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Bryant 340MAV Furnace User Manual

1. DRAIN TUBE COUPLING v PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX EXTENSION TUBE INDUCER HOUSING DRAIN TUBE VIOLET CONDENSATE TRAP COLLECTOR BOX EXTENSION DRAIN TUBE 00296 Fig 9 Downflow Tube Configuration Right Hand Trap Installation 1 Collector Box Drain Tube a Remove factory installed plug from LOWER collector box drain tube blue and white striped label b Install removed clamp and plug into UPPER collector box drain tube blue label which was connected to condensate trap c Connect LOWER collector box drain connection to condensate trap 1 Condensate Trap Located on Left Side of Casing a Connect LOWER collector box drain tube blue and white striped label to condensate trap Tube does not need to be cut b Clamp tube to prevent any condensate leakage 2 Condensate Trap Located on Right Side of Casing a Install drain tube coupling factory supplied in loose parts bag into collector box drain tube blue and white striped label which was pre viously plugged b Connect larger diameter drain tube factory supplied in loose parts bag to drain tube coupling extending collector box drain tube for connection to condensate trap c Route extended collect
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3. Protection FURNACE LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on downstream side of furnace to avoid condensation in heat exchanger When installed parallel with a furnace dampers or other means used to control flow of air shall prevent chilled air from entering furnace If dampers are manually operated they must be equipped with a means to prevent operation of either unit unless damper is in full heat or full cool position Ill HAZARDOUS LOCATIONS 18 IN MINIMUM TO BURNERS A93044 Fig 16 Installation in a Garage WARNING When furnace is installed in a residential garage it must be installed so that burners and ignition sources are located a minimum of 18 in above floor The AN 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 accor dance with NFGC or NSCNGPIC See Fig 16 INSTALLATION l LEVELING LEGS IF DESIRED When furnace is used in upflow position with side inlet s leveling legs may be desired See Fig 17 Install field supplied corrosion resistant 5 16 in machine bolts and nuts 89014 Fig 17 Leveling Legs NOTE The maximum length of bolt should not exceed 1 1 2 in 1 Position furnace on its back Locate and drill a 5 16 in diameter hole
4. COMBUSTION COMBUSTION AIR 4 P AIR VENT 7 NI VENT 14 COMBUSTION 4 gt COMBUSTION NOTE Select 1 vent pipe connection and NOTE Select 1 vent pipe connection and 1 combustion air pipe connection 1 combustion air pipe connection elbows Therefore 2 1 2 in diameter pipe must be used for both vent and combustion air pipes since larger required VENT diameter must always be used for both pipes If same installation were in Albuquerque elevation 5250 ft above sea level installation would require 2 1 2 in vent pipe and combustion air pipe At 5001 to 6000 ft elevation 2 in pipe is only good for 17 ft with 5 elbows and 2 1 2 in pipe is good for 70 ft with 5 elbows AIR An AIR FLOW Combustion Air Vent Pipe Attachment UPFLOW DOWNFLOW a NOTE All pipe joints must be cemented except attachment of combustion air pipe to inlet housing connection since it may be COMBUSTION AIR necessary to remove pipe for servicing An VENT VENT 1 Attach combustion air pipe as follows AIR FLOW FLOW a 45 b c If required per Table 7 insert perforated disk assembly factory supplied in loose parts bag in intake housing where combustion air intake pipe will be connected If half disk set is required install with shoulder o
5. WIDE CASINGS ONLY INSTALL FIELD SUPPLIED FILTER FILLER STRIP UNDER FILTER WASHABLE FILTER y FILTER SUPPORT Fig 24 Bottom Filter Arrangement RETAINER 00290 VI BOTTOM CLOSURE PANEL These furnaces are shipped with bottom enclosure panel installed in bottom return air opening This panel MUST be in place when side return air is used To remove bottom closure panel perform following 1 Tilt or raise furnace and remove 2 screws holding front filler panel See Fig 25 2 Rotate front filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall front filler panel and screws Vil GAS PIPING Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the United States Canadian installations must be made in accordance with NSCNG PIC and all authorities having jurisdiction Gas supply line should be a separate line running directly from meter to furnace if possible Refer to Table 3 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to propane gas BOTTOM CLOSURE S PANEL FRONT FILLER PANEL 93
6. 1 1 2 50 45 44 2 70 70 70 024060 036060 048060 2 Pipe or 2 in Concentric 1 1 2 5 NA NA 2 58 53 52 036080 048080 060080 2 Pipe or 2 in Concentric 2 26 21 20 2 1 2 70 70 70 048100 060100 2 Pipe or 3 in Concentric 2 1 2 13 12 3 67 62 57 060120 2 Pipe or 3 in Concentric 3t no disk 40 33 26 4T no disk 70 70 70 060140 2 Pipe or 3 in Concentric 3T no disk 13 9 5 4T no disk 59 54 49 ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBO WS 3 4 5 5001 to 60004 024040 036040 2 Pipe or 2 in Concentric 1 1 2 47 42 40 2 70 70 70 024060 036060 048060 2 Pipe or 2 in Concentric 1 1 2 NA NA NA 54 49 48 036080 048080 060080 048100 060100 2 Pipe or 2 in Concentric 2 Pipe or 3 in Concentric 23 18 17 2 1 2 70 12 70 11 70 NA 3 62 57 52 060120 2 Pipe or 3 in Concentric 3t no disk 29 22 15 4T no disk 70 70 70 060140 2 Pipe or 3 in Concentric 3T no disk NA NA NA 4T no disk 32 27 22 ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBO WS 3 4 5 6001 to
7. DIRECT VENTING The 340MAV Furnaces require a dedicated one 340MAV furnace only direct vent system In a direct vent system all air for combustion is taken directly from outdoor atmosphere and all flue gases are discharged to outdoor atmosphere 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 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 2002 NFPA 54 2002 or the CSA B149 1 Natural Gas and Propane Installation Code and these instructions Determine that there is no blockage or restriction leakage corrosion and other def
8. N W Washington DC 20001 CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario MOW 1R3 Canada COMBUSTION AND VENTILATION AIR US Section 8 3 of the NFGC Air for Combustion and Ventilation CANADA Part 7 of the NSCNGPIC Venting Systems and Air Supply for Appliances IV DUCT SYSTEMS US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Con Inducer housing drain tube 1 2 in CPVC street elbow Drain tube coupling Drain tube coupling grommet Vent and combustion air pipe support Condensate trap hole filler plug Vent and combustion air intake hole filler plug Combustion air pipe perforated disk assembly Vent Pipe Extension ONLY supplied with some furnaces For accessory installation details refer to accessory installation p a HISHUCUODS tractors National Association SMACNA or American Soci ety of Heating Refrigeration and Air Conditioning Engineers CODES AND STANDARDS uz ASHRAE 2001 Fundamentals Handbook Chapter 34 Follow all national and local codes and standards in addition to V ACOUSTICAL LINING AND FIBROUS GLASS DUCT these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and US and CANADA current edition of SMACNA NFPA 90B as other codes In absence of loc
9. obtained at thermostat subbase terminals R and W Fig 53 illustrates an easy method of obtaining actual amp draw The amp reading should be taken after blower motor has started and furnace is heating Connect ammeter wires as shown in Fig 53 The thermostat anticipator ahould NOT be in the circuit while measuring current If thermostat has no subbase the thermostat must be disconnected from R and W wires during current measurement See thermostat manufacturer s instructions for ad justing heat anticipator and for varying heating cycle length For an electronic thermostat set cycle rate for 3 cycles per hour CHECK SAFETY CONTROLS This section covers the safety controls that must be checked before the installation is complete The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED HOOK AROUND VOLT AMMETER im FROM UNIT 24 VOLT TERMINAL BLOCK EXAMPLE 5 0 AMPS ON AMMETER 0 5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS A80201 Fig 53 Amp Draw Check with Ammeter CHECK PRIMARY LIMIT CONTROL This control shuts off gas control system and energizes circulating blower motor if furnace overheats Recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes As soon as limit control
10. 42 3 7 42 3 8 41 3 6 42 3 3 42 3 4 42 3 5 42 3 6 42 3 7 43 3 7 42 3 2 42 3 3 42 3 4 42 3 5 43 3 5 43 3 6 43 3 8 42 3 2 42 3 3 43 3 3 43 3 4 43 3 6 43 3 7 43 3 8 43 3 1 43 3 3 43 3 4 43 3 5 43 3 6 43 3 0 43 3 1 43 3 2 43 3 3 43 3 4 43 2 8 43 2 9 43 3 0 43 3 1 43 3 2 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE eat vaLUE oss 060 gt oam RANGE FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure Pressure No Pressure No Pressure Pressure 11 derate SPECIFIC GRAVITY OF NATURAL GAS ALUDE o o5 J 98 RANGE FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure Pressure No Pressure No Pressure Pressure to 7000 13 derate Orifice numbers shown in BOLD are factory installed Percents of derate are based on midpoints of U S altitude ranges 9 EXAMPLE 0 2000 ft altitude using Table 9 Heating value 1050 Btu cu ft Specific gravity 0 62 Therefore Orifice No 45 Manifold pressure 3 6 in wc Furnace is shipped with No 45 orifices In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate Check and ver
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12. 7 or tube routing label on main furnace door to check for proper connections G Upper Collector Box and Inducer Housing Unused Drain Connections UPPER COLLECTOR BOX DRAIN CONNECTION Attached to the UPPER collector box drain connection is a factory installed corrugated plugged tube blue and white striped label This tube is plugged to prevent condensate leakage in this application Ensure this tube is plugged NOTE See Fig 6 or 7 or tube routing label on main furnace door to check for proper connections UPPER INDUCER HOUSING DRAIN CONNECTION Attached to the UPPER unused inducer housing drain connection is acap and clamp This cap is used to prevent condensate leakage in this application Ensure this connection is capped NOTE See Fig 6 or 7 or tube routing label on main furnace door to check for proper connections COLLECTOR BOX DRAIN TUBE BLUE CAP PLUG COLLECTOR BOX TUBE GREEN COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE PINK COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX EXTENSION TUBE E 5 CONDENSATE Md INDUCER HOUSING DRAIN TUBE VIOLET 00262 Fig 8 Downflow Tube Configuration Left Hand Trap Installation H Condensate Trap Freeze Protection Refer to Condensate Drain Protectio
13. Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed WARNING Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated Failure to follow this warning could result in electrical shock fire personal injury or death 4 Install condensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 5 Fill unused condensate trap casing holes with plastic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 10 or tube routing label on main furnace door to check for proper connections 1 Collector Box Drain Tube a Install drain tube coupling factory supplied in loose parts bag into collector box drain tube blue label which was previously connected to condensate trap b Connect large diameter drain tube and clamp factory supplied in loose parts bag to drain tube coupling extending collector box drain tube c Route extended tube blue label to condensate trap and cut to appropriate length d Clamp tube to prevent any condensate leakage 2 Inducer Housing Drain Tube a Remove and discard LOWER molded inducer housing drain tube which was previously connected t
14. The minimum combustion air and vent pipe length each for these furnaces is 5 ft Short pipe lengths 5 8 ft may discharge water droplets These droplets may be undesirable and a 12 in minimum offset pipe section is recommended as shown in Fig 34 to reduce excessive droplets from exiting vent pipe outlet B Combustion Air and Vent Pipe Diameter Determine combustion air and vent pipe diameter 1 Using Table 7 individually determine the smallest combustion air and vent pipe diameters permitted for each pipe Pick the larger of these 2 pipe diameters and use this diameter for both combustion air and vent pipes Primer For PVC Cellular Core Schedule 40 amp DWV 2 When installing vent systems of short pipe length use the smallest allowable pipe diameter Do not use pipe size greater than required or incomplete combustion flame disturbance or flame sense lockout may occur NOTE Do not count elbows or pipe sections in terminations or within furnace See shaded areas in Fig 36 37 38 39 and 40 EXAMPLE An 036080 size furnace located in Indianapolis elevation 650 ft above sea level could be installed in an application requiring 3 elbows and 32 ft of vent pipe along with 5 elbows and 34 ft of combustion air pipe Table 7 indicates this application would allow a 2 in diameter vent pipe but require a 2 1 2 in diameter combustion air pipe 2 in pipe FLOW is good for 35 ft with 3 elbows but only 30 ft with 5
15. 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 conden sate 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 conden sate 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 Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures D Pressure Switch Tubing One collector box pressure tube pink label is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications This tube MUST be disconnected and used for the condensate trap relief port tube The other collector box pressure tube green label which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications NOTE See Fig 12 or tube routing label on main furnace door to check
