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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. Connect collector box pressure tube (green label) to pres-

sure switch connection labeled COLLECTOR BOX.

4. Extend collector box pressure tube (pink label) which was

previously connected to pressure switch by splicing to
remaining small diameter tube (factory-supplied in loose
parts bag).

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

relief port connection.

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

7. Clamp tube to relief port connection.

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 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.

CAUTION:

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor
property damage.
Local codes may require a drain pan under entire furnace
and condensate trap when a condensing furnace is used in
an attic application or over a finished ceiling.

NOTE:

In Canada, installations shall be in accordance with

current NSCNGPIC and/or local codes.

A.

Condensate Trap Location

The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2 or 11.

To relocate condensate trap from the blower shelf to desired
location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs

inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2

or 11.)

4. Install casing hole filler cap (factory-supplied in loose parts

bag) into blower shelf hole where trap was removed.

Fig. 11—Horizontal Left Tube Configuration

A02288

CONDENSATE

TRAP

AUXILIARY

"

J

"

BOX

PLUG

CAP

INDUCER HOUSING
DRAIN TUBE (VIOLET)

COLLECTOR BOX
DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

060, AND 080 HEATING INPUT FURNACES

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)

DRAIN TUBE COUPLING

COLLECTOR BOX
TUBE (GREEN)

COLLECTOR

BOX EXTENSION

DRAIN TUBE

—10—

«
...
8
9
10
11
12
...
»

Содержание CONDENSING GAS FURNACE 355MAV

Страница 1: ...es from Common Vent Systems 22 Combustion Air and Vent Piping 25 Concentric Vent and Combustion Air Termination Kit Installation 31 Multiventing and Vent Terminations 34 Condensate Drain 34 General 34 Application 34 Condensate Drain Protection 35 START UP ADJUSTMENTS AND SAFETY CHECK 35 General 35 Select Setup Switch Positions 36 Prime Condensate Trap With Water 37 Purge Gas Lines 37 Sequence of O...

Страница 2: ... design certified for natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA listed gas conversion kit is required to convert furnace for use with propane gas See Fig 3 for required clearances to combustibles Maintain a 1 in clearance from combust...

Страница 3: ...ttom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM 17 5 16 24 1 2 27 9 16 TYP 27 5 8 29 11 16 TYP 30 13 16 32 5 8 TYP 33 1 4 TYP CONDENSATE DRAIN TRAP LOCATION ALTERNATE UPFLOW 7 8 IN DIA ACCESSORY POWER ENTRY 7 8 IN DIA POWER CONN CONDENSATE DRAIN TRAP LOCATION DOWNFLOW HORIZONTAL LEFT 26 15 16 24 1 2 22 5 16 2 IN COMBUSTION AIR CONN 1 2 IN DI...

Страница 4: ...ve or closet at Minimum Inches Clearance To Combustible Construction as described below This furnace requires a special venting system Refer to the installation instructions for parts list and method of installation This furnace is for use with schedule 40 PVC PVC DWV CPVC or ABS DWV pipe and must not be vented in common with other gas fired appliances Construction through which vent air intake pi...

Страница 5: ...frigeration and Air Conditioning Engineers ASHRAE 2001 Fundamentals Handbook Chapter 34 V ACOUSTICAL LINING AND FIBROUS GLASS DUCT US and CANADA current edition of SMACNA NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts VI GAS PIPING AND GAS PIPE PRESSURE TESTING US NFGC chapters 5 6 7 and 12 and national plumbing codes In the state of Massachusetts This product must be installed ...

Страница 6: ...ling NOTE In Canada installations shall be in accordance with current NSCNGPIC and or local codes 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 fac...

Страница 7: ...ameter 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 8 NOTE If the alternate left hand side of casing l...

Страница 8: ...s tube is plugged NOTE See Fig 7 or 8 or tube routing label on main furnace door to check for proper connections UPPER INDUCER HOUSING DRAIN CONNECTION Attached to the UPPER unused inducer housing drain connection is a cap and clamp This cap is used to prevent condensate leakage in this application Ensure this connection is capped NOTE See Fig 7 or 8 or tube routing label on main furnace door to c...

