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recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch un-
grounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with

static electricity), firmly touch furnace again before touch-
ing 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 355MAV Multipoise Condensing Gas-Fired Furnaces are
A.G.A./C.G.A. certified for natural and propane gases and for
installation in alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory-shipped for use
with natural gas. An A.G.A./C.G.A. listed gas conversion kit is
required to convert furnace for use with propane gas.
These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring. In
downflow installations, accessory floor base MUST be used when
installed on combustible materials and wood flooring. Special base
is not required when this furnace is installed on manufacturer’s
Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No.
KCAKC is used. The design of this furnace line is not
A.G.A./C.G.A. certified for installation in mobile homes, recre-
ation vehicles, or outdoors. These furnaces are suitable for
installation in a residence built on site or a manufactured residence
completed at final site.
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.
These furnaces are shipped with the following materials to assist in
proper furnace installation. These materials are shipped in the main
blower compartment.

Installer Packet includes:

Installation, Start-Up, and Operating Instructions
Service and Maintenance Procedures
User’s Information Manual
Warranty Certificate

Loose Parts Bag includes:

Quantity

Pressure tube extension

1

Collector box or condensate trap extension tube

1

Inducer housing drain tube

1

1/2-in. CPVC street elbow

2

Drain tube coupling

1

Drain tube coupling grommet

1

Vent and combustion-air pipe support

2

Combustion-air pipe perforated disk assembly

1

Before installing the furnace in the United States, refer to the
current edition of the NFGC and the NFPA 90B. For further
information, the NFGC and the NFPA 90B are available from
National Fire Protection Association Inc., Batterymarch Park,
Quincy, MA 02269; American Gas Association, 1515 Wilson
Boulevard, Arlington, VA 22209; or from Literature Distribution.
Before installing the furnace in Canada, refer to the current edition
of the NSCNGPIC. Contact Standards Department of Canadian
Gas Association, 55 Scarsdale Road, Don Mills, Ontario, Canada
M3B 2R3.

Installations must comply with regulations of serving gas supplier
and local building, heating, plumbing, or other codes in effect in
area in which installation is made. In absence of local codes,
installation must conform with NFGC.

Canadian installations must be made in accordance with NSCNG-
PIC and all authorities having jurisdiction.

These instructions cover minimum requirements for a safe instal-
lation and conform to existing national standards and safety codes.
In some instances, these instructions exceed certain local codes
and ordinances, especially those that may not have kept pace with
changing residential construction practices. We require these
instructions as a minimum for a safe installation.

CAUTION:

Application of this furnace should be in-

doors with special attention given to vent sizing and
material, gas input rate, air temperature rise, unit leveling,
and unit sizing. Improper installation or misapplication of
furnace can require excessive servicing or cause prema-
ture component failure.

WARNING:

Improper 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.

For accessory installation details, refer to applicable installation
literature.

APPLICATIONS

I.

GENERAL

Some assembly and modifications are required for furnaces
installed in any of the 4 applications shown in Fig. 1. All drain and
pressure tubes are connected as shown in Fig. 5. See appropriate
application instructions for these procedures.

II.

UPFLOW APPLICATIONS

An upflow furnace application is where furnace blower is located
below combustion and controls section of furnace, and conditioned
air is discharged upwards.

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.

B.

Condensate Trap Tubing (Factory-Shipped

Orientation)

NOTE:

See Fig. 5 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

—4—

Summary of Contents for 355M-40-4

Page 1: ...26 29 Multiventing and Vent Terminations 29 CONDENSATE DRAIN 29 General 29 Application 29 Condensate Drain Protection 29 SEQUENCE OF OPERATION 31 34 Self Test Mode 31 Heating Mode 31 32 Heating Mode T...

Page 2: ...TLET 26 15 16 28 1 2 22 5 16 19 13 16 5 8 5 16 1 39 7 8 22 1 4 TYP 11 16 7 16 24 3 16 BOTTOM INLET 18 1 4 22 11 16 2 IN COMBUSTION AIR CONN 1 2 IN DIA GAS CONN 7 8 IN DIA POWER CONN 1 2 IN DIA THERMOS...

Page 3: ...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...

Page 4: ...rican Gas Association 1515 Wilson Boulevard Arlington VA 22209 or from Literature Distribution Before installing the furnace in Canada refer to the current edition of the NSCNGPIC Contact Standards De...

Page 5: ...ation An alternate location for the condensate trap is the left hand side of casing See Fig 2 and 6 NOTE If the alternate left hand side of casing location is used the factory connected drain and reli...

Page 6: ...ck 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 inst...

Page 7: ...nnected 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 st...

Page 8: ...ction E Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommenda tions and procedures IV HORIZONTAL LEFT SUPPLY AIR DISCHARGE APPLICATIONS A horizontal left furnac...

Page 9: ...ace 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 cond...

Page 10: ...sure tube pink label is factory connected to the pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications This tube MUST be dis connected and used for the condensate...

Page 11: ...lution or ventilation air This furnace must be installed so electrical components are protected from water Locate furnace as close to center of air distribution system as possible Locate furnace so co...

Page 12: ...rtant for low fire only installation III 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...

Page 13: ...talled from Table 1 2 Construct hole in floor per dimensions specified in Table 1 and Fig 13 3 Construct plenum to dimensions specified in Table 1 and Fig 13 4 If downflow subbase KGASB is used instal...

Page 14: ...lications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 19 19 20 20 24 1 2 Upflow Applications 23 24 1 8 23 5 8 24 3 4 Downflow Applications o...

Page 15: ...on 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 F...

Page 16: ...d 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 fille...

Page 17: ...gas valve See Fig 48 Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace has been attached In Canada refer to current edition of NSCNGPIC If pr...

