself.
II. HEATING MODE
When thermostat calls for heat, R-W/W1 circuit closes.
→
→
NOTE: The heat cycle can start in either high or low heat. If a high-heat cycle is initiated, the inducer continues increasing its speed after low-pressure switch closes. When high-pressure switch closes, inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in high-heat mode.
HEAT TAPE
Fig. 42—Condensate Trap Heat Tape
SEQUENCE OF OPERATION
CAUTION: Furnace control must be grounded for
proper operation, or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw.
1. Prepurge period—The inducer motor is turned on and
slowly comes up to speed. When low-pressure switch closes, inducer motor RPM is noted by microprocessor, and a 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in low-heat mode.
2. Humidifier (HUM)—The HUM terminal is energized
whenever the inducer prepurge period is completed.
3. Ignitor warm up—At end of prepurge period, the hot
surface ignitor (HSI) is energized for a 17-sec HSI warm-up period.
4. Ignition sequence—After HSI ignitor warm-up period is
completed, the gas valve opens, permitting gas flow to burners where it is ignited. After 5 sec, the HSI is de-energized and a 2-sec flame-sensing period begins.
A93036
NOTE: The initial heat mode after 115-v or 24-v power interrup­tion will be LOW HEAT. Low heat remains energized for 16 minutes before high heat is initiated, providing thermostat is still calling for heat.
After the initial cycle, the microprocessor evaluates the length of low- and high-heat operating times and calculates optimum length of low and high heat for next heat cycle. This accommodates the heat load requirement seen as a result of thermostat operating time.
5. Flame sensing—When burner flame is sensed, the control
center holds gas valve open and begins blower on delay period.
NOTE: Ignition sequence repeats 3 additional times before a lockout occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning 115-v or 24-v power off (not at thermostat) for 3 sec minimum, then turning on again.
→
6. Inducer speed reduction—If cycle starts in low heat,
inducer speed reduces slightly after the flame sense. If cycle starts in high heat, inducer speed increases 15 sec after flame sense. The reduction in speed in low heat is to optimize combustion for maximum efficiency.
7. Blower on delay—The blower starts 60 sec after flame
sense if cycle started in low heat or 35 sec after flame sense if cycle started in high heat.
NOTE: The blower starts at approximately 400-500 RPM. After 20 sec, the motor is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide proper airflow for heating mode.
8. Electronic Air Cleaner—The EAC-1 terminal is energized
whenever the blower operates.
9. Blower off delay—When thermostat is satisfied, the
R-W/W1 signal is terminated, de-energizing gas valve (stopping gas flow to burners) and HUM terminal is de-energized.
The blower reduces its speed to low-heat RPM. The blower and EAC remain operating 90, 135, 180, or 225 sec (depending on blower off time selection). The furnace is factory set for a 90 sec blower off delay.
10. Post purge—The inducer continues operating for 15 sec
after gas valve is de-energized.
III. HEATING MODE—TWO STAGE
The control center provides 2-stage heating using a single-stage thermostat. The control center maximizes comfort while optimiz­ing efficiency to meet the demands of the conditioned area when a thermostat R-W/W1 signal is received.
If thermostat control over furnace staging is desired, a 2-stage thermostat can be used. When control center receives a thermostat R-W/W1 and R-W2 signal, high heat is energized and when R-W/W1 signal is received, low heat is energized. This method overrides microprocessor control of high or low heat.
NOTE: When using 2-stage thermostat operation with R-W/W1 and R-W2 signals, setup switch SW-2 MUST be in ON position.
The heat cycle operates as stated in Heating Mode section. To allow for greater comfort, a 2-stage thermostat control is
recommended when zone systems are used.
IV. EMERGENCY HEAT MODE NOTE: The furnace should not be operated in emergency heat
mode for extended periods of time. Operation is only recom­mended to provide heat until replacement components can be obtained or fault resolved.
In this mode, the microprocessor is bypassed and the motors operate at full speed with high-heat operation. The heat exchang­ers, motors, and electronics can be overstressed and may reduce the life of the components if operated for an extended period.
—30—
Page 31
NOTE: No safeties are bypassed when using emergency heat mode.
Emergency heat mode can be selected using setup switch SW-4. SW-4 should be used when a fault condition exists or difficult to resolve problems occur. This allows heating until the fault can be corrected.
In emergency heat mode, the normal heat mode outlined in Heating Mode section is not followed. The following sequence will occur:
When thermostat calls for heat, the R-W/W-1 circuits close.
1. Prepurge period—The inducer motor is turned on IMME-
DIATELY operating at maximum speed, closing low- and high-pressure switches. Prepurge begins 25 sec after high­pressure switch closes.
