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Series G 383KAV

Bryant Series G 383KAV Installation, Start-up, And Operating Instructions Manual

installation, start-up,
383KAV
and operating instructions
UPFLOW GAS-FIRED INDUCED-COMBUSTION FURNACES
NOTE: Read the entire instruction manual before starting the installation.
This symbol → indicates a change since the last issue. Index Page
SAFETY CONSIDERATIONS.....................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE........................................................................1-2
Dimensional Drawing ..............................................................2
Clearances From Combustible Materials.................................3
LOCATION ..................................................................................4
General......................................................................................4
Location Relative to Cooling Equipment ................................4
Hazardous Locations.................................................................4
AIR FOR COMBUSTION AND VENTILATION......................4
Unconfined Space.....................................................................4
Confined Space......................................................................4-5
AIR DUCTS................................................................................5-6
General Requirements ...........................................................5-6
Ductwork Acoustical Treatment...............................................6
Supply-Air Connections............................................................6
Return-Air Connections............................................................6
LEVELING LEGS (IF REQUIRED)............................................6
ELECTRICAL CONNECTIONS...............................................8-9
115-v Wiring..........................................................................8-9
24-v Wiring...............................................................................9
Accessories................................................................................9
VENTING ......................................................................................9
START-UP, ADJUSTMENT, AND SAFETY CHECK.........9-16
General.................................................................................9-10
Sequence Of Operation...........................................................10
Heating Mode..........................................................................10
Cooling Mode .........................................................................10
Continuous Blower Mode.......................................................10
Heat Pump Mode....................................................................10
Start-Up Procedures...........................................................10-12
Adjustments .......................................................................12-16
Set Gas Input Rate ............................................................12-15
Set Temperature Rise..............................................................15
Set Thermostat Heat Anticipator ......................................15-16
Check Safety Controls............................................................16
Checklist..................................................................................16
Series G
Cancels: II 383K-35-10 II 383K-35-11
ama
CANADIAN GAS ASSOCIATION
®
REGISTERED QUALITY SYSTEM
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Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54-1996/ANSI Z223.1-1996 and the Installation Standards, Warm Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1- and .2-M95 Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.
Recognize safety information. This is the safety-alert symbol When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury.
These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residen­tial construction practices. We require these instructions as a minimum for a safe installation.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
APPROVED
R
9-98
.
SAFETY CONSIDERATIONS
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 the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.
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—
39 7⁄8″
28 1⁄2″
VENT CONN
7
⁄8-IN. DIA HOLE
POWER ENTRY
7
⁄8-IN. DIA
ACCESSORY
1 3⁄4-IN. DIA HOLE
GAS ENTRY
1
⁄2-IN. DIA HOLE
THERMOSTAT
WIRE ENTRY
2 1⁄16″ 1″
5 3⁄8″
5 13⁄16″
2 3⁄8″
12 5⁄16″
AIRFLOW
A D
13
⁄16″
5 3⁄8″
5 13⁄16″
2 3⁄8″
2 11⁄16″
2 1⁄16″
1″
OUTLET
7
⁄8-IN. DIA
POWER ENTRY
1 1⁄2-IN. DIA R.H. GAS ENTRY
7
⁄8-IN. DIA ACCESSORY
1
⁄2-IN. DIA THERMOSTAT
WIRE ENTRY
19″
13
⁄16″
SIDE INLET
TYP 1″
11
11
⁄16″
NOTES:
24 5⁄16″
AIR INLET
1. Two additional 7⁄8-in. dia holes are located in the top plate.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer's recommendations for equivalent diameters.
3. Minimum return-air opening at furnace: a. For 800 CFM–16-in. round or 141⁄2 x 12-in. rectangle. b. For 1200 CFM–20-in. round or 141⁄2 x 191⁄2-in. rectangle. c. For 1600 CFM–22-in. round or 141⁄2 x 231⁄4-in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
3″
11
⁄16″
E
⁄16″
5
TYP
⁄8″
SIDE INLET
231⁄4″
SIDE RETURN
DUCT LOCATION
1″
Fig. 1—Dimensional Drawing TABLE 1—DIMENSIONS (IN.)
UNIT SIZE A D E VENT CONN SHIP. WT (LB)
024045 14-3/16 12-9/16 12-11/16 4 122 036045 14-3/16 12-9/16 12-11/16 4 124 024070 14-3/16 12-9/16 12-11/16 4 132 036070 14-3/16 12-9/16 12-11/16 4 134 042091 17-1/2 15-7/8 16 4 150 048091 21 19-3/8 19-1/2 4 154 036110 17-1/2 15-7/8 16 4 160 048111 21 19-3/8 19-1/2 4 166 060111 24-1/2 22-7/8 23 4 184 048135 21 19-3/8 19-1/2 5 178 060135 24-1/2 22-7/8 23 5 194 060155 24-1/2 22-7/8 23 5 204
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.
