Bryant 345MAV Installation, Start-Up, And Operating Instructions Manual

installation, start-up, and operating instructions

4-WAY MULTIPOISE

FIXED-CAPACITY

CONDENSING GAS FURNACE

Cancels: II 345M-40-7

AIRFLOW

345MAV

Series F

II 345M-40-8

12-03

UPFLOW

A93040

NOTE: Read the entire instruction manual before starting the installation.

This symbol

→ indicates a change since the last issue.

Table of Contents Page

DIMENSIONAL DRAWING........................................................2

SAFETY CONSIDERATIONS .....................................................3

Clearances to Combustibles......................................................3

CODES AND STANDARDS........................................................4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........5

INTRODUCTION ..........................................................................5

APPLICATIONS............................................................................5

General ......................................................................................5

Upflow Applications.................................................................6

Downflow Applications ............................................................7

Horizontal Left (Supply-Air Discharge) Applications ............9

Horizontal Right (Supply-Air Discharge) Applications ........11

LOCATION..................................................................................12

General ....................................................................................12

Furnace Location Relative to Cooling Equipment ................13

Hazardous Locations...............................................................13

AIR FOR COMBUSTION AND VENTILATION ....................13

General ....................................................................................13

Unconfined Space ...................................................................14

Confined Space .......................................................................14

INSTALLATION .........................................................................15

Leveling Legs (If Desired) .....................................................15

Installation In Upflow or Downflow Applications................17

Installation In Horizontal Applications ..................................17

Air Ducts.................................................................................17

General Requirements .......................................................17

Ductwork Acoustical Treatment .......................................17

Supply Air Connections ....................................................17

Return Air Connections.....................................................18

Filter Arrangement ............................................................18

Bottom Closure Panel........................................................19

Gas Piping..........................................................................19

Electrical Connections ............................................................20

115-v Wiring......................................................................21

24-v Wiring........................................................................21

Accessories ........................................................................22

Venting ....................................................................................22

Removal of Existing Furnaces from Common

Vent Systems .....................................................................22

Combustion-Air and Vent Piping .....................................23

Vent Termination...............................................................31

Multiventing.......................................................................31

—1—

AIRFLOW

HORIZONTAL

LEFT

DOWNFLOW

HORIZONTAL

RIGHT

AIRFLOW

AIRFLOW

Fig. 1—Multipoise Orientations ama

A93041

CERTIFIED

As an ENERGY STAR® Partner, BRYANT Heating & Cooling Systems Company has determined that this product meets the ENERGY STAR® guidelines for energy efficiency.

REGISTERED QUALITY SYSTEM

Condensate Drain....................................................................31

General...............................................................................31

Application.........................................................................33

Condensate Drain Protection.............................................33

START-UP, ADJUSTMENTS AND

SAFETY CHECK...................................................................33

General...............................................................................33

Prime Condensate Trap With Water.................................34

Purge Gas Lines ................................................................34

Sequence of Operation ......................................................34

Heating Mode...............................................................34

Cooling Mode...............................................................35

Continuous Blower Mode ............................................35

Heat Pump Mode .........................................................35

Component Test ...........................................................35

Adjustments .......................................................................36

Set Gas Input Rate .......................................................36

Set Temperature Rise...................................................40

Blower Off Delay (Heat Mode) ..................................41

Set Thermostat Heat Anticipator .................................41

Check Safety Controls.......................................................41

Check Primary Limit Control ......................................41

Check Pressure Switch.................................................41

CHECKLIST......................................................................42

SAFETY CONSIDERATIONS

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.

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.

WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

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.

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

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.

Understand these signal words DANGER, WARNING, CAU-

TION, 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

INSTALLATION

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 may be installed in a manufactured (mobile) home when stated on rating plate and using factory authorized kit.

This furnace may be installed on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below.

This furnace requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC,

PVC-DWV, CPVC, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

LEVEL (0")TO

1/2" MAX

MIN 1/4" TO 1/2" MAX

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 IMPORTANT unit support details on horizontal applications.

FRONT

FRONT

UPFLOW OR

DOWNFLOW

HORIZONTAL

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 building joists, studs, or framing.

§

Ø

Clearance shown is for air inlet and air outlet ends.

120 and 140 size furnaces require 1 inch bottom clearance to combustible materials.

This furnace is approved for UPFLOW, DOWNFLOW and

HORIZONTAL installations.

Clearance arrows do not change with furnace orientation.

† †

0"

B

A

C

K

§

0"

S I

D E

1"

0"

S I

D E

F

A C

E

U

R N

F R

ON

T

F

R

O

N

T

3"

S

E

R V

I

C

E

§

*

MIN

328066-201 REV. A

LIT -TOP

Clearance in inches.

0"

Ø

†

Vent clearance to combustibles 0".

A02248

Fig. 3—Clearances to Combustibles

—2—

—3—

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 345MAV 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 design of this furnace 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.

These furnaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment.

Fig. 4—Return-Air Temperature

A94163

—4—

Installer Packet includes:

Installation, Startup, and Operating Instructions

Service and Maintenance Instructions

User’s Information Manual

Warranty Certificate

Loose Parts Bag includes:

Pressure tube extension

Collector Box or condensate trap extension tube

Inducer housing drain tube

1/2-in CPVC street elbow

Drain tube coupling

Drain tube coupling grommet

Vent and combustion-air pipe support

Condensate trap hole filler plug

Vent and combustion-air intake hole filler plug

Combustion-air pipe perforated disk assembly

Vent Pipe Extension

* ONLY supplied with some furnaces.

Quantity

1

1

1

2

1

1

2

1

2

3

1*

CODES AND STANDARDS

Follow all national and local codes and standards in addition to

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 5.3 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 2, 3, 4, and 9 and national plumbing codes

• CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E, and H.

VII.

ELECTRICAL CONNECTIONS

• US: National Electrical Code (NEC) ANSI/NFPA 70-2002

• CANADA: Canadian Electrical Code CSA C22.1

BLOWER SHELF

CONDENSATE

TRAP (INSIDE)

FURNACE

DOOR

CONDENSATE

TRAP

FURNACE

SIDE

FURNACE

DOOR FURNACE

SIDE

ALTERNATE DRAIN

TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

4

78

FIELD

DRAIN

CONN

26

1 4

SIDE VIEW

1 1 2

FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

4

5

3 4

5

3 4

4

26

1 4

FIELD

DRAIN

CONN

END VIEW

3 4

FRONT VIEW

HORIZONTAL

APPLICATIONS

3 4

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

1

1 2

1

3 4

7 1 8

1 ⁄

4

OD

COLLECTOR BOX TO

TRAP RELIEF PORT

1 ⁄

2

OD

INDUCER HOUSING

DRAIN CONNECTION

5 ⁄

8

OD

COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

1 ⁄

2

-IN. PVC OR CPVC

WIRE TIE

GUIDES

(WHEN USED)

7 8

2

1 4

FRONT VIEW SIDE VIEW

A93026

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.

Fig. 5—Condensate Trap

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 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 345MAV 4-way multipoise, Gas-Fired, Category IV, condensing furnaces are available in model sizes ranging in gas input rates of 40,000 to 120,000 Btuh.

For accessory installation details, refer to applicable installation literature.

APPLICATIONS

2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (for example; DO

NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch metal surface again before touching control or wires.

I.

CAUTION: 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.

GENERAL

Local codes may require a drain pan under

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.

—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)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

CONDENSATE

TRAP

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

DRAIN TUBE

COUPLING (RIGHT

DRAIN OPTION)

A94163

Fig. 6—Factory-Shipped Upflow Tube Configuration

(Shown With Blower Access Panel Removed)

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. 6.)

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 are factory attached to the 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).

—6—

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A94164

Fig. 7—Alternate Upflow Tube Configuration and

Trap Location

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 (factorysupplied 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 condensate trap.

c. Determine appropriate length, cut, and connect tube.

d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube a. Connect relief port tube (green label) to condensate trap.

b. Use smaller diameter tube (factory-supplied in loose parts bag) to extend this tube if required.


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.

—7—

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.


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.


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:








B.

Condensate Trap Tubing


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.

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)

A94165

Fig. 8—Downflow Tube Configuration

(Left-Hand Trap Installation)

(b.) Clamp tube to prevent any condensate leakage.

(2.) Condensate Trap Located on Right Side of Casing

(a.) Install drain tube coupling (factory-supplied in loose parts bag) into collector box drain tube

(blue and white striped label) which was previously plugged.

(b.) Connect larger diameter drain tube (factorysupplied 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 between gas valve and inlet housing 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 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 factorysupplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate trap.

—8—

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

DRAIN TUBE

COUPLING

A94166

Fig. 9—Downflow Tube Configuration

(Right-Hand Trap Installation)

(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) between gas valve and inlet housing behind collector box drain tube.

(b.) Determine appropriate length and cut.

(c.) Connect tube to condensate trap.

(d.) Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure.

C.



D.


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.


Relocate tubes 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 collector box pressure tube (green label) which was previously connected to condensate trap relief port connection.

3. Connect collector box pressure tube (green label) to pressure switch connection labeled "collector box."

4. Use remaining smaller diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch.

5. Route this extended tube (pink label) to condensate trap relief port connection.

6. Determine appropriate length, cut, and connect tube.

7. Clamp tube to relief port connection.

E.



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.


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.


PLUG

CAP

AUXILIARY " J " BOX






4. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.


B.


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 (factorysupplied 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.


COLLECTOR BOX

DRAIN TUBE

(BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040, 060, AND 080 HEATING INPUT FURNACES

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

DRAIN TUBE (BLUE)

Fig. 10—Horizontal Left Tube Configuration

—9—

A00215

COMBUSTION–AIR

INTAKE

A 3-IN. MINIMUM CLEARANCE

TO COMBUSTION-AIR INTAKE

IS REQUIRED.

VENT

30-IN. MIN

WORK AREA

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.

5 3 ⁄ 4

″

MANUAL

SHUTOFF

GAS VALVE

ACCESS OPENING

FOR TRAP

SEDIMENT

TRAP

DRAIN

CONDENSATE

TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING

FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

C.

A96184

2. Inducer Housing Drain Tube

Fig. 11—Attic Location and Working Platform

Modify tube as described below.

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 condensate trap.

2. Use smaller diameter tube (factory-supplied in loose parts bag) to extend tube disconnected in item 1.

3. Route extended tube: c. Determine appropriate length, cut, and connect tube.


a. Behind inducer housing.

b. Between blower shelf and inducer housing.

c. Behind inducer motor bracket.

d. Between inducer motor and pressure switch.

3. Relief Port Tube a. Use smaller diameter tube (factory-supplied in loose parts bag) to extend collector box tube (green label) which was previously connected to the condensate trap.

4. Determine appropriate length, cut, and reconnect tube to pressure switch connection labeled COLLECTOR BOX.

b. Route extended collector box pressure tube to relief port connection on the condensate trap.



E.





F.

Construct a Working Platform

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 11.)

D.


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.


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:

Table 6.)

Vent pipe length is restricted to a minimum of 5 ft. (See

—10—

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

AUXILARY “J” BOX RELOCATED HERE

CONDENSATE

TRAP

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

A00214

NOTE: A 12-in. minimum horizontal pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11 or 38.)

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:

Fig. 12—Horizontal Right Tube Configuration

In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes.

A.


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.









B.



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.


2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER inducer housing drain connection.

—11—

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.



D.


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.


Relocate tubes as described below.


