Bryant 330AAV Instructions and recipes

NOTE: Read the entire instruction manual before starting the
installation.
This symbol →indicates a change since the last issue.
Index Page
SAFETY CONSIDERATIONS.....................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE...........................................................................3
Dimensional Drawing...............................................................2
Clearances to Combustibles......................................................3
INTRODUCTION.......................................................................3-4
LOCATION....................................................................................4
General......................................................................................4
Location Relative to Cooling Equipment ................................4
Hazardous Locations.................................................................4
AIR FOR COMBUSTION AND VENTILATION...................4-5
Unconfined Space..................................................................4-5
Confined Space......................................................................5-6
AIR DUCTS...................................................................................6
General......................................................................................6
Ductwork Acoustical Treatment...............................................6
Supply Air Connections............................................................6
Return Air Connections............................................................6
FILTER ARRANGEMENT .......................................................6-7
LEVELING LEGS (IF REQUIRED)............................................7
GAS PIPING..................................................................................8
ELECTRICAL CONNECTIONS...............................................8-9
115-v Wiring..........................................................................8-9
24-v Wiring...............................................................................9
Accessories................................................................................9
VENTING ....................................................................................10
START-UP, ADJUSTMENT, AND
SAFETY CHECK..............................................................10-21
General....................................................................................10
Sequence of Operation......................................................11-14
Adaptive Heating Mode....................................................11-12
Non-Adaptive Heating Mode .................................................12
Cooling Mode .........................................................................12
Continuous Blower Mode.......................................................14
Heat Pump Mode....................................................................14
Defrost.....................................................................................14
Start-Up Procedures...........................................................14-15
Adjustments .......................................................................15-20
Set Gas Input Rate..................................................................15
Set Temperature Rise........................................................16-20
Set Thermostat Heat Anticipator............................................20
Check Safety Controls.......................................................20-21
Checklist..................................................................................21
SAFETY CONSIDERATIONS
Installation and servicing of heating equipment can be hazardous
due to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. In the United States, refer to the National
Fuel Gas Code (NFGC) NFPA No. 54-1999/ANSI Z223.1-1999.
In Canada, refer to the current edition of the National Standard of
Canada CAN/CGA- B149.1- and .2-M95 Natural Gas and Propane
Installation Codes (NSCNGPIC) and Amendment No. 1. Wear
safety glasses and work gloves. Have fire extinguisher available
during start-up and adjustment procedures and service calls.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and CAU-
TION. These words are used with the safety-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard 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.
These instructions cover 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 resi-
dential construction practices. We require these instructions as a
minimum for a safe installation.
ama
CERTIFIED
REGISTERED QUALITY SYSTEM
installation, startup,
and operating instructions
UPFLOW 2-SPEED,
2-STAGE, INDUCED-COMBUSTION
GAS-FIRED FURNACE
Cancels: II 330A-40-8 II 330A-40-9
12-00
330AAV
Series B
or C
—1—

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
CAUTION: Electrostatic discharge can affect electronic
components. Take precautions during furnace installation
and servicing to protect the furnace electronic control.
Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the
procedure. These precautions will help to avoid exposing
the control to electrostatic discharge by putting the
furnace, the control, and the person at the same electro-
static potential.
1. Disconnect all power to the furnace. DO NOT TOUCH
THE CONTROL OR ANY WIRE CONNECTED TO THE
CONTROL PRIOR TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.
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.).
TABLE 1—DIMENSIONS (IN.)
UNIT SIZE A D E FLUE COLLAR SHIP. WT
036040 14-3/16 12-9/16 12-11/16 4 124
024060 14-3/16 12-9/16 12-11/16 4 132
036060 14-3/16 12-9/16 12-11/16 4 134
042080 17-1/2 15-7/8 16 4 150
048080 21 19-3/8 19-1/2 4 154
036100 17-1/2 15-7/8 16 4 160
048100 21 19-3/8 19-1/2 4 166
060100 24-1/2 22-7/8 23 4 184
048120 21 19-3/8 19-1/2 5 178
060120 24-1/2 22-7/8 23 5 194
060135 24-1/2 22-7/8 23 5 204
→Fig. 1—Dimensional Drawing A00210
A
D13⁄16″
E11⁄16″
11⁄16″
28 1⁄2″
39 7⁄8″
24 5⁄16″
11⁄16″3″
2 1⁄16″
1″
12 5⁄16″
5 3⁄8″
5 13⁄16″
2 3⁄8″
AIR INLET
7⁄8-IN. DIA HOLE
POWER ENTRY
7⁄8-IN. DIA
ACCESSORY
1 3⁄4-IN.DIA HOLE
GAS ENTRY
1⁄2-IN. DIA HOLE
THERMOSTAT
WIRE ENTRY
SIDE INLET
VENT CONN
1. Two additional 7⁄8-in. dia holes are located in the top plate.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer's recommendations for equivalent diameters.
