Bryant 355M-40-4 Instruction manual

355AAV
4--WAY MULTIPOISE
VARIABLE--CAPACITY CONDENSING GAS FURNACE
FOR SIZES 040--120, SERIES C
Installation Instructions
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ama
NOTE: Read the entire instruction manual before starting
the installation. Please retain these instructions with the furnace
after installation for future reference.
ISO 9001:2000
CERTIFIED
NOTE: This furnace can be installed as a (2-pipe) direct vent
or (1-pipe) non-direct vent condensing gas furnace.
REGISTERED
Special Venting Requirements for Installations in Canada
Consignes spéciales pour l’installation de ventillation au Canada
Installation in Canada must conform to the requirements of CSA
B149 code. Vent systems must be composed of pipe, fittings,
cements, and primers listed to ULC S636. The special vent fittings
and accessory concentric vent termination kits and accessory
external drain trap have been certified to ULC S636 for use with
those IPEX PVC vent components which have been certified to
this standard. In Canada, the primer and cement must be of the
same manufacturer as the vent system -- IPEX System 636,
PVC/CPVC Primer, Purple Violet for Flue Gas Venting and IPEX
System 636(1)t, PVC Cement for Flue Gas Venting, rated Class
IIA, 65 deg C. must be used with this venting system -- do not mix
primers and cements from one manufacturer with a vent system
from a different manufacturer.
Follow the manufacturer’s
instructions in the use of primer and cement and never use primer
or cement beyond its expiration date.
The safe operation, as defined by ULC S636, of the vent system is
based on following these installation instructions, the vent system
manufacturer’s installation instructions, and proper use of primer
and cement. All fire stop and roof flashing used with this system
must be UL listed material. Acceptability under Canadian standard
CSA B149 is dependent upon full compliance with all installation
instructions. Under this standard, it is recommended that the vent
system be checked once a year by qualified service personnel.
The authority having jurisdiction (gas inspection authority,
municipal building department, fire department, etc) should be
consulted before installation to determine the need to obtain a
permit.
L’installation faite au Canada doit se conformer aux exigences du
code CSA B149. Ce systême de ventillation doit se composer de
tuyaux, raccords, ciments et apprêts conformes au ULC S636. La
tuyauterie de ventillation des gaz, ses accessoires, le terminal
concentrique mural ainsi que l’ensemble du drain de condensat
extérieur ont été certifiés ULCS 636 pour l’application des
composantes IPEX PVC qui sont certifiées à ce standard. Au
Canada l’apprêt et le ciment doivent être du même manufacturier
que le systême de ventillation -- IPEX Système 636, Apprêt
PVC/CPVC. Mauve Violette pour conduit en évacuation des gaz et
IPEX Système 636(1)t, ciment pour PVC pour conduit en
évacuation des gaz, évalué CLASSE IIA, 65 deg. C. doit ëtre
utilisé avec ce systèeme d’évacuation -- ne pas mélanger l’apprêt et
le ciment d’un manufacturier avec le systême de ventillation d’un
autre manufacturier. Bien suivre les indications du manufacturier
lors de l’utilisation de l’apprêt et du ciment et ne pas utiliser
ceux--ci si la date d’expiration est atteinte.
L’opération sécuritaire, tel que définit par ULC S636, du système
de ventilation est basé sur les instructions d’installation suivantes,
ainsi que l’usage approprié de l’apprêt et ciment. Tout arrët feu et
solin de toit utilisés avec ce système doivent être des matériaux
listés UL. L’acceptation du standard Canadien CSA B419 est
directement relié à l’installation conforme aux instructions ci-- haut
mentionnées. Le standard Canadien recommande l’ inspection par
un personel qualifié et ce, une fois par année.
Les autoritées ayant juridiction (inspecteurs de gas, inspecteurs en
bâtiments, département des incendies, etc) devraient être consultées
avant l’installation afin de déterminer si un permis est requis.
(1) System 636 is a trademark of IPEX Inc.
1
Required Notice for Massachusetts Installations
355A
IMPORTANT
The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:
5.08: Modifications to NFPA--54, Chapter 10
2) Revise 10.8.3 by adding the following additional requirements:
a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an
alarm and battery back--up is installed on the floor level where the gas equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on
each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It
shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of
hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back--up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall
have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print size no less than one--half (1/2) inch in size, ”GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a)1 through 4.
5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
(1.) The equipment listed in Chapter 10 entitled ”Equipment Not Required To Be Vented” in the most current edition of NFPA
54 as adopted by the Board; and
(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential purposes.
c. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the
manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or
venting system components with the equipment, the instructions provided by the manufacturer for installation of the
equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
d. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the
manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts
for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by
the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,
all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with
the appliance or equipment at the completion of the installation.
For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers and
Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617--727--9952.
2
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TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
FURNACE RELIABILITY HAZARD
IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START ---UP, ADJUSTMENTS AND SAFETY CHECK . . . 43
AIRFLOW
UPFLOW
HORIZONTAL
LEFT
HORIZONTAL
RIGHT
DOWNFLOW
AIRFLOW
AIRFLOW
AIRFLOW
A93041
Fig. 1 -- Multipoise Orientations
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local building
codes, the current editions of the National Fuel Gas Code (NFGC)
NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC)
NFPA 70.
In Canada, refer to the current editions of the National Standards of
Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation Codes, and Canadian Electrical Code CSA C22.1
.
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may 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.
!
SAFETY CONSIDERATIONS
!
WARNING
CAUTION
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental
polution.
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Remove and recycle all components or materials (i.e., oil,
refrigerant, control boards, etc.) before unit final disposal.
Failure to follow this warning could result in dangerous
operation, serious injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use could cause carbon monoxide
poisoning, explosion, fire, electrical shock, or other
conditions which may cause personal injury or property
damage. Consult a qualified service agency, local gas
supplier, or your distributor or branch for information or
assistance. The qualified service agency must use only
factory--authorized and listed kits or accessories when
modifying this product.
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
3
355A
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.
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . 6
APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CAUTION
26 15⁄16" (684 mm)
26 1⁄4" (667 mm)
(14 mm)
A
22 5⁄16" (567 mm)
2-IN. (51 mm) COMBUSTIONAIR CONN
28 1⁄2" (724 mm)
26 15⁄16" (684 mm)
26 1⁄4" (667 mm)
AIRFLOW
24 1⁄2" (622 mm)
13/16"
(21 mm)
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL LEFT)
OUTLET
DIA (22mm)
POWER CONN
DIA
GAS CONN
. 2-IN (51mm)
VENT CONN
30 13⁄16"
(783 mm)
1⁄2-IN.
DIA (13mm)
THERMOSTAT ENTRY
355A
22 11⁄16"
(576 mm)
14 1⁄2"
TYP
(368 mm)
SIDE INLET
11⁄4" (32 mm)
1"
(25mm)
(591 mm)
23 1⁄4" TYP
SIDE INLET
29 11⁄16"
TYP
(754 mm)
7⁄8-IN.
DIA (22mm)
ACCESSORY
POWER ENTRY
CONDENSATE
DRAIN TRAP
LOCATION
(ALTERNATE
UPFLOW)
9 7⁄16"
TYP
(240 mm)
27 5⁄8"
(702 mm)
27 9⁄16"
TYP
(700 mm)
24 1⁄2"
(622 mm)
22 5⁄16" (567 mm)
19" (483 mm)
OUTLET
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL RIGHT)
OR ALTERNATE
1⁄2-IN. DIA GAS CONN
7⁄8-IN.
1⁄2-IN. (13mm)
9
⁄16"
TYP
13/16"
(21 mm)
D
2-IN. (51mm)
COMBUSTION-AIR CONN
1⁄2-IN.
DIA (13mm)
GAS CONN
13⁄16"
5⁄8"
(21 mm)
(16 mm)
5
⁄16"
(16 mm)
7⁄8-IN.
DIA (22mm)
POWER CONN
33 1⁄4"
TYP
(845 mm)
1⁄2-IN.
DIA (13 mm)
THERMOSTAT ENTRY
30 1⁄2"
(775 mm)
32 5⁄8"
TYP
(829 mm)
39 7⁄8"
(1013 mm)
2-IN. (51 mm)
VENT CONN
22 11⁄16"
(576 mm)
18 1⁄4"
(464 mm)
17 5⁄16"
(439 mm)
INLET
CONDENSATE
DRAIN LOCATION
(UPFLOW)
11/16"
(17 mm)
11/16"
(17 mm)
E
26 15⁄16" TYP
(684 mm)
CONDENSATE
DRAIN LOCATION
(UPFLOW)
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
SIDE INLET
(25 mm)
1"
22 1⁄4" TYP
(565 mm)
24 3⁄16"
BOTTOM INLET
(614 mm)
7
⁄16" (11 mm)
11⁄16"
(25 mm)
NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturerís recommendations for equivalent diameters.
2. Minimum return-air opening at furnace:
a. For 800 CFM–16-in. (406mm) round or 141/2 (368 mm)x 12-in. (305 mm)
. rectangle
b. For 1200 CFM–20-in. (508mm) round or 141/2 (368mm)x 19 1/2-in. (495mm) .rectangle
.
c. For 1600 CFM–22-in. (559mm) round or 141/2 (368mm)x 23 1/4-in.(591mm) 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.
A05124
Dimensions -- In. (mm)
UNIT SIZE
A
D
E
040---14 / 042040
24--- 1/2 (622)*
22--- 7/8 (581)*
23 (584)*
060---14 / 042060
17--- 1/2 (445)
15--- 7/8 (403)
16 (406)
080---14 / 042080
21 (533)
19--- 3/8 (492)
19--- 1/2 (495)
080---20 / 060080
21 (533)
19--- 3/8 (492)
19--- 1/2 (495)
100---20 / 060100
21 (533)
19--- 3/8 (492)
19--- 1/2 (495)
120---20 / 060120
24--- 1/2 (622)
22--- 7/8 (581)
23 (584)
*These dimensions reflect the wider casing for the Trophy (96.6% AFUE) furnace.
Fig. 2 -- Dimensional Drawing
The 355AAV Multipoise Condensing Gas--Fired Furnaces are CSA
(formerly AGA and CGA) design--certified for natural and propane
gases (see furnace rating plate) and for installation in alcoves,
attics, basements, closets, utility rooms, crawlspaces, and garages.
The furnace is factory--shipped for use with natural gas. A CSA
listed gas conversion kit is required to convert furnace for use with
propane gas.
See Fig. 3 for required clearances to combustibles.
Maintain a 1--in. (25 mm) clearance from combustible materials to
supply air ductwork for a distance of 36 inches (914.4 mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring. In
downflow installations, factory accessory floor base MUST be
used when installed on combustible materials and wood flooring.
Special base is not required when this furnace is installed on
Manufacturer’s Coil Assembly or when Manufacturer’s Coil Box
is used. These furnaces are suitable for installation in a structure
built on site or a manufactured building completed at final site. The
design of this furnace line is NOT CSA design--certified for
installation in recreation vehicles, manufactured (mobile) homes or
outdoors.
This furnace is designed for continuous return--air minimum
temperature of 60_F (16_C) db or intermittent operation down to
55_F (13_C) db such as when used with a night setback
thermostat. Return--air temperature must not exceed 80_F (27_C)
db. Failure to follow these return air limits may affect reliability of
heat exchangers, motors and controls. (See Fig. 4.)
These furnaces are shipped with the drain and pressure tubes
connected for UPFLOW applications. Minor modifications are
required when used in DOWNFLOW, HORIZONTAL RIGHT, or
HORIZONTAL LEFT (supply--air discharge direction)
applications as shown in Fig. 1. See details in Applications section.
Install this furnace only in a location and position as specified in
LOCATION and INSTALLATION sections of these instructions.
Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in the
Combustion Air and Vent piping sections of these instructions.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections as specified in the GAS PIPING section of
these instructions.
Always install the furnace to operate within the furnace’s intended
rise range with a duct system which has an external static pressure
within the allowable range as specified in the SET
TEMPERATURE RISE section of these instructions.
4
355A
335122-201 REV. B LIT TOP
A08435
Fig. 3 -- Clearances to Combustibles
When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace, the
return air shall also be handled by ducts sealed to the furnace
casing and terminating outside the space containing the furnace.
A gas--fired furnace for installation in a residential garage must be
installed as specified in the Hazardous Locations section of these
instructions and Fig. 5.
The furnace may be used for construction heat provided that the
furnace installation and operation complies with the first
CAUTION in the LOCATION section of these instructions.
This gas furnace may be used for construction heat provided that:
S The furnace is permanently installed with all electrical wiring,
piping, air filters, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the space
containing the furnace. This prevents a negative pressure
condition as created by the circulating air blower, causing a
flame rollout and/or drawing combustion products into the
S
S
S
S
S
5
structure.
The furnace is controlled by a thermostat. It may not be “hot
wired” to provide heat continuously to the structure without
thermostatic control.
Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other
construction materials. It also prevents the entrainment of
drywall dust into combustion air, which can cause fouling and
plugging of furnace components.
The temperature of the return air to the furnace is maintained
between 55_F (13_C) and 80_F (27_C), with no evening
setback or shutdown. The use of the furnace while the structure
is under construction is deemed to be intermittent operation per
our installation instructions.
The air temperature rise is within the rated rise range on the
furnace rating plate, and the firing rate has been set to the
nameplate value.
The filters used to clean the circulating air during the
355A
construction process must be either changed or thoroughly
cleaned prior to occupancy.
S The furnace, ductwork and filters are cleaned as necessary to
remove drywall dust and construction debris from all HVAC
system components after construction is completed.
S After construction is complete, verify furnace operating
conditions including ignition, input rate, temperature rise and
venting, according to the manufacturer’s instructions. If this
furnace is installed with a direct--vent (combustion air and flue)
system, a factory accessory termination kit must be installed. In a
direct--vent system, all air for combustion is taken directly from
the outside atmosphere. See furnace and factory accessory
termination kit instructions for proper installation.
S 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 Instructions
User’s Information Manual
Warranty Certificate
Loose Parts Bag includes:
Quantity
Pressure tube extension
1
Collector Box or condensate trap extension tube
1
Inducer Housing drain tube
1
1/2--- in. (13 mm) CPVC street elbow
2
Drain tube coupling
1
Drain tube coupling grommet
1
Gas line grommet
1
Vent pipe grommet
1
Combustion--- air pipe grommet
2
Gas line entry hole filler plug
1
Power entry hole filler plug
2
Condensate trap hole filler plug
3
Vent and combustion--- air intake hole filler plug
2
Combustion--- air pipe perforated disk assembly
1
S CANADA: National Standard of Canada, Natural Gas and
Propane Installation Code (NSCNGPIC) CAN/CSA B149.1--05
Step 2 — General Installation
S US: NFGC and the NFPA 90B. For copies, contact the National
Fire Protection Association Inc., Batterymarch Park, Quincy,
MA 02269; or for only the NFGC contact the American Gas
Association, 400 N. Capitol, N.W., Washington DC 20001
S CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard,
Step 3 — Combustion and Ventilation Air
S NFPA 54--2006/ANSI Z223.1--2006, Air for Combustion and
Ventilation
S CANADA: Part 8 of the NSCNGPIC CAN/CSA B149.1--05,
Venting Systems and Air Supply for Appliances
Step 4 — Duct Systems
S US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning
Contractors National Association (SMACNA), or American
Society of Heating, Refrigeration, and Air Conditioning
Engineers (ASHRAE) 2005 Fundamentals Handbook Chapter
35.
Step 5 — Acoustical Lining and Fibrous Glass
Duct
S US and CANADA: current edition of SMACNA, NFPA 90B as
tested by UL Standard 181 for Class I Rigid Air Ducts
Step 6 — Gas Piping and Gas Pipe Pressure
Testing
S US: NFGC; chapters 5, 6, 7, and 8 and national plumbing codes
S CANADA: NSCNGPIC Parts 4, 5, 6 and 9. In the state of
Massachusetts:
S This product must be installed by a licensed plumber or gas
fitter.
S When flexible connectors are used, the maximum length shall
not exceed 36 inches.
S The furnace shall be installed so that the electrical components
are protected from water.
S For accessory installation details, refer to applicable installation
literature.
80
/ 27 C
60
/ 16 C
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these instructions. The installation must comply with regulations of
the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must comply
with the national codes listed below and all authorities having
jurisdiction in Canada.
In the United States and Canada, follow all codes and standards for
the following:
Step 1 — Safety
S US: National Fuel Gas Code (NFGC) NFPA 54--2006/ANSI
Z223.1--2006 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
A06745
Fig. 4 -- Return--Air Temperature
6
6. Before removing a new control from its container, discharge
your body’s electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 5 before bringing the
control or yourself into contact with the furnace. Put all
used AND new controls into containers before touching
ungrounded objects.
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
INTRODUCTION
The model 355AAV 4--way multipoise, Gas--Fired, Category IV,
direct vent and non--direct vent condensing furnace is available in
model sizes ranging in input capacities of 40,000 to 120,000 Btuh.
A93044
Fig. 5 -- Installation in a Garage
S When lever type gas shutoffs are used they shall be T--handle
type.
S The use of copper tubing for gas piping is not approved by the
state of Massachusetts.
APPLICATIONS
Step 1 — 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. 7. See appropriate
application instructions for these procedures.
!
MINOR PROPERTY DAMAGE
Step 7 — Electrical Connections
Failure to follow this caution may result in minor property
damage.
S US: National Electrical Code (NEC) ANSI/NFPA 70--2008
S CANADA: Canadian Electrical Code CSA C22.1
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.
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to unit
components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will prevent
electrostatic discharges from personnel and hand tools which
are held during the procedure. These precautions will help to
avoid exposing the control to electrostatic discharge by putting
the furnace, the control, and the person at the same
electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S ELECTROSTATIC
CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in a
person’s hand during grounding will be satisfactorily
discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch
ungrounded objects, etc.)
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before
touching control or wires.
5. Use this procedure for installed and uninstalled
(ungrounded) furnaces.
CAUTION
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
Step 2 — 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.
Condensate Trap Tubing (Factory-- Shipped Orientation)
The condensate trap is factory installed in the blower shelf and
factory connected for UPFLOW applications. A factory--supplied
tube is used to extend the condensate trap drain connection to the
desired furnace side for field drain attachment. See Condensate
Trap Tubing (Factory--Shipped Orientation) section for drain tube
extension details. (See Fig. 7.)
NOTE: See Fig. 7 or tube routing label on main furnace door to
confirm location of these tubes.
1. Collector Box Drain, Inducer Housing Drain, Relief Port,
and Pressure Switch Tubes These tubes should be factory
attached to condensate trap and pressure switch ready for
use in UPFLOW applications. These tubes can be identified
by their connection location and also by a color label on
each tube. These tubes are identified as follows: collector
box drain tube (blue label), inducer housing drain tube
(violet label or molded), relief port tube (green label), and
pressure switch tube (pink label).
2. Condensate Trap Drain Tube
The condensate trap drain connection must be extended for
field attachment by doing the following:
a. Determine location of field drain connection. (See Fig. 2
or 7.)
NOTE: If internal filter or side filter/media cabinet is used, drain
tube should be located to opposite side of casing from return duct
attachment to assist in filter removal.
7
355A
18-IN. (457.2 mm)
MINIMUM TO BURNERS
355A
b. Remove and discard casing drain hole plug button from
desired side.
c. Install drain tube coupling grommet (factory--supplied
in loose parts bag) in selected casing hole.
d. Slide drain tube coupling (factory--supplied in loose
parts bag) through grommet so long end of coupling
faces blower.
e. Cement 2 factory--supplied 1/2--in. (13 mm)street CPVC
elbows to rigid drain tube connection on condensate
trap. (See Fig. 7.) These elbows must be cemented
together and cemented to condensate trap drain
connection.
NOTE: Failure to use CPVC elbows may allow drain to kink,
preventing draining.
f. Connect larger diameter drain tube and clamp
(factorysupplied in loose parts bag) to condensate trap
and clamp securely.
g. Route tube to coupling and cut to appropriate length.
h. Attach tube to coupling and clamp securely.
Tubing (Alternate Upflow Orientation) section for tubing
attachment.
To relocate condensate trap to the left--hand side, perform the
following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory--supplied in loose parts
bag) into blower shelf hole where trap was removed.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the equipment
room.
Condensate Trap Tubing (Alternate Upflow
Orientation)
4. Install condensate trap into left--hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory--supplied in loose parts bag).