2. Blower on—The blower motor is turned on IMMEDI-
ATELY and slowly increases to maximum speed as soon as a call for heat is received. No blower calibration occurs.
3. Electronic Air Cleaner—The EAC-1 terminal does not
operate in emergency heat mode.
→
4. Humidifier—The HUM terminal is energized IMMEDI-
ATELY.
5. Ignitor warm up—The HSI is energized for a 17 sec
warm-up period after prepurge period is completed.
6. Ignition sequence—After HSI warm-up period has com-
pleted, the gas valve is energized, permitting gas flow to burners where it is ignited. After 5 sec, the HSI is de-energized and a 2-sec flame-sensing period begins.
NOTE: Emergency heat mode only operates in high heat.
7. Flame sensing—When burner flame is sensed, control
center holds gas valve open. If burner flame is not sensed, control center de-energizes gas valve and ignition sequence is repeated.
→
NOTE: Ignition sequence repeats 3 additional times before lock­out occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning 115-v or 24-v power off (not at thermostat) for 3 sec minimum, then turning on again. Fault codes will not flash in emergency heat mode.
8. Blower off delay—When thermostat is satisfied, the
R-W/W1 signal is terminated, de-energizing gas valve (stopping gas flow to burners) and HUM terminal is de-energized. In addition, blower stops immediately.
9. Post purge—Post purge does NOT occur. The inducer
stops immediately.
V. COOLING MODE
When thermostat calls for cooling, the R-G and R-Y/Y2 circuits close.
1. Cooling unit—The cooling unit starts when thermostat
R-Y signal is received.
2. Blower on—The control center starts blower immediately
when it receives an R-Y/Y2 and R-G signal. The blower starts at approximately 400-500 RPM. After 20 sec, the blower is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide selected cooling airflow.
NOTE: In cooling mode, the microprocessor adjusts blower RPM to operate at 400 CFM per ton as selected on the A/C setup switches. See Air Conditioning Setup Switches section. There is also a chart on wiring diagram. (See Fig. 23.)
NOTE: If Y/Y2 thermostat lead is not connected to furnace control center, blower motor operates in continuous fan speed and indoor coil freeze-up may occur.
3. Electronic Air Cleaner—The EAC-1 terminal is energized whenever blower operates.
4. Cooling unit—The cooling unit stops when thermostat R-Y signal is terminated.
5. Blower off delay—When thermostat is satisfied, the R-Y/Y2 and R-G signals are terminated, and blower re­mains operating for 90 sec.
→
VI. HEAT PUMP MODE
When furnace is operating in heat pump heating mode, R-Y/Y2 and R-G circuits are closed energizing heat pump, and blower operates at cooling speed. When heat pump defrost is required, R-W/W1 circuits close starting gas heat cycle, and blower adjusts to low-heat speed.
1. Prepurge period—The inducer motor is turned on and slowly comes up to speed. When low-pressure switch closes, inducer motor RPM is noted by microprocessor, and a 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in low-heat mode.
NOTE: The heat cycle can start in either high or low heat. If a high-heat cycle is initiated, inducer continues increasing its speed after low-pressure switch closes. When high-pressure switch closes, inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is used to determine required RPM necessary to operate inducer in high-heat mode.
2. Humidifier—The HUM terminal is energized whenever inducer prepurge period is completed.
3. Ignitor warm up—After prepurge period, HSI is energized for 17 sec.
4. Ignition sequence—After HSI warm-up period is com­pleted, the gas valve is energized, permitting gas flow to the burners where it is ignited. After 5 sec, the HSI is de-energized and a 2-sec flame-sensing period begins.
5. Flame sensing—When burner flame is sensed, control center holds gas valve open.
If burner flame is not sensed, control center de-energizes gas valve and ignition sequence is repeated.
6. Blower off period—Ten sec after gas valve is energized, the blower stops for 25 sec to allow heat exchangers to warm up.
7. Blower on delay—After blower off period, blower starts.
NOTE: The blower starts at approximately 400-500 RPM. After 20 sec, the motor is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide proper airflow for heating mode.
8. Electronic Air Cleaner—The EAC-1 terminal is energized whenever blower operates.
9. Inducer speed reduction—If cycle starts in low heat, inducer speed reduces slightly after the flame sense. If cycle starts in high heat, inducer speed increases 15 sec after flame sense. The reduction in speed in low heat is to optimize combustion for maximum efficiency.
10. Call for heat terminated—When the call for heat is
satisfied, the R-W/W1 signal is terminated, de-energizing gas valve (stopping gas flow to burners) and HUM terminal is de-energized.
a. R-W/W1 signal terminated with R-Y/Y2 and R-G
still present—The blower changes its speed to cooling RPM.
