Bryant Series J Installation, Start-up, And Operating Instructions Manual
installation, start-up,
and operating instructions
4-WAY MULTIPOISE
FIXED-CAPACITY DIRECT-VENT
CONDENSING GAS FURNACE
A93040
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index Page
DIMENSIONAL DRAWING........................................................3
SAFETY CONSIDERATIONS..................................................1-2
Clearances to Combustibles......................................................4
CODES AND STANDARDS ....................................................4-5
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS....5-6
INTRODUCTION..........................................................................6
APPLICATIONS ......................................................................6-12
General......................................................................................6
Upflow Applications..............................................................6-8
Downflow Applications.........................................................8-9
Horizontal Left (Supply-Air Discharge) Applications ..........10
Horizontal Right (Supply-Air Discharge) Applications...10-12
LOCATION ............................................................................12-14
General...............................................................................12-13
Furnace Location Relative to Cooling Equipment................13
Hazardous Locations...............................................................14
INSTALLATION.........................................................................14
Leveling Legs (If Desired).....................................................14
Installation In Upflow or Downflow Applications................14
Installation In Horizontal Applications..................................14
AIR DUCTS............................................................................14-19
General Requirements .......................................................14-16
Ductwork Acoustical Treatment .......................................16-17
Supply Air Connections..........................................................17
Return Air Connections..........................................................17
Filter Arrangement..................................................................17
Bottom Closure Panel.............................................................18
Gas Piping..........................................................................18-19
ELECTRICAL CONNECTIONS...........................................19-22
115-v Wiring...........................................................................20
24-v Wiring.............................................................................20
Wiring Diagram......................................................................21
Accessories ........................................................................20-22
DIRECT VENTING ...............................................................22-34
Removal of Existing Furnaces from
Common Vent Systems.....................................................22
Combustion-Air and Vent Piping .....................................22-30
Concentric Vent and Combustion-Air Termination
Kit Installation..............................................................30-31
Multiventing and Vent Termination .................................31-34
CONDENSATE DRAIN..............................................................34
General....................................................................................34
340MAV
Series J
Cancels: II 340M-40-10 II 340M-40-11
10-03
Application..............................................................................34
Condensate Drain Protection..................................................34
SEQUENCE OF OPERATION..............................................35-36
Heating Mode...............................................................................35
Cooling Mode...............................................................................35
Continuous Blower Mode............................................................35
Heat Pump Mode....................................................................35-36
Component Test ...........................................................................36
START-UP PROCEDURES ..................................................36-44
General....................................................................................36
Prime Condensate Trap With Water......................................36
Purge Gas Lines......................................................................36
Adjustments .......................................................................36-44
Set Gas Input Rate ............................................................36-44
Set Temperature Rise..............................................................44
Blower Off Delay (Heat Mode).............................................44
Set Thermostat Heat Anticipator............................................44
CHECK SAFETY CONTROLS ............................................44-45
Check Primary Limit Control.................................................45
Check Pressure Switch ...........................................................45
CHECKLIST................................................................................45
ama
As an ENERGY STAR®
Partner, Bryant Heating &
Cooling Systems Company has determined that
this product meets the ENERGY STAR® guidelines
for energy efficiency.
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.
REGISTERED QUALITY SYSTEM
SAFETY CONSIDERATIONS
CERTIFIED
—1—
AIRFLOW
UPFLOW
HORIZONTAL
RIGHT
AIRFLOW
A93041
AIRFLOW
HORIZONTAL
LEFT
DOWNFLOW
AIRFLOW
Fig. 1—Multipoise Orientations
WARNING: Improper installation, adjustment, alter-
ation, 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.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained
personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating
equipment, observe precautions in literature, on tags, and on labels
attached to or shipped with unit and other safety precautions that
may apply.
These instructions cover the minimum requirements and conform
to existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residential construction practices. We require these instructions as a
minimum for a safe installation.
Wear safety glasses and work gloves. Have a fire extinguisher
available during start-up and adjustment procedures and service
calls.
CAUTION: Sheet metal parts may have sharp edges or
burrs. Use care and wear appropriate protective clothing
and gloves when handling parts. Failure to follow this
caution could result in personal injury.