An alternate location for the condensate trap is the left--hand side of
casing. (See Fig. 2 and 8.)
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
FURNACE
DOOR
BLOWER SHELF
CONDENSATE
TRAP
CONDENSATE
TRAP (INSIDE)
WARNING
!
FURNACE
DOOR
FURNACE
SIDE
4 7 8 (124mm)
4
(102mm)
FURNACE
SIDE
5 3 4(146mm)
5 3 4 (146mm)
4
(102mm)
FIELD
DRAIN
CONN
ALTERNATE DRAIN
TUBE LOCATION
26 1 4
(667mm)
11 2
(38mm)
SIDE VIEW
CONDENSATE TRAP
DRAIN TUBE LOCATION
26 1 4
(667mm)
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
(19mm)
1/4” (6mm)
COLLECTOR BOX TO
TRAP RELIEF PORT
1 1 2 (88mm)
1/2 (13mm)
INDUCER HOUSING
DRAIN CONNECTION
(19mm) 3 4
5/8 (16mm)
COLLECTOR BOX
DRAIN CONNECTION
(181mm) 7 1 8
SCREW HOLE FOR
UPFLOW OR DOWNFLOW APPLICATIONS
(OPTIONAL)
13 4 (44mm)
WIRE TIE
GUIDES
(WHEN USED)
FRONT VIEW
(3mm) 7 8
21 4
(57mm)
1/2 IN. (13mm) PVC OR CPV
SIDE VIEW
A07459
Fig. 6 -- Condensate Trap
8
PLUG
CAP
PLUG
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (GREEN)
CONDENSATE
TRAP
CONDENSATE
TRAP
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
1Ú 2
355A
COLLECTOR BOX
DRAIN TUBE (BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
A94213
A94214
Fig. 7 -- Factory--Shipped Upflow Tube Configuration
(Shown with Blower Access Panel Removed)
Condensate Trap Tubing (alternate Upflow Orientation)
NOTE: See Fig. 8 or tube routing label on main furnace door to
confirm location of these tubes.
1. Collector Box Drain Tube
Connect collector box drain tube (blue label) to condensate
trap.
NOTE: On 17--1/2--in. (445 mm) wide furnaces ONLY, cut tube
between corrugated sections to prevent kinks.
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
condensate trap.
c. Determine appropriate length, then cut and connect
tube.
d. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
a. Connect relief port tube (green label) to condensate trap.
b. Extend this tube (if required) by splicing to small
diameter tube (factory--supplied in loose parts bag).
Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
Fig. 8 -- Alternate Upflow Tube Configuration and Trap
Location
Pressure Switch Tubing
The LOWER collector box pressure tube (pink label) is factory
connected to the pressure switch and should not require any
modification.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
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. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
Upper Inducer Housing Drain Connection
Attached to the UPPER (unused) inducer housing drain connection
is a cap and clamp. This cap is used to prevent condensate leakage
in this application. Ensure this connection is capped.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations
and procedures.
Step 3 — 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.
9
COLLECTOR BOX
DRAIN TUBE (BLUE)
CAP
COLLECTOR BOX
TUBE (GREEN)
PLUG
PLUG
CAP
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (PINK)
355A
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
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
A94215
A94216
Fig. 9 -- Downflow Tube Configuration
(Left--Hand Trap Installation)
Fig. 10 -- Downflow Tube Configuration
(Right--Hand Trap Installation)
Condensate Trap Location
Condensate Trap Tubing
The condensate trap must be removed from the factory--installed
blower shelf location and relocated in selected application location
as shown in Fig. 2, 9, or 10.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.
3. Remove casing hole filler cap from casing hole. (See Fig. 2
and 10.)
4. Install casing hole filler cap (factory--supplied in loose parts
bag) into blower shelf hole where trap was removed.
NOTE: See Fig. 9 or 10 or tube routing label on main furnace
door to check for proper connections.
1. Collector Box Drain Tube
a. Remove factory--installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was connected to
condensate trap.
c. Connect LOWER collector box drain connection to
condensate trap.
S Condensate Trap Located on Left Side of Casing
!
WARNING
CARBON MONOXIDE POISONING HAZARD
a. Connect LOWER collector box drain tube (blue and white
striped label) to condensate trap. Tube does not need to be
cut.
b. Clamp tube to prevent any condensate leakage.
S Condensate Trap Located on Right Side of Casing
Failure to follow this warning could result in personal injury
or death.
a. Install drain tube coupling (factory--supplied in loose parts
bag) into collector box drain tube (blue and white striped
label) which was previously plugged.
b. Connect larger diameter drain tube (factorysupplied in loose
parts bag) to drain tube coupling, extending collector box
drain tube for connection to condensate trap.
c. Route extended collector box drain tube between gas valve
and inlet housing as shown in Fig. 10.
d. Determine appropriate length and cut.
e. Connect to condensate trap.
f. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove factory--installed cap and clamp from LOWER
inducer housing drain connection.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the equipment
room
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.
6. Fill unused condensate trap casing holes with plastic filler
caps (factory--supplied in loose parts bag).
10
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)
355A
AUXILIARY "J" BOX
CONDENSATE
TRAP
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR
BOX EXTENSION
DRAIN TUBE
COLLECTOR BOX
DRAIN TUBE (BLUE)
DRAIN TUBE COUPLING
COLLECTOR BOX TUBE (PINK)
RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR
060, AND 080 HEATING INPUT FURNACES
A02288
Fig. 11 -- Horizontal Left Tube Configuration
a.
b.
c.
a.
b.
c.
d.
3.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to
condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain tube (violet label and
factorysupplied in loose parts bag) to connect LOWER
inducer housing drain connection to the condensate trap.
e. Connect inducer housing drain connection to
condensate trap.
(1.) Condensate Trap Located on Left Side of Casing
Determine appropriate length and cut.
Connect tube to condensate trap.
Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
Route inducer housing drain tube (violet label) directly
from inducer housing to condensate trap.
Determine appropriate length and cut.
Connect tube to condensate trap.
Clamp tube to prevent any condensate leakage.
Relief Port Tube
Refer to Pressure Switch Tubing section for connection procedure.
Condensate Trap Field Drain Attachment
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. 9 or 10 or tube routing label on main furnace
door to check for proper connections.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label) attached
to pressure switch.
2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port
connection by splicing to small diameter tube
(factory--supplied in loose parts bag).
3. Connect collector box pressure tube (green label) to
pressure switch connection labeled COLLECTOR BOX.
4. Extend collector box pressure tube (pink label) which was
previously connected to pressure switch by splicing to
remaining small diameter tube (factory--supplied in loose
parts bag).
5. Route this extended tube (pink label) to condensate trap
relief port connection.
6. Determine appropriate length, cut, and connect tube.
7. Clamp tube to relief port connection.
Refer to Condensate Drain section for recommendations and
procedures.
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
or HORIZONTAL LEFT applications. This tube MUST be
11
COMBUSTION - AIR
INTAKE
VENT
A 12-IN. (305 mm) MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT / 1.5 TO 2.4 M) VENT
SYSTEMS TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
30″ (762 mm)MIN
WORK AREA
355A
5 3/4″ (146 mm)
MANUAL
SHUTOFF
GAS VALVE
ACCESS OPENING
FOR TRAP
SEDIMENT
TRAP
DRAIN
CONDENSATE
TRAP
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
A93031
Fig. 12 -- Attic Location and Working Platform for Direct Vent (2--Pipe) Application -- All Sizes
Condensate Trap Freeze Protection
3. Remove casing hole filler cap from casing hole. (See Fig. 2
or 11.)
4. Install casing hole filler cap (factory--supplied in loose parts
bag) into blower shelf hole where trap was removed.
Refer to Condensate Drain Protection section for recommendations
and procedures.
Step 4 — 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.
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
CAUTION
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the equipment
room.
MINOR PROPERTY HAZARD
Failure to follow this caution may result in minor property
damage.
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.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
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:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
WARNING
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.
6. Fill unused condensate trap casing holes with plastic filler
caps (factory--supplied in loose parts bag).
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. 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.
12
A 3-IN.(76mm) MINIMUM CLEARANCE
TO COMBUSTION-AIR INTAKE
IS REQUIRED.
VENT
COMBUSTION AIR
INTAKE
A 12-IN. (305mm) MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT / 1.5 TO 2.4M) VENT
SYSTEMS TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
30-IN. (762mm) MIN
WORK AREA
355A
5 3/4 IN. (146mm)
MANUAL
SHUTOFF
GAS VALVE
ACCESS OPENING
FOR TRAP
SEDIMENT
TRAP
DRAIN
CONDENSATE
TRAP
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
A96184
Fig. 13 -- Attic Location and Working Platform for Non--Direct Vent (1--Pipe) Applications -- Sizes 040 through 120 Only
c. Route extended tube (blue label) to condensate trap and
cut to appropriate length.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove and discard LOWER (molded) inducer housing
drain tube which was previously connected to
condensate trap.
b. Use inducer housing drain extension tube (violet label
and factory--supplied in loose parts bag) to connect
LOWER inducer housing drain connection to
condensate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
a. Extend collector box tube (green label) which was
previously connected to condensate trap by splicing to
small diameter tube (factory--supplied in loose parts
bag).
b. Route extended collector box pressure tube to relief port
connection on condensate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.
Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
Pressure Switch Tubing
The LOWER collector box pressure tube (pink label) is factory
connected to the High 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 for 060 and
080 heating input furnaces.
NOTE: See Fig. 11 or tube routing label on main furnace door to
check for proper connections.
Modify tube as described below.
1. Disconnect collector box pressure tube (pink label) attached
to High Pressure Switch.
2. Use smaller diameter tube (factory--supplied in loose parts
bag) to extend tube disconnected in item 1.
3. Route extended tube:
a. Behind inducer housing.
b. Between blower shelf and inducer housing.
4. Determine appropriate length, cut, and reconnect tube to
High Pressure Switch connection labeled COLLECTOR
BOX.
Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations
and procedures.
Construct a Working Platform
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 12 or 13.)
13
CAP
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
PLUG
355A
COLLECTOR BOX TUBE (PINK)
AUXILIARY "J" BOX RELOCATED HERE
CONDENSATE
TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
A02289
Fig. 14 -- Horizontal Right Tube Configuration
!
CAUTION
NOTE: The auxiliary junction box (J--box) MUST be relocated to
opposite side of furnace casing. (See Fig. 13.) See Electrical
Connection section for J--box relocation.
UNIT MAY NOT OPERATE
Condensate Trap Location
Failure to follow this caution may result in intermittent unit
operation.
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 14.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory--supplied in loose parts
bag) into blower shelf hole where trap was removed.
The condensate trap MUST be installed below furnace. See
Fig. 6 for dimensions. The drain connection to condensate trap
must also be properly sloped to an open drain.
NOTE: A 12--in. (305 mm) minimum offset pipe section is
recommended with short (5 to 8 ft./ 1.5 -- 2.4 M) vent systems.
This recommendation is to reduce excessive condensate droplets
from exiting the vent pipe. (See Fig. 12, 13 or 42.)
Step 5 — 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.
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
CAUTION
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the equipment
room.
MINOR PROPERTY DAMAGE
Failure to follow this caution may result in minor property
damage.
4. Install condensate trap into right--hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory--supplied in loose parts bag).
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.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC Installation Codes and/or local codes.
WARNING
Condensate Trap Tubing
NOTE: See Fig. 14 or tube routing label on main furnace door to
check for proper connections.
14
Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.
LEVEL 0″
TO
1⁄2″ MAX
(0 to 13 mm)
FRONT
MIN 1⁄4″
TO
1⁄2″ MAX
(6 to 13 mm)
UPFLOW OR DOWNFLOW
FRONT
HORIZONTAL
A02146
Fig. 15 -- Proper Condensate Drainage
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
or HORIZONTAL LEFT 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. 14 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. Use remaining small diameter tube (factory--supplied in
loose parts bag) to extend collector box pressure tube (pink
label) which was previously connected to pressure switch.
5. Route this extended tube (pink label) to condensate trap
relief port connection.
6. Determine appropriate length, cut, and connect tube.
7. Clamp tube to relief port connection.
Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommendations
and procedures.
Construct a Working Platform
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 12 or 13.)
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation.
The condensate trap MUST be installed below furnace. See
Fig. 6 for dimensions. The drain connection to condensate trap
must also be properly sloped to an open drain.
NOTE: A 12--in. (305 mm) minimum offset pipe section is
recommended with short (5 to 8 ft./ 1.5 -- 2.4 M) vent systems.
This recommendation is to reduce excessive condensate droplets
from exiting the vent pipe. (See Fig. 12, 13 or 42.)
LOCATION
Step 1 — General
This furnace must
S be installed so the electrical components are protected from
water.
S not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).
S be located so combustion--air and vent pipe maximum lengths
are not exceeded. Refer to Table 11.
S be located where available electric power and gas supplies meet
specifications on the furnace rating plate.
S be attached to an air distribution system and be located as close
to the center of the distribution system as possible. Refer to Air
Ducts section.
S be provided with ample space for servicing and cleaning.
Always comply with minimum fire protection clearances shown
on the furnace clearance--to--combustibles label. (See Fig. 3.)
This furnace may be located in a confined space without special
provisions for dilution or ventilation air.
NOTE: For upflow/downflow applications install furnace so that
it is level or pitched forward within 1/2--in. (13 mm) for proper
furnace operation. For horizontal applications pitch 1/4--in. (6
mm) minimum to 1/2--in. (13 mm) maximum forward to ensure
proper condensate drainage from secondary heat exchangers. (See
Fig. 15.)
When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace, the
return air shall also be handled by 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.
15
355A
1. Collector Box Drain Tube
a. Remove factory--installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was previously
connected to condensate trap.
c. Connect LOWER collector box drain tube (blue and
white striped label) to condensate trap. Tube does not
need to be cut.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove factory--installed cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to
condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain extension tube (violet label
and factory--supplied in loose parts bag) to connect
LOWER inducer housing drain connection to
condensate trap.
e. Determine appropriate length, cut, and connect tube to
condensate trap.
f. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection procedure.
!
WARNING
CAUTION
!
FIRE, INJURY OR DEATH HAZARD
UNIT DAMAGE HAZARD
Failure to follow this warning could result in fire, property
damage, personal injury, or death.
Failure to follow this caution may result in minor property or
unit damage.
Do NOT install furnace on its back. (See Fig. 16.) Safety
control operation will be adversely affected. Never connect
return--air ducts to back of furnace.
If these furnaces are installed in an unconditioned space where
ambient temperatures may be 32_F (0_C) or lower, freeze
protection measures must be taken. (See Fig. 17.)
!
CAUTION
FRONT
355A
UNIT DAMAGE HAZARD
This gas furnace may be used for construction heat provided
that:
B
A
C
K
--The furnace is permanently installed with all electrical
wiring, piping, air filters, venting and ducting installed
according to these installation instructions. A return air duct is
provided, sealed to the furnace casing, and terminated outside
the space containing the furnace. This prevents a negative
pressure condition as created by the circulating air blower,
causing a flame rollout and/or drawing combustion products
into the structure.
--The furnace is controlled by a thermostat. It may not be “hot
wired” to provide heat continuously to the structure without
thermostatic control.
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other
construction materials. It also prevents the entrainment of
drywall dust into combustion air, which can cause fouling and
plugging of furnace components.
--The temperature of the return air to the furnace is maintained
between 55_F (13_C) and 80_F (27_C), with no evening
setback or shutdown. The use of the furnace while the
structure is under construction is deemed to be intermittent
operation per our installation instructions.
--The air temperature rise is within the rated rise range on the
furnace rating plate, and the firing rate has been set to the
nameplate value.
--The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
--The furnace, ductwork and filters are cleaned as necessary to
remove drywall dust and construction debris from all HVAC
system components after construction is completed.
--After construction is complete, verify furnace operating
conditions including ignition, input rate, temperature rise and
venting, according to the manufacturer’s instructions.
The furnace and its return air system shall be designed and installed
so that negative pressure created by the air circulating fan cannot
affect another appliance’s combustion air supply or act to mix
products of combustion with circulating air, and that the air
circulating fan of the furnace, if installed in an enclosure
communicating with another fuel--burning appliance not of the
direct--vent type, shall be operable only when any door or panel
covering an opening in the furnace fan compartment or in a return
air plenum on ducts is in the closed position.
BACK
FRONT
A93043
Fig. 16 -- Prohibit Installation on Back
A07911
Fig. 17 -- Freeze Protection
Step 2 — Low--Heat Only Installation
This 355AAV furnace can be installed to operate in the low--heat
only heating mode when sized using the low--heat heating capacity.
This is accomplished by placing setup switch SW1--2 in the ON
position to provide only low--heat operation. See Fig. 37 and Table
13. With this setup, high--heat operation will not occur.
16
NON--DIRECT VENT (1--PIPE) APPLICATION
CAUTION
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in minor property or
unit damage.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in intermittent unit
operation.
The furnace can operate in the high--heat mode when certain
fault conditions occur. The following precautions should be
taken:
1. Size gas piping based on the high--heat input
2. Check the high--heat input and adjust it per the main
literature instruction.
Do not install furnace in a corrosive or contaminated
atmosphere. Make sure all combustion and circulating air
requirements are met.
Refer to the AIR FOR COMBUSTION AND VENTILATION
section for details.
Step 3 — Furnace Location Relative to Cooling
Equipment
The cooling coil must be installed parallel with or on downstream
side of furnace to avoid condensation in heat exchanger. When
installed parallel with a furnace, dampers or other means used to
control flow of air shall be adequate to prevent chilled air from
entering furnace. If dampers are manually operated, they must be
equipped with a means to prevent operation of either unit unless
damper is in full--heat or full--cool position.
Step 4 — Hazardous Locations
!
AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
S U.S. Installations: Section 9.3 of the NFGC, Air for Combustion
and Ventilation and applicable provisions of the local building
codes.
S Canadian Installations: Part 8 of the NFPA54/ANSI
Z223.1--2006 CAN/CSA--B149.1--05, Venting Systems and Air
Supply for Appliances and all authorities having jurisdiction.
!
WARNING
WARNING
FURNACE CORROSION HAZARD
FIRE, EXPLOSION, INJURY OR DEATH HAZARD
Failure to follow this warning could result in reduced furnace
component life.
Improper location or inadequate protection could result in fire
or explosion.
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. (457 mm) above floor. The furnace must
be located or protected to avoid physical damage by vehicles.
When furnace is installed in a public garage, airplane hangar,
or other building having a hazardous atmosphere, unit must be
installed in accordance with requirements of National Fire
Protection Association, Inc. (See Fig. 18.)
Step 5 — Furnace Location and Application
DIRECT VENT (2--PIPE) APPLICATION
Furnace may be located in a confined space without special
provisions for dilution or ventilation air.
18-IN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 18 -- Installation in a Garage
CAUTION
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements could corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
S Commercial buildings
S Buildings with indoor pools
S Laundry rooms
S Hobby or craft rooms, and
S Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
S Permanent wave solutions
S Chlorinated waxes and cleaners
S Chlorine based swimming pool chemicals
S Water softening chemicals
S De--icing salts or chemicals
S Carbon tetrachloride
S Halogen type refrigerants
S Cleaning solvents (such as perchloroethylene)
S Printing inks, paint removers, varnishes, etc.
S Hydrochloric acid
S Cements and glues
S Antistatic fabric softeners for clothes dryers
S Masonry acid washing materials
All fuel--burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
17
355A
!
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return--air duct to
prevent pulling air from the burner area.
355A
!
Indoor combustion air is permitted for combustion, ventilation,
and dilution, if the Standard or Known--Air--Infiltration Rate
Method is used.
WARNING
WARNING
!
CARBON MONOXIDE POISONING HAZARD
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Failure to follow this warning could result in personal injury
or death.
The operation of exhaust fans, kitchen ventilation fans, clothes
dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make--up air MUST be provided for the ventilation devices, in
addition to that required by the furnace. Refer to the Carbon
Monoxide Poisoning Hazard warning in the venting section of
these instructions to determine if an adequate amount of
make--up air is available.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume of
at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
S Spaces having less than 50 cubic feet per 1,000 Btuh require the
OUTDOOR COMBUSTION AIR METHOD.
S Spaces having at least 50 cubic feet per 1,000 Btuh may use the
INDOOR COMBUSTION AIR, STANDARD or
KNOWN--AIR INFILTRATION METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper combustion,
ventilation, and dilution of flue gases using permanent
horizontal or vertical duct(s) or opening(s) directly
communicating with the outdoors or spaces that freely
communicate with the outdoors.
