Bryant 398B Installation Instructions Manual

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a ELECTRONIC CONDENSING FU RNACES ©
INTRODUCTION
NOTE: Read the entire instruction before starting the
installation.
Reference should also be made to the regulations of the
serving gas supplier and the local building, heating, plumb-
ing, or other codes in effect in the area in which the installa-
tion is made.
Portions of the following instruction have been adopted in
part from the current edition of the National Fuel Gas Code
NFPA No. 54-1988/ANSI Z223.1-1988. For further details,
consult this publication, or the current edition available
from National Fire Protection Association, Inc.,
Batterymarch Park, Quincy, MA 02269, or American Gas
Association, 1515 Wilson Boulevard, Arlington, VA 22209.
These instructions cover minimum requirements and con-
form 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 standard procedures as a minimum for a
safe installation.
Installations made in Canada must comply with CAN/
CGA1-B149.1 and .2 National Installation Codes for natural
gas burning appliances and equipment.
NOTE: The qualified installer or agency must use only fac-
tory authorized kits or accessories when modifying this
product.
This furnace is designed for a minimum continuous return
air temperature of 60 degrees F DB or an intermittent oper-
ation down to 55 degrees F DB such as when used with a
thermostat t night setback.
These instructions have the following sections:
I. Inspection
IT. Canadian Installations
_398B
Cancels: : SPOS- 7
11/1/88
III. Location and Air for Ventilation
IV. Gas Piping
V. Combustion-Air, Vent, and Condensate =n ] [
УТ. Electrical
УП. Startup, Adjustment, and Safety Check Е
VIII. Accessory Hookup |
IX. Service Diagnostics |
|. INSPECTION | i р
Check the available power supply to be sure t ets
the specifications on the furnace rating plate and all motors
in the equipment.
Check the available gas supply to see that it conforms to
the gas specification on the A.G.A. rating plate.
It. CANADIAN INSTALLATIONS
The outlet duct shall be provided with a removable access
panel. This panel shall be accessible when installed and be of
a size to permit the observance of light or smoke, indicating
the presence of a leak in the heat exchanger. Panel must be
attached to prevent leaks.
Ш. LOCATION AND AIR FOR VENTILATION
Locate the furnace as near the center of the air distribution
system as possible.
NOTE: For proper - furnace “operation, the furnace must be
installed within 1/2 inch of level.
This furnace may be located in a confined space without
special provisions for dilution or ventilation air.
Provide ample space for servicing and cleaning. Always
comply with the minimum fire protection clearances shown
on the unit rating plate. This furnace must NOT be installed
directly on carpeting, tile, or any combustible material other
than wood flooring.
When a furnace is installed so that the supply ducts carry
air to areas outside the space containing the furnace, the
return air must also be handled by duct(s) sealed to the fur- |
nace casing and terminating outside the space containing :
the furnace to ensure there will not be a negative pressure
condition within the equipment room or space.
A. Furnace Location Relative to Cooling Equipment
The cooling coil must be installed parallel with, or on the
downstream side of, the furnace to avoid condensation in
the heat exchanger. When installed parallel with a furnace,
dampers or other means used to control the flow of air must
prevent chilled air from entering the furnace. 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.
B. Special Locations
When the furnace is installed in a residential garage, it must
—1—
HIP. 398B- 60- 1
be installed so that it is protected from physical damage by
vehicles.
When a furnace is installed in public garages, airplane han-
gars, or other buildings having hazardous atmospheres, the
unit must be installed in accordance with the requirements
of the National Fire Protection Association, Inc.
IV. GAS PIPING
Gas piping must be installed in accordance with national
and local codes.
The gas supply line should be a separate line running
directly from the meter to the furnace, if possible. Refer to
Table I for the recommended gas pipe sizing. It is best to
slope all pipe 1/4-inch in 15-feet to prevent traps. All hori-
: ¿ong ab Tans should slope away from the meter to risers. Ris-
. ess
в j ot compounds (pipe dope) should be applied sparingly
and we Ep..the male threads of the joints. Consult your
5 local Sas $ Shpplier for the type of compound to be used. This
PC ipé done müst be resistant to the action of propane gas.
Bh,
Kopie be used to connect to the furnace and to the
ES
¿Instala " dient trap in the riser leading to the furnace.
This trap will serve as a trap for dirt and condensate. The
trap can be installed by connecting a tee to the riser leading
to the furnace, so that the straight-through section of the
tee is vertical. Then connect a capped nipple into the lower
- end of the tee. The capped nipple should extend below the
level of the gas controls. See Figure 1.
Where a gum filter is required by local codes, install it in
accordance with their requirements.
An accessible manual shut-off valve must be installed
upstream of the furnace. A 1/8-inch NPT plugged tapping,
accessible for test gauge connection, must be installed
immediately upstream of the gas supply connection to the
furnace and downstream of the manual shut-off valve.
Place a ground joint union between the gas control manifold
and the manual gas shut-off valve. See AN 1.
Protect all segments of the piping system against physical
and thermal damage. Support all piping with appropriate
straps, hangers, etc. Use a minimum of one hanger every 6
feet. For pipe sizes larger than 1/2 inch, follow the recom-
mendations of national codes.
Piping should be pressure-tested in accordance with local
and national plumbing and gas codes before the furnace has
been attached. If the pressure exceeds 0.5 psig (14 inch wc),
the gas supply pipe must be disconnected from the furnace
before the pressure test. If the test pressure is equal to or
less than 0.5 psig (14 inch we), close the manual shut-off
valve located on the gas valve before the test. It is recom-
` mended that the ground joint union be loosened before pres-
sure testing.