Understand these signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert
symbol. DANGER identifies the most serious hazards which will
result in severe personal injury or death. WARNING signifies
hazards which could result in personal injury or death. CAUTION
is used to identify unsafe practices which would result in minor
personal injury or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
The 340MAV Multipoise Condensing Gas-Fired Furnaces are
CSA (formerly AGA and CGA) design-certified for natural and
propane gases (see furnace rating plate) and for installation in
alcoves, attics, basements, closets, utility rooms, crawlspaces, and
garages. The furnace is factory-shipped for use with natural gas. A
CSA (formerly AGA and CGA) listed gas conversion kit is
required to convert furnace for use with propane gas.
See Fig. 3 for required clearances to combustibles.
Maintain a 1-in. clearance from combustible materials to supply air
ductwork for a distance of 36 inches horizontally from the furnace.
See NFPA 90B or local code for further requirements.
These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring. In
downflow installations, factory accessory floor base MUST be
used when installed on combustible materials and wood flooring.
Special base is not required when this furnace is installed on
manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil
Box Part No. KCAKC is used.
The 340MAV 040 through 120 size units are CSA (formerly AGA
and CGA) design-certified for use in manufactured (mobile)
homes when factory accessory conversion kit is used. The 140 size
unit is NOT design-certified for use in manufactured (mobile)
homes. These furnaces are suitable for installation in a structure
built on site or a manufactured building completed at final site. The
design of this furnace line is NOT CSA (formerly AGA and CGA)
design-certified for installation in recreation vehicles or outdoors.
This furnace is designed for continuous return-air minimum
temperature of 60°F db or intermittent operation down to 55°F db
such as when used with a night setback thermostat. Return-air
temperature must not exceed 85°F db. Failure to follow these
return-air limits may affect reliability of heat exchangers, motors,
and controls. (See Fig. 4.)
These furnaces are shipped with the drain and pressure tubes
connected for UPFLOW applications. Minor modifications are
required when used in DOWNFLOW, HORIZONTAL RIGHT, or
HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 1. See details in Applications section.
This furnace must be installed with a direct-vent (combustion air
and flue gas) system and a factory accessory termination kit. In a
direct-vent system, all air for combustion is taken directly from the
outdoor atmosphere and flue gases are discharged to the outdoor
atmosphere. See furnace and factory accessory termination kit
instructions for proper installation.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
—2—
A02147
"
8
⁄
"
16
"
16
⁄
13
⁄
5
"
8
⁄
5
7
39
1"
"
"
16
⁄
16
⁄
7
11
"
16
⁄
5
19"
"
22
4
⁄
1
"
16
⁄
15
"
2
⁄
26
1
28
AIRFLOW
OUTLET
26
A
2-IN. COMBUSTION-
"
16
⁄
9
TYP
TRAP LOCATION
"
16
/
CONDENSATE DRAIN
13
D
OUTLET
"
16
/
13
⁄2-IN. DIA
1
GAS CONN
AIR CONN
(DOWNFLOW &
OR ALTERNATE
-IN. DIA GAS CONN
2
⁄
1
HORIZONTAL RIGHT)
⁄8-IN. DIA
POWER CONN
7
"
4
⁄
1
TYP
33
⁄2-IN. DIA
THERMOSTAT ENTRY
1
"
8
⁄
5
TYP
32
"
16
⁄
13
30
"
2
⁄
1
30
2-IN. VENT CONN
"
16
⁄
11
29
TYP
5
"
16
⁄
11
22
SIDE INLET
"
4
⁄
1
18
1
" TYP
4
⁄
22
"
16
⁄
3
24
(UPFLOW)
BOTTOM INLET
HANGING
CONDENSATE
DRAIN LOCATION
FOR HORIZONTAL
DIMPLE LOCATORS
"
16
/
11
INLET
E
"
16
/
11
-in. rectangle.
-in. rectangle.
2
4
/
/
1
1
x 19
x 23
2
2
/
/
x 12-in. rectangle.
1
1
2
/
1
DIMENSIONS (IN.)
Fig. 2—Dimensional Drawing
"
8
⁄
27
"
16
⁄
9
TYP
"
27
2
⁄
1
24
"
16
⁄
5
17
see flex duct manufacturer’s recommendations for equivalent diameters.