Страница 9: ...conden sate trap as shown in Fig 8 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...

Страница 10: ...perty damage Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling NOTE In Canada installations shall be in accordance with current NSCNGPIC and or local codes A Condensate Trap Location The condensate trap must be removed from the factory installed blower shelf location and relocated in sel...

Страница 11: ...d connect tube d Clamp tube to prevent any condensate leakage 3 Relief Port Tube a Extend collector box tube green label which was previously connected to condensate trap by splicing to small diameter tube factory supplied in loose parts bag b Route extended collector box pressure tube to relief port connection on condensate trap c Determine appropriate length cut and connect tube d Clamp tube to ...

Страница 12: ...conditioned air is discharged to the right CAUTION MINOR PROPERTY DAMAGE Failure to follow this caution may result in minor property damage Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling NOTE In Canada installations shall be in accordance with current NSCNGPIC Installation Codes and or l...

Страница 13: ...e switch in DOWNFLOW or HORIZON TAL RIGHT applications NOTE See Fig 13 or tube routing label on main furnace door to check for proper connections Relocate tubes as described below 1 Disconnect collector box pressure tube pink label attached to pressure switch 2 Extend collector box pressure tube green label which was previously connected to condensate trap relief port connec tion by splicing to sm...

Страница 14: ...ions The air temperature rise is within the rated rise range on the furnace rating plate and the firing rate has been set to the nameplate value The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all...

Страница 15: ... Fig 18 Holes in bottom closure panel may be used as guide locations 2 For each hole install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement NOTE Bottom closure must be used when leveling legs...

Страница 16: ...plications 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 on Non Combustible Flooring 22 7 8 19 23 1 2 19 5 8 Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 1 8 19 23 3 ...

Страница 17: ...on supports See Fig 23 Cut hanger bolts 4 each 3 8 in all thread rod to desired length Use 1 X 3 8 in flat washers 3 8 in lockwashers and 3 8 in nuts on hanger rods as shown in Fig 23 Dimples are provided for hole locations See Fig 2 Fig 22 Duct Flanges A93029 NO YES YES PERFORATED DISCHARGE DUCT FLANGE 210 MIN Fig 23 Crawlspace Horizontal Application A93304 NOTES ANGLE IRON OR EQUIVALENT B A ROD ...

Страница 18: ...ut 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 ins...

Страница 19: ... front filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall front filler panel and screws VII GAS PIPING Gas piping must be installed in accordance with national and local codes Refer to NFGC in the U S Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction Gas supply line should be a separate line running directly...

Страница 20: ...lacing it into service The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON at HI HEAT and OFF VIII ELECTRICAL CONNECTIONS See Fig 28 for field wiring diagram showing typical field 115 v and 24 v wiring Check all factory and field electrical connections for tightness WARNING ELECTRICAL SHOCK HAZARD Failure to ...

Страница 21: ...D GND FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 208 230 460 V WIRING 208 230 OR 460 V THREE PHASE 208 230 V SINGLE PHASE W W1 Y Y2 G C NOTES 1 2 3 4 5 Connect Y or Y Y2 terminal as shown for proper cooling operation Proper polarity must be maintained for 115 v wiring Use W2 with 2 stage thermostat when zoning If any of the original wire as supplied must be re...

Страница 22: ... connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115VAC 1 0 amps maximum and are energized during blower motor operation See Fig 32 2 Humidifier HUM Connect an accessory 24 VAC 0 5 amp maximum humidi fier if used to the 1 4 in male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip The HUM terminal is energized when...

Страница 23: ...HSI IDM Connector PL3 4 Circuit ECM BLWM Connector PL4 4 Circuit Model Plug Connector PL7 4 Circuit Communication Connector PL9 2 Circuit OAT Connector PL10 2 Circuit HSI Connector PL11 IDM Connector 12 Circuit PL12 1 Circuit Inductor Splice Connector PL13 16 Circuit ECM Blower Ctrl Connector PL14 5 Circuit ECM Blower Power Connector SW1 1 Manual Switch Status Code Recall SPST N O SW1 2 Manual Swi...

Страница 24: ... 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 corre...