2. Fig. 18 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air openings to the outdoors.
a. One opening MUST commence within 12” (300 mm)
of the ceiling and the second opening MUST commence
within 12” (300 mm) of the floor.
b. Size openings and ducts per Fig. 19 and Table 1.
c. TWO HORIZONTAL DUCTS require 1 square inch of
free area per 2,000 Btuh (1,100 mm2/kW) of combined
input for all gas appliances in the space per Fig. 19 and
Table 1.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of free area per 4,000 Btuh (550 mm2/kW)
for combined input of all gas appliances in the space per
Fig. 19 and Table 1.
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of free area per 3,000 Btuh (734
mm2/kW) for combined input of all gas appliances in
the space per Table 1 and Fig. 19.
b. Not less than the sum of the areas of all vent connectors
in the space. The opening shall commence within 12”
(300 mm) of the ceiling. Appliances in the space shall
have clearances of at least 1” (25 mm) from the sides
and back and 6” (150 mm) from the front. The opening
shall directly communicate with the outdoors or shall
communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
Indoor Combustion AirE NFPA & AGA
Standard and Known--Air--Infiltration Rate Methods
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40 air
changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 2 or Equations 1 and 2.
Determine the minimum required volume for each appliance in the
space and add the volumes together to get the total minimum
required volume for the space.
Table 2--Minimum Space Volumes were determined by using the
following equations from the National Fuel Gas Code ANSI
Z223.1--2006/NFPA 54--2006, 9.3.2.2:
1. For other than fan--assisted appliances, such as a draft
hood--equipped water heater:
Volume
3
I other
= 21ft
Other
ACH 1000 Btu/hr
A04002
2. For fan--assisted appliances such as this furnace:
Volume
Fan
3
I fan
= 15ft
ACH 1000 Btu/hr
A04003
If Iother = combined input of all other than fan--assisted appliances
in Btu/hr
Ifan = combined input of all fan--assisted appliances in Btu/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closable doors between rooms.
18
Table 1 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
FURNACE
INPUT
(BTUH)
40,000
60,000
80,000
100,000
120,000
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)
TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of Opening
and Duct (Sq. In.)
20
30
40
50
60
Free Area of Opening
and Duct (sq In.)
13.4
20
26.7
33.4
40
Free Area of Opening
and Duct (Sq In.)
10
15
20
25
30
Round Duct (in.
Dia)
6
7
8
8
9
Round Duct (in.
Dia)
5
6
6
7
8
Round Duct (In.
Dia)
4
5
6
6
7
EXAMPLES: Determining Free Area
FURNACE
WATER HEATER
TOTAL INPUT
+
40,000
=
(140,000 divided by 4,000)
=
35.0 Sq. In. for each two Vertical Ducts or Openings
60,000
+
40,000
=
(100,000 divided by 3,000)
=
33.4 Sq. In. for a Single Duct or Opening
80,000
+
30,000
=
(110,000 divided by 2,000)
=
55.0 Sq. In. for each of two Horizontal Ducts
355A
100,000
Table 2 – Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors
ACH
0.60
0.50
0.40
0.30
0.20
0.10
0.00
OTHER THAN FAN---ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
30
40
50
1,050
1,260
1,575
2,100
3,150
6,300
NP
1,400
1,680
2,100
2,800
4,200
8,400
NP
40
Space Volume (ft3)
1,750
1,000
2,100
1,200
2,625
1,500
3,500
2,000
5,250
3,000
10,500
6,000
NP
NP
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.2/1,000 Btuh (2,000
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in.2 (0.06 m2). One
opening shall commence within 12” (300 mm) of the
ceiling and the second opening shall commence within
12” (300 mm) of the floor. The minimum dimension of
air openings shall be at least 3 in. (80 mm). (See Fig.
20.)
c. Combining space on different floor levels. The volumes
of spaces on different floor levels shall be considered as
communicating spaces if connected by one or more
permanent openings in doors or floors having free area
of at least 2 in.2/1,000 Btuh (4,400 mm2/kW) of total
input rating of all gas appliances.
2. An attic or crawlspace may be considered a space that freely
communicates with the outdoors provided there are
adequate permanent ventilation openings directly to
outdoors having free area of at least 1--in.2/4,000 Btuh of
total input rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for
combustion, permanent ventilation and dilution of flue
gases. However, in buildings with unusually tight
construction, additional air MUST be provided using the
methods described in the Outdoor Combustion Air
Method section.
FAN---ASSISTED TOTAL
(1000’S BTUH GAS INPUT RATE)
60
80
100
1,500
1,800
2,250
3,000
4,500
9,000
NP
2,000
2,400
3,000
4,000
6,000
12,000
NP
2,500
3,000
3,750
5,000
7,500
15,000
NP
120
3,000
3,600
4,500
6,000
9,000
18,000
NP
Unusually tight construction is defined as
Construction with:
a. Walls and ceilings exposed to the outdoors have a
continuous, sealed vapor barrier. Openings are gasketed
or sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall--ceiling joints, between
wall panels, at penetrations for plumbing, electrical and
gas lines, etc.
NOTE: In determining the free area of an opening, the blocking
effect of the louvers, grilles, and screens must be considered. If the
free area of a louver or grille design is unknown, it may be
assumed that wood louvers have a 20 percent free area, and metal
louvers or grilles have a 60 percent free area. Screens, when used,
must not be smaller than 1/4--in. (6 mm) mesh. Louvers and grilles
must be constructed so they cannot be closed.
19
1 SQ IN.
PER 4000
BTUH*
1 SQ IN.
PER 2000
BTUH*
(305mm) 12″ MAX
A
1 SQ IN.
PER
4000
BTUH*
INTERIOR
HEATED
SPACE
1 SQ IN.
PER
4000
BTUH*
E
G
12" MAX (305mm)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6" MIN (152mm)
(FRONT)Ü
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12″ (305mm)
MAX
C
12" MAX (305mm)
12″ MAX
(305mm)
CIRCULATING AIR DUCTS
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
355A
DUCTS
TO
OUTDOORS
VENT THROUGH ROOF
F
OUTDOORS
B
CIRCULATING AIR
DUCTS
12″ (305mm)
MAX
D
VENT
THROUGH
ROOF
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
(76mm)
(305mm) 12″ MAX
1 SQ IN.
PER 2000
BTUH*
CIRCULATING
AIR DUCTS
DUCTS
TO
OUTDOORS
DUCT
TO
OUTDOORS
CIRCULATING AIR DUCTS
1 SQ IN.
PER 4000
BTUH*
* Minimum opening size is 100 sq in. with minimum dimensions of 3 in. (76 mm)
† Minimum of 3 in. (76 mm) when type-B1 vent is used.
*Minimum dimensions of 3 in. (76 mm).
Use any of the following combinations of openings:
A&BC&DD&EF&G
A03174
Fig. 19 -- Air for Combustion, Ventilation, and Dilution for
Outdoors
A03175
Fig. 20 -- Air for Combustion, Ventilation, and Dilution from
Indoors
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.)
When combustion air ducts are used, they must be of the same
cross sectional area as the free area of the openings to which they
connect. The minimum dimension of ducts must not be less than 3
in. (76 mm).
Combination of Indoor and Outdoor Air
5/ 16″
(8mm)
1. Indoor openings shall compy with the Indoor Combustion
Air Method below and,
2. Outdoor openings shall be located as required in the
Outdoor Combustion Air Method mentioned previously
and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The
minimum dimension of air openings shall be not less
than 3 in. (76 mm).
(8mm)
5/ 16″
1 3/4″
(44mm)
1 3/4″
(44mm)
(8mm)
5/16″
(8mm)
5/ 16″
(44mm) 1 3/ 4″
3/
(44mm) 1 4″
INSTALLATION
A89014
Fig. 21 -- Leveling Legs
Step 1 — Leveling Legs (If Desired)
When furnace is used in upflow position with side inlet(s), leveling
legs may be desired. (See Fig. 21.) Install field--supplied,
corrosion--resistant 5/16--in. (8 mm) machine bolts and nuts.
NOTE: The maximum length of bolt should not exceed 1--1/2 in.
(38 mm).
1. Position furnace on its back. Locate and drill a 5/16--in. (8
mm) diameter hole in each bottom corner of furnace. (See
Fig. 21.) Holes in bottom closure panel may be used as
guide 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.
Step 2 — Installation in Upflow or Downflow
Applications
NOTE: This furnace is approved for use on combustible flooring.
Special base is not required when this furnace is installed on
20
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
Do not bend duct flanges inward as shown in Fig. 25. 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. 25.
Step 3 — Installation in Horizontal Applications
These furnaces can be installed 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. 26.) Cut hanger bolts (4 each 3/8--in. (10 mm)
all--thread rod) to desired length. Use 1 X 3/8--in. (10 mm) flat
washers, 3/8--in. (10 mm) lock washers, and 3/8--in. (10 mm) nuts
on hanger rods as shown in Fig. 26. Dimples are provided for hole
locations. (See Fig. 2.)
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
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.
Step 4 — Air Ducts
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 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.
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air 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.
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. (25 mm) clearance from combustible materials to
supply air ductwork for a distance of 36 in. (914 mm) horizontally
from the furnace. See NFPA 90B or local code for further
requirements.
For a furnace not equipped with a cooling coil, the outlet duct shall
be provided with a removable access panel. This opening shall be
accessible when the furnace is installed and shall be of such a size
that the heat exchanger can be viewed for possible openings using
light assistance or a probe can be inserted for sampling the air
stream. The cover attachment shall prevent leaks.
DUCTWORK ACOUSTICAL TREATMENT
Metal duct systems that do not have a 90 degree elbow and 10 ft.
(3.0 M) 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.
SUPPLY AIR CONNECTIONS
Upflow Furnaces
Connect supply--air duct to 3/4--in. (19.1 mm) flange on furnace
supply--air outlet. The supply--air duct attachment must ONLY be
connected to furnace supply--/outlet--air duct flanges or air
conditioning coil casing (when used). DO NOT cut main furnace
casing to attach supply side air duct, humidifier, or other
accessories. All accessories MUST be connected external to
furnace main casing.
Downflow Furnaces
Connect supply--air duct to supply--air opening on furnace. The
supply--air duct attachment must ONLY be connected to furnace
supply/outlet or air conditioning coil casing (when used), when
installed on non--combustible material. When installed on
combustible material, supply--air duct attachment must ONLY be
connected to an accessory subbase or factory approved air
conditioning coil casing. DO NOT cut main furnace casing to
attach supply side air duct, humidifier, or other accessories. All
accessories MUST be connected external to furnace main casing.
Supply air opening duct flanges must be modified per Fig. 25.
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.
21
355A
Manufacturer’s Coil Assembly or when Manufacturer’s Coil Box is
used.
1. Determine application being installed from Table 3.
2. Construct hole in floor per dimensions specified in Table 3
and Fig. 22.
3. Construct plenum to dimensions specified in Table 3 and
Fig. 22.
4. If downflow subbase is used, install as shown in Fig. 23.
5. If coil assembly is used, install as shown in Fig. 24.
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 hand
seamers, wide duct pliers or duct flange tool to bend flange back
and forth until it breaks off. Be careful of sharp edges. (See Fig.
25.)
FURNACE
FACTORY SUPPLIED
CASED COIL OR COIL BOX
COMBUSTIBLE
FLOORING
A
PLENUM
OPENING
D
B
SHEET METAL
PLENUM
FLOOR
OPENING
FLOOR
OPENING
355A
C
A96283
A07586
Fig. 22 -- Floor and Plenum Opening Dimensions
Fig. 24 -- Furnace, Plenum, and Coil Assembly or Coil Box
Installed on a Combustible Floor
PERFORATED
DISCHARGE DUCT
FLANGE
FURNACE
(OR OTHER MANUFACTURER’S
COIL CASING WHEN USED)
NO
COMBUSTIBLE
FLOORING
YES
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
210 DEG.
MIN
YES
A07585
A93029
Fig. 23 -- Furnace, Plenum, and Subbase Installed
on a Combustible Floor
Fig. 25 -- Duct Flanges
22
Table 3 – Opening Dimensions --- In. (mm)
PLENUM OPENING
APPLICATION
A
B
C
D
16
(406)
15-7/8
(403)
24-1/8
(613)
19
(483)
16-5/8
(422)
16-1/2
(419)
24-3/4
(629)
19-5/8
(498)
Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC Coil Box
15-1/8
(384)
19
(483)
16-3/4
(425)
20-3/8
(518)
Downflow Applications on Combustible Flooring NOT Using KGASB
Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or
KCAKC Coil Box
15-1/2
(394)
19
(483)
16-1/2
(419)
20
(508)
19-1/2
(495)
19-3/8
(492)
24-1/8
(613)
19
(483)
20-1/8
(511)
20
(508)
24-3/4
(629)
19-5/8
(498)
Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC Coil Box
18-5/8
(473)
19
(483)
20-1/4
(514)
20-3/8
(518)
Downflow Applications on Combustible Flooring NOT Using KGASB
Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or
KCAKC Coil Box
19
(483)
19
(483)
20
(508)
20
(508)
23
(584)
22-7/8
(581)
24-1/8
(613)
19
(483)
23-5/8
(600)
23-1/2
(597)
24-3/4
(629)
19-5/8
(498)
Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC Coil Box
22-1/8
(562)
19
(483)
23-3/4
(603)
20-3/8
(518)
Downflow Applications on Combustible Flooring NOT Using KGASB
Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or
KCAKC Coil Box
22-1/2
(572)
19
(483)
23-1/2
(597)
20
(508)
Upflow Applications
Downflow Applications on Non-Combustible Flooring
17-1/2
(445)
Upflow Applications
Downflow Applications on Non-Combustible Flooring
21
(533)
Upflow Applications
Downflow Applications on Non-Combustible Flooring
24-1/2
(622)
FLOOR OPENING
COMBUSTION-AIR INTAKE
(NON-DIRECT VENT/1-PIPE
APPLICATION)
COMBUSTION-AIR PIPE
(DIRECT VENT/2-PIPE
APPLICATION,ALL SIZES)
VENT
3-IN. MINIMUM CLEARANCE TO
COMBUSTION-AIR INTAKE IS REQUIRED
(NON-DIRECT VENT/1-PIPE
APPLICATION,)
3/8-IN. (10mm) ROD
ANGLE
IRON OR
EQUIVALENT
5 3/4″ (146mm)
ALTERNATE SUPPORT
LOCATION 4-IN. (102mm) MIN
8-IN. (203mm) 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. (21mm) MAX
ALTERNATE SUPPORT
LOCATION FROM BACK
NOTES: 1. A 1 In. (25mm) clearance minimum between
top of furnace and combustible material.
2. The entire length of furnace must be
supported when furnace is used in horizontal
position to ensure proper drainage.
3. For non-direct vent/1-pipe application,
bottom side combustion-air entry cannot be
used when furnace is installed with hangers
as shown.
A93304
Fig. 26 -- Crawlspace Horizontal Application for Direct Vent / 2--Pipe Installation (Sizes 040 through 140) and for Non--Direct Vent
/ 1--Pipe Installation (Sizes 040 through 120 Only)
23
355A
FURNACE
CASING
WIDTH
RETURN AIR CONNECTIONS
!
WARNING
CUT HAZARD
FIRE HAZARD
Failure to follow this caution may result in personal injury.
Failure to follow this warning could result in fire, personal
injury or death.
Use care when cutting support rods in filters to protect against
flying pieces and sharp rod ends. Wear safety glasses, gloves,
and appropriate protective clothing.
Never connect return--air ducts to the back of the furnace.
Return--air duct connections on furnace side(s) permitted in
upflow applications only.
!
Upflow Furnaces
355A
CAUTION
!
UNIT MAY NOT OPERATE
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. 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.
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
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.
Downflow and Horizontal Furnaces
The return--air duct must be connected to return--air opening
provided. 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.
Step 5 — Filter Arrangement
!
FIRE, CARBON
HAZARD
WARNING
MONOXIDE
AND
NOTE: Side return--air openings can ONLY be used in UPFLOW
configurations. Install filter(s) as shown in Fig. 27.
For bottom return--air applications, filter may need to be cut to fit
some furnace widths. Install filter as shown in Fig. 28.
POISONING
Table 4 – Filter Information
Failure to follow this warning could result in personal injury
or death.
AIR FILTER LOCATED IN BLOWER COMPARTMENT
Furnace
Filter Size --- In. (mm)
Casing
Filter Type
Width
Framed
Side
Return*{
Bottom
Return*
In. (mm)
Never operate unit without a filter or with filter access door
removed.
The air filter arrangement will vary due to application, furnace
orientation, and filter type. The filter may be installed in an
external Filter/Media cabinet (if provided) or the furnace blower
compartment. Factory supplied washable filters are shipped in the
blower compartment.
If a factory--supplied external Filter/Media cabinet is provided,
instructions for its application, assembly, and installation are
packaged with the cabinet. The Filter/Media cabinet can be used
with the factory--supplied washable filter or a factory--specified
high--efficiency disposable filter (see cabinet instructions). If
installing the filter in the furnace blower compartment, determine
location for filter and relocate filter retaining wire, if necessary. See
Table 4 to determine correct filter size for desired filter location.
Table 4 indicates filter size, location, and quantity shipped with this
furnace. See Fig. 2 for location and size of bottom and side
return--air openings.
CAUTION
17---1/2
(445)
21
(533)
(1) 16 X 25 X 3/4
(406 X 635 X 19)
(1) 16 X 25 X 3/4
(406 X 635 X 19)
Washable
(1) 16 X 25 X 3/4
(1) 20 X 25 X 3/4
Washable
(406 X 635 X 19)
(508 X 635 X 19)
(1 or 2) 16 X 25
24--- 1/2
(1) 24 X 25 X 3/4
X 3/4
Washable
(622)
(609 X 635 X 19)
(406 X 635 X 19)
* Factory ---provided with the furnace. Filters may be field modified by cutting filter material and support rods (3) in filters. Alternate sizes can be
ordered from your distributor or dealer.
{ Upflow only. Alternate sizes and additional filters may be ordered from
your dealer.
24
Step 6 — Bottom Closure Panel
WASHABLE
FILTER
FILTER
RETAINER
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
side return air is used.
To remove bottom closure panel, perform following:
1. Tilt or raise furnace and remove 2 screws holding front filler
panel. (See Fig. 29.)
2. Rotate front filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall front filler panel and screws.
A93045
Fig. 27 -- Filter Installed for Side Inlet
171⁄2-IN. (444mm) WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
21-IN. (533mm) WIDE
CASINGS ONLY:
SUPPORT RODS (3)
EXTEND 1/4" (6mm) ON
EACH SIDE OF FILTER AND
REST ON CASING FLANGE
Gas piping must be installed in accordance with national and local
codes. Refer to NFGC NFPA54/ANSI Z2223.1--2006 in the U.S.
Canadian installations must be made in accordance with
CAN/CSA--B149.1--05 and all authorities having jurisdiction. Gas
supply line should be a separate line running directly from meter to
furnace, if possible. Refer to Table 5 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. (1.8 M). Joint compound (pipe
dope) should be applied sparingly and only to male threads of
joints. Pipe dope must be resistant to propane gas.
!
WARNING
FIRE OR EXPLOSION HAZARD
3″
(76mm)
Failure to follow this warning could result in fire, explosion,
personal injury or death.
24 1/2″
(533mm)
-- Connect gas pipe to furnace using a backup wrench to avoid
damaging gas controls.
-- Gas valve shutoff switch MUST be facing forward or tilted
upward.
-- Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.
-- Use proper length of pipe to avoid stress on gas control
manifold.
-- If a flexible connector is required or allowed by authority
having jurisdiction, black iron pipe shall be installed at furnace
gas valve and extend a minimum of 2 in. (51 mm) outside
furnace casing.
--Protect gas valve from water and debris. Gas valve inlet
and/or inlet piping must remain capped until gas supply line is
permanently installed to protect the valve from moisture and
debris. Also, install a sediment trap in the gas supply piping at
the inlet to the gas valve.
1″
(25.4mm)
WASHABLE
FILTER
FILTER
SUPPORT
FILTER
RETAINER
A00290
Fig. 28 -- Bottom Filter Arrangement
NOTE: Remove and discard bottom closure panel when bottom
inlet is used.
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. 30.)