16. air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing as shown in Fig 2 Bypass humidifier may be attached into unused side return air portion of the furnace casing DO NOT V FILTER ARRANGEMENT CAUTION Never operate a unit without a filter or with A filter access door removed Failure to follow this caution will result in minor unit operation or performance satis faction Factory supplied washable framed filters are shipped in blower compartment Determine location for filter and relocate filter retaining wire if necessary See Table 2 to determine correct filter size for desired filter location Table 2 indicates filter size location and quantity shipped with this furnace See Fig 2 for location and size of bottom and side return air openings CAUTION Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends Wear safety glasses gloves and appropriate protective cloth ing Failure to follow this caution could result in minor personal injury CAUTION 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 A 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 Failure to follow this caution will result in minor unit ope
17. desired length Use 1 X 3 8 in flat washers 3 8 in lockwashers and 3 8 in nuts on hanger rods as shown in Fig 22 Dimples are provided for hole locations See Fig 2 AIR DUCTS 1 GENERAL REQUIREMENTS The duct system should be designed and sized according to accepted national standards such as those published by Air Conditioning Contractors Association Sheet Metal and PLENUM OPENING D FLOOR OPENING 96283 Fig 18 Floor and Plenum Opening Dimensions FURNACE FURNACE OWEN USED CD5 OR CK 5 5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING 7 NO DOWNFLOW A A SHEET METAL BBASE um A A fin 7 PLENUM NG FLOOR kN ____ FLOOR _____ OPENING A96284 POSER Fig 20 Furnace Plenum and Coil Fig 19 Furnace Plenum and Subbase Assembly or Coil Box Installed Installed on a Combustible Floor on a Combustible Floor TABLE 1 0OPENING DIMENSIONS IN FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications Downflow Applications on Non Combustible Flooring Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace
18. exchang ers causing failures See Fig 51 a Obtain average gas heat value at installed altitude from local gas supplier b Obtain average gas specific gravity from local gas supplier cT TABLE 9 MODEL 340 ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY TABULATED DATA BASED ON 20 000 BTUH PER BURNER DERATED 2 FOR EACH 1000 FT ABOVE SEA LEVEL ALTITUDE HEATNALUE oss 060 gt p RANGE FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure No Pressure 43 3 7 43 3 8 42 3 2 42 3 3 42 3 4 43 3 5 43 3 6 43 3 7 43 3 8 42 3 2 44 3 7 43 3 4 43 3 5 43 3 6 43 3 7 44 3 5 44 3 7 44 3 8 43 3 4 43 3 5 44 3 4 44 3 5 44 3 6 44 3 7 44 3 8 to 44 3 2 44 3 3 44 3 4 44 3 5 44 3 6 45 3 7 45 3 8 44 3 2 44 3 4 44 3 5 2000 45 3 5 45 3 6 45 3 7 44 3 2 44 3 3 45 3 3 45 3 4 45 3 6 45 3 7 45 3 8 0 45 3 2 45 3 3 45 3 4 45 3 5 45 3 6 derate 47 3 6 47 3 7 45 3 2 45 3 4 45 3 5 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 058 500 02 904 066 Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure No Pressure U S A Altitudes 2001 to 3000 or Canada Altitudes 2001 to 4500 5 derate U S A and C
19. has shut off burners return air opening should be unblocked to permit normal air circulation By using this method to check limit control it can be established that limit is functioning properly and operates if there is a restricted return air duct or motor failure If limit control does not function during this test cause must be determined and corrected CHECK PRESSURE SWITCH This control proves operation of draft inducer Check switch operation as follows 1 Turn off 115 v power to furnace 2 Remove main furnace door and disconnect inducer motor lead wires from wire harness 3 Turn on 115 v power to furnace 4 Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface igniter should NOT glow and control status code LED flashes a Status Code 31 If hot surface igniter glows when inducer motor is disconnected shut furnace down immediately Determine reason pressure switch did not function properly and correct condition 5 Turn off 115 v power to furnace 6 Reconnect inducer motor leads reinstall main furnace door and turn on 115 v power supply CHECKLIST Put away tools and instruments Clean up debris Verify flame rollout manual reset switch has continuity Verify that blower and main access doors are properly installed Cycle test furnace with room thermostat Check operation of accessories per manufacturer s instru
20. may be necessary to remove pipe for service of ignitor or flame sensor See Fig 35 2 Attach vent pipe as follows 3 8 in tube This tube should be routed to open condensate drain for furnace and A C if used and should be trapped COMBUSTION AIR INTAKE HOUSING PLUG a Determine location of vent pipe connection to inducer FITTING housing as shown in Fig 33 for application 26 ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN TABLE 7 MAXIMUM ALLOWABLE PIPE LENGTH FT NUMBER OF 90 ELBOWS 0 to 2000 024040 036040 2 Pipe or 2 in Concentric 1 1 1 2 2 70 70 70 024060 036060 048060 2 2 1 1 2 10 5 2 70 70 70 036080 048080 060080 2 2 1 1 2 2 35 30 30 2 1 2 70 70 70 048100 060100 2 3 2 2 1 2 20 20 10 3 70 70 70 060120 2 Pipe or 3 in Concentric 2 1 2 one disk NA NA NA 3t 35 30 25 3t no disk 70 70 70 060140 2 Pipe or 3 in Concentric 2 1 2 one disk NA NA NA 3T one disk 30 25 20 3t no disk 52 48 44 4T no disk 70 70 70 ALTITUDE FT 2001 to 3000 UNIT SIZE 024040 036040 024060 036060 048060 TERMINATIO
21. s 4 Deburr inside and outside of pipe 5 Chamfer outside edge of pipe for better distribution of primer and cement 6 Clean and dry all surfaces to be joined 7 Check dry fit of pipe and mark insertion depth on pipe NOTE It is recommended that all pipes be cut prepared and preassembled before permanently cementing any joint 8 After pipes have been cut and preassembled apply gener ous 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 9 While cement is still wet twist pipe into socket with 1 4 turn Be sure pipe is fully inserted into fitting socket 10 Wipe excess cement from joint A continuous bead of cement will be visible around perimeter of a properly made joint 11 Handle pipe joints carefully until cement sets 12 Support combustion air and vent piping a minimum of every 5 ft 3 ft for SDR 21 or 26 PVC using perforated metal hanging strap 13 Slope combustion air and vent pipes downward toward furnace a minimum of 1 4 in per linear ft with no sags between hangers 14 Use appropriate methods to seal openings where vent and combustion air pipes pass through roof or side wall Ill CONCENTRIC VENT AND COMBUSTION AIR TERMINATION KIT INSTALLATION NOTE If these instructions
22. temperature of the return air to the furnace is no less than 55 F with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the firing rate has been set to the nameplate value The filters used to clean the circulating air during the construction process must be either changed ot thoroughly cleaned prior to occupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed d M N 4 FRONT Fig 14 Prohibit Installation on Back A93043 WARNING Do not install furnace on its back Safety control operation will be adversely affected Never con AN nect return air ducts to back of furnace Failure to follow this warning could result in fire personal injury or death See Fig 14 CAUTION If these furnaces are installed in an uncon ditioned space where the ambient temperatures may be A 32 F or lower freeze protection measures must be taken Failure to follow this caution will result in minor property or unit damage See Fig 15 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED oF 93058 Fig 15
23. the detection of leaks to check all connections A fire or explosion may result causing property damege per sonal injury or loss of life An accessible manual shutoff valve MUST be installed external to furnace casing and within 6 ft of furnace A 1 8 in NPT plugged tapping accessible for test gage connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve NOTE The gas valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas valve See Fig 50 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 After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be disconnected from furnace and capped before pressure test If test pressure is equal to or less than 0 5 psig 14 in wc turn off electric shutoff switch located on furnace gas control valve and accessible manual shutoff valve before test The gas supply pressure shall be within the maximum and minimum inlet supply pressure marked on the rating plate with the furnace burners ON and OFF ELECTRICAL CONNECTIONS See Fig 27 for field wiring diagram showing t
24. 047 Fig 25 Removing Bottom Closure Panel CAUTION Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls Failure to follow this caution will result in intermittent unit operation or performance satisfaction WARNING Gas valve shutoff switch MUST be facing A forward or tilted upward Failure to follow this warning could result in property damage or death WARNING Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A failure to follow this warning could result in fire explo sion personal injury or death WARNING Use proper length of pipe to avoid stress on gas control manifold Failure to follow this warning could result in a gas leak resulting in fire explosion personal injury or death TABLE 3 MAXIMUM CAPACITY OF PIPE NOMINAL IRON PIPE SIZE IN INTERNAL LENGTH OF PIPE FT DIAMETER IN 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 12 2 NFPA 54 2002 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 C
25. 3 SPEED SELECTOR FACTORY SHIPPED CONNECTION Black Yellow When Present Blue Red White High Medium High Medium Low Low Common TABLE 14 BLOWER OFF DELAY SETUP POSITION PINS ____ 2 2AND3 3 AND4 4 ANDS 90 19 150 180 WARNING Disconnect 115 v electrical power before changing speed tap Failure to follow this warning could result in personal injury 4 To change blower motor speed selections for heating mode remove blower motor lead from control center HEAT terminal See Fig 31 Select desired blower motor speed lead from 1 of the other motor leads and relocate it to HEAT terminal See Table 13 for lead color identification Recon nect original lead on SPARE terminal Follow this same procedure for proper selection of COOL speed selection C Blower Off Delay Heat Mode The blower off delay has 4 adjustable settings from 90 sec to 180 sec See Table 14 The blower off delay jumpers are located on the furnace control board See Fig 31 To change the blower off delay setting move the jumper from one set of pins on the control board to the pins used for the desired blower off delay Factory blower off delay setting is 120 sec D Set Thermostat Heat Anticipator When using a nonelectronic thermostat the thermostat heat anticipator must be set to match amp draw of the electrical components in R W circuit Accurate amp draw readings can be
26. 5309 M VIQ NIS eee NU AYLNA 4 26 IWLSOWHAHL NIH EF 9 fc 1N3A NFZ NNOO SVO NIA 31VNH3LIv LHOIY WLNOZIHOH NNOO SSS VIO NI dvu L 1 1 6 1521 ANON 3 NNOO NIMES 191110 V 31VSN3QNOO ey NOILSNAWOD NIC 22 4492 These furnaces shipped with the following materials to assist in SAFETY proper furnace installation These materials are shipped in the main US National Fuel Gas Code NFGC 54 2002 ANSI blower compartment Z223 1 2002 and the Installation Standards Warm Air Heating Installer Packet includes and Air Conditioning Systems ANSI NFPA 90B Installation Startup and Operating Instructions CANADA National Standard of Canada Natural Gas and Service and Maintenance Instructions Propane Installation Code NSCNGPIC CSA B149 1 00 User s Information Manual ll GENERAL INSTALLATION Warranty Certificate US NFGC and the NFPA 90B For copies contact the National Loose Parts Bag includes Quantity Fire Protection Association Inc Batterymarch Park Quincy Pressure tube extension 1 MA 02269 or for only the NFGC contact the American Gas Collector Box or condensate trap extension tube Association 400 N Capitol
27. 70004 024040 036040 2 Pipe or 2 in Concentric 1 1 2 43 68 38 67 37 024060 036060 048060 2 Pipe or 2 in Concentric NA NA 50 45 036080 048080 060080 2 Pipe or 2 in Concentric 21 16 2 1 2 68 67 048100 060100 2 Pipe or 3 in Concentric 2 1 2 10 9 3 58 53 060120 2 Pipe or 3 in Concentric 3t no disk 18 11 4T disk 70 70 060140 2 Pipe or 3 in Concentric 4T no disk 7 ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBO WS 7001 to 80004 See notes at end of table 024040 036040 2 Pipe or 2 in Concentric 1 1 2 2 024060 036060 048060 2 Pipe or 2 in Concentric 1 1 2 2 036080 048080 060080 2 Pipe or 2 in Concentric 2 2 1 2 048100 060100 2 Pipe or 3 in Concentric 2 1 2 3 060120 2 Pipe or 3 in Concentric 3t no disk 4T no disk 060140 ALTITUDE FT TABLE 7 MAXIMUM ALLOWABLE PIPE LENGTH FT CONTINUED NUMBER OF 90 ELBOWS UNIT SIZE TERMINATION TYPE PIPE DIA IN 3 4 8001 to 9000 024040 036040 2 Pipe or 2 i Concentric 1 1 2 36 31 2 58 56 024060 036060 048060 2 Pipe or 2 i Concentric 1 1 2 NA NA 2 42 37 036080 048080 060080 2 Pipe
28. ATED for use in DOWNFLOW and HORIZONTAL applications Condensate trap MUST be used for all applications An external trap is not required when connecting the field drain to this condensate trap The field drain connection condensate trap or drain tube coupling is sized for 1 2 in CPVC 1 2 in PVC or 5 8 in ID tube connection Drain pipe and fittings must conform to ANSI standards and ASTM D1785 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 listed schedule 40 CPVC or PVC drain pipe fittings and cement When a condensate pump is required select a pump which is approved for condensing furnace applications To avoid conden sate spillage select a pump with an overflow switch CAUTION Unit must not be installed operated and then turned off and left in an unoccupied structure during cold weather when temperature drops to 32 F and below unless drain trap and drain line have adequate freeze protection See Service and Maintenance Instructions for winterizing procedure See Fig 15 Failure to follow this caution will result in minor unit operation 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 Il APPLICATION The furnace A C and humidi
29. As an alternative fibrous ductwork may be used ALTERNATE SUPPORT LOCATION 4 IN MIN 8 IN MAX 13 16 MAX ALTERNATE SUPPORT LOCATION FROM BACK 1 A 1 In clearance minimum between top of furnace and combustible material 2 The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage 93304 Fig 22 Crawlspace Horizontal Application 16 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 A Upflow Furnaces Connect supply air duct to 3 4 in flange on furnace supply air outlet The supply air duct attachment must ONLY be connected to furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accesso ries 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 combus tible material supply air duct attachment must ONLY be con nected to an acce