2. Use smaller diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection.

3. 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.

→

LEVEL (0

″

)

TO

1

⁄

2

″

MAX

FRONT FRONT

MIN 1

⁄

4

″

1

TO

⁄

2

″

MAX

UPFLOW OR DOWNFLOW HORIZONTAL

A02146

Fig. 13—Proper Condensate Drainage

—12—

E.



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: Vent pipe length is restricted to a minimum of 5 ft. (See

Table 6.)

NOTE: A 12-in. minimum horizontal pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11 or 38.)

LOCATION

I.

GENERAL

This furnace must:

• be provided with air for combustion, ventilation, and dilution of flue gases in accordance with the NFGC or NSCNGPIC. The furnace MUST NOT be located in a confined space without special provisions for dilution or ventilation air. See AIR FOR

COMBUSTION AND VENTILATION section.

• 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 6.

• 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.

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.)

• be provided with ample space for servicing and cleaning.

Always comply with minimum fire protection clearances shown on the furnace clearance-to-combustibles label.

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 equipment room or space.

32

°

F MINIMUM INSTALLED

AMBIENT OR FREEZE

PROTECTION REQUIRED

A93058

Fig. 15—Freeze Protection

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 or 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.

CAUTION: Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met. Failure to follow this caution will result in intermittent unit operation or performance satisfaction.

III.

HAZARDOUS LOCATIONS

WARNING: When the furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, unit must be installed in accordance with requirements of National Fire Protection

Association, Inc. (See Fig. 16.)

CAUTION: If these furnaces are installed in an unconditioned space where ambient temperatures may be 32°F or lower, freeze protection measures must be taken. (See

Fig. 15.) Failure to follow this caution will result in minor property damage.

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 be adequate to 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—

AIR FOR COMBUSTION AND VENTILATION

I.

GENERAL

Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3, Air for Combustion and

Ventilation, of the NFGC or applicable provisions of the local building codes.

Canadian installations must be in accordance with Section 7.2 of the Air Supply Determination for Central Heating Furnaces,

Boilers, and Hot Water Heaters, and 7.3, Air Supply Openings and

Ducts, of the NSCNGPIC and all authorities having jurisdiction.

CAUTION:

18-IN. MINIMUM

TO BURNERS

Fig. 16—Leveling Legs

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Failure to follow this caution will result in minor unit damage.

A89014 and ventilation openings must be sized the same as for a confined space as defined below. Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room.

III.

CONFINED SPACE

A confined space has a volume of less than 50 cu ft per 1000 Btuh of the total input rating for all appliances installed in that space. A confined space MUST have 2 permanent openings, 1 within 12 in.

of the ceiling, and the other within 12 in. of the floor which freely communicate with an unconfined space or the outdoors. (See Fig.

17 or 18.)

NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area, and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed.

The size of the openings depends upon whether the air comes from outside of the structure or an unconfined space inside the structure.

A.

All Air from Inside the Structure

1. Each opening MUST have at least 1 sq in. of free area per

1000 Btuh of the total input for all equipment within the confined space, but not less than 100 sq in. per opening.

(See Fig. 17.) The minimum dimension of air openings shall not be less than 3 in.

For Example:

COMBUSTION AIR FROM UNCONFINED SPACE

345MAV Furnace

Input Btuh

Free Area per Opening

(Sq In.)

40,000

60,000

80,000

100,000

120,000

100

100

100

100

120

All fuel-burning equipment must be supplied with air for combustion of the fuel. Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space. In addition, a positive seal MUST be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and draft safeguard opening into the circulating air.

CAUTION: The operation of exhaust fans, kitchen ventilation fans, clothes dryers, fireplaces, or other appliances including attic and crawlspace exhaust fans could create a negative air pressure condition at the furnace.

Make-up air must be provided for these devices, in addition to that required by the furnace. Failure to follow this caution will result in intermittent unit operation or performance satisfaction.

The requirements for combustion and ventilation air depend upon whether the furnace is located in a CONFINED or UNCONFINED space.

II.

UNCONFINED SPACE

An unconfined space must have at least 50 cu ft for each 1000

Btuh of total input for all the appliances (such as furnaces, clothes dryers, water heaters, etc.) in the space.

For Example:

MINIMUM FLOOR AREA FOR UNCONFINED SPACE

345MAV Furnace

Input Btuh

40,000

Minimum Sq Ft With

7-1/2 Ft Ceiling

267

60,000

80,000

100,000

120,000

400

533

667

800

If the unconfined space is of unusually tight construction, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors. Combustion

—14—

2. If the building is constructed unusually tight, in addition to the 2 permanent openings that freely communicate with an unconfined space, a permanent opening directly communicating with the outdoors should be provided. This opening shall have a minimum free area of 1 sq in. per 4000 Btuh of total input rating for all equipment in the enclosure.

3. If the furnace is installed on a raised platform to provide a return-air plenum, and return air is taken directly from the hallway or space adjacent to the furnace, all air for combustion must come from outdoors. (See Fig. 18.)

B.

All Air from Outside the Structure

1. If combustion air is taken from outdoors through vertical ducts, the openings and ducts MUST have at least 1 sq in.

of free area per 4000 Btuh of the total input for all equipment within the confined space. (See Fig. 18.)

For Example:

COMBUSTION AIR FROM OUTDOORS THROUGH

VERTICAL DUCTS

345MAV Furnace

Input Btuh


(Sq In.)

Round Pipe

(In. Dia)

40,000

60,000

80,000

100,000

120,000

10.0

15.0

20.0

25.0

30.0

4

5

6

6

7

NOTE: The maximum length of bolt should not exceed 1-1/2 in.

DUCTS

TO

OUTDOORS

PER 4000

BTUH*

SUPPLY

AIR VENT THROUGH ROOF

OR SIDEWALL

12

″

MAX

1 SQ IN.

PER 2000

BTUH*

A

SUPPLY

AIR

D

VENT

THROUGH

ROOF

OR

SIDEWALL

F

12

″

MAX

INTERIOR

HEATED

SPACE

12

″

MAX

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

UNCONFINED

SPACE

3

″

MIN

(FRONT)

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

DUCTS

TO

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

1 SQ IN.

PER 4000

BTUH*

1 SQ IN.

PER 2000

BTUH*

12

″

MAX

B

C

E

G

12

″

MAX

12

″

MAX

12

″

MAX

RETURN AIR

* Minimum opening size is 100 sq. in. with

minimum dimensions of 3-In.

NOTE: Side clearance required as needed for combustion-air pipe and termination, vent pipe, and gas and electrical connections.

A96185

Fig. 17—Confined Space: Air for Combustion and

Ventilation from an Unconfined Space

2. If combustion air is taken from outdoors through horizontal ducts, the openings and ducts MUST have at least 1 sq in.

of free area per 2000 Btuh of the total input for all equipment within the confined space. (See Fig. 18.)

For Example:

COMBUSTION AIR FROM OUTDOORS THROUGH

HORIZONTAL DUCTS

345MAV Furnace

Input Btuh

40,000


(Sq In.)

20.0

Round Pipe

(In. Dia)

6

60,000

80,000

100,000

120,000

30.0

40.0

50.0

60.0

7

8

8

9

RETURN AIR

DUCT

TO

OUTDOORS

*Minimum dimensions of 3-In.

NOTES: 1. Use any of the following

combinations of openings:

A & B C & D D & E F & G

1 SQ IN.

PER 4000

BTUH*

2. Side clearance required as needed for

combustion-air pipe and termination,

vent pipe, and gas and electrical connections.

A96186

Fig. 18—Confined Space: Air for Combustion and

Ventilation from Outdoors

5 ⁄

16

″

1 3 ⁄

4

″

5 ⁄

16

″

1 3 ⁄

4

″

5 ⁄

16

″

3. When ducts are used, they must be of the same crosssectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in. (See Fig. 18.)

INSTALLATION

I.

LEVELING LEGS (IF DESIRED)

When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 19.) Install field-supplied, corrosion-resistant 5/16-in. machine bolts and nuts.

—15—

1 3 ⁄

4

″

1 3 ⁄

4

″

5 ⁄

16

″

Fig. 19—Leveling Legs

A89014

B

A

PLENUM

OPENING

D

FLOOR

C

OPENING

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96283

Fig. 20—Floor and Plenum Opening Dimensions

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 21—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

TABLE 1—OPENING DIMENSIONS (IN.)

FURNACE

CASING

WIDTH

APPLICATION

17-1/2

21

24-1/2

Upflow Applications

Downflow Applications on Non-Combustible Flooring

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






Upflow Applications






Fig. 22—Furnace, Plenum, and Coil

Assembly or Coil Box Installed on a Combustible Floor

PLENUM OPENING

A

16

15-7/8

B

24-1/8

19

15-1/8 19

15-1/2

19-1/2

19-3/8

18-5/8

19

23

22-7/8

22-1/8

22-1/2

19

24-1/8

19

19

19

24-1/8

19

19

19

FLOOR OPENING

C

16-5/8

16-1/2

D

24-3/4

19-5/8

16-3/4 20-3/8

16-1/2

20-1/8

20

20-1/4

20

23-5/8

23-1/2

23-3/4

23-1/2

A96284

20

24-3/4

19-5/8

20-3/8

20

24-3/4

19-5/8

20-3/8

20

—16—

1. Position furnace on its back. Locate and drill a 5/16-in.

diameter hole in each bottom corner of furnace. (See Fig.

19.) Holes in bottom closure panel may be used as guide locations.

2. For each hole, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

NOTE: Bottom closure must be used when leveling legs are used.

See Bottom Closure Panel section.

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.

If Coil Assembly Part No. CD5 or CK5 or Coil Box Part

No. KCAKC is used, install as shown in Fig. 22.

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. 23.)

III.

1. Determine application being installed from Table 1.

2. Construct hole in floor per dimensions specified in Table 1 and Fig. 20.

3. Construct plenum to dimensions specified in Table 1 and

Fig. 20.

4. If downflow subbase (KGASB) is used, install as shown in

Fig. 21.

WARNING: Do not bend duct flanges inward as shown in Fig. 23. This will affect airflow across heat exchangers and may cause limited cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 23.

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. 24.) 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. 24. Dimples are provided for hole locations. (See Fig. 2.)

IV.

AIR DUCTS

A.

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

—17—

PERFORATED

DISCHARGE DUCT

FLANGE

210°

MIN

NO

YES

YES

A93029

Fig. 23—Duct Flanges

Air Conditioning Contractors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) or consult The Air Systems Design Guide-

lines reference tables available from your local distributor. The duct system should be sized to handle the required system design

CFM at the design static pressure.

When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork used.

Seal supply- and return-duct connections to furnace with code approved tape or duct sealer.

Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1-in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See

NFPA 90B or local code for further requirements.

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

B.

Ductwork Acoustical Treatment

Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take-off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of

SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA

90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

C.

Supply Air Connections

UPFLOW FURNACES

Connect supply-air duct to 3/4-in. flange on furnace supply-air outlet. The supply-air duct attachment must ONLY be connected to furnace supply-/outlet-air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

DOWNFLOW FURNACES

Connect supply-air duct to supply-air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used), when installed on non-combustible material. When installed on combustible material, supply-air duct attachment must ONLY be connected to an accessory subbase or factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories

MUST be connected external to furnace main casing.

HORIZONTAL FURNACES

Connect supply-air duct to supply air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

D.