Страница 25: ...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 a warm humid space CAUTION UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit operation When vent pipe is exposed to temperatures below freez ing such as when it passes through an unheated space or when a chimney is...

Страница 26: ...terline extended above or below vent terminal of the furnace to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 30 cm 12 30 cm O Clearance from a plumbing vent stack 3 91 cm 3 91 cm 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code 18 46 cm above roof s...

Страница 27: ... 5 elbows COMBUSTION AIR AND VENT PIPE ATTACHMENT NOTE All pipe joints must be cemented except attachment of combustion air pipe to inlet housing connection since it may be necessary to remove pipe for servicing 1 Attach combustion air pipe as follows a Determine location of combustion air intake pipe con nection to combustion air intake housing as shown in Fig 34 for application b Reposition comb...

Страница 28: ... pipe must be installed and fully seated against inducer housing internal stop Clamp must be tightened to prevent any condensate leakage 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 ...

Страница 29: ...0 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 15 10 5 NA 2 70 70 70 70 70 70 060100 2 Pipe or 2 In Concentric 2 38 33 28 23 18 13 2 1 2 70 70 70 70 70 70 060120 2 Pipe or 3 In Concentric 3 29 24 10 NA NA NA 3 59 59 58 57 57 56 Altitude Unit Size...

Страница 30: ...60100 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 Pipe Diameter In Number of 90 Elbows 1 2 3 4 5 6 9001 to 10000 042040 2 Pipe or 2 In Concentric 1 1 2 27 22 17 12 7 NA 2 57 55 53 51 49 47 042060 2 Pipe or 2 In Concentric 1 1 2 27 22 17 12 7 NA 2 57 55 53 51 49 47 042080 060080 2 Pipe ...

Страница 31: ...ing of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system EXTENDED EXPOSED SIDEWALL PIPES Sidewall combustion air and vent pipe terminations may be extended beyond area shown in Fig 40 or 41 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...

Страница 32: ...TAIN 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 OR ROOF COMBUSTION AIR ELBOW PARALLEL TO WALL Fig 39 Concentric Vent and Combustion Air Side Termination A93055 MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GR...

Страница 33: ...um Separation A93056 COMBUSTION AIR VENT VENT A Fig 46 Sidewall Termination of More Than 12 in Dimension A is Touching or 2 In Maximum Separation A96130 COMBUSTION AIR COMBUSTION AIR VENT A Fig 44 Concentric Vent and Combustion Air Side Termination Dimension A is Touching or 2 In Maximum Separation A93057 COMBUSTION AIR VENT A VENT 1 MAXIMUM TYP Fig 42 Rooftop Termination Dimension A is Touching o...

Страница 34: ...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 ...

Страница 35: ...ecommenda tions 1 Fold heat tape in half and wrap on itself 3 times 2 Locate heat tape between sides of condensate trap back See Fig 49 3 Use wire ties to secure heat tape in place Wire ties can be positioned in notches of condensate trap sides See Fig 49 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 manufacture...

Страница 36: ... desired airflow when thermostat is in continuous fan mode or to select low cooling airflow for two speed cooling units This setup feature allows continuous fan airflow or low cooling airflow to be adjusted To set desired continuous fan airflow or low cooling airflow 1 Remove main furnace door and blower access door 2 Locate CF setup switches on furnace control See Fig 32 3 Determine desired conti...

Страница 37: ... will start a 90 second blower only ON period two seconds after power is restored if the thermostat is still calling for gas heating The amber LED light will flash code 12 during the 90 second period after which the LED will be ON continuous as long as no faults are detected After the 90 second period the furnace will respond to the thermostat normally The blower door must be installed for power t...

Страница 38: ...cessary to operate the inducer motor during the low heat prepurge period and low heat mode NOTE The heat cycle can start in either high or low heat If a high heat cycle is initiated the furnace control CPU will de energize the high heat pressure switch relay HPSR to close the NC contact and continues to increase the inducer motor speed after the low heat pressure switch LPS closes When the high he...

