Sharp R-340M W Operating instructions

installation, start-up,
and operating instructions
340MAV
4-WAY MULTIPOISE
FIXED-CAPACITY DIRECT-VENT
CONDENSING GAS FURNACE
Series E
Cancels:
II 340M-40-5
II 340M-40-6
4-99
ama
®
CANADIAN GAS ASSOCIATION
A PP R O VED
R
As an ENERGY STAR®
Partner, Bryant Heating &
Cooling Systems Company has determined that
this product meets the ENERGY STAR® guidelines
for energy efficiency.
A93040
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index
Page
DIMENSIONAL DRAWING........................................................2
SAFETY CONSIDERATIONS .....................................................3
Clearances to Combustibles......................................................3
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ....3-4
INTRODUCTION ..........................................................................4
APPLICATIONS ......................................................................4-11
General ......................................................................................4
Upflow Applications..............................................................4-7
Downflow Applications.........................................................7-8
Horizontal Left (Supply-Air Discharge) Applications .........8-9
Horizontal Right (Supply-Air Discharge) Applications...10-11
LOCATION ............................................................................11-13
General...............................................................................11-12
Furnace Location Relative to Cooling Equipment ................12
Hazardous Locations...............................................................13
INSTALLATION....................................................................13-17
Leveling Legs (If Desired) .....................................................13
Installation In Upflow or Downflow Applications................13
Installation In Horizontal Applications ..................................13
Air Ducts............................................................................13-16
Filter Arrangement..................................................................16
Bottom Closure Panel........................................................16-17
Gas Piping...............................................................................17
ELECTRICAL CONNECTIONS...........................................17-19
115-v Wiring......................................................................18-19
24-v Wiring.............................................................................19
Accessories..............................................................................19
Wiring Diagram ......................................................................20
DIRECT VENTING ...............................................................19-30
Removal of Existing Furnaces from
Common Vent Systems.....................................................19
Combustion-Air and Vent Piping .....................................19-27
Concentric Vent and Combustion-Air Termination
Kit Installation..............................................................27-30
Multiventing and Vent Termination.......................................30
CONDENSATE DRAIN ........................................................30-32
General ....................................................................................30
Application ..............................................................................30
REGISTERED QUALITY SYSTEM
AIRFLOW
UPFLOW
HORIZONTAL
LEFT
HORIZONTAL
RIGHT
DOWNFLOW
AIRFLOW
AIRFLOW
AIRFLOW
Fig. 1—Multipoise Orientations
A93041
Condensate Drain Protection ..................................................30
SEQUENCE OF OPERATION..............................................30-33
Heating Mode ....................................................................30-32
Cooling Mode .........................................................................32
Continuous Blower Mode.......................................................32
Heat Pump Mode...............................................................32-33
Component Test ......................................................................33
START-UP PROCEDURES ..................................................33-42
General ....................................................................................33
Prime Condensate Trap With Water.................................33-34
Purge Gas Lines......................................................................34
Adjustments .......................................................................34-42
Set Gas Input Rate ............................................................34-41
Set Temperature Rise ........................................................41-42
Blower Off Delay (Heat Mode) .............................................42
Set Thermostat Heat Anticipator............................................42
CHECK SAFETY CONTROLS..................................................42
Check Primary Limit Control.................................................42
Check Pressure Switch ...........................................................42
CHECKLIST...........................................................................42-43
—1—
—2—
1 1⁄4"
1"
14 1⁄2"
TYP
26 15⁄16"
1⁄2-IN.
26 15⁄16" TYP
23 1⁄4" TYP
SIDE INLET
SIDE INLET
DIA THERMOSTAT
ENTRY
22 11⁄16"
2-IN. VENT CONN
DIA
GAS CONN
1⁄2-IN.
2-IN. COMBUSTIONAIR CONN
22 5⁄16"
24 1⁄2"
26 1⁄4"
UNIT SIZE
024040
036040
024060
036060
048060
036080
048080
060080
048100
060100
060120
060140
17
E
INLET
OUTLET
D
11/16"
18 1⁄4"
D
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
19-3/8
19-3/8
19-3/8
22-7/8
22-7/8
→ Fig. 2—Dimensional Drawing
A
17-1/2
17-1/2
17-1/2
17-1/2
17-1/2
17-1/2
17-1/2
21
21
21
24-1/2
24-1/2
DIMENSIONS (IN.)
TYP
9⁄16"
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
CONDENSATE
DRAIN LOCATION
(UPFLOW)
30
1⁄2"
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL RIGHT)
OR ALTERNATE
1⁄2-IN. DIA GAS CONN
13/16"
NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer’s recommendations for equivalent diameters.
2. Minimum return-air opening at furnace:
a. For 800 CFM–16-in. round or 141/2 x 12-in. rectangle.
b. For 1200 CFM–20-in. round or 141/2 x 191/2-in. rectangle.
c. For 1600 CFM–22-in. round or 141/2 x 231/4-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data
literature for specific use of single side inlets. The use of both side inlets, a
combination of 1 side and the bottom, or the bottom only will ensure adequate
return air openings for airflow requirements above 1800 CFM.
11/16"
33 1⁄4"
TYP
32 5⁄8"
TYP
30 13⁄16"
29 11⁄16"
TYP
27 5⁄8"
27 9⁄16"
TYP
24 1⁄2"
5⁄16"
CONDENSATE
DRAIN LOCATION
(UPFLOW)
9
TYP
7⁄16"
CONDENSATE
DRAIN TRAP
LOCATION
(ALTERNATE
UPFLOW)
DIA
ACCESSORY
POWER ENTRY
7⁄8-IN.
DIA
POWER CONN
7⁄8-IN.
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL LEFT)
13/16"
A
AIRFLOW
E
16
16
16
16
16
16
16
19-1/2
19-1/2
19-1/2
23
23
24
BOTTOM INLET
3⁄16"
22 1⁄4" TYP
SIDE INLET
22 11⁄16"
2-IN. VENT CONN
DIA
THERMOSTAT ENTRY
1⁄2-IN.
DIA
POWER CONN
7⁄8-IN.
DIA
GAS CONN
1⁄2-IN.
2-IN. COMBUSTIONAIR CONN
OUTLET
19"
22 5⁄16"
26 1⁄4"
28 1⁄2"
26 15⁄16"
A99112
11⁄16"
7⁄16"
1"
39 7⁄8"
5⁄16"
5⁄8"
13⁄16"
SAFETY CONSIDERATIONS
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.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained
personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating
equipment, observe precautions in literature, on tags, and on labels
attached to or shipped with unit and other safety precautions that
may apply.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
CAUTION: Electrostatic discharge can affect electronic
components. Take precautions during furnace installation
and servicing to protect the furnace electronic control.
Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the
procedure. These precautions will help to avoid exposing
the control to electrostatic discharge by putting the
furnace, the control, and the person at the same electrostatic potential.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA
54-1996/ANSI Z223.1-1996 and the Installation Standards, Warm
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 90B. In Canada, refer to the current edition of the
CAN/CGA-B149.1- and .2-M95 National Standard of Canada,
Natural Gas and Propane Installation Codes (NSCNGPIC). Wear
safety glasses and work gloves. Have a fire extinguisher available
during start-up and adjustment procedures and service calls.
1. Disconnect all power to the furnace. DO NOT TOUCH
THE CONTROL OR ANY WIRE CONNECTED TO THE
CONTROL PRIOR TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on unit or in instructions and manuals,
be alert to potential for personal injury.
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.
Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
3. After touching the chassis you may proceed to service the
control or connecting wires as long as you do nothing that
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 clearance from combustible material.
This appliance requires a special venting system. Refer to the installation
instructions for parts list and method of installation. This furnace is for use with
schedule-40 PVC, PVC-DWV, or ABS-DWV pipe, and must not be vented in
common with other gas-fired appliances. Construction through which vent/air
intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4
inches (19 mm) thickness (including roofing materials).
Furnace must be installed level, or pitched forward within 1/2 inch of
level for proper drainage. Failure will result in equipment or property
damage. See Installation Manual for IMPORTANT unit support details
on horizontal applications.
LEVEL (0")
TO
1/2" MAX
UPFLOW OR
DOWNFLOW
MINIMUM INCHES CLEARANCE TO
COMBUSTIBLE CONSTRUCTION
FRONT
FRONT
Minimum front clearance for service 30 inches (762mm).
††
DOWNFLOW POSITIONS:
0"B
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.
A
1"
TOP/PLENUM
Clearance arrows
do not change with
furnace orientation.
†† 140 size furnaces require 1 inch back clearance to combustible materials.
†
FU
RN
AC
FR
Clearance shown is for air inlet and air outlet end.
Line contact is permissible only between lines formed by intersections of
top and two sides of furnace jacket, and building joists, studs, or framing.
120 and 140 size Furnaces require 1 inch bottom clearance to combustible
materials.
324999-201 REV. A
(LIT. TOP)
D
SI
E
ON
T
SE
SI
§
DE
FR
0"
Clearance in inches .
O
E
NT
3"
RV
IC
E
*
30
MIN
BOTTOM
Ø
0" §
CK
HORIZONTAL POSITIONS:
§
HORIZONTAL
This furnace is approved for UPFLOW, DOWNFLOW and
HORIZONTAL installations.
ALL POSITIONS:
*
LEVEL (0")
TO
1/2" MAX
0"
†Ø
Vent clearance to
combustibles 0".
A99101
→ Fig. 3—Clearances to Combustibles
—3—
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching control or wires.
This furnace must be installed with a direct-vent (combustion air
and flue) system and a factory accessory termination kit. In a
direct-vent system, all air for combustion is taken directly from the
outside atmosphere and all flue products are discharged to the
outside atmosphere. See furnace and factory accessory termination
kit instructions for proper installation.
5. Use this procedure for installed and uninstalled (ungrounded) furnaces.
Before installing the furnace in the United States, refer to the
current edition of the NFGC and the NFPA 90B.
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.
For copies of the NFGC and NFPA 90B, contact the National Fire
Protection Association Inc., Batterymarch Park, Quincy, MA
02269; or American Gas Association, 1515 Wilson Boulevard,
Arlington, VA 22209.
Before installing the furnace in Canada, refer to the current edition
of the NSCNGPIC. Contact Standard Sales, CSA International,
178 Rexdale Boulevard, Etobicoke, (Toronto) Ontario, Canada
M9W 1R3
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
Installation must comply with regulations of serving gas supplier
and local building, heating, plumbing or other codes in effect in the
area in which installation is made. In the absence of local codes,
installation must comply with the NFGC in the United States and
the NSCNGPIC in Canada.
INTRODUCTION
model 340MAV, Series E Furnaces are available in sizes
40,000 through 138,000 Btuh input capacities.
The 340MAV Multipoise Condensing Gas-Fired Furnaces are
A.G.A./C.G.A. design certified for natural and propane gases and
for installation in alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory-shipped for use
with natural gas. An A.G.A./C.G.A. listed gas conversion kit is
required to convert furnace for use with propane gas. The
340MAV 040 through 120 size units are A.G.A./C.G.A. approved
for use in manufactured (mobile) homes when factory accessory
conversion kit is used. The 140 size unit is not approved for use in
manufactured (mobile) homes. These furnaces are suitable for
installation in a residence built on site or a manufactured residence
completed at final site. The design of this furnace line is NOT
A.G.A./C.G.A. certified for installation in recreation vehicles or
outdoors.
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.
These furnaces are shipped with the drain and pressure tubes
connected for UPFLOW applications. Minor modifications are
required when used in DOWNFLOW, HORIZONTAL RIGHT, or
HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 1. See details in Applications section.
These furnaces are shipped with the following materials to assist in
proper furnace installation. These materials are shipped in the main
blower compartment.
Installer Packet includes:
Installation, Start-Up, and Operating Instructions
Service and Maintenance Procedures
User’s Information Manual
Warranty Certificate
Loose Parts Bag includes:
Quantity
Pressure tube extension
1
Collector box or condensate trap extension tube
1
Inducer housing drain tube
1
1/2-in. CPVC street elbow
2
Drain tube coupling
1
Drain tube coupling grommet
1
Vent and combustion-air pipe support
2
Combustion-air pipe perforated disk assembly
1
Vent Pipe Extension
1*
* ONLY supplied with some furnaces.
→ The
These instructions cover minimum requirements for a safe installation and conform to existing national standards and safety codes.
In some instances, these instructions exceed certain local codes
and ordinances, especially those that may not have kept pace with
changing residential construction practices. We require these
instructions as a minimum for a safe installation.
CAUTION: Application of this furnace should be indoors with special attention given to vent sizing and
material, gas input rate, air temperature rise, unit leveling,
and unit sizing. Improper installation or misapplication of
furnace can require excessive servicing or cause premature component failure.
WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon
monoxide poisoning, explosion, fire, electrical shock, or
other conditions which may cause personal injury or
property damage. Consult a qualified installer, service
agency, local gas supplier, or your distributor or branch
for information or assistance. The qualified installer or
agency must use only factory-authorized and listed kits or
accessories when modifying this product. Failure to
follow this warning could result in electrical shock, fire,
personal injury, or death.
For accessory installation details, refer to applicable installation
literature.
APPLICATIONS
I.
GENERAL
Some assembly and modifications are required for furnaces
installed in any of the 4 applications shown in Fig. 1. All drain and
pressure tubes are connected as shown in Fig. 5. See appropriate
application instructions for these procedures.
II.
UPFLOW APPLICATIONS
An upflow furnace application is where furnace blower is located
below combustion and controls section of furnace, and conditioned
air is discharged upwards.