TABLE I—MAXIMUM CAPACITY OF PIPE*
Nominal Internal
iron Pipe Diameier Length of Pipe (ft)
Size (in.) п.) 10 20 30 40 50
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
1-1/2 1.610 2100 1460 1180 990 900
Ref: Table C-4 NFPA 54-1988
*Cubic ft of gas per hour, for gas pressures of 0.5 psig (14 inch we) or
less, and a pressure drop of 0.5 inch we (based on a 0.60 specific gravity
gas).
Fi
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After final connection to the furnace has been made, purge
the lines and check for leakage with regulated gas supply
pressure.
V. COMBUSTION-AIR, VENT, AND CONDENSATE
PIPING
Combustion-air and vent pipes for this unit can be of
schedule-40 PVC, PVC-DWV, SDR-21 PVC, SDR-26 PVC,
or ABS-DWV pipe and terminate through either the roof or
a sidewall.
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.
Roof termination is preferable. Sidewall terminations must
be located to prevent damage to shrubs and siding materi-
als. See Table II for clearance requirements.
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== ЕКО =
NOTE: When a previously common-vented system (furnace
and water heater) is converted to water heater only, the
vent system may be drastically oversized for the water
heater. Consult the National Fuel Gas Code or CAN/CGAI-
B149.1 and .2 Codes in Canada for proper sizing of the vent
and revise the system if necessary.
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VALVE
SEDIMENT
TRAP
UNION
С А84218
Figure 1—Gas Piping Arrangement
TABLE II—COMBUSTION-AIR AND VENT
TERMINAL CLEARANCES
Location
Dryer vent 3
From plumbing vent stack
Gas appliance vent terminal
From any opening where vent gases could enter building
Above grade and anticipated snow depth
Above grade when adjacent to public walkway
Clearance Feet
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A. Combustion-Air and Vent Piping
The combustion-air and vent pipes and fittings must con-
form to American National Standards Institute (ANSI)
standards and American Society for Testing and Materials
(ASTM) standards D1785, D2661, D2241, or D2665. The
pipe cement and primer must conform to > ASTM D2235 or
D2564.
In Canada construct all combustion-air vent pipes for this
unit of CSA or ULC certified schedule-40 PVC, PVC-DWV
or ABS-DWYV pipe and pipe cement.
See Table TIT for maximum allowable pipe lengths and Fig-
ures 2 through 7 for piping arrangements.
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The furnace is shipped from the factory assembled for
right-hand vent pipe connection. When left-hand vent con-
nection is desired, interchange the rubber vent pipe connec-
tor with the rubber seal cap. Both the vent pipe connector
and the seal cap are located on the inducer outlet box.
Remove the plastic plug from the left-hand casing side panel
and install it in the right-hand casing side panel.
1. Determine maximum allowable pipe length (for applica-
tions from 0 to 10,000 feet above sea level) using Table
ITI.
EXAMPLE: A 100-size furnace located in Indianapolis, ele- _
vation 650 feet above sea level, could be installed in an
application requiring three elbows and 28 feet of pipe.
Table III indicates this application would require 2-1/2-inch
pipe since 2-inch pipe is good only for lengths up to 15 feet.
If the same 100-size furnace, requiring three elbows and 28
_ feet of pipe, was to be installed in Albuquerque, elevation
5250 feet above sea level, the pipe diameter required would
be 3-inches, because Table ПТ shows 2-1/2-inch diameter
pipe and three elbows can only be used up to 26 feet of pipe.
Consult Application Engineering when pipe length of
combustion-air or vent pipe needed is longer than allowed i in
Table ITI.
NOTE: Do not count the elbows to which the terminal
bracket attaches or any elbow between the bracket and open
end of the pipe.
2. Working from furnace to outside, cut pipe to required
length(s).
3. Deburr inside and outside of pipe. Remove all dirt and
debris from inside of pipe.
4. Chamfer outside edge of pipe for better distribution of
primer and cement. |
5. Clean and dry all surfaces to be joined.
6. 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.
TABLE Ili—MAXIMUM ALLOWABLE PIPE. LENGTH |
Altitude (feet Furnace Pipe Number of 90 Degree Elbows
above sea level) Size Size 1 2 3 4 5
060 & 080 2 35 35 35 35 35
0-2000 100 2 25 20 15 — —
21/2 35 35 35 35 35
060 & 2 35 35 35 32 29
080 2 1/2 35 35 35 35 35
2001-3000 2 22 16 12 — —
100 2 1/2 35 35 35 32 29
3 35 35 35 35 35
060 & 2 35 35 31 28 24
080 2 1/2 35 35 35 35 35
3001-4000 2 20 14 9 — —
100 21/2 35 35 31 28 24
3 35 35 35 35 35
060 & 2 35 33 29 26 22
080 2 1/2 35 35 35 35 35
4001-5000 2 18 12 8 — —
400 2 1/2 35 33 29 26 22
3 35 35 35 35 35
060 & 2 34 30 26 22 18
080 2 1/2 35 35 35 35 35
5001-6000 2 16 10 6 — —
100 21/2 34 30 26 22 18
3 35 35 35 35 35
060 & 2 32 28 24 20 16
080 21/2 35 35 35 35 35
6001-7000 2 15 8 5 — —
100 21/2 32 28 24 20 16
3 35 35 35 35 35
060 & 2 29 25 20 16 11
080 2 1/2 35 35 35 35 35
7001-8000 2 13 6 — — —
100 21/2 29 25 20 16 11
3 35 35 35 35 35
060 & 2 27 23 18 14 9
080 21/2 35 35 35 35 35
8001-9000 2 11 — — — —
100 2 1/2 27 23 18 14 9
3 35 35 35 35 35
060 & 2 25 20 15 10 5
080 21/2 35 35 35 35 35
9001-10,000 2 9 — — — —
100 2 1/2 25 20 15 10 5
3 35 35 35 35 35
NOTES:
1. Pipe length applies to individual combustion-air or vent pipe.
2. Elbows and pipe section supplied in the vent terminal kit should not
be included in the count.