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.
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INTRODUCTION
The Model 383KAV, Series G Furnace is available in sizes 45,000 through 155,000 Btuh input capacities.
141⁄2″
1
3
⁄4″
A98520
—2—
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
This forced air furnnace is equipped for use with
atural gas at altitude s 0 - 10,000 f t (0-3,050m).
An accessory kit , supplied by the mmanufacturer,
hall be used to convert to propane gas use or
ay be required for some natural gas applications. Thiss furnace is for indoor installation in building constructed on site. This f
urnace may be installled on combustible
oorring in alcove or closet at minimum clearance
f
om combustible material.
f
This furnace ma
a
nd may be vented in common with other gas-fired
a
ppliances.
For furnaces wider than 14.25 inches
#
(362mm) may be 0 inches. For s in g le w all ven t ty p e 6 inc h es.
#
#
For Type B-1 v ent type 3 inches.
y be used with a Type B-1 Vent
This furnace is approved for UPFL OW installations only.
1"
0"
B
A
C
K
E
D
I
S
TOP / PLENUM
N
R
U
F
F
R
1" #
BOTTOM
Clearance in inches.
Vent Clearance to comb ustibles:
For Single Wall vents 6 inches (6 po). For Type B-1 ve nt type 1 inch (1 po).
DESSOUS
"
0
E
C
A
T
N
O
R
F
O
N
T
##
320325-101 RE V. H
S
1"
#
E
D
I
S
E
R
V
I
C
E
30"
MIN
→ Fig. 2—Clearances to Combustibles
The design of the upflow gas-fired furnace is A.G.A./C.G.A. certified for natural and propane gas and for installation on combustible flooring, in alcoves, attics, basements, closets, or utility rooms. The furnace is factory-shipped for use with natural gas. A factory accessory gas conversion kit, as listed on the furnace rating plate is required to convert furnace for use with propane gas. The design of this furnace line is not A.G.A./C.G.A. certified for installation in mobile homes, recreation vehicles, or outdoors.
Before installing the furnace in the United States, refer to the current edition of the NFGC/NFPA 54/Z223.1 and the NFPA 90B. For futher information, the NFGC/NFPA 54/Z223.1 and NFPA 90B are available from National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Asso­ciation, 1515 Wilson Boulevard, Arlington, VA 22209.
Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. Contact Standards Department of International Approval Services of Canada, 178 Rexdale Boulevard, Etobicoke, Ontario, Canada M9W 1R3.
Installation must comply with regulations of serving gas supplier and local building, heating, plumbing or other codes in effect in the 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 natonal 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.
A98122
CAUTION: Application of this furnace should be in­doors with special attention given to vent sizing and material, gas input rate, air temperature rise, and unit sizing. Improper installation or misapplication of the furnace can require excessive servicing or cause prema­ture component failure.
This furnace is designed for a minimum continuous return-air temperature of 60°F db or an intermittent operation down to 55°F db such as when used with a night setback thermostat. Return-air temperature must not exceed a maximum of 85°F db.
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 can cause electrical shock, fire, personal injury, or death.
For accessory installation details, refer to the applicable instruction literature.
—3—
I. LOCATION A. General
CAUTION: Do not install furnace in a corrosive or
contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.
CAUTION: Do not use this furnace during construction when adhesives, sealers, and/or new carpets are being installed. If the 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 cause corrosion of the heat exchangers and metal vent system. Some of these compounds are found in paneling and dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction pro­cess. Excessive exposure to contaminated combustion air will result in safety and performance related problems.
This furnace must be installed so the electrical components are protected from water. This furnace shall not be installed directly on carpeting, tile, or any combustible material other than wood flooring.
Locate furnace as close to the chimney/vent and as near the center of the air distribution system as possible. The furnace should be installed as level as possible.
Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearances shown on the unit rating plate.
B. Location Relative to Cooling Equipment
The cooling coil must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with a furnace, dampers or other means used to control the flow of air must prevent chilled air from entering the unit. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full-heat or full-cool position.
C. Hazardous Locations
II. AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3 of the NFGC, Air for Combustion and Ventilation, or applicable provisions of the local building codes.
Canadian installations must be installed in accordance with NSC­NGPIC and all authorities having jurisdiction.