30. CATION When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 in horizontally from the furnace See NFPA 90B or local code for further requirements For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take off may require internal acoustical lining
31. COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BLUE CONDENSATE INDUCER HOUSING DRAIN TUBE VIOLET A00289 Fig 7 Alternate Upflow Tube Configuration and Trap Location APPLICATIONS CAUTION Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling Failure to follow this caution will result in minor property damage GENERAL Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig 1 All drain and pressure tubes are connected as shown in Fig 6 See appropriate application instructions for these procedures Il UPFLOW APPLICATIONS An upflow furnace application is where furnace blower is located below combustion and controls section of furnace and conditioned air Is discharged upwards A Condensate Trap Location Factory Shipped Orientation The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications A factory supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment See Condensate Trap Tubing Factory Shipped Orientation section for drain tube extension details See Fig 5 B Condensate Trap Tubing Factory Shipped Or
32. D LOCATION s gi N BTI B 1 1 A00212 Fig 29 Relocating J Box WARNING The cabinet MUST have an uninterrupted or unbroken ground according to ANSI NFPA 70 2002 and Canadian Electrical Code CSA C22 1 or local codes to minimize personal injury if an electrical AN fault should occur This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes Do not use gas piping as an electrical ground Failure to follow this warning could result in electrical shock fire or death J BOX RELOCATION 1 Remove 2 screws holding auxiliary J box See Fig 29 2 Rotate J box 180 and attach box to right side using holes provided CAUTION If manual disconnect switch is to be mounted on furnace select a location where a drill or AN fastener will not contact electrical or gas components Failure to follow this caution will result in intermittent unit operation or performance satisfaction 24 V WIRING Make field 24 v thermostat connections at 24 v terminal block on furnace control For proper cooling operation Y wire from thermostat MUST be connected to Y terminal on furnace control center as shown in Fig 27 The 24 v terminal block is marked for easy connection of field wiring See Fig 30 The 24 v circuit contains a 3 amp automotive type fuse located on furnace control See Fig 31 Any elect
33. ION FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE FIELD INSTALLED FACTORY SUPPLIED FIELD INSTALLED FACTORY SUPPLIED Ve IN CPVC STREET DRAIN TUBE ELBOWS 2 FOR COUPLING RIGHT LEFT DRAIN OPTION DRAIN OPTION 00288 Fig 6 Factory Shipped Upflow Tube Configuration Shown With Blower Access Panel Removed 4 If you touch ungrounded objects and recharge your body with static electricity firmly touch a clean unpainted metal surface of the furnace again before touching control or wires 5 Use this procedure for installed and uninstalled un grounded furnaces 6 Before removing a new control from its container dis charge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 5 before bringing the control or yourself into contact with the furnace Put all used AND new controls into containers before touching ungrounded objects 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage INTRODUCTION The model 340MAV 4 way multipoise Gas Fired Category IV direct vent condensing furnace is available in model sizes ranging in input capacities of 40 000 to 138 000 Btuh 6 PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK
34. N TYPE 2 Pipe or 2 in Concentric PIPE DIA IN MBER OF 90 ELBOWS 3 57 4 5 52 52 70 70 70 2 Pipe or 2 in Concentric 7 NA NA 66 61 61 036080 048080 060080 2 Pipe or 2 in Concentric 30 25 25 70 70 70 048100 060100 2 Pipe or 3 in Concentric 16 16 6 3 70 70 66 060120 2 Pipe or 3 in Concentric 3 NA NA NA 3t no disk 63 56 50 4T no disk 70 70 70 060140 2 Pipe or 3 in Concentric 3T one disk 10 5 NA 3T no disk 31 27 23 4T no disk 70 70 70 ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN MBER OF 90 ELBOWS 3 4 5 3001 to 4000 See notes at end of table 024040 036040 2 Pipe or 2 in Concentric 1 1 2 54 49 48 024060 036060 048060 2 Pipe or 2 in Concentric 036080 048080 060080 048100 060100 2 Pipe or 2 in Concentric 2 Pipe or 3 in Concentric 2 1 2 3 060120 2 Pipe or 3 in Concentric 3T no disk 4T no disk 060140 2 Pipe or 3 in Concentric 3T one disk 3T no disk 4T no disk ALTITUDE FT TABLE 7 MAXIMUM ALLOWABLE PIPE LENGTH FT CONTINUED NUMBER OF 90 ELBOWS UNIT SIZE TERMINATION TYPE PIPE DIA IN 3 4 5 4001 to 5000 024040 036040 2 Pipe or 2 in Concentric
35. PACITYT 024040 115 60 1 127 104 8 4 44 15 036040 115 60 1 127 104 10 0 37 15 024060 115 60 1 127 104 8 4 44 15 036060 115 60 1 127 104 048060 115 60 1 9 8 38 15 036080 115 60 1 048080 115 60 1 060080 115 60 1 048100 115 60 1 060100 115 60 1 060120 115 60 1 060140 115 60 1 Permissible limits of voltage range at which unit will operate satisfactorily T Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating components humidifier etc full load amps t 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 NOTE DO NOT connect furnace control HUM terminal to HUM humidifier terminal on Thermidistat Zone Controller or simi lar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connection 2 Humidifier HUM quick connect terminal HUM and screw terminal 24 v are provided for 24 v humidifier connection See Fig 30 HUM terminal is energized with 24v 0 5 amp maxi mum when gas valve is energized NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation
36. ST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER 15 GREATER 93055 Fig 38 Vent and Combustion Air Side Termination OVERHANG OR ROOF 12 MINIMUM 12 IN SEPARATION BETWEEN BOTTOM OF t t COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER 15 GREATER COMBUSTION AIR ELBOW PARALLEL TO WALL 87226 Fig 40 Sidewall Termination of Less than 12 in 96128 COMBUSTION AIR bos A93056 93057 Fig 42 Vent and Combustion Air Fig 43 Vent and Combustion Air Roof Termination Side Termination Dimension A is Touching or 2 In Maximum Separation Dimension A is Touching or 2 In Maximum Separation COMBUSTION AIR 96129 96130 Fig 44 Sidewall Termination of 12 or Less Fig 45 Sidewall Termination of More Than 12 in Dimension A is Touching or 2 In Maximum Separation Dimension A is Touching or 2 In Maximum Separation 33 It is important that vent terminations be made as shown to avoid recirculation of flue gases Dimension A in Fig 41 42 43 44 and 45 represents distance between pipes or rain shields as touching or 2 in maximum separation CONDENSATE DRAIN GENERAL Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications Condensate trap must be RELOC
37. TE Combustion air and vent pipes are restricted to a mini mum length of 5 ft See Table 7 NOTE A 12 in minimum offset pipe section is recommended with short 5 to 8 ft vent systems This recommendation is to reduce excessive condensate droplets from exiting the vent pipe See Fig 11 or 34 LOCATION 1 GENERAL This furnace must be installed so the electrical components are protected from water e not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS be located so combustion air and vent pipe maximum lengths are not exceeded Refer to Table 7 belocated where available electric power and gas supplies meet specifications on the furnace rating plate e be attached to an air distribution system and be located as close to the center of the distribution system as possible Refer to Air Ducts section be provided with ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label NOTE For upflow downflow applications install furnace so that it is level or pitched forward within 1 2 in for proper furnace operation For horizontal applications pitch 1 4 in minimum to 1 2 in maximum forward to ensure proper condensate drainage from secondary heat exchangers See Fig 13 When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside t
38. ade outside furnace casing in vertical pipe See Fig 32 This allows proper drainage of vent condensate 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 5 for required clearances Furnace combustion air and vent pipe connections must be at tached as shown in Fig 27 Combustion air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications NOTE Slope combustion air and vent pipes a minimum of 1 4 in per linear ft with no sags between hangers CAUTION When combustion air pipe is installed above a suspended ceiling pipe must be insulated with 3 8 in thick Armaflex type insulation Combustion air pipe should also be insulated when it passes through warm humid space CAUTION When vent pipe is exposed to temperatures below freezing such as when it passes through an AN unheated space or when a chimney is used as a raceway pipe must be insulated as shown in Table 8 with Armaflex type insulation Failure to follow this caution will result in intermittent unit operation An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion air and vent pipes Each furnace must have its own set of combustion air and vent pipes and be terminated individually as shown in Fig 42 Other gas appliances wi
39. al codes the installation must tested by UL Standard 181 for Class I Rigid Air Ducts comply with the national codes listed below and all authorities VI GAS PIPING AND GAS PIPE PRESSURE TESTING having jurisdiction US NFGC chapters 5 6 7 and 12 and national plumbing In the United States and Canada follow all codes and standards for codes the following CANADA NSCNGPIC Parts 3 4 5 A B E and H INSTALLATION 05 forced air furnace is equipped for use with natural gas at altitudes 0 10 000 ft 0 3 050m except 140 size furnaces are only approved for altitudes 0 7 000 ft arasan kit cn by the manufacturer shall be used to convert to propane gas use or be required for some natural gas applications This 5 for indoor installation in a building constructed on site This furnace may be installed in a manufactured mobile home when stated on rating plate and using factory authorized e eh tere may be installed on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below This furnace requires Special venting system Refer to the installation instructions for parts list and method of installation This furnace is for use with schedule 40 PVC PVC DWV CPVC or DWV and must not vented common with other gas fired appliances Construction through which vent air intake pipes may be installed is maximu
40. anada 6 6 o 6 4 d 2 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEATNALUE 838 J gt RANGE FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure Pressure Pressure Pressure No Pressure to 4000 7 derate Orifice numbers shown in BOLD are factory installed Percents of derate are based on midpoints of U S altitude ranges 38 ALTITUDE RANGE FT U S A Only TABLE 9 MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY TABULATED DATA BASED ON 20 000 BTUH PER BURNER DERATED 2 FOR EACH 1000 FT ABOVE SEA LEVEL ALTITUDE RANGE U S A Only FT 11 derate ALTITUDE U S A Only RANGE FT to 7000 13 derate AT ALTITUDE BTU CU FT AVG GAS Orifice Orifice Manifold No Pressure No Manifold Orifice Manifold Orifice No Pressure No Pressure Pressure AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT Orifice No Manifold SPECIFIC GRAVITY OF NATURAL GAS HEATVALUE ose J gt oa os Manifold Orifice No Pri essure Manifold Orifice Manifold Manifold Orifice Pressure Pressure No P
41. apped nipple should extend below level of gas controls Place a ground joint union between gas control manifold and manual gas shutoff valve See Fig 26 ex GAS 7 SUPPLY MANUAL SHUTOFF VALVE oa SEDIMENT TRAP UNION A93324 Fig 26 Typical Gas Pipe Arrangement CAUTION If a flexible connector is required or al lowed by authority having jurisdiction black iron pipe A shall be installed at furnace gas valve and extend a minimum of 2 in outside furnace casing Failure to follow this caution will result in intermittent unit opera tion or performance satisfaction If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do not use a connector which has previously served another gas appliance NOTE 2 FIVE WIRE THREE WIRE HEATING ONLY BLOWER DOOR SWITCH 1 LUN ra ah Olin H 4 1 H 0 LN Teen 5 SHE eke 115 V FIELD AUXILIARY SUPPLIED _ L DISCONNECT C aa 24 V TERMINAL BLOCK FURNACE WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for
42. ar safety glasses and work gloves Have a fire extinguisher available during start up and adjustment procedures and service calls CAUTION Sheet metal parts may have sharp edges or A burrs Use care and wear appropriate protective clothing and gloves when handling parts Failure to follow this caution could result in personal injury Recognize safety information This is the safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury 2 Understand these signal words DANGER WARNING CAU TION and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation The 340MAV Multipoise Condensing Gas Fired Furnaces are CSA formerly AGA and CGA design certified for natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA formerly AGA and CGA listed gas conversion kit is required to convert furnace for use wit
43. aution will result in intermittent unit operation or performance satisfaction 1 Remove upper inducer housing drain connection cap See Fig 48 2 Connect field supplied 1 2 in ID tube to upper inducer housing drain connection 3 Insert field supplied funnel into tube 4 Pour 1 quart of water into funnel tube Water should run through inducer housing overfill condensate trap and flow into open field drain See Fig 49 5 Remove funnel and tube from inducer housing and replace drain connection cap and clamp Ill PURGE GAS LINES WARNING Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use commercially available soap solution made specifically for the detection of leaks to check all connections Failure to follow this warning could result in fire explosion personal injury or death If not previously done purge lines after all connections have been made and check for leaks IV ADJUSTMENTS A Set Gas Input Rate Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft In the U S A the input ratings for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level In Canada the input ratings must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level Furnace input rate must be within 2 percent of input on furnace rating plate adjusted for altitude Verify furnace m