3. Two 45-degree elbows are equal to one 90-degree elbow. Long radius
elbows are desirable.
4. The installer may use one pipe size larger than what is specified (up
to 3-inches diameter maximum).
5. The minimum air pipe length on the 060 size with 2-inch diameter pipe
and one elbow is 10-feet.
— 3
7. 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 light, uniform coat on inside
of socket to prevent buildup of excess cement. Apply
second coat.
8. While the cement is still wet, insert pipe into socket
with a 1/4-turn twist. Be sure pipe is fully inserted into
the fitting socket.
9. Wipe excess cement from joint. A continuous bead of
cement will be visible around the perimeter of a prop-
erly made joint.
10. Handle pipe joints carefully until cement sets.
11. Support piping at minimum of every 5 feet (3 feet for
SDR-21 or -26 PVC) using perforated metal hanging
strap. Slope combustion-air and vent pipes toward fur-
nace a minimum of 1/4 inch per lineal foot with no sags
between hangers.
12. Use appropriate methods to seal openings where vent
and combustion-air pipes pass through roof or sidewall.
B. Vent Terminal Kit Installation
NOTE: If these instructions differ from those packaged
with the vent terminal kit, follow the kit instructions.
The combustion-air and vent pipes must terminate outside
the structure. A factory-supplied termination kit must be
installed as in one of the installations shown in Figures 2
through 7. Roof termination is preferred. See Figure 2. Two
terminal kits are available. The 2-inch kit is for 1-1/2-inch
and 2-inch diameter pipe systems. The 3-inch kit is for 2-1/2-
inch and 38-inch diameter pipe systems. Each kit will have
extra parts. See Figures 2 through 7 for the different
applications.
The shaded parts in Figures 2 through 7 are provided in the
termination kit; therefore, do not count them when deter-
mining the pipe diameter.
1. Rooftop terminal installation. See Figures 2 and 3.
a. Remove one 90-degree elbow from elbow-and-
bracket assembly provided in kit and loosen screw
so other elbow can turn.
b. Loosely install elbow with bracket on combustion-
air pipe. |
N
N
N
8-INCH MAXIMUM |
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BRACK т-| K
N '
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SA N
LA Ey 11 \
NS > T4 N
MI
QE fi < N
< > N
VERTICAL SEPARATION | L Y >| N <
BETWEEN BOTTOM OF. <> AT y Q
COMBUSTION AIR AND LIA <
TOP OF VENT: >> < = <
= —
А. FOR ZIN. TERMINAL < < SQ
6 SIN. FOR 31N. TERMINAL N ARK
Ñ N + MN N
ROOF: \
LE 12-INCH CLEARANCE MUST
BE MAINTAINED ABOV
HIGHEST ANTICIPATED SNOW
LEVEL. MAXIMUM NOT TO
EXCEED 24 INCHES ABOVE
ROOF.
. . A84143
Figure 2—Rooftop Termination
—A—
c. Loosely install pipe coupling, provided in kit, on
properly cut vent pipe. The position of the coupling
must be so that the bracket will mount as shown in
Figure 2.
d. Disassemble loose pipe fittings. Clean and cement
using same procedures as used for system piping.
e. Install bracket as shown in Figure 2.
f. For applications using combustion-air pipe option
as shown in Figure 3, install 90-degree street ell into
90-degree elbow, making a U-fitting.
g. Install open end of street ell on combustion-air pipe.
. Sidewall terminal installation when combustion-air and
vent pipes exit through sidewall 12 inches or more
above highest anticipated snow level or grade. See Fig-
ures 4 and 5. In Canada, pipes must exit a minimum of
36 inches above grade.
a. Loosely install elbow and bracket assembly on
combustion-air and vent pipes.
b. Remove and disassemble elbow and bracket
assembly.
c. Install elbows as shown in Figure 4 or 5 using same
procedures for cementing as used for system piping.
d. Install bracket as shown in Figure 4 or 5.
e. Position vent outlet pipe and elbow as to maintain
12-inch separation between vent pipe outlet and
combustion-air inlet. Cement vent pipe in elbow as
shown in Figure 4 or 5.
f. For applications using vent pipe option as shown in :
Figure 5, rotate vent elbow 90 degrees from position
shown in Figure 4.
. Sidewall terminal installation when combustion-air and
vent pipes exit through sidewall below highest antici-
pated snow level or grade. See Figures 6 and 7.
a. Remove one elbow from bracket assembly.
b. Install 90-degree street ell into elbow remaining in
bracket, making U-fitting.
c. Loosely install coupling on end of vent pipe.
d. Loosely install U-fitting and bracket as shown in
Figure 6. Position U-fitting so open end is against
structure wall.
e. Loosely install vent outlet pipe and elbow in cou-
pling as shown in Figure 6 or 7.