a. For 800 CFM–16-in. round or 141⁄2x 12-in. rectangle.
b. For 1200 CFM–20-in. round or 141⁄2x 191⁄2-in. rectangle.
c. For 1600 CFM–22-in. round or 141⁄2x 231⁄4-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific
use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
NOTES:
5 3⁄8″
5 13⁄16″
2 3⁄8″
2 11⁄16″
1″
2 1⁄16″19″
13⁄16″
7⁄8-IN. DIA
POWER ENTRY
AIRFLOW
OUTLET
1 1⁄2-IN.DIA
R.H. GAS ENTRY
7⁄8-IN. DIA ACCESSORY
1⁄2-IN. DIA THERMOSTAT
WIRE ENTRY
SIDE INLET 141⁄2″
1″
231⁄4″
SIDE RETURN
DUCT LOCATION
13⁄4″
TYP 1″
5⁄8″
TYP
—2—

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 model 330AAV Series B or C Furnace is available in sizes
40,000 through 133,000 Btuh input capacities.
The design of the upflow gas-fired furnace is CSA (A.G.A. and
C.G.A.) design-certified for use with natural and propane gases
and for installation on combustible wood flooring, in alcoves,
attics, basements, closets, or utility rooms. The design of this
furnace line is not CSA (A.G.A. and C.G.A.) design-certified for
installation in mobile homes, recreation vehicles, or outdoors.
Before installing the furnace in the United States, refer to the
current edition of the NFGC/NFPA 54/Z223.1 and the NFPA 90B.
For further information, the NFGC/NFPA 54/Z223.1 and NFPA
90B are available from National Fire Protection Association Inc.,
Batterymarch Park, Quincy, MA 02269; or American Gas Asso-
ciation, 1515 Wilson Boulevard, Arlington, VA 22209.
Before installing the furnace in Canada, refer to the current edition
of the NSCNGPIC. Contact Standard Sales CSA International
Approval Services of Canada, 178 Rexdale Boulevard, Etobicoke,
(Tronto) Ontario, Canada M9W 1R3.
Canadian installations must be made in accordance with NSCNG-
PIC and all authorities having jurisdiction.
Installation must comply with regulations of serving gas supplier
and local building, heating, plumbing or other codes in effect in the
area in which installation is made. In absence of local codes,
installation must conform with NFGC.
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, and unit
sizing. Improper installation or misapplication of the
furnace can require excessive servicing or cause prema-
ture component failure.
To aid in installation, troubleshooting, and service, a status code
label is located on the blower compartment door. This label
explains how to use the LED status indicator on the furnace control
which is viewed through the sight glass on the door.
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. A failure to
follow this warning can cause electrical shock, fire,
personal injury, or death.
For high-altitude installations, the high-altitude conversion kit
MUST be installed at or above 5500 ft above sea level. Obtain
high-altitude conversion kit from your area authorized distributor.
For accessory installation details, refer to applicable installation
literature.
NOTE: Remove all shipping brackets and materials before oper-
ating furnace.
Fig. 2—Clearances to Combustibles A98122
320325-101 REV. H
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
his forced air furn
nace is equipped for use with
atural gasat altitudes 0 - 10,000 ft (0-3,050m).
n accessory kit, supplied by the m
m
anufacturer,
all be used to convert to propane gas use or
y be required for some natural gas applications.
his
s
furnace is for indoor installation in
uilding constructed onsite.
his f
f
f
urnace may be install
led on combustible
oor
ring in alcove or closet at minimum clearance
mcombustible material.
his furnace ma
a
a
y be used with a Type B-1 Vent
nd may be vented in common with other gas-fired
pliances.