Return Air Connections

The furnace and its return air system shall be designed and installed so that negative pressure created by the air ciculating fan cannot affect another appliance’s combustion air supply or act to mix products of combustion with circulating air, and that the air circulating fan of the furnace, if installed in an enclosure communicating with another fuel-burning appliance not of the direct-vent type, shall be operable only when any door or panel covering an opening in the furnace fan compartment or in a return air plenum on ducts is in the closed position.

A 3-IN. MINIMUM

CLEARANCE TO

COMBUSTION-AIR INTAKE

IS REQUIRED.

COMBUSTION-AIR

INTAKE

WARNING: Never connect return-air ducts to the back of the furnace. Return-air duct connections on furnace side(s) permitted in upflow applications only. A failure to follow this warning could result in fire, personal injury, or death.

UPFLOW FURNACES

The return-air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 2. Bypass humidifier may be attached into unused side return air portion of the furnace casing. DO NOT connect any portion of return-air duct to back of furnace casing.

DOWNFLOW AND HORIZONTAL FURNACES

The return-air duct must be connected to return-air opening provided as shown in Fig. 2. DO NOT cut into casing sides or back to attach any portion of return-air duct. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

E.

Filter Arrangement

CAUTION: Never operate unit without a filter or with blower access panel removed. Failure to follow this caution wil result in intermittent unit operation or performance satisfaction.

VENT

3 ⁄

8

-IN. ROD

ANGLE

IRON OR

EQUIVALENT

5

3

⁄

4

″

ALTERNATE SUPPORT

LOCATION 4-IN. MIN

8-IN. MAX

(B)

(A)

(B) DRAIN

(A)

(B)

(A) ROD LOCATION

USING DIMPLE

LOCATORS

(SEE DIMENSIONAL

DWG FOR

LOCATIONS)

3 /

8

-IN. HEX NUT

& WASHER (4)

REQD PER ROD

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

(A)

NOTES:

(B)

13 /

16

-IN. MAX

ALTERNATE SUPPORT

LOCATION FROM BACK

1. A 1 In. clearance minimum between top of furnace and combustible material.

2. The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage.

3. Bottom side combustion-air entry cannot be used when furnace is installed with hangers as shown.

A96209

Fig. 24—Crawlspace Horizontal Application

—18—

Factory-supplied washable framed filters are shipped in blower compartment. Determine location for filter and relocate filter retaining wire if necessary. See Table 2 to determine correct filter size for desired filter location. Table 2 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings.

CAUTION: Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropriate protective clothing. Failure to follow this caution could result in minor personal injury.

CAUTION: Air delivery above 1800 CFM requires that both sides, a combination of 1 side and bottom, or bottom only of furnace be used for return air. Failure to follow this caution will result in intermittent unit operation or performance satisfaction.

NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 25.

Bottom return-air opening may be used with all 4 orientations.

Filter may need to be cut to fit some furnace widths. Install filter as shown in Fig. 26.

NOTE: Remove and discard bottom closure panel when bottom inlet is used.

F.

Bottom Closure Panel

These furnaces are shipped with bottom enclosure panel installed in bottom return-air opening. This panel MUST be in place when side return air is used.

To remove bottom closure panel, perform following:

1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 27.)

2. Rotate front filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

G.

Gas Piping

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the United States.

Canadian installations must be made in accordance with NSCNG-

PIC and all authorities having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 3 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

TABLE 2—FILTER INFORMATION

FURNACE

CASING

WIDTH (IN.)

17-1/2

21

24-1/2

FILTER SIZE (IN.)*

Side Return Bottom Return

(1) 16 X 25 X 1† (1) 16 X 25 X 1†

(1) 16 X 25 X 1 (1) 20 X 25 X 1†

(1 or 2) 16 X 25 X 1 (1) 24 X 25 X 1†

FILTER TYPE

FRAMED

Cleanable

Cleanable

Cleanable

* Filters may be field modified by cutting filter material and support rods (3) in filters. Alternate sizes can be ordered from your distributor or dealer.

† Factory-provided with furnace.

—19—

CAUTION: Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls. Failure to follow this caution will result in intermittent unit operation or performance satisfaction.

A00217

Fig. 25—Filter Installed for Side Inlet

17 1

⁄

2

-IN. WIDE

CASINGS ONLY:

INSTALL FIELD-SUPPLIED

FILTER FILLER STRIP

UNDER FILTER.

21-IN. WIDE

CASINGS ONLY:

SUPPORT RODS (3)

EXTEND 1/4" ON EACH

SIDE OF FILTER AND

REST ON CASING FLANGE

3

″

24 1 /

2

″

1

″

FILTER

SUPPORT

FILTER

RETAINER

WASHABLE

FILTER

Fig. 26—Bottom Filter Arrangement

A00290

WARNING: Gas valve ON and OFF switch MUST be facing forward or tilted upward. (See Fig. 46.) Failure to follow this warning could result in property damage or death.

CAUTION: If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe shall be installed at furnace gas control valve and extend a minimum of 2 in. outside furnace casing. Failure to follow this caution will result in potential chaffing of flexible gas connection.

WARNING: Never purge a gas line into a combustion chamber. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A failure to follow this warning could result in fire, explosion, personal injury, or death.

WARNING: Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death.

Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight-through section of tee is vertical. Then connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and manual gas shutoff valve. (See Fig. 28.)

BOTTOM

CLOSURE

PANEL

FRONT FILLER

PANEL

Fig. 27—Removing Bottom Closure Panel

A93047

TABLE 3—MAXIMUM CAPACITY OF PIPE

(CU FT PER HR)*

NOMINAL

IRON

PIPE

SIZE

(IN.)

1/2

3/4

1

1-1/4

1-1/2

INTERNAL

DIAMETER

(IN.)

0.622

0.824

1.049

1.380

1.610

10

175

360

680

LENGTH OF PIPE (FT)

20

120

250

465

1400 950

30

97

200

375

40

82

170

320

50

73

151

285

770 660 580

2100 1460 1180 990 900

* For gas pressures of 0.5 psig (14-in. wc) or less, and a pressure drop of

0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 12.2 NFPA

54-2002.

—20—

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance.

WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damege, personal injury or loss of life.

An accessible manual shutoff valve MUST be installed external to furnace casing and within 6 ft of furnace. A 1/8-in. NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve.

NOTE: The gas valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. wc) stated on gas valve. (See

Fig. 46.)

If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff switch located on furnace gas valve and accessible manual shutoff valve before test.

The gas supply pressure shall be within the maximum and minimum inlet pressures marked on the rating plate with the furnace burners ON and OFF.

V.

ELECTRICAL CONNECTIONS

See Fig. 30 for field wiring diagram showing typical field 115-v and 24-v wiring. Check all factory and field electrical connections for tightness.

Field-supplied wiring shall conform with the limitations of 63°F

(35°C) rise.

GAS

SUPPLY

MANUAL

SHUTOFF

VALVE

(REQUIRED)

SEDIMENT

TRAP

UNION

Fig. 28—Typical Gas Pipe Arrangement

A93324

TABLE 4—ELECTRICAL DATA

UNIT

SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

VOLTS—

HERTZ—

PHASE

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

OPERATING

VOLTAGE RANGE

Max*

127

Min*

104

127

127

127

127

127

127

127

127

127

127

104

104

104

104

104

104

104

104

104

104

MAX

UNIT

AMPS

6.1

7.3

6.1

7.1

9.5

7.6

10.0

14.1

10.2

14.8

14.6

UNIT

AMPACITY†

8.4

10.0

8.4

9.8

12.8

10.4

13.4

18.4

13.5

19.3

19.1

MIN

WIRE

SIZE

14

14

14

14

14

14

14

12

14

12

12

MAX WIRE

LENGTH (FT)‡

44

37

44

38

29

36

28

31

27

30

30

MAX FUSE OR

CKT BKR AMPS**

15

15

15

15

15

15

15

20

15

20

20

* Permissible limits of voltage range at which unit will operate satisfactorily.

† Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load amps.

‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

** Time-delay type is recommended.

WARNING: Blower access door switch opens 115-v power to control center. No component operation can occur. Do not bypass or close switch with panel removed.

Failure to follow this warning could result in personal injury or death.

Use a separate, fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace. See Table 4 for wire size and fuse specifications. A disconnecting means must be located within sight from and readily accessible to furnace.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control center fault code indicator light will flash rapidly and furnace will NOT operate.

CAUTION: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw. Failure to follow this caution will result in intermittent unit operation.

WARNING: The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA

70-2002 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death.

A.

115-v Wiring

Before proceeding with electrical connections, make certain that voltage, frequency, and phase correspond to that specified on furnace rating plate. Also, check to be sure that service provided by power supply is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 4 for equipment electrical specifications.

Make all electrical connections in accordance with National

Electrical Code (NEC) ANSI/NFPA 70-2002 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with Canadian

Electrical Code CSA C22.1 or authorities having jurisdiction.

J-BOX RELOCATION

1. Remove 2 screws holding auxiliary J-box. (See Fig. 31.)

2. Rotate J-box 180° and attach box to right side, using holes provided.

CAUTION: If manual disconnect switch is to be mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components.

Failure to follow this caution will result in intermittent unit operation or performance satisfaction.

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

ALUMINUM

WIRE

Fig. 29—Disconnect Switch and Furnace

A93033

CAUTION: Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

(See Fig. 29.) Failure to follow this caution will result in intermittent unit operation or performance satisfaction.

B.

24-v Wiring

Make field 24-v thermostat connections at 24-v terminal block on furnace control. For proper cooling operation, Y wire from thermostat MUST be connected to Y terminal on furnace control, as shown in Fig. 30. The 24-v terminal block is marked for easy connection of field wiring. (See Fig. 32.) The 24-v circuit contains a 3-amp, automotive-type fuse located on furnace control. (See

Fig. 33.) Any electrical shorts of 24-v wiring during installation, service, or maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of identical size (3 amp) and type.

The control will flash code 24 when fuse needs replacement.

NOTE: Use AWG No. 18 color-coded copper thermostat wire for lengths up to 100 ft. For wire lengths over 100 ft, use AWG No.

16 wire.

—21—

FIVE WIRE

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

NOTE 2

W C R

FIELD 24-V WIRING

FIELD 115-, 208/230-, 460-V WIRING

FACTORY 24-V WIRING

FACTORY 115-V WIRING

G Y

THERMOSTAT

TERMINALS FIELD-SUPPLIED

DISCONNECT

208/230- OR

460-V

THREE

PHASE

BLK

WHT

BLK

WHT

GND

115-V FIELD-

SUPPLIED

DISCONNECT

GND

AUXILIARY

J-BOX

W

T

R

O

L

C

O

N

R

G

COM

Y

24-V

TERMINAL

BLOCK

FURNACE

208/230-V

SINGLE

PHASE

GND

NOTE 1

TWO

WIRE

CONDENSING

UNIT

NOTES: 1.

2.

3.

Connect Y-terminal in furnace as shown for proper blower operation.

Some thermostats require a "C" terminal connection as shown.

If any of the original wire, as supplied, must be replaced, use same type or equivalent wire.

ALTERNATE

FIELD

LOCATION

Fig. 30—Typical Heating and Cooling Application Wiring Diagram

FACTORY

INSTALLED

LOCATION

A00212

Fig. 31—Relocating J-Box

C.

Accessories

1. Electronic Air Cleaner (EAC)

Two quick-connect terminals marked EAC-1 and EAC-2 are provided for EAC connection. (See Fig. 33.) These terminals are energized with 115v (1.0-amp maximum) during blower motor operation.