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Sn
BR
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IN 7 - < | ti
VERTICAL SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR AND
TOP OF VENT:
4 IN. FOR 2IN. TERMINAL
6 Zn. FOR 3 IN, TERMINAL
Е
12-INCH CLEARANCE MUST
BE MAINTAINED ABOVE
HIGHEST ANTICIPATED SNOW
LEVEL. MAXIMUM NOT TO
EXCEED 24 INCHES ABOVE
ROOF,
. | . A84144
Figure 3—Rooftop Termination
f. Check required dimensions as shown in Figure 6
or 7.
g. Disassemble loose pipe fittings. Clean and cement
using same procedures as used for system piping.
h. Install bracket as shown in Figure 6 or 7.
C. Condensate Drain
NOTE: Condensate must be disposed of in a nonfreezing
area.
The 1/2-inch diameter schedule 40 PVC or CPVC condensate
drain pipe fittings must conform to ANSI standards and
ASTM D1785 and D2846. The schedule 40 PVC or CPVC
cement and primer must conform to ASTM F493 or D2564.
In Canada use CSA or ULC certified schedule 40 PVC or
CPVC drain piping and cement.
For proper condensate drainage from the furnace, the fur-
nace must be within 1/2 inch of level. That is, the highest
corner of the furnace must not be more than 1/2 inch higher
OVERHANG
12-INCH MINIMUM
12-INCH SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR AND
ac „о BOTTOM OF VENT.
— Do Y
Soon a À
BRACKET>~<—" |. Je
! Е SV AT
AT
> 12- INCH CLEARANCE MUST
> BE MAINTAINED ABOVE
HIGHEST ANTICIPATED SNOW
COMBUSTION LEVEL OR GRADE.
a
AT IN CANADA:
MAINTAIN 36 IN. CLEARANCE
ABOVE GRADE OR [2 IN
Pe | CLEARANCE ABOVE HIGHEST
ae ANTICIPATED SNOW LEVEL
A84145
Figure 4—Sidewall Termination Above Snow Level
or Grade
OVERHANG
12- INER MINIMUM
12-INCH SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR AND
BOTTOM OF VENT.
12- INCH CLEARANCE MUST
BE MAINTAINED ABOVE
HIGHEST ANTICIPATED SNOW
LEVEL OR GRADE
COMBUSTION
AIR
Г a
Figure 5—Sidewall Termination Above Snow Level
or Grade
IN CANADA:
MAINTAIN 36 IN. CLEARANCE
ABOVE GRADE OR 12 IN
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
WHICHEVER IS GREATER .
A84146
than the lowest corner.
When a condensate pump is required to dispose of conden:
sate, use a pump with parts that are resistant to acidic
water.
NOTE: The furnace contains an internal condensate trap;
an external trap must not be installed.
1. Determine which side of furnace drain will exit, then
cut and preassemble drain piping (not provided)
directly to an open drain. Refer to Section IV A,
“Combustion-Air and Vent Piping”, for instructions on
preparing and cementing plastic pipe.
2. Cement elbow on pipe assembly (provided) to conden-
sate trap mounted on blower housing.
OVERHANG
12- INCH MINIMUM
¡A
Г )—COMBUSTION AIR |
(OPEN END AGAINST
STRUCTURE WALL)
12-INCH CLEARANCE
MUST BE MAINTAINED
ABOVE HIGHEST ANTIC-
IPATED SNOW LEVEL
| OR GRADE.
IN CANADA:
MAINTAIN 36 IN. CLEARANCE
ABOVE GRADE OR 12 IN,
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
WHICHEVER 1$ GREATER
A84147
Figure 6—Sidewall Termination Below Snow Level
or Too Close to Grade
OVERHANG
12-INCH MINIMUM
12- [NCH IÓN
E COMBUSTION А ANO
PJ COMBUSTION AIR
(OPEN END AGAINST
STRUCTURE WALL)
12-INCH CLEARANCE
MUST BE MAINTAINED
ABOVE HIGHEST ANTIC-
IPATED SNOW LEVEL
1 OR GRADE.
IN CANADA:
18 INCH MAINTAIN 36 IN. CLEARANCE
MAXIMUM ABOVE GRADE O
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
WHICHEVER IS GREATER ,
A84148
Figure 7 —Sidewall Termination Below Snow Level
or Too Close to Grade
—5—
3. Using backup wrench, attach first section of drain pipe
to compression coupling (provided).
4. When using schedule 40 PVC drain pipe, connect
adapter (provided) to end of pipe installed in compres-
sion fitting.
5. Attach schedule 40 PVC adapter (field-supplied) to
threaded factory adapter.
6. Cement remaining pipe joints.
VI. ELECTRICAL
IMPORTANT: Before proceeding with the electrical con-
nections, make certain that voltage, frequency, and phase
correspond to that specified on the unit rating plate. Also,
check to be sure that the service provided by the utility is
sufficient to handle the load imposed by this equipment.
Refer to the unit rating plate for equipment electrical
requirements.
The specific furnace Installation Instructions contain wir-
ing diagrams which show the proper field 115- and 24-volt-
age wiring. Make all connections in accordance with the
National Electrical Code, CSA C22.1 Electrical Code in Can-
ada, and any local codes and ordinances that might apply.
proKen- srounda
sr A A A A
_———_EE- > — _— === __—_
NOTE: Use only copper conductors between the disconnect
switch and the furnace.
Check all electrical connections (both factory and field) for
tightness. This check should also be done after the unit has
reached operating temperatures.
VIL STARTUP, ADJUSTMENT, AND SAFETY CHECK
A. Fill condensate trap with water.
1. Disconnect condensate drain tube from inducer outlet
box.
2. Insert funnel into tube and pour one quart of water
into tube. This should overfill the trap and flow into an
open drain.