—31—
Page 32
b. R-W/W1 with R-Y/Y2 and R-G signals terminated—
The blower continues to operate completing a normal blower off delay.
11. Post purge—The inducer continues operating for 15 sec
after gas valve is de-energized.
VII. CONTINUOUS FAN MODE
1. Operating with continuous fan only. a. Call for continuous fan—The thermostat closes R-G
circuit.
b. Blower on—The blower starts immediately.
NOTE: The blower starts at approximately 400-500 RPM. After 20 sec, the motor is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide proper airflow for heating mode.
NOTE: The continuous fan speed is the same as low-heat speed unless it is field adjusted to another desired airflow. See Continu­ous Fan Setup Switches section. There is also a chart on wiring diagram. (See Fig. 23.)
c. Electronic Air Cleaner—The EAC-1 terminal is ener-
gized whenever blower operates, regardless of operating mode.
→
2. Operating with continuous fan (R-G) and call for heat (R-W/W1) is received—Same as heat pump mode except
blower on delay is 10 sec less than the heat mode. After call for heat (R-W/W1) is terminated, the blower remains operating at low-heat speed for selected blower off delay before resuming continuous fan speed.
3. Operating with continuous fan (R-G) and call for cool- ing (R-Y/Y2) is received—See Cooling Mode section. After call for cooling (R-Y/Y2) is terminated, the blower remains operating at cooling speed for 90 sec before resuming continuous fan speed.
VIII. COMPONENT TEST
All components are functionally operated except gas valve with component test feature.
This feature helps diagnose a system problem in case of a component failure.
NOTE: Setup switch SW-1 MUST be in OFF position or Fault Code 22 (setup error) will occur.
NOTE: NO thermostat signal may be present at control center, and all blower time delay off periods must be completed.
To initiate component test feature, proceed with the following:
1. Leave 115-v power to furnace turned on.
2. Remove main furnace door.
3. Remove blower access panel.
4. Turn setup switch SW-6 to ON position.
5. Manually close blower access panel door switch.
→
→
WARNING: Blower access panel door switch opens 115-v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in personal injury or death.
When items 1-5 have been completed, the following will occur:
1. The control center goes through a brief self test. This self test takes approximately 2 sec to complete. After door switch is closed, red (microprocessor) LED briefly comes on. Then green LED comes on for 1 sec, followed by 1 sec where both green and yellow LEDs are on. During this time, the microprocessor is checking itself.
2. Inducer motor operates for 20 sec at low speed, operates 20 sec at high speed, then turns off.
3. Hot surface ignitor is energized for 15 sec, then de­energized.
4. Main blower motor operates for 20 sec at low speed, operates for 20 sec at high speed, then turns off.
5. After component operation test is completed, 1 or more fault codes (11, 22, 41, or 42) will flash. See service label on back of main furnace door for explanation of fault codes.
NOTE: To repeat component test, turn setup switch SW-6 to OFF and then back to ON.
After component test, perform the following:
1. Release blower panel access door switch and turn setup switch SW-6 to OFF position.
2. If applicable, replace blower access panel and check LED status by removing plug in blower access panel.
3. Reinstall main furnace door if all LEDs are off, indicating furnace is ready to operate when a signal from thermostat is received.
→
IX. BYPASS HUMIDIFIER MODE
When setup switch SW-3 BPH is in ON position, RPM calculated for low heat is multiplied by 1.15 for all furnace model sizes. This compensates for increased return-air temperature caused by by­passed air supply.
→
X. DEHUMIDIFICATION MODE
If dehumidification input is energized with a 24-vac input, RPM calculated for cooling and continuous fan is multiplied by 0.85 for all furnace model sizes. This compensates for high humidity conditions during cooling operation.
→
XI. ZONE MODE
When setup switch SW-5 MZ is in ON position, blower motor control is the same as above except with the following exceptions:
1. While blower is operating in either low heat or continuous fan, the coast down calibration is performed once a minute to update blower RPM for zone damper position changes during a given cycle unless the blower pulse width to blower motor is greater than 60 percent. This prevents nuisance faults from occurring when a high continuous fan CFM has been selected.
2. While blower is operating in either high heat or cooling, blower pulse width to blower motor is frozen when blower RPM is within 10 percent of calculated blower RPM for 5 sec.
START-UP PROCEDURES
I. GENERAL
1. Furnace must have a 115-v power supply properly con­nected and grounded.
NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control center fault indicator light flashes rapidly and furnace does not operate.