—4—
FURNACE
DOOR
BLOWER SHELF
CONDENSATE
TRAP
CONDENSATE
TRAP (INSIDE)
FURNACE
DOOR
FURNACE
SIDE
4 78
FURNACE
SIDE
4
534
534
4
FIELD
DRAIN
CONN
ALTERNATE DRAIN
TUBE LOCATION
26 1 4
26 1 4
11 2
SIDE VIEW
CONDENSATE TRAP
DRAIN TUBE LOCATION
FIELD
DRAIN
CONN
FRONT VIEW
END VIEW
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
FRONT VIEW
HORIZONTAL
APPLICATIONS
DOWNFLOW AND ALTERNATE
EXTERNAL UPFLOW APPLICATIONS
UPFLOW APPLICATIONS
34
1⁄4
OD
COLLECTOR BOX TO
TRAP RELIEF PORT
11 2
1⁄2
OD
INDUCER HOUSING
DRAIN CONNECTION
34
5⁄8
OD
COLLECTOR BOX
DRAIN CONNECTION
71 8
SCREW HOLE FOR
UPFLOW OR DOWNFLOW APPLICATIONS
(OPTIONAL)
13 4
WIRE TIE
GUIDES
(WHEN USED)
FRONT VIEW
78
21 4
1⁄2-IN.
PVC OR CPVC
SIDE VIEW
A93026
Fig. 4—Condensate Trap
A. Condensate Trap Location (Factory-Shipped
NOTE: If internal filter is used, drain tube should be located to
Orientation)
opposite side of casing of return duct attachment to assist in filter
removal.
The condensate trap is factory installed in the blower shelf and
factory connected for UPFLOW applications. A factory-supplied
b. Remove and discard casing drain hole plug button from
tube is used to extend the condensate trap drain connection to the
desired side.
desired furnace side for field drain attachment. See Condensate
c. Install drain tube coupling grommet (factory-supplied in
Trap Tubing (Factory-Shipped Orientation) section for drain tube
loose parts bag) in selected casing hole.
extension details.
d. Slide drain tube coupling (factory-supplied in loose parts
B. Condensate Trap Tubing (Factory-Shipped Orientabag) through grommet ensuring long end of coupling
tion)
faces blower.
NOTE: See Fig. 5 or tube routing label on main furnace door to
e. Cement 2 factory-supplied 1/2-in. street CPVC elbows to
confirm location of these tubes.
the rigid drain tube connection on the condensate trap.
1. Collector Box Drain, Inducer Housing Drain, Relief Port,
(See Fig. 5.) These elbows must be cemented together
and Pressure Switch Tubes
and cemented to condensate trap drain connection.
These tubes should be factory attached to condensate trap
NOTE: Failure to use CPVC elbows may allow drain to kink and
and pressure switch ready for use in UPFLOW applications.
prevent draining.
These tubes can be identified by their connection location
f. Connect larger diameter drain tube and clamp (factoryand also by a color label on each tube. These tubes are
supplied in loose parts bag) to condensate trap and clamp
identified as follows: collector box drain tube (blue label),
inducer housing drain tube (violet label or molded), relief
securely.
port tube (green label), and pressure switch tube (pink
g. Route tube to coupling and cut to appropriate length.
label).
h. Attach tube to coupling and clamp securely.
2. Condensate Trap Drain Tube
C. Condensate Trap Location (Alternate Upflow
The condensate trap drain connection must be extended for
Orientation)
field attachment by doing the following:
a. Determine location of field drain connection. (See Fig. 2
An alternate location for the condensate trap is the left-hand side
of casing. (See Fig. 2 and 6.)
or 5.)
—5—
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
PLUG
CAP
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (GREEN)
CONDENSATE
TRAP
COLLECTOR BOX
DRAIN TUBE (BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
CONDENSATE
TRAP
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
1⁄2-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
A94163
A94164
→ Fig. 6—Alternate Upflow Tube Configuration and
Trap Location
→ Fig. 5—Factory-Shipped Upflow Tube Configuration
(Shown With Blower Access Panel Removed)
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:
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.
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Remove casing hole filler cap from casing hole. (See Fig. 2
or 6.)
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.
4. Install casing hole filler cap into blower shelf hole where
trap was removed.
3. Relief Port Tube
a. Connect relief port tube (green label) to condensate trap.
5. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
b. Extend this tube (if required) by splicing to small
diameter tube (factory-supplied in loose parts bag).
c. Determine appropriate length, cut, and connect tube.
E. Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
F. Pressure Switch Tubing
The LOWER collector box pressure tube (pink label) is factory
connected to the pressure switch and should not require any
modification.
D. Condensate Trap Tubing (Alternate Upflow
Orientation)
NOTE: See Fig. 6 or tube routing label on main furnace door to
confirm location of these tubes.
1. Collector Box Drain Tube
Connect collector box drain tube (blue label) to condensate
trap.
—6—
NOTE: See Fig. 5 or 6 or tube routing label on main furnace door
to check for proper connections.
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Remove casing hole filler cap from casing hole. (See Fig. 2,
7, or 8.)
4. Install casing hole filler cap into blower shelf hole where
trap was removed.
5. Install condensate trap into desired casing hole by inserting
tube connection stubs through casing hole and rotating until
tabs snap into locking position.
B. Condensate Trap Tubing
G. Upper Collector Box and Inducer Housing (Unused)
Drain Connections
UPPER COLLECTOR BOX DRAIN CONNECTION
Attached to the UPPER collector box drain connection is a
factory-installed corrugated, plugged tube (blue and white striped
label). This tube is plugged to prevent condensate leakage in this
application. Ensure this tube is plugged.
NOTE: See Fig. 5 or 6 or tube routing label on main furnace door
to check for proper connections.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
UPPER INDUCER HOUSING DRAIN CONNECTION
Attached to the UPPER (unused) inducer housing drain connection
is a cap and clamp. This cap is used to prevent condensate leakage
in this application. Ensure this connection is capped.
NOTE: See Fig. 5 or 6 or tube routing label on main furnace door
to check for proper connections.
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was connected to
condensate trap.
H. Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations and procedures.
c. Connect LOWER collector box drain connection to
condensate trap.
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.
(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.
A. Condensate Trap Location
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2, 7, or 8.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
(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.
COLLECTOR BOX
DRAIN TUBE (BLUE)
CAP
PLUG
PLUG
CAP
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
EXTENSION TUBE
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
CONDENSATE
TRAP
CONDENSATE
TRAP
COLLECTOR BOX
EXTENSION
DRAIN TUBE
INDUCER HOUSING
DRAIN TUBE (VIOLET)
DRAIN TUBE
COUPLING
A94165
A94166
→ Fig. 8—Downflow Tube Configuration
(Right-Hand Trap Installation)
→ Fig. 7—Downflow Tube Configuration
(Left-Hand Trap Installation)
—7—
(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.
4. Extend collector box pressure tube (pink label) which was
previously connected to pressure switch by splicing to
remaining small diameter tube (factory-supplied in loose
parts bag).
(c.) Route extended collector box drain tube directly from collector box drain to condensate
trap as shown in Fig. 8.
5. Route this extended tube (pink label) to condensate trap
relief port connection.
(d.) Determine appropriate length and cut.
7. Clamp tube to relief port connection.
6. Determine appropriate length, cut, and connect tube.
(e.) Connect to condensate trap.
E.
(f.) Clamp tube to prevent any condensate leakage.
Refer to Condensate Drain Protection section for recommendations and procedures.
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
Condensate Trap Freeze Protection
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.
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.
CAUTION: Local codes may require a drain pan under
entire furnace and condensate trap when a condensing
furnace is used in an attic application or over a finished
ceiling.
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.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
NOTE: The auxiliary junction box (J-Box) MUST be relocated to
opposite side of furnace casing. (See Fig. 9.) See Electrical
Connection section for J-Box relocation.
(1.) Condensate Trap Located on Left Side of Casing
(a.) Determine appropriate length and cut.
(b.) Connect tube to condensate trap.
A. Condensate Trap Location
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2 or 9.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
(c.) Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
(a.) Route inducer housing drain tube (violet label)
directly from inducer housing to condensate
trap as shown in Fig. 8.
(b.) Determine appropriate length and cut.
1. Remove 3 tubes connected to condensate trap.
(c.) Connect tube to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
(d.) Clamp tube to prevent any condensate leakage.
3. Remove casing hole filler cap from casing hole. (See Fig. 2
or 9.)
3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection
procedure.
C. Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
D. Pressure Switch Tubing
One collector box pressure tube (pink label) is factory connected to
the pressure switch for use when furnace is installed in UPFLOW
applications. This tube MUST be disconnected and used for the
condensate trap relief port tube. The other collector box pressure
tube (green label) which was factory connected to the condensate
trap relief port connection MUST be connected to the pressure
switch in DOWNFLOW or HORIZONTAL RIGHT applications.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in
loose parts bag).
3. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.
4. Install casing hole filler cap into blower shelf hole where
trap was removed.
5. Install condensate trap into casing hole by inserting tube
connection stubs through casing hole and rotating until tabs
snap into locking position.
B. Condensate Trap Tubing
NOTE: See Fig. 9 or tube routing label on main furnace door to
check for proper connections.
1. Collector Box Drain Tube
a. Install drain tube coupling (factory-supplied in loose
parts bag) into collector box drain tube (blue label)
which was previously connected to condensate trap.
b. Connect large diameter drain tube and clamp (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.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove and discard LOWER (molded) inducer housing
drain tube which was previously connected to condensate trap.
—8—
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.
d. Clamp tube to prevent any condensate leakage.
b. Between blower shelf and inducer housing.
c. Behind inducer motor bracket.
3. Relief Port Tube
a. Extend collector box tube (green label) which was
previously connected to the condensate trap by splicing
to small diameter tube (factory-supplied in loose parts
bag).
d. Between inducer motor and pressure switch.
4. Determine appropriate length, cut, and reconnect tube to
pressure switch connection labeled COLLECTOR BOX.
E.
b. Route extended collector box pressure tube to relief port
connection on the condensate trap.
Condensate Trap Freeze Protection
c. Determine appropriate length, cut, and connect tube.
Refer to Condensate Drain Protection section for recommendations and procedures.
d. Clamp tube to prevent any condensate leakage.
F.
C. Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
Construct a Working Platform
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 10.)
CAUTION: The condensate trap MUST be installed
below furnace. See Fig. 4 for dimensions. The drain
connection to condensate trap must also be properly
sloped to an open drain.
D. Pressure Switch Tubing
The LOWER collector box pressure tube (pink label) is factory
connected to the pressure switch for use when furnace is installed
in UPFLOW applications. This tube MUST be disconnected,
extended, rerouted, and then reconnected to the pressure switch in
HORIZONTAL LEFT applications.
NOTE: See Fig. 9 or tube routing label on main furnace door to
check for proper connections.
Modify tube as described below.
NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.)
NOTE: A 12-in. minimum offset pipe section is recommended
with short (5 to 8 ft) vent systems. This recommendation is to
reduce excessive condensate droplets from exiting the vent pipe.
(See Fig. 10 or 28.)
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)
AUXILIARY "J" BOX
RELOCATED HERE
CONDENSATE
TRAP
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR
BOX EXTENSION
DRAIN TUBE
COLLECTOR BOX
EXTENSION TUBE
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
DRAIN TUBE (BLUE)
DRAIN TUBE COUPLING
COLLECTOR BOX TUBE (PINK)
RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR
040, 060, AND 080 HEATING INPUT FURNACES
A93302
→ Fig. 9—Horizontal Left Tube Configuration
—9—
COMBUSTION – AIR
INTAKE
VENT
30″ MIN
WORK AREA
5 3⁄4″
MANUAL
SHUTOFF
GAS VALVE
A 12-IN. MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT) VENT SYSTEMS
TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
ACCESS OPENING
FOR TRAP
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.
A93031
Fig. 10—Attic Location and Working Platform
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.
B.
Condensate Trap Tubing
NOTE: See Fig. 11 or tube routing label on main furnace door to
check for proper connections.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
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.
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.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC Installation Codes and/or local codes.
d. Clamp tube to prevent any condensate leakage.
A. Condensate Trap Location
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2 or 11.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
1. Remove 3 tubes connected to condensate trap.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
3. Remove casing hole filler cap from casing hole. (See Fig. 2
or 11.)
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.
4. Install casing hole filler cap into blower shelf hole where
trap was removed.
e. Determine appropriate length, cut, and connect tube to
condensate trap.
5. Install condensate trap into casing hole by inserting tube
connection stubs through casing hole and rotating until tabs
snap into locking position.
f. Clamp tube to prevent any condensate leakage.
—10—
CAP
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX TUBE (PINK)
PLUG
CONDENSATE
TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
A93303
→ Fig. 11—Horizontal Right Tube Configuration
3. Relief Port Tube
7. Determine appropriate length, cut, and connect tube.
Refer to Pressure Switch Tubing section for connection
procedure.
8. Clamp tube to relief port connection.
E. Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations and procedures.
C. Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
F. Construct a Working Platform
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 10.)
D. Pressure Switch Tubing
One collector box pressure tube (pink label) is factory connected to
the pressure switch for use when furnace is installed in UPFLOW
applications. This tube MUST be disconnected and used for the
condensate trap relief port tube. The other collector box pressure
tube (green label) which was factory connected to the condensate
trap relief port connection MUST be connected to the pressure
switch in DOWNFLOW or HORIZONTAL RIGHT applications.
NOTE: See Fig. 11 or tube routing label on main furnace door to
check for proper connections.
Relocate tubes as described below.
CAUTION: The condensate trap MUST be installed
below furnace. See Fig. 4 for dimensions. The drain
connection to condensate trap must also be properly
sloped to an open drain.
NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.)
NOTE: A 12-in. minimum offset pipe section is recommended
with short (5 to 8 ft) vent systems. This recommendation is to
reduce excessive condensate droplets from exiting the vent pipe.
(See Fig. 10 or 28.)
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in
loose parts bag).
LOCATION
I. GENERAL
When a furnace is installed so that supply ducts carry air to areas
outside the space containing the furnace, return air must also be
handled by ducts sealed to furnace casing. The ducts terminate
outside the space containing the furnace to ensure there will not be
a negative pressure condition within equipment room or space.
Furnace may be located in a confined space without special
provisions for dilution or ventilation air. This furnace must be
installed so electrical components are protected from water.
Locate furnace as close to center of air distribution system as
possible.
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.
—11—
FRONT
LEVEL (0″)
TO
1⁄2″ MAX
FRONT
LEVEL (0″)
TO
1⁄2″ MAX
UPFLOW OR DOWNFLOW
FRONT
B
A
C
K
HORIZONTAL
BACK
A93025
NOTE: For proper furnace operation, install furnace so that it is
level or pitched forward within 1/2 in. to ensure proper condensate
drainage from secondary heat exchangers.