A02174

2. Humidifier (HUM)

A quick-connect terminal (HUM) and screw terminal (C

OM

24v) are provided for 24-v humidifier connection. (See Fig.

26.) HUM terminal is energized with 24v (0.5-amp maximum) After the inducer pre-purge period. (HK42FZoB

Control Board)

NOTE: A field-supplied, 115-v controlled relay connected to

EAC terminals may be added if humidifier operation is desired during blower operation.

VI.

VENTING

The 345MAV Furnaces require a dedicated, (one 345MAV furnace only) sealed vent system. All air for combustion is taken from the area adjacent to furnace, and all flue gases are discharged to outdoor atmosphere.

A.

Removal of Existing Furnaces from

Common Venting Systems

When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the remaining attached appliances. An improperly sized Category

I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, spillage of combustion products into the living space, etc.

—22—

TABLE 5—APPROVED COMBUSTION-AIR AND VENT PIPE, FITTING AND CEMENT MATERIALS

ASTM SPECIFICATION

(MARKED ON MATERIAL)

D1527

D1785

D2235

D2241

D2466

D2468

D2564

D2661

D2665

F438

F441

F442

F493

F628

F656

F891

MATERIAL PIPE FITTINGS SOLVENT CEMENT AND PRIMERS

ABS

PVC

For ABS

PVC

PVC

ABS

For PVC

ABS

PVC

CPVC

CPVC

CPVC

For CPVC

ABS

For PVC

PVC

Pipe

Pipe

—

Pipe

—

—

—

—

—

—

—

Fittings

Fittings

—

Pipe Fittings

Pipe Fittings

—

Pipe

Pipe

—

Pipe

—

Pipe

Fittings

—

—

—

—

—

—

—

—

Solvent

Cement

—

—

—

Solvent

Cement

—

—

—

—

—

Solvent

Cement

—

Primer

—

DESCRIPTION

Schedule-40

Schedule-40

For ABS

SDR-21 & SDR-26

Schedule-40

Schedule-40

For PVC

DWV at Schedule-40 IPS sizes

DWV

Schedule-40

Schedule-40

SDR

For CPVC

Cellular Core DWV at Schedule-40 IPS sizes

For PVC

Cellular Core Schedule-40 & DWV

WARNING:

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1-2002/NFPA

54-2002 or the CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National

Fuel Gas Code, ANSI Z223.1-2002/NFPA 54-2002 and/or CSA B149.1, Natural Gas and Propane Installation Code.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired appliance to their previous conditions of use.

Vent system or vent connectors may need to be resized. For any other applicanes when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size determined in appropriate table in NFGC or NSCNGPIC.

B.

C.

Combustion-Air and Vent Piping

General

WARNING: Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well-ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes. Failure to follow this warning could result in fire, property damage, personal injury, or death.

standards. See Table 5 for approved materials for use in the U.S.A.

See Table 6 for maximum pipe lengths and Fig. 39, 40, and 41 for exterior piping arrangements.

In Canada, construct all combustion-air and vent pipes for this unit of CSA or ULC listed schedule-40 PVC, PVC-DWV or ABS-

DWV pipe and pipe cement. SDR pipe is NOT approved in

Canada.

Vent pipe termination must be installed with adequate clearances to building openings and equipment to comply with national and local codes.

See Table 8 for required clearances.

Combustion-air and vent pipe, fittings, primers, and solvents must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM)

—23—

N TRA

PRINTED CIRCIUT BOARD

HSI

PRINTED CIRCIUT BOARD

11 0 91 8 7 6 5 4 3 2 1

8 E #

RAL

NOT

NEUT

BLW

—24—

ALTITUDE (FT)

0 to 2000

ALTITUDE (FT)

2001 to 3000

ALTITUDE (FT)

3001 to 4000

024040

036040

024060

036060

048060

036080

048080

060080

UNIT SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

UNIT SIZE

048100

060100

060120

UNIT SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT)

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2

NA

NUMBER OF 90° ELBOWS

3 4 5

NA NA NA

70

70

65

70

60

70

60

70

15 10 5 NA

2 Pipe or 2-in

Concentric

PIPE DIA

(IN.)*

1

1-1/2

2

1-1/2

1

5

70

70

20

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2

1-1/2

2

2-1/2

2

2-1/2

3

2-1/2 one disk

3†

3† no disk

PIPE DIA

(IN.)*

1-1/2

2

1–1/2

1

67

70

17

70

10

45

70

10

55

70

5

40

70

70 70 70 70

2

62

70

12

NA

50

70

NA

30

70

NA

35

70

NA

20

70

NA

30

70

NA

20

70

NA

40

NA

35

NA

30

NA

25

70 70 70

NUMBER OF 90° ELBOWS

70

3

57

70

7

4

52

70

NA

5

52

70

NA

NA

30

70

NA

10

70

2 Pipe or 2-in

Concentric 2 70 67 66 61 61

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2

2-1/2

2–1/2

3

3

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1–1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

1

64

70

16

68

46

70

33

70

65

70

49

70

35

70

14

70

70

63

41

70

24

70

58

70

44 30 25 25

70 70 70 70

26

70

9

70

16

70

NA

63

16

70

NA

56

70 70 70


70

2

59

70

3

54

70

4

49

70

5

48

70

6

66

NA

50

11 6 NA NA

62

28

70

15

70

51

70

57

23

70

14

66

44

70

57

22

70

5

61

38

70

6

47

70

NA

61

See notes at end of table

COMBUSTION AIR PIPE

CAUTION: Combustion air must not be taken from inside a structure that is frequently contaminated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household products.

Locate combustion-air inlet as far as possible from swimming pool and swimming pool pump house.

Excessive exposure to contaminated combustion air will result in safety and performance related problems.

NOTE: Furnace combustion-air connections are sized for 2-in.

pipe. The combustion-air pipe will be 2-in. diameter in all installations.

—25—

→

See Table 8 for required clearances.

Furnace combustion-air connection must be attached as shown in

Fig. 34. Combustion-air intake housing plug may need to be relocated in some applications.

Combustion-air pipe must terminate outside of furnace casing with

1 elbow. Orient elbow so that opening faces down for upflow or downflow applications. Orient elbow so that it faces sideways (left or right) for horizontal left or horizontal right applications. (See

Fig. 34.) Maintain a 3-in. minimum clearance between the opening of the combustion-air inlet pipe and any object.

NOTE: All pipe joints must be cemented except attachment of combustion-air inlet pipe to inlet housing connection, since it may be necessary to remove pipe for servicing.

Install combustion air inlet pipe as follows:

1. Assemble combustion-air inlet pipe.

6

43

70

NA

56

13

70

NA

56

31

70

70

NA

20

70

NA

NA

70

NA

20

70

6

NA

55

70

NA

15

70

NA

61

NA

43

70

ALTITUDE (FT)

4001 to 5000‡

ALTITUDE (FT)

5001 to 6000‡

ALTITUDE (FT)

6001 to 7000‡

ALTITUDE (FT)

7001 to 8000‡

TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT) (CONTINUED)

UNIT SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

UNIT SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

UNIT SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

UNIT SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2–1/2

2–1/2

3

3† no disk

4† no disk

1

60

70

15

64

44

1

57

70

14

70

31

70

53

70

60

41

1

53

70

13

70

29

70

42

70

57

38

1

49

66

12

70

27

68

31

70

53

36

66

25

63

20

61

55

36

52

33

48

31

65

17

58

13

56

2

55

70


3 4 5

50

70

45

70

44

70

10 5 NA NA

59

39

58

26

53

21

70

22

70

46

70

2

52

70

9

70 70 70

13

67

40

70

12

62

33

70


3 4

47 42

5

40

70 70 70

NA

57

26

70

NA NA NA

54

23

49

18

70

21

67

35

70

2

48

70

70 70 70

12

62

29

70

11

57

22

70


3 4

43

68

38

67

5

37

66

NA

52

15

70

8 NA NA NA

50

21

45

16

70 68 67 66

2

44

65

7

19

63

24

70

10

58

18

9

53

11

NA

48

NA

70 70


67

3

39

63

4

34

62

5

33

60

NA NA NA

46

19

63

8

53

7

51

41

14

62

7

48

NA

46

52

20

48

17

44

15

40

12

60

NA

43

NA

41

See notes at end of table a. Permanently install perforated disk assembly (factorysupplied in loose parts bag) in combustion-air elbow using RTV or by cementing. (See Fig. 35.)

For 120,000 Btuh size units only: Separate the 2 halves of perforated disk assembly and use only the shouldered disk half.

b. Determine length of straight portion of combustion-air inlet pipe from table in Fig. 35.

c. Cut field-supplied 2-in diameter PVC pipe to determined length.

d. Permanently attach elbow/perforated disk assembly to straight portion of pipe using RTV or by cementing. (See

Fig. 35.)

6

39

70

NA

52

11

70

NA

52

20

70

6

35

70

NA

47

8

70

NA

47

9

70

6

28

59

NA

38

NA

59

NA

38

NA

36

6

32

64

NA

43

6

64

NA

43

NA

62

—26—

TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT) (CONTINUED)

ALTITUDE (FT) UNIT SIZE

024040

036040

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

PIPE DIA

(IN.)*

1-1/2

2

1

46

62

2

41

60


3 4

36 31

5

29

58 56 55

6

24

53

8001 to 9000‡

024060

036060

048060

036080

048080

060080

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

1-1/2

2

2

2-1/2

11

49

33

62

6

44

28

60

NA

42

17

58

NA

37

12

56

NA

35

10

55

NA

34

NA

53

ALTITUDE (FT)

048100

060100

060120

UNIT SIZE

024040

036040

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2-1/2

3

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

23

59

10

35

1

42

57

15

54

NA

30

2

37

55

7

49

NA

25

5

44

NA

20


3 4

32 27

5

25

53 51 49

NA

39

NA

15

NA

34

NA

10

6

20

47

9001 to 10,000‡

024060

036060

048060

036080

048080

060080

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2

2

2-1/2

45

30

57

40

25

55

38

14

53

33

9

51

31

7

49

29

NA

47

048100

060100

060120

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2-1/2

3

4† no disk

21

54

10

13

49

5

5

44

NA

NA

39

NA

NA

34

NA

NA

29

NA

Disk usage-Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag). If one disk is stated, separate 2 halves of perforated disk assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box.

†Wide radius elbow.

‡Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction.

NA-Not Allowed; pressure switch will not make.

NOTES:

1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.

2. Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes.

3. Assume two 45° elbows equal one 90° elbow. Long radius elbows are desirable and may be required in some cases.

4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.

5. The minimum pipe length is 5 ft for all applications.

6. Use 3-in. diameter vent termination kit for installations requiring 4-in diameter pipe.

2. Attach combustion-air inlet pipe.

a. Determine location of combustion-air intake pipe connection to combustion-air intake housing as shown in

Fig. 34 for application.

b. Reposition combustion-air intake housing plug fitting in appropriate unused intake housing connection.

c. Install pipe support (factory-supplied in loose parts bag) into selected furnace casing combustion-air pipe hole.

Pipe support should be positioned at bottom of casing hole.

d. Insert assembled combustion-air inlet pipe into intake housing.

e. Make sure elbow is oriented in an acceptable direction and that the minimum clearance of 3 in. is observed. (See

Fig. 34.) f. Drill a 1/8-in. hole in 2-in. combustion-air inlet pipe using hole in intake housing as a guide.

g. Install a field-supplied No. 6 or No. 8 sheet metal screw into combustion-air pipe.