An accessible manual shutoff valve MUST be installed external to
furnace casing and within 6 ft. (1.8 M) of furnace. A 1/8--in. (3
mm) NPT plugged tapping, accessible for test gauge connection,
MUST be installed immediately upstream of gas supply connection
to furnace and downstream of manual shutoff valve.
Gas line grommet (factory--supplied loose parts bag) should be
used when installing gas piping. Gas line entry hole filler plug
should be installed in unused gas line entry hole. (See Fig. 31.)
NOTE: The gas valve inlet pressure tap connection is suitable to
use as test gauge connection providing test pressure DOES NOT
exceed maximum 0.5 psig (14--in. wc) stated on gas valve. (See
Fig. 59.)
25
355A
Step 7 — Gas Piping
Table 5 – Maximum Capacity of Pipe*
NOMINAL
IRON
PIPE SIZE
IN. (MM)
INTERNAL
DIA.
IN. (MM)
1/2 (13)
GAS
SUPPLY
LENGTH OF PIPE --- FT. (M)
10
(3.0)
20
(6.0)
30
(9.1)
40
(12.1)
0.622
(158)
175
120
97
82
73
3/4 (19)
0.824 (21)
360
250
200
170
151
1 (25)
1.049 (27)
680
465
375
320
285
1-1/4 (32)
1.380 (35)
1400
950
770
660
580
1-1/2 (38)
1.610 (41)
2100
1460
1180
990
900
MANUAL
SHUTOFF
VALVE
(REQUIRED)
50
(15.2)
SEDIMENT
TRAP
UNION
355A
* 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 9.2 NFGC.
Piping should be pressure and leak tested in accordance with
NFGC in the United States or NSCNGPIC in Canada, local, and
national plumbing and gas codes before the furnace has been
connected. 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 at furnace prior to placing it into service.
The gas supply pressure shall be within the maximum (13.6--in.
wc) and and minimum (4.5--in. wc) inlet supply pressures marked
on the rating plate with the furnace burners ON at HI--HEAT and
OFF.
A93324
Fig. 30 -- Typical Gas Pipe Arrangement
Step 8 — Electrical Connections
See Fig. 32 for field wiring diagram showing typical field 115--v
and 24--v wiring. Check all factory and field electrical connections
for tightness.
!
WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury
or death.
Blower access door switch opens 115--v power to furnace
control. No component operation can occur. Do not bypass or
close switch with panel removed.
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation.
BOTTOM
CLOSURE
PANEL
Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through
green/yellow wire connected to gas valve and burner box
screw.
FRONT FILLER
PANEL
A93047
Fig. 29 -- Removing Bottom Closure Panel
115--V WIRING Before proceeding with electrical connections,
make certain that voltage, frequency, and phase correspond to that
specified on furnace rating plate. Also, check to be sure that service
provided
26
COMBUSTION-AIR PIPE GROMMET
UNUSED 1-3/4 -IN. (44 mm)
DIAMETER GAS
CONN. HOLE
COMBUSTION
-AIR PIPE
GAS LINE
GAS LINE ENTRY
HOLE FILLER PLUG
355A
VENT PIPE
GAS LINE GROMMET
VENT PIPE GROMMET
NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER
PLUGS ARE INCLUDED IN FACTORY-SUPPLIED
LOOSE PARTS BAG
A05057
Fig. 31 -- Casing Pipe Grommets
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-, 208/230-, 460-V WIRING
NOTE 5
W
FIVE
WIRE
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
DISCONNECT
THREE-WIRE
HEATING
ONLY
208/230- OR
460-V
THREE PHASE
W/W1
115-V
SINGLE
PHASE
W2
R
AUXILIARY
115-V
FIELD-SUPPLIED J-BOX
DISCONNECT
SWITCH
FURNACE
CONTROL
CENTER
GND
NOTE
3
GND
208/230-V
SINGLE
PHASE
G
C
GND
NOTE 1
Y/Y2
24-V
TERMINAL
BLOCK
GND
CONDENSING
UNIT
TWO WIRE
NOTES:
1. Connect Y or Y/Y2 terminal as shown for proper cooling operation.
2. Proper polarity must be maintained for 115-v wiring.
3. Use W2 with 2-stage thermostat when zoning.
4. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
5. Some thermostats require a "C" terminal connection as shown.
A98325
Fig. 32 -- Heating and Cooling Application Wiring Diagram
27
Table 6 – Electrical Data
OPERATING VOLTAGE
RANGE
Minimum*
MAXIMUM
UNIT
AMPS
MINIMUM
WIRE SIZE
MAXIMUM
WIRE LENGTH
FT. (M)}
MAXIMUM FUSE
OR CKT BKR
AMPS**
104
8.90
14
31 (9)
15
104
8.90
14
31 (9)
15
127
104
8.90
14
30 (9)
15
115--- 60--- 1
127
104
14.00
12
31 (9)
20
100--- 20 / 060100
115--- 60--- 1
127
104
14.00
12
31 (9)
20
120--- 20 / 060120
115--- 60--- 1
127
104
14.00
12
31 (9)
20
UNIT SIZE
VOLTS--HERTZ--PHASE
Maximum*
040--- 14 / 042040
115--- 60--- 1
127
060--- 14 / 042060
115--- 60--- 1
127
080--- 14 / 042080
115--- 60--- 1
080--- 20 / 060080
355A
* 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.
by power supply is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 6 for equipment electrical
specifications.
Make all electrical connections in accordance with National
Electrical Code (NEC) ANSI/NFPA 70--2008 and any local codes
or ordinances that might apply. For Canadian installations, all
electrical connections must be made in accordance with Canadian
Electrical Code CSA C22.1 or authorities having jurisdiction.
Field--supplied wiring shall conform with the limitations of 63_F
(33_C) rise.
The furnace must be electrically grounded in accordance with local
codes; or in the absence of local codes, with the National Electric
Code ANSI/NFPA 70 and/or the Canadian Electric Code, CSA
C22.1, Part I, if an external electrical source is utilized.
Use a separate branch electrical circuit containing a properly sized
fuse or circuit breaker for this furnace. See Table 6 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, furnace control status code indicator light will
flash rapidly and furnace will NOT operate.
!
ELECTRIC
DISCONNECT
SWITCH
COPPER
WIRE ONLY
ALUMINUM
WIRE
A93033
Fig. 33 -- Disconnect Switch and Furnace
Factory Installed J-- Box Location
Install power entry hole filler plugs (factory--supplied in loose parts
bag) in unused power entry holes. (See Fig. 34.)
J-- Box Relocation
1. Remove 2 screws holding auxiliary J--box. (See Fig. 35.)
2. Rotate J--box 180_ and attach box to left side, using holes
provided.
3. Install power entry hole filler plugs (factory--supplied loose
parts bag) in unused power entry holes. (See Fig. 35.)
WARNING
FIRE HAZARD
!
Failure to follow this warning could result in intermittent
operation or performance satisfaction.
FIRE OR ELECTRICAL SHOCK HAZARD
Do not connect aluminum wire between disconnect switch and
furnace. Use only copper wire. (See Fig. 33.)
!
Failure to follow this warning could result in intermittent unit
operation or performance satisfaction.
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.
WARNING
ELECTRICAL AND FIRE HAZARD
Failure to follow this warning could result in electrical shock,
fire or death.
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC ANSI/NFPA 70--2008 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.
WARNING
CONTINUOUS FAN (CF) SETUP SWITCHES
The CF setup switches are used to select desired airflow when
thermostat is in continuous fan mode or to select low--cooling
airflow for two--speed cooling units. This setup feature allows
continuous fan airflow or low--cooling airflow to be adjusted. To
set desired continuous fan airflow or low--cooling airflow:
1. Remove main furnace door and blower access panel.
2. Locate CF setup switches on furnace control. (See Fig. 37.)
3. Determine desired continuous fan airflow or low--cooling
airflow.
4. Use Fig. 47 or wiring schematic to determine proper setup
position of CF switches. (See Fig. 36.)
5. Replace main furnace door and blower access panel.
28
2. Humidifier (HUM)
Connect an accessory 24 VAC, 0.5 amp maximum
humidifier (if used) to the 1/4--in. (6 mm) male
quick--connect HUM terminal and COM--24V screw
terminal on the control board thermostat strip. The HUM
terminal is energized when blower is energized in heating.
(See Fig. 37.)
FACTORY
INSTALLED
LOCATION
UNUSED 7/8-IN. (22 mm)
DIAMETER POWER
ENTRY HOLES
!
UNIT DAMAGE HAZARD
A05113
Fig. 34 -- Factory Installed J-Box Location
Failure to follow this caution may result in unit component
damage.
SETUP SWITCHES (SW1)
The furnace control has 8 setup switches that may be set to meet
the application requirements. Position these setup switches for the
appropriate requirement.
1. Remove main furnace door and blower access panel.
2. Locate setup switches on furnace control. (See Fig. 37.)
3. See Table 13 for setup switch description.
4. Replace main furnace door and blower access panel.
NOTE: If a bypass humidifier is used, setup switch SW1--3 (Low
HEAT Rise Adjust) should be in ON position. This compensates
for the increased temperature in return air resulting from bypass.
NOTE:
If modulating dampers are used, blower motor
automatically compensates for modulating dampers. 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.
24-- V Wiring
Make field 24--v thermostat connections at 24--v terminal block on
furnace control. Y wire from thermostat MUST be connected to
Y/Y2 terminal on control, as shown in Fig. 32, for proper cooling
operation. The 24--v terminal block is marked for easy connection
of field wiring. (See Fig. 37.) The 24--v circuit contains a 3--amp,
automotive--type fuse located on furnace control. (See Fig. 37.)
Any electrical shorts of 24--v wiring during installation, service, or
maintenance may cause fuse to blow. If fuse replacement is
required, use only a fuse of identical size (3 amp) and type. The
furnace control will flash status code 24 when fuse needs
replacement.
NOTE: Use AWG No. 18 color--coded copper thermostat wire for
lengths up to 100 ft. (30 M). For wire lengths over 100 ft. (30 M),
use AWG No. 16 wire.
NOTE: For additional thermostat connection diagrams, reference
Fig. 51--58.
ACCESSORIES
1. Electronic Air Cleaner (EAC)
The furnace control EAC terminals are energized with 115v
(1.0--amp maximum) during blower operation.
Connect an accessory Electronic Air Cleaner (if used) using
1/4--in. (6 mm) female quick connect terminals to the two
male 1/4--in. (6 mm) quick--connect terminals on the control
board marked EAC--1 and EAC--2. The terminals are rated
for 115VAC, 1.0 amps maximum and are energized during
blower motor operation. (See Fig. 37.)
CAUTION
DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistatt, Zone Controller or
similar device. See Thermidistatt, Zone Controller,
thermostat, or controller manufacturer’s instructions for proper
connection.
Step 9 — Removal of Existing Furnaces from
Common Vent Systems
When an existing Category I furnace is removed or replaced, the
original venting system may no longer be sized to properly vent
the remaining attached appliances. An improperly sized Category I
venting system could cause the formation of condensate in the
furnace and vent, leakage of condensate and combustion products,
spillage of combustion products into the living space, etc.
Step 10 — Combustion Air and Vent Pipe Systems
GENERAL
For additional venting information, contact www.Bryant.com.
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
NFPA54/ANSI Z223.1--2006 or CAN/CSA--B149.1--05.
The 355AAV can be vented as either a direct vent or as a
non--direct vent application. A direct vent system shall be installed
in accordance with the direct vent (2--pipe) procedures in the
following Combustion Air and Vent Pipe Systems section. For
non--direct vent (1--pipe) applications, refer to the non--direct vent
(1--pipe) procedures in the same section.
Common venting prohibited.
DIRECT VENT/2--PIPE SYSTEM (ALL SIZES)
In a direct--vent (2--pipe) system, all air for combustion is taken
directly from outdoor atmosphere, and all flue products are
discharged to outdoor atmosphere. A factory accessory vent
termination kit MUST be used in a direct vent (2--pipe) system.
NON--DIRECT VENT/1--PIPE SYSTEM (SIZES
040 THROUGH 120 ONLY)
In a non--direct vent (1--pipe) system, all air for combustion is
taken from the area adjacent to furnace, and all flue products are
discharged to outdoor atmosphere. A factory--supplied perforated
disk assembly (in loose parts bag) MUST be used in combustion
air pipe elbow.
29
355A
POWER ENTRY HOLE
FILLER PLUG (FACTORYSUPPLIED LOOSE PARTS BAG)
ALTERNATE
FIELD
LOCATION
FACTORY
INSTALLED
LOCATION
POWER ENTRY HOLE
FILLER PLUG (FACTORYSUPPLIED LOOSE PARTS BAG)
POWER ENTRY HOLE
FILLER PLUG (FACTORYSUPPLIED LOOSE PARTS BAG)
UNUSED 7/8-IN. (22 mm) DIAMETER
POWER ENTRY HOLES
355A
UNUSED 7/8-IN. (22 mm) DIAMETER
POWER ENTRY HOLES
A05058
Fig. 35 -- Relocating J-Box
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance
connected to the venting system being placed into operation
could result in carbon monoxide poisoning or death.
MATERIALS
Combustion--air and vent pipe, fittings, primers, and solvents must
conform to American National Standards Institute (ANSI)
standards and American Society for Testing and Materials (ASTM)
standards. See Table 7 for approved materials for use in the U.S.A.
!
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1--2006/NFPA 54--2006 or the CSA B149.1--05, Natural
Gas and Propane Installation Code and these instructions.
Determine that there is no blockage or restriction, leakage,
corrosion and other deficiencies, which could cause an unsafe
condition.
3. As far as practical, close all building doors and windows
and all doors between the space in which the appliance(s)
connected to the venting system are located and other spaces
of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they are operating at
maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being
inspected into operation. Adjust the thermostat so appliance is
operating continuously.
7. Test for spillage from draft hood equipped appliances at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above
tests, the venting system must be corrected in accordance with
the National Fuel Gas Code, ANSI Z223.1-- 2006/NFPA
54--2006 and/or CSA B149.1--05, Natural Gas and Propane
Installation Code.
9. After it has been determined that each appliance connected
to the venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, fireplace dampers
and any other gas--fired burning appliance to their previous
conditions of use.
WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in fire, property
damage, personal injury or death.
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.
In Canada, construct all combustion--air and vent pipes for this unit
of CSA or ULC listed schedule--40 PVC, PVC--DWV or
ABSDWV pipe and pipe cement. SDR pipe is NOT approved in
Canada.
In direct vent (2--pipe) systems, combustion air and vent pipes
must terminate together in same atmospheric pressure zone, either
through roof or sidewall (roof termination preferred), using
accessory termination kit. See Table 8 for required clearances.
In non--direct vent (1--pipe) system, vent pipe termination must be
installed with adequate clearances to building openings and
equipment to comply with national and local codes. See Table 9 for
required clearances.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in property damage,
personal injury, or death.
All combustion--air and vent pipes must be airtight and
watertight. Pipes must also terminate exactly as shown in Fig.
43 for direct vent (2--pipe) system and Fig. 44 for non--direct
vent (1--pipe) system.
30
Table 7 – Approved Combustion--Air and Vent Pipe, Fitting and Cement Materials
MATERIAL
PIPE
FITTINGS
SOLVENT CEMENT AND
PRIMERS
ABS
PVC
For ABS
PVC
PVC
ABS
For PVC
ABS
PVC
CPVC
CPVC
CPVC
For CPVC
Pipe
Pipe
—
Pipe
—
—
—
Pipe
Pipe
—
Pipe
Pipe
—
—
—
—
—
Fittings
Fittings
—
Fittings
Fittings
Fittings
—
—
—
—
—
Solvent Cement
—
—
—
Solvent Cement
—
—
—
—
—
Solvent Cement
F628
ABS
Pipe
—
—
F656
F891
For PVC
PVC
—
Pipe
—
—
Primer
—
An abandoned masonry chimney may be used as a raceway for
properly insulated and supported combustion--air (when
applicable) and vent pipes. Each furnace must have its own set of
combustion--air and vent pipes and be terminated individually, as
shown in Fig. 43 for Direct Vent (2--Pipe) system and Fig. 44 for
Non--Direct Vent (1--Pipe) system.
A furnace shall not be connected to a chimney flue serving a
separate appliance designed to burn solid fuel.
Other gas appliances with their own venting system may also use
the abandoned chimney as a raceway providing it is permitted by
local code, the current edition of the National Fuel Gas Code and
the vent or liner manufacturer’s installation instructions. Care must
be taken to prevent the exhaust gases from one appliance from
contaminating the combustion air of other gas appliances.
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation.
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 10 with Armaflex--type insulation.
!
Schedule—40
Schedule—40
For ABS
SDR—21 & SDR—26
Schedule—40
Schedule—40
For PVC
DWV at Schedule—40 IPS sizes
DWV
Schedule—40
Schedule—40
SDR
For CPVC
Cellular Core DWV at Schedule--- 40
IPS sizes
For PVC
Cellular Core Schedule--- 40 & DWV
CAUTION
UNIT CORROSION HAZARD
Excessive exposure to contaminated combustion air may result
in safety and performance related problems.
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. pipe.
NOTE: All pipe joints must have cemented attachment of
combustion--air inlet pipe to inlet housing connection, since it may
be necessary to remove pipe for servicing.
Assembly of Combustion Air Pipe (Non-- Direct
Vent/1-- Pipe System ONLY)
1. Permanently install perforated disk assembly (factory supplied in loose parts bag) in combustion--air elbow using
RTV or by cementing, as shown in Fig. 39. For 120,000
Btuh size units only: separate the 2 halves of perforated disk
assembly and use only the shouldered disk half.
2. Determine the length of straight portion of combustion--air
inlet pipe from Fig. 39.
3. Cut field--supplied 2--in. (51 mm) diameter PVC pipe to
length as determined per Fig. 39.
4. Permanently attach elbow/perforated disk assembly to
straight portion of pipe using RTV or by cementing as
shown in Fig. 39.
Furnace combustion air and vent pipe connections are sized for
2--in. (51 mm) pipe. Any pipe size change should be made outside
furnace casing in vertical pipe. The transition has to be made as
close to the furnace as reasonably possible. See Fig. 40.
COMBUSTION AIR PIPE
General
Furnace combustion--air connection must be attached as shown in
Fig. 38. Combustion--air intake housing plug may need to be
relocated in some applications.
For Non--Direct Vent (1--Pipe) system, combustion--air must
terminate outside of furnace casing with 1 elbow. Orient elbow so
that its opening faces down for upflow or downflow applications.
Orient elbow so that its opening faces sideways (left or right) for
horizontal left or horizontal right applications (See Fig. 38.)
Maintain a 3--in minimum clearance between the opening of the
combustion--air inlet pipe and any object.
DESCRIPTION
Assembly of Combustion Air Pipe (Direct Vent-- 2-- Pipe
System ONLY)
1. Using Table 11, individually determine the smallest
combustion air and vent pipe diameters permitted for each
pipe. Pick the larger of these two pipe diameters and use this
for both combustion--air and vent pipes.
NOTE: Do not count elbows or pipe sections in terminations or
within furnace (All elbows shown in Fig. 43 are not to be counted).
31
355A
ASTM SPECIFICATION
(MARKED ON
MATERIAL)
D1527
D1785
D2235
D2241
D2466
D2468
D2564
D2661
D2665
F438
F441
F442
F493
V
355A
V
12 inches (30 cm) for applieances >10,000 Btuh(3 kW)
and < 100,000 Btuh(30kW), 36 inches (91cm) for
appliances > 100,000 Btuh(30kW)
A08600
Table 8 – Direct Vent Termination Clearance
32
355A
A08601
Table 9 – Other than Direct Vent Termination Clearance
33
355A
A07902
Fig. 36 -- Wiring Diagram
34
MODEL PLUG
CONNECTOR
USER INTERFACE
OR ADVANCED
PRODUCT
MONITOR
CONNECTOR
CONTINUOUS FAN
(CF) AIRFLOW
SETUP SWITCHES
OAT
CONNECTOR
SW4 SETUP
SWITCHES
SW1 SETUP
SWITCHES AND
BLOWER OFFDELAY
AIR CONDITIONING
(A/C) AIRFLOW
SETUP SWITCHES
HUMIDIFIER
TERMINAL (24-VAC
0.5 AMP MAX.
ACRDJ – AIR
CONDITIONING
RELAY DISABLE
JUMPER
24-V THERMOSTAT
TERMINALS
355A
FLASH
UPGRADE
CONNECTOR
(FACTORY
ONLY)
STATUS AND COMM
LED LIGHTS
PL3 – ECM BLOWER
HARNESS
CONNECTOR
3-AMP FUSE
TRANSFORMER 24-VAC
CONNECTIONS
BOARD SERIAL
NUMBER
115-VAC (L2) NEUTRAL
CONNECTIONS
EAC-1 TERMINAL
(115 -VAC 1.0 AMP MAX.)