3. Reconnect drain tube to inducer outlet box.
B. Ignition System Check
Check to be sure that all connections have been properly
made, then proceed as follows:
Start the furnace using the procedure outlined on the Light-
ing Instructions attached to the furnace; however, when
starting the furnace for the first time, perform the following
additional steps:
1. If the gas supply was not purged before connecting the
furnace, the line will be full of air. It is recommended
that the ground joint union be loosened, and the supply
line be allowed to purge until the odor of gas is
detected. Never purge gas lines into a combustion
chamber. Immediately upon detection of a gas odor,
retighten the union. Check gas supply pressure Lo be
sure it is within rating plate limits. Allow 5 minutes to
elapse, then start the furnace in accordance with the
lighting instructions on the furnace.
2. After the pilot lights, the main burners should light in
| 25 to 75 seconds. If the main burners do not light
within the prescribed time period check; the pilot
flame, electrical supply to gas valve, burner crossover
alignment, gas supply pressure, manifold, and orifice
alignment.
3. The pilot flame should be soft blue in color and it must
provide good impingement on the pilot switching ele-
ment. The flame should extend above the burner carry-
over port to provide proper burner ignition. When the
pilot flame requires adjustment:
a. Locate adjustment screw marked “PILOT ADJ” on
top of gas valve.
b. Remove cap and turn adjustment screw clockwise
to decrease pilot gas flow. Turn screw counter-
clockwise to increase pilot gas flow.
‘с. When proper adjustment is obtained, replace screw
cap.
C. Gas Input
1. Determine natural gas orifice size and manifold pres-
sure for correct input during high- and low-heat opera-
tion by using Table V. Adjust manifold pressure per
step 3. |
NOTE: Be sure all pressure tubing, combustion-air and vent
pipes, and burner enclosure front are in place when checking
input.
a. Obtain average yearly heat value for local gas
supply.
TABLE IV—GAS RATE—CU FT/HR
Seconds SIZE OF TEST DIAL Seconds SIZE OF TEST DIAL
for One 1 2 5 for One 1 2 5
Revolution | cu ft cu ft cu ft Revolution cu ft cu ft cu ft
10 360 720 1800 50 72 144 360
11 327 655 1636 51 71 141 355
12 300 600 1500 52 69 138 346
13 277 555 1385 53 68 136 340
14 257 514 1286 54 67 133 333
15 240 480 1200 55 65 131 327
16 225 450 1125 56 64 129 321
17 212 424 1059 57 63 126 316
18 200 400 1000 58 62 124 310
19 189 379 947 59 61 122 305
20 180 360 900 60 60 120 300
21 171 343 857 62 58 116 290
22 164 327 818 64 56 112 | 281
23 157 313 783 66 54 109 273
24 150 300 750 68 53 106 265
25 144 288 720 70 51 103 257
26 138 277 692 72 50 100 250
27 133 267 667 74 48 97 243
28 129 257 643 76 47 95 237
29 124 248 621 78 46 ‚ 92 231
30 120 240 600 80 45 90 225
31 116 232 581 82 44 88 220
32 113 225 563 84 43 86 214
33 109 218 545 86 42 84 209
34 106 212 529 88 41 82 205
35 103 206 514 90 40 80 200
36 100 200 500 92 39 78 196
37 97 195 486 94 38 76 192
38 95 189 474 96 38 75 188
39 92 185 462 98 37 74 184
40 90 180 450 100 36 72 180
41 88 176 439 102 35 71 178
42 86 | 172 429 104 35 69 173
43 84 167 419 106 34 68 170
44 82 164 409 108 33 67 167
A5 80 160 400 110 33 65 164
46 78 157 391 112 32 64 161
47 76 153 383 116 31 62 155
48 75 . 150 375 120 30 60 150
49 73 147 367
_6—
im
—— mn?
b. Obtain average yearly specific gravity for local gas
supply.
c. Verify the furnace model. Table V can only be used
for Model 398B Furnaces.
Check and verify orifice size in furnace. NEVER
ASSUME THE ORIFICE SIZE, ALWAYS
CHECK AND VERIFY. |
e. Find natural gas heat value and specific gravity in
Table V.
f. 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 natu-
ral gas condition. |
EXAMPLE:
Heat value 1050 Btu/cu feet
Specific gravity 0.58
Therefore; Orifice No. 45*
High-heat manifold pressure 3.8-inch we
Low-heat manifold pressure 1.8-inch we
*The furnace is shipped with No. 44 orifices. Therefore, in
this example all main burner orifices must be changed.
g. Check input rate by clocking meter as described in
step 2.
2. Determine natural gas input rates during high- and
low-heat operation by clocking gas meter and adjusting
manifold pressure per step 3.
NOTE: Be sure all pressure tubing, combustion-air and vent
pipes, and burner enclosure front are in place when checking
input.
a. Turn off all other gas appliances and pilots.
b. Measure time (in seconds) for gas meter test dial to
complete one revolution.
c. Refer to Table IV for cubic ft of gas per hour.
Multiply gas rate (cu ft/hr) x heating value (Btu/cu
ft). Obtain heating value from local gas utility.
e. Measured gas input must not exceed gas input on
unit rating plate.
ea
EXAMPLE:
Btu heating input = Btu/cu ft times cu ft/hr
Heating value of gas = 1070 Btu/cu ft
Time for one revolution of 2-cu-ft dial = 72 sec
Gas rate = 100 cu ft/hr (from Table IV)
Btu heating input = 100 x 1070 = 107,000 Btuh
3. To adjust input rate:
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.
TABLE V—MODEL 398B ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT RATE*
(Tabulated data based on altitude up to 2000 feet.)