2. Minimum return-air opening at furnace:
literature for specific use of single side inlets. The use of both side inlets, a
c. For 1600 CFM–22-in. round or 14
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data
b. For 1200 CFM–20-in. round or 14
a. For 800 CFM–16-in. round or 14
combination of 1 side and the bottom, or the bottom only will ensure adequate
return air openings for airflow requirements above 1800 CFM at 0.5” W.C. ESP.
⁄8-IN. DIA
POWER CONN
7
CONDENSATE
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL LEFT)
"
16
⁄
"
15
4
⁄
1
"
26
2
⁄
1
26
"
16
⁄
24
5
22
2-IN. COMBUSTION-
AIR CONN
⁄2-IN. DIA
1
GAS CONN
2-IN. VENT CONN
ENTRY
⁄2-IN. DIA THERMOSTAT
1
7
11
⁄8-IN. DIA
"
16
⁄
22
ACCESSORY
POWER ENTRY
DRAIN TRAP
LOCATION
(ALTERNATE
UPFLOW)
SIDE INLET
"
2
⁄
1
TYP
14
"
16
⁄
7
TYP
CONDENSATE
DRAIN LOCATION
1
"
4
⁄
1
1
(UPFLOW)
" TYP
" TYP
16
4
⁄
⁄
15
23
SIDE INLET
26
1"
9
NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
024040 17-1/2 15-7/8 16
036040 17-1/2 15-7/8 16
024060 17-1/2 15-7/8 16
036060 17-1/2 15-7/8 16
048060 17-1/2 15-7/8 16
036080 17-1/2 15-7/8 16
048080 17-1/2 15-7/8 16
060080 21 19-3/8 19-1/2
048100 21 19-3/8 19-1/2
060100 21 19-3/8 19-1/2
060120 24-1/2 22-7/8 23
UNIT SIZE A D E
060140 24-1/2 22-7/8 23
—3—
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, Startup, 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
Condensate trap hole filler plug 3
Vent and combustion-air intake hole filler plug 2
Combustion-air pipe perforated disk assembly 1
Vent Pipe Extension 1*
* ONLY supplied with some furnaces.
For accessory installation details, refer to accessory installation
instructions.
CODES AND STANDARDS
Follow all national and local codes and standards inadditionto
these instructions. The installation must comply with regulations
of the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction.
In the United States and Canada, follow all codes and standards for
the following:
I. SAFETY
• US: National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI
Z223.1-2002 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
• CANADA: National Standard of Canada, Natural Gas and
Propane Installation Code (NSCNGPIC) CSA B149.1-00.
II. GENERAL INSTALLATION
• US: NFGC and the NFPA 90B. For copies, contact the National
Fire Protection Association Inc., Batterymarch Park, Quincy,
MA 02269; or for only the NFGC contact the American Gas
Association, 400 N. Capitol, N.W., Washington DC 20001
• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke
(Toronto), Ontario, M9W 1R3, Canada
III. COMBUSTION AND VENTILATION AIR
• US: Section 8.3 of the NFGC, Air for Combustion and
Ventilation
• CANADA: Part 7 of the NSCNGPIC, Venting Systems and Air
Supply for Appliances
IV. DUCT SYSTEMS
• US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 2001 Fundamentals Handbook Chapter 34.
V. ACOUSTICAL LINING AND FIBROUS GLASS DUCT
• US and CANADA: current edition of SMACNA, NFPA 90B as
tested by UL Standard 181 for Class I Rigid Air Ducts
VI. GAS PIPING AND GAS PIPE PRESSURE TESTING
• US: NFGC; chapters 5, 6, 7, and 12 and national plumbing
codes
• CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E, and H.
This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft.
(0 - 2,135m).
An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications.
This furnace is for indoor installation in a building constructed on site. This furnace ma y be installed in a manufactured (mobile) home when stated on rating plate and
using factory authorized kit.
This furnace may be installed on comb ustible flooring in alcove or closet at
This furnac e req uires a s pe cial ve nting sy ste m . Refe r to the installation in struc tions for parts list and m e thod of installatio n. This furnace is for use with schedule-40 PVC,
PVC-DWV, CPVC , or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through w hich vent/air intake pipes may be
installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).
For upflow and downflow applications, furnace must be installed level, or pitched within 1/2" of level. For a
horizontal application, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper
drainage. See Installation Manual for IMPO R TANT unit support details on horizontal applications.