PL1 – LOW VOLTAGE MAIN
HARNESS CONNECTOR
V12
SOFTWARE
VERSION
NUMBER
115-VAC (L1) LINE
VOLTAGE CONNECTIONS
EXAMPLE:
HK42FZ022 3407
PART
NUMBER
PL2 – HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
DATE
CODE
A07422
Fig. 37 -- Control Center
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in incomplete
combustion, flame disturbance, or flame sense lockout.
When installing combustion air and vent system of short pipe
length, the smallest allowable pipe diameter must be used.
NOTE: A 2--in. (51 mm) diameter pipe must be used within
furnace casing. Make all pipe diameter transitions outside furnace
casing per Fig. 40.
2. Unless noted in Table 11, insert perforated disk assembly
(factory--supplied in loose parts bag) in intake housing
where combustion air pipe will be connected. If half disk set
is required, install only shouldered disk half.
Attachment of Combustion Air Pipe
1. Determine location of combustion air intake pipe
connection to combustion air intake housing as shown in
Fig. 38 for application.
2. Reposition combustion air intake housing plug fitting in
appropriate unused intake housing connection.
3. Install combustion--air pipe grommet (factory--supplied in
loose parts bag) into selected furnace casing combustion--air
pipe hole.
A07898
Fig. 38 -- Combustion--Air and Vent Pipe Connections
35
Table 10 – Maximum Allowable Exposed Vent Pipe Length (Ft / M) with Insulation in
Winter Design Temperature Ambient*
UNIT SIZE
040
060
080
355A
100
120
WINTER DESIGN
TEMPERATURE
F (C)
20_F (--- 6.7_)
0_F (--- 17.8_)
--- 20_F (--- 28.9_)
20_F (--- 6.7_)
0_F (--- 17.8_)
--- 20_F (--- 28.9_)
20_F (--- 6.7_)
0_F (--- 17.8_)
--- 20_F (--- 28.9_)
20_F (--- 6.7_)
0_F (--- 17.8_)
--- 20_F (--- 28.9_)
20_F (--- 6.7_)
0_F (--- 17.8_)
--- 20_F (--- 28.9_)
MAXIMUM PIPE
DIAMETER
IN. (mm)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2--- 1/2 (64)
2--- 1/2 (64)
2--- 1/2 (64)
3 (76)
3 (76)
3 (76)
INSULATION THICKNESS --- IN. (mm)†
0 (0)
3/8” (10)
1/2” (13)
3/4” (19)
1” (25)
21 (6)
10 (3)
5 (2)
30 (9)
16 (5)
9 (3)
37 (11)
20 (6)
11 (3)
41 (13)
21 (6)
11 (3)
49 (15)
26 (8)
15 (5)
37 (11)
22 (7)
14 (4)
55 (17)
33 (10)
23 (7)
65 (20)
39 (12)
27 (8)
70 (21)
42 (13)
28 (8)
70 (21)
51 (16)
35 (11)
42 (13)
25 (8)
17 (5)
61 (19)
38 (12)
26 (8)
70 (21)
45 (14)
31 (9)
70 (21)
48 (15)
33 (10)
70 (21)
58 (18)
40 (12)
50 (15)
30 (9)
21 (6)
70 (21)
46 (14)
33 (10)
70 (21)
55 (17)
39 (12)
70 (21)
59 (18)
41 (13)
70 (21)
70 (21)
50 (15)
57 (17)
35 (11)
25 (8)
70 (21)
53 (16)
38 (12)
70 (21)
63 (19)
45 (14)
70 (21)
68 (21)
49 (15)
70 (21)
70 (21)
59 (18)
* Pipe length (ft./m) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable
pipe length as specified in Table 11.
†Insulation thickness based on R value of 3.5 per in. (25 mm)
FIELD-SUPPLIED
2-IN. (51 mm) DIA.
PVC 90 ELBOW
FIELD-SUPPLIED
2-IN. (51 mm) DIA.
PVC PIPE
A
COMBUSTION-AIR DISC LOCATION-NON DIRECT
VENT/1-PIPE SYSTEM (FACTORY-SUPPLIED IN
LOOSE PARTS BAG)
A05122
CASING WIDTH
A
8--- 1/2 +/--- ½
17--- 1/2 (445)
(216 +/--- 13)
10--- 1/2 +/--- ½
21 (533)
(267 +/--- 13)
12 +/--- ½
24--- 1/2 (622)
(305 +/--- 13)
Fig. 39 -- Combustion--Air Inlet Pipe Assembly -- In. (mm)
4. Insert assembled combustion air inlet pipe into intake
housing as shown in Fig. 38.
5. Drill a 1/8--in. hole in 2--in, combustion air pipe using the
hole in intake housing as a guide.
6. Install a field--supplied No. 6 or No. 8 sheet metal screw
into combustion air pipe.
7. Install casing hole filler cap (factory--supplied in loose parts
bag) in unused combustion air pipe casing hole.
NOTE: Do not attach combustion air intake pipe permanently to
combustion air intake housing since it may be necessary to remove
pipe for service of igniter or flame sensor.
Attachment of Combustion Air Intake Housing Plug
Fitting
The combustion--air intake plug fitting must be installed in unused
combustion air intake housing. This fitting must be attached by
using RTV sealant, or by drilling a 1/8--in. (3 mm) hole in fitting,
using hole in intake housing as a guide. Install a field--supplied No.
6 or No. 8 sheet metal screw.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage of intake
housing or fitting may cause air leakage to occur.
A plugged drain connection has been provided on this fitting for
use when moisture is found in combustion air intake pipe and
combustion box. If use of this drain connection is desired, drill out
fitting’s tap plug with 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, as shown in
Fig. 41.
NOTE:
(Direct Vent/2--Pipe System ONLY). Moisture in
combustion air intake may be a result of improper termination.
Ensure combustion air pipe termination is similar to those as
shown in Fig. 43 so that it will not be susceptible to area where
light snow or others sources of moisture could be pulled in.
VENT PIPE
General
Furnace vent connection must be attached as shown in Fig. 38.
!
WARNING
CARBON MONOXIDE POISONING AND PROPERTY
DAMAGE HAZARD
Failure to follow this warning could result in property damage,
personal injury, or death.
Vent pipes must be airtight. NOTE: A 2--in. (51 mm) diameter
pipe must be used within the furnace casing. Make all pipe
diameter transitions outside furnace casing per Fig. 40.
NOTE: A 2--in. (51 mm) diameter pipe must be used within the
furnace casing. Make all pipe diameter transitions outside furnace
casing per Fig. 40.
36
Table 11 – Maximum Allowable Pipe Length (Ft. / M)
0 to 2000
(0 to 610)
ALTITUDE
2001 to 3000
(610 to 914)
ALTITUDE
UNIT SIZE
(BTUH)
40,000
2 Pipe or 2 ---In.
(51) Concentric
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
UNIT SIZE
(BTUH)
40,000
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
UNIT SIZE
(BTUH)
4001 to 5000‡
(1219 to 1524)
ALTITUDE
5001 to 6000‡
(1524 to 1829)
Termination
Type
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
60,000
ALTITUDE
Termination
Type
2 Pipe or 2 ---In.
(51) Concentric
40,000
3001 to 4000
(914 to 1219)
Termination
Type
UNIT SIZE
(BTUH)
Termination
Type
40,000
2 Pipe or 2 ---In.
(51) Concentric
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
UNIT SIZE
(BTUH)
Termination
Type
40,000
2 Pipe or 2 ---In.
(51) Concentric
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
2 ---1/2 (64)
3 (76)
3 (76)†
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
3 (76)
3 (76)†
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
3 (76)
3 (76)†
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
50 (15)
70 (21)
50 (15)
70 (21)
30 (9)
70 (21)
45 (14)
70 (21)
10 (3)
35 (11)
70 (21)
3 (76)†
45 (14)
70 (21)
45 (14)
70 (21)
25 (8)
70 (21)
40 (13)
70 (21)
NA
30 (9)
70 (21)
NUMBER OF 90_ ELBOWS
3
4
5
6
40 (13)
70 (21)
40 (13)
70 (21)
20 (6)
70 (21)
35 (11)
70 (21)
NA
15 (5)
70 (21)
35 (11)
70 (21)
35 (11)
70 (21)
15 (5)
70 (21)
30 (9)
70 (21)
NA
NA
70 (21)
30 (9)
70 (21)
30 (9)
70 (21)
10 (3)
70 (21)
25 (8)
70 (21)
NA
NA
70 (21)
25 (8)
70 (21)
25 (8)
70 (21)
5 (2)
70 (21)
20 (6)
70 (21)
NA
NA
70 (21)
NUMBER OF 90_ ELBOWS
1
2
3
4
5
6
45 (14)
70 (21)
45 (14)
70 (21)
26 (8)
70 (21)
40 (12)
70 (21)
31 (9)
63 (19)
40 (13)
70 (21)
40 (13)
70 (21)
21 (6)
70 (21)
35 (11)
70 (21)
26 (8)
62 (19)
35 (11)
70 (21)
35 (11)
70 (21)
16 (5)
70 (21)
30 (9)
70 (21)
12 (4)
62 (19)
30 (9)
70 (21)
30 (9)
70 (21)
11 (3)
70 (21)
25 (8)
70 (21)
NA
61 (19)
25 (8)
70 (21)
25 (8)
70 (21)
6 (2)
70 (21)
20 (6)
70 (21)
NA
61 (19)
20 (6)
70 (21)
20 (6)
70 (21)
NA
70 (21)
15 (5)
70 (21)
NA
61 (19)
1
2
3
4
5
6
42 (13)
70 (21)
42 (13)
70 (21)
25 (8)
70 (21)
38 (12)
70 (21)
29 (9)
59 (18)
37 (11)
70 (21)
37 (11)
70 (21)
20 (6)
70 (21)
33 (10)
70 (21)
24 (7)
59 (18)
32 (10)
70 (21)
32 (10)
70 (21)
15 (5)
70 (21)
28 (9)
70 (21)
10 (3)
58 (18)
27 (8)
70 (21)
27 (8)
70 (21)
10 (3)
70 (21)
23 (7)
70 (21)
NA
57 (17)
22 (7)
70 (21)
22 (7)
70 (21)
5 (2)
70 (21)
18 (6)
70 (21)
NA
57 (17)
17 (5)
70 (21)
17 (5)
70 (21)
NA
70 (21)
13 (4)
70 (21)
NA
56 (17)
1
2
3
4
5
6
40 (12)
70 (21)
40 (12)
70 (21)
23 (7)
70 (21)
36 (11)
70 (21)
35 (11)
70 (21)
35 (11)
70 (21)
18 (6)
70 (21)
31 (9)
70 (21)
30 (9)
70 (21)
30 (9)
70 (21)
13 (4)
70 (21)
26 (8)
70 (21)
25 (8)
70 (21)
25 (8)
70 (21)
8 (2)
70 (21)
21 (6)
70 (21)
20 (6)
70 (21)
20 (6)
70 (21)
NA
70 (21)
16 (5)
70 (21)
15 (10)
70 (21)
15 (10)
70 (21)
NA
68 (21)
11 (3)
70 (21)
56 (17)
55 (17)
54 (17)
53 (16)
52 (16)
52 (16)
NUMBER OF 90_ ELBOWS
NUMBER OF 90_ ELBOWS
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
1
2
3
4
5
6
37 (11)
70 (21)
37 (11)
70 (21)
22 (7)
70 (21)
33 (10)
70 (21)
32 (10)
70 (21)
32 (10)
70 (21)
17 (5)
70 (21)
28 (9)
70 (21)
27 (8)
70 (21)
27 (8)
70 (21)
12 (4)
70 (21)
23 (7)
70 (21)
22 (7)
70 (21)
22 (7)
70 (21)
7 (2)
70 (21)
18 (6)
70 (21)
17 (5)
70 (21)
17 (5)
70 (21)
NA
68 (21)
13 (4)
70 (21)
12 (4)
70 (21)
12 (4)
70 (21)
NA
63 (19)
8 (2)
70 (21)
3 (76)†
53 (16)
52 (16)
50 (15)
49 (15)
48 (15)
47 (14)
NUMBER OF 90_ ELBOWS
*See notes on next page.
37
355A
ALTITUDE
FT. (M)
VARIABLE SPEED VENT SIZING TABLE
Direct & Non--Direct Pipe
Dia.
1
2
In. (mm)*
Table 11 — Maximum Allowable Pipe Length (Ft. / M) (Continued)
Variable Speed Vent Sizing Table
ALTITUDE
FT. (M)
6001 to 7000‡
(1829 to 2134)
355A
ALTITUDE
7001 to 8000‡
(2134 to 2438)
ALTITUDE
8001 to 9000
Ft.‡
(2438 to 2743)
ALTITUDE
9001 to 10000 ‡
(2743 to 3048)
UNIT SIZE
(BTUH)
Termination
Type
40,000
2 Pipe or 2 ---In.
(51) Concentric
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
UNIT SIZE
(BTUH)
Termination
Type
40,000
2 Pipe or 2 ---In.
(51) Concentric
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
UNIT SIZE
(BTUH)
Termination
Type
40,000
2 Pipe or 2 ---In.
(51) Concentric
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
120,000
2 Pipe or 3 ---In.
(76) Concentric
UNIT SIZE
(BTUH)
Termination
Type
40,000
2 Pipe or 2 ---In.
(51) Concentric
60,000
2 Pipe or 2 ---In.
(51) Concentric
80,000
2 Pipe or 2 ---In.
(51) Concentric
100,000
2 Pipe or 2 ---In.
(51) Concentric
NUMBER OF 90_ ELBOWS
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
1
2
3
4
5
6
35 (11)
70 (21)
35 (11)
70 (21)
20 (6)
70 (21)
31 (9)
70 (21)
30 (9)
70 (21)
30 (9)
70 (21)
15 (5)
70 (21)
26 (8)
70 (21)
25 (8)
68 (21)
25 (8)
68 (21)
10 (3)
68 (21)
21 (6)
68 (21)
20 (6)
67 (20)
20 (6)
67 (20)
5 (2)
67 (20)
16 (5)
67 (20)
15 (5)
66 (20)
15 (5)
66 (20)
NA
62 (19)
11 (3)
66 (20)
10 (3)
64 (20)
10 (3)
64 (20)
NA
57 (17)
6 (2)
64 (20)
3 (76)†
49 (15)
48 (15)
47 (14)
45 (14)
44 (13)
43 (13)
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
1
2
3
4
5
6
32 (10)
66 (20)
32 (10)
66 (20)
18 (6)
66 (20)
29 (9)
66 (20)
27 (8)
65 (20)
27 (8)
65 (20)
13 (4)
65 (20)
24 (7)
65 (20)
22 (7)
63 (19)
22 (7)
63 (19)
8 (2)
63 (19)
19 (6)
63 (19)
17 (5)
62 (19)
17 (5)
62 (19)
NA
62 (19)
14 (4)
62 (19)
12 (4)
60 (18)
12 (4)
60 (18)
NA
57 (17)
9 (3)
60 (18)
7 (2)
59 (18)
7 (2)
59 (18)
NA
52 (16)
NA
59 (18)
3 (76)†
46 (14)
44 (13)
43 (13)
41 (13)
40 (12)
38 (12)
NUMBER OF 90_ ELBOWS
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
1
2
3
4
5
6
30 (9)
62 (19)
30 (9)
62 (19)
17 (5)
62 (19)
27 (8)
62 (19)
25 (8)
60 (18)
25 (8)
60 (18)
12 (3)
60 (18)
22 (7)
60 (18)
20 (6)
58 (18)
20 (6)
58 (18)
7 (2)
58 (18)
17 (5)
58 (18)
15 (5)
56 (17)
15 (5)
56 (17)
NA
56 (17)
12 (4)
56 (17)
10 (3)
55 (17)
10 (3)
55 (17)
NA
51 (16)
7 (2)
55 (17)
5 (2)
53 (16)
5 (2)
53 (16)
NA
46 (14)
NA
53 (16)
3 (76)†
43 (13)
41 (13)
39 (12)
37 (11)
35 (11)
34 (10)
1
2
3
4
5
6
27 (8)
57 (17)
27 (8)
57 (17)
15 (5)
57 (17)
24 (7)
57 (17)
22 (7)
55 (17)
22 (7)
55 (17)
10 (3)
55 (17)
19 (6)
55 (17)
17 (5)
53 (16)
17 (5)
53 (16)
5 (2)
53 (16)
14 (4)
53 (16)
12 (4)
51 (16)
12 (4)
51 (16)
NA
51 (16)
9 (3)
51 (16)
7 (2)
49 (15)
7 (2)
49 (15)
NA
46 (14)
NA
49 (15)
NA
47 (14)
NA
47 (14)
NA
41 (13)
NA
47 (14)
Direct & Non--Direct Pipe
Dia. In. (mm)*
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
1 ---1/2 (38)
2 (51)
2 (51)
2 ---1/2 (64)
NUMBER OF 90_ ELBOWS
NUMBER OF 90_ ELBOWS
2 Pipe or 3 ---In.
3 (76)†
39 (12)
37 (11)
35 (11)
33 (10)
31 (10)
29 (9)
(76) Concentric
* Disk usage ---Unless otherwise stated, use perforated disk assembly (factory ---supplied in loose parts bag).
{ Wide radius elbow.
} Vent sizing for Canadian installations over 4500 ft. (1372 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, determine the smallest diameter allowed by the table for each pipe, 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. (1.5 M) for all applications.
120,000
38
!
CAUTION
UNIT DAMAGE HAZARD
FURNACE
Failure to follow this caution may result in unit component
damage.
NOT IN
HORIZONTAL
SECTION
PIPE DIAMETER
TRANSITION IN
VERTICAL SECTION
A93034
Fig. 40 -- Combustion--Air and Vent Pipe Diameter Transition
Location and Elbow Configuration
COMBUSTION AIR
INTAKE HOUSING
3/8" (10 mm) ID TUBE
3/16"
DRILL
TRAP
BURNER
BOX
COMBUSTION
AIR PIPE
4. Install combustion--air pipe grommet (factory--supplied in
loose parts bag) into selected furnace casing vent pipe hole.
(See Fig. 31.)
5. Be certain that mating surfaces of inducer housing
connection elastomeric (rubber) coupling, and 2--in. (51
mm) 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. (51 mm)
diameter vent pipe through the elastomeric (rubber)
coupling and fully into inducer housing connection until it
touches a stop inside the inducer housing outlet. Tighten the
screws on both clamps to 15--in--lb. of torque. pipe to
inducer housing. Tighten the clamp screws to 15 in.--lb. of
torque.
NOTE: Starting at furnace, slope vent pipe a minimum of 1/4--in.
(6 mm) per linear ft. with no sags between hangers.
!
4″
(102 mm)
MIN
CAUTION
UNIT DAMAGE HAZARD
TO OPEN
DRAIN
Failure to follow this caution may result in unit component
damage.
A93035
Vent pipe must be installed and fully seated against inducer
housing internal stop. Clamp must be tightened to prevent any
condensate leakage.
Fig. 41 -- Intake Housing Plug Fitting Drain
The minimum vent pipe length for these furnaces is 5 ft. (1.5 M)
Short pipe lengths (5--8 ft. / 1.5 -- 8 M) may discharge condensate
droplets. These condensate droplets may be undesirable. A 12--in.
(304.8 mm) minimum offset pipe section is recommended to
reduce excessive condensate droplets from exiting vent pipe outlet.
(See Fig. 42.)
Attachment of Vent Pipe
Determine combustion--air and vent pipe diameter.
1. Using Table 11, individually determine the smallest
combustion--air and vent pipe diameters permitted for eahc
pipe. Pick the larger of these two pipe diameters and use
this diameter for both combustion--air and vent pipes.
NOTE: (Direct Vent/2--Pipe ONLY) vent pipe system has the
same diameter and same length as combustion air pipe as
mentioned in section “Assembly of Combustion Air Pipe (Direct
Vent/2--Pipe system ONLY).”
NOTE: Do not count elbows or pipe sections in terminations or
within furnace (all elbows shown in Fig. 43 and Fig. 44 are not be
counted).