44. bility 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 applica tions as shown in Fig 1 See details in Applications section This furnace must be installed with a direct vent combustion air and flue gas system and a factory accessory termination kit In a direct vent system all air for combustion is taken directly from the outdoor atmosphere and flue gases are discharged to the outdoor atmosphere See furnace and factory accessory termination kit instructions for proper installation 471207 jeuoisuewig z 614 071 090 021 090 001090 001 80 080090 080870 080960 090870 090960 090720 070960 WOLLOS be GEN 22 7 CNI SNOISN3WIG dS3 9 M S 01e N3O 0081 10 unjal ayenbape aul JO eui pue epis jo 5 opis 100 jo esn y slajul epis 8 5 jo esn 2142905 10 ejeg 1 agel 29S 41420 0081 sjuawasinbad 1047 4 6 49 13Ni3QlS
45. c tions Review User s Guide with owner Leave literature packet near furnace CHECKLIST INSTALLATION LOAD CALCULATION Heating Load Btuh Cooling Load Btuh Furnace Model Selection COMBUSTION AIR VENT PIPING Termination Location Roof or Sidewall Termination Kit 2 Pipe or Concentric Combustion Air Pipe Length Combustion Air Elbow Quantity Vent Pipe Length Vent Pipe Elbow Quantity Pipe Diameter Determined from Sizing Table Pipe Sloped To Furnace Pipe Insulation Over Ceilings Low Ambient Exposed Pipes 46 Condensate Drain Unit Level or Pitched Forward Internal Tubing Connections Free of Kinks and Traps External Drain Connection Leak Tight and Sloped Condensate Trap Primed before Start Up Heat Tape Installed if Required CHECKLIST START UP Gas Input Rate Set Within 2 percent of Rating Plate Temperature Rise Adjusted Thermostat Anticipator Anticipator Setting Adjusted or Cycle Rate 3 Cycles per Hr Selected Safety Controls Check Operation Primary Limit Pressure Switch 2003 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis 46231 48 Printed in U S A 340 4011 Catalog No 5334 016
46. ce burner enclosure front and verify adjusted gas input rate using method outlined in item 3 g Look through sight glass in burner enclosure and check burner flame Burner flame should be clear blue almost transparent See Fig 52 h Remove jumper from R and W BURNER FLAME E BURNER ECTS Fig 52 Burner Flame A89020 TABLE 11 ALTITUDE DERATE MULTIPLIER DERATE MULTIPLIER FACTOR FOR U S A ALTITUDE FT 0 2000 2001 3000 3001 4000 4001 5000 5001 6000 6001 7000 7001 8000 8001 9000 9001 10 000 Derate multiplier factor is based on midpoint altitude for altitude range OF DERATE 3 Verify natural gas input rate by clocking gas meter NOTE Be sure all pressure tubing combustion air and vent pipes and burner enclosure front are in place when checking input by clocking gas meter a Calculate high altitude adjustment if required UNITED STATES At altitudes above 2000 ft this furnace has been ap proved for a 2 derate for each 1000 ft above sea level See Table 11 for derate multiplier factor EXAMPLE 100 000 BTUH INPUT FURNACE INSTALLED AT 4300 FT Derate X Multiplier Factor 0 91 Furnace Input Rate at Installation Altitude 91 000 Furnace Input Rate at Sea Level 100 000 X CANADA At installation altitudes from 2000 to 4500 ft this furnace must be derated 5 by an authorized Gas Conversion Station or Dealer To determ
47. ce 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 electro static 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 un grounded objects etc PLUG CAP COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN N INDUCER HOUSING MOLDED DRAN KO A TUBE BEHIND COLLECTOR BOX F DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE FIELD INSTALLED f FACTORY SUPPLIED DRAIN TUBE COUPLING LEFT DRAIN OPT
48. chment 1 Fold heat tape in half and wrap on itself 3 times 2 Locate heat tape between sides of condensate trap back See Fig 47 3 Use wire ties to secure heat tape in place Wire ties can be positioned in notches of condensate trap sides See Fig 4T 4 Wrap field drain pipe with remaining heat tape approxi mately 1 wrap per ft 5 When using field supplied heat tape follow heat tape manufacturer s instructions for all other installation guide lines CONDENSATE TRAP WIRE TIE S HEAT TAPE 8 WRAPS MINIMUM Fig 47 Condensate Trap Heat Tape 93036 SEQUENCE OF OPERATION CAUTION Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and burner box screw Failure to follow this caution will result in intermittent unit operation Using schematic diagram follow sequence of operation through different modes See Fig 30 Read and follow wiring diagram carefully NOTE If a power interruption occurs during a call for heat W the control will start a 90 second blower only ON period two seconds after power is restored if the thermostat is still calling for gas heating The red LED light will flash code 12 during the 90 second period after which the LED will be ON continuous as long as no faults are detected After the 90 second period the furnace will respond to the thermostat normall
49. condensate trap must be removed from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 or 12 To relocate condensate trap from the blower shelf to desired location perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed WARNING Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated Failure to follow this warning could result in electrical shock fire personal injury or death 4 Install condensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 5 Fill unused condensate trap casing holes with plastic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 12 or tube routing label on main furnace door to check for proper connections 1 Collector Box Drain Tube a Remove factory installed plug from LOWER collector box drain tube blue and white striped label b Install removed clamp and plug into UPPER collector box drain tube blue label which was previously con nected to condensate trap c Connect LOWER collector box drain tube blue and white striped label to condensate trap
50. d flange back and forth until it breaks off Be careful of sharp edges See Fig 21 WARNING Do not bend duct flanges inward as shown in Fig 21 This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure Remove duct flange completely or bend it inward a minimum of 210 as shown in Fig 21 NOTE For 140 size unit when installed in downflow orientation cut the white jumper wire off between terminals PL1 7 and PL1 9 Do not cut white jumper between terminals PL1 7 and PLI 11 Refer to Fig 30 for location of jumper Cut jumper close to connector and remove wire to avoid a short circuit Ill INSTALLATION IN HORIZONTAL APPLICATIONS CAUTION The entire length of furnace MUST be supported when furnace is used in a horizontal position to ensure proper draining When suspended bottom brace supports sides and center blower shelf When unit is supported from the ground blocks or pad should support sides and center blower shelf area Failure to follow this caution will result in intermittent unit operation or per formance satisfaction These furnaces can be installed horizontally in either horizontal left or right discharge position In a crawlspace furnace can either be hung from floor joist or installed on suitable blocks or pad Furnace can be suspended from each corner by hanger bolts and angle iron supports See Fig 22 Cut hanger bolts 4 each 3 8 in all thread rod to
51. differ from those packaged with termination kit follow kit instructions Combustion air and vent pipes must terminate outside structure A factory accessory termination kit must be installed in 1 of the installations shown in Fig 36 37 38 39 and 40 Four termination kits are available 1 The 2 in termination bracket kit is for l in 1 1 2 in and 2 in diameter 2 pipe termination systems 2 The 3 in termination bracket kit is for 2 1 2 in 3 in and 4 in diameter 2 pipe termination systems 3 2 in concentric vent air termination kit is for l in 1 1 2 in 2 in and 2 1 2 in diameter pipe systems when single penetration of wall or roof is desired 30 4 3 in concentric vent air termination kit is for 2 1 2 in 3 in and 4 in diameter pipe systems when single penetra tion of wall or roof is desired NOTE Shaded parts in Fig 36 37 38 39 and 40 are considered to be termination These components should NOT be counted when determining pipe diameter Roof termination is preferred since it is less susceptible to damage has reduced chances to take in contaminants and has less visible vent vapors See Fig 36 or 37 Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system A Extended Exposed Sidewall Pipes Sidewall combustion air and vent pipe terminations may be extended beyond a
52. e trap drain connection NOTE Failure to use CPVC elbows may allow drain to kink and prevent draining f Connect larger diameter drain tube and clamp factory supplied in loose parts bag to condensate trap and clamp securely g Route tube to coupling and cut to appropriate length h Attach tube to coupling and clamp securely C Condensate Trap Location Alternate Upflow Orientation An alternate location for the condensate trap is the left hand side of casing See Fig 2 and 7 NOTE If the alternate left hand side of casing location is used the factory connected drain and relief port tubes must be discon nected and modified for attachment See Condensate Trap Tubing Alternate Upflow Orientation section for tubing attachment To relocate condensate trap to the left hand side perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed WARNING Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated Failure to follow this warning could result in electrical shock fire personal injury or death 4 Install condensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking pos
53. ended tube a Behind inducer housing b Between blower shelf and inducer housing c Behind inducer motor bracket d Between inducer motor and pressure switch 4 Determine appropriate length cut and reconnect tube to pressure switch connection labeled COLLECTOR BOX E Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures F Construct a Working Platform Construct working platform where all required furnace clearances are met See Fig 3 and 11 CAUTION The condensate trap MUST be installed below furnace See Fig 5 for dimensions The drain connection to condensate trap must also be properly sloped to an open drain Failure to follow this caution will result in intermittent unit operation NOTE Combustion air and vent pipes are restricted to a mini mum length of 5 ft See Table 7 NOTE A 12 in minimum offset pipe section is recommended with short 5 to 8 ft vent systems This recommendation is to reduce excessive condensate droplets from exiting the vent pipe See Fig 11 or 34 V HORIZONTAL RIGHT SUPPLY AIR DISCHARGE APPLICATIONS A horizontal right furnace application is where furnace blower is located to the left of combustion and controls section of furnace and conditioned air is discharged to the right CAUTION Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used i
54. ent sess Supply Air Connections Return Air Connections nnn ttt tetro 17 Filter Arrangement seen eee ub a te o 17 Bottom Closure Pafiel ritenere 18 guinicd 18 19 ELECTRICAL CONNECTIONS 19 22 115v WAflBg stipite eO 20 DAN WITING e TP 20 Wiring Dia Sram isc 21 JACCOSSOFIGS 20 22 DIRECT 22 34 Removal of Existing Furnaces from Common Vent Systems ace secet eni en 22 Combustion Air and Vent Piping esses 22 30 Concentric Vent and Combustion Air Termination Kit InstallaBOn a aas ecreter Multiventing and Vent Termination CONDENSATE DRAIN eee Cancels 340 40 10 11 340M 40 11 10 03 san ree ety so ineo aea sea de eee DER E INA 34 Condensate Drain Protection eee 34 SEQUENCE OF OPERATION 55 6550550507754556 55555 055 arana 35 36 Heating Mode 35 Cooling 35 Continuous Blower Mode rnnt 35 Heat Pump Mode aote iia tede err Pt tenete 35 36 Component Test ies ed 36 START UP PROCEDURES 36 44 Gene
55. enter No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in electrical shock personal injury or death Remove blower access door Disconnect the thermostat R lead from furnace control Manually close blower door switch For approximately 2 sec short jumper the Com 24v terminal on control to the TEST TWIN 3 16 inch quick connect terminal on control until the LED goes out Remover jumper from terminals See Fig 31 NOTE If TEST TWIN and 24 terminals are jumpered longer than 2 sec LED will flash rapidly and ignore component test request Component test sequence is as follows a LED will display previous status code 4 times gt b Inducer motor starts and continues to run until Step f of component test sequence c After 7 seconds the hot surface igniter is energized for 15 sec then off d Blower motor operates on HEAT speed for 10 sec e Blower motor operates on COOL speed for 10 sec f Inducer motor stops 5 Reconnect R lead to furnace control remove tape from blower door switch and re install blower door 6 Operate furnace per instruction on outer door 7 Verify furnace shut down by lowering thermostat setting below room temperature 8 Verify that furnace restarts by raising thermostat setting above room temperature START UP PROCEDURES GENERAL 1 F
56. f disk against stop in combustion air inlet a Determine location of combustion air intake pipe con nection to combustion air intake housing as shown in Fig 33 for application ra Reposition combustion air intake housing plug fitting in appropriate unused intake housing connection HORIZONTAL LEFT DISCHARGE HORIZONTAL RIGHT DISCHARGE 96187 Fig 33 Combustion Air and Vent Pipe Connections 25 A y a 12 MIN VENT PIPE NI VENT PIPE mu HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL Y A COMBUSTION AIR PIPE VENT PIPE COMBUSTION AIR PIPE 12 MIN 12 MIN VENT PIPE VERTICAL TO ROOF VERTICAL TO SIDEWALL NOTE A 12 In minimum offset pipe section is recommended with short 5 to 8 ft vent systems This recommendation is to reduce excessive condensate droplets from exiting the vent pipe Fig 34 Short Vent 5 to 8 Ft System d Install pipe support factory supplied in loose parts bag The combustion air intake plug fitting must be installed in into selected furnace casing combustion air pipe hole unused combustion air intake housing This fitting must be Pipe support should be positioned at bottom of casing attached by using RTV sealant or by drilling a 1 8 in hole hole in fitting using hole in intake ho