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
ALL POSITIONS:
Minimum front clearance for service 30 inches (762mm).
*
†
†
140 size furnaces require 1 inch back clearance to combustible materials.
DOWNFLOW POSITIONS:
†
For installation on combustible floors only when installed on special base No. KGASB0201ALL,
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.
HORIZONTAL POSITIONS:
Line contact is permissible only between lines formed by intersections of top and two sides of
furnace jacket, and b uilding joists, studs, or framing.
Clearance shown is for air inlet and air outlet ends.
§
120 and 140 size furnaces require 1 inch bottom clearance to combustible materials.
Ø
INST ALLATION
Minimum Inches Clearance To Combustible Construction
LEVEL (0")
1/2" MAX
UPFLOW OR
DOWNFLO W
This furnace is approved for UPFLOW, DOWNFLOW and
HORIZONTAL installations.
Clearance arrows
do not change with
furnace orientation.
†
†
0"
B
A
C
K
I
S
0"
§
328066-201 REV. A
LIT -TO P
Clearance in inches.
TO
E
D
as described below.
MIN 1/4" TO 1/2" MAX
FRONT
1"
TOP/PLENUM
E
C
A
N
R
U
F
N
O
R
F
F
R
O
N
BOTTOM
0"
Ø
†
FRONT
HORIZONTAL
I
S
T
S
E
R
T
3"
Vent clearance to
combustibles 0".
D
§
0"
E
V
I
C
E
*
30
MIN
A02248
Fig. 3—Clearances to Combustibles
—4—
BLOWER SHELF
CONDENSATE
TRAP (INSIDE)
ALTERNATE DRAIN
TUBE LOCATION
CONDENSATE TRAP
DRAIN TUBE LOCATION
UPFLOW APPLICATIONS
FURNACE
DOOR
FIELD
DRAIN
CONN
EXTERNAL UPFLOW APPLICATIONS
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
1
1
2
3
4
WIRE TIE
GUIDES
(WHEN USED)
CONDENSATE
TRAP
FURNACE
SIDE
7
4
8
1
26
4
1
1
2
FURNACE
DOOR
FIELD
DRAIN
CONN
FURNACE
SIDE
4
3
5
4
4
1
26
4
3
5
3
4
SIDE VIEW FRONT VIEW END VIEW FRONT VIEW
DOWNFLOW AND ALTERNATE
1
7
8
3
1
4
7
8
1
2
4
1
⁄4 OD
COLLECTOR BOX TO
TRAP RELIEF PORT
1
⁄2 OD
INDUCER HOUSING
DRAIN CONNECTION
5
⁄8 OD
COLLECTOR BOX
DRAIN CONNECTION
SCREW HOLE FOR
UPFLOW OR DOWNFLOW APPLICATIONS
(OPTIONAL)
1
⁄2-IN. PVC OR CPVC
HORIZONTAL
APPLICATIONS
4
FRONT VIEW SIDE VIEW
Fig. 5—Condensate Trap
VII. ELECTRICAL CONNECTIONS
• US: National Electrical Code (NEC) ANSI/NFPA 70-2002
• CANADA: Canadian Electrical Code CSA C22.1
A94163
Fig. 4—Return-Air Temperature
A93026
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
CAUTION: Electrostatic discharge can affect electronic
components. Take precautions during furnace installation
and servicing to protect the furnace electronic control.
Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the
procedure. These precautions will help to avoid exposing
the control to electrostatic discharge by putting the
furnace, the control, and the person at the same electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S ELECTROSTATIC
CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
a person’s hand during grounding will be satisfactorily
discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).
—5—
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)
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. 6—Factory-Shipped Upflow Tube Configuration
(Shown With Blower Access Panel Removed)
A00288
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
CONDENSATE
TRAP
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
Fig. 7—Alternate Upflow Tube Configuration and
Trap Location
A00289
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted metal
surface of the furnace again before touching control or
wires.
5. Use this procedure for installed and uninstalled (ungrounded) furnaces.
6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect
the control from damage. If the control is to be installed in
a furnace, follow items 1 through 5 before bringing the
control or yourself into contact with the furnace. Put all
used AND new controls into containers before touching
ungrounded objects.
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
INTRODUCTION
The model 340MAV 4-way multipoise, Gas-Fired, Category IV,
direct-vent condensing furnace is available in model sizes ranging
in input capacities of 40,000 to 138,000 Btuh.