2. Determine location of vent pipe connection to inducer
housing as shown in Fig. 38 for application.
3. Reposition elastomeric (rubber) inducer housing outlet cap
and clamp to appropriate unused inducer housing
connection. Tighten clamp.
6. Install casing hole filler cap (factory--supplied in loose parts
bag) in unused vent pipe casing hole.
Installation Guidelines for Combustion Air Pipe and
Vent Pipe
It is recommended that all pipes be cut, prepared, and preassembled
before permanently cementing any joint.
1. Attach combustion air pipe and vent pipe per instructions in
sections “Combustion Air Pipe” and “Vent Pipe.”
2. Working from furnace to outside, cut pipe to required
length(s).
3. Deburr inside and outside of pipe.
4. Chamfer outside edge of pipe for better distribution of
primer and cement.
5. Clean and dry all surfaces to be joined.
6. Check dry fit of pipe and mark insertion depth on pipe.
7. After pipes have been cut and preassembled, apply generous
layer of cement primer to pipe fitting socket and end of pipe
to insertion mark. Quickly apply approved cement to end of
pipe and fitting socket (over primer). Apply cement in a
light, uniform coat on inside of socket to prevent buildup of
excess cement. Apply second coat.
8. While cement is still wet, twist pipe into socket with 1/4
turn. Be sure pipe is fully inserted into fitting socket.
9. Wipe excess cement from joint. A continuous bead of
cement will be visible around perimeter of a properly made
joint.
10. Handle pipe joints carefully until cement sets.
39
355A
Inducer housing outlet cap must be installed and fully seated
against inducer housing. Clamp must be tightened to prevent
any condensate leakage.
355A
11. Horizontal portions of the venting system shall be
supportive to prevent sagging support. Support combustion
air piping (if applicable) and vent piping a minimum of
every 5 ft. (1.5 M)(3 ft. (.91 M) for SDR--21 or --26 PVC)
using perforated metal hanging strap.
12. Slope combustion air piping (if applicable) and vent piping
downward towards furnace a minimum of 1/4 in. (6 mm)
per linear ft. with no sags between hangers.
13. Horizontal portions of the venting system shall be installed
so as to prevent the accumulation of condensate.
14. Use appropriate methods to seal openings where
combustion air pipe (if applicable) and vent pipe pass
through roof or sidewall.
EXAMPLE
An 100--14 size furnace located in Indianapolis, elevation 650
ft. (198 M) above sea level, could be installed as either a direct
vent/2--pipe system that requires 3 elbows and 28 ft. (8.5 M)
of vent pipe, along with 5 elbows and 34 ft. (10.3 M) of
combustion--air pipe OR a non--direct vent/1--pipe system that
requires 3 elbows and 28 ft. (8.5 M) vent pipe.
For a direct vent/2--pipe system, Table 11 indicates this
application would allow a 2--in. (51 mm) diameter vent pipe,
but require a 2--1/2 in. (64 mm) diameter combustion air pipe.
According to Table 11, 2--in. (51 mm) diameter pipe is good
for 30 ft. (9.1 M) with 3 elbows, but only 20 ft. (6.1 M) with 5
elbows. Therefore, 2--1/2 in. (64 mm) diameter pipe must be
used for both vent and combustion air pipes since larger
required diameter must always be used for both pipes.
For a non--direct vent/1--pipe system, Table 11 indicates that
this application would allow a 2--in. (51 mm) diameter vent
pipe. If same installations were in Albuquerque, elevation
5250 ft. (1600 M) above sea level:
For a direct vent/2--pipe system, Table 11 indicates that 2--1/2
in. (64 mm) diameter vent pipe and combustion--air pipe are
required.
For a non--direct vent/1--pipe system, Table 11 indicates that
2--1/2--in. (64 mm) diameter vent pipe is required. If same
applications are to be installed at 5001-- to 6000 ft. (1524 -1829 M) elevation:
For a direct vent/2--pipe system, 2--in. (51 mm) pipe is only
good for 23 ft. (7.0 M) (with 3 elbows) and 13 ft. (3.9 M)
(with 5 elbows). Therefore, 2--1/2 in. (64 mm) diameter
combustion air and vent pipe must be used.
For a non--direct vent/1--pipe system, a 2--in. (51 mm)
diameter pipe is only good for 23 ft. (7.0 M) with 3 elbows. A
2--1/2--in. (64 mm) diameter vent pipe must be used.
VENT TERMINATION
General
Combustion--air (direct vent/2--pipe system only) and vent pipe
must terminate outside structure, either through sidewall or roof.
For vent termination clearance, refer to Table 8 for Direct
Vent/2--Pipe system and Table 9 for Non--direct Vent/1--Pipe
system. For exterior piping arrangements, refer to Fig. 43 for
Direct Vent/2--Pipe system and Fig. 44 for Non--Direct/1--Pipe
system.
Roof termination is preferred since it is less susceptible to damage
or contamination, and it has less visible vent vapors. Sidewall
termination require sealing or shielding of building surfaces with a
corrosive resistance material due to corrosive combustion products
of vent system.
NOTE: (Direct Vent/2--Pipe system ONLY) A factory accessory
termination kit MUST be used. See section “Vent Termination Kit
(Direct Vent/2--Pipe System Only)” in this instruction.
When determining appropriate location for termination, consider
the following guidelines:
1. Comply with all clearance requirements stated in Table 8 or
Table 9 per application.
2. Termination or termination kit should be positioned where
vent vapors will not damage plants/shrubs or air
conditioning equipment.
3. Termination or termination kit should be positioned so that
it will not be affected by wind eddy, such as inside building
corners, nor by recirculation of flue gases, airborne leaves,
or light snow.
4. Termination or termination kit should be positioned where it
will not be damaged by or subjected to foreign objects such
as stones, balls, etc.
5. Termination or termination kit should be positioned where
vent vapors are not objectionable.
Extended Exposed Sidewall Pipes
Sidewall combustion air pipe termination (direct vent/2--pipe
system only) and vent pipe termination may be extended beyond
area shown in Fig. 43 or in Fig. 44 per application in outside
ambient by insulating pipe as indicated in Table 10.
1. Determine combustion air pipe diameter (direct vent/2--pipe
system only) and vent pipe diameter, as stated above, using
total pipe length and number of elbows.
2. Using winter design temperature (used in load calculations),
find appropriate temperature for your application and
furnace model.
3. Determine required insulation thickness for exposed pipe
length(s).
NOTE: Pipe length (ft. / M) specified for maximum pipe lengths
located in unconditioned spaces cannot exceed total allowable pipe
length as specified in Table 11.
Vent Termination Kit (Direct Vent/2-- Pipe System
Only)
NOTE: Always refer to the instructions in termination kit for the
latest version.
Combustion air and vent pipes MUST terminate outside structure.
A factory accessory termination kit must be installed as shown in
Table 12. There are four options of vent/combustion air
termination kits available as shown in Table 12.
NOTE: Combustion air pipe must have the same diameter as vent
pipe.
Concentric Vent/Combustion Air Termination Kit
(Direct Vent/ 2-- Pipe System Only)
Determine an appropriate location for termination kit using the
guidelines provided in section “Vent Termination: General” in this
instruction.
1. Cut one 4--in. (102 mm) diameter hole for 2--in. (51 mm)
kit, or one 5--in. (125 mm) diameter hole for 3--in. (76 mm)
kit.
2. Loosely assemble concentric vent/combustion air
termination components together using instructions in kit.
3. Slide assembled kit with rain shield REMOVED through
hole.
NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole.
Roof terminations–Locate assembly through roof to appropriate
height as shown in Fig. 43.
Sidewall terminations--Locate assembly through sidewall with
rain shield positioned no more than 1--in. (25 mm) from wall as
shown in Fig. 43.
4. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
5. Check required dimensions as shown in Fig. 43.
40
12″ MIN
(305mm)
12″ MIN
(305mm)
VENT PIPE
VENT PIPE
COMBUSTION-AIR PIPE
COMBUSTION-AIR PIPE
HORIZONTAL TO ROOF
HORIZONTAL TO SIDEWALL
355A
COMBUSTION-AIR PIPE
VENT PIPE
COMBUSTION-AIR PIPE
12″ MIN
(304.8mm)
12″ MIN
(304.8mm)
VENT PIPE
VERTICAL TO ROOF
VERTICAL TO SIDEWALL
NOTE: A 12-in. (304.8mm) minimum offset pipe section is recommended
with short (5 to 8 ft / 1.5 to 2.5M) vent systems. This recommendation
is to reduce excessive condensate droplets.
A96230
Fig. 42 -- Short Vent (5 to 8 Ft. or 1.5M -- 2.4M) System
Two-- Pipe Termination Kit (Direct Vent/2-- Pipe System
Only
Determine an appropriate location for termination kit using the
guidelines provided in section “Vent Termination: General” in this
instruction.
1. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size
being used.
2. Loosely install elbow in bracket and place assembly on
combustion--air pipe.
Roof terminations--Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so bracket
will mount as shown in Fig. 43.
For applications using combustion--air pipe option, indicated by dashed lines in Fig. 43, install 90_ street elbow into
90_ elbow, making a U--fitting. A 180_ U--fitting may be
used.
Sidewall terminations--Install bracket as shown in Fig. 43.
For applications using vent pipe option indicated by dashed
lines in Fig. 43, rotate vent elbow 90_ from position shown
in Fig. 43.
3. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
4. Check required dimensions as shown in Fig. 43.
Multiventing and Vent Terminations
When 2 or more 355AAV Furnaces are vented near each other,
each furnace must be individually vented. NEVER common vent
or breach vent 355AAV furnaces.
(Direct Vent/2--Pipe System ONLY)--When 2 or more 355AAV
furnaces are vented near each other, 2 vent terminations may be
installed as shown in Fig. 43, but next vent termination must be at
least 36 in. (914 mm) away from first 2 terminations. It is
important that vent terminations be made as shown in Fig. 43 to
avoid recirculation of flue gases.
Step 11 — Condensate Drain
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. (13 mm) CPVC, 1/2--in. PVC (13 mm), or
5/8--in. (16 mm) ID tube connection.
Drain pipe and fittings must conform to ANSI standards and
ASTM D1785, D2466, or D2846. CPVC or PVC cement must
conform to ASTM D2564 or F493. Primer must conform to
ASTM F656. 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.
41
Roof Te rmination (Preferred)
At least 36 in.
(914mm)
Concentric Vent and Combustion Air
Roof Termination (preferred)
A
Vertical separation
between combustion
air and vent
8 3/4 in. (222mm)for 3 in. (76mm)kit
6 3/4 in. (172mm)for 2 in. (51mm) ki t 18 in. maximum (457mm)
A
At least
36 in.
(914mm)
Maintain 12 in. (305mm)min
.
clearance above
highest anticipated
snow level
Maximum of 24 in.(614mm)
above roof
Maintain 12 in. (305mm)
min. clearance above
highest anticipated
snow level, maximum of
24 in. above roof
1 in. (25mm) maximum (typ) from wall to inlet
Abandoned masonry
used as raceway
(per code)
12 in. (305mm) minimum from
overhang or roof
Note: "A" denotes 0 to < 2 in. (51mm)
Between the first 2 vents
Third vent must be > 36 in. away
(914mm)
At
le
36 ast
in
.
12 in. min from
overhang or roof
(typ)
A
Maintain 12 in. (305mm)
min. clearance above
highest anticipated
snow level or grade
whichever is greater
355A
Concentric Vent
and Combustion - Air
Side Te rmination
A
At least 36 in.
(914mm)
12 in. (305mm)
separation between
bottom ofcombustion air and
bottom of vent (typ)
90°
A
Side wall termination
of less than 12 in. (305mm) above highest snow level
Maintain 12 in. (305mm)
min. clearance above
highest anticipated
snow level or grade
whichever is greater (typ)
6 in.
ast 3
At le mm)
(914
A05090
Fig. 43 -- Combustion Air and Vent Pipe Termination for Direct Vent (2-pipe) System
Roof Termination (Preferred)
Vent
Maintain 12 in (305mm)
.
minimum clearance
above highest anticipated
snow level maximum of
24 in. (610mm) above. roof
Abandoned masonry
used as raceway
(per code)
12 in. min. (305 mm)from
overhang or roof
6 in. (152mm) minimum clearance
between wall and end of vent pipe.
10 in. (254mm) maximum pipe length
Maintain 12 in. (305mm)
minimum clearance
above highest anticipated
snow level or grade
whichever is greater
12 in. (305 mm) min. from
overhang or roof
Sidewall Termination
with Straight Pipe (preferred)
90°
Maintain 12 in. (305mm)
minimum clearance
above highest anticipated
snow level or grade
whichever is greater.
Side wall termination
with 2 elbows (preferred)
A05091
Fig. 44 -- Vent Pipe Termination for Ventilated Combustion Air System
42
Table 12 – Vent Termination Kit for Direct Vent / 2--Pipe System
TERMINATION SYSTEM
2--- in. (51 mm) Concentric Vent Kit
Single Penetration of Wall or Roof
3--- in. (76 mm) Concentric Vent Kit
2--- in. (51 mm)Termination Bracket Kit
3--- in. (76 mm) Termination Bracket Kit
Single Penetration of Wall or Roof
2Pipe Termination System
2Pipe Termination System
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.
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. 45 for example of possible field drain attachment using
1/2--in. (13 mm) 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.
!
DIAMETER OF COMBUSTION AIR AND
VENT PIPES --- IN. (MM)
1, 1--- 1/2, 2, or 2--- 1/2
(25, 38, 51, or 64)
2--- 1/2, 3 or 4 (64, 76, or 102)
1, 1--- 1/2 or 2 (25, 38, or 51)
2--- 1/2, 3 or 4 (64, 76, or 102)
NOTE: Proper polarity must be maintained for 115--v wiring. If
polarity is incorrect, control status indicator light flashes rapidly
and furnace does not operate.
2. Thermostat wire connections at terminals R, W/W1, G, and
Y/Y2 must be made at 24--v terminal block on furnace
control.
3. Natural gas service pressure must not exceed 0.5 psig
(14--in. wc), but must be no less than 0.16 psig (4.5--in. wc).
4. Blower access panel must be in place to complete 115--v
electrical circuit to furnace.
WARNING
OPEN STAND
PIPE FOR
A/C OR
HUMIDIFIER
DRAIN
PERSONAL INJURY HAZARD
Failure to follow this warning could result in property damage
and personal injury or death.
TEE
Caution should be taken to prevent draining causing slippery
conditions . Excessive condensate draining may cause
saturated soil conditions which may result in damage to plants.
TO OPEN
DRAIN
CONDENSATE DRAIN PROTECTION
Freezing condensate left in condensate trap and drain line may
cause cracks, and possible water damage may occur. If freeze
protection is required, use condensate freeze protection accessory
or equivalent 3 to 6 watt per ft. at 120v and 40_F (4_C)
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. 46.)
3. Use wire ties to secure heat tape in place. Wire ties can be
positioned in notches of condensate trap sides. (See Fig.
46.)
4. Wrap field drain pipe with remaining heat tape,
approximately 1 wrap per ft.
5. When using field--supplied heat tape, follow heat tape
manufacturer’s instructions for all other installation
guidelines.
START--UP, ADJUSTMENTS AND SAFETY
CHECK
Step 1 — General
A94054
Fig. 45 -- Example of Field Drain Attachment
CONDENSATE TRAP
WIRE TIE(S)
HEAT TAPE
(3 WRAPS MINIMUM)
1. Furnace must have a 115--v power supply properly
connected and grounded.
A93036
Fig. 46 -- Condensate Trap Heat Tape
43
355A
DIRECT VENT (2 PIPE) TERMINATION KIT
AIR CONDITIONING
TONS (12,000 BTU/HR)
1--- 1/2
2
2--- 1/2
3
3--- 1/2
4
5
6
040,060 & 080---14
MODEL
X
X
X
X
X
AIRFLOW* (CFM)
525 (600)
700 (800)
875 (1000)
1050 (1200)
1225 (1400)
1400 (1600)
1750 (2000)
2100 (2100)
080---20 & 100 MODEL
120 MODEL
X
X
X
X
X
X
X
X
X
X
X
X
X
X Indicates an allowable selection.
* Airflow shown in parentheses is airflow unit that the unit will deliver when setup switch SW1 ---5 is ON (selects 400 CFM/ton)
AIR CONDITIONING (A/C) OR CONTINUOUS-FAN (CF)
AIRFLOW SELECTION CHART
355A
BASED ON 350 CFM/TON (SETUP SWITCH SW1-5 OFF)
SETUP SWITCH SW2 & SW3 POSITIONS
MODEL
SIZE
040, 060, 3.5T080
DEF.
525 2
700
875
1050 1
1225
1225
1225
5T080, 100
DEF.
700 2
875
1050
1225
1400
1750 1
1750
120
DEF.
700
875 2
1050
1225
1400
1750 1
2100
BASED ON 400 CFM/TON (SETUP SWITCH SW1-5 ON)
SETUP SWITCH SW2 & SW3 POSITIONS
MODEL
SIZE
A07907
Fig. 48 -- Example of Setup Switch in Off Position
040, 060, 3.5T080
DEF.
600 2
800
1000
1200 1
1400
1400
1400
5T080, 100
DEF.
800 2
1000
1200
1400
1600
2000 1
2000
120
DEF.
800
1000 2
1200
1400
1600
2000 1
2100
1. DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION
2. DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION
3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM
A07899
Fig. 47 -- A/C or CF Airflow Selection Chart Based on 350
and 400 CFM/Ton
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
These furnaces are equipped with a manual reset limit switch
in burner box. This switch opens and shuts off power to the
gas valve if an overheat condition (flame rollout) occurs in
burner enclosure. Correct inadequate combustion--air supply
or improper venting condition before resetting switch. DO
NOT jumper this switch.
Before operating furnace, check flame rollout manual reset switch
for continuity. If necessary, press button to reset switch.
2. Locate A/C setup switches on furnace control. (See Fig. 37.)
3. Determine air conditioning tonnage used.
4. Use Fig. 47 or wiring schematic to determine proper setup
position of A/C switches. (See Fig. 36 and 48.)
NOTE: Excessive airflow caused by improper A/C switch setup
may cause condensate blowoff in cooling mode.
5. Replace main furnace door and blower access panel.
NOTE: EAC--1 terminal is energized whenever blower operates.
HUM terminal is only energized when blower is energized in
heating.
CONTINUOUS FAN (CF) SETUP SWITCHES
The CF setup switches are used to select desired airflow when
thermostat is in continuous fan mode or to select low--cooling
airflow for two--speed cooling units. This setup feature allows
continuous fan airflow or low--cooling airflow to be adjusted. To
set desired continuous fan airflow or low--cooling airflow:
1. Remove main furnace door and blower access panel.
2. Locate CF setup switches on furnace control. (See Fig. 37.)
3. Determine desired continuous fan airflow or low--cooling
airflow.
4. Use Fig. 47 or wiring schematic to determine proper setup
position of CF switches. (See Fig. 36 and 48.)
5. Replace main furnace door and blower access panel.
Step 2 — Select Setup Switch Positions
AIR CONDITIONING (A/C) SETUP SWITCHES
The air conditioning setup switches are used to match furnace
airflow to cooling unit used.
To set the desired cooling airflow:
1. Remove main furnace door and blower access panel.
44
Table 13 – Furnace Setup Switch Description
SWITCH NAME
NORMAL
POSITION
SW1--- 1
Status Code Recovery
OFF
SW1--- 2
Adaptive Heat Mode
OFF
SW1--- 3
Low Heat Rise Adjust
OFF
SW1--- 4
Comfort/Efficiency Adjustment
ON
SW1--- 5
CFM per ton adjust
OFF
SW1--- 6
Component Self--- Test
OFF
SW1--- 7
Blower OFF delay
ON or OFF
SW1--- 8
Blower OFF delay
ON or OFF
DESCRIPTION OF USE
Turn ON to retrieve up to 7 stored status codes for troubleshooting
assistance when R thermostat lead is disconnected.
Allows 2--- stage operation with a single stage thermostat. Turn ON
when using 2 stage thermostat to allow Low Heat operation when
R to W/W1 closes and High Heat operation when R to W/W1 and
W2 close.
Turn ON to increase Low Heat airflow by 18 percent. This compensates for increased return air temperature caused with bypass
humidifier.
Turn ON to decrease Low Heat airflow by 7 percent and High Heat
airflow 8 percent for maximum comfort. On 040 unit will decrease
Low--- Heat Airflow 11 percent and High--- Heat Airflow 10 percent.