FRONT
A93043
WARNING: Do not install furnace on its back. Safety
control operation will be adversely affected. Never connect return-air ducts to back of furnace. Failure to follow
this warning could result in fire, personal injury, or death.
FRONT
°F
°F
RETURN
AIR
MAX 85°F
MIN 55°F
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
A93042
NOTE: These furnaces are designed for a minimum continuous
return-air temperature of 60°F or intermittent operation down to 55°F
such as when used with a night setback thermostat. Return-air
temperature must not exceed a maximum of 85°F. Failure to follow
these return-air temperature limits may affect reliability of heat
exchangers, motors, and controls.
A93058
Locate furnace so combustion-air pipe maximum lengths are not
exceeded. Refer to Table 6—Maximum Allowable Pipe Length.
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.
CAUTION: If these furnaces are used during construction when adhesives, sealers, and/or new carpets are
being installed, make sure all combustion and circulating
air requirements are followed. If operation of furnace is
required during construction, use clean outside air for
combustion and ventilation. Compounds of chlorine and
fluorine, when burned with combustion air, form acids
which will cause corrosion of heat exchangers. Some of
these compounds are found in paneling, dry wall adhesives, paints, thinners, masonry cleaning materials, and
many other solvents commonly used in construction
process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
Provide ample space for servicing and cleaning. Always comply
with minimum fire protection clearances shown on unit’s clearance to combustibles label. (See Fig. 3.) Locate furnace where
available electric power and gas supplies meet specifications on
furnace rating plate.
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 must prevent chilled air from entering furnace.
If dampers are manually operated, they must be equipped with a
means to prevent operation of either unit unless damper is in
full-heat or full-cool position.
—12—
III.
HAZARDOUS LOCATIONS
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
18-IN. MINIMUM
TO BURNERS
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 in
not required when this furnace is installed on manufacturer’s Coil
Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is
used.
1. Determine application being installed from Table 1.
2. Construct hole in floor per dimensions specified in Table 1
and Fig. 13.
3. Construct plenum to dimensions specified in Table 1 and
Fig. 13.
4. If downflow subbase (KGASB) is used, install as shown in
Fig. 14.
If coil assembly CD5 or CK5 or Coil Box KCAKC is used,
install as shown in Fig. 15.
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. 16.)
A93044
WARNING: When furnace is installed in a residential
garage, it must be installed so that burners and ignition
sources are located a minimum of 18 in. above floor. The
furnace must be located or protected to avoid physical
damage by vehicles. When furnace is installed in a public
garage, airplane hangar, or other building having a
hazardous atmosphere, unit must be installed in accordance with requirements of National Fire Protection
Association, Inc.
INSTALLATION
I. LEVELING LEGS (IF DESIRED)
When furnace is used in upflow position with side inlet(s), leveling
legs may be desired. (See Fig. 12.) Install field-supplied,
corrosion-resistant 5/16-in. machine bolts and nuts.
WARNING: Do not bend duct flanges inward as shown
in Fig. 16. This will affect airflow across heat exchangers
and may cause limit cycling or premature heat exchanger
failure. Remove duct flange completely or bend it inward
a minimum of 210° as shown in Fig. 16.
5⁄16″
NOTE: For 140 size unit when installed in downflow orientation,
cut the white jumper wire off between terminals PL1-6 and PL1-9.
Refer to Fig. 24 for location of jumper. Cut jumper close to
connector and remove wire to avoid a short circuit.
III. INSTALLATION IN HORIZONTAL APPLICATIONS
These furnaces can be installed horizontally in either horizontal
left or right discharge position. In a crawlspace, furnace can either
be hung from floor joist or installed on suitable blocks or pad.
Furnace can be suspended from each corner by hanger bolts and
angle iron supports. (See Fig. 17.) Cut hanger bolts (4 each 3/8-in.
all-thread rod) to desired length. Use 1 X 3/8-in. flat washers,
3/8-in. lockwashers, and 3/8-in. nuts on hanger rods as shown in
Fig. 17. Dimples are provided for hole locations. (See Fig. 2.)
5⁄16″
1 3⁄4″
1 3⁄4″
5⁄16″
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.
5⁄16″
1 3⁄4″
1 3⁄4″
A89014
IV.
Fig. 12—Leveling Legs
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
Air Conditioning Contractors National Association (SMACNA) or
American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE). Or consult factory The Air Systems Design
Guidelines reference tables available from your local distributor.
The duct system should be sized to handle the required system
design CFM at the design static pressure.
NOTE: The maximum length of bolt should not exceed 1-1/2 in.
1. Position furnace on its back. Locate and drill a 5/16-in.
diameter hole in each bottom corner of furnace. (See Fig.
12.) Holes in bottom closure panel may be used as guide
locations.
2. For each hole, install nut on bolt and then install bolt and
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install flat
washer if desired.)
—13—
A
PLENUM
OPENING
D
B
FLOOR
OPENING
C
A96283
Fig. 13—Floor and Plenum Opening Dimensions
FURNACE
FURNACE
(OR COIL CASING
WHEN USED)
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
SHEET METAL
PLENUM
FLOOR
OPENING
FLOOR
OPENING
A96284
A96285
Fig. 15—Furnace, Plenum, and Coil
Assembly or Coil Box Installed
on a Combustible Floor
Fig. 14—Furnace, Plenum, and Subbase
Installed on a Combustible Floor
TABLE 1—OPENING DIMENSIONS (IN.)
FURNACE
CASING
WIDTH
17-1/2
21
24-1/2
PLENUM OPENING
APPLICATION
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
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
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
—14—
FLOOR OPENING
A
B
C
D
16
15-7/8
24-1/8
19
16-5/8
16-1/2
24-3/4
19-5/8
15-1/8
19
16-3/4
20-3/8
15-1/2
19
16-1/2
20
19-1/2
19-3/8
24-1/8
19
20-1/8
20
24-3/4
19-5/8
18-5/8
19
20-1/4
20-3/8
19
19
20
20
23
22-7/8
24-1/8
19
23-5/8
23-1/2
24-3/4
19-5/8
22-1/8
19
23-3/4
20-3/8
22-1/2
19
23-1/2
20
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.
PERFORATED
DISCHARGE DUCT
FLANGE
NO
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.
YES
210°
MIN
YES
C.
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
A93029
Fig. 16—Duct Flanges
SUPPLY AIR CONNECTIONS
When a furnace is installed so that the supply ducts carry air to
areas outside the space containing the furnace, the return air must
also be handled by 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.
3⁄8-IN.
ANGLE
IRON OR
EQUIVALENT
ROD
5 3⁄4″
ALTERNATE SUPPORT
LOCATION 4-IN. MIN
8-IN. MAX
(B)
(A)
DRAIN
(B)
(A)
(A) ROD LOCATION
USING DIMPLE
LOCATORS
(SEE DIMENSIONAL
DWG FOR
LOCATIONS)
(B)
3/8-IN.
HEX NUT
& WASHER (4)
REQD PER ROD
(A) PREFERRED ROD LOCATION
(B) ALTERNATE ROD LOCATION
(A)
(B)
13/16-IN.
MAX
ALTERNATE SUPPORT
LOCATION FROM BACK
NOTES: 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.
A93304
Fig. 17—Crawlspace Horizontal Application
—15—
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
WASHABLE
FILTER
FILTER
RETAINER
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. 1. 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. 1. 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.
V. FILTER ARRANGEMENT
A93045
Fig. 18—Filter Installed for Side Inlet
171⁄2-IN. WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
CAUTION: Never operate unit without a filter or with
blower access panel removed.
241⁄2-IN. WIDE
CASINGS ONLY:
CUT AND FOLD
FACTORY-PROVIDED
FILTERS AS SHOWN
TO DESIRED SIZE.
3″
24 1/2″
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.
1″
TABLE 2—FILTER INFORMATION
FURNACE
FILTER SIZE (IN.)*
FILTER TYPE
CASING
FRAMED
Side
Return
Bottom
Return
WIDTH (IN.)
17-1/2
(1) 16 X 25 X 1† (1) 16 X 25 X 1
Cleanable
21
(1) 16 X 25 X 1 (1) 20 X 25 X 1†
Cleanable
24-1/2
(2) 16 X 25 X 1† (1) 24 X 25 X 1
Cleanable
* Filters can be field modified by cutting frame as marked and folding to
desired size. Alternate sizes can be ordered from your distributor or dealer.
† Factory-provided with furnace.
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.
WASHABLE
FILTER
NOTE: Side return-air openings can ONLY be used in UPFLOW
configurations. Install filter(s) as shown in Fig. 18.
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. 19.
NOTE: Remove and discard bottom closure panel when bottom
inlet is used.
VI. BOTTOM CLOSURE PANEL
These furnaces are shipped with bottom enclosure panel installed
in bottom return-air opening. This panel MUST be in place when
side return air is used.
FILTER
SUPPORT
FILTER
RETAINER
A96030
Fig. 19—Bottom Filter Arrangement
—16—
TABLE 3—MAXIMUM CAPACITY OF PIPE*
To remove bottom closure panel, perform following:
NOMINAL
IRON
PIPE
SIZE
(IN.)
1/2
3/4
1
1-1/4
1-1/2
1. Tilt or raise furnace and remove 2 screws holding front
filler panel. (See Fig. 20.)
2. Rotate front filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall front filler panel and screws.
LENGTH OF PIPE (FT)
INTERNAL
DIAMETER
(IN.)
10
20
30
40
50
0.622
0.824
1.049
1.380
1.610
175
360
680
1400
2100
120
250
465
950
1460
97
200
375
770
1180
82
170
320
660
990
73
151
285
580
900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and
a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref:
Table 10-2 NFGC.
Install a sediment trap in riser leading to furnace. Trap can be
installed by connecting a tee to riser leading to furnace so
straight-through section of tee is vertical. Then connect a capped
nipple into lower end of tee. Capped nipple should extend below
level of gas controls. Place a ground joint union between gas
control manifold and manual gas shutoff valve. (See Fig. 21.)
GAS
SUPPLY
BOTTOM
CLOSURE
PANEL
MANUAL
SHUTOFF
VALVE
(REQUIRED)
FRONT FILLER
PANEL
SEDIMENT
TRAP
UNION
A93047
Fig. 20—Removing Bottom Closure Panel
VII. GAS PIPING
Gas piping must be installed in accordance with national and local
codes. Refer to current edition of NFGC. Canadian installations
must be made in accordance with NSCNGPIC and all authorities
having jurisdiction. Gas supply line should be a separate line
running directly from meter to furnace, if possible. Refer to Table
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.
A93324
Fig. 21—Typical Gas Pipe Arrangement
CAUTION: If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe
shall be installed at gas valve and extend a minimum of
2 in. outside furnace casing.
CAUTION: Connect gas pipe to furnace using a backup
wrench to avoid damaging gas controls.
An accessible manual shutoff valve MUST be installed upstream
of furnace gas controls and within 6 ft of furnace. A 1/8-in. NPT
plugged tapping, accessible for test gage connection, MUST be
installed immediately upstream of gas supply connection to
furnace and downstream of manual shutoff valve.
NOTE: The gas valve inlet press tap connection is suitable to use
as test gage connection providing test pressure DOES NOT exceed
maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 44.)
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before furnace is attached. In
Canada, refer to current edition of NSCNGPIC. If pressure
exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected
from furnace and capped before pressure test. If test pressure is
equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff
switch located on gas valve before test. It is recommended that
ground joint union be loosened before pressure testing. After all
connections have been made, purge lines and check for leakage.
WARNING: Gas valve shutoff switch MUST be facing
forward or tilted upward. Failure to follow this warning
could result in property damage or death.
WARNING: Never purge a gas line into a combustion
chamber. Never use matches, candles, flame, or other
sources of ignition for purpose of checking leakage. Use
a soap-and-water solution to check for leakage. A failure
to follow this warning could result in fire, explosion,
personal injury, or death.
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.
ELECTRICAL CONNECTIONS
See Fig. 22 for field wiring diagram showing typical field 115-v
and 24-v wiring. Check all factory and field electrical connections
for tightness.
—17—
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
NOTE 2
W
FIVE
WIRE
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
DISCONNECT
THREE-WIRE
HEATINGONLY
BLK
BLK
W
WHT
WHT
R
GND
GND
AUXILIARY
115-V
FIELD-SUPPLIED J-BOX
CONTROL
DISCONNECT
BOX
208/230- OR
460-V
THREE
PHASE
208/230-V
SINGLE
PHASE
G
C
GND
NOTE 1
CONDENSING
UNIT
Y
24-V
TERMINAL
BLOCK
FURNACE
TWO
WIRE
NOTES: 1. Connect Y-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A98209
→ Fig. 22—Heating and Cooling Application Wiring Diagram
TABLE 4—ELECTRICAL DATA
UNIT
SIZE
VOLTS—
HERTZ—
PHASE
024040
036040
024060
036060
048060
036080
048080
060080
048100
060100
060120
060140
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
115—60—1
OPERATING
VOLTAGE RANGE
Max*
Min*
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
MAX
UNIT
AMPS
UNIT
AMPACITY†
MIN
WIRE
GAGE
MAX WIRE
LENGTH
(FT)‡
MAX FUSE
OR CKT BKR
AMPS**
6.1
7.3
6.1
7.1
9.5
7.6
10.0
14.1
10.2
14.8
14.6
14.3
8.4
10.0
8.4
9.8
12.8
10.4
13.4
18.4
13.5
19.3
19.1
18.8
14
14
14
14
14
14
14
12
14
12
12
12
44
37
44
38
29
36
28
31
27
30
30
30
15
15
15
15
15
15
15
20
15
20
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.
rating plate. Also, check to be sure that service provided by utility
is sufficient to handle load imposed by this equipment. Refer to
rating plate or Table 4 for equipment electrical specifications.
WARNING: Blower access panel 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.
Make all electrical connections in accordance with National
Electrical Code (NEC) ANSI/NFPA 70-1999 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 subauthorities having jurisdiction.
CAUTION: Furnace control must be grounded for
proper operation or control will lock out. Control is
grounded through green wire routed to gas valve and
burner box screw.
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 LED status indicator light will
flash rapidly and furnace will NOT operate.