2. Thermostat wire connections at terminals R, W/W1, G, and Y/Y2 must be made at 24-v terminal block on control center.
3. Natural gas service pressure must not exceed 0.5 psig (14-in. wc), but must be no less than 0.16 psig (4.5-in. wc).
4. Blower access panel must be in place to complete 24-v electrical circuit to furnace.
—32—
Page 33
TABLE 7—AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCH POSITION
AIR CONDITIONER
(TONS)
Default
1-1/2 600 ON OFF OFF X X X — — —
2 800OFFONOFFXXXXXX
2-1/2 1000 ON ON OFF XXXXXX
3 1200 OFF OFF ON XXXXXX
3-1/2 1400 ON OFF ON XXXXXX
4 1600 OFF ON ON — — — X X X 5 2000 ON ON ON — — — X X X
X—Indicates allowable selection.
CFM AIRFLOW
1200 or
2000
A/C SETUP
SWITCH POSITION
A/C-1 A/C-2 A/C-3 042040 042060 042080 →060080 060100 →060120
OFF OFF OFF
CAUTION: These furnaces are equipped with a manual reset limit switch in burner box. This switch opens if an overheat condition (rollout) occurs in burner enclosure. Correct inadequate combustion-air supply or improper venting condition and reset switch. DO NOT jumper this switch.
Before operating furnace, check each manual reset switch for continuity. If necessary, press button to reset switch.
II. SELECT SETUP SWITCH POSITIONS A. Air Conditioning (A/C) Setup Switches
The air conditioning setup switches are used to match furnace airflow to the cooling unit used. This furnace will provide 400 CFM per selected air conditioning tonnage.
To set the desired cooling airflow:
1. Remove main furnace door and blower access panel.
2. Locate the A/C setup switches on the control center. (See Fig. 25.)
3. Determine the air conditioning tonnage used.
4. Use Table 7 or wiring schematic to determine the proper setup position of A/C switches. (See Fig. 23 and 43.)
1
3 Tons
1200 CFM
ALLOWABLE FURNACE MODEL SETUP
3 Tons
1200 CFM
3 Tons
1200 CFM
5 Tons
2000 CFM
5 Tons
2000 CFM
5 Tons
2000 CFM
1. Remove main furnace door and blower access panel.
2. Locate the CF setup switches on the control center. (See Fig. 25.)
3. Determine the desired continuous fan airflow.
4. Use Table 8 or wiring schematic to determine the proper setup position of CF switches. (See Fig. 23 and 43.)
NOTE: The CF switches are factory set to provide the continuous fan airflow equal to the low-heat mode.
5. Replace main furnace door and blower access panel.
C. Setup Switches (SW)
The control center has 8 setup switches that may be set to meet the application requirements. Position these setup switches for the appropriate requirement.
1. Remove main furnace door and blower access panel.
2. Locate setup switches on the control center. (See Fig. 25.)
3. See Table 9 for setup switch description. (See Fig. 23 and
43.)
4. Replace main furnace door and blower access panel.
NOTE: If a bypass humidifier is used, setup switch SW-3 (BPH) should be in ON position. This prevents nuisance limit trips caused by the increased temperature in the return air resulting from the bypass.
NOTE: If modulating dampers are used, setup switch SW-5 (MZ) should be in ON position. This allows the furnace control center to compensate for the modulating dampers. The control will re­calibrate for the new system static conditions once every minute while operating in the low-heat or continuous fan modes.
III. PRIME CONDENSATE TRAP WITH WATER
OFF
Fig. 43—Example of Setup Switch in OFF Position
NOTE: Excessive airflow caused by improper A/C switch setup
may cause condensate blow off in the cooling mode.
5. Replace main furnace door and blower access panel.
NOTE: EAC-1 terminal is energized whenever the blower oper­ates. HUM terminal is only energized when the gas valve is energized.
B. Continuous Fan (CF) Setup Switches
The CF setup switches are used to select desired airflow when the thermostat is in the continuous fan mode. This setup feature will allow the continuous fan airflow to be adjusted. To set the desired continuous fan airflow:
A95198
CAUTION: Condensate trap must be PRIMED or proper draining may not occur. The condensate trap has 2 internal chambers which can ONLY be primed by pour­ing water into the inducer drain side of condensate trap.
1. Remove upper inducer housing drain connection cap. (See Fig. 44.)
2. Connect field-supplied 1/2-in. ID tube to upper inducer housing drain connection.
3. Insert field-supplied funnel into tube.
4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 45.)
5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp.
IV. PURGE GAS LINES
If not previously done, purge the lines after all connections have been made and check for leaks.