Page 18: ...n of field wiring See Fig 24 The 24 v circuit contains a 3 amp automotive type fuse located on control center See Fig 25 Any electrical shorts of 24 v wiring during installation service or maintenance...

Page 19: ...2 CIRCUIT HSI CONNECTOR PL5 6 CIRCUIT MODEL PLUG PL6 3 CIRCUIT COMM CONNECTOR PL7 12 CIRCUIT INDUCER MTR CONNECTOR PL9 2 CIRCUIT HSI CONNECTOR PL10 9 CIRCUIT BLOWER ADAPTER CONNECTOR PL11 1 CIRCUIT I...

Page 20: ...or 12 gage maximum solid or stranded wire 4 Route EAC leads through right hand wire grommet TABLE 4 ELECTRICAL DATA UNIT SIZE VOLTS HERTZ PHASE OPERATING VOLTAGE RANGE MAXIMUM UNIT AMPS UNIT AMPACITY...

Page 21: ...ppliance shall operate continuously 5 Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner opera tion Use the flame of a match or candle 6 Af...

Page 22: ...ckout may occur NOTE Do not count elbows or pipe sections in terminations or within furnace See shaded areas in Fig 31 32 33 34 and 35 TABLE 5 COMBUSTION AIR AND VENT PIPE TERMINATION CLEARANCES LOCAT...

Page 23: ...take housing plug fitting in appropriate unused intake housing connection c Insert perforated disk assembly factory supplied in intake housing where combustion air intake pipe will be connected d Inst...

Page 24: ...2 Pipe or 2 In Concentric 1 1 2 42 37 32 27 22 17 2 70 70 70 70 70 70 042060 2 Pipe or 2 In Concentric 1 1 2 42 37 32 27 22 17 2 70 70 70 70 70 70 042080 060080 2 Pipe or 2 In Concentric 1 1 2 25 20...

Page 25: ...7 NA NA NA 2 62 60 58 56 51 46 060100 2 Pipe or 2 In Concentric 2 27 22 17 12 7 NA 2 1 2 62 60 58 56 55 53 060120 2 Pipe or 3 In Concentric 3 43 41 39 37 35 34 ALTITUDE UNIT SIZE TERMINATION TYPE PIP...

Page 26: ...ide 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 b...

Page 27: ...AIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER 90 VENT 12 IN SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT BRACKET COUPLING 12 MINIMUM OVERHANG...

Page 28: ...tall 90 street elbow into 90 elbow making U fitting A 180 U fitting may be used Sidewall terminations Install bracket as shown in Fig 34 or 35 For applications using vent pipe option indicated by dash...

Page 29: ...e to corrosive nature of this condensate a condensate pH neutralizing filter may be desired Check with local authorities to determine if a pH neutralizer is required II APPLICATION The furnace A C and...

Page 30: ...m Separation A93056 COMBUSTION AIR VENT VENT A Fig 40 Sidewall Termination of More Than 12 in Dimension A is Touching or 2 In Maximum Separation A96130 VENT A COMBUSTION AIR COMBUSTION AIR Fig 38 Conc...

Page 31: ...4 Ignition sequence After HSI ignitor warm up period is completed the gas valve opens permitting gas flow to burners where it is ignited After 5 sec the HSI is de energized and a 2 sec flame sensing...

Page 32: ...ame is sensed control center holds gas valve open If burner flame is not sensed control center de energizes gas valve and ignition sequence is repeated NOTE Ignition sequence repeats 3 additional time...

Page 33: ...nues to operate completing a normal blower off delay 11 Post purge The inducer continues operating for 15 sec after gas valve is de energized B Two Speed Applications For details on 2 speed heat pump...

Page 34: ...5 for all furnace model sizes This compensates for high humidity conditions during cooling operation XI ZONE MODE When setup switch SW 5 MZ is in ON position blower motor control is the same as above...

Page 35: ...med by pour ing water into the inducer drain side of condensate trap 1 Remove upper inducer housing drain connection cap See Fig 46 2 Connect field supplied 1 2 in ID tube to upper inducer housing dra...

Page 36: ...are used In this mode main blower speed is recalculated once every minute while furnace is in low heat or continuous fan mode SW 6 COMP TEST OFF Turn switch to ON to initiate component test Furnace wi...

Page 37: ...e measured with the burner box cover REMOVED b Remove caps that conceal adjustment screws for low and high heat gas valve regulators See Fig 48 c Turn setup switch SW 2 on control center to ON positio...

Page 38: ...nada U S A 775 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 Altitudes 800 43 3 5 1 5 43 3 7 1 5 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 2001 825 44 3 8 1 6 43 3 4 1 5 43 3 6 1 5 43 3 7 1 5 43 3 8 1...

Page 39: ...2 1 3 42 3 3 1 4 42 3 4 1 4 725 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 750 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 775 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 43 3...

Page 40: ...No Manifold Pressure High Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low U S A Only 600 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 625 43 3 5 1 5 43 3 6 1...

Page 41: ...er hr k Multiply gas rate cu ft hr by heating value Btu cu ft l Turn setup switch SW 2 to OFF position and jumper R and W2 thermostat connections See Fig 25 This keeps furnace locked in high heat oper...

Page 42: ...and for varying heating cycle length NOTE When using an electronic thermostat set cycle rate for 3 cycles per hr 3 Return setup switch SW 2 to OFF position and replace thermostat on subbase CHECK SAFE...

Page 43: ...CM inducer motor is disconnected the furnace will shut itself down immediately Determine the reason pressure switches did not function properly and correct the condition 5 Turn off 115 v power to furn...

Page 44: ...nt of Rating Plate ________ Temperature Rise Adjusted Thermostat Anticipator ________ Anticipator Setting Adjusted or ________ Cycle Rate 3 Cycles per Hr Selected Safety Controls Check Operation _____...

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