NOTE: Do not attach combustion-air intake pipe permanently to combustion-air intake housing since it may be necessary to remove pipe for service of igniter or flame sensor.

COMBUSTION-AIR INTAKE HOUSING PLUG

FITTING

The combustion-air intake plug fitting must be installed in unused combustion-air intake housing. This fitting must be attached by using RTV sealant, or by drilling a 1/8-in. hole in fitting, using hole in intake housing as a guide. Install a field-supplied No. 6 or No. 8 sheet metal screw.

NOTE: DO NOT OVERTIGHTEN SCREW. Breakage of intake housing or fitting may cause air leakage to occur.

A plugged drain connection has been provided on this fitting for use when moisture is found in combustion-air intake pipe and combustion box. If use of this drain connection is desired, drill out fitting’s tap plug with a

3/16-in. drill and connect a field-supplied 3/8-in. tube. This tube should be routed to open condensate drain for furnace and A/C (if used), and should be trapped. (See Fig. 36.)

VENT PIPE

NOTE: Furnace vent pipe connections are sized for 2-in. pipe.

Any vent pipe size change should be made outside furnace casing in vertical pipe. (See Fig. 37.) This allows proper drainage of vent condensate.

Determine vent pipe diameter and maximum pipe lengths using

Table 6.

Furnace vent pipe connection must be attached as shown in Fig.

34. Inducer housing alternate vent cap may need to be relocated in some applications.

NOTE: Starting at furnace, slope vent pipe a minimum of 1/4 in.

per linear ft upward to termination(s) with no sags between hangers.

—27—

TABLE 7—MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH (FT) WITH AND WITHOUT INSULATION IN WINTER

DESIGN TEMPERATURE AMBIENT*

FURNACE

SIZE

040

060

080

100

120

WINTER DESIGN

TEMPERATURE

(°F)

20

0

-20

20

0

-20

20

0

-20

20

0

-20

20

0

-20

20

0

-20

20

0

-20

20

0

-20

20

0

-20

MAX PIPE

DIAMETER

(IN.)

1.5

1.5

1.5

2

2

2

2

2

2

2

2

2

2.5

2.5

2.5

2.5

2.5

2.5

3

3

3

3

3

3

4

4

4

WITHOUT

INSULATION

40

38

70

50

28

70

48

30

70

47

28

40

61

37

70

48

23

45

22

10

65

51

28

16

35

20

55

WITH 3/8–IN. OR

THICKER INSULATION†

40

40

70

70

70

70

55

55

70

70

70

40

70

70

70

70

70

70

70

58

70

70

70

70

70

70

55

* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 7.

† Insulation thickness based on R value of 3.5 per in.

CAUTION: When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as described in Table 7 with

Armaflex-type insulation. Failure to follow this caution will result in intermittent unit operation.

EXAMPLE:

An 036080 size furnace located in Indianapolis, elevation

650 ft above sea level, could be installed in an application requiring 3 elbows and 32 ft of vent pipe. Table 4 indicates this application would allow a 2-in. diameter vent pipe. At

0-2000 ft elevation, 2-in. pipe is good for up to 35 ft with

3 elbows. If same installation were in Albuquerque, elevation 5250 ft above sea level, installation would require 2-1/2 in. vent pipe. At 5001- to 6000-ft elevation, 2-in. pipe is allowed for up to 23 ft with 3 elbows, but 2-1/2 in. pipe can be used for up to 70 ft with 3 elbows.

An abandoned masonry chimney may be used as a raceway for a properly insulated and supported vent pipe. Each furnace must have its own vent pipe and be terminated individually, as shown in

Fig. 41.

Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code and the vent or liner manufacturer’s installation instructions. Care must be taken to prevent the exhaust gases from one appliance from contaminating the combustion air of other gas appliances.

WARNING: Vent pipes must be airtight and watertight.

Failure to follow this warning could result in property damage, personal injury, or death.

Install vent pipe as follows:

1. Determine location of vent pipe connection to inducer housing as shown in Fig. 34 for application.

2. Reposition elastomeric (rubber) inducer housing outlet cap and clamp to appropriate unused inducer housing connection. Tighten clamp.

WARNING: Inducer housing outlet cap must be installed and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage.

Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

NOTE: The minimum vent pipe length for these furnaces is 5 ft.

Short pipe lengths (5-8 ft) may discharge water droplets. These droplets may be undesirable, and a 12-in. minimum offset pipe section is recommended to reduce excessive droplets from exiting vent pipe outlet. (See Fig. 38.)

NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 40.

3. Install pipe support (factory-supplied in loose parts bag) into selected furnace casing vent pipe hole. Pipe support should be positioned at bottom of casing hole.

—28—

O

Y

Y

D

V

E

B

V

F

C

FIXED

CLOSED

OPERABLE

B

B

V

B

OPERABLE

FIXED

CLOSED

X

J

B

A

B

X

AIR SUPPLY INLET

H

I

L

K

X

G

V

A

V

M

N

25--24--65--2

V

VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITED

Item

A

B

Clearance Descriptions

Clearance above grade, veranda, porch, deck, balcony, or anticipated snow level

Clearance to a window or door that may be opened

12˝ (30cm) #

Canadian Installation (1)

12˝ (30 cm)

U.S. Installation (2)

C

D

Clearance to a permanently closed window

Vertical clearance to a ventilated soffit located above the terminal within a horizontal distance of 2´(61cm) from the centerline of the terminal

Clearance to an unventilated soffit

6˝ (15 cm) for appliances ≤ 10,000 BTUH (3kW), 12˝ (30 cm) for appliances > 10,000 Btuh (3 kW) and

≤

100,000 Btuh

(30 kW), 36˝ (91 cm) for appliances > 100,000 Btuh (30 kW)

* above the opening.

*

* *

E

F

G

H

*

*

*

*

I

J

Clearance to an outside corner

Clearance to an inside corner

Clearance to each side of the centerline extended above electrical meter or gas service regulator assembly

Clearance to service regulator vent outlet

Clearance to non--mechanical air supply inlet to building or the combustion air inlet to any other appliance

* *

3´ (91 cm) within 15´(4.5 m) above the meter/regulator assembly

3´ (91 cm)

3´ (91 cm) within 15´(4.5 m) above the meter/regulator assembly

*

6˝ (15 cm) for appliances

≤

10,000 BTUH (3kW), 12˝ (30 cm) for appliances > 10,000 Btuh (3 kW) and ≤ 100,000 Btuh

(30 kW), 36˝ (91 cm) for appliances > 100,000 Btuh (30 kW)

6´ (1.83 m)

12˝ (30 cm) +

4´ (1.2 m) below or to the side of opening: 1´(30 cm) above opening.

3´ (91 cm) above if within 10´(3m horizontally)

*

K

L

Clearance to a mechanical air supply inlet

Clearance under a veranda, porch, deck, or balcony

M

N

Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer or water heater vent, or other appliance’s direct vent intake or exhaust.

Clearance to the vent terminal of a dryer vent, water heater vent, or other appliances direct vent intake or exhaust.

Clearance from a plumbing vent stack

*

*

*

*

*

O *

(1.) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

(2.) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

# 18˝ (46 cm) above roof surface

+ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

*

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances shall be in accordance with local installation codes and the requirements of the gas supplier and the

Manufacturer’s installation instructions.

Notes:

1.

The vent for this appliance shall not terminate a. Over public walkways; or b. Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nusiance or hazard or property damage; or c. Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

2.

When locating vent terminations, consideration must be given to prevailing winds, location, and other c onditions which may cause recirculation of the combustiob products of adjacent vents.

Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of the heat exchangers.

A03228

→

Table 8—Other than Direct Vent Termination Clearance

—29—

WARNING: Vent pipe must be installed and fully seated against inducer housing internal stop. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

5. Working from furnace to outside, cut pipe to required length(s).

6. Deburr inside and outside of pipe.

7. Chamfer outside edge of pipe for better distribution of primer and cement.

8. Clean and dry all surfaces to be joined.

NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing.

9. Check dry fit of pipe and mark insertion depth on pipe.

4. Be certain that mating surfaces of inducer housing connection, elastomeric coupling, and 2-in. diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2-in. diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it bottoms on the internal stop. Tighten both clamps to secure the pipe to inducer housing. Tighten the clamp screws to 15 in.-lb. of torque.

VENT EXTENSION PIPE

Some furnaces are supplied with a PVC vent extension pipe

(2-in. diameter by 12-in. long). This pipe has a built-in channel to assist vent condensate disposal. When this vent extension pipe is supplied, it must be used to connect the field vent pipe to furnace inducer housing on ALL upflow

NOTE: It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint.

10. After pipes have been cut and preassembled, apply generous layer of cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat.

11. While cement is still wet, twist pipe into socket with 1/4 turn. Be sure pipe is fully inserted into fitting socket.

12. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint.

13. Handle pipe joints carefully until cement sets.

and downflow applications.

NOTE: See label on vent extension pipe for proper installation.

This pipe may be shortened if an elbow is used to connect vent extension tube to field-installed vent pipe.

BLOWER OFF-DELAY

TWINNING AND/OR

COMPONENT TEST

TERMINAL

14. Support vent piping a minimum of every 5 ft (3 ft for

SDR-21 or -26 PVC) using perforated metal hanging strap.

15. Slope vent pipe downward toward furnace a minimum of

1/4 in. per linear ft with no sags between hangers.

J2 JUMPER

BLOWER OFF-DELAY

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

24-V THERMOSTAT

TERMINALS

TRANSFORMER 24-VAC

CONNECTIONS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

TEST/TWIN

HUM

0.5 AMP@24VAC

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

COOL

HEAT

SPARE-1 SPARE-2

BLOWER SPEED

SELECTION TERMINALS

SPARE-1

SPARE-2

1-AMP@

EAC-1

115VAC

PR-1

PL2 1

115 VAC (L1) LINE

VOLTAGE CONNECTION

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

Fig. 33—Control Center

—30—

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A02100

16. Use appropriate methods to seal openings where vent pipe passes through roof or sidewall.

HOUSING

PLUG

3/8

″

ID TUBE

COMBUSTION–AIR

INTAKE HOUSING

BURNER

BOX

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

COMBUSTION-

AIR

VENT

AIR

FLOW

COMBUSTION-

AIR

VENT

VENT

VENT

AIR

FLOW

UPFLOW

COMBUSTION-

AIR

VENT

HORIZONTAL-LEFT DISCHARGE

COMBUSTION-

AIR

AIR

FLOW

COMBUSTION-

AIR

DOWNFLOW

COMBUSTION-

AIR VENT

AIR

FLOW

HORIZONTAL-RIGHT DISCHARGE

A96188

CAUTION: Make sure there is adequate clearance (3-in.

minimum) to any fixed or loose objects in order to ensure an adequate combustion-air supply. Failure to follow this caution will result in intermittent unit operation or performance satisfaction.

Fig. 34—Combustion-Air and Vent Pipe Connections

FIELD-SUPPLIED

2-IN. DIAMETER

PVC 90

°

ELBOW

FIELD-SUPPLIED

2-IN. DIAMETER

PVC PIPE

3/16

″

DRILL

COMBUSTION–

AIR PIPE

4

″

MIN

TRAP

TO OPEN

DRAIN

A96190

Fig. 36—Air Intake Housing Plug Fitting Drain

D.