—6—
APPLICATIONS
→
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. Failure to follow this caution will result in minor
property damage.
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. 6. 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. (See Fig. 5.)
B. Condensate Trap Tubing (Factory-Shipped
Orientation)
NOTE: See Fig. 6 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 6.)
NOTE: If internal filter is used, drain tube should be located to
opposite side of casing from return duct attachment to assist in
filter removal.
b. Remove and discard casing drain hole plug button from
desired side.
c. Install drain tube coupling grommet (factory-supplied in
loose parts bag) in selected casing hole.
d. Slide drain tube coupling (factory-supplied in loose parts
bag) through grommet ensuring long end of coupling
faces blower.
e. Cement 2 factory-supplied 1/2-in. street CPVC elbows to
the rigid drain tube connection on the condensate trap.
(See Fig. 6.) These elbows must be cemented together
and cemented to condensate trap drain connection.
NOTE: Failure to use CPVC elbows may allow drain to kink and
prevent 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 7.)
NOTE: If the alternate left-hand side of casing location is used,
the factory-connected drain and relief port tubes must be disconnected and modified for attachment. See Condensate Trap Tubing
(Alternate Upflow Orientation) section for tubing attachment.
To relocate condensate trap to the left-hand side, perform the
following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
WARNING: Casing hole filler cap must be installed in
blower shelf hole when condensate trap is relocated.
Failure to follow this warning could result in electrical
shock, fire, personal injury or death.
4. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
D. Condensate Trap Tubing (Alternate Upflow
Orientation)
NOTE: See Fig. 7 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 from occurring.
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. Connect relief port tube (green label) to condensate trap.
b. Extend this tube (if required) by splicing to small
diameter tube (factory-supplied in loose parts bag).
c. Determine appropriate length, cut, and connect tube.
E. Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
F. Pressure Switch Tubing
The LOWER collector box pressure tube (pink label) is factory
connected to the pressure switch and should not require any
modification.
NOTE: See Fig. 6 or 7 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. 6 or 7 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. 6 or 7 or tube routing label on main furnace door
to check for proper connections.
—7—
COLLECTOR BOX
DRAIN TUBE (BLUE)
CAP
PLUG
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
EXTENSION TUBE
CONDENSATE
TRAP
INDUCER HOUSING
DRAIN TUBE (VIOLET)
A00262
Fig. 8—Downflow Tube Configuration
(Left-Hand Trap Installation)
H. Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations and procedures.
III. DOWNFLOW APPLICATIONS
A downflow furnace application is where furnace blower is located
above combustion and controls section of furnace, and conditioned
air is discharged downwards.
A. Condensate Trap Location
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2, 8, 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. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
WARNING: Casing hole filler cap must be installed in
blower shelf when condensate trap is relocated. Failure to
follow this warning could result in electrical shock, fire,
personal injury or death.
4. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
B. Condensate Trap Tubing
NOTE: See Fig. 8 or 9 or tube routing label on main furnace door
to check for proper connections.
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
EXTENSION TUBE
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
CONDENSATE
TRAP
COLLECTOR BOX
EXTENSION
DRAIN TUBE
COUPLING
DRAIN TUBE
Fig. 9—Downflow Tube Configuration
(Right-Hand Trap Installation)
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was connected to
condensate trap.
c. Connect LOWER collector box drain connection to
condensate trap.
(1.) Condensate Trap Located on Left Side of Casing
(a.) Connect LOWER collector box drain tube
(blue and white striped label) to condensate
trap. Tube does not need to be cut.
(b.) Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
(a.) Install drain tube coupling (factory-supplied in
loose parts bag) into collector box drain tube
(blue and white striped label) which was previously plugged.
(b.) Connect larger diameter drain tube (factory-
supplied in loose parts bag) to drain tube
coupling, extending collector box drain tube
for connection to condensate trap.
(c.) Route extended collector box drain tube di-
rectly from collector box drain to condensate
trap as shown in Fig. 9.
(d.) Determine appropriate length and cut.
(e.) Connect to condensate trap.