57. fier drains may be combined and drained together The A C drain must have an external field supplied 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 46 for example of possible field drain attachment using 1 2 in CPVC or PVC tee for vent and A C or humidifier drain connection Outdoor draining of the furnace is permissible if allowed by local codes Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining WARNING Caution should be taken to prevent drain ing where slippery conditions may cause personal inju ries Excessive condensate draining may cause saturated soil conditions which may result in damage to plants Ill CONDENSATE DRAIN PROTECTION Freezing condensate left in condensate trap and drain line may cause cracks and possible water damage may occur If freeze protection is required use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40 F self regulating shielded and waterproof heat tape See Installation Instructions supplied with accessory or heat tape manufacturer s recommenda tions OPEN STAND PIPE FOR A C OR HUMIDIFIER DRAIN TO OPEN DRAIN A94054 Fig 46 Example of Field Drain Atta
58. 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 connec tion by splicing to small diameter tube factory supplied in loose parts bag 3 Route extended collector box pressure tube behind inducer motor bracket then between inducer motor and pressure switch 4 Connect collector box pressure tube green label to pres sure switch connection labeled COLLECTOR BOX 5 Use remaining smaller diameter tube factory supplied in loose parts bag to extend collector box pressure tube pink label which was previously connected to pressure switch 6 Route this extended tube pink label to condensate trap relief port connection 7 Determine appropriate length cut and connect tube 8 Clamp tube to relief port connection E Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures F Construct a Working Platform Construct working platform where all required furnace clearances are met See Fig 3 and 11 CAUTION The condensate trap MUST be installed below furnace See Fig 5 for dimensions The drain AN connection to condensate trap must also be properly sloped to an open drain Failure to follow this caution will result in intermittent unit operation NO
59. h propane gas See Fig 3 for required clearances to combustibles Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace See NFPA 90B or local code for further requirements These furnaces SHALL NOT be installed directly on carpeting tile or any other combustible material other than wood flooring In downflow installations factory accessory floor base MUST be used when installed on combustible materials and wood flooring Special base is not required when this furnace is installed on manufacturer s Coil Assembly Part CD5 or 5 or when Coil Box Part No KCAKC is used The 340MAV 040 through 120 size units are CSA formerly AGA and CGA design certified for use in manufactured mobile homes when factory accessory conversion kit is used The 140 size unit is NOT design certified for use in manufactured mobile homes These furnaces are suitable for installation in a structure built on site or a manufactured building completed at final site The design of this furnace line is NOT CSA formerly AGA and CGA design certified for installation in recreation vehicles or outdoors This furnace is designed for continuous return air minimum temperature of 60 F db or intermittent operation down to 55 F db such as when used with a night setback thermostat Return air temperature must not exceed 85 F db Failure to follow these return air limits may affect relia
60. he space containing the furnace the return air shall also be handled by duct s sealed to furnace casing and terminating outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space This furnace may be located in a confined space without special provisions for dilution or ventilation air CAUTION This gas furnace may be used for construction heat provided that LEVEL 0 TO 1 Ve MAX MIN 1 4 TO Ve MAX HORIZONTAL A02146 UPFLOW OR DOWNFLOW Fig 13 Furnace Location for Proper Condensate Drainage The furnace is permanently installed with all electrical wiring piping venting and ducting installed according to these installation instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame rollout and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The
61. hes LIT TOP A02248 Fig 3 Clearances to Combustibles 4 BLOWER SHELF FURNACE DOOR CONDENSATE CONDENSATE TRAR FURNACE TRAP INSIDE EUBN GE DOOR FURNACE SIDE SIDE 1 oo Vis NG Ve ic ii de 59 qd 5 ce F p Wh a A FIELD 1 FIELD DRAIN DRAIN ALTERNATE DRAIN CONN CONN TUBE LOCATION CONDENSA TETRAP SIDE VIEW FRONT VIEW END VIEW FRONT VIEW DRAIN TUBE LOCATION DOWNFLOW AND ALTERNATE HORIZONTAL UPFLOW APPLICATIONS EXTERNAL UPFLOW APPLICATIONS APPLICATIONS SLOT FOR SCREW HORIZONTAL APPLICATION OPTIONAL 172 abs 11 WIRE TIE GUIDES WHEN USED 34 FRONT VIEW 74 OD COLLECTOR BOX TO TRAP RELIEF PORT Ve OD INDUCER HOUSING DRAIN CONNECTION 9 OD COLLECTOR BOX DRAIN CONNECTION SCREW HOLE FOR UPFLOW OR DOWN FLOW APPLICATIONS OPTIONAL Ve IN PVC OR CPVC SIDE VIEW 93026 Fig 5 Condensate Trap Vil ELECTRICAL CONNECTIONS US National Electrical Code NEC ANSI NFPA 70 2002 CANADA Canadian Electrical Code CSA C22 1 ENDI 85 F 20 E RETURN xz AIR SUZ MIN 55 F A94163 Fig 4 Return Air Temperature 5 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS CAUTION Electrostatic discharge can affect electronic components Take precautions during furna
62. htened to prevent any condensate leakage Failure to follow this warning could result in electrical shock fire personal injury or death NOTE A 2 in diameter pipe must be used within the furnace casing Make all pipe diameter transitions outside furnace casing d Be certain that mating surfaces of inducer housing connection elastomeric coupling and 2 in diameter vent pipe are clean and dry Assemble the elastomeric rubber vent coupling with 2 loose clamps onto inducer housing connection Insert the 2 in diameter vent pipe through the elastomeric rubber coupling and fully into inducer housing connection until it bottoms on the internal stop Tighten both clamps to secure the pipe to inducer housing Tighten the clamp screws to 15 in Ib of torque Install casing hole filler cap factory supplied in loose parts bag in unused vent pipe casing hole VENT EXTENSION PIPE Some furnaces are supplied with a PVC vent extension pipe 2 in diameter by 12 in long This pipe has a built in channel to assist vent condensate disposal When this vent extension pipe is supplied it must be used to connect the field vent pipe to furnace inducer housing on ALL upflow and downflow applications NOTE See label on vent extension pipe for proper installation This pipe may be shortened if an elbow is used to connect vent extension tube to field installed vent pipe 3 Working from furnace to outside cut pipe to required length
63. iciencies 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 A venting system are located and other spaces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 2002 NFPA 54 2002 and or CSA B149 1 Natural Gas and Propane Installation Code 9 After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired appliance to their previous conditions of use Vent system or vent connectors may need to be resized For any Il COMBUSTION AIR AND VENT PIPING other appliances when resizing vent systems
64. ientation NOTE See Fig 6 or tube routing label on main furnace door to confirm location of these tubes 1 Collector Box Drain Inducer Housing Drain Relief Port and Pressure Switch Tubes These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications These tubes can be identified by their connection location and also by a color label on each tube These tubes are identified as follows collector box drain tube blue label inducer housing drain tube violet label or molded relief port tube green label and pressure switch tube pink label 2 Condensate Trap Drain Tube The condensate trap drain connection must be extended for field attachment by doing the following a Determine location of field drain connection See Fig 2 or 6 NOTE If internal filter is used drain tube should be located to opposite side of casing from return duct attachment to assist in filter removal b Remove and discard casing drain hole plug button from desired side c Install drain tube coupling grommet factory supplied in loose parts bag in selected casing hole d Slide drain tube coupling factory supplied in loose parts bag through grommet ensuring long end of coupling faces blower e Cement 2 factory supplied 1 2 in street CPVC elbows to the rigid drain tube connection on the condensate trap See Fig 6 These elbows must be cemented together and cemented to condensat
65. ify burner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY 2 Adjust manifold pressure to obtain input rate NOTE Manifold pressure must always be measured with burner enclosure front REMOVED Gas meter must always be clocked with burner enclosure front INSTALLED a Remove burner enclosure front b Remove cap that conceals adjustment screw for gas valve regulator See Fig 50 c Jumper R and W thermostat connections on control to start furnace operation d Turn adjusting screw counterclockwise out to decrease manifold pressure or clockwise in to increase manifold pressure NOTE This furnace has been approved for a manifold pressure of 3 2 in we to 3 8 in wc when installed at altitudes up to 2000 ft For altitudes above 2000 ft the manifold pressure can be adjusted from 2 0 in we to 3 8 in we If manifold pressure is outside this range change burner orifices to obtain pressure in this range CAUTION DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics e Replace gas valve regulator adjustment screw cap f Repla
66. in each bottom corner of furnace See Fig 12 Holes in bottom closure panel may be used as guide locations 14 2 For each hole install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement NOTE Bottom closure must be used when leveling legs are used See Bottom Closure Panel section Il INSTALLATION IN UPFLOW DOWNFLOW APPLICATIONS NOTE For downflow applications this furnace is approved for use on combustible flooring when special base available from manufacturer Part No KGASB0201ALL is used Special base is not required when this furnace is installed on manufacturer s Coil Assembly Part No CD5 or 5 or Coil Box Part No KCAKC is used 1 Determine application being installed from Table 1 2 Construct hole in floor per dimensions specified in Table 1 and Fig 18 3 Construct plenum to dimensions specified in Table 1 and Fig 18 4 If downflow subbase KGASB is used install as shown in Fig 19 If coil assembly CD5 or CK5 or Coil Box KCAKC is used install as shown in Fig 20 NOTE Remove furnace perforated discharge duct flanges when they interfere with mating flanges on coil on downflow subbase To remove furnace perforated discharge duct flange use wide duct pliers or duct flange tool to ben
67. ine correct input rate for altitude see example above and use 0 95 as derate multiplier factor Reinstall burner box cover Gas valve regulator seal cap MUST be installed a Turn off all other gas appliances and pilots Start furnace and let operate for 3 minutes Measure time in sec for gas meter test dial to complete 1 revolution g Refer to Table 12 for cu ft of gas per hr h Multiply gas rate cu ft hr X heating value Btu cu ft using natural gas utility supplier heating value from local gas EXAMPLE 0 2000 ft altitude Furnace input from rating plate is 100 000 Btuh Btu heating input Btu cu ft X cu ft hr Heating value of gas 975 Btu cu ft Time for 1 revolution of 2 cu ft dial 70 sec Gas rate 103 cu ft hr from Table 12 Btu heating input 103 X 975 100 425 Btuh In this example the orifice size and manifold pressure adjustment is within 2 percent of the furnace input rate B Set Temperature Rise CAUTION Temperature rise must be within limits specified on furnace rating plate Recommended opera A tion is at midpoint of rise range or slightly above Failure to follow this caution may result in primary and second ary heat exchangers failure Determine and adjust air temperature rise as follows 1 Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see heat exchanger so that radiant heat does n
68. installation adjustment alter ation service maintenance or use can cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agency local gas supplier or your distributor or branch for information or assistance The qualified installer or agency must use only factory authorized and listed kits or accessories when modifying this product Failure to follow this warning could result in electrical shock fire personal injury or death Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified person nel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions such as clean ing and replacing air filters All other operations must be per formed by trained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with unit and other safety precautions that may apply These instructions cover the minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation We
69. installation start up and operating instructions 4 WAY MULTIPOISE FIXED CAPACITY DIRECT VENT CONDENSING GAS FURNACE A93040 NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue Index Page DIMENSIONAL DRA WING 3 irte edes 3 SAFETY CONSIDERATIONS Clearances to Combustibles ccccccccsssccccessseceecsseeesessseeeeees 4 CODES AND STANDARDS 4 5 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 5 6 INTRODUCTION terere rte AS 6 APPLICATIONS 6 12 G neral gg Aa 6 Upflow Applications 6 8 Downflow Applications eere 8 9 Horizontal Left Supply Air Discharge Applications 10 Horizontal Right Supply Air Discharge Applications 10 12 LOCATION General As adan aira panda ni pi reed t wis Furnace Location Relative to Cooling Equipment 13 Hazardous Locations tiere iens 14 INSTALLATION nrbe ere ines 14 Leveling Legs If Desired erre 14 Installation In Upflow or Downflow Applications 14 Installation In Horizontal 14 AIR PDUCTS sirarsa a 14 19 General RedgulTementss s sassas san aana asy ag re 14 16 Ductwork Acoustical Treatm