Extended Exposed Sidewall Pipes

Sidewall vent pipe termination may be extended beyond area shown in Fig. 40 and in outside ambient by insulating pipe as indicated in Table 7.

1. Determine vent pipe diameter, as stated above, using total pipe length and number of elbows.

2. Find appropriate temperature for your application and furnace model using winter design temperature (used in load calculations).

3. Determine required insulation thickness for exposed pipe lengths.

NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 6.

E.

Vent Termination

Vent pipe must terminate either through roof or sidewall. See

Table 8 for required clearances. See Fig. 39, 40, and 41 for exterior piping arrangements.

F.

Multiventing

When 2 or more 345MAV Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 345MAV furnaces.

VII.

CONDENSATE DRAIN

A.

General

Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be

RELOCATED for use in DOWNFLOW and HORIZONTAL applications.

A

FURNACE

COMBUSTION-AIR DISC

(FACTORY-SUPPLIED IN

LOOSE PARTS BAG)

A96211

LENGTH OF STRAIGHT PIPE PORTION OF

COMBUSTION-AIR INLET PIPE ASSEMBLY (IN.)

CASING WIDTH

17-1/2

21

24-1/2

A

8-1/2

±

1/2

10-1/2

±

1/2

12

±

1/2

Fig. 35—Combustion-Air Inlet Pipe Assembly

—31—

NOT IN

HORIZONTAL

SECTION

PIPE DIAMETER

TRANSITION IN

VERTICAL SECTION

A93034

Fig. 37—Vent Pipe Diameter Transition Location and

Elbow Configuration

12

″

MIN

12

″

MIN

VENT PIPE

VENT PIPE

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

VENT PIPE

12

″

MIN

12 ″ MIN

VENT PIPE

VERTICAL TO ROOF VERTICAL TO SIDEWALL

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.

A96189

Fig. 38—Short Vent (5 to 8 Ft) System

Condensate trap MUST be used for all applications.

An external trap is not required when connecting the field drain to

CAUTION: Unit must not be installed, operated, and this condensate trap.

then turned off and left in an unconditioned structure during cold weather when temperature drops to 32

The field drain connection (condensate trap or drain tube coupling) degrees F and below unless drain trap and drain line have is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube connection.

adequate freeze protection. See Service and Maintenance

Instructions for winterizing procedures. (See Fig. 15.)

Drain pipe and fittings must conform to ANSI standards and

Failure to follow this caution will result in intermittent

ASTM D1785, D2466 or D2846. CPVC or PVC cement must unit operation.

conform to ASTM D2564 or F493. Primer must conform to ASTM

F656. In Canada, use CSA or ULC listed schedule 40 CPVC or

PVC drain pipe, fittings, and cement.

When a condensate pump is required, select a pump which is approved for condensing furnace applications. To avoid condensate spillage, select a pump with an overflow switch.

OVERHANG OR ROOF

VENT

12

″

MINIMUM

ROOF

90

°

VENT

MAINTAIN 12-IN. MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL.

MAXIMUM OF 24 IN.

ABOVE ROOF.

Fig. 39—Roof Termination (Preferred)

A96191

—32—

MAINTAIN 12-IN.

CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

A96192

Fig. 40—Sidewall Termination with 2 Elbows (Preferred)

Furnace condensate is mildly acidic, typically in the pH range of

3.2 to 4.5. Due to corrosive nature of unneutralized condensate, a condensate pH neutralizing filter may be desired. Check with local authorities to determine if a pH neutralizer is required.

B.

Application

The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, fieldsupplied trap prior to the furnace drain connection. All drain connections (furnace, A/C, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment’s drain.

See Fig. 42 for example of possible field drain attachment using

1/2-in. CPVC or PVC tee for vent and A/C or humidifier drain connection.

Outdoor draining of the furnace is permissible if allowed by local codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining.

WARNING: Caution should be taken to prevent draining where slippery conditions may cause personal injuries. Excessive condensate draining may cause saturated soil conditions which may result in damage to plants.

C.

Condensate Drain Protection

Freezing condensate left in condensate trap and drain line may cause cracks, and possible water damage may occur. If freeze protection is required, use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40°F self-regulating, shielded, and waterproof heat tape. See Installation Instructions supplied with accessory or heat tape manufacturer’s recommendations.

1. Fold heat tape in half and wrap on itself 3 times.

2. Locate heat tape between sides of condensate trap back.

(See Fig. 43.)

3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig.

43.)

4. Wrap field drain pipe with remaining heat tape, approximately 1 wrap per ft.

5. When using field-supplied heat tape, follow heat tape manufacturer’s instructions for all other installation guidelines.

OVERHANG OR ROOF

START-UP, ADJUSTMENTS AND SAFETY CHECK

I.

GENERAL

1. Furnace must have a 115-v power supply properly connected and grounded. Proper polarity must be maintained for correct operation.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control center fault indicator light will flash rapidly and furnace will not operate.

2. Thermostat wire connections at terminals R, W, G, and Y must be made at 24-v terminal block on furnace control center.

3. Natural gas service pressure must not exceed 0.5 psig

(14-in. wc), but must be no less than 0.16 psig (4.5-in. wc).

4. Blower access panel must be in place to complete 115-v electrical circuit to furnace.

OPEN STAND

PIPE FOR

A/C OR

HUMIDIFIER

DRAIN

TEE

TO OPEN

DRAIN

Fig. 42—Example of Field Drain Attachment

A94054

CONDENSATE TRAP

VENT

12

″

MINIMUM

6-IN. MINIMUM

CLEARANCE BETWEEN

WALL AND END OF VENT

PIPE.

10-IN. MAXIMUM PIPE LENGTH

WIRE TIE(S)

MAINTAIN 12-IN.

CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

A96210

Fig. 41—Sidewall Termination with Straight Pipe

—33—

HEAT TAPE

(3 WRAPS MINIMUM)

Fig. 43—Condensate Trap Heat Tape

A93036

CAUTION: These furnaces are equipped with a manual reset limit switch in burner box. This switch will open and shut off power to gas valve if an overheat condition

(flame rollout) occurs in burner enclosure. Correct inadequate combustion-air supply or improper venting condition and reset switch. DO NOT jumper this switch.

Failure to follow this caution will result in minor unit operation or performance satisfaction.

Before operating furnace, check flame rollout manual reset switch for continuity. If necessary, press button to reset switch.

II.

PRIME CONDENSATE TRAP WITH WATER

CAUTION: Condensate trap must be PRIMED or proper draining may not occur. The condensate trap has 2 internal chambers which can ONLY be primed by pouring water into the inducer drain side of condensate trap.

Failure to follow this caution will result in minor unit operation or performance satisfaction.

1. Remove upper inducer housing drain connection cap. (See

Fig. 44.)

2. Connect field-supplied 1/2-in. ID tube to upper inducer housing drain connection.

3. Insert field-supplied funnel into tube.

4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 45.)

5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp.

III.

PURGE GAS LINES

WARNING: Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. Failure to follow this warning could result in fire, explosion, personal injury, or death.

IV.

SEQUENCE OF OPERATION

If not previously done, purge lines after all connections have been made and check for leaks.

Using the schematic diagram in Fig. 32, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

CAUTION: Furnace control must be grounded for proper operation, or control will lock out. Control is grounded throug green/yellow wire connected to gas valve and burner box screw. Failure to follow this caution will result in intermittent unit operation.

NOTE: If a power interruption occurs during a call for heat (W), the control will start a 90-second blower-only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The red LED light will flash code 12 during the

90-second period, after which the LED will be ON continuous, as long as no faults are detected. After the 90-second period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot-surface igniter HSI, and gas valve GV.

—34—

Fig. 44—Inducer Housing Drain Cap

A99118

A99119

Fig. 45—Filling Condensate Trap

1. Heating

(See Fig. 30 for thermostat connections.)

The wall thermostat

″ calls for heat

″

, closing the R to W circuit. The furnace control performs a self-check, verifies the pressure switch contacts PRS are open, and starts the inducer motor IDM.

a. Inducer Prepurge Period- As the inducer motor IDM comes up to speed, the pressure switch contacts PRS close, 24 vac power is supplied for a field installed humidifier at the HUM terminal and the control begins a

15-second prepurge period.

b. Igniter Warm-Up- At the end of the prepurge period, the Hot-Surface Igniter HSI is energized for a 17-second igniter warm-up period.

c. Trial-for-Ignition SequenceWhen the igniter warm-up period is completed, the main gas valve relay contacts GVR close to energize the gas valve GV, the gas valve opens. The gas valve GV permits gas flow to the burners where it is ignited by the Hot Surface Igniter

HSI. Five seconds after the GVR closes, a 2-second flame period begins. The HSI igniter will remain energized until the flame is sensed or until the 2-second flame proving period begins.

d. Flame-Proving- When the burner flame is proved at the flame-proving sensor electrode FSE, the furnace control

CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV, and the control CPU will repeat the ignition sequence for up to three more Trials-For-

Ignition before going to Ignition-Lockout. Lockout will

be reset automatically after three hours, by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W, G, R, etc.)

If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM until flame is no longer proved.

e. Blower-On Delay- If the burner flame is proven, the blower motor is energized on HEAT speed 66 seconds after the gas valve GV is energized.

Simultaneously, the electronic air cleaner terminal

EAC-1 is energized and remains energized as long as the blower motor BLWM is energized.

f. Blower-Off Delay- When the thermostat is satisfied, the

R-to-W circuit is opened, de-energizing the gas valve

GV, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 15-second post-purge period.

The blower motor BLWM and air cleaner terminal

EAC-1 will remain energized for 90, 120, 150, or 180 seconds (depending on the blower-OFF delay selection).

The furnace control CPU is factory-set for a 120-second blower-OFF delay.

2. Cooling Mode

(See Fig. 30 for thermostat connections)

The thermostat closes the R-to-G-and-Y circuits. The

R-to-Y circuit starts the outdoor unit, and the R-to-G-and-Y circuits start the furnace blower motor BLWM on COOL speed.

The electronic air cleaner terminal EAC-1 is energized with

115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds. Cut jumper J2 to reduce the cooling off-delay to 5 seconds. (See Fig. 33.)

—35—

3. Continuous Blower Mode

When the R-to-G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous-blower speed (same as HEAT speed). Terminal EAC-1 is energized as long as the blower motor BLWM is energized.

During a call for heat, the blower BLWM will stop during igniter warm-up (17 seconds), ignition (7 seconds), and blower-ON delay (66 seconds), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at HEAT speed.

In heating, the furnace control CPU will continue running the blower motor BLWM at HEAT speed after the selected blower-OFF delay period is completed.

When the thermostat

″ calls for cooling

″

, the blower motor

BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back HEAT speed. Jumper J2 can be cut to reduce the cooling off-delay to 5 seconds. (See Fig. 31.)

When the R-to-G circuit is opened, the blower motor

BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

4. Heat Pump

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the

R-to-W-and-Y or R-to-W-and-Y-and-G circuits are energized the furnace control CPU will continue to turn on the blower motor BLWM at HEAT speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HEAT speed. When the W input signal disappears, the furnace control begins a normal inducer post-purge period and the blower switches to COOL speed after a 3 second delay. If the R-to-W-and-Y-and-G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower-OFF delay period. If the

R-to-W-and-Y signals disappear, leaving the G signal, the blower motor BLWM will continue running the blower motor BLWM at HEAT speed after the selected blower-

OFF delay period is completed.

A.