(f.) Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
A00296
—8—
AUXILIARY "J" BOX
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)
CONDENSATE
RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR
TRAP
COLLECTOR
BOX EXTENSION
DRAIN TUBE
040, 060, AND 080 HEATING INPUT FURNACES
Fig. 10—Horizontal Left Tube Configuration
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain tube (violet label and factory-
supplied in loose parts bag) to connect LOWER inducer
housing drain connection to the condensate trap.
e. Connect inducer housing drain connection to condensate
trap.
(1.) Condensate Trap Located on Left Side of Casing
(a.) Determine appropriate length and cut.
(b.) Connect tube to condensate trap.
(c.) Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
(a.) Route inducer housing drain tube (violet label)
directly from inducer housing to condensate
trap as shown in Fig. 9.
(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.
COLLECTOR BOX
EXTENSION TUBE
DRAIN TUBE COUPLING
COLLECTOR BOX TUBE (PINK)
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
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. 8 or 9 or tube routing label on main furnace door
to check for proper connections.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in
loose parts bag).
3. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.
4. Extend collector box pressure tube (pink label) which was
previously connected to pressure switch by splicing to
remaining small diameter tube (factory-supplied in loose
parts bag).
5. Route this extended tube (pink label) to condensate trap
relief port connection.
6. Determine appropriate length, cut, and connect tube.
7. Clamp tube to relief port connection.
E. Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations and procedures.
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
DRAIN TUBE (BLUE)
A00215
—9—
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.
NOTE: The auxiliary junction box (J-Box) MUST be relocated to
opposite side of furnace casing. (See Fig. 10.) 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 10.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
WARNING: Casing hole filler cap must be installed in
blower shelf hole when condensate trap is relocated.
Failure to follow this warning could result in electrical
shock, fire, personal injury or death.
4. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
B. Condensate Trap Tubing
NOTE: See Fig. 10 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. Extend collector box tube (green label) which was
previously connected to the condensate trap by splicing
to small diameter tube (factory-supplied in loose parts
bag).
b. Route extended collector box pressure tube to relief port
connection on 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 for use when furnace is installed
in UPFLOW applications. This tube MUST be disconnected,
extended, rerouted, and then reconnected to the pressure switch in
HORIZONTAL LEFT applications.
NOTE: See Fig. 10 or tube routing label on main furnace door to
check for proper connections.
Modify tube as described below.
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Use smaller diameter tube (factory-supplied in loose parts
bag) to extend tube disconnected in item 1.
3. Route extended tube:
a. Behind inducer housing.
b. Between blower shelf and inducer housing.
c. Behind inducer motor bracket.
d. Between inducer motor and pressure switch.
4. Determine appropriate length, cut, and reconnect tube to
pressure switch connection labeled COLLECTOR BOX.
E. Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations and procedures.
F. Construct a Working Platform
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 11.)
→
→
CAUTION: The condensate trap MUST be installed
below furnace. See Fig. 5 for dimensions. The drain
connection to condensate trap must also be properly
sloped to an open drain. Failure to follow this caution will
result in intermittent unit operation.
NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 7.)
NOTE: A 12-in. minimum offset pipe section is recommended
with short (5 to 8 ft) vent systems. This recommendation is to
reduce excessive condensate droplets from exiting the vent pipe.
(See Fig. 11 or 34.)
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. Failure to follow this caution will result in minor
property damage.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC Installation Codes and/or local codes.
NOTE: The auxiliary junction box (J-Box) MUST be relocated to
opposite side of furnace casing. (See Fig. 12.) See Electrical
Connection section for J-Box relocation.
—10—
MANUAL
SHUTOFF
GAS VALVE
COMBUSTION – AIR
SEDIMENT
TRAP
INTAKE
3
5
⁄4″
CONDENSATE
TRAP
VENT
30″ MIN
WORK AREA
DRAIN
A 12-IN. MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT) VENT SYSTEMS
TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
ACCESS OPENING
FOR TRAP
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
Fig. 11—Attic Location and Working Platform
CAP
PLUG
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
A93031
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX TUBE (PINK)
AUXILARY “J” BOX RELOCATED HERE
CONDENSATE
TRAP
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
A00214
Fig. 12—Horizontal Right Tube Configuration
—11—
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 12.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
WARNING: Casing hole filler cap must be installed in
blower shelf hole when condensate trap is relocated.
Failure to follow this warning could result in electrical
shock, fire, personal injury or death.
4. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
B. Condensate Trap Tubing
NOTE: See Fig. 12 or tube routing label on main furnace door to
check for proper connections.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was previously connected to condensate trap.
c. Connect LOWER collector box drain tube (blue and
white striped label) to condensate trap. Tube does not
need to be cut.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain extension tube (violet label
and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to condensate trap.
e. Determine appropriate length, cut, and connect tube to
condensate trap.
f. Clamp tube to prevent any condensate leakage.
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
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. 12 or tube routing label on main furnace door to
check for proper connections.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in
loose parts bag).
3. Route extended collector box pressure tube behind inducer
motor bracket then between inducer motor and pressure
switch.
4. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.
5. Use remaining smaller diameter tube (factory-supplied in
loose parts bag) to extend collector box pressure tube (pink
label) which was previously connected to pressure switch.
6. Route this extended tube (pink label) to condensate trap
relief port connection.
7. Determine appropriate length, cut, and connect tube.
8. 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 11.)
→
CAUTION: The condensate trap MUST be installed
below furnace. See Fig. 5 for dimensions. The drain
connection to condensate trap must also be properly
sloped to an open drain. Failure to follow this caution will
result in intermittent unit operation.
NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 7.)
NOTE: A 12-in. minimum offset pipe section is recommended
with short (5 to 8 ft) vent systems. This recommendation is to
reduce excessive condensate droplets from exiting the vent pipe.
(See Fig. 11 or 34.)
LOCATION
I. GENERAL
This furnace must
• be installed so the electrical components are protected from
water.
• not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).
• be located so combustion-air and vent pipe maximum lengths
are not exceeded. Refer to Table 7.
• be located where available electric power and gas supplies meet
specifications on the furnace rating plate.
• be attached to an air distribution system and be located as close
to the center of the distribution system as possible. Refer to Air
Ducts section.
• be provided with ample space for servicing and cleaning.
Always comply with minimum fire protection clearances
shown on the furnace clearance to combustible label.
—12—
NOTE: For upflow/downflow applications install furnace so that
it is level or pitched forward within 1/2-in. for proper furnace
operation. For horizontal applications pitch 1/4-in. minimum to
1/2-in. maximum forward to ensure proper condensate drainage
from secondary heat exchangers. (See Fig. 13.)
When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace,
the return air shall also be handled by duct(s) sealed to furnace
casing and terminating outside the space containing the furnace to
ensure there will not be a negative pressure condition within
LEVEL (0″)
TO
1
⁄2″ MAX
UPFLOW OR DOWNFLOW HORIZONTAL
FRONT
MIN
TO
1
⁄2″ MAX
1
⁄4″
FRONT
equipment room or space.
This furnace may be located in a confined space without special
provisions for dilution or ventilation air.
Fig. 13—Furnace Location for Proper Condensate
Drainage
CAUTION: This gas furnace may be used for construction heat provided that:
-The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation
instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This
prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion
products into the structure.
-The furnace is controlled by a thermostat. It may not be ″hot wired″ to provide heat continuously to the structure without thermostatic
control.
-Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction
materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace
components.
-The temperature of the return air to the furnace is no less than 55°F, with no evening setback or shutdown. The use of the furnace while
the structure is under construction is deemed to be intermittent operation per our installation instructions.
-The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the nameplate value.
-The filters used to clean the circulating air during the construction process must be either changed ot thoroughly cleaned prior to
occupancy.
-The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system
components after construction is completed.
A02146
→
FRONT
B
A
C
K
BACK
FRONT
A93043
Fig. 14—Prohibit Installation on Back
WARNING: Do not install furnace on its back. Safety
control operation will be adversely affected. Never connect return-air ducts to back of furnace. Failure to follow
this warning could result in fire, personal injury, or death.
(See Fig. 14.)
CAUTION: If these furnaces are installed in an unconditioned space where the ambient temperatures may be
32°F or lower, freeze protection measures must be taken.
Failure to follow this caution will result in minor property
or unit damage. (See Fig. 15.)
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
A93058
Fig. 15—Freeze Protection
II. FURNACE LOCATION RELATIVE TO COOLING
EQUIPMENT
The cooling coil must be installed parallel with or on downstream
side of furnace to avoid condensation in heat exchanger. When
installed parallel with a furnace, dampers or other means used to
control flow of air shall 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.