70. ition 5 Fill unused condensate trap casing holes with plastic filler caps factory supplied in loose parts bag D Condensate Trap Tubing Alternate Upflow Orientation NOTE See Fig 7 or tube routing label on main furnace door to confirm location of these tubes 1 Collector Box Drain Tube Connect collector box drain tube blue label to condensate trap NOTE On 17 1 2 in wide furnaces ONLY cut tube between corrugated sections to prevent kinks from occurring 2 Inducer Housing Drain Tube a Remove and discard LOWER molded inducer housing drain tube which was previously connected to conden sate trap b Use inducer housing drain extension tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to the con densate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage 3 Relief Port Tube a Connect relief port tube green label to condensate trap b Extend this tube if required by splicing to small diameter tube factory supplied in loose parts bag c Determine appropriate length cut and connect tube E Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures F Pressure Switch Tubing The LOWER collector box pressure tube pink label is factory connected to the pressure switch and should not require any modification NOTE See Fig 6 or
71. l which was previously connected to condensate trap relief port connec tion by splicing to small diameter tube factory supplied in loose parts bag Connect collector box pressure tube green label to pres sure switch connection labeled COLLECTOR BOX 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 Route this extended tube pink label to condensate trap relief port connection 6 As Determine appropriate length cut and connect tube Clamp tube to relief port connection E Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures 9 IV HORIZONTAL LEFT SUPPLY AIR DISCHARGE APPLICATIONS A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace and conditioned air is discharged to the left NOTE The auxiliary junction box J Box MUST be relocated to opposite side of furnace casing See Fig 10 See Electrical Connection section for J Box relocation A Condensate Trap Location The condensate trap must be removed from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 or 10 To relocate condensate trap from the blower shelf to desired location perform the following 1
72. lower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV and the control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to Ignition Lockout Lockout will be reset automatically after three hours by momentarily interrupting 115 vac power to the furnace or by inter rupting 24 vac power at SEC1 or SEC2 to the furnace control CPU not at W G R etc If flame is proved when flame should not be present the furnace control CPU will lock out of Gas Heating mode and operate the inducer motor IDM until flame is no longer proved e Blower On Delay If the burner flame is proven the blower motor is energized on HEAT speed 66 seconds 040 through 120 sizes or 45 seconds 140 size after the gas valve GV is energized Simultaneously the electronic air cleaner terminal EAC 1 is energized and remains energized as long as the blower motor BLWM is energized f Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV stopping gas flow to the burners and de energizing the humidifier terminal HUM The inducer motor IDM will remain energized for a 15 second 040 through 120 sizes or 5 second 140 size post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized for 90 120 150 or 180 seconds depending
73. m 24 inches 600 mm minimum 3 4 inches 19 mm thickness including Tooling materials LEVEL 0 TO MIN 1 4 TO 1 2 MAX 1 2 MAX E For upflow and downflow applications furnace must be installed level or pitched within 1 2 of level Fora T 4 horizontal application the furnace must be pitched minimum 1 4 to maximum of 1 2 forward for proper FR drainage See Installation Manual for IMPORTANT unit support details on horizontal applications UPFLOW OR FRONT DOWNFLOW HORIZONTAL MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION ALL POSITIONS This furnace is approved for UPFLOW DOWNFLOW and Minimum front clearance for service 30 inches 762mm HORIZONTAL installations tt 140 size furnaces require 1 inch back clearance to combustible materials DOWNFLOW POSITIONS Clearance arrows t For installation on combustible floors only when installed on special base No KGASB0201ALL do not change with Coil Assembly Part No CD5 or Coil Casing Part No KCAKC furnace orientation HORIZONTAL POSITIONS Line contact is permissible only between lines formed by intersections of top and two sides of furnace jacket and building joists studs or framing Clearance shown is for air inlet and air outlet ends 120 140 size furnaces require 1 inch bottom clearance to combustible materials TOP PLENUM Vent clearance to combustibles 0 328066 201 REV A Clearance in inc
74. n attic application or over a finished ceiling Failure to follow this caution will result in minor property damage NOTE In Canada installations shall be in accordance with current NSCNGPIC Installation Codes and or local codes NOTE The auxiliary junction box J Box MUST be relocated to opposite side of furnace casing See Fig 12 See Electrical Connection section for J Box relocation COMBUSTION AIR INTAKE VENT 12 IN MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT 5 TO 8 FT VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM 30 MIN EXITING THE VENT PIPE MANUAL SHUTOFF GAS VALVE ACCESS OPENING FOR TRAP SEDIMENT TRAP 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 11 Attic Location and Working Platform CAP COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE GREEN COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE PINK AUXILARY J BOX RELOCATED HERE CONDENSATE COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED INDUCER HOUSING DRAIN TUBE VIOLET COLLECTOR BOX EXTENSION TUBE A00214 Fig 12 Horizontal Right Tube Configuration 11 A Condensate Trap Location The
75. n section for recommenda tions and procedures Ill DOWNFLOW APPLICATIONS A downflow furnace application is where furnace blower is located above combustion and controls section of furnace and conditioned air is discharged downwards A Condensate Trap Location The condensate trap must be removed from the factory installed blower shelf location and relocated in selected application location as shown in Fig 2 8 or 9 To relocate condensate trap from the blower shelf to desired location perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed WARNING Casing hole filler cap must be installed in AN blower shelf when condensate trap is relocated Failure to follow this warning could result in electrical shock fire personal injury or death 4 Install condensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 5 Fill unused condensate trap casing holes with plastic filler caps factory supplied in loose parts bag B Condensate Trap Tubing NOTE See Fig 8 or 9 or tube routing label on main furnace door to check for proper connections ME NE
76. n to condensate trap 1 Condensate Trap Located on Left Side of Casing a Determine appropriate length and cut b Connect tube to condensate trap c Clamp tube to prevent any condensate leakage 2 Condensate Trap Located on Right Side of Casing a Route inducer housing drain tube violet label directly from inducer housing to condensate trap as shown in Fig 9 b Determine appropriate length and cut c Connect tube to condensate trap d Clamp tube to prevent any condensate leakage 3 Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure C Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures D Pressure Switch Tubing One collector box pressure tube pink label is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications This tube MUST be disconnected and used for the condensate trap relief port tube The other collector box pressure tube green label which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications NOTE See Fig 8 or 9 or tube routing label on main furnace door to check for proper connections Relocate tubes as described below 1 Disconnect collector box pressure tube pink label attached to pressure switch Extend collector box pressure tube green labe
77. nd G3TIVLSNI AHOLOV SALLOWOLN dW ISNA 3004199713 393 CO N LSdS 13938 5 LNOTIOH sus NOWINOO NOLLO3NNOO YANV310 2INOH103 3 2 071 OVA 911 NOLLO3NNOO HIV OINOH1O373 1 ov3 ONY HOSS300HdOHOIN fido 24470 HOLIOVdVO LIIdS IN3NVINH3d YOLOW wag O N LSdS HOLOW H3MO18 uma 1095 03345 HOLOW HOLIMS LOSNNOOSIC ASNA mm e3uvas 3uvas 7000 YIO IHE sl n e TANNED elo elo JHM jo 8 ros coss IHM TANNYD 9i ILON SEIN TAANED gt eru d Sud S1 NHO day nms 5 W t a NO e ma ol Awe 5 TAA e wo amp 5 ost e o 8 e _ 1097199 idi Xe d 2 d AV HQ 440 H3MO 18 TABLE 4 ELECTRICAL DATA VOLTS OPERATING ei HERTZ VOLTAGE RANGE PHASE Min MAX WIRE MAX FUSE LENGTH OR CKT BKR AMPS UNIT AM
78. o conden sate trap b Use inducer housing drain extension tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to the con densate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage 3 Relief Port Tube a Extend collector box tube green label which was previously connected to the condensate trap by splicing to small diameter tube factory supplied in loose parts bag b Route extended collector box pressure tube to relief port connection on the condensate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage C Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures D Pressure Switch Tubing The LOWER collector box pressure tube pink label is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications This tube MUST be disconnected extended rerouted and then reconnected to the pressure switch in HORIZONTAL LEFT applications NOTE See Fig 10 or tube routing label on main furnace door to check for proper connections Modify tube as described below 1 Disconnect collector box pressure tube pink label attached to pressure switch 2 Use smaller diameter tube factory supplied in loose parts bag to extend tube disconnected in item 1 3 Route ext
79. odel and size Table 9 only be used for model 340MAV furnaces with heating sizes of 040 through 120 Table 10 can only be used for model 340MAV furnaces with a heating size of 140 d Find installation altitude in Table 9 or 10 NOTE For Canada altitudes of 2000 to 4500 ft use U S A altitudes of 2001 to 3000 ft in Table 9 or 10 e Find closest natural gas heat value and specific gravity in Table 9 or 10 f Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation REGULATOR SEAL CAP CR REGULATOR ADJUSTMENT SCREW ON OFF SWITCH ORF REGULATOR SPRING A99118 PROPANE WHITE 6 TURNS Fig 48 Inducer Housing Drain Cap NATURAL SILVER 10 TURNS GAS PRESSURE REGULATOR INLET ADJUSTMENT PRESSURE TAP SS C MANIFOLD b PRESSURE TAP 03142 gt Fig 50 Redundant Automatic Gas Valve D BURNER N o ORIFICE HEEL ELE JO A93059 A99119 Fig 49 Filling Condensate Trap Fig 51 Burner Orifice 1 Determine natural gas orifice size and manifold pressure for CAUTION DO NOT redrill orifices Improper drilling correct input burrs out of round holes etc can cause excessive A burner noise and misdirection of burner flames This can result in flame impingement of burners and heat
80. on the blower OFF delay selection The furnace control CPU is factory set for 120 second blower OFF delay COOLING MODE See Fig 27 for thermostat connections The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and Y circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac when the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuits are opened The outdoor unit will stop and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds Cut jumper J2 to reduce the cooling off delay to 5 seconds Ill CONTINUOUS BLOWER MODE When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous blower speed same as HEAT speed Terminal EAC 1 is energized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will stop during igniter warm up 17 seconds ignition 7 seconds and blower ON delay 66 or 45 seconds for 040 through 120 sizes or for 140 size allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at HEAT speed In heating the furnace control CPU will continue running the blower motor BLWM at HEAT speed after the selected blower OFF delay period is completed When the thermostat call
81. oor combustion inlet condensate problems and accelerated corrosion of heat exchangers 3 Vent termination can not terminate less than 2 ft horizontal and 7 ft above public walkway or where condensate vapor or droplets may be a hazard 4 Vent termination must be at least 3 feet above any forced draft inlets within 10 feet horizontal Vent termination must be at least 3 feet horizontal from other direct vent appliances intake unless otherwise specified by manufac turer 5 3 ft radius of furnace air intake terminal and 1 ft horizontally from vertical centerline of furnace air intake terminal 6 Above a meter regulator within 3 feet horizontally of vertical centerline of meter regulator vent outlet to a maximum vertical distance of 15 feet TABLE 6 APPROVED COMBUSTION AIR AND VENT PIPE FITTING AND CEMENT MATERIALS ASTM SPECIFICATION MARKED ON MATERIAL MATERIAL ABS FITTINGS SOLVENT CEMENT AND PRIMERS DESCRIPTION Schedule 40 PVC Schedule 40 For ABS Solvent Cement For ABS PVC SDR 21 amp SDR 26 PVC Fittings Schedule 40 ABS Fittings Schedule 40 For PVC Solvent Cement For PVC ABS Fittings DWV at Schedule 40 IPS sizes PVC Fittings DWV CPVC Fittings Schedule 40 CPVC Schedule 40 CPVC SDR For CPVC Solvent Cement For CPVC ABS Cellular Core DWV at Schedule 40 IPS sizes For PVC NOTE
82. or 2 i Concentric 2 17 12 2 1 2 58 56 048100 060100 2 Pipe or 3 in Concentric 2 1 2 7 5 3 49 44 060120 2 Pipe or 3 in Concentric 3t no disk NA NA 4 no disk 25 20 060140 ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBO 3 4 024040 2 Pipe or 2 in 1 1 2 32 27 036040 024060 036060 048060 Concentric 2 Pipe or 2 in Concentric 53 51 026080 2 2 048080 060080 9001 to 10 0004 048100 060100 2 3 2 3 pone Concentric 4T no disk 060140 Disk usage Unless otherwise specified use perforated disk assembly factory supplied in loose parts bag If one disk is stated separate 2 halves of perforated disk assembly and use shouldered disk half When using shouldered disk half install screen side toward inlet box TWide radius elbow Vent sizing for Canadian installations over 4500 ft 1370 m above sea level are subject to acceptance by the local authorities having jurisdiction NA Not Allowed pressure switch will not make NOTES 1 Do not use pipe size greater than those specified in table or incomplete combustion flame disturbance or flame sense lockout may occur 2 Size both the combustion air and vent pipe inde