Turn ON for 400 CFM per ton. Turn OFF for 350 CFM per ton.
Turn ON to initiate Component Self--- Test for troubleshooting assistance when R thermostat lead is disconnected. Turn OFF when
Self--- Test is completed.
Control blower Off Delay time. Used in conjunction with SW1--- 8.
See Table 14.
Control blower Off Delay time. Used in conjunction with SW1--- 7.
See Table 14.
SETUP SWITCHES (SW1)
The furnace control has 8 setup switches that may be set to meet
the application requirements. Position these setup switches for the
appropriate requirement.
1. Remove main furnace door and blower access panel.
2. Locate setup switches on furnace control. (See Fig. 37.)
3. See Table 13 for setup switch description. (See Fig. 36 and
48.)
4. Replace main furnace door and blower access panel.
NOTE: If a bypass humidifier is used, setup switch SW1--3 (Low
HEAT Rise Adjust) should be in ON position. This compensates
for the increased temperature in return air resulting from bypass.
NOTE:
If modulating dampers are used, blower motor
automatically compensates for modulating dampers.
!
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
Never purge a gas line into a combustion chamber. Never test
for gas leaks with an open flame. Use a commercially available
soap solution made specifically for the detection of leaks to
check all connections.
Step 5 — Sequence of Operation
!
Step 3 — Prime Condensate Trap With Water
!
Failure to follow this caution may result in intermittent unit
operation.
Furnace control must be grounded for proper operation, or
control will lock out. Control is grounded through
green/yellow wire routed to gas valve and burner box screw.
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
1. Remove upper inducer housing drain connection cap. (See
Fig. 49.)
2. Connect field--supplied 1/2--in. (13 mm) 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. 50.)
5. Remove funnel and tube from inducer housing and replace
drain connection cap and clamp.
Step 4 — Purge Gas Lines
CAUTION
UNIT MAY NOT OPERATE
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.
WARNING
Using schematic diagram, follow sequence of operation through
different modes. (See Fig. 36.) Read and follow wiring diagram
carefully.
NOTE: If a power interruption occurs during a call for heat
(W/W1 or W/W1--and--W2), the control will start a 90--second
blower--only ON period two seconds after power is restored, if the
thermostat is still calling for gas heating. The amber LED light will
flash code 12 during the 90--second period, after which the LED
will be ON continuous, as long as no faults are detected. After the
90--second period, the furnace will respond to the thermostat
normally.
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hot--surface igniter HSI, and gas valve GV.
If not previously done, purge the lines after all connections have
been made and check for leaks.
45
355A
SETUP SWITCH
NO.
355A
A99118
A99119
Fig. 49 -- Inducer Housing Drain Tube
SINGLE--STAGE THERMOSTAT AND TWO-STAGE HEATING (ADAPTIVE MODE)
See Fig. 32 or 58 for thermostat connections
NOTE:
Low--heat--only switch, SW1--2, selects either the
low--heat-- only operation mode when ON, (see item 2. below) or
adaptive heating mode when OFF, in response to a call for heat.
(See Fig. 37.) When the W2 thermostat terminal is energized, it
will always cause high--heat operation when the R to W circuit is
closed, regardless of the setting of the low--heat only switch.
DESIRED
HEATING
MODE
BLOWER OFF
DELAY (SEC)
90
120
150
180
SETUP SWITCH (SW1---7 AND SW1---8)
POSITION
SW1--- 7
SW1--- 8
OFF
ON
OFF
ON
OFF
OFF
ON
ON
This furnace can operate as a two--stage furnace with a single--stage
thermostat because furnace control CPU includes a programmed
adaptive sequence of controlled operation, which selects low--heat
or high--heat operation. This selection is based upon the stored
history of the length of previous gas heating periods of the
single--stage thermostat.
The furnace will start up in either low-- or high--heat. If the furnace
starts up in low--heat, the furnace control CPU determines the
low--heat on time (from 0 to 16 minutes) which is permitted before
switching to high--heat.
Fig. 50 -- Filling Condensate Trap
If power is interrupted, the stored history is erased. When this
happens, the control CPU will initially select low--heat for up to 16
minutes and then switch to high--heat, as long as the thermostat
continues to call for heat. Subsequent selection is based on stored
history of thermostat cycle times.
The wall thermostat “calls for heat”, closing the R to W circuit. The
furnace control CPU performs a self--check, verifies the low--heat
and high--heat pressure switch contacts LPS and HPS are open.
1. Inducer Prepurge Period -- The furnace control CPU turns
on inducer motor IDM and slowly increases the inducer
motor speed. When the low--heat pressure switch LPS
closes, inducer motor RPM is noted by the furnace control
CPU, and a 25--sec. prepurge period begins. The RPM is
used to evaluate vent system resistance. This evaluation is
then used to determine the required RPM necessary to
operate the inducer motor during the low--heat prepurge
period and low--heat mode.
NOTE: The heat cycle can start in either high--or low--heat. If a
high--heat cycle is initiated, the furnace control CPU will
deenergize the high--heat pressure switch relay HPSR to close the
NC contact and continues to increase the inducer motor speed after
the low--heat pressure switch LPS closes. When the high--heat
pressure switch closes, inducer motor RPM is noted by the furnace
control CPU before the 25--sec prepurge period begins. The RPM
is used to evaluate vent system resistance. This evaluation is then
used to determine the required RPM necessary to operate the
inducer motor in high--heat mode.
2. Igniter Warm--Up -- At end of the prepurge period, the Hot
Surface Igniter HSI is energized for a 17--sec igniter
warm--up period.
3. Trial--For--Ignition Sequence -- When the igniter warm--up
period is completed, the main gas valve relay contacts GVR
close to energize the gas valve GV, the gas valve opens. The
gas valve GV permits gas flow to the burners where it is
46
5.
6.
7.
8.
9.
TWO--STAGE THERMOSTAT AND TWO-STAGE HEATING
See Fig. 57 for thermostat connections.
NOTE: In this mode, the low--heat only switch SW1--2 must be
ON to select the low--heat only operation mode in response to
closing the thermostat R--to--W1 circuit. Closing the thermostat
R--to--W1--and--W2 circuits always causes high--heat operation,
regardless of the setting of the low--heat--only switch.
The wall thermostat “calls for heat”, closing the R to W1 circuit for
low--heat or closing the R to W1--and--W2 circuits for high--heat.
The furnace control performs a self--check and verifies the
low--heat and high--heat pressure switch contacts LPS and HPS are
open.
The start--up and shutdown functions and delays described in Item
1. above apply to 2--stage heating mode as well, except for
switching from low-- to high--heat and vice versa.
1. Switching From Low-- To High-- Heat--If the thermostat R
to W1 circuit is closed and the R toW2 circuit closes, the
furnace control CPU will de--energize the high--heat
pressure switch relay HPSR to close the NC contact and
slowly increase the inducer motor speed until the high--heat
pressure switch HPS closes. When the high--heat pressure
switch closes, the highheat gas valve solenoid GV--HI is
energized and the inducer motor RPM is noted by the
furnace control CPU. The RPM is used to evaluate vent
system resistance. This evaluation is then used to determine
the required RPM necessary to operate the inducer motor in
high--heat mode. The blower motor BLWM will transition
to high--heat airflow five seconds after the R to W2 circuit
closes.
2. Switching From High-- To Low-- Heat-- If the thermostat
R to W2 circuit opens, and the R to W1 circuit remains
closed, the furnace control CPU will energize the high--heat
pressure switch relay HPSR to open the NC contact and
slowly decrease the inducer motor speed to the required
low--heat RPM. When the high--heat pressure switch HPS
opens, the high--heat gas valve solenoid GV--HI is
de--energized. When the inducer motor IDM reduces
pressure sufficiently, the high--heat pressure switch HPS
will open. The gas valve solenoid GV--M will remain
energized as long as the low--heat pressure switch LPS
remains closed. The blower motor BLWM will transition to
low--heat airflow five seconds after the R to W2 circuit
opens.
COOLING MODE
The thermostat “calls for cooling”.
1. Single--Speed Cooling (See Fig. 32 and Fig. 51 for
thermostat connections.)
The thermostat closes R--to--G--and--Y circuits. The R--to--Y
circuit starts the outdoor unit, and R--to--G--and--Y/Y2
circuits start the furnace blower motor BLWM on cooling
airflow. Cooling airflow is based on the A/C selection
shown in Fig. 47.
The electronic air cleaner terminal EAC--1 is energized with
115--v when blower motor BLWM is operating.
When the thermostat is satisfied, the R--to--G--and--Y
circuits are opened. The outdoor unit will stop, and furnace
blower motor BLWM will continue operating at cooling
airflow for an additional 90 sec. Jumper Y/Y2 to DHUM to
reduce the cooling off--delay to 5 seconds. (See Fig. 37.)
2. Single--Stage Thermostat and Two--Speed Cooling
(Adaptive Mode)
(See Fig. 58 for thermostat connections.)
This furnace can operate a two--speed cooling unit with a
single--stage thermostat because the furnace control CPU
includes a programmed adaptive sequence of controlled
47
355A
4.
ignited by the Hot Surface Igniter HSI. Five seconds after
the GVR closes, a 2--second flame period begins. The HSI
igniter will remain energized until the flame is sensed or
until the 2--second flame proving period begins.
If the furnace control CPU selects high--heat operation, the
high--heat gas valve solenoid GV--HI is also energized.
Flame--Proving -- When burner flame is proved at the
flameproving sensor electrode FSE, the furnace control
CPU begins the blower--ON delay period and continues to
hold the gas valve GV--M open. If the burner flame is not
proved within two seconds, the control CPU will close the
gas valve GV--M, and the furnace control CPU will repeat
the ignition sequence for up to three more Trials--For--Ignition before going to Ignition--Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting 115 vac power to the furnace, or by interrupting 24
vac power at SEC1 or SEC2 to the furnace control CPU
(not at W/W1, G, R, etc.). If flame is proved when flame
should not be present, the furnace control CPU will lock out
of Gas--Heating mode and operate the inducer motor IDM
on high speed until flame is no longer proved.
Inducer Speed Change -- If the cycle starts in low--heat,
the furnace control CPU reduces the inducer speed slightly
after flame sense. If cycle starts in high--heat, the furnace
control CPU increases the inducer speed 15 seconds after
flame sense. The reduction in speed in low--heat is to optimize combustion for maximum efficiency.
Blower--On delay -- If the burner flame is proven, the
blower--ON delay for low--heat and high--heat are as follows:
Low--heat--60 seconds after the gas valve GV--M is opened,
the BLWM is turned ON at low--heat airflow.
High--heat--35 seconds after gas valve GV--M is opened,
the BLWM is turned ON at high--heat airflow. Simultaneously, the humidifier terminal HUM and electronic air
cleaner terminal EAC--1 are energized and remain energized
throughout the heating cycle.
Switching From Low-- To High-- Heat -- If the furnace
control CPU switches from low--heat to high--heat, the furnace control CPU will de--energize the the high--heat pressure switch relay HPSR to close the NC contact and slowly
increase the inducer motor speed until the high--heat pressure switch HPS closes. When the high--heat pressure
switch HPS closes, the high--heat gas valve solenoid GV-HI is energized and the inducer motor RPM is noted by the
furnace control CPU. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine the
required RPM necessary to operate the inducer motor in
high--heat mode. The blower motor BLWM will transition
to high--heat airflow five seconds after the furnace control
CPU switches from low--heat to high--heat.
Switching From High-- To Low-- Heat -- The furnace control CPU will not switch from high--heat to low--heat while
the thermostat R--to--W circuit is closed when using a
single--stage thermostat.
Blower--Off delay -- When the thermostat is satisfied, the R
to W circuit is opened, de--energizing the gas valve GV--M,
stopping gas flow to the burners, and de--energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 15--second post--purge period. The
blower motor BLWM and air cleaner terminal EAC--1 will
remain energized at low--heat airflow or transition to low-heat airflow for 90, 120, 150, or 180 seconds (depending on
selection at blower--OFF delay switches). The furnace control CPU is factory--set for a 120--second blower--OFF
delay.
355A
operation, which selects low--cooling or high--cooling
operation. This selection is based upon the stored history of
the length of previous cooling period of the single--stage
thermostat.
NOTE: The air conditioning relay disable jumper ACRDJ must
be connected to enable the adaptive cooling mode in response to a
call for cooling. (See Fig. 37.) When in place the furnace control
CPU can turn on the air conditioning relay ACR to energize the
Y/Y2 terminal and switch the outdoor unit to high--cooling.
The furnace control CPU can start up the cooling unit in either
low-- or high--cooling. If starting up in low--cooling, the furnace
control CPU determines the low--cooling on--time (from 0 to 20
minutes) which is permitted before switching to high--cooling.
If the power is interrupted, the stored history is erased and the
furnace control CPU will select low--cooling for up to 20 minutes
and then energize the air conditioning relay ACR to energize the
Y/Y2 terminal and switch the outdoor unit to high--cooling, as
long as the thermostat continues to call for cooling. Subsequent
selection is based on stored history of the thermostat cycle times.
The wall thermostat “calls for cooling”, closing the R to G--and--Y
circuits. The R to Y1 circuit starts the outdoor unit on low--cooling
speed, and the R to G--and--Y1 circuits starts the furnace blower
motor BLWM at low--cooling airflow which is the true on--board
CF selection as shown in Fig. 47.
If the furnace control CPU switches from low--cooling to
high--cooling, the furnace control CPU will energize the air
conditioning relay ACR. When the air conditioning relay ACR is
energized the R to Y1--and--Y2 circuits switch the outdoor unit to
high--cooling speed, and the R to G--and--Y1--and--Y/Y2 circuits
transition the furnace blower motor BLWM to highcooling airflow.
High--cooling airflow is based on the A/C selection shown in Fig.
47.
NOTE: When transitioning from low--cooling to high--cooling the
outdoor unit compressor will shut down for 1 minute while the
furnace blower motor BLWM transitions to run at high--cooling
airflow.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R to G--and--Y circuit are
opened. The outdoor unit stops, and the furnace blower BLWM
and electronic air cleaner terminal EAC--1 will remain energized
for an additional 90 seconds. Jumper Y1 to DHUM to reduce the
cooling off--delay to 5 seconds. (See Fig. 37.)
3. Two--Stage Thermostat and Two--Speed Cooling
(See Fig. 57 for thermostat connections)
NOTE: The air conditioning relay disable jumper ACRDJ must
be disconnected to allow thermostat control of the outdoor unit
staging. (See Fig. 37.)
The thermostat closes the R to G and--Y1 circuits for low cooling
or closes the R to G and--Y1--and--Y2 circuits for high--cooling.
The R to Y1 circuit starts the outdoor unit on low--cooling speed,
and the R to G--and--Y1 circuit starts the furnace blower motor
BLWM on low--cooling airflow which is the true on--board CF
selection as shown in Fig. 47. The R to Y1--and--Y2 circuits start
the outdoor unit on high--cooling speed, and the R to G--and--Y/Y2
circuits start the furnace blower motor BLWM at high--cooling
airflow. High--cooling airflow is based on the A/C selection shown
in Fig. 47.
The electronic air cleaner terminal EAC--1 is energized with 115
vac whenever the blower motor BLWM is operating.
When the thermostat is satisfied, the R to G--and--Y1 or R to
G--and--Y1--and--Y2 circuits are opened. The outdoor unit stops,
and the furnace blower BLWM and electronic air cleaner terminal
EAC--1 will remain energized for an additional 90 seconds. Jumper
Y1 to DHUM to reduce the cooling off--delay to 5 seconds. (See
Fig. 37.)
THERMIDISTAT MODE
See Fig. 51--54 for Thermidistat connections.
The dehumidification output, DHUM on the Thermidistat should
be connected to the furnace control thermostat terminal DHUM.
When there is a dehumidify demand, the DHUM input is activated,
which means 24 vac signal is removed from the DHUM input
terminal. In other words, the DHUM input logic is reversed. The
DHUM input is turned ON when no dehumidify demand exists.
Once 24 vac is detected by the furnace control on the DHUM
input, the furnace control operates in Thermidistat mode. If the
DHUM input is low for more than 48 hours, the furnace control
reverts back to non--Thermidistat mode.
The cooling operation described in item 3. above applies to
operation with a Thermidistat. The exceptions are listed below:
a. Low cooling--When the R to G--and--Y1 circuit is closed
and there is a demand for dehumidification, the furnace
blower motor BLWM will drop the blower airflow to 86%
of low--cooling airflow which is the true on--board CF
selection as shown in Fig. 47.
b. High cooling--When the R to G--and Y/Y2 circuit is closed
and there is a demand for dehumidification, the furnace
blower motor BLWM will drop the blower airflow to 86%
of high--cooling airflow. High--cooling airflow is based on
the A/C selection shown in Fig. 47.
c. Cooling off--delay--When the “call for cooling” is satisfied
and there is a demand for dehumidification, the cooling
blower--off delay is decreased from 90 seconds to 5
seconds.
SUPER--DEHUMIDIFY MODE
Super--Dehumidify mode can only be entered if the furnace control
is in Thermidistat mode and there is a demand for
dehumidification. The cooling operation described in Item 3.
above also applies to operation with a Thermidistat. The exceptions
are listed below:
a. Low cooling--When the R to Y1 circuit is closed, R to
G circuit is open, and there is a demand for
dehumidification, the furnace blower motor BLWM will
drop the blower airflow to 65% of low--cooling airflow
for a maximum of 10 minutes each cooling cycle or
until the R to G circuit closes or the demand for
dehumidification is satisfied. Low--cooling airflow is the
true on--board CF selection as shown in Fig. 47.
b. High cooling--When the R to Y/Y2 cicuit is closed, R
to G circuit is open, and there is a demand for
dehumidifiation, the furnace blower motor BLWM will
drop the blower to 65% of high--cooling airflow for a
maximum of 10 minutes each cooling cycle or until the
R to G circuit closes or the demand for dehumidification
is satisfied. High--cooling airflow is based on the A/C
selection shown in Fig. 47.
c. Cooling off--delay--When the “call for cooling” is
satisfied and there is a demand for dehumidification, the
cooling blower--off delay is decreased from 90 seconds
to 5 seconds.
CONTINUOUS BLOWER MODE
When the R to G circuit is closed by the thermostat, the blower
motor BLWM will operate at continuous--blower airflow.
Continuous blower airflow selection is initially based on the CF
selection shown in Fig. 47. Factory default is shown in Fig. 47.
Terminal EAC--1 is energized as long as the blower motor BLWM
is energized.
During a call for heat, the blower BLWM will transition the blower
motor BLWM to continuous blower airflow, low--heat airflow, or
the mid--range airflow, whichever is lowest. The blower motor
OFF and remain OFF for the blower--ON delay (60 seconds in
low--heat and 35 seconds in high--heat) allowing the furnace heat
48
CONTINUOUS BLOWER SPEED SELECTION
FROM THERMOSTAT
To select different continuous--blower speeds from the room
thermostat, momentarily turn off the FAN switch or pushbutton on
the room thermostat for 1--3 seconds after the blower motor
BLWM is operating. The furnace control CPU will shift the
continuous--blower airflow from the factory setting to the next
highest CF selection airflow as shown in Fig. 47. Momentarily
turning off the FAN switch again at the thermostat will shift the
continuous--blower airflow up one more increment. If you repeat
this procedure enough, you will eventually shift the
continuous--blower airflow to the lowest CF selection as shown in
Fig. 47. The selection can be changed as many times as desired and
is stored in the memory to be automatically used following a power
interruption.
This feature is disabled when blower off delay is set for 180 sec.
HEAT PUMP
See Fig. 53--56 for thermostat connections.
When installed with a heat pump, the furnace control automatically
changes the timing sequence to avoid long blower off times during
demand defrost cycles. Whenever W/W1 is energized along with
Y1 or Y/Y2, the furnace control CPU will transition to or bring on
the blower motor BLWM at cooling airflow, low--heat airflow, or
the mid--range airflow, whichever is the lowest. The blower motor
BLWM will remain on until the main burners ignite, then shut OFF
and remain OFF for 25 seconds before coming back on at heating
airflow. When the W/W1 input signal disappears, the furnace
control begins a normal inducer post--purge period while changing
the blower airflow. If Y/Y2 input is still energized, the furnace
control CPU will transition the blower motor BLWM airflow to
cooling airflow. If Y/Y2 input signal disappears and the Y1 input is
still energized, the furnace control CPU will transition the blower
motor BLWM to low--cooling airflow. If both the Y1 and Y/Y2
signals disappear at the same time, the blower motor BLWM will
remain on at low--heat airflow for the selected blower--OFF delay
period. At the end of the blower--OFF delay, the blower motor
BLWM will shut OFF unless G is still energized, in which case the
blower motor BLWM will operate at continuous blower airflow.
b. After waiting 15 seconds, the furnace control CPU turns
the hot surface igniter ON for 15 seconds, then OFF.
c. The furnace control CPU then turns the blower motor
BLWM ON at mid--range airflow for 15 seconds, then
OFF.
d. After shutting the blower motor BLWM OFF, the
furnace control CPU shuts the inducer motor IDM OFF.