Страница 39: ...delays described in item 1 above apply to 2 stage heating mode as well except for switching from low to high heat and vice versa 1 Switching From Low To High Heat If the thermostat R to W1 circuit is closed and the R to W2 circuit closes the furnace control CPU will de energize the high heat pressure switch relay HPSR to close the NC contact and slowly increase the inducer motor speed until the hi...

Страница 40: ...ed by the furnace control on the DHUM input the furnace control operates in Thermidistat mode If the DHUM input is low for more than 48 hours the furnace control reverts back to non Thermidistat mode The cooling operation described in item 3 above applies to operation with a Thermidistat The exceptions are listed below a Low cooling When the R to G and Y1 circuit is closed and there is a demand fo...

Страница 41: ...expired Turn on setup switch SW1 6 See Fig 32 NOTE The component test feature will not operate if the control is receiving any thermostat signals or until all time delays have expired The component test sequence is as follows a The furnace control CPU turns the inducer motor IDM ON at medium speed and keeps it ON through step c b After waiting 15 seconds the furnace control CPU turns the hot surfa...

Страница 42: ...ith Single Speed Air Conditioner Fig 55 Two Stage Furnace with Two Speed Air Conditioner A00276 A00277 Fig 56 Two Stage Furnace with Single Speed Heat Pump Dual Fuel A00278 Fig 57 Two Stage Furnace with Two Speed Heat Pump Dual Fuel 42 ...

Страница 43: ... Pump A00281 Fig 60 Two Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner See note 2 A00280 Fig 59 Dual Fuel Thermostat With Two Stage Furnace and Two Speed Heat Pump A02348 Fig 61 Single Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner 43 ...

Страница 44: ...pplications 10 NO connection should be made to the furnace HUM terminal when using a Thermidistat 11 Optional connection If wire is connected dip switch SW1 2 on furnace control should be set in ON position to allow Thermidistat Thermostat to control furnace staging 12 Optional connection If wire is connected ACRDJ jumper on furnace control should be removed to allow Thermidistat Thermostat to con...

Страница 45: ... 1 4 44 3 4 1 4 44 3 5 1 5 925 45 3 7 1 5 45 3 8 1 6 44 3 2 1 4 44 3 3 1 4 950 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 45 3 8 1 6 750 43 3 7 1 6 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 4001 775 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 800 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 to 825 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 850 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 5000 875 45 3 8 1 6 44 3 2 1 ...

Страница 46: ... 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 800 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 44 3 2 1 4 825 45 3 3 1 4 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 625 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 42 3 4 1 5 8001 650 43 3 5 1 5 43 3 6 1 5 43 3 8 1 6 42 3 2 1 3 675 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 to 700 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 44 3 8 1 6 725 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 9000 750 45 3 ...

Страница 47: ...ame should be clear blue almost transparent See Fig 64 j Remove jumpers R to W W1 and R to W2 3 Verify natural gas input rate by clocking gas meter NOTE Be sure all pressure tubing combustion air and vent pipes and burner enclosure front are in place when checking input by clocking gas meter a Calculate high altitude adjustment if required UNITED STATES At altitudes above 2000 ft this furnace has ...

Страница 48: ... Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings This practice is particularly important with straight run ducts 2 When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE Temperature rise can be determined for low heat opera tion by placing setup switch SW1 2 on furnace contr...

Страница 49: ...ol is to gradually block off return air after furnace has been operating for a period of at least 5 minutes 2 As soon as limit control has shut off burners a 33 status code will appear on furnace control 3 The return air opening should be quickly unblocked to permit normal air circulation By using this method to check the limit control it can be established that the limit is functioning properly a...

Страница 50: ...e Sloped To Furnace Pipe Insulation ________ Over Ceilings ________ Low Ambient Exposed Pipes Condensate Drain ________ Unit Level or Pitched Forward ________ Internal Tubing Connections Free of Kinks and Traps ________ External Drain Connection Leak Tight and Sloped ________ Condensate Trap Primed before Start Up ________ Heat Tape Installed if Required CHECKLIST START UP ________ Gas Input Rate ...

Страница 51: ... 51 ...

Страница 52: ...video based formats and materials All include video and or slides plus companion book Classroom ServiceTraining plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 644 5544 Packaged Service Training Classroom Service Training 2005 Br...

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