Clearance in inches.
0"
##
1" #
0"
1"
1"
30"
MIN
SIDE
FRONT
BCK
A
SERVIE
C
FRONT
SIE
U
FRNACE
#
TOP / PLENUM
D
For furnaces wider than 14.25 inches
(362mm) may be 0 inches.
For single wall vent type 6inches.
For Type B-1 vent type 3 inches.
#
#
Vent Clearance to combustibles:
For Single Wall vents 6 inches (6 po).
For Type B-1 vent type 1 inch (1 po).
This furnace is approved for UPFLOW installations only.
BOTTOM
DESSOUS
—3—

I. LOCATION
A. General
CAUTION: Do not use this furnace during construction
when adhesives, sealers, and/or new carpets are being
installed and curing. If the furnace is required during
construction, use clean outside air for combustion and
ventilation. Compounds of chlorine and fluorine, when
burned in combustion air, form acids which will cause
corrosion of the heat exchangers and metal vent system.
Some of these compounds are released from paneling and
dry wall adhesives, paints, thinners, masonry cleaning
materials, and many other solvents commonly used in the
construction process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
CAUTION: Do not install furnace in a corrosive or
contaminated atmosphere. Make sure all combustion and
circulating air requirements are met.
This furnace must be installed so the electrical components are
protected from water.
Locate furnace as near the center of the air distribution system and
chimney or vent as possible. The furnace should be installed as
level as possible. When a furnace is installed so that supply ducts
carry air to areas outside the space containing the furnace, return
air must also be handled by a duct(s) sealed to the furnace casing
and terminating outside the space containing the furnace.
Provide ample space for servicing and cleaning. Always comply
with minimum fire protection clearances shown on unit clearance
label. This furnace shall not be installed directly on carpeting, tile,
or any combustible material other than wood flooring.
B. Location Relative to Cooling Equipment
The cooling coil must be installed parallel with or on downstream
side of furnace to avoid condensation in heat exchangers. When
installed parallel with a furnace, dampers or other means used to
control the flow of air must prevent chilled air from entering
furnace. If dampers are manually operated, they must be equipped
with means to prevent operation of either unit unless damper is in
full-heat or full-cool position.
C. Hazardous Locations
II. AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3, Air for Combustion and
Ventilation, of the NFGC or applicable provisions of the local
building codes.
Canadian installations must be in accordance with NSCNGPIC
and all authorities having jurisdiction.
CAUTION: Air for combustion must not be contami-
nated by halogen compounds, which include fluoride,
chloride, bromide, and iodide. These elements are found
in aerosol sprays, detergents, bleaches, cleaning solvents,
salts, air fresheners, and other household products.
All fuel-burning equipment must be supplied with air for combus-
tion of fuel. Sufficient air MUST be provided to ensure there will
not be a negative pressure in the equipment room or space. In
addition, a positive seal MUST be made between furnace cabinet
and return-air duct to prevent pulling air from burner area and draft
safeguard opening into the circulating air.
CAUTION: The operation of exhaust fans, kitchen ven-
tilation fans, clothes dryers, or fireplaces could create a
negative air pressure condition at the furnace. Make-up
air must be provided for these devices, in addition to that
required by the furnace.
Combustion air requirements are determined by whether furnace is
in an UNCONFINED or CONFINED space.
A. Unconfined Space
An unconfined space must have at least 50 cu ft for each 1000
Btuh of input for all appliances (such as furnaces, clothes dryer,
water heaters, etc.) in the space.
NOTE: These furnaces are designed for a minimum continu-
ous return-air temperature of 60°F or intermittent operation
down to 55°F such as when used with a night setback
thermostat. Return-air temperature must not exceed a maxi-
mum of 85°F. Failure to follow these return-air temperature
limits may affect reliability of heat exchangers, motors, and
controls.