NOTE: The EAC terminals are energized when the blower is
operating.
After the component test is completed, 1 or more status codes (11,
25, 41, or 42) will flash. See Service Label on blower access panel
or Service/Status Code Instructions for explanation of status codes.
NOTE: To repeat component test, turn setup switch SW1--6 to
OFF and then back ON.
Step 6 — Adjustments
SET GAS INPUT RATE
Furnace gas input rate on rating plate is for installations at altitudes
up to 2000 ft. (610 M).
In the U.S.A., the input rating for altitudes above 2000 ft. (610 M)
must be reduced by 2 percent for each 1000 ft. (305 M) above sea
level.
In Canada, the input rating must be derated by 5 percent for
altitudes of 2000 ft. to 4500 ft. (610 to 1372 M) above sea level.
Adjust manifold pressure to obtain input rate.
Furnace input rate must be within +/--2 percent of input rate on
furnace rating plate.
1. Determine natural gas orifice size and manifold pressure for
correct input.
a. Obtain average heat value (at installed altitude) from
local gas supplier.
b. Obtain average specific gravity from local gas supplier.
c. Verify furnace model. Table 14 can only be used for
model 355AAV Furnaces.
d. Find installation altitude in Table 14.
NOTE: For Canadian altitudes of 2000 to 4500 ft. (610 to 1372
M), use U.S.A. altitudes of 2001 to 3000 ft. (610 to 914 M) in
Table 14.
e. Find closest natural gas heat value and specific gravity in
Table 14.
f. Follow heat value and specific gravity lines to point of
intersection to find orifice size and low-- and high--heat
manifold pressure settings for proper operation.
EXAMPLE: 0--2000 ft. altitude (0--610 M)
Heating value = 1050 Btu/cu ft.
Specific gravity = 0.62
Therefore: Orifice No. 45
Manifold pressure:
3.8--in. wc for high heat
1.6--in. wc for low heat
* 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 proper input rate.
COMPONENT TEST
The furnace features a component test system to help diagnose a
system problem in the case of a component failure. To initiate the
component test procedure, ensure that there are no thermostat
inputs to the control and all time delays have expired. Turn on
setup switch SW1--6 (See Fig. 37.)
NOTE: The component test feature will not operate if the control
is receiving any thermostat signals or until all time delays have
expired.
The component test sequence is as follows:
a. The furnace control CPU turns the inducer motor IDM
ON at medium speed and keeps it ON through step c.
g. Check and verify burner orifice size in furnace. NEVER
ASSUME ORIFICE SIZE; ALWAYS CHECK AND
VERIFY.
49
355A
exchangers to heat more quickly, then restarts at the end of the
blower--ON delay period at low--heat or high--heat airflow
respectively.
The blower motor BLWM will revert to continuous--blower
airflow after the heating cycle is completed. In high--heat, the
furnace control CPU will drop the blower motor BLWM to
low--heat airflow during the selected blower--OFF delay period
before transitioning to continuous--blower airflow.
When the thermostat “calls for high--cooling”, the blower motor
BLWM will operate at high--cooling airflow. When the thermostat
is satisfied, the blower motor BLWM will operate an additional 90
seconds at high--cooling airflow before transitioning back to
continuous--blower airflow.
When the R to G circuit is opened, the blower motor BLWM will
continue operating for an additional 5 seconds, if no other function
requires blower motor BLWM operation.
355A
A00275
A00277
Fig. 51 -- Two--Stage Furnace with Single--Speed
Air Conditioner
Fig. 53 -- Two--Stage Furnace with Single--Speed
Heat Pump (Dual Fuel)
A00276
A00278
Fig. 52 -- Two--Stage Furnace with Two--Speed
Air Conditioner
Fig. 54 -- Two--Stage Furnace with Two--Speed
Heat Pump (Dual Fuel)
50
355A
A00279
A00281
Fig. 55 -- Dual Fuel Thermostat with Two--Stage Furnace and
Single--Speed Heat Pump
Fig. 57 -- Two--Stage Thermostat with Two--Stage Furnace
and Two--Speed Air Conditioner
See note 2
A00280
Fig. 56 -- Dual Fuel Thermostat with Two--Stage Furnace and
Two--Speed Heat Pump
A02348
Fig. 58 -- Single--Stage Thermostat with Two--Stage Furnace
and Two--Speed Air Conditioner
51
Notes for Fig. 51--58:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
355A
12.
13.
14.
15.
16.
17.
Heat pump MUST have a high pressure switch for dual fuel applications.
Refer to outdoor equipment Installation Instructions for additional information and setup procedure.
Select the “ZONE” position on the two--speed heat pump control.
Outdoor Air Temperature Sensor must be attached in all dual fuel applications.
Dip switch No.1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.
Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.
Dip switch No. 2 on Thermidistat should be set in OFF position for single--speed compressor operation. This is factory default.
Dip switch No. 2 on Thermidistat should be set in ON position for two--speed compressor operation.
Configuration Option No. 10 “Dual Fuel Selection” must be turned ON in all dual fuel applications.
NO connection should be made to the furnace HUM terminal when using a Thermidistat.
Optional connection. If wire is connected, dip switch SW1--2 on furnace control should be set in ON position to allow
Thermidistat/Thermostat to control furnace staging.
Optional connection. If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to
control outdoor unit staging.
Furnace must control its own high--stage heating operation via furnace control algorithm. This is factory default.
The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.
DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two--speed heat pump control board. This
is controlled internally by the Thermidistat/Dual Fuel Thermostat.
Dip switch D on Dual Fuel Thermostat should be set in OFF position for single--speed compressor operation. This is factory default.
Dip switch D on Dual Fuel Thermostat should be set in ON position for two--speed compressor operation.
52
355A
Table 14 – Orifice Size* and Manifold Pressures for Gas Input Rate
(Tabulated Data Based on 20,000 Btuh High--Heat/13,000 Btuh Low--Heat Per Burner,
Derated 2%/1,000 Ft. (305 M) Above Sea Level)
A08376A
53
355A
Table 14 — Orifice Size* and Manifold Pressures for Gas Input Rate
(Tabulated Data Based on 20,000 Btuh High--Heat/13,000 Btuh Low--Heat Per Burner,
Derated 2%/1,000 Ft. (305 M) Above Sea Level) (Cont)
A08376B
54
!
REGULATOR COVER SCREW
PLASTIC ADJUST SCREW
ON/OFF SWITCH
REGULATOR SPRING
1/2˝ NPT INLET
HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT
LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT
INLET
PRESSURE TAP
MANIFOLD
PRESSURE TAP
1/2˝ NPT OUTLET
A04167
Fig. 59 -- Redundant Automatic Gas Valve
355A
2. Adjust manifold pressure to obtain input rate.
a. Remove burner enclosure front.
NOTE: Manifold pressure MUST always be measured with the
burner box cover REMOVED.
b. Remove regulator seal caps that conceal adjustment
screws for low-- and high--heat gas valve regulators.
(See Fig. 59.)
c. Move setup switch SW1--2 on control center to ON
position. (See Fig. 37.) This keeps furnace locked in
low--heat operation.
d. Jumper R and W/W1 thermostat connections on control
to start furnace.
e. Turn low--heat adjusting screw (3/32) hex Allen
wrench) counterclockwise (out) to decrease input rate or
clockwise (in) to increase input rate.
NOTE: DO NOT set low--heat manifold pressure less than 1.3--in.
wc or more than 1.7--in. wc for natural gas. If manifold pressure is
outside this range, change main burner orifices to obtain manifold
pressure in this range.
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace
life or property damage.
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.
BURNER
ORIFICE
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.
f. Move setup switch SW1--2 to OFF position after
completing low--heat adjustment.
g. Jumper R and W/W1 and W2 thermostat connections
on furnace control. (See Fig. 37) This keeps furnace
locked in high--heat operation.
h. Turn high--heat adjusting screw (3/32 hex Allen
wrench) counterclockwise (out) to decrease input rate or
clockwise (in) to increase rate.
NOTE: DO NOT set high--heat manifold pressure less than
3.2--in. wc or more than 3.8--in. wc for natural gas. If manifold
pressure is outside this range, change main burner orifices to obtain
manifold pressures in this range.
i. When correct input is obtained, replace caps that
conceal gas valve regulator adjustment screws. Main
burner flame should be clear blue, almost transparent.
(See Fig. 61.)
j. Remove jumpers R to W/W1 and R to W2.
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.
A93059
Fig. 60 -- Burner Orifice
a. Calculate high--altitude adjustment (if required).
UNITED STATES
At altitudes above 2000 ft. (610 M), this furnace has
been approved for a 2 percent derate for each 1000 ft.
(305 M) above sea level. See Table 15 for derate
multiplier factor and example.
55
;;;;
e. Check and verify orifice size in furnace. NEVER
ASSUME THE ORIFICE SIZE. ALWAYS CHECK
AND VERIFY.
f. Turn off all other gas appliances and pilots.
g. Move setup switch SW1--2 to ON position. (See Fig.
37.) This keeps furnace locked in low--heat operation.
h. Jumper R to W/W1.
i. Let furnace run for 3 minutes in low--heat operation.
j. Measure time (in sec) for gas meter to complete 1
revolution. Note reading.
k. Refer to Table 16 for cubicft. of gas per hr.
l. Multiply gas rate cu ft./hr by heating value (Btu/cu ft.).
m. Move setup switch SW1--2 to OFF position and jumper
R and W/W1 and W2 thermostat connections. (See Fig.
37.) This keeps furnace locked in high--heat operation.
Repeat items i through l for high--heat operation.
BURNER FLAME
BURNER
MANIFOLD
A89020
355A
Fig. 61 -- Burner Flame
EXAMPLE: (High--heat operation at 0--2000ft. (0--610 M)
altitude)
Furnace input from rating plate is 100,000 Btuh
Btu heating input = Btu/cuft. 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 16)
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.
Table 15 – Altitude Derate Multiplier for USA.
ALTITUDE
FT (M)
0–2000
(0---610)
2001–3000
(610---914)
3001–4000
(914---1219)
4001–5000
(1219---1524)
5001–6000
1524---1829)
6001–7000
(1829---2134)
7001–8000
(2134---2438)
8001–9000
(2438---2743)
9001–10,000
(2743---3048)
PERCENT OF
DERATE
DERATE MULTIPLIER
FACTOR*
0
1.00
4--- 6
0.95
6--- 8
0.93
8--- 10
0.91
10--- 12
0.89
12--- 14
0.87
14--- 16
0.85
16--- 18
0.83
18--- 20
0.81
NOTE: Measured gas inputs (high heat and low heat) must be
within +/--2 percent of that stated on furnace rating plate when
installed at sea level or derated per that stated above when installed
at higher altitudes.
n. Remove jumper across R, W/W1, and W2 thermostat
connections to terminate call for heat.
* Derate multiplier factors are based on midpoint altitude for altitude range.
EXAMPLE:
100,000 BTUH HIGH--HEAT INPUT
FURNACE INSTALLED AT 4,300 FT. (1311 M)
Furnace Input Rate at Sea Level X Derate Multiplier Factor
= Furnace Input Rate at Installation Altitude
100,000
X 0.91 = 91,000
CANADA
At installation altitudes from 2000 to 4500 ft, (610 to 1372 M) this
furnace must be derated 5 percent 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.
b. Reinstall burner box cover.
NOTE: Clocking gas input rate MUST always be performed with
the burner box cover INSTALLED.
c. Check that gas valve adjustment caps are in place for
proper input to be clocked.
d. Obtain average heat value (at altitude) from local gas
supplier.
NOTE: Be sure heating value of gas used for calculations is
correct for your altitude. Consult local gas utility for altitude
adjustment of gas heating value.
56
Table 16 – Gas Rate Cu Ft./Hr
SIZE OF TEST DIAL
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
1
cuft.
360
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
2
cuft.
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
267
257
248
240
232
225
218
212
206
200
195
189
185
180
176
172
167
164
160
157
153
150
5
cuft.
1800
1636
1500
1385
1286
1200
1125
1059
1000
947
900
857
818
783
750
720
692
667
643
621
600
581
563
545
529
514
500
486
474
462
450
439
429
419
409
400
391
383
375
49
73
147
367
SET TEMPERATURE RISE
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in overheating the
heat exchangers or condensing flue gases in heat exchanger
areas not designed for condensate.
Temperature rise must be within limits specified on unit rating
plate. Operation is within a few degrees of midpoint of rise
range when setup switch SW1--4 is OFF.
Furnace must operate within ranges of temperature rise specified
on the furnace rating plate. Determine air temperature rise as
follows:
1. Place thermometers in return and supply ducts as near
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.
SECONDS
FOR 1
REVOLUTION
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
116
120
SIZE OF TEST DIAL
1
cuft.
72
71
69
68
67
65
64
63
62
61
60
58
56
54
53
51
50
48
47
46
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
31
30
2
cuft.
144
141
138
136
133
131
129
126
124
122
120
116
112
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
74
72
71
69
68
67
65
64
62
60
5
cuft.
360
355
346
340
333
327
321
316
310
305
300
290
281
273
265
257
250
243
237
231
225
220
214
209
205
200
196
192
188
184
180
178
173
170
167
164
161
155
150
NOTE: Temperature rise can be determined for low--heat
operation by placing setup switch SW1--2 on furnace control in
ON position. For high--heat operation, place setup switch SW1--2
in OFF position and jumper R--W2 on furnace control. DO NOT
forget to return setup switch to OFF position and remove R--W2
jumper upon completion of testing. (See Fig. 37 for switch and
terminal location.)
3. This furnace is capable of automatically providing proper
airflow to maintain the temperature rise within the range
specified on furnace rating plate. If temperature rise is
outside this range, proceed as follows:
a. Check gas input for low-- and high--heat operation.
b. Check derate for altitude if applicable.
c. Check all return and supply ducts for excessive
restrictions causing static pressure greater than 0.5--in.
wc.
d. Ensure Low Heat Rise Adjust switch SW1--3 on furnace
control is in ON position when a bypass humidifier is
used. (See Fig. 37 for switch location.)
e. Check Troubleshooting Guide for Variable--Speed
2--Stage Electronic Condensing Furnaces Series 170 and
later.
57
355A
SECONDS
FOR 1
REVOLUTION
355A
SET THERMOSTAT HEAT ANTICIPATOR
CHECK PRIMARY LIMIT CONTROL
When using a non--electronic thermostat, the thermostat heat
anticipator must be set to match the amp draw of components in
the R--W/W1 circuit. Accurate amp draw measurements can be
obtained only at the thermostat subbase terminals R and W.
The thermostat and anticipator should NOT be in the circuit while
measuring current. If thermostat has no subbase, the thermostat
must be disconnected from R and W/W1 wires during current
measurement.
Fig. 62 illustrates an easy method of obtaining thermostat amp
draw measurements. The amp reading should be taken after blower
motor has started and furnace is operating in low--heat.
1. To operate furnace in low--heat, turn setup switch SW1--2 to
ON position (See Fig. 37) and connect ammeter leads across
thermostat subbase R--W.
2. See thermostat manufacturer’s instructions for adjusting the
heat anticipator and for varying heating cycle length.
NOTE: When using an electronic thermostat, set cycle rate for 3
cycles per hr.
This control shuts off the gas control system and energizes the
air--circulating blower motor if furnace overheats.
1. The 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.
2. As soon as limit control has shut off burners, a status code
33 will appear on furnace control.
3. The return--air opening should be unblocked to permit
normal air circulation.
By using this method to check the limit control, it can be
established that the limit is functioning properly and the furnace
will operate safely if there is a restricted return--air duct or motor
failure. If the limit control does not function during this test, the
cause must be determined and corrected.
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK-AROUND
AMMETER
R Y W G
10 TURNS
CHECK PRESSURE SWITCHES
This control proves operation of the draft inducer. Check switch
operation as follows:
1. Turn off 115--v power to furnace.
2. Remove control access door and disconnect inducer motor
12--pin wire harness at inducer motor.
3. Turn on 115--v power to furnace.
4. Set thermostat to “call for heat.” When pressure switches are
functioning properly, status code 42 will flash on furnace
control approximately 20 sec after thermostat switch is
closed. If either a status code 31 or 32 is flashed when
inducer motor is disconnected, the furnace will shut itself
down immediately. Determine the reason pressure switches
did not function properly and correct the condition.
5. Turn off 115--v power to furnace.
6. Reconnect inducer motor wire harness. Reinstall furnace
access door.
7. Turn on 115--v power to furnace.
8. Reset thermostat to desired temperature.
CHECKLIST
1. Put away tools and instruments. Clean up debris.
2. Verify flame rollout manual reset switch has continuity.
3. Verify that blower and main access doors are properly
installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s
instructions.
6. Review User’s Manual with owner.
7. Leave literature packet near furnace.
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
A96316
Fig. 62 -- Amp Draw with Ammeter
3. Return setup switch SW1--2 to OFF position and replace
thermostat on subbase.
Step 7 — Check Safety Controls
This section covers the safety controls that must be checked before
the installation is complete. The flame sensor, gas valve, and
pressure switches were all checked in the Start--up procedure
section as part of normal operation.
58
CHECKLIST — DIRECT VENT (2 ---PIPE) INSTALLATION
LOAD CALCULATION
Heating Load (Btuh)
Cooling Load (Btuh)
________________
Condensate Drain
Furnace Model Selection
COMBUSTION AND VENT PIPING
Termination Location
________________
Roof or Sidewall
________________
Termination Kit --- 2 Pipe or Concentric
________________
________________
Unit Level or Pitched Forward
________________
Internal Tubing Connections
Free of Kinks and Traps
________________
External Drain Connection Leak
Tight and Sloped
________________
Condensate Trap Primed before
Start--- Up
Heat Tape Installed if Required
CHECKLIST --- START ---UP
________________
Combustion--- Air Pipe Length
________________
Gas Input Rate (Set Within 2
percent of Rating Plate)
________________
Combustion--- Air Pipe Elbow
Quantity
________________
Vent Pipe Length
________________
Vent Pipe Elbow Quantity
________________
Anticipator Setting Adjusted or
________________
Pipe Diameter Determined from
Sizing Table
________________
Cycle Rate (3 Cycles per Hr)
Selected
________________
Thermostat Anticipator
Safety Controls Check Operation
Pipe Sloped To Furnace
Pipe Insulation
________________
________________
Temperature Rise Adjusted
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
59
________________
Primary Limit
________________
Pressure Switches
355A
________________
________________
CHECKLIST — DIRECT VENT (1 ---PIPE) INSTALLATION
LOAD CALCULATION
________________
Heating Load (Btuh)
________________
Cooling Load (Btuh)
________________
Condensate Drain
Furnace Model Selection
VENT PIPING
Termination Location
________________
Roof or Sidewall
________________
Vent Pipe Length
355A
________________
Pipe Diameter Determined from
Sizing Table
________________
Pipe Sloped to Furnace
Over Ceilings
________________
Low--- Ambient Exposed Pipes
E2008 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231
________________
Internal Tubing Connections
Free of Kinks and Traps
________________
External Drain Connection Leak
Tight and Sloped
________________
Condensate Trap Primed before
Start--- Up
CHECKLIST --- START ---UP
________________
________________
Gas Input Rate (Set Within 2
percent of Rating Plate)
Temperature Rise Adjusted
Thermostat Anticipator
Pipe Insulation
________________
Unit Level or Pitched Forward
Heat Tape Installed if Required
Vent Pipe Elbow Quantity
________________
________________
________________
Anticipator Setting Adjusted or
________________
Cycle Rate (3 Cycles per Hr)
Selected
Safety Controls Check Operation
Printed in U.S.A.
________________
Primary Limit
________________
Pressure Switches
Edition Date: 12/08
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
60
Catalog No. II355A ---40---4
Replaces: II355A--- 40--- 3