Gas SPECIFIC GRAVITY OF NATURAL GAS
Heat 0.54 0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70 0,72
Value Or| Heat ;Or| Heat |Orl Heat |Or| Heat |Or! Heat |Or| Heat |Or! Heat |Ori Heat |Ог| Heat |Or! Heat
a (Btu/cu ft) No. High/Low Мо. High/Low No. High/Low No. High/Low No. High/Low |No.| High/Low No. High/Low |No.| High/Low ¡No.| High/Low No. High/Low
. 900 43| 3.5/1.7 |43| 3.6/1.7 ¡43| 3.7/1.8 142| 3.21.5 |42| 3.31.6 |42| 3.4/1.6 142| 3.5/1.7 [42] 3.6/1.7 |42| 3.74.8 142| 3.8/1.8
| 41| 3.2/1.5 |41| 3.3/1.6 [41] 3.4/1.6
915 44| 3.8/1.8 |43) 3.5/1.7 143! 3.6/1.7 |43| 3.7/1.8 !42| 3.2/1.5 1421 3.3/1.6 |42i 3.4/1.6 |42! 3.5/1.7 142| 3.6/1.7 |42| 3.7/1.8
43| 3.4/1.6 | 41| 3.21.5 !41| 3.3/1.6
930 441 3.7/1.8 |43| 3.4/1.6 143] 3.5/1.7 |43| 3.6/1.7 |43! 3.7/1.8 |42| 3.2/1.5 |42| 3.3/1.6 [42] 3.4/1.6 |42| 3.5/1.7 142! 3.6/1.7
43| 3.3/1.6 41| 3.2/1.5
945 44| 3.6/1.7 |44; 3.7/1.8 |43| 3.41.6 |43| 3.5/1.7 [43] 3.6/1.7 (48) 3.7/1.8 |42| 3.2/1.5 [42] 3.3/1.6 142] 3.4/1.6 142| 3.4/1.6
43| 3.2/1.5 |43] 3.3/1.6
960 44| 3.5/1.6 |44| 3.6/1.7 |44| 3.8/1.8 |43| 3.4/1.6 |431 3.5/1.7 |43| 3.6/1.7 |43! 3.7/1.8 la2| 3.21.5 |42| 3.2/1.5 |42] 3.3/1.6
43! 3.2/1.5 |43| 3.3/1.6
975 44| 3.4/1.6 |44| 3.5/1.7 1441 3.6/1.7 |44) 3.8/1.8 143| 3.49.6 |43| 3.5/1.7 143| 3.6/7.7 148] 3.74.8 |43| 3.8/1.8 143) 3.2/1.5
43| 3.2/1.5 143| 3.3/1.6
990 44| 3.3/1.5 |44) 3.4/1.6 |44| 3.5/1.7 |44| 3.6/1.7 |44;) 3.8/1.8 143] 3.4/1.6 |43| 3.5/1.7 |43| 3.6/1.7 143| 3.7/1.8 [43] 3.8/7.8
43! 3.2/1.5 143| 3.31.5 |.
1005 . |441 3.2/1.5 |44| 3.3/1.6 [44] 3.4/1.6 (44| 3.5/1.7 |44| 3.7/1.7 |44| 3.8/1.8 |43| 3.49.6 (43| 3.51.7 143] 3.69.7 \a3| 3.7/1.8
43! 3.2/1.5 143] 3.3/1.6
1020 45| 3.8/1.8 |44) 3.21.5 |44| 33/16 |44| 3.41.6 |44| 3.6/1.7 |44| 3.7/1.7 144| 3.8/1.8 |43| 3.4/1.6 |43| 35/17 143| 36/17
43| 3.2/1.5 [43] 3.3/1.6
1035 45| 3.7/1.7 |45| 3.8/1.8 |44) 3.2/1.5 |44| 3.3/1.6 |44| 3.4/1.6 |44| 3.6/1.7 |44! 3.7/1.7 \44| 38118 |43] 3.4/1.6 [438] 3.5/1.7
; 143; 3.2/1.5 |43| 3.3/1.6 o
1050 46| 3.7/1.8 |45| 3.7/1.8 |45| 3.8/1.8 144! 3.2/1.5 |44| 3.4/1.6 |44| 3.5/1.6 144| 3.6/1.7 144| 3.7/1.8 |44! 38/18 |[43! 3.4/1.6
45! 3.5/1.7 | | 43; 3.2/1.5 |43| 3.3/1.6
| 1065 46| 3.6/1.7 146! 3.8/1.8 145] 3.7/1.8 |45| 3.8/1.8 144! 3.3/1.6 [44] 3.4/1.6 144! 3.5/1.7 |44| 3.6/1.7 144] 37/18 |44] 38/18
| 45| 3.4/1.6 |145¡ 3.6/1.7 44! 3.2/1.5 43; 3.2/1.5 [43) 3.3/1.6
| | ; 1080 46| 3.51.7 |46| 3.7/1.7 |46| 3.8/1.8 |45| 3.7/1.8 |44| 3.2/1.5 |44] 3.3/1.6 |44| 3.4/1.6 |44| 3.5/1.7 |44| 3.6/1.7 |44! 3.7/1.8
| 45| 3.41.6 |45| 3.5/1.7 |45 3.6/1.7 43| 3.2/1.5
| 1095 46| 3.4/1.6 |46| 3.6/1.7 ¡46| 3.7/1.8 146| 3.8/1.8 (45; 3.71.8 |44) 3.2/1.5 |44| 3.3/1.6 |44| 3.4/1.6 |44| 3.5/1.7 |44| 3.6/1.7
45| 3.3/1.6 145| 3.4/1.6 |45| 3.5/1.7 145| 3.6/1.7
1110 46; 3.3/1.8 |46| 3.5/1.6 |46| 3.6/1.7 |46| 3.7/7.8 |46| 3.8/1.8 145| 3.8/1.8 |44! 3.2/1.5 |44| 3.3/1.6 144| 3.4/7.6 |44| 3.5/1.7
45| 3.2/1.5 |45! 3.3/1.6 45| 3.4/1.6 |45| 3.5/1.7 |45¡| 3.6/1.7
1125 47| 3.7/1.6 !46| 3.4/1.6 ¡46| 3.5/1.7 146) 3.6/1.7 146| 3.74.8 |45| 3.7/1.7 |45| 3.8/1.8 [44] 3.2715 |44! 331.6 |44! 3.4/1.6
46; 3.2/1.5 145| 3.2/1.5 |45| 3.3/1.6 ¡45| 3.4/1.6 |45| 3.5/1.7 a, |
1140 47| 3.6/1.7 |47| 3.71.8 146] 3.4/1.6 |46| 3.5/1.7 1|46| 3.6/1.7 146] 3.7/1.8 145) 3.7/1.8 145| 3.8/1.8 [44] 3.2/1.5 [44] 3.3/1.6
46| 3.2/1.5 |46! 3.3/1.6 (45) 3.2/1.5 145! 3.3/1.6 (45! 3.5/1.6 145] 3.6/1.7