CAUTION: Air for combustion must not be contami­nated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.
All fuel-burning equipment must be supplied with air for combus­tion of the fuel. Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space. In addition, a positive seal MUST be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and blocked vent safeguard opening.
CAUTION: The operation of exhaust fans, kitchen ven­tilation fans, clothes dryers, or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST BE PROVIDED for the ventilation devices, in addition to that required by the furnace.
The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space.
A. Unconfined Space
For Example:
383KAV FURNACE
INPUT BTUH
44,000 293 66,000 440
88,000 587 110,000 733 132,000 880 154,000 1026
MINIMUM SQ FT WITH
7-1/2 FT CEILING
If the unconfined space is of unusually tight construction, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors. Combustion and ventilation openings must be sized the same as for a confined space as defined below. Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room.
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B. Confined Space
A confined space is defined as a space whose volume is less than 50 cu ft per 1000 Btuh of total input ratings of all appliances installed in that space. A confined space MUST have provisions for supplying air for combustion, ventilation, and dilution of flue gases using 1 of the following methods. (See Fig. 4 and Table 2.) NOTE: In determining free area of an opening, the blocking effect of louvers, grilles, and screens must be considered. If free area of louver or grille design is unknown, assume that wood louvers have a 20 percent free area and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed. The size of the openings depends upon whether air comes from outside of the structure or an unconfined space inside the structure.
1. All air from inside the structure requires 2 openings (for structures not usually tight): a. Each opening MUST have at least 1 sq in. of free area
per 1000 Btuh of total input for all equipment within the confined space, but not less than 100 sq in. per opening. (See Fig. 4 and Table 2.) The minimum dimension of air openings shall not be less than 3 in.
—4—
SUPPLY
AIR
VENT THROUGH ROOF
DUCTS
TO
OUTDOORS
1 SQ IN. PER 4000 BTUH*
INTERIOR
HEATED
SPACE
RETURN AIR
* Minimum opening size is 100 sq in. with minimum dimensions of 3 in.
†
Minimum of 3 in. when type-B1 vent is used.
Fig. 3—Air For Combustion and Ventilation
(Inside Air)
12″ MAX
1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL
UNCONFINED SPACE
CONFINED
SPACE
6″ MIN (FRONT)
1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL
†
12″ MAX
A89012
12″ MAX
1 SQ IN. PER 2000 BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN. PER 2000 BTUH*
12
″ MAX
RETURN AIR
*Minimum dimensions of 3 in.
Use any of the following
NOTE:
combinations of openings: A & B C & D D & E F & G
A
SUPPLY
AIR
B
D
VENT THROUGH ROOF
C
DUCT
TO
OUTDOORS
CONFINED
SPACE
E
12″ MAX
Fig. 4—Air For Combustion and Ventilation
(Outside Air)
12″ MAX
F
1 SQ IN.
PER
4000
BTUH*
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
G
12″ MAX
1 SQ IN. PER 4000 BTUH*
A89013
b. If building is constructed unusually tight, a permanent
opening directly communicating with the outdoors shall be provided. See item 2 below.
c. If furnace is installed on a raised platform to provide a
return-air plenum, and return air is taken directly from hallway or space adjacent to furnace, all air for combus­tion must come from outdoors.
2. Air from outside the structure requires 1 of the following methods:
a. If combustion air is taken from outdoors through 2
vertical ducts, the openings and ducts MUST have at least 1 sq in. of free area per 4000 Btuh of total input for all equipment within the confined space. (See Fig. 4 and Table 2.)
b. If combustion air is taken from outdoors through 2
horizontal ducts, the openings and ducts MUST have at least 1 sq in. of free area per 2000 Btuh of total input for all equipment within the confined space. (See Fig. 4 and Table 2.)
c. If combustion air is taken from outdoors through a single
opening or duct (horizontal or vertical) commencing within 12 in. of the top of the confined space, opening and duct MUST have at least 1 sq in. of free area per 3000 Btuh of the total input for all equipment within the confined space and not less than the sum of the areas of all vent connectors in the confined space. (See Fig. 4 and
Table 2.) Equipment clearances to the structure shall be at least 1 in. from the sides and back and 6 in. from the front of the appliances.
When ducts are used, they must be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in. (See Fig.
4.)
WARNING: Do not install the furnace on its back or sides. Safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. A failure to follow this warning can cause a fire, personal injury, or death.
→ AIR DUCTS
I. GENERAL REQUIREMENTS
The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE). Or consult factory The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design static pressure.
—5—
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