A99075
FRONT
RETURN
AIR
MAX 85°F MIN 55°F
°F°F
WARNING: When furnace is installed in a residential
garage, it must be installed so that burners and ignition
sources are located a minimum of 18 in. above floor. The
furnace must be located or protected to avoid physical
damage by vehicles. When furnace is installed in a public
garage, airplane hangar, or other building having a
hazardous atmosphere, unit must be installed in accor-
dance with requirements of National Fire Protection
Association, Inc.
A93044
18-IN. MINIMUM
TO BURNERS
—4—

For Example:
330AAV FURNACE HIGH-FIRE
INPUT BTUH MINIMUM SQ FT WITH 7-1/2 FT CEILING
40,000 267
60,000 400
80,000 534
100,000 667
120,000 800
133,000 887
If the unconfined space is of unusually tight construction, air for
combustion and ventilation MUST come from either the outdoors
or spaces freely communicating with the outdoors. Combustion
and ventilation openings must be sized the same as for a confined
space as defined below. Return air must not be taken from the
room unless an equal or greater amount of air is supplied to the
room.
B. Confined Space
A confined space is defined as a space whose volume is less than
50 cu ft per 1000 Btuh of total input ratings of all appliances
installed in that space. A confined space MUST have provisions
for supplying air for combustion, ventilation, and dilution of flue
gases using 1 of the following methods. (See Fig. 3 and Table 2.)
NOTE: In determining free area of an opening, the blocking
effect of louvers, grilles, and screens must be considered. If free
area of louver or grille design is unknown, assume that wood
louvers have a 20 percent free area and metal louvers or grilles
have a 60 percent free area. Screens, when used, must not be
smaller than 1/4-in. mesh. Louvers and grilles must be constructed
so they cannot be closed.
The size of the openings depends upon whether air comes from
outside of the structure or an unconfined space inside the structure.
1. All air from inside the structure requires 2 openings (for
structures not usually tight):
a. Each opening MUST have at least 1 sq in. of free area
per 1000 Btuh of total input for all equipment within the
confined space, but not less than 100 sq in. per opening.
(See Fig. 3 and Table 2.) The minimum dimension of air
openings shall not be less than 3 in.
b. If building is constructed unusually tight, a permanent
opening directly communicating with the outdoors shall
be provided. See item 2 below.
c. If furnace is installed on a raised platform to provide a
return-air plenum, and return air is taken directly from
hallway or space adjacent to furnace, all air for combus-
tion must come from outdoors.
2. Air from outside the structure requires 1 of the following
methods:
a. If combustion air is taken from outdoors through 2
vertical ducts, the openings and ducts MUST have at
least 1 sq in. of free area per 4000 Btuh of total input for
all equipment within the confined space. (See Fig. 4 and
Table 2.)
b. If combustion air is taken from outdoors through 2
horizontal ducts, the openings and ducts MUST have at
least 1 sq in. of free area per 2000 Btuh of total input for
all equipment within the confined space. (See Fig. 4 and
Table 2.)
c. If combustion air is taken from outdoors through a single
opening or duct (horizontal or vertical) commencing
within 12 in. of the top of the confined space, opening
and duct MUST have at least 1 sq in. of free area per
3000 Btuh of the total input for all equipment within the
confined space and not less than the sum of the areas of
all vent connectors in the confined space. (See Fig. 4 and
Fig. 3—Confined Space: Air for Combustion and Ventilation
from an Unconfined Space
A89012
SUPPLY
AIR
6″MIN
(FRONT) †
RETURN AIR
VENT THROUGH ROOF
1 SQ IN.
PER 1000
BTUH*IN DOOR
OR WALL
12″MAX
1 SQ IN.
PER 1000
BTUH*IN DOOR
OR WALL
12″MAX
INTERIOR
HEATED
SPACE
* Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
†Minimum of 3 in. when type-B1 vent is used.
UNCONFINED
SPACE
CONFINED SPACE
Fig. 4—Confined Space: Air for Combustion and Ventilation
from Outdoors
A89013
1 SQ IN.
PER
4000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
SUPPLY
AIR
VENT
THROUGH
ROOF
D
B
A
C
E
1 SQ IN.
PER 4000
BTUH*
DUCT
TO
OUTDOORS
RETURN AIR
1 SQ IN.
PER 2000
BTUH*
1 SQ IN.
PER 2000
BTUH*
DUCTS