I. 115-V WIRING
Before proceeding with electrical connections, make certain that
voltage, frequency, and phase correspond to that specified on unit
—18—
automotive-type fuse located on control center. (See Fig. 25.) Any
electrical shorts of 24-v wiring during installation, service, or
maintenance may cause fuse to blow. If fuse replacement is
required, use only a fuse of identical size (3 amp).
NOTE: Use AWG No. 18 color-coded copper thermostat wire for
lengths up to 100 ft. For wire lengths over 100 ft, use AWG No.
16 wire.
III. ACCESSORIES
ELECTRIC
DISCONNECT
SWITCH
COPPER
WIRE ONLY
1. Electronic Air Cleaner (EAC)
Two quick-connect terminals marked EAC-1 and EAC-2
are provided for EAC connection. (See Fig. 25.) These
terminals are energized with 115v (1.5-amp maximum)
during blower motor operation.
2. Humidifier (HUM)
A quick-connect terminal (HUM) and screw terminal (COM)
are provided for 24-v humidifier connection. (See Fig. 24.)
HUM terminal is energized with 24v (0.5-amp maximum)
after inducer motor prepurge period.
NOTE: A field-supplied, 115-v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
ALUMINUM
WIRE
A93033
CAUTION: Do not connect aluminum wire between
disconnect switch and furnace. Use only copper wire.
WARNING: The cabinet MUST have an uninterrupted
or unbroken ground according to NEC ANSI/NFPA
70-1999 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.
DIRECT VENTING
The 340MAV Furnaces require a dedicated (one 340MAV furnace
only) direct-vent system. In a direct-vent system, all air for
combustion is taken directly from outside atmosphere, and all flue
products are discharged to outside atmosphere.
I. REMOVAL OF EXISTING FURNACES FROM COMMON VENT SYSTEMS
If furnace being replaced was connected to a common vent system
with other appliances, the following steps shall be followed with
each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system
are not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal
pitch as required in the NFGC or NSCNGPIC and these
instructions. Determine that there is no blockage or restriction, leakage, corrosion, and other deficiencies which could
cause an unsafe condition.
3. In so far as is 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. 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 shall operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
4. Follow the lighting instructions. Place the appliance being
inspected in operation. Adjust thermostat so appliance shall
operate continuously.
5. Test for draft hood equipped appliance spillage at the draft
hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.
6. 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-burning appliance to their previous
conditions of use.
7. If improper venting is observed during any of above tests,
the venting system must be corrected.
Vent system or vent connectors may need to be resized. For any
other appliances when resizing vent systems or vent connectors,
system or connector must be sized to approach minimum size as
determined using appropriate table found in the NFGC or NSCNGPIC.
J-BOX RELOCATION
1. Remove 2 screws holding auxiliary J-box. (See Fig. 23.)
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.
FACTORY
INSTALLED
LOCATION
ALTERNATE
FIELD
LOCATION
A93051
Fig. 23—Relocating J-Box
II. 24-V WIRING
Make field 24-v thermostat connections at 24-v terminal block on
control center. For proper cooling operation, Y wire from thermostat MUST be connected to Y terminal on control center, as shown
in Fig. 22. The 24-v terminal board is marked for easy connection
of field wiring. (See Fig. 24.) The 24-v circuit contains a 3-amp,
—19—
SEE NOTE #10
(NOT ON ALL MODELS)
SW2
BLOWER
OFF
DELAY SW1
BLOWER OFF DELAY
SELECTION CHART
G
R
Y
W
COM
HUM
PRS
RED
225 SEC
3 2 1
WHT
LS
SEC-1
SEC-2
BLU
1
2
3
PR2
WHT
BLK
1
1
2
PL2
PL5
HSI
M
PR1
PR2
115VAC
OL
1
3
24VAC
2
TEST/TWIN FU1
BLU (MED LO)
BRN
SEC-1
FRS
SEC-2
GVR-2
LS
7
1
R
AUX
IDM
WHT
ILK
HSIR
FUSED DISCONNECT
SWITCH (WHEN REQ'D)
NOTE #4
JB
OL
BLK
GRN
BLWR
IDR
HI/LO
FU2
PL1
GVR
NEUTRAL
PL1
PL2
PL3
PL4
PL5
PRS
SW1 & 2
TEST/TWIN
TRAN
GVR-1
CPU
9-CIRCUIT CONNECTOR
2-CIRCUIT PCB CONNECTOR
3-CIRCUIT IDM CONNECTOR
3-CIRCUIT IDM EXTENSION CONNECTOR
2-CIRCUIT HSI/PCB CONNECTOR
PRESSURE SWITCH, SPST-(N.O.)
BLOWER OFF DELAY
COMPONENT TEST & TWIN TERMINAL
TRANSFORMER-115VAC/24VAC
JUNCTION
UNMARKED TERMINAL
PCB TERMINAL
FACTORY WIRING (115VAC)
FACTORY WIRING (24VAC)
FIELD WIRING (115VAC)
FIELD WIRING (24VAC)
CONDUCTOR ON PCB
FIELD WIRING TERMINAL
FIELD EARTH GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
NOTE #6
PRS
3
L1
3-P
GV
2
1-M
GND
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FLAME PROVING ELECTRODE
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD INSTALLED & SUPPLIED)
EQUIPMENT GROUND
GAS VALVE-REDUNDANT OPERATORS
GAS VALVE RELAY, DPST-(N.O.)
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
HOT SURFACE IGNITOR (115 VAC)
HOT SURFACE IGNITOR RELAY, SPST-(N.O.)
24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)
INDUCED DRAFT MOTOR
INDUCED DRAFT RELAY, SPST-(N.O.)
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES
LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LIMIT SWITCH, AUTO RESET, SPST(N.C.)
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.
PRINTED CIRCUIT BOARD
(WHEN USED)
4
BRN
M
LGPS
W
CAP -2
LEGEND
GND
GV
GVR
HI/LO
HSI
HSIR
HUM
IDM
IDR
ILK
JB
LED
LGPS
LS
OL
PCB
CAP -2
2
GRN
BLWR
BLWM
CAP
CPU
EAC-1
EAC-2
FRS
FSE
FU1
FU2
BRN
NOTE #7
NOTE #12
HUM
BLWM
RED (LO)
BRN
PL4
PL3
CAP -1
AUX
1
3
TRAN
YEL (MED HI)
START
IDM
OL
2
IDR
WHT
WHT
BLK
BRN
CAP-1
BLWM
EAC-2
BRN
NOTE #8
START
OL
NOTE #5
WHT (COM)
1 2 3 PL4
GRN
HSI
EAC-2
COM
GRN
WHT
WHT
BLK
BLK
BLK
BLK
WHT
2
HSIR
WHT (COM)
GRN
BLK (HI)
1.5 AMP
PL3
PL5
1
24 VAC-3A
FUSE
COOL SPARE-1
BLOWER
SPEED
SELECT
HEAT SPARE-2
EAC-1
L2
BLWR
1
2
SPARE-1
NOTE #8
COOL
COM
COM
EAC-1
2-C
BLK
RED
FU1
120 VAC
L1 PR1
GV
FSE
RED
HI/LO
RELAY
PL2
FRS
HI/LO
BLWR
3-P
GRN
GVR
IDR
1-M
WHT
6 5 4
9 8 7
L1
L2
LO
MED LO
MED HI
HI
SPARE-2
HEAT
YEL
BLU
RED
PL1
EQUIPMENT GROUND
ILK
LED
135 SEC
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
GND
ORN
NOTE #6
90 SEC
HSIR
L1
TEST/TWIN
180 SEC
TO 115VAC FIELD DISCONNECT
NOTE #4
NEUTRAL
(WHEN USED)
LGPS
TRAN
PCB
Y
8
G
5
2-C
NOTE #5
FSE
6
COM
NOTES:
9
1. IF ANY OF THE ORIGINAL EQUIPMENT WIRE IS REPLACED USE WIRE RATED FOR 105˚C.
2. INDUCER (IDM) AND BLOWER (BLWM) MOTORS CONTAIN INTERNAL
AUTO-RESET THERMAL OVERLOAD SWITCHES (OL).
3. BLOWER MOTOR SPEED SELECTIONS ARE FOR AVERAGE CONDITIONS, SEE INSTALLATION
INSTRUCTIONS FOR DETAILS ON OPTIMUM SPEED SELECTION.
4. USE ONLY COPPER WIRE BETWEEN THE DISCONNECT SWITCH AND THE
FURNACE JUNCTION BOX (JB).
5. THIS WIRE MUST BE CONNECTED TO FURNACE SHEETMETAL FOR CONTROL TO PROVE
FLAME.
6. FACTORY CONNECTED WHEN LGPS NOT USED.
7. REPLACE ONLY WITH A 3 AMP FUSE.
8. YELLOW LEAD NOT ON ALL MOTORS.
9. BLOWER-ON DELAY, GAS HEATING 60 SECONDS, COOLING OR HEAT PUMP 2 SECONDS.
10. BLOWER-OFF DELAY, GAS HEATING 90, 135, 180 OR 225 SECONDS, COOLING OR
HEAT PUMP 90 SECONDS. (135 SECONDS ONLY ON SOME MODELS)
11. IGNITION-LOCKOUT WILL OCCUR AFTER FOUR CONSECUTIVE UNSUCCESSFUL
TRIALS-FOR-IGNITION. CONTROL WILL AUTO-RESET AFTER THREE HOURS.
12. SOME MODELS MAY HAVE SPADE QUICK CONNECT TERMINALS.
322854-101 REV. D (LIT)
A99106
→ Fig. 24—Wiring Diagram
—20—
COM W Y R G
24V
TEST/TWIN
HUM
24-V THERMOSTAT
TERMINALS
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX)
LED OPERATION &
DIAGNOSTIC LIGHT
HARNESS CONNECTOR
SEC-1
24-V TRANSFORMER SEC-2
3-AMP FUSE
SPARE-1
COOL
HEAT
BLOWER SPEED
SELECTION TERMINALS
SPARE-2
EAC-1
EAC-ELECTRONIC AIR CLEANER
TERMINALS (115-VAC 1.5 AMP MAX)
115-VAC (L1)
POWER SUPPLY
HOT SURFACE
IGNITOR CONNECTOR
EAC-2
115-VAC (L2) NEUTRAL
CONNECTION
INDUCER MOTOR
CONNECTOR
Fig. 25—Control Center
II.
COMBUSTION-AIR AND VENT PIPING
A95086
Furnace combustion-air and vent pipe connections must be attached as shown in Fig. 27. Combustion-air intake plug fitting and
inducer housing alternate vent cap may need to be relocated in
some applications.
→ A.
General
Combustion-air and vent pipe fittings must conform to American
National Standards Institute (ANSI) standards and American
Society for Testing and Materials (ASTM) standards D1785
(schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and
SDR-26 PVC), D2661 (ABS-DWV), F628 (schedule-40 ABS),
F891 (PVC-DWV cellular core) or F441 (schedule-40 CPVC pipe)
and F438 (schedule-40 CPVC fittings). Pipe cement and primer
must conform to ASTM standards D2564 or F493 (PVC or CPVC)
or D2235 (ABS). See Table 6 for maximum pipe lengths and Fig.
30, 31, 32, 33, and 34 for exterior piping arrangements.
NOTE: Slope combustion-air and vent pipes a minimum of 1/4
in. per linear ft with no sags between hangers.
CAUTION: When combustion-air pipe is installed
above a suspended ceiling, pipe must be insulated with
3/8-in. thick Armaflex-type insulation. Combustion-air
pipe should also be insulated when it passes through
warm, humid space.
In Canada construct all combustion-air and vent pipes for this unit
of CSA or ULC certified schedule-40 PVC, PVC-DWV or
ABS-DWV pipe and pipe cement. SDR pipe is NOT approved in
Canada.
CAUTION: When vent pipe is exposed to temperatures
below freezing, such as when it passes through an
unheated space or when a chimney is used as a raceway,
pipe must be insulated as shown in Table 7 with
Armaflex-type insulation.
NOTE: Furnace combustion-air and vent pipe connections are
sized for 2-in. pipe. Any pipe size change should be made outside
furnace casing in vertical pipe. (See Fig. 26.) This allows proper
drainage of vent condensate.
Combustion-air and vent pipes must terminate together in same
atmosphere pressure zone, either through roof or sidewall (roof
termination preferred), using accessory termination kit. See Table
5 for required clearances.
—21—
NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and
1 combustion-air pipe connection.
1 combustion-air pipe connection.
COMBUSTIONAIR
FURNACE
AIR
FLOW
COMBUSTIONAIR
VENT
VENT
VENT
VENT
NOT IN
HORIZONTAL
SECTION
COMBUSTIONAIR
PIPE DIAMETER
TRANSITION IN
VERTICAL SECTION
UPFLOW
AIR
FLOW
COMBUSTIONAIR
DOWNFLOW
A93034
Fig. 26—Combustion-Air and Vent Pipe Diameter
Transition Location and Elbow Configuration
COMBUSTIONAIR
TABLE 5—COMBUSTION-AIR AND VENT PIPE
TERMINATION CLEARANCES
LOCATION
Above grade level or above anticipated snow depth
Dryer vent
From plumbing vent stack
From any mechanical fresh air intake
For furnaces with an input capacity of
100,000 Btuh or less—from any nonmechanical air supply (windows or
doors which can be opened) or
combustion-air opening
For furnaces with an input capacity
greater than 100,000 Btuh—from any
non-mechanical air supply (windows
or doors which can be opened) or
combustion-air opening
From service regulator vent, electric
and gas meters, and relief equipment
Above grade when adjacent to public
walkway
1†
3
3
1
3
3
6
1
1
VENT
VENT
AIR
FLOW
CLEARANCE (FT)
U.S.A.
Canada
1
COMBUSTIONAIR
AIR
FLOW
HORIZONTAL-LEFT DISCHARGE
HORIZONTAL-RIGHT DISCHARGE
A96187
Fig. 27—Combustion-Air and Vent Pipe Connections
1
3
4*
6‡
Note 3
Note 3
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.
* Horizontal distance.
† 18 in. above roof surface in Canada.