—33—
Page 34
TABLE 8—CONTINUOUS FAN (CF) AIRFLOW SETUP SWITCH POSITION
CONTINUOUS
FAN (CFM)
Default OFF OFF OFF 565* 515* 690* 690* 860* 1035*
600 ON OFF OFF X X X — — —
800 OFFONOFFXXXXXX 1000 ONONOFFXXXXXX 1200 OFFOFFONXXXXXX 1400 ONOFFONXXXXXX 1600 OFF ON ON — — — X X X 2000 ON ON ON — — — X X X
* Add 15% additional CFM when Bypass Humidifier switch SW-3 on control board is used. X—Indicates allowable selection.
CF-1 CF-2 CF-3 042040 042060 042080 →060080 060100 →060120
CF SETUP
SWITCH POSITION
ALLOWABLE FURNACE MODEL SETUP
Fig. 44—Inducer Housing Drain Tube
WARNING: Never purge a gas line into a combustion
chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning could result in fire, explosion, personal injury, or death.
V. ADJUSTMENTS A. Set Gas Input Rate
There are 2 methods of adjusting gas input rate. The preferred method is by using Table 11 and following instructions in item 1. The second method is by clocking the gas meter as outlined in item
2. Item 2 must be used for altitudes above 2000 ft.
1. Determine natural gas orifice size and manifold pressure for correct input by using Table 11.
A94208
A94209
Fig. 45—Filling Condensate Trap
a. Obtain average yearly heat value for local gas supply. b. Obtain average yearly specific gravity for local gas
supply.
c. Verify the furnace model. Table 11 can only be used for
model 355MAV Furnaces.
d. Find natural gas heat value and specific gravity in Table
11.
e. Follow heat value line and specific gravity line to point
of intersection to find orifice size and manifold pressure settings for proper operation at given natural gas condi­tion.
—34—
Page 35
TABLE 9—SETUP SWITCH DESCRIPTION
SETUP
SWITCH NO.
SW-1 (FLT)
SW-2
(LOW)
SW-3
(BPH)
SW-4
(EMER HEAT)
SW-5
(MZ)
SW-6
(COMP TEST)
SW-7 and -8
(Blower
Off Delay)
NORMAL
POSITION
OFF
OFF
OFF
OFF
OFF
OFF
See
Table
10
DESCRIPTION OF USE
Turn switch to ON for fault history dis­play. No thermostat signal can be present for fault history display. Turn switch to ON to lock furnace in low­heat mode only. Turn switch to ON when a bypass hu­midifier is used. This will compensate for higher return-air temperature and provide 5 percent more airflow in low-heat mode only. Turn switch to ON to bypass micropro­cessor control. Furnace will operate at high heat only with main blower and in­ducer motor operating at maximum RPM. NO safeties are bypassed. Turn switch to ON when modulating dampers are used. In this mode, main blower speed is recalculated once every minute while furnace is in low-heat or continuous fan mode. Turn switch to ON to initiate component test. Furnace will operate inducer motor 20 sec low speed, 20 sec high speed, HSI 15 sec or IID 0 sec, blower 20 sec low speed, and blower 20 sec high speed. SW-1 must be in OFF position. No thermostat signal can be present for component test to be initiated. Adjust switches to provide desired heat­ing mode blower off delay time, 90, 135, 180, or 225 sec.
TABLE 10—BLOWER OFF DELAY SETUP SWITCH
POSITION
DESIRED HEATING
MODE BLOWER
OFF DELAY (SEC)
90 OFF OFF 135 ON OFF 180 OFF ON 225 ON ON
SETUP SWITCH (SW-7 AND -8) POSITION
SW-7 SW-8
EXAMPLE: Heat value = 1010 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 44* with manifold pressure 3.3-in. wc for high heat and 1.4-in. wc for low heat. * Furnace is shipped with No. 45 orifices. In this example all main burner orifices must be changed and the manifold pressure adjusted.
f. Check and verify orifice size in furnace. NEVER AS-
SUME THE ORIFICE SIZE; ALWAYS CHECK AND VERIFY.
g. Proceed to item 3 to adjust manifold pressure. h. Check input rate by clocking meter as described in item
2.
2. Determine natural gas input rate by clocking gas meter and adjusting manifold pressure per item 3.
NOTE: Be sure all pressure tubing, combustion-air and vent pipes, and burner enclosure front are in place when checking input by clocking the gas meter.
a. Obtain average yearly heat value for local gas supply.
NOTE: Be sure heating value of gas used for calculations is correct for your altitude. Consult local gas utility for altitude adjustments of gas heating value.
b. Turn off all other gas appliances and pilots. c. Start furnace and let run for 3 minutes. d. Measure time (in sec) for gas meter test dial to complete
1 revolution.
e. Refer to Table 12 for cubic ft of gas per hr. f. Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft).
Obtain heating value from local gas utility.