—13—
III. HAZARDOUS LOCATIONS
18-IN. MINIMUM
TO BURNERS
Fig. 16—Installation in a Garage
WARNING: When furnace is installed in a residential
garage, it must be installed so that burners and ignition
sources are located a minimum of 18 in. above floor. The
furnace must be located or protected to avoid physical
damage by vehicles. When furnace is installed in a public
garage, airplane hangar, or other building having a
hazardous atmosphere, unit must be installed in accordance with NFGC or NSCNGPIC. (See Fig. 16.)
A93044
2. For each hole, install nut on bolt and then install bolt and
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat
washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
NOTE: Bottom closure must be used when leveling legs are used.
See Bottom Closure Panel section.
II. INSTALLATION IN UPFLOW OR DOWNFLOW
APPLICATIONS
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when special base (available from
manufacturer) Part No. KGASB0201ALL is used. Special base is
not required when this furnace is installed on manufacturer’s Coil
Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is
used.
1. Determine application being installed from Table 1.
2. Construct hole in floor per dimensions specified in Table 1
and Fig. 18.
3. Construct plenum to dimensions specified in Table 1 and
Fig. 18.
4. If downflow subbase (KGASB) is used, install as shown in
Fig. 19.
If coil assembly CD5 or CK5 or Coil Box KCAKC is used,
install as shown in Fig. 20.
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. 21.)
INSTALLATION
I. LEVELING LEGS (IF DESIRED)
When furnace is used in upflow position with side inlet(s), leveling
legs may be desired. (See Fig. 17.) 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. 17—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.
WARNING: Do not bend duct flanges inward as shown
in Fig. 21. This will affect airflow across heat exchangers
and may cause limit cycling or premature heat exchanger
failure. Remove duct flange completely or bend it inward
a minimum of 210° as shown in Fig. 21.
NOTE: For 140 size unit when installed in downflow orientation,
cut the white jumper wire off between terminals PL1-7 and PL1-9.
Do not cut white jumper between terminals PL1-7 and PLI-11.
Refer to Fig. 30 for location of jumper. Cut jumper close to
connector and remove wire to avoid a short circuit.
III. INSTALLATION IN HORIZONTAL APPLICATIONS
→
CAUTION: The entire length of furnace MUST be
supported when furnace is used in a horizontal position to
ensure proper draining. When suspended, bottom brace
supports sides and center blower shelf. When unit is
supported from the ground, blocks or pad should support
sides and center blower shelf area. Failure to follow this
caution will result in intermittent unit operation or performance satisfaction.
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 and
angle iron supports. (See Fig. 22.) 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. 22. Dimples are provided for hole locations. (See Fig. 2.)
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
—14—
A
PLENUM
OPENING
B
C
FLOOR
OPENING
D
A96283
Fig. 18—Floor and Plenum Opening Dimensions
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
A96285
Fig. 19—Furnace, Plenum, and Subbase
Installed on a Combustible Floor
FURNACE
CASING
WIDTH
Upflow Applications 16 24-1/8 16-5/8 24-3/4
Downflow Applications on Non-Combustible Flooring 15-7/8 19 16-1/2 19-5/8
17-1/2
21
24-1/2
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box
Downflow Applications on Combustible Flooring NOT Using KGASB Subbase
Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box
Upflow Applications 19-1/2 24-1/8 20-1/8 24-3/4
Downflow Applications on Non-Combustible Flooring 19-3/8 19 20 19-5/8
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box
Downflow Applications on Combustible Flooring NOT Using KGASB Subbase
Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box
Upflow Applications 23 24-1/8 23-5/8 24-3/4
Downflow Applications on Non-Combustible Flooring 22-7/8 19 23-1/2 19-5/8
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box
Downflow Applications on Combustible Flooring NOT Using KGASB Subbase
Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box
TABLE 1—OPENING DIMENSIONS (IN.)
APPLICATION
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
A96284
Fig. 20—Furnace, Plenum, and Coil
Assembly or Coil Box Installed
on a Combustible Floor
PLENUM OPENING FLOOR OPENING
ABCD
15-1/8 19 16-3/4 20-3/8
15-1/2 19 16-1/2 20
18-5/8 19 20-1/4 20-3/8
19 19 20 20
22-1/8 19 23-3/4 20-3/8
22-1/2 19 23-1/2 20
—15—
Loading...