‡ 36 in. to electric meter in Canada only.
NOTES:
1. If installing 2 adjacent 340MAV Furnaces, refer to Multiventing and Vent
Terminations section for proper vent configurations.
2. When locating combustion-air and vent terminations, consideration must be
given to prevailing winds, location, and other conditions which may cause
recirculation of the appliance’s own flue products or the flue products of
adjacent vents. Recirculation can cause poor combustion, inlet condensate
problems, and accelerated corrosion of heat exchangers.
3. Vent termination can not terminate less than 2 ft horizontal and 7 ft above
public walkway or where condensate vapor or droplets may be a hazard.
WARNING: All combustion-air and vent pipes must be
airtight and watertight. Pipes must also terminate exactly
as shown in Fig. 30, 31, 32, 33, or 34. Failure to follow
this warning could result in property damage, personal
injury, or death.
NOTE: The minimum combustion-air and vent pipe length (each)
for these furnaces is 5 ft. Short pipe lengths (5-8 ft) may discharge
water droplets. These droplets may be undesirable, and a 12-in.
minimum offset pipe section is recommended, as shown in Fig. 28,
to reduce excessive droplets from exiting vent pipe outlet.
CAUTION: Combustion air must not be taken from
inside structure because inside air is frequently contaminated by halogens, which include fluorides, chlorides,
bromides, and iodides. These elements are found in
aerosols, detergents, bleaches, cleaning solvents, salts, air
fresheners, adhesives, paint, and other household products. Locate combustion-air inlet as far as possible from
swimming pool and swimming pool pump house.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
B. Combustion-Air and Vent Pipe Diameter
Determine combustion-air and vent pipe diameter.
1. Using Table 6, individually determine the combustion-air
and vent pipe diameters. Pick the larger of these 2 pipe
diameters and use this diameter for both combustion-air and
vent pipes.
2. When installing vent systems of short pipe length, use the
smallest allowable pipe diameter. Do not use pipe size
greater than required or incomplete combustion, flame
disturbance, or flame sense lockout may occur.
NOTE: Do not count elbows or pipe sections in terminations or
within furnace. See shaded areas in Fig. 30, 31, 32, 33, and 34.
—22—
12″ MIN
12″ MIN
VENT PIPE
VENT PIPE
COMBUSTION-AIR PIPE
HORIZONTAL TO ROOF
COMBUSTION-AIR PIPE
HORIZONTAL TO SIDEWALL
COMBUSTION-AIR PIPE
VENT PIPE
COMBUSTION-AIR 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.
A96230
Fig. 28—Short Vent (5 to 8 Ft) System
b. Reposition combustion-air intake housing plug fitting in
appropriate unused intake housing connection.
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, along with 5
elbows and 34 ft of combustion-air pipe. Table 6 indicates
this application would allow a 2-in. diameter vent pipe, but
require a 2-1/2 in. diameter combustion air pipe (2-in. pipe
is good for 35 ft with 3 elbows, but only 30 ft with 5
elbows). Therefore, 2-1/2 in. diameter pipe must be used
for both vent and combustion-air pipes since larger required
diameter must always be used for both pipes. If same
installation were in Albuquerque, elevation 5250 ft above
sea level, installation would require 2-1/2 in. vent pipe and
combustion-air pipe. At 5001- to 6000-ft elevation, 2-in.
pipe is only good for 17 ft with 5 elbows, and 2-1/2 in. pipe
is good for 70 ft with 5 elbows.
c. If required, insert perforated disk assembly (factorysupplied in loose parts bag) in intake housing where
combustion-air intake pipe will be connected. If half disk
set is required, install with shoulder of disk against stop
in combustion-air inlet.
d. 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.
e. Insert 2-in. diameter pipe into intake housing.
NOTE: A 2-in. diameter pipe must be used within the furnace
casing. Make all pipe diameter transitions outside furnace casing.
f. Drill a 1/8-in. hole in 2-in. combustion-air pipe using
hole in intake housing as a guide.
g. Install a field-supplied No. 6 or No. 8 sheet metal screw
into combustion-air pipe.
C. Combustion-Air and Vent Pipe Attachment
NOTE: All pipe joints must be watertight except attachment of
combustion-air pipe to inlet housing connection, since it may be
necessary to remove pipe for servicing.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake
housing or fitting may cause air leakage to occur.
NOTE: Do not attach combustion-air intake pipe permanently to
combustion-air intake housing since it may be necessary to remove
pipe for service of ignitor or flame sensor.
1. Attach combustion-air pipe as follows:
a. Determine location of combustion-air intake pipe connection to combustion-air intake housing as shown in
Fig. 27 for application.
—23—
TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT)
ALTITUDE (FT)
0 to 2000
ALTITUDE (FT)
ALTITUDE (FT)
3001 to 4000
NUMBER OF 90° ELBOWS
2
3
4
5
NA
NA
NA
NA
70
65
60
60
70
70
70
70
6
NA
55
70
1-1/2
20
15
NA
2
70
70
70
70
70
70
1-1/2
2
2-1/2
2
2-1/2
3
2-1/2 one disk
3†
3† no disk
4† no disk
2-1/2 one disk
3† one disk
3† no disk
4† no disk
10
55
70
5
40
70
10
45
70
70
5
40
60
70
NA
50
70
NA
30
70
NA
40
70
70
NA
35
56
70
NA
35
70
NA
20
70
NA
35
70
70
NA
30
52
70
NA
30
70
NA
20
70
NA
30
70
70
NA
25
48
70
NA
30
70
NA
10
70
NA
25
70
70
NA
20
44
70
NA
20
70
NA
NA
70
NA
20
70
70
NA
15
40
70
2
62
70
NUMBER OF 90° ELBOWS
3
4
5
57
52
52
70
70
70
6
47
70
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
024060
036060
048060
2 Pipe or 2-In.
Concentric
10
5
NA
036080
048080
060080
2 Pipe or 2-In.
Concentric
048100
060100
2 Pipe or 3-In.
Concentric
060120
2 Pipe or 3-In.
Concentric
060140
2 Pipe or 3-In.
Concentric
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
1-1/2
2
1
67
70
2 Pipe or 2-In.
Concentric
1-1/2
17
12
7
NA
NA
NA
2
70
67
66
61
61
61
2 Pipe or 2-In.
Concentric
2
49
44
30
25
25
15
024060
036060
048060
036080
048080
060080
2001 to 3000
1
1-1/2
2
1
5
70
70
TERMINATION
TYPE
UNIT SIZE
2-1/2
70
70
70
70
70
70
2-1/2
3
3
3† no disk
4† no disk
3† one disk
3† no disk
4† no disk
35
70
14
70
70
20
39
70
26
70
9
70
70
15
35
70
16
70
NA
63
70
10
31
70
16
70
NA
56
70
5
27
70
6
66
NA
50
70
NA
23
70
NA
61
NA
43
70
NA
19
70
2
59
70
NUMBER OF 90° ELBOWS
3
4
5
54
49
48
70
70
70
6
43
70
048100
060100
2 Pipe or 3-In.
Concentric
060120
2 Pipe or 3-In.
Concentric
060140
2 Pipe or 3-In.
Concentric
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
1-1/2
2
1
64
70
2 Pipe or 2-In.
Concentric
1-1/2
16
11
6
NA
NA
NA
2
68
63
62
57
57
56
2 Pipe or 2-In.
Concentric
2
46
41
28
23
22
13
024060
036060
048060
036080
048080
060080
048100
060100
2 Pipe or 3-In.
Concentric
060120
2 Pipe or 3-In.
Concentric
060140
2 Pipe or 3-In.
Concentric
2-1/2
70
70
70
70
70
70
2-1/2
3
3† no disk
4† no disk
3† one disk
3† no disk
4† no disk
33
70
65
70
11
30
70
24
70
58
70
6
26
70
15
70
51
70
NA
22
70
14
66
44
70
NA
18
70
5
61
38
70
NA
14
70
NA
56
31
70
NA
10
70
See notes on page 26.
—24—
TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT)
ALTITUDE (FT)
4001 to 5000‡
ALTITUDE (FT)
5001 to 6000‡
ALTITUDE (FT)
6001 to 7000‡
ALTITUDE(FT)
7001 to 8000‡
Continued
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
1-1/2
2
1
60
70
NUMBER OF 90° ELBOWS
2
3
4
5
55
50
45
44
70
70
70
70
2 Pipe or 2-In.
Concentric
1-1/2
15
10
5
NA
NA
NA
2
64
59
58
53
52
52
2 Pipe or 2-In.
Concentric
2
44
39
26
21
20
11
2-1/2
70
70
70
70
70
70
31
70
53
70
21
69
22
70
46
70
17
64
13
67
40
70
13
59
12
62
33
70
9
54
NA
57
26
70
5
49
NA
52
20
70
NA
44
2
52
70
NUMBER OF 90° ELBOWS
3
4
5
47
42
40
70
70
70
6
35
70
024060
036060
048060
036080
048080
060080
6
39
70
048100
060100
2 Pipe or 3-In.
Concentric
060120
2 Pipe or 3-In.
Concentric
060140
2 Pipe or 3-In.
Concentric
2-1/2
3
3† no disk
4† no disk
3† no disk
4† no disk
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
1-1/2
2
1
57
70
2 Pipe or 2-In.
Concentric
1-1/2
14
9
NA
NA
NA
NA
2
60
55
54
49
48
47
2 Pipe or 2-In.
Concentric
2
41
36
23
18
17
8
2-1/2
70
70
70
70
70
70
29
70
42
70
12
42
21
67
35
70
8
37
12
62
29
70
NA
32
11
57
22
70
NA
27
NA
52
15
70
NA
22
NA
47
9
70
NA
17
2
48
70
NUMBER OF 90° ELBOWS
3
4
5
43
38
37
68
67
66
6
32
64
024060
036060
048060
036080
048080
060080
048100
060100
2 Pipe or 3-In.
Concentric
060120
2 Pipe or 3-In.
Concentric
060140
2 Pipe or 3-In.
Concentric
2-1/2
3
3† no disk
4† no disk
3† no disk
4† no disk
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
1-1/2
2
1
53
70
2 Pipe or 2-In.
Concentric
1-1/2
13
8
NA
NA
NA
NA
2
57
52
50
45
44
43
024060
036060
048060
036080
048080
060080
2 Pipe or 2-In.
Concentric
2
38
33
21
16
15
6
2-1/2
70
70
68
67
66
64
2-1/2
3
3† no disk
4† no disk
27
68
31
70
19
63
24
70
10
58
18
70
9
53
11
70
NA
48
NA
67
NA
43
NA
62
17
12
7
NA
NA
NA
2
44
65
NUMBER OF 90° ELBOWS
3
4
5
39
34
33
63
62
60
6
28
59
048100
060100
2 Pipe or 3-In.
Concentric
060120
2 Pipe or 3-In.
Concentric
060140
2 Pipe or 3-In.
Concentric
4† no disk
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
1-1/2
2
1
49
66
2 Pipe or 2-In.
Concentric
1-1/2
12
7
NA
NA
NA
2
53
48
46
41
40
38
2 Pipe or 2-In.
Concentric
2
36
31
19
14
12
NA
024060
036060
048060
036080
048080
060080
048100
060100
2 Pipe or 3 In.
Concentric
060120
2 Pipe or 3-In.
Concentric
NA
2-1/2
66
65
63
62
60
59
2-1/2
3
3† no disk
4† no disk
25
63
20
61
17
58
13
56
8
53
7
51
7
48
NA
46
NA
43
NA
41
NA
38
NA
36
060140
NA
See notes on page 26.
—25—
TABLE 6—MAXIMUM ALLOWABLE PIPE LENGTH (FT)
ALTITUDE (FT)
8001 to 9000‡
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
024060
036060
048060
036080
048080
060080
1-1/2
2
2
41
60
2 Pipe or 2-In.
Concentric
1-1/2
11
6
NA
NA
NA
2
49
44
42
37
35
34
2 Pipe or 2-In.
Concentric
2
33
28
17
12
10
NA
2-1/2
9001 to 10,000‡
6
24
53
NA
62
60
58
56
55
53
23
59
10
35
NA
15
54
NA
30
7
49
NA
25
5
44
NA
20
NA
39
NA
15
NA
34
NA
10
1-1/2
2
1
42
57
2
37
55
NUMBER OF 90° ELBOWS
3
4
5
32
27
25
53
51
49
6
20
47
2
45
40
38
048100
060100
2 Pipe or 3-In.
Concentric
060120
2 Pipe or 3-In.
Concentric
2-1/2
3
3† no disk
4† no disk
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
024040
036040
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
024060
036060
048060
036080
048080
060080
NUMBER OF 90° ELBOWS
3
4
5
36
31
29
58
56
55
1
46
62
060140
ALTITUDE (FT)
Continued
33
31
29
2 Pipe or 2-In.
Concentric
2
30
25
14
9
7
NA
2-1/2
57
55
53
51
49
47
048100
060100
2 Pipe or 3-In.
Concentric
2-1/2
3
21
54
13
49
5
44
NA
39
NA
34
NA
29
060120
2 Pipe or 3-In.
Concentric
4† no disk
10
5
NA
NA
NA
NA
060140
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.
The combustion-air intake plug fitting must be installed in
unused combustion-air intake housing. This fitting must be
attached by using RTV sealant, or by drilling a 1/8-in. hole
in fitting, using hole in intake housing as a guide. Install a
field-supplied No. 6 or No. 8 sheet metal screw.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake
housing or fitting may cause air leakage to occur.
A plugged drain connection has been provided on this
fitting for use when moisture is found in combustion-air
intake pipe and combustion box.
NOTE: Moisture in combustion-air intake may be result of
improper termination. Ensure combustion-air intake pipe is similar
to that shown in Fig. 30, 31, 32, 33, or 34 so it will not be
susceptible to areas where light snow or other sources of moisture
could be pulled in.
BURNER
BOX
3/16"
DRILL
COMBUSTION –
AIR PIPE
4″
MIN
TRAP
TO OPEN
DRAIN
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. 29.)
→
COMBUSTION – AIR
INTAKE HOUSING
3/8" ID TUBE
A93035
Fig. 29—Intake Housing Plug Fitting Drain
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.