EXAMPLE: Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 1010 Btu/cu ft Time for 1 revolution of 2-cu-ft dial = 72 sec Gas rate = 100 cu ft/hr (from Table 12) Btu heating input = 100 X 1010 = 101,000 Btuh In this example, the orifice size and manifold pressure adjustment is within ±2 percent of the furnace input rate.
g. Measured gas input must not exceed gas input on unit
rating plate.
NOTE: High altitude—Gas input on rating plate is for altitudes up to 2000 ft. Ratings for altitudes over 2000 ft must be 4 percent less for each 1000 ft above sea level. To obtain the adjusted altitude rating, adjust the manifold pressure (see item 3) and replace the main burner orifices as needed. Refer to NFGC Appendix F, Table F-4 for proper orifice sizing at high altitudes.
NOTE: In Canada, from 2000 to 4500 ft above sea level, derate the unit 10 percent from the Conversion Station.
h. Proceed to item 3 to adjust manifold pressure.
3. Adjust gas input.
NOTE: Manifold pressure must always be measured with the burner enclosure front REMOVED. The gas meter must always be clocked with the burner enclosure front INSTALLED. The gas valve has been nominally set at 3.5-in. wc high heat and 1.5-in. wc low heat for natural gas.
a. Remove burner enclosure front and caps that conceal
adjustment screws for gas valve regulator. (See Fig. 46.)
b. Turn setup switch SW-2 on control center to ON
position. (See Fig. 25.) This will keep furnace locked in low-heat operation.
c. Turn low-heat adjusting screw (5/64 hex Allen wrench)
counterclockwise (out) to decrease input rate or clock­wise (in) to increase rate. When adjusting input rate, DO NOT set manifold pressure less than 1.3-in. or more than
1.7-in. wc for natural gas. Make any major adjustments by changing main burner orifices.
d. Turn setup switch SW-2 to OFF position after low fire
adjustment.
e. Jumper R-W2 on control center thermostat connections.
(See Fig. 25.) This will keep furnace locked in high-heat operations.
f. Turn high-heat adjusting screw (5/64 hex Allen wrench)
counterclockwise (out) to decrease input rate or clock­wise (in) to increase rate. When adjusting input rate, DO NOT set manifold pressure less than 3.2-in. or more than
3.8-in. wc for natural gas. Make any major adjustment by changing main burner orifices.
NOTE: If orifices are changed, both high-heat and low-heat input rate must be readjusted. NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check the orifice hole with a numbered drill bit of the correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics.
g. Remove jumper R-W2 after high-heat adjustment. h. Replace burner enclosure front and measure adjusted gas
input rate using method outlined in item 2.
i. Replace caps that conceal gas valve regulator adjustment
screws.
—35—
Page 36
TABLE 11—MODEL 355MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT RATE
(Tabulated Data Based on Altitude Up to 2000 ft and 20,000 Btuh High Heat/13,000 Btuh Low Heat Per Burner)
GAS HEAT
VALUE
(BTU/CU FT)
860 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.5
875 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4
890 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4
905
920
935 44 3.6/1.5
950 44 3.5/1.5 44 3.6/1.5
965 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5
980 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5
995
1010 45 3.7/1.6
1025
1040
1055
1070
1085
1100
0.58 0.60 0.62 0.64 0.66 0.68 0.70 0.72
Orf
Heat
No.
High/Low
43443.3/1.3
3.7/1.5
43443.2/1.3
3.7/1.54344
44453.2/1.3
3.8/1.6
45463.6/1.5
3.8/1.6
45463.5/1.5
3.7/1.64546
45463.4/1.4
3.6/1.54546
45463.3/1.4
3.5/1.54546
45
3.2/1.4
46
3.4/1.4
47
3.8/1.6
46473.3/1.4
3.7/1.64546
Orf
Heat
No.
High/Low
43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4
3.3/1.4
3.8/1.6
43443.2/1.4
3.7/1.64344
44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5
44453.2/1.3
3.8/1.6
45 3.7/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5
3.6/1.5
3.8/1.6
3.5/1.5
3.7/1.64546
3.4/1.4
3.6/1.54546
45463.3/1.4
3.5/1.54546
3.2/1.4
3.4/1.44546
Orf No.
43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 43 3.8/1.5 42 3.2/1.3 42 3.3/1.3
43443.2/1.4
44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5
45 3.7/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5
CAUTION: Be sure burner enclosure front is in place after adjustments have been made.
SPECIFIC GRAVITY OF NATURAL GAS
Heat
High/Low
3.3/1.4
3.8/1.6
3.7/1.64344
3.6/1.5
3.8/1.6
3.5/1.5
3.7/1.64546
3.4/1.5
3.6/1.54546
3.4/1.4
3.5/1.54546
Orf
Heat
No.