83. or box drain tube di rectly from collector box drain to condensate trap as shown in Fig 9 d Determine appropriate length and cut e Connect to condensate trap f Clamp tube to prevent any condensate leakage 2 Inducer Housing Drain Tube AUXILIARY J BOX 7 CAP COLLECTOR BOK DRAIN TUBE BLUE AND WHITE STRIPED AN Eu in lt 5 LI co CONDENSATE d COLLECTOR BOX EXTENSION DRAIN TUBE COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE GREEN INDUCER HOUSING DRAIN TUBE VIOLET COLLECTOR BOX DRAIN TUBE BLUE DRAIN TUBE COUPLING COLLECTOR BOX TUBE PINK RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040 060 AND 080 HEATING INPUT FURNACES A00215 Fig 10 Horizontal Left Tube Configuration Remove factory installed cap and clamp from LOWER inducer housing drain connection Remove and discard UPPER molded inducer housing drain tube which was previously connected to conden sate trap Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed Use inducer housing drain tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to the condensate trap Connect inducer housing drain connectio
84. or vent connectors system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSC A General Combustion air and vent pipe fittings primers and solvents must NGPIC conform to American National Standards Institute ANSI stan dards and American Society for Testing and Materials ASTM standards See Table 6 for approved materials for use in the U S A TWINNING AND OR BLOWER OFF DELAY COMPONENT TEST TERMINAL J2 JUMPER HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX 24 V THERMOSTAT TERMINALS TRANSFORMER 24 VAC CONNECTIONS TEST TWIN 3 2 SEC LED OPERATION amp DIAGNOSTIC LIGHT PL1 LOW VOLTAGE MAIN 115 VAC L2 NEUTRAL HARNESS CONNECTOR CONNECTIONS 1 1 11 5 PRA 115 VAC L1 LINE PL2 HOT SURFACE VOLTAGE CONNECTION IGNITER amp INDUCER BLOWER SPEED MOTOR CONNECTOR SELECTION TERMINALS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02100 Fig 31 Control Center 23 and Canada Canada construct all combustion air and vent pipes for this unit of CSA or ULC listed schedule 40 PVC PVC DWV or ABS DWV pipe and pipe cement SDR pipe is NOT approved in Canada See Table 7 for maximum pipe lengths and Fig 36 37 38 39 and 40 for exterior piping arrangements NOTE Furnace combustion air and vent pipe connections are sized for 2 in pipe Any pipe size change should be m
85. ot affect readings This practice is particularly important with straight run ducts 2 When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise 3 Adjust temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise TABLE 12 GAS RATE CU FT HR SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 1 2 5 FOR 1 REVOLUTION ft cuft REVOLUTION 10 360 720 1800 50 11 327 655 1636 51 12 300 600 1500 52 13 277 555 1385 53 14 257 514 1286 54 15 240 480 1200 55 16 225 450 1125 56 17 212 424 1059 57 18 200 400 1000 58 19 189 379 947 59 20 180 360 900 60 21 171 343 857 62 22 164 327 818 64 23 157 313 783 66 24 150 300 750 68 25 144 288 720 70 26 138 277 692 72 27 133 267 667 74 28 129 257 643 76 29 124 248 621 78 30 120 240 600 80 31 116 232 581 82 32 113 225 563 84 33 109 218 545 86 34 106 212 529 88 35 103 206 514 90 36 100 200 500 92 37 97 195 486 94 38 95 189 474 96 39 92 185 462 98 40 90 180 450 100 41 88 176 439 102 42 86 172 429 104 43 84 167 419 106 44 82 164 409 108 45 80 160 400 110 46 78 157 391 112 47 76 153 383 116 48 75 150 375 120 49 73 147 367 124 44 TABLE 1
86. own in Fig 37 or 38 IV MULTIVENTING AND VENT TERMINATIONS When 2 or more 340MAV Furnaces are vented near each other each furnace must be individually vented NEVER common vent or breach vent 340MAV furnaces When 2 or more 340MAV furnaces are vented near each other 2 vent terminations may be installed as shown in Fig 41 42 43 44 and 45 but next vent termination must be at least 36 in away from first 2 terminations 5 5 ROOF 48 MAXIMUM SSS as 55 E M EU lt DS 7 COMBUSTION C VERTICAL SEPARATION WS AIR REDEEM CS E CO 1 a 5 83 4 FOR 3 VT 25 22 63 4 FOR 2 KIT CS Coe ose ANTICIPATED SNOW LEVEL Cas MAXIMUM OF 24 IN ABOVE ROOF Fig 36 Roof Termination Preferred SO 05 a yw wx US S SS oS 7 A MAINTAIN 12 IN 18 IN FOR CANADA MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE ROOF A93054 Fig 37 Concentric Vent and Combustion Air Roof Termination Preferred OVERHANG OR ROOF 12 MINIMUM Bo 12 IN SEPARATION lt T BETWEEN BOTTOM OF gt COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE COMBUSTION AIR WHICHEVER IS GREATER 87225 Fig 39 Sidewall Termination of 12 in More A87224 OVERHANG OR ROOF _ a a INU n s 1 MAXIMUM COMBUSTION AIR MAINTAIN 12 IN CLEARANCE ABOVE HIGHE
87. pendently then use the larger diameter for both pipes 3 Assume two 45 elbows equal one 90 elbow Long radius elbows are desirable and may be required in some cases 4 Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count 5 The minimum pipe length is 5 ft for all applications 6 Use 3 diameter vent termination kit for installations requiring 4 in diameter pipe COMBUSTION AIR INTAKE HOUSING 3 8 ID TUBE BURNER P i BOX ee ee MI 1 A le 3 16 DRILL COMBUSTION AIR PIPE oP TRAP MIN 93035 Fig 35 Intake Housing Plug Fitting Drain b Reposition elastometric rubber inducer housing outlet cap and clamp to appropriate unused inducer housing connection Tighten clamp 29 WARNING Inducer housing outlet must be stalled and fully seated against inducer housing Clamp must be tightened to prevent any condensate leakage Failure to follow this warning could result in electrical shock fire personal injury or death c Install pipe support factory supplied in loose parts bag into selected furnace casing vent pipe hole Pipe support should be positioned at bottom of casing hole WARNING Vent pipe must be installed and fully seated against inducer housing internal stop Clamp must be tig
88. ral e 36 Prime Condensate Trap With Water 36 Puree Gas Lines i ene 36 PANG juk nng Laa AN ANAN ERE ERE e n e beast 36 44 Set Gras Input Rate cecidere eet 36 44 Set Temperature osea cocti 44 Blower Off Delay Heat 44 Set Thermostat Heat Antcipator sseseeeeene 44 CHECK SAFETY CONTROLS 44 45 Check Primary Limit Control ttr 45 Check Pressure Switch creer tnt GANG HASTA 45 CHECKLIST those p ee tego 45 EFFICIENCY RATING CERTIFIED ama mms AN CERTIFIED As an ENERGY STAR O 9001 620 Partner Bryant Heating amp Cooling Systems Com pany has determined tht REGISTERED QUALITY SYSTEM this product meets the EN ERGY STAR guidelines for energy efficiency SAFETY CONSIDERATIONS CAUTION Application of this furnace should be in doors with special attention given to vent sizing and 5 5 A material gas input rate air temperature rise unit leveling and unit sizing Improper installation or misapplication of furnace can require excessive servicing or cause prema ture component failure AIRFLOW lt gt 4 UPFLOW HORIZONTAL HORIZONTAL RIGHT DOWNFLOW AIRFLOW AIRFLOW AIRFLOW A93041 Fig 1 Multipoise Orientations WARNING Improper
89. ration or perfor mance satisfaction NOTE Side return air openings can ONLY be used in UPFLOW configurations Install filter s as shown in Fig 23 Bottom return air opening may be used with all 4 orientations Filter may need to be cut to fit some furnace widths Install filter as shown in Fig 24 WASHABLE FILTER FILTER RETAINER SPRING Fig 23 Filter Installed for Side Inlet 0277 NOTE Remove and discard bottom closure panel when bottom inlet is used TABLE 2 FILTER INFORMATION FURNACE FILTER SIZE IN connect any portion of return air duct to back of furnace casing FILTER TYPE CASING FRAMED WIDTH IN Side Return 17 1 2 1 16 X25 X 11 21 1 16 25 1 1 20 25 14 24 1 2 1 or 2 16 25 171 1 24 X 25 X 11 Filters can be field modified by cutting frame as marked and folding to desired size Alternate sizes can be ordered from your distributor or dealer T Factory provided with furnace Bottom Return 1 16 X 25 X 1 B Downflow and Horizontal Furnaces Cleanable Cleanable Cleanable The return air duct must be connected to return air opening provided as shown in Fig 2 DO NOT cut into casing sides or back to attach any portion of return air duct Bypass humidifier connec tions should be made at ductwork or coil casing sides exterior to furnace 21 IN WIDE CASINGS ONLY SUPPORT RODS 3 EXTEND 1 4 ON EACH SIDE OF FILTER AND REST ON CASING FLANGE 1772
90. rea shown in Fig 39 or 40 in outside ambient by insulating pipes as indicated in Table 8 1 Determine combustion air and vent pipe diameters 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 fur nace model 3 Determine required insulation thickness for exposed pipe lengths NOTE Pipe length ft specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 7 B Two Pipe Termination Kit 1 Determine location for termination Consideration of the following should be made when determining an appropriate location for termination kit a Comply with all clearance requirements as stated in Table 5 b Termination kit should be positioned where vent vapors will not damage plants shrubs or air conditioning equip ment c Termination kit should be positioned so that it will not be affected by wind eddy such as inside building corners or allow recirculation of flue gases airborne leaves or light snow d Termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones balls etc e Termination kit should be positioned where vent vapors are not objectionable 2 Cut 2 holes 1 for each pipe of appropriate size for pipe size being used 3 Loosely install elbow in bracke
91. ressure No Orifice Manifold Orifice Manifold No Pressure No Manifold Orifice Manifold Orifice Pressure Pressure No Pressure No Orifice numbers shown in BOLD are factory installed Percents of derate are based on midpoints of U S altitude ranges AVG GAS SPECIFIC GRAVITY OF NATURAL GAS Manifold HEAT VALUE AT ALTITUDE Orifice Manifold BTU CU FT No Pressure Orifice No Pressure Orifice No SPECIFIC GRAVITY OF NATURAL GAS Manifold Pressure TABLE 9 MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued FOR USE WITH 040 THROUGH 120 SIZE FURNACES ONLY TABULATED DATA BASED ON 20 000 BTUH PER BURNER DERATED 2 FOR EACH 1000 FT ABOVE SEA LEVEL ALTITUDE vaLUE oss 060 gt oss RANGE ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure No Pressure 43 3 8 42 3 3 42 3 4 42 3 5 42 3 6 43 3 5 43 3 7 43 3 8 42 3 2 42 3 3 44 3 8 43 3 4 43 3 5 43 3 6 43 3 7 44 3 5 44 3 6 44 3 8 43 3 4 43 3 5 44 3 3 44 3 4 44 3 5 44 3 6 44 3 7 45 3 7 45 3 8 44 3 3 44 3 4 44 3 5 45 3 5 45 3 6 45 3 7 45 3 8 44 3 3 45 3 3 45 3 4 45 3 5 45 3 6 45 3 7 45 3 1 45 3 2 45 3 3 45 3 4 45 3 5 45 2 9 45 3 0 45 3 1 45 3 2 45 3 3 SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE eat vaLUE oss 060 gt os
92. rical shorts of 24 v wiring during instal lation service or maintenance may cause fuse to blow If fuse replacement is required use only a fuse of identical size 3 amp and type The control will flash code 24 when fuse needs replacement NOTE Use AWG No 18 color coded copper thermostat wire for lengths up to 100 ft For wire lengths over 100 ft use AWG No 16 wire Ill ACCESSORIES 1 Electronic Air Cleaner Two quick connect terminals marked EAC 1 and EAC 2 are provided for EAC connection See Fig 31 These terminals are energized with 115v 1 0 amp maximum during blower motor operation 17220 weibeiq V 061826 n9 SI 2 spuooes G Jo spuooes 06 yeay spuooes 081 10 061 OZ 06 suonoejes seb pL spuooes 2 dund y 10 00 spuooes 09 EL sinoy Jaye Jasel oyne 20 5 21 njsseoonsun JNO Jaye 11220 IM Noydo UONUB 21 pesn jou SI S45 ueuM 4 LL Sjojou uo jou MOTIBA OL peeds UO 5 10
93. rifice No Manifold Pressure AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT Orifice No Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure SPECIFIC GRAVITY OF NATURAL GAS Orifice Manifold No Pressure Manifold Pressure AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT Orifice Manifold No Pressure Orifice No Orifice No Manifold Pressure Manifold Pressure Orifice No Orifice No Manifold Pressure Orifice No Manifold Pressure Manifold Pressure Orifice No Manifold Pressure Orifice numbers shown in BOLD are factory installed Percents of derate are based on midpoints of U S altitude ranges 41 SPECIFIC GRAVITY OF NATURAL GAS 058 Orifice No Manifold Pressure TABLE 10 MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT Continued FOR USE WITH 140 SIZE FURNACES ONLY TABULATED DATA BASED ON 23 000 BTUH PER BURNER DERATED 2 FOR EACH 1000 FT ABOVE SEA LEVEL ALUDE wear vawue ose p 88 08 RANGE AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure No Pressure 41 3 6 41 3 7 41 3 8 40 3 6 40 3 8 42 3 7 42 3 8 41 3 6 41 3 7 41 3 8 42 3 5 42 3 6
94. s oe RANGE FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure Pressure No Pressure Pressure Pressure to 9000 17 derate SPECIFIC GRAVITY OF NATURAL GAS o 5 oe J 09 98 RANGE FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure Pressure to 10 000 19 derate Orifice numbers shown in BOLD are factory installed Percents of derate are based on midpoints of U S altitude ranges 40 TABLE 10 MODEL 340MAV ORIFICE SIZE AND MANIFOLD PRESSURE FOR CORRECT INPUT FOR USE WITH 140 SIZE FURNACES ONLY TABULATED DATA BASED ON 23 000 BTUH PER BURNER DERATED 2 FOR EACH 1000 FT ABOVE SEA LEVEL SPECIFIC GRAVITY OF NATURAL GAS AVG GAS HEAT VALUE oss J ow gt 54 956 ALTITUDE RANGE FT to 2000 U S A and Canada 0 derate ALTITUDE RANGE FT U S A Altitudes 2001to 3000 or Canada Altitude 2001 to 4500 5 derate 5 6 S lt 2 ALTITUDE RANGE FT to U S A Only 4000 7 derate AT ALTITUDE BTU CU FT Orifice Manifold No Pressure O
95. s for cooling the blower motor BL WM will operate at COOL speed When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to HEAT speed Jumper J2 can be cut to reduce the cooling off delay to 5 seconds See Fig 31 When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation IV HEAT PUMP MODE When installed with a heat pump the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles When the R to W and Y or R to W and Y and G circuits are energized the furnace control CPU will continue to turn on the blower motor BLWM at HEAT speed and begin a heating cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HEAT speed When the W input signal disappears the furnace control begins a normal inducer post purge period and the blower switches to COOL speed after a 3 second delay If the R to W and Y and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W and Y signals disappear leaving the G signal the blower motor BLWM will continue running the blower motor BLWM at HEAT speed after the selected blower OFF delay period is completed Control ini