2. Attach vent pipe as follows:
a. Determine location of vent pipe connection to inducer
housing as shown in Fig. 27 for application.
b. Reposition elastomeric (rubber) inducer housing outlet
cap and clamp to appropriate unused inducer housing
connection. Tighten clamp.
—26—
→
→
III. CONCENTRIC VENT AND COMBUSTION-AIR
TERMINATION KIT INSTALLATION
c. 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.
NOTE: If these instructions differ from those packaged with
termination kit, follow kit instructions.
d. 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.
Combustion-air and vent pipes must terminate outside structure. A
factory accessory termination kit must be installed in 1 of the
installations shown in Fig. 30, 31, 32, 33, or 34. Four termination
kits are available.
1. The 2-in. termination bracket kit is for 1-in., 1-1/2 in., and
2-in. diameter 2-pipe termination systems.
2. The 3-in. termination bracket kit is for 2-1/2 in., 3-in., and
4-in. diameter 2-pipe termination systems.
3. The 2-in. concentric vent/air termination kit is for 1-in.,
1-1/2 in., 2-in., and 2-1/2 in. diameter pipe systems when
single penetration of wall or roof is desired.
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.
4. The 3-in. concentric vent/air termination kit is for 2-1/2 in.,
3-in., and 4-in. diameter pipe systems when single penetration of wall or roof is desired.
NOTE: Shaded parts in Fig. 30, 31, 32, 33, and 34 are considered
to be termination. These components should NOT be counted
when determining pipe diameter. Roof termination is preferred
since it is less susceptible to damage, has reduced chances to take
in contaminants, and has less visible vent vapors. (See Fig. 30 or
31.) Sidewall termination may require sealing or shielding of
building surfaces with a corrosive resistance material due to
corrosive combustion products of vent system.
NOTE: A 2-in. diameter pipe must be used within the furnace
casing. Make all pipe diameter transitions outside furnace casing.
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
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.
A. Extended Exposed Sidewall Pipes
Sidewall combustion-air and vent pipe terminations may be
extended beyond area shown in Fig. 33 or 34 in outside ambient by
insulating pipes as indicated in Table 7.
1. Determine combustion-air and vent pipe diameters, as
stated above, using total pipe length and number of elbows.
3. Working from furnace to outside, cut pipe to required
length(s).
2. Using winter design temperature (used in load calculations),
find appropriate temperature for your application and furnace model.
4. Deburr inside and outside of pipe.
5. Chamfer outside edge of pipe for better distribution of
primer and cement.
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.
6. Clean and dry all surfaces to be joined.
7. Check dry fit of pipe and mark insertion depth on pipe.
NOTE: It is recommended that all pipes be cut, prepared, and
preassembled before permanently cementing any joint.
B.
8. After pipes have been cut and preassembled, apply generous layer of cement primer to pipe fitting socket and end of
pipe to insertion mark. Quickly apply approved cement to
end of pipe and fitting socket (over primer). Apply cement
in a light, uniform coat on inside of socket to prevent
buildup of excess cement. Apply second coat.
Two-Pipe Termination Kit
1. Determine location for termination.
Consideration of the following should be made when
determining an appropriate location for termination kit.
a. Comply with all clearance requirements as stated in
Table 5.
b. Termination kit should be positioned where vent vapors
will not damage plants/shrubs or air conditioning equipment.
9. While cement is still wet, twist pipe into socket with 1/4
turn. Be sure pipe is fully inserted into fitting socket.
10. Wipe excess cement from joint. A continuous bead of
cement will be visible around perimeter of a properly made
joint.
c. Termination kit should be positioned so that it will not be
affected by wind eddy (such as inside building corners)
or allow recirculation of flue gases, airborne leaves, or
light snow.
11. Handle pipe joints carefully until cement sets.
12. Support combustion-air and vent piping a minimum of
every 5 ft (3 ft for SDR-21 or -26 PVC) using perforated
metal hanging strap.
d. Termination kit should be positioned where it will not be
damaged by or subjected to foreign objects, such as
stones, balls, etc.
13. Slope combustion-air and vent pipes toward furnace a
minimum of 1/4 in. per linear ft with no sags between
hangers.
e. Termination kit should be positioned where vent vapors
are not objectionable.
2. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size
being used.
14. Use appropriate methods to seal openings where vent and
combustion-air pipes pass through roof or side wall.
—27—
→ TABLE 7—MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH (FT) WITH AND WITHOUT INSULATION
IN WINTER DESIGN TEMPERATURE AMBIENT*
UNIT
SIZE
040
060
080
100
120
140
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
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
3
3
3
4
4
4
WITHOUT
INSULATION
WITH 3/8-IN. OR
THICKER INSULATION†
51
28
16
45
22
10
65
35
20
55
48
30
70
47
28
40
40
38
70
50
28
70
61
37
70
48
23
60
60
44
70
57
30
70
70
70
70
70
58
70
70
70
55
55
55
70
70
70
40
40
40
70
70
70
70
70
70
70
70
70
60
60
60
70
70
70
* 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 6.
† Insulation thickness based on R value of 3.5 (ft.2-°F-hr.)/(Btu-in.)
3. Loosely install elbow in bracket and place assembly on
combustion-air pipe.
b. Termination kit should be positioned where vent vapors
will not damage plants/shrubs or air conditioning equipment.
Roof terminations—Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so bracket
will mount as shown in Fig. 30.
c. Termination kit should be positioned so it will not be
affected by wind eddy (such as inside building corners)
or that may allow recirculation of flue gases, airborne
leaves, or light snow.
For applications using combustion-air pipe option, indicated by dashed lines in Fig. 30, install 90° street elbow into
90° elbow, making U-fitting. A 180° U-fitting may be used.
d. Termination kit should be positioned where it will not be
damaged by or subjected to foreign objects, such as
stones, balls, etc.
Sidewall terminations—Install bracket as shown in Fig. 33
or 34.
e. Termination kit should be positioned where vent vapors
are not objectionable.
For applications using vent pipe option indicated by dashed
lines in Fig. 33, rotate vent elbow 90° from position shown
in Fig. 33.
2. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in.
diameter hole for 3-in. kit.
4. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
3. Loosely assemble concentric vent/air termination components together using instructions in kit.
5. Check required dimensions as shown in Fig. 30, 33, or 34.
C.
Concentric Vent/Air Termination Kit
4. Slide assembled kit with rain shield REMOVED through
hole.
1. Determine location for termination.
NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole.
Consideration of the following should be made when
determining an appropriate location for termination kit.
a. Comply with all clearance requirements as stated in
Table 5.
Roof terminations—Locate assembly through roof to appropriate height as shown in Fig. 31.
—28—
ROOF
18″ MAXIMUM
BRACKET
COUPLING
COMBUSTION
AIR
VERTICAL SEPARATION
BETWEEN COMBUSTION
AIR AND VENT
8 3/4″ FOR 3″ KIT
6 3/4″ FOR 2″ KIT
VENT
MAINTAIN 12 IN. MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL.
MAXIMUM OF 24 IN. ABOVE ROOF.
A87224
Fig. 30—Roof Termination (Preferred)
OVERHANG OR ROOF
12″ MINIMUM
1″ MAXIMUM
VENT
COMBUSTION-AIR
VENT
COMBUSTION
AIR
MAINTAIN 12 IN.
CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
WHICHEVER IS
GREATER.
MAINTAIN 12 IN.
(18 IN. FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24 IN. ABOVE ROOF.
A93055
A93054
Fig. 32—Concentric Vent and Combustion-Air Side
Termination
Fig. 31—Concentric Vent and Combustion-Air Roof
Termination (Preferred)
OVERHANG OR ROOF
OVERHANG OR ROOF
12″ MINIMUM
12″ MINIMUM
VENT
VENT
90°
90°
BRACKET
COUPLING
BRACKET
12 IN. SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR AND
BOTTOM OF VENT
MAINTAIN 12 IN.
CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
COMBUSTION-AIR WHICHEVER IS
GREATER.
COMBUSTION-AIR
(ELBOW PARALLEL
TO WALL)
A87225
Fig. 33—Sidewall Termination of 12 in. or More
12 IN. SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR AND
BOTTOM OF VENT
MAINTAIN 12 IN.
CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
WHICHEVER IS
GREATER.
A87226
Fig. 34—Sidewall Termination of Less than 12 in.
—29—
A
A96128
Fig. 35—Rooftop Termination (Dimension "A" is Touching or 2-In. Maximum Separation)
1″ MAXIMUM
(TYP)
VENT
VENT
A
COMBUSTION AIR
VENT
COMBUSTION
AIR
A
VENT
A93056
A93057
Fig. 36—Concentric Vent and Combustion-Air
Roof Termination
(Dimension "A" is Touching or 2-In. Maximum Separation)
Fig. 37—Concentric Vent and Combustion-Air
Side Termination
(Dimension "A" is Touching or 2-In. Maximum Separation)
VENT
VENT
COMBUSTION AIR
COMBUSTION AIR
COMBUSTION AIR
COMBUSTION AIR
A
A
A96129
A96130
Fig. 38—Sidewall Termination of 12 in. or Less
(Dimension "A" is Touching or 2-In. Maximum Separation)
Fig. 39—Sidewall Termination of More Than 12 in.
(Dimension "A" is Touching or 2-In. Maximum Separation)
—30—
Sidewall terminations—Locate assembly through sidewall
with rain shield positioned no more than 1-in. from wall as
shown in Fig. 32.
5. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
6. Check required dimensions as shown in Fig. 31 or 32.
IV.
MULTIVENTING AND VENT TERMINATIONS
When 2 or more 340MAV Furnaces are vented near each other,
each furnace must be individually vented. NEVER common vent
or breach vent 340MAV furnaces. When 2 or more 340MAV
furnaces are vented near each other, 2 vent terminations may be
installed as shown in Fig. 35, 36, 37, 38, or 39, but next vent
termination must be at least 36 in. away from first 2 terminations.
It is important that vent terminations be made as shown to avoid
recirculation of flue gases. Dimension "A" in Fig. 35, 36, 37, 38,
and 39 represents distance between pipes or rain shields, as
touching or 2-in. maximum separation.
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
CONDENSATE DRAIN
I. GENERAL
Condensate trap is shipped installed in the blower shelf and factory
connected for UPFLOW applications. Condensate trap must be
RELOCATED for use in DOWNFLOW and HORIZONTAL
applications.
Condensate trap MUST be used for all applications.
An external trap is not required when connecting the field drain to
this condensate trap.
The field drain connection (condensate trap or drain tube coupling)
is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube
connection.
Drain pipe and fittings must conform to ANSI standards and
ASTM D1785 or D2846. CPVC or PVC cement and primer must
conform to ASTM D2564 or F493. In Canada, use CSA or ULC
certified schedule 40 CPVC or PVC drain pipe, fittings, and
cement.
When a condensate pump is required, select a pump which is
approved for condensing furnace applications. To avoid condensate spillage, select a pump with an overflow switch.
Furnace condensate is mildly acidic, typically in the pH range of
3.2 to 4.5. Due to corrosive nature of this condensate, a condensate
pH neutralizing filter may be desired. Check with local authorities
to determine if a pH neutralizer is required.
II. 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. 40 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.
A93058
CAUTION: Unit must not be installed, operated, and
then turned off and left in an unoccupied structure during
cold weather when temperature drops to 32°F and below
unless drain trap and drain line have adequate freeze
protection. See Service and Maintenance Instructions for
winterizing procedure.
OPEN STAND
PIPE FOR
A/C OR
HUMIDIFIER
DRAIN
TEE
TO OPEN
DRAIN
A94054
Fig. 40—Example of Field Drain Attachment
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. 41.)
3. Use wire ties to secure heat tape in place. Wire ties can be
positioned in notches of condensate trap sides. (See Fig.
41.)
4. Wrap field drain pipe with remaining heat tape, approximately 1 wrap per ft.
WARNING: Caution should be taken to prevent draining where slippery conditions may cause personal injuries. Excessive condensate draining may cause saturated
soil conditions which may result in damage to plants.
III. CONDENSATE DRAIN PROTECTION
Freezing condensate left in condensate trap and drain line may
cause cracks, and possible water damage may occur. If freeze
protection is required, use condensate freeze protection accessory
—31—
5. When using field-supplied heat tape, follow heat tape
manufacturer’s instructions for all other installation guidelines.
6. Blower off delay—When thermostat is satisfied, circuit
between R-W is opened, de-energizing gas valve (stopping
gas flow to burners) and humidifier. Blower motor and
electronic air cleaner remain energized for 135 sec.
SEQUENCE OF OPERATION
7. Post purge—Inducer motor remains energized 15 sec after
burners are extinguished (5 sec if jumper has been cut for
140 size unit in downflow orientation).
CAUTION: Furnace control must be grounded for
proper operation, or control will lock out. Control is
grounded through green wire routed to gas valve and
burner box screw.
II.
Using schematic diagram, follow sequence of operation through
different modes. (See Fig. 24.) Read and follow wiring diagram
carefully.
NOTE: If 115-v power supply to furnace or blower access panel
switch is interrupted during a call for heat, blower operates for 90
sec when power is restored before heating cycle is resumed.
When thermostat is satisfied, R-G and R-Y circuits are opened,
furnace blower continues operating on cooling speed for an
additional 90 sec.
III.
I. HEATING MODE
When wall thermostat calls for heat, R-W circuit closes. Furnace
control performs a self-check, verifies pressure switch contacts are
open, and starts inducer motor.
1. Prepurge period—As inducer motor comes up to speed,
pressure switch contacts close to begin a 15-sec prepurge
period.
2. Ignitor warm up—At end of prepurge period, ignitor is
energized for a 17-sec ignitor warm-up period.
3. Ignition sequence—When ignitor warm-up period is completed, gas valve opens, permitting gas flow to burners
where it is ignited. After 5 sec, ignitor is de-energized and
a 2-sec flame-sensing period begins.
HUM terminal on control center is energized with gas
valve. See Accessories — Humidifier section.
4. Flame sensing—When burner flame is sensed, control
begins blower on delay period and continues holding gas
valve open.
If burner flame is not sensed, control center de-energizes
gas valve and ignition sequence is repeated.