High/Low
43 3.5/1.5 43 3.6/1.5 43 3.7/1.5 43 3.8/1.6 42 3.2/1.3
3.3/1.4
3.8/1.6
43443.2/1.4
3.7/1.64344
45 3.8/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5
3.7/1.5
3.8/1.6
3.6/1.5
3.7/1.6
3.5/1.5
3.6/1.54546
Orf
No.
High/Low
43 3.4/1.5 43 3.6/1.5 43 3.7/1.5 43 3.8/1.6
3.3/1.4
3.8/1.6
43443.2/1.4
3.7/1.64344
45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4
45 3.7/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4
3.6/1.5
3.8/1.6
OFF position and jumper R-W2 on control center. DO NOT forget to return setup switch to OFF position and remove R-W2 jumper upon completion of testing. (See Fig. 25 for switch and terminal
Heat
Orf
Heat
No.
High/Low
41423.2/1.4
3.6/1.54142
43 3.4/1.5 43 3.5/1.5 43 3.6/1.5
3.3/1.4
3.8/1.6
43443.2/1.4
3.7/1.64344
45 3.7/1.6 45 3.8/1.6 44 3.2/1.4
Orf
Heat
No.
High/Low
3.3/1.4
3.7/1.54142
41423.2/1.3
3.5/1.54142
43 3.4/1.5 43 3.5/1.5
3.3/1.4
3.8/1.6
43443.2/1.4
3.7/1.64344
location.)
j. Look through sight glass in burner enclosure and check
burner flame. The burner flame should be clear blue, almost transparent. (See Fig. 47.)
B. Set Temperature Rise
CAUTION:
Temperature rise must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or above. Failure to follow this caution may result in condensing or overheating the heat exchangers.
3. This furnace is capable of automatically providing the proper airflow to maintain the temperature rise within the range specified on the unit rating plate. If the temperature rise is outside this range, proceed as follows:
a. Check gas input for low- and high-heat operation. b. Check derate for altitude if applicable. c. Check all return and supply ducts for excessive restric-
tions causing static pressure greater than 0.5-in. wc.
d. Ensure bypass humidifier switch (BPH) setup switch
SW-3 on control center is in ON position when a bypass
Furnace must operate within range of temperature rise specified on the unit rating plate. Determine air temperature rise as follows:
1. Place thermometers in return and supply ducts as near furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight-run ducts.
2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.
NOTE: Temperature rise can be determined for low-fire opera­tion by placing setup switch SW-2 on control center in the ON position. For high-heat operation, place setup switch SW-2 in the
C. Set Thermostat Heat Anticipator
The thermostat heat anticipator must be set to match the amp draw of the components in the R-W/W1 circuit. Accurate amp draw measurements can be obtained at the thermostat subbase terminals R and W.
Fig. 48 illustrates an easy method of obtaining thermostat amp draw measurements. The amp reading should be taken after the blower motor has started and furnace is operating in low heat.
humidifier is used. (See Fig. 25 for switch location.)
e. Check Troubleshooting Guide for Gas-Fired Condensing
Furnaces.
Orf
Heat
No.
High/Low
3.4/1.4
3.8/1.6
3.3/1.4
3.6/1.5
41423.2/1.3
3.5/1.5
43 3.4/1.4
3.3/1.4
3.8/1.6
43443.2/1.4
3.7/1.6
—36—
Page 37
SECONDS
BURNER FLAME
BURNER
MANIFOLD
FOR 1
REVOLUTION
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
TABLE 12—GAS RATE CU FT/HR
1800 1636 1500 1385 1286 1200 1125 1059 1000
947 900 857 818 783 750 720 692 667 643 621 600 581 563 545 529 514 500 486 474 462 450 439 429 419 409 400 391 383 375 367
SECONDS
FOR 1
REVOLUTION
50 51 52 53 54 55 56 57 58 59 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96
98 100 102 104 106 108
110 112 116 120
SIZE OF TEST DIAL
1
cu ft2cu ft5cu ft
72 71 69 68 67 65 64 63 62 61 60 58 56 54 53 51 50 48 47 46 45 44 43 42 41 40 39 38 38 37 36 35 35 34 33
33 32 31 30
SIZE OF TEST DIAL
1
cu ft2cu ft5cu ft
360
720
327
655
300
600
277
555
257
514
240
480
225
450
212
424
200
400
189
379
180
360
171
343
164
327
157
313
150
300
144
288
138
277
133
267
129
257
124
248
120
240
116
232
113
225
109
218
106
212
103
206
100
200
97
195
95
189
92
185
90
180
88
176
86
172
84
167
82
164
80
160
78
157
76
153
75
150
73
147
144 141 138 136 133 131 129 126 124 122 120 116 112 109 106 103 100
97 95 92 90 88 86 84 82 80 78 76 75 74 72 71 69 68 67
65 64 62 60
360 355 346 340 333 327 321 316 310 305 300 290 281 273 265 257 250 243 237 231 225 220 214 209 205 200 196 192 188 184 180 178 173 170 167
164 161 155 150
BURNER 
ORIFICE
A93059
CAUTION: DO NOT redrill orifices. Improper drilling (burrs, out-of-round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of burners and heat exchang­ers, causing failures.