1155 471 3.5/1.7 ¡47| 3.6/1.7 |47| 3.71.8 146| 3.4/1.6 |46| 3.5/1.7 |46| 3.7/1.7 |46| 3.8/1.8 |45| 3.7/1.8 145| 3.8/1.8 |44] 3.2/1.5
46| 3.2/1.5 |46| 3.3/1.6 |45| 3.3/1.6 |45| 3.4/1.6 |45| 3.5/1.7 145! 3.6/1.7
1170 47| 3.4/1.6 |47! 3.5/1.7 |47| 3.6/11.7 |46] 3.3/1.6 !46| 3.4/1.6 ¡46! 3.6/1.7 |46| 3.7/1.7 |46| 3.8/1.8 l45| 37/18 |45] 38/18
46| 3.2/1.5 ¡45| 3.2/1.5 145| 3.31.6 |45| 3.4/1.6 145| 3.5/1.7 |45| 3.6/1.7
1185 48| 3.8/1.8 |47| 3.4/1.6 |47) 3.6/1.7 ¡47| 3.7/1.8 |46| 3.4/1.6 |46| 3.5/1.7 |46! 3.6/1.7 |46| 3.7/1.8 [46] 3.8/1.8 145! 3.7/1.8
47| 3.3/1.6 46; 3.3/1.6 |45! 3.2/1.5 145! 3.3/1.6 |45| 3.4/1.6 145! 3.5/1.7 145| 3.6/1.7
*The correct input rate per burner is: high-heat 21,000 Btuh; low-heat 14,500 Btuh.
_ 7
a. Remove burner enclosure front and low-fire regula-
tor adjustment seal cap. See Figure 10.
b. Put setup switch No. 2 on microprocessor control
board in ON position to provide continuous low-fire
operation. See Figure 11.
c. Turn Allen-head adjustment screw either counter-
clockwise (out) to decrease low-input rate or clock-
wise (in) to increase low-input rate. DO NOT set
manifold pressure less than 1.4 or more than 1.8
inches we for natural gas. If manifold pressure can-
not be obtained with these settings, replace the
main burner orifices within one size of that pres-
ently installed.
NOTE: If orifice hole appears damaged or it is suspected to
have been redrilled, check the orifice hole with the correct
size numbered drill. Never redrill an orifice. A burr-free and
squarely aligned orifice hole is essential for proper flame
characteristics.
d. Return setup switch No. 2 on microprocessor con-
trol board to OFF position and put setup switch No.
3 to the ON position to provide continuous high-fire
operation. See Figure 11.
e. Replace low-fire regulator adjustment seal cap, and
remove high-fire regulator adjustment seal cap. See
Figure 10.
£ Turn Allen-head adjustment screw either counter-
clockwise (out) to decrease high-input rate or clock-
wise (in) to increase high-input rate. DO NOT set
BURNER FLAME
PILOT FLAME
BURNER
MANIFOLD
A84076
Il И
TERMINALS —>|_®© © ® © |
HOOK-AROUND
et VOLT/AMMETER
FROM UNIT LOW-VOLTAGE
TERMINAL BLOCK OF FURNACE
5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT SETTING
EXAMPLE:
A80201
Figure 9—Amp Draw Check With Ammeter
manifold pressure less than 3.2 or more than 3.8
inches we for natural gas. If manifold pressure can-
not be obtained with these settings, replace the
main burner orifices within one size of that pres-
ently installed.
g. Return setup switch No. 3 on microprocessor con-
trol board to OFF position and replace high-fire reg-
ulator adjustment seal cap.
h. Replace burner enclosure front and recycle furnace ,
before measuring adjusted gas input using method
outlined in step 1 or 2.
4. Look through sight glass in burner enclosure and check
burner and pilot flame. The main burner flame should
be clear blue, almost transparent. The pilot flame
should be well defined. See Figure 8.
5. High Altitude
Input ratings are for altitudes up to 2000 feet. Ratings
for altitudes over 2000 feet must be 4% less for each
1000 feet above sea level. To obtain the altitude
adjusted rating, adjust the manifold pressure and
replace the main burner orifices as needed. In Canada,
from 2000 to 4500 feet above sea level, derate the unit
10%.