NOTE: Ignition sequence repeats 3 additional times before a
lockout occurs. Lockout automatically resets after 3 hr or can be
manually reset by turning off 115v (not at thermostat) for 3 sec
minimum, then turning it on again.
5. Blower on delay—Sixty sec after burner flame is proven
(40 sec if jumper has been cut for 140 size unit in downflow
orientation), blower motor is energized on heating speed.
Simultaneously, electronic air cleaner terminal EAC-1 is
energized.
CONTINUOUS BLOWER MODE
When R-G circuit is made, blower motor operates on heating
speed.
NOTE: Electronic air cleaner EAC-1 terminal is energized with
115v whenever blower is operating.
If a call for heat (R-W) occurs while thermostat is in continuous
blower mode, blower stops to allow furnace heat exchangers to
heat up more quickly, then restarts at end of blower on delay
period of 60 sec (40 sec if jumper has been cut for 140 size unit in
downflow orientation).
Blower reverts to continuous operation after heating cycle is
completed.
If a call for cooling (R-Y) occurs while thermostat is in continuous
blower mode, blower changes from continuous blower speed
(heating speed) to cooling speed.
When thermostat cooling call is satisfied, R-Y opens and blower
operates an additional 90 sec at cooling speed before reverting
back to continuous operation (heating speed).
IV. HEAT PUMP MODE
When installed with a heat pump, furnace control automatically
changes blower on delay timing sequence to avoid no blower
operation time during demand defrost cycles. When R-W and R-Y
or R-W, R-Y, and R-G thermostat inputs are received at the same
time at furnace control center, control starts blower in heating
speed. Then a gas heat mode begins. Blower remains operating at
heating speed for 15 sec or until end of prepurge period, then
blower shuts off until end of ignitor warm up and trial for ignition
periods (a total of 24 sec). Blower restarts at heating speed.
When R-W thermostat call disappears, control completes inducer
post-purge period of 15 sec (5 sec if jumper has been cut for 140
size unit in downflow orientation) and changes to cooling speed
after a 2-sec delay.
If R-W, R-Y, and R-G thermostat signals should disappear
simultaneously, blower remains on for heating blower off delay
period of 135 sec, and the inducer goes through 15 sec post-purge
period (5 sec if jumper has been cut for 140 size unit in downflow
orientation). If R-W and R-Y thermostat signals should disappear,
leaving R-G thermostat signal, blower remains on in heating speed
and inducer remains on for 15 sec to complete post-purge period (5
sec if jumper has been cut for 140 size unit in downflow
orientation).
Control initiates a 90-sec blower only on period before starting
another heat pump cycle if there is a power interruption. Anytime
control senses false flame, control locks out of heating mode. This
reaction occurs because control ignores W input due to false flame
signal and, as a result, sees only Y input and goes into cooling
mode blower off delay. All other control functions remain in
standard format.
CONDENSATE TRAP
WIRE TIE(S)
HEAT TAPE
(3 WRAPS MINIMUM)
Fig. 41—Condensate Trap Heat Tape
COOLING MODE
When thermostat calls for cooling, R-G and R-Y circuits close.
R-Y circuit starts outdoor condensing unit, and combined R-Y and
R-G circuit starts furnace blower motor on cooling speed. Electronic air cleaner EAC-1 terminal is energized with 115v whenever
blower is operating.
A93036
—32—
NOTE: EAC-1 terminal is energized whenever blower operates.
HUM terminal is only energized when gas valve is energized.
V.
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.
COMPONENT TEST
A. Component Test Sequence
NOTE: All components are functionally operated except the gas
valve.
When component test is initiated, the following sequence of events
occurs:
4. BRIEFLY short (jumper) TEST, 1/4-in. quick-connect
terminal on control center (adjacent to the LED diagnostic
light) and the COM terminal on thermostat connection block.
(See Fig. 25.)
NOTE: If TEST to COM terminals are jumpered longer than 2 sec,
LED will flash rapidly, and retrieval request will be ignored.
1. LED flashes a status code 4 times.
2. Inducer motor starts and continues to run for remainder of
component test.
3. Hot surface ignitor is energized for 15 sec, then deenergized.
5. When above items have been completed, the component
test sequence will occur as described in the Component Test
Sequence section above.
NOTE: Be sure to record the status code which is flashed 4 times
at start of component test for further troubleshooting.
4. Main blower operates at cooling speed for 10 sec, then turns
off.
5. Main blower operates at heating speed for 10 sec, then turns
off.
6. After component test is completed and furnace is operating
properly, release blower access panel door switch, replace
blower access panel, and replace main furnace door.
6. Inducer motor stops.
Component test can be initiated by one of the following procedures.
START-UP PROCEDURES
I.
B. Initiating Component Test By Removing Main Limit
Switch Wire
NOTE: NO thermostat signal may be present at control center
and all blower time delay off periods must be completed.
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 LED status light will flash
rapidly and furnace will not operate.
1. Leave 115-v power to furnace turned on.
2. Remove main furnace door.
3. Look into blower access panel sight glass for current LED
status.
2. Thermostat wire connections at terminals R, W, G, and Y
must be made at 24-v terminal block on control center.
NOTE: Leave blower access panel installed to maintain power to
control center to view current LED status.
3. Natural gas service pressure must not exceed 0.5 psig
(14-in. wc), but must be no less than 0.16 psig (4.5-in. wc).
4. Blower access panel must be in place to complete 24-v
electrical circuit to furnace.
4. BRIEFLY remove either wire from the main limit switch
until the LED goes out, then reconnect it.
CAUTION: These furnaces are equipped with a manual
reset limit switch in burner box. This switch will open if
an overheat condition (rollout) occurs in burner enclosure. Correct inadequate combustion-air supply or improper venting condition and reset switch. DO NOT
jumper this switch.
CAUTION: Make sure limit switch wire does not contact any metallic component such as the gas valve. If wire
is shorted, 3-amp fuse on control center will blow.
NOTE: If wire to main limit is disconnected longer than 4 sec, the
control senses limit circuit is open. Main blower will start, and
status code retrieval request will be ignored.
Before operating furnace, check each manual reset switch for
continuity. If necessary, press button to reset switch.
5. When above items have been completed, the component
test sequence will occur as described in the Component Test
Sequence section above.
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.
NOTE: Be sure to record the status code which is flashed 4 times
at start of component test for further troubleshooting.
6. After component test is completed and LED is ON continuously indicating the furnace is ready to operate when a
signal from the thermostat is received, replace main furnace
door.
1. Remove upper inducer housing drain connection cap. (See
Fig. 42.)
C. Initiating Component Test By Jumpering Control
TEST Terminal
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. 43.)
1. Remove main furnace door.
2. Remove blower access panel.
3. Manually close blower access panel door switch. Use a
piece of tape to hold switch closed.
—33—
5. Remove funnel and tube from inducer housing and replace
drain connection cap and clamp.
III. PURGE GAS LINES
If not previously done, purge lines after all connections have been
made and check for leaks.
WARNING: Never purge a gas line into a combustion
chamber. Never use matches, candles, flame, or other
sources of ignition for purpose of checking leakage. Use
a soap-and-water solution to check for leakage. Failure to
follow this warning could result in fire, explosion, personal injury, or death.
IV.
ADJUSTMENTS
A.
Set Gas Input Rate
Furnace gas input rate on rating plate is for installations at altitudes
up to 2000 ft.
In the U.S.A., the input ratings for altitudes above 2000 ft must be
reduced by 2 percent for each 1000 ft above sea level.
In Canada, the input ratings must be derated by 5 percent for
altitudes of 2000 ft to 4500 ft above sea level.
Furnace input rate must be within ±2 percent of input on furnace
rating plate adjusted for altitude.
1. Determine natural gas orifice size and manifold pressure for
correct input.
a. Obtain average yearly heat value (at installed altitude)
from local gas supplier.
b. Obtain average yearly specific gravity from local gas
supplier.
A99118
→ Fig. 42—Inducer Housing Drain Tube
c. Verify furnace model and size. Table 8 can only be used
for model 340MAV furnaces with heating sizes of 040
through 120. Table 9 can only be used for model
340MAV furnaces with a 140 heating size.
d. Find installation altitude in Table 8 or 9.
NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A.
altitudes of 2001 to 3000 ft in Table 8 or 9.
e. Find closest natural gas heat value and specific gravity in
Table 8 or 9.
f. Follow heat value and specific gravity lines to point of
intersection to find orifice size and manifold pressure
settings for proper operation.
EXAMPLE: (0—2000 ft altitude using Table 8)
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.
A99119
→ Fig. 43—Filling Condensate Trap
—34—
TABLE 8—MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT
FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY
(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
0
to
2000
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
4500
U.S.A. Only
ALTITUDE
RANGE
(FT)
3001
to
4000
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
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
750
775
800
825
850
875
900
925
950
975
1000
0.58
Orifice
Manifold
No.
Pressure
43
3.7
43
3.5
44
3.7
44
3.5
44
3.4
44
3.2
45
3.7
45
3.5
45
3.3
45
3.2
47
3.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
43
3.8
43
3.4
43
3.5
43
3.6
44
3.7
44
3.8
43
3.4
44
3.5
44
3.6
44
3.7
44
3.3
44
3.4
44
3.5
45
3.8
44
3.2
44
3.4
45
3.6
45
3.7
44
3.2
45
3.4
45
3.6
45
3.7
45
3.3
45
3.4
45
3.5
47
3.7
45
3.2
45
3.4
Orifice
No.
42
42
43
43
44
44
44
44
45
45
45
0.66
Manifold
Pressure
3.4
3.2
3.7
3.5
3.8
3.6
3.5
3.3
3.8
3.6
3.5
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.8
44
3.6
44
3.4
44
3.2
45
3.7
45
3.5
45
3.3
45
3.1
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.2
42
3.3
42
3.4
43
3.7
43
3.8
42
3.2
43
3.4
43
3.6
43
3.7
44
3.7
44
3.8
43
3.5
44
3.5
44
3.6
44
3.7
44
3.3
44
3.4
44
3.5
45
3.8
44
3.2
44
3.3
45
3.6
45
3.7
45
3.8
45
3.4
45
3.5
45
3.6
45
3.2
45
3.4
45
3.5
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.5
3.3
3.8
3.6
3.4
3.6
3.4
3.3
3.8
3.6
3.4
0.58
Orifice
Manifold
No.
Pressure
43
3.7
43
3.5
44
3.7
44
3.5
44
3.3
45
3.8
45
3.6
45
3.4
45
3.2
45
3.0
45
2.9
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.8
42
3.3
42
3.4
43
3.6
43
3.7
43
3.8
43
3.4
43
3.5
43
3.6
44
3.6
44
3.8
43
3.4
44
3.4
44
3.5
44
3.7
44
3.2
44
3.3
44
3.5
45
3.7
45
3.8
44
3.3
45
3.5
45
3.6
45
3.7
45
3.3
45
3.4
45
3.5
45
3.2
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
Orifice
No.
42
42
43
43
44
44
44
44
45
45
45
0.66
Manifold
Pressure
3.5
3.2
3.7
3.5
3.8
3.6
3.4
3.2
3.7
3.5
3.3
*Orifice numbers shown in BOLD are factory installed.
—35—
TABLE 8—MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (Continued)
FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY
(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)
U.S.A. Only
ALTITUDE
RANGE
(FT)
4001
to
5000
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
U.S.A. Only
ALTITUDE
RANGE
(FT)
6001
to
7000
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
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
650
675
700
725
750
775
800
825
850
875
0.58
Orifice
Manifold
No.
Pressure
43
3.7
43
3.4
44
3.7
44
3.5
44
3.2
45
3.7
45
3.5
45
3.3
45
3.1
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.8
42
3.2
42
3.3
43
3.5
43
3.7
43
3.8
44
3.8
43
3.4
43
3.5
44
3.6
44
3.7
44
3.8
44
3.4
44
3.5
44
3.6
45
3.8
44
3.3
44
3.4
45
3.6
45
3.7
44
3.2
45
3.4
45
3.5
45
3.6
45
3.2
45
3.3
45
3.4
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.4
3.2
3.7
3.4
3.7
3.5
3.3
3.8
3.6
3.4
0.58
Orifice
Manifold
No.
Pressure
43
3.6
43
3.4
44
3.6
44
3.4
44
3.2
45
3.6
45
3.4
45
3.2
45
3.0
45
2.9
45
2.7
45
2.6
45
2.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.7
42
3.2
42
3.3
43
3.5
43
3.6
43
3.7
44
3.7
43
3.4
43
3.5
44
3.5
44
3.6
44
3.7
44
3.3
44
3.4
44
3.5
45
3.7
44
3.2
44
3.3
45
3.5
45
3.6
45
3.8
45
3.3
45
3.4
45
3.6
45
3.1
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
45
2.8
45
2.9
45
3.0
45
2.7
45
2.8
45
2.9
45
2.5
45
2.6
45
2.7
Orifice
No.
42
43
43
43
44
44
44
45
45
45
45
45
45
0.66
Manifold
Pressure
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
0.58
Orifice
Manifold
No.
Pressure
42
3.2
43
3.6
44
3.8
44
3.6
44
3.3
45
3.8
45
3.5
45
3.3
45
3.1
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.3
42
3.4
42
3.5
43
3.7
43
3.8
42
3.2
43
3.4
43
3.6
43
3.7
44
3.7
44
3.8
43
3.4
44
3.4
44
3.6
44
3.7
44
3.2
44
3.3
44
3.4
45
3.7
45
3.8
44
3.2
45
3.4
45
3.6
45
3.7
45
3.2
45
3.4
45
3.5
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.6
3.3
3.8
3.5
3.8
3.5
3.3
3.8
3.6
3.4
*Orifice numbers shown in BOLD are factory installed.
—36—
TABLE 8—MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (Continued)
FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY
(TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)
U.S.A. Only
ALTITUDE
RANGE
(FT)
7001
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
9000
U.S.A. Only
ALTITUDE
RANGE
(FT)
9001
to
10,000
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
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
575
600
625
650
675
700
725
750
775
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.8
44
3.5
44
3.3
45
3.7
45
3.5
45
3.3
45
3.1
45
2.9
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.3
42
3.4
42
3.5
43
3.7
43
3.8
42
3.2
43
3.4
43
3.5
43
3.6
44
3.6
44
3.8
43
3.4
44
3.4
44
3.5
44
3.6
45
3.8
44
3.3
44
3.4
45
3.6
45
3.7
45
3.8
45
3.4
45
3.5
45
3.6
45
3.2
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
Orifice
No.