Fig. 46—Redundant Automatic Gas Valve
1. To operate furnace in low heat, turn setup switch SW-2 to ON position (See Fig. 25) and connect ammeter leads across thermostat subbase R-W.
2. See the thermostat manufacturer’s instructions for adjusting the heat anticipator and for varying the heating cycle length.
NOTE: When using an electronic thermostat, set the cycle rate for 3 cycles per hr.
3. Return setup switch SW-2 to OFF position and replace thermostat on subbase.
CHECK SAFETY CONTROLS
I. CHECK PRIMARY LIMIT CONTROL
This control shuts off the combustion control system and energizes the air-circulating blower motor if the furnace overheats.
1. The recommended method of checking this limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes.
A93085
A89020
Fig. 47—Burner Flame
2. As soon as the limit control has shut off the burners, a 33 fault will appear on the control center.
3. The return-air opening should be unblocked to permit normal air circulation.
By using this method to check the limit control, it can be established that the limit is functioning properly and the furnace will operate safely if there is a restricted return-air supply or motor failure. If the limit control does not function during this test, the cause must be determined and corrected.
II. CHECK PRESSURE SWITCH
This control proves operation of the draft inducer. Check switch operation as follows:
1. Turn off 115-v power to furnace.
2. Remove control access door and disconnect inducer motor 12-pin wire harness at inducer motor.
3. Turn on 115-v power to furnace.
4. Set thermostat to "call for heat." When the pressure switches are functioning properly, fault code 42 will flash on the control center approximately 10 sec after the thermostat switch is closed. If either fault code 31 or 32 is
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Page 38
THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED
HOOK-AROUND
VOLT/AMMETER
5. Turn off 115-v power to furnace.
6. Reconnect inducer motor wire harness. Reinstall furnace access door.
7. Turn on 115-v power to furnace.
R Y W G
10 TURNS
FROM UNIT 24-VOLT TERMINAL BLOCK
EXAMPLE:
5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT SETTING
Fig. 48—Amp Draw Check with Ammeter
flashed when the ICM inducer motor is disconnected, the furnace will shut itself down immediately. Determine the reason the pressure switches did not function properly and correct the condition.
A80201
8. Reset thermostat to desired temperature.
CHECKLIST
1. Put away tools and instruments. Clean up debris.
2. Verify manual reset switch has continuity.
3. Verify that blower and control access doors are properly installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instruc­tions.
6. Review User’s Manual with owner.
7. Leave literature packet near furnace.
—38—
Page 39
CHECKLIST—INSTALLATION
Load Calculation
____________ Heating Load (Btuh)
____________ Cooling Load (Btuh)
Condensate Drain
________ Unit Level or Pitched Forward
________
Internal Tubing Connections Free of Kinks and Traps
____________ Furnace Model Selection
COMBUSTION AND VENT PIPING
Termination Location
________ Roof or Sidewall
________ Termination Kit — 2 Pipe or Concentric
________ Combustion-Air Pipe Length
________ Combustion-Air Pipe Elbow Quantity
________ Vent Pipe Length
________ Vent Pipe Length Quantity
________
________ Pipe Sloped To Furnace
________ Over Ceilings
Pipe Diameter Determined from Sizing Table
Pipe Insulation
________
________
________ Heat Tape Installed if Required
________
________ Temperature Rise Adjusted
________ Anticipator Setting Adjusted or
________ Cycle Rate (3 Cycles per Hr) Selected
Safety Controls Check Operation
________ Primary Limit
________ Pressure Switch
External Drain Connection Leak Tight and Sloped
Condensate Trap Primed before Start-Up
CHECKLIST—START-UP
Gas Input Rate (Set Within 2 percent of Rating Plate)
Thermostat Anticipator
________ Low-Ambient Exposed Pipes
—39—
Page 40
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:  • Unit Familiarization • Maintenance  • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book.  Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog. 
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training [ ] Classroom Service Training
A94328
© 1995 BDP Co. • P.O. Box 70 • Indianapolis, IN 46206 Printed in U.S.A.
—40—
355m403 Catalog No. BDP-3335-504
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