Component Test

NOTE: The furnace control component test allows all components to run for a short time; except the gas valve and humidifier terminal HUM are not energized for safety reason. The EAC-1 terminal is energized when the blower is energized. This feature helps diagnose a system problem in case of a component failure.

The component test feature will not operate if any thermostat signal is present and the control and not until all time delays are completed.

NOTE: Record the status code BEFORE opening the blower access door and before shutting off power to the furnace. Opening the blower access door will open the blower door switch and shut off power within the furnace. When power to the furnace is shut off by either method, the status code will be lost because the code is not stored while power is removed for any reason.

To Begin Component Self-Test:

WARNING: Blower access panel door switch opens

115-v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death.

1. Remove blower access door.

2. Disconnect the thermostat R lead from furnace control.

3. Manually close blower door switch.

4. For approximately 2 sec, short (jumper) the C

OM

-24v terminal on control to the TEST/TWIN 3/16-inch quickconnect terminal on control until the LED goes out.

Remover jumper from terminals. (See Fig. 33.)

NOTE: If TEST/TWIN and C

OM

-24v terminals are jumpered longer than 2 sec, LED will flash rapidly and ignore component test status code retrieval request.

Component test sequence is as follows: a. LED will display previous status code 4 times.

b. Inducer motor starts and continues to run until Step g of component test sequence.

c. After 7 seconds the hot surface igniter is energized for 15 sec., then off.

d. Blower motor operates on Continuous-FAN speed for 10 sec.

e. Blower motor operates on HEAT speed for 10 sec.

f. Blower motor operates on COOL speed for 10 sec.

g. Inducer motor stops.

5. Reconnect R lead to furnace control, remove tape from blower door switch, and re-install blower door.

6. Operate furnace per instruction on outer door.

7. Verify furnace shut down by lowering thermostat setting below room temperature.

8. Verify that furnace restarts by raising thermostat setting above room temperature.

V.

ADJUSTMENTS

A.

Set Gas Input Rate

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. Furnace input rate must be within

±

2 percent of input on furnace rating plate.

1. Determine natural gas orifice size and manifold pressure for correct input.

a. Obtain average gas heat value (at installed altitude) from local gas supplier.

b. Obtain average gas specific gravity from local gas supplier.

c. Verify furnace model. Table 9 can only be used for model 345MAV furnaces with heating size of 120.

d. Find installation altitude in Table 9.

NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A.

altitudes of 5001 to 6000 ft in Table 9.

e. Find closest natural gas heat value and specific gravity on Table 9.

f. Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation.

—36—

EXAMPLE: (0—2000 altitude)

Heating value = 1050 Btu/cu ft

Specific gravity = 0.62

Therefore: Orifice No. 45

Manifold pressure 3.6-in. wc

* Furnace is shipped with No. 45 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate.

Check and verify burner orifice size in furnace. NEVER ASSUME

ORIFICE SIZE; ALWAYS CHECK AND VERIFY.

2. Adjust manifold pressure to obtain input rate.

NOTE: Manifold pressure must always be measured with burner enclosure front REMOVED. Gas meter must always be clocked with burner enclosure front INSTALLED.

a. Remove burner enclosure front.

b. Remove cap that conceals adjustment screw for gas valve regulator. (See Fig. 46.) c. Jumper R and W thermostat connections on control to start furnace operation.

d. Turn adjusting screw, counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure.

NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft.

For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc. If manifold pressure is outside this range, change burner orifices to obtain pressure in this range.

CAUTION: DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics.

e. Replace gas valve regulator adjustment screw cap.

f. Replace burner enclosure front and verify adjusted gas input rate using method outlined in item 3.

g. Look through sight glass in burner enclosure and check burner flame. Burner flame should be clear blue, almost transparent. (See Fig. 48.) h. Remove jumper from R and W.

3. Verify natural gas input rate by clocking gas meter.

NOTE: Be sure all pressure tubing, combustion-air and vent pipes, and burner enclosure front are in place when checking input by clocking gas meter.

a. Calculate high-altitude adjustment

UNITED STATES

At altitudes above 2000 ft, this furnace has been approved for a 2% derate for each 1000 ft above sea level.

See Table 11 for derate multiplier factor.

EXAMPLE: 100,000 BTUH INPUT FURNACE INSTALLED AT

4300 FT.

Furnace Input Rate at Sea Level

100,000

X

X

Derate

Multiplier

Factor

0.91

=

=

Furnace Input Rate at Installation

Altitude

91,000

TABLE 9—MODEL 345MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT

(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL) *

ALTITUDE

RANGE

(FT)

0 to

2000

0% derate

ALTITUDE

RANGE

(FT)

U.S.A.

Altitudes

2001 to

3000 or

Canada

Altitudes

2001 to

4000

5% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

850

875

900

925

950

975

1000

1025

1050

1075

1100

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

775

800

825

850

875

900

925

950

975

1000

1025

45

45

47

44

44

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.7

3.5

3.7

3.5

3.4

3.2

3.7

3.5

3.3

3.2

3.6

44

44

44

45

45

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

3.8

3.5

3.8

3.6

3.4

3.2

3.7

3.5

3.3

3.1

3.0

ALTITUDE

RANGE

(FT)

3001 to

4000

7% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

750

775

800

825

850

875

900

925

950

975

1000

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

44

45

45

45

45

45

45

3.7

3.5

3.7

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.9

* Orifice numbers 45 are factory installed.

Percents of derate are based on midpoints of U.S. altitude ranges.

45

45

47

44

44

45

45

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

43

44

3.8

3.6

3.4

3.7

42

43

43

44

3.2

3.7

3.5

3.8

42

43

43

43

3.3

3.8

3.6

3.4

3.5

3.3

3.8

3.6

3.4

3.3

3.7

44

44

44

45

45

45

45

3.6

3.4

3.2

3.7

3.6

3.4

3.2

44

44

44

44

45

45

45

3.7

3.5

3.4

3.2

3.7

3.5

3.4

44

44

44

45

45

45

45

45


Orifice

No.

0.60

Manifold

Pressure

Orifice

No.

0.62

Manifold

Pressure

Orifice

No.

0.64

Manifold

Pressure

42

43

43

3.2

3.7

3.4

42

43

43

3.3

3.8

3.6

42

42

43

3.4

3.2

3.7

3.7

3.5

3.3

3.8

3.6

3.4

3.2

3.1

44

44

44

44

45

45

45

45

3.8

3.6

3.4

3.2

3.7

3.5

3.4

3.2

43

44

44

44

45

45

45

45

3.5

3.7

3.5

3.3

3.8

3.6

3.5

3.3

44

44

45

45

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

43

44

3.8

3.6

3.4

3.6

42

43

43

44

3.3

3.7

3.5

3.8

42

43

43

43

3.4

3.8

3.6

3.4

3.4

3.2

3.7

3.5

3.3

3.2

3.0

44

44

45

45

45

45

45

3.5

3.3

3.8

3.6

3.4

3.3

3.1

44

44

44

45

45

45

45

3.7

3.5

3.3

3.7

3.5

3.4

3.2

45

45

45

44

44

44

44

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.4

3.2

3.7

3.5

3.8

3.6

3.5

3.3

3.8

3.6

3.5

43

43

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

3.5

3.3

3.8

3.6

3.4

3.6

3.4

3.3

3.8

3.6

3.4

44

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.5

3.2

3.7

3.5

3.8

3.6

3.4

3.2

3.7

3.5

3.3

—37—

TABLE 9—MODEL 345MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued


ALTITUDE

RANGE

(FT)

4001 to

5000

9% derate

ALTITUDE

RANGE

(FT)

5001 to

6000

11% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725

750

775

800

825

850

875

900

925

950

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

700

725

750

775

800

825

850

875

900

925

950

975

1000

44

45

45

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.7

3.4

3.7

3.5

3.2

3.7

3.5

3.3

3.1

3.0

45

45

45

44

45

45

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.6

3.4

3.6

3.4

3.2

3.6

3.4

3.2

3.0

2.9

2.7

2.6

2.5

ALTITUDE

RANGE

(FT)

6001 to

7000

13% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650

675

700

725

750

775

800

825

850

875

Orifice

No.

0.58

Manifold

Pressure

42

43

44

44

44

45

45

45

45

45

3.2

3.6

3.8

3.6

3.3

3.8

3.5

3.3

3.1

3.0



44

45

45

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

44

44

3.8

3.5

3.8

3.6

42

43

43

44

3.2

3.7

3.4

3.7

42

43

43

44

3.3

3.8

3.5

3.8

3.4

3.8

3.6

3.4

3.2

3.1

44

44

45

45

45

45

3.5

3.3

3.7

3.5

3.3

3.2

44

44

44

45

45

45

3.6

3.4

3.2

3.6

3.4

3.3

45

45

45

44

45

45

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

44

44

3.7

3.5

3.7

3.5

42

43

43

44

3.2

3.6

3.4

3.6

42

43

43

44

3.3

3.7

3.5

3.7

3.3

3.7

3.5

3.3

3.1

3.0

2.8

2.7

2.5

44

44

45

45

45

45

45

45

45

3.4

3.2

3.6

3.4

3.3

3.1

2.9

2.8

2.6

44

44

45

45

45

45

45

45

45

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.9

2.7

44

44

44

45

45

45

45


Orifice

No.

0.60

Manifold

Pressure

Orifice

No.

0.62

Manifold

Pressure

Orifice

No.

0.64

Manifold

Pressure

42

43

43

3.3

3.7

3.4

42

43

43

3.4

3.8

3.6

42

42

43

3.5

3.2

3.7

3.7

3.4

3.2

3.7

3.4

3.2

3.1

44

44

44

45

45

45

45

3.8

3.6

3.3

3.8

3.6

3.4

3.2

43

44

44

44

45

45

45

3.4

3.7

3.4

3.2

3.7

3.5

3.3

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.4

3.2

3.7

3.4

3.7

3.5

3.3

3.8

3.6

3.4

45

45

45

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

43

43

43

3.4

3.8

3.6

3.4

3.6

3.4

3.2

3.7

3.5

3.3

3.1

2.9

2.8

43

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

3.6

3.3

3.8

3.5

3.8

3.5

3.3

3.8

3.6

3.4

—38—

TABLE 9—MODEL 345MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued


ALTITUDE

RANGE

(FT)

7001 to

8000

15% derate

ALTITUDE

RANGE

(FT)

8001 to

9000

17% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

625

650

675

700

725

750

775

800

825

850

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

600

625

650

675

700

725

750

775

800

44

45

45

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.8

3.5

3.8

3.5

3.3

3.7

3.5

3.3

3.1

2.9

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.8

3.5

3.7

3.5

44

45

45

45

45

3.2

3.6

3.4

3.2

3.0

ALTITUDE

RANGE

(FT)

9001 to

10,000

19% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

575

600

625

650

675

700

725

750

775

Orifice

No.

43

0.58

Manifold

Pressure

3.8

43

44

44

45

45

45

45

45

3.5

3.7

3.4

3.8

3.6

3.3

3.1

2.9



44

45

45

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

42

43

43

44

3.3

3.7

3.4

3.6

42

43

43

44

3.4

3.8

3.5

3.8

42

42

43

43

3.5

3.2

3.6

3.4

3.4

3.8

3.6

3.4

3.2

3.0

44

44

45

45

45

45

3.5

3.3

3.7

3.5

3.3

3.1

44

44

45

45

45

45

3.6

3.4

3.8

3.6

3.4

3.2

44

45

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

42

43

43

44

3.3

3.6

3.4

3.6

42

43

43

44

3.4

3.8

3.5

3.7

42

42

43

44

3.5

3.2

3.6

3.8

3.3

3.8

3.5

3.3

3.1

44

44

45

45

45

3.4

3.2

3.6

3.4

3.2

44

44

45

45

45

3.6

3.3

3.8

3.5

3.3

Orifice

No.