42
42
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.6
3.3
3.7
3.5
3.7
3.5
3.3
3.7
3.5
3.3
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.7
44
3.5
44
3.2
45
3.6
45
3.4
45
3.2
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.3
42
3.4
42
3.5
43
3.6
43
3.8
42
3.2
43
3.4
43
3.5
43
3.6
44
3.6
44
3.7
44
3.8
44
3.3
44
3.4
44
3.6
45
3.8
44
3.2
44
3.3
45
3.5
45
3.6
45
3.8
45
3.3
45
3.4
45
3.5
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
44
44
44
45
45
0.66
Manifold
Pressure
3.6
3.3
3.7
3.4
3.7
3.4
3.2
3.6
3.4
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.7
44
3.4
45
3.8
45
3.6
45
3.3
45
3.1
45
2.9
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.2
42
3.3
42
3.5
43
3.6
43
3.7
42
3.2
44
3.8
43
3.5
43
3.6
44
3.5
44
3.7
44
3.8
44
3.3
44
3.4
44
3.5
45
3.7
45
3.8
44
3.3
45
3.4
45
3.6
45
3.7
45
3.2
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
Orifice
No.
42
42
43
43
44
44
45
45
45
0.66
Manifold
Pressure
3.6
3.3
3.7
3.4
3.6
3.4
3.8
3.5
3.3
*Orifice numbers shown in BOLD are factory installed.
—37—
TABLE 9—MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT
FOR USE WITH 140 SIZE FURNACES ONLY
(TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
0
to
2000
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2001
to
4500
U.S.A. Only
ALTITUDE
RANGE
(FT)
3001
to
4000
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
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
750
775
800
825
850
875
900
925
950
975
1000
0.58
Orifice
Manifold
No.
Pressure
41
3.6
42
3.8
42
3.5
42
3.4
42
3.2
43
3.7
43
3.5
43
3.3
43
3.2
44
3.5
44
3.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.7
41
3.8
40
3.6
41
3.5
41
3.6
41
3.7
42
3.7
42
3.8
41
3.5
42
3.5
42
3.6
42
3.7
42
3.3
42
3.4
42
3.5
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
42
3.2
43
3.4
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
44
3.6
43
3.2
43
3.3
44
3.4
44
3.5
43
3.2
Orifice
No.
40
41
41
42
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.8
3.8
3.6
3.8
3.6
3.4
3.3
3.8
3.6
3.4
3.3
0.58
Orifice
Manifold
No.
Pressure
41
3.7
42
3.8
42
3.6
42
3.4
42
3.2
43
3.7
43
3.5
43
3.3
43
3.1
43
3.0
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.8
40
3.6
40
3.7
41
3.6
41
3.7
41
3.8
42
3.7
41
3.5
41
3.6
42
3.5
42
3.6
42
3.7
42
3.3
42
3.4
42
3.5
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
42
3.2
43
3.4
43
3.5
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
Orifice
No.
39
40
41
41
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.6
3.6
3.7
3.5
3.6
3.4
3.3
3.8
3.6
3.4
3.2
0.58
Orifice
Manifold
No.
Pressure
41
3.6
42
3.8
42
3.5
42
3.3
43
3.8
43
3.6
43
3.4
43
3.2
43
3.1
43
2.9
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.8
40
3.6
40
3.7
41
3.5
41
3.6
41
3.7
42
3.7
42
3.8
41
3.5
42
3.4
42
3.6
42
3.7
42
3.2
42
3.4
42
3.5
43
3.7
42
3.2
42
3.3
43
3.5
43
3.6
43
3.8
43
3.3
43
3.5
43
3.6
43
3.2
43
3.3
43
3.4
43
3.0
43
3.1
43
3.2
43
2.9
43
3.0
43
3.0
Orifice
No.
40
40
41
42
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.8
3.6
3.6
3.8
3.6
3.4
3.2
3.7
3.5
3.3
3.1
*Orifice numbers shown in BOLD are factory installed.
—38—
TABLE 9—MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT (Continued)
FOR USE WITH 140 SIZE FURNACES ONLY
(TABULATED DATA BASED ON 23,000 BTUH PER BURNER, DERATED 2% FOR EACH 1000 FT ABOVE SEA LEVEL)
ALTITUDE
RANGE
(FT)
U.S.A. Only
4001
to
5000
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
ALTITUDE
RANGE
(FT)
U.S.A. Only
6001
to
7000
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
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
650
675
700
725
750
775
800
825
850
875
0.58
Orifice
Manifold
No.
Pressure
41
3.6
42
3.7
42
3.5
42
3.3
43
3.7
43
3.5
43
3.3
43
3.1
43
3.0
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.7
41
3.8
40
3.6
42
3.8
41
3.6
41
3.7
42
3.6
42
3.7
42
3.8
42
3.4
42
3.5
42
3.6
42
3.2
42
3.3
42
3.4
43
3.6
43
3.8
42
3.2
43
3.4
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
Orifice
No.
40
41
41
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.8
3.8
3.6
3.7
3.5
3.3
3.8
3.6
3.4
3.2
0.58
Orifice
Manifold
No.
Pressure
41
3.5
42
3.7
42
3.4
42
3.2
43
3.7
43
3.5
43
3.3
43
3.1
43
2.9
43
2.7
43
2.6
43
2.5
43
2.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.7
41
3.8
40
3.6
42
3.8
41
3.5
41
3.6
42
3.5
42
3.7
42
3.8
42
3.3
42
3.4
42
3.5
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
43
3.8
43
3.4
43
3.5
43
3.6
43
3.2
43
3.3
43
3.4
43
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
43
2.7
43
2.8
43
2.9
43
2.6
43
2.6
43
2.7
43
2.4
43
2.5
43
2.6
Orifice
No.
40
41
41
42
42
42
43
43
43
43
43
43
43
0.66
Manifold
Pressure
3.7
3.8
3.5
3.7
3.4
3.2
3.7
3.5
3.3
3.1
3.0
2.8
2.7
0.58
Orifice
Manifold
No.
Pressure
41
3.8
41
3.5
42
3.6
42
3.4
43
3.8
43
3.6
43
3.4
43
3.2
43
3.0
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
40
3.6
40
3.7
40
3.8
41
3.6
41
3.7
40
3.6
42
3.7
41
3.5
41
3.6
42
3.5
42
3.6
42
3.7
42
3.3
42
3.4
42
3.5
43
3.7
43
3.8
42
3.3
43
3.5
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
Orifice
No.
39
40
41
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.7
3.7
3.7
3.8
3.6
3.4
3.8
3.6
3.4
3.2
*Orifice numbers shown in BOLD are factory installed.
—39—
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. 44.)
c. 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.
BURNER
ORIFICE
A93059
CAUTION: DO NOT redrill orifices. Improper drilling
(burrs, out-of-round holes, etc.) can cause excessive
burner noise and misdirection of burner flames. This can
result in flame impingement of burners and heat exchangers causing failures.
ON AND
OFF SWITCH
GAS
PRESSURE
REGULATOR
ADJUSTMENT
BURNER FLAME
BURNER
ENCLOSURE
REFERENCE
PRESSURE
TAP
INLET
PRESSURE TAP
BURNER
MANIFOLD
PRESSURE TAP
A95622
Fig. 44—Redundant Automatic Gas Valve
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.
MANIFOLD
A89020
Fig. 45—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
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.
d. Replace gas valve regulator adjustment screw cap.
e. Replace burner enclosure front and verify adjusted gas
input rate using method outlined in item 3.
f. Look through sight glass in burner enclosure and check
burner flame. Burner flame should be clear blue, almost
transparent. (See Fig. 45.)
% 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.
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.
EXAMPLE:
100,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT.
Derate
Furnace Input Rate
Furnace Input Rate
X Multiplier =
at Installation
at Sea Level
Factor
Altitude
100,000
X
0.91
=
91,000
a. Calculate high-altitude adjustment (if required).
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 10 for derate multiplier factor.
—40—
TABLE 11—GAS RATE (CU FT/HR)
CANADA
At installation altitudes from 2000 to 4500 ft, this
furnace must be derated 5% by an authorized Gas
Conversion Station or Dealer. To determine correct input
rate for altitude, see example above and use 0.95 as
derate multiplier factor.
SECONDS
FOR 1
REVOLUTION
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
b. Turn off all other gas appliances and pilots.
c. Start furnace and let operate for 3 minutes.
d. Measure time (in sec) for gas meter test dial to complete
1 revolution.
e. Refer to Table 11 for cu ft of gas per hr.
f. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft)
using natural gas heating value from local gas
utility/supplier.
EXAMPLE: (0—2000 ft altitude)
Furnace input from rating plate is 100,000 Btuh.
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.
B.
Set Temperature Rise
CAUTION: Temperature rise must be within limits
specified on unit rating plate. Recommended operation is
at midpoint of rise or above. Failure to follow this caution
may result in condensing or overheating the heat exchangers.
SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL
1
2
5
1
2
5
FOR 1
cu ft cu ft cu ft REVOLUTION cu ft cu ft cu ft
360
720 1800
50
72
144
360
327
655 1636
51
71
141
355
300
600 1500
52
69
138
346
277
555 1385
53
68
136
340
257
514 1286
54
67
133
333
240
480 1200
55
65
131
327
225
450 1125
56
64
129
321
212
424 1059
57
63
126
316
200
400 1000
58
62
124
310
189
379
947
59
61
122
305
180
360
900
60
60
120
300
171
343
857
62
58
116
290
164
327
818
64
56
112
281
157
313
783
66
54
109
273
150
300
750
68
53
106
265
144
288
720
70
51
103
257
138
277
692
72
50
100
250
133
267
667
74
48
97
243
129
257
643
76
47
95
237
124
248
621
78
46
92
231
120
240
600
80
45
90
225
116
232
581
82
44
88
220
113
225
563
84
43
86
214
109
218
545
86
42
84
209
106
212
529
88
41
82
205
103
206
514
90
40
80
200
100
200
500
92
39
78
196
97
195
486
94
38
76
192
95
189
474
96
38
75
188
92
185
462
98
37
74
184
90
180
450
100
36
72
180
88
176
439
102
35
71
178
86
172
429
104
35
69
173
84
167
419
106
34
68
170
82
164
409
108
33
67
167
80
160
400
110
33
65
164
78
157
391
112
32
64
161
76
153
383
116
31
62
155
75
150
375
120
30
60
150
73
147
367
Follow this same procedure for proper selection of COOL
speed selection.
Determine and adjust air temperature rise as follows:
TABLE 12—SPEED SELECTOR
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.
COLOR
SPEED
Black
Yellow (When Present)
Blue
Red
White
High
Medium High
Medium Low
Low
Common
FACTORYSHIPPED
CONNECTION
Cool
Spare
Heat
Spare
Com
C. Blower Off Delay (Heat Mode)
The main blower off time delay period is factory-set at 135 sec and
is not field-adjustable.
WARNING: Disconnect 115-v electrical power before
changing speed tap. Failure to follow this warning could
result in personal injury.
D. Set Thermostat Heat Anticipator
Thermostat heat anticipator must be set to match amp draw of
components in R-W circuit. Accurate amp draw measurements can
be obtained at thermostat subbase terminals R and W.
4. To change blower motor speed selections for heating mode,
remove blower motor lead from control center HEAT
terminal. (See Fig. 25.) Select desired blower motor speed
lead from 1 of the other terminals and relocate it to HEAT
terminal. See Table 12 for lead color identification. Reconnect original lead on SPARE terminal.
Fig. 46 illustrates an easy method of obtaining these measurements. Amp reading should be taken after blower motor has
started. See thermostat manufacturer’s instructions for adjusting
heat anticipator and for varying heating cycle length.
—41—
II.
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
CHECK PRESSURE SWITCH
This control proves operation of draft inducer. Check switch
operation as follows:
HOOK-AROUND
VOLT/AMMETER
1. Turn off 115-v power to furnace.
2. Remove main furnace door and disconnect inducer motor
lead wires from wire harness.
R Y W G
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 ignitor
should NOT glow, and control center diagnostic light
flashes a Status Code 31. If hot surface ignitor glows when
inducer motor is disconnected, shut furnace down immediately. Determine reason pressure switch did not function
properly and correct condition.
10 TURNS
5. Turn off 115-v power to furnace.
FROM UNIT 24-VOLT
TERMINAL BLOCK
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
6. Reconnect inducer motor leads, reinstall main furnace door,
and turn on 115-v power supply.
= 0.5 AMPS FOR THERMOSTAT SETTING
CHECKLIST
A80201
Fig. 46—Amp Draw Check with Ammeter
1. Put away tools and instruments. Clean up debris.
CHECK SAFETY CONTROLS
2. Verify manual reset switch has continuity.
I. 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.
3. Verify that blower and control access doors are properly
installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instructions.
6. Review User’s Guide with owner.
7. Leave literature packet near furnace.
—42—
CHECKLIST—INSTALLATION
LOAD CALCULATION
Condensate Drain
________
Heating Load (Btuh)
________
Cooling Load (Btuh)
________
Furnace Model Selection
________
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
COMBUSTION AND VENT PIPING
Termination Location
________
Roof or Sidewall
________
Termination Kit — 2 Pipe or
Concentric
________
Combustion-Air Pipe Length
________
Combustion-Air Pipe Elbow
Quantity
________
Vent Pipe Length
________
Vent Pipe Elbow Quantity
________
Pipe Diameter Determined from
Sizing Table
________
Pipe Sloped To Furnace
CHECKLIST—START-UP
Over Ceilings
________
Low-Ambient Exposed Pipes
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
Pipe Insulation
________
________
—43—
________
Primary Limit
________
Pressure Switch
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization
• Maintenance
• Installation Overview
• Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training
[ ] Classroom Service Training
A94328
© 1999 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
—44—
Printed in U.S.A.
340m406
Catalog No. 5334-004