96. s in kit 4 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 C Concentric Vent Air Termination Kit 1 Determine location for termination Consideration of the following should be made when determining an appropriate location for termination kit a Comply with all clearance requirements as stated in Table 5 Roof terminations Locate assembly through roof to ap em propriate height as shown in Fig 37 b Termination kit should be positioned where vent vapors will not damage plants shrubs or air conditioning equip ment c Termination kit should be positioned so it will not be affected by wind eddy such as inside building corners or that may allow recirculation of flue gases airborne leaves or light snow d Termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones balls etc e Termination kit should be positioned where vent vapors are not objectionable Cut one 4 in diameter hole for 2 in kit or one 5 diameter hole for 3 in kit 8 Sidewall terminations Locate assembly through sidewall with rain shield positioned no more than 1 in from wall as shown in Fig 38 5 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping 6 Check required dimensions as sh
97. ssory subbase or factory approved air condition ing 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 C 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 IV RETURN AIR CONNECTIONS 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 commu nicating 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 in the closed position WARNING Never connect return air ducts to the back of the furnace Return air duct connections on furnace side s permitted in upflow applications only A failure to follow this warning could result in fire personal injury or death A Upflow Furnaces The return
98. t and place assembly on combustion air pipe Roof terminations Loosely install pipe coupling on prop erly cut vent pipe Coupling must be positioned so bracket will mount as shown in Fig 36 For applications using combustion air pipe option indi cated by dashed lines in Fig 36 install 90 street elbow into 90 elbow making U fitting A 180 U fitting may be used Sidewall terminations Install bracket as shown in Fig 39 or 40 For applications using vent pipe option indicated by dashed lines in Fig 39 rotate vent elbow 90 from position shown in Fig 39 4 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping TABLE 8 MAXIMUM ALLOWABLE EXPOSED VENT PIPE LENGTH FT WITH AND WITHOUT INSULATION WINTER DESIGN TEMPERATURE AMBIENT WINTER DESIGN MAX PIPE TEMPERATURE DIAMETER CF FURNACE SIZE WITHOUT WITH 3 8 IN OR INSULATION THICKER INSULATIONT PO PO PO PO PO PO Pipe length ft specified for maximum pipe lengths located in unconditioned spaces Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 7 T Insulation thickness based R value of 3 5 per in 5 Check required dimensions as shown in Fig 36 39 or 40 3 Loosely assemble concentric vent air termination compo nents together using instruction
99. t be airtight and watertight Pipes must also terminate exactly as shown in Fig 36 37 38 39 or 40 Failure to follow this warning could result in property damage personal injury or death TABLE 5 COMBUSTION AIR AND VENT PIPE TERMINATION CLEARANCES NGETEN CLEARANCE FT U S A Canada Above grade level or above antici 1 m pated snow depth Water heater Dryer vent See Note 5 See Note 5 From plumbing vent stack 3 From any mechanical fresh air intake See Note 4 For furnaces with an input capacity equal to or less than 100 000 Btuh from any non mechanical air supply windows or doors which can be opened or combustion air opening For furnaces with an input capacity greater than 100 000 Btuh from any nonmechanical air supply windows or doors which can be opened or combustion air opening From service regulator vent electric and gas meters and relief equipment See Note 6 See Note 6 Above grade when adjacent to public walkway T 18 in above roof surface in Canada NOTES Note 3 Note 3 1 If installing 2 adjacent Furnaces refer to Multiventing and Vent Terminations section for proper vent configurations 2 When locating combustion air and vent terminations consideration must be given to prevailing winds location and other conditions which may cause recirculation of the appliance s own flue products or the flue products of adjacent vents Recirculation can cause p
100. th 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 NFGC or NSCNGPIC 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 FURNACE NOT IN HORIZONTAL SECTION PIPE DIAMETER TRANSITION IN VERTICAL SECTION A93034 Fig 32 Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration 9A CAUTION Combustion air must not be taken from inside structure because inside air is frequently contami nated 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 prod ucts Locate combustion air inlet as far as possible from swimming pool and swimming pool pump house Excessive exposure to contaminated combustion air will result in safety and performance related problems WARNING Solvent cements are combustible Keep away from heat sparks and open flame Use only in well ventilated areas Avoid breathing in vapor or allowing contact with skin or eyes Failure to follow this warning could result in fire property damage personal injury or death WARNING combustion air and vent pipes mus
101. tiates 90 sec blower only on period before starting another heat pump cycle if there is a power interruption Anytime control senses false flame control locks out of heating mode This reaction occurs because control ignores W input due to false flame signal and as a result sees only Y input and goes into cooling mode blower off delay All other control functions remain in standard format NOTE EAC 1 terminal is energized whenever blower operates HUM terminal is only energized when gas valve is energized V COMPONENT TEST NOTE The furnace control component test allows all compo nents to run for a short time except the gas valve and humidifier terminal HUM are not energized for safety reasons The EAC 1 terminal is energized when the blower is energized This feature helps diagnose a system problem in case of a component failure The component test feature will not operate if any thermostat signal is present ant the control and not until all time delays are completed NOTE Record the status code BEFORE opening the blower access door and before shutting off power to the furnace Opening the blower access door will open the blower door switch and shut off power within the furnace When power to the furnace is shut off by either method the status code will be lost because the code is not stored while power is removed for any reason To Begin Component Self Test WARNING Blower access panel door switch opens 115 power to control c
102. urnace must have a 115 v power supply properly con nected and grounded Proper polarity must be maintained for correct operation NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control center LED status light will flash rapidly and furnace will not operate 2 Thermostat wire connections at terminals R W G and Y 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 CAUTION These furnaces are equipped with a manual reset limit switch in burner box This switch will open and shut off power to gas control if an overheat condition flame rollout occurs in burner enclosure Correct inad equate combustion air supply or improper venting condi tion and reset switch DO NOT jumper this switch Failure to follow this caution will result in intermittent unit operation or performance satisfaction Before operating furnace check flame rollout manual reset switch for continuity If necessary press button to reset switch PRIME CONDENSATE TRAP WITH WATER CAUTION Condensate trap must be PRIMED or proper draining may not occur The condensate trap has 2 internal chambers which can ONLY be primed by pour ing water into the inducer drain side of condensate trap Failure to follow this c
103. using as a guide Install a e Insert 2 in diameter pipe into intake housing teld supplied No G or Nor Se metal NOTE A 2 in diameter pipe must be used within the furnace housing or fitting may cause air leakage to occur casing Make all pipe diameter transitions outside furnace casing a COMBUSTION AIR PIPE COMBUSTION AIR PIPE NOTE DO NOT OVERTIGHTEN SCREW Breakage of intake A plugged drain connection has been provided on this f Install casing hole filler cap factory supplied in loose fitting for use when moisture is found in combustion air parts bag in unused combustion air pipe casing hole intake pipe and combustion box g Drill a 1 8 in hole in 2 in combustion air pipe using hole in intake housing as a guide NOTE Moisture in combustion air intake may be result of improper termination Ensure combustion air intake pipe termina tion is similar to that shown in Fig 36 37 38 39 and 40 so it will h Install a field supplied No 6 or No 8 sheet metal screw not be susceptible to areas where light snow or other sources of into combustion air pipe moisture could be pulled in NOTE DO NOT OVERTIGHTEN SCREW Breakage of intake If use of this drain connection is desired drill out fitting s housing or fitting may cause air leakage to occur tap plug with a 3 16 in drill and connect a field supplied NOTE Do not attach combustion air intake pipe permanently to combustion air intake housing since it
104. vid3o3u 30185 01915 HLHV3 IVNIAH3 L M3HOS Od 10H1NOO 07314 OVASL L 4 2 OVAS HL ONIHIM TWNIWY3L 1OHLNOO 808 TWNIWYAL GAY VIANQ OWAPZ OWAS LL H3INHOJSNVH L TWNIWY3L 9 1531 LN3NOdWOO O N LSdS HOLIMS 3unssaud NOISN31X3 LINDYIO HOLO3NNOO ISH LINDYIO 2 LINDYIO 2 YOLOSNNOO 89d OU1NOO QHVO8 LINDYIO Q31NIHd HOLIMS 1 QVOTH3AO HOLOW 1VNH3LNI L3S38 OL0V NIML LSSL Sud 99 10 ON 1545 L3S3Y OLNV HOLIMS 51 O N LSdS HOLIMS SHNSSAYd SVD Sd91 53800 SNIWLS HOS 9NLLLIN3 LHOTT KOS ar H3dlAnr 130 440 er 80193136 3 0 H3MO 18 O N LSdS HOLIMS M90 IH31NI TANVd 55300 O N LSdS HOLOW OSd YOLOW 14 50 NOLLO3NNOO YAISICINNH WnH 07 1595 H31IN9I SOVSYNS LOH YISH OVA SLL 3OWSYNS LOH ISH 15 SAIVASVD 21 HAD ANVONNGS3Y 3A1VA SVD NO 1N3MdIno3 aariadns 9 GATIVLSNI 01315 391430 14 8 LINOYIO HO ISNA e
105. with CD5 or CK5 Coil Assembly or KCAKC Coil Box Upflow Applications Downflow Applications on Non Combustible Flooring Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box Upflow Applications Downflow Applications on Non Combustible Flooring Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 15 PERFORATED DISCHARGE DUCT FLANGE NO YES YES A93029 Fig 21 Duct Flanges Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guide lines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design static pressure ANGLE IRON OR EQUIVALENT A ROD LOCATION USING DIMPLE LOCATORS SEE DIMENSIONAL 3 g IN HEX NUT DWG FOR amp WASHER 4 LOCATIONS REQD PER ROD A PREFERRED ROD LOCATION NOTES B ALTERNATE ROD LO
106. with electrical connections make certain that voltage frequency and phase correspond to that specified on unit rating plate Also check to be sure that service provided by power supply is sufficient to handle load imposed by this equipment Refer to rating plate or Table 4 for equipment electrical specifi cations Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2002 and any local codes or ordinances that might apply For Canadian installations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authorities having jurisdiction Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace See Table 4 for wire size and fuse specifications A disconnecting means must be located within sight from and readily accessible to furnace CAUTION Do not connect aluminum wire between A disconnect switch and furnace Use only copper wire See Fig 28 Failure to follow this caution will result in intermittent unit operation or performance satisfaction NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control center LED status indicator light will flash rapidly and furnace will NOT operate ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY amp Fig 26 Bottom Filter Arrangement A00290 ALTERNATE FIELD LOCATION FACTORY Bros y INSTALLE
107. y 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 HEATING MODE See Fig 27 for thermostat connections The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the pressure switch contacts PRS are open and starts the inducer motor IDM a Inducer Prepurge Period As the inducer motor IDM comes up to speed the pressure switch contacts PRS close 24 vac power is supplied for a field installed humidifier at the HUM terminal and the control begins a 15 second prepurge period b Igniter Warm Up At the end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 second igniter warm up period 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 ignited by the Hot Surface Igniter HSI Five seconds after the GVR closes a 2 second flame period begins The HSI igniter will remain ener gized until the flame is sensed or until the 2 second flame proving period begins d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the b
108. ypical field 115 v and 24 v wiring Check all factory and field electrical connections for tightness FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING THERMOSTAT TERMINALS FIELD SUPPLIED DISCONNECT 208 230 OR e 460 V THREE PHASE _ 5 4 PHASE CONDENSING UNIT TWO WIRE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire 02174 Fig 27 Typical Heating and Cooling Application Wiring Diagram 19 Field supplied wiring shall conform with the limitations of 63 F 35 C rise WARNING Blower access panel door switch opens 115 power to control center No component operation can occur Do not bypass or close switch with panel removed Failure to follow this warning could result in personal injury or death CAUTION Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and burner box screw Failure to follow this caution will result in intermittent unit operation 1 115 V WIRING Before proceeding

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