D. Temperature Rise
The furnace must not be operated outside the range of tem-
LOW-FIRE
ADJUSTMENT
ALLEN SCREW
HIGH" FIRE
ADJUSTMENT
ALLEN SCREW
A88322
Figure 10—Gas Valve
ACCESSORY
LED FAULT LEADS
DISPLAY
ACCESSORY
HOOKUP
RELAY
SETUP
SWITCHES
| COOLING AIR-FLOW
ADJUSTMENT
BLOWER OFF-TIME
ADJUSTMENT
A87335
Figure 11— Microprocessor Control Center
perature rise specified on the unit rating plate. Determine
the air temperature rise as follows:
1. Place thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not ‘‘see”’
heating element 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 deter-
mine air temperature rise. |
NOTE: Temperature rise can be determined for low-fire
operation by placing setup switch No. 2 on microprocessor
control board in the ON position. For high-fire operation
return setup switch No. 2 to the OFF position and place
setup switch No. 3 in the ON position. DO NOT forget to
return setup switches to OFF position upon completion. See
Figure 11.
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 tem-
perature rise is outside this range do the following:
a. Check gas input for low- and high-fire operation.
b. Check derate for altitude if applicable.
c. Check all return and supply ducts for excessive
restrictions causing static pressure greater than 0.5
inch we.
d. Check to make sure bypass humidifier switch
(marked BPH) on microprocessor control board is in
ON position when a bypass humidifier has been
installed. See Figure 11.
e. Check “Troubleshooting Guide for Deluxe Gas-
Fired Condensing Furnace.”
E. Thermostat Heat Anticipator Adjustment
The thermostat heat anticipator must be set to match the
amp draw of the components in the R-W circuit while oper-
ating in low heat. Accurate amp draw measurements can be
obtained at the thermostat subbase terminals R & W.
Figure 9 illustrates an easy method of obtaining these
measurements. The amp reading should be taken while the
furnace is operating in the low-heat mode. To operate the
furnace in low heat reset the power and energize the thermo-
stat, low heat will last for 6 minutes which should be suffi-
cient time to obtain the amp draw readings.
F. Safety Check of Limit Control
The control shuts off the combustion gas supply and ener-
gizes the circulating-air blower motor if the furnace
overheats.
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. As soon as
the limit control functions, the return-air opening should be
ACCESSORY
RELAY CONTACTS
120-VOLT 0 —————— STA ELECTRONIC
POWER SUPPLY COM NO AIR CLEANER
= ee ee ee ee ee ee ee ee ee ee ee
——— FIELD LOW - VOLTAGE WIRING
—— FACTORY WIRING
— —- FIELD HIGH - VOLTAGE WIRING
QUICK CONNECTS - FIELD CONNECTIONS
Figure 12—Electronic Air Cleaner ^87330
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 “fail-
safe” if there is a restricted circulating air supply or motor
failure. If the limit control does not function during this
test, the cause must be determined and corrected.
G. Safety Check of Flow-Sensing Switch
This control proves operation of the draft inducer.
Check switch operation as follows:
1. Turn off 115-volt power to furnace.
2. Remove control access panel and disconnect ECM
inducer motor leads at 6-circuit connector on ECM
inducer control box.
3. Turn on 115-volt power to furnace.
4. Set thermostat to “call for heat.” When the flow-sens-
ing switches are functioning properly, fault 42 will
flash on the LED fault display 10 seconds after the
thermostat switch is closed. If either fault 31 or 32 is
flashed when the ECM inducer motor is disconnected,
the furnace will shut itself down immediately. Deter-
mine the reason the flow-sensing switches did not func-
tion and correct the condition.
5. Turn off 115-volt power to furnace.
6. Reconnect inducer motor leads, reinstall control access
panel, turn on 115-volt power supply, and reset thermo-
stat to desired temperature.
Vill. ACCESSORY HOOKUP (Electronic Air Cleaner and/
or Humidifier)
An isolated set of normally open contacts (not connected to
24V AC or 120VAC) are available to operate any accessory
such as an electronic air cleaner or humidifier. The relay
contact will close whenever the blower motor is operat-
ing. These contacts are accessible by two 1/4-inch quick-
connects mounted directly on the relay as shown in Figure
11. Wire leads with quick-connects have been supplied as
ACCESSORY
RELAY CONTACTS
120-VOLT AO "=== HH MARS ELECTRONIC
POWER SUPPLY _____ | COM. NO AIR CLEANER
j
Lux) 124 МАС 40 VA
=== _ | TRANSFORMER
CA — —
HUMIDIFIER
——— FIELD LOW - VOLTAGE WIRING
—— FACTORY WIRING
——— FIELD HIGH - VOLTAGE WIRING
QUICK CONNECTS - FIELD CONNECTIONS
A87328
Figure 13—Electronic Air Cleaner and Humidifier
ACCESSORY
RELAY CONTACTS
24- VOLT
POWER SUPPLY COM NO HUMIDIFIER
— i ee ee eee ee ee
——— FIELD LOW - VOLTAGE WIRING
—— FACTORY WIRING
——— FIELD HIGH - VOLTAGE WIRING
QUICK CONNECTS - FIELD CONNECTIONS
Figure 14—Humidifier eee
—9—
THE FOLLOWING TABLE CAN BE USED TO KEEP ALOG OF ANY SERVICES PERFORMED.
DATE
TECHNICIAN
COMPANY
SERVICE PERFORMED
FAULT HISTORY
Carrier Corporation
—12—
Catalog Мо. BDP-3339-812