42


0.60

0.62

0.64

Manifold

Pressure

3.2

Orifice

No.

42

Manifold

Pressure

3.3

Orifice

No.

42

Manifold

Pressure

3.5

43

44

44

44

45

45

45

45

3.6

3.8

3.5

3.3

3.7

3.4

3.2

3.0

43

43

44

44

45

45

45

45

3.7

3.5

3.7

3.4

3.8

3.6

3.3

3.1

42

43

44

44

44

45

45

45

3.2

3.6

3.8

3.5

3.3

3.7

3.4

3.2

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.6

3.3

3.7

3.5

3.7

3.5

3.3

3.7

3.5

3.3

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.6

3.3

3.7

3.4

44

44

44

45

45

3.7

3.4

3.2

3.6

3.4

Orifice

No.

42

0.66

Manifold

Pressure

3.6

42

43

43

44

44

45

45

45

3.3

3.7

3.4

3.6

3.4

3.8

3.5

3.3

—39—

CANADA

At installation altitudes from 2000 to 4500 ft, this furnace must be derated 5% by an authorized Gas

Conversion Station. To determine correct input rate for altitude, see example above and use 0.95 as derate multiplier factor.

b. Reinstall burner box cover.

NOTE: Burner box cover MUST be isntalled while clocking gas input rate.

c. Gas valve regulator seal cap MUST be installed.

d. Turn off all other gas appliances and pilots.

e. Start furnace and let operate for 3 minutes.

f. Measure time (in sec) for gas meter test dial to complete

1 revolution.

g. Refer to Table 11 for cu ft of gas per hr.

ON/OFF SWITCH

INLET

PRESSURE TAP h. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using natural gas heating value from local gas utility/supplier.

EXAMPLE:

Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft

Time for 1 revolution of 2-cu ft dial = 70 sec

Gas rate = 103 cu ft/hr (from Table 11)

Btu heating input = 103 X 975 = 100,425 Btuh

In this example, the orifice size and manifold pressure adjustment is within

±

2 percent of the furnace input rate.

REGULATOR

SEAL CAP

REGULATOR

ADJUSTMENT

SCREW

B.

Set Temperature Rise

CAUTION: Temperature rise must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or slightly above. Failure to follow this caution may result in primary and secondary heat exchangers failure.

REGULATOR SPRING

(PROPANE - WHITE, 6 TURNS

NATURAL - SILVER, 10 TURNS)

GAS PRESSURE

REGULATOR

ADJUSTMENT

MANIFOLD

PRESSURE TAP

Determine and adjust air temperature rise as follows:

1. Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight-run ducts.

2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.

3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

BURNER FLAME

BURNER

Fig. 46—Redundant Automatic Gas Valve

A03142

BURNER

ORIFICE

A93059

Fig. 47—Orifice Holes

CAUTION: DO NOT redrill orifices. Improper drilling

(burrs, out-of-round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of burners and heat exchangers causing failures.

—40—

MANIFOLD

A89020

Fig. 48—Burner Flame

TABLE 10—ALTITUDE DERATE MULTIPLIER FOR U.S.A.

ALTITUDE

(FT)

0—2000

2001—3000

3001—4000

4001—5000

5001—6000

6001—7000

7001—8000

8001—9000

9001—10,000

% OF

DERATE

0

4—6

6—8

8—10

10—12

12—14

14—16

16—18

18—20

DERATE MULTIPLIER

FACTOR FOR U.S.A*

1.00

0.95

0.93

0.91

0.89

0.87

0.85

0.83

0.81

* Derate multiplier factor is based on midpoint altitude for altitude range.

TABLE 11—GAS RATE (CU FT/HR)

SECONDS

FOR 1

REVOLUTION

10

11

12

13

14

15

30

31

32

33

34

35

26

27

28

29

20

21

22

23

24

25

16

17

18

19

40

41

42

43

44

45

36

37

38

39

46

47

48

49

100

97

95

92

90

88

86

84

82

80

78

76

75

73

SIZE OF TEST DIAL SECONDS

1 2 5 FOR 1 cu ft

360 cu ft

720 cu ft

1800

REVOLUTION

50

327

300

277

257

240

655

600

555

514

480

1636

1500

1385

1286

1200

51

52

53

54

55

277

267

257

248

240

232

225

218

212

206

450

424

400

379

360

343

327

313

300

288

138

133

129

124

120

116

113

109

106

103

225

212

200

189

180

171

164

157

150

144

1125

1059

1000

947

900

857

818

783

750

720

692

667

643

621

600

581

563

545

529

514

80

82

84

86

88

90

72

74

76

78

60

62

64

66

68

70

56

57

58

59

200

195

189

185

180

176

172

167

164

160

157

153

150

147

500

486

474

462

450

439

429

419

409

400

391

383

375

367

92

94

96

98

100

102

104

106

108

110

112

116

120

124

36

35

35

34

33

33

39

38

38

37

32

31

30

29

45

44

43

42

41

40

50

48

47

46

60

58

56

54

53

51

64

63

62

61

SIZE OF TEST DIAL

1 2 5 cu ft

72 cu ft

144 cu ft

360

71

69

68

67

65

141

138

136

133

131

355

346

340

333

327

100

97

95

92

90

88

86

84

82

80

129

126

124

122

120

116

112

109

106

103

250

243

237

231

225

220

214

209

205

200

321

316

310

305

300

290

281

273

265

257

72

71

69

68

67

65

78

76

75

74

64

62

60

58

196

192

188

184

180

178

173

170

167

164

161

155

150

145

WARNING: Disconnect 115-v electrical power before changing speed tap. Failure to follow this warning could result in personal injury.

TABLE 13—BLOWER OFF DELAY SETUP POSITION

PINS

Time (in sec)

1 AND 2 2 AND 3 3 AND 4 4 AND 5

90 120 150 180

D.

Set Thermostat Heat Anticipator

When using a nonelectronic thermostat, the thermostat heat anticipator must be set to match amp draw of the electrical components in R-W circuit. Accurate amp draw readings can be obtained at thermostat subbase terminals R and W. Fig. 49 illustrates an easy method of obtaining actual amp draw. The amp reading should be taken after blower motor has started and furnace is heating. Connect ammeter wires as shown in Fig. 49. The thermostat anticipator should NOT be in the circuit while measuring current. If thermostat has no subbase, the thermostat must be disconnected from R and W wires during current measurement.

See thermostat manufacturer’s instructions for adjusting heat anticipator and for varying heating cycle length.

For an electronic thermostat, set cycle rate for 3 cycles per hour.

VI.

CHECK SAFETY CONTROLS

This section covers the safety controls that must be checked before the installation is complete. The flame sensor, gas valve, and pressure switch were all checked in the Start-up prodecure section as part of normal operation.

A.

Check Primary Limit Control

This control shuts off combustion control system and energizes air-circulating blower motor if furnace overheats. Recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least

5 minutes. As soon as limit control has shut off burners, return-air opening should be unblocked to permit normal air circulation. By using this method to check limit control, it can be established that limit is functioning properly and operates if there is a restricted return-air supply or motor failure. If limit control does not function during this test, cause must be determined and corrected.

B.

Check Pressure Switch

This control proves operation of draft inducer. Check switch operation as follows:

1. Turn off 115-v power to furnace.

2. Remove main furnace door and disconnect inducer motor lead wires from wire harness.

THERMOSTAT SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

HOOK-AROUND

VOLT/AMMETER

4. To change blower motor speed selections for heating mode, remove blower motor lead from control center HEAT terminal. (See Fig. 33.) Select desired blower motor speed lead from 1 of the other motor leads and relocate it to HEAT terminal. See Table 12 for lead color identification. Reconnect original lead on SPARE terminal.

Follow this same procedure for proper selection of COOL speed selection.

TABLE 12–SPEED SELECTOR

COLOR

Black

Yellow (When Present)

Blue

Red

White

SPEED

High

Medium High

Medium Low

Low

Common

FACTORY-

SHIPPED

CONNECTION

Cool

Spare

Heat

Fan

Com

R Y W G

10 TURNS

C.

Blower Off Delay (Heat Mode)

The blower off delay has 4 adjustable settings from 90 sec to 180 sec. (See Table 13.) The blower off delay jumpers are located on the furnace control board (See Fig. 33.) To change the blower off delay setting, move the jumper from one set of pins on the control board to the pins used for the desired blower off delay. Factory blower off delay setting is 120 sec.

—41—

FROM UNIT 24-VOLT

TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER

10 TURNS AROUND JAWS

= 0.5 AMPS FOR THERMOSTAT SETTING

A80201

Fig. 49—Amp Draw Check with Ammeter

3. Turn on 115-v power to furnace.

4. Set thermostat to "call for heat" and wait 1 minute. When pressure switch is functioning properly, hot surface igniter should NOT glow, and status code LED flashes a 31 fault.

If hot surface igniter glows when inducer motor is disconnected, shut furnace down immediately. Determine reason pressure switch did not function properly and correct condition.

5. Turn off 115-v power to furnace.

6. Reconnect inducer motor leads, reinstall main furnace door, and turn on 115-v power supply.

CHECKLIST

1. Put away tools and instruments. Clean up debris.

2. Verify manual flame rollout reset switch has continuity.

3. Verify that blower and main access doors are properly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review User’s Guide with owner.

7. Leave literature packet near furnace.

—42—

CHECKLIST—INSTALLATION

LOAD CALCULATION

____________ Heating Load (Btuh)

____________ Cooling Load (Btuh)

____________ Furnace Model Selection

VENT PIPING

Termination Location

________

________

________

________

________

________

________

Roof or Sidewall

Vent Pipe Length

Vent Pipe Elbow Quantity

Pipe Diameter Determined from Sizing Table

Pipe Sloped To Furnace

Pipe Insulation

Over Ceilings

Low-Ambient Exposed Pipes

________

________

________

________

________

Condensate Drain

Unit Level or Pitched Forward

Internal Tubing Connections Free of Kinks and Traps

External Drain Connection Leak Tight and

Sloped

Condensate Trap Primed before Start-Up

Heat Tape Installed if Required

________

________

CHECKLIST—START-UP

Gas Input Rate (Set Within 2 percent of

Rating Plate)

Temperature Rise Adjusted

________

________

Thermostat Anticipator

Anticipator Setting Adjusted or

Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

________

________

Primary Limit

Pressure Switch

—43—

© 2003 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231 —44— Printed in U.S.A.

345m408 Catalog No. 5334-520

Bryant 345MAV Installation, Start-Up, And Operating Instructions Manual

installation, start-up, and operating instructions

4-WAY MULTIPOISE

FIXED-CAPACITY

CONDENSING GAS FURNACE

345MAV

Series F

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

§

§

§

*

→

→

Related manuals

Table of contents

Bryant 345MAV Installation, Start-Up, And Operating Instructions Manual

installation, start-up, and operating instructions

4-WAY MULTIPOISE

FIXED-CAPACITY

CONDENSING GAS FURNACE

345MAV

Series F

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

§

§

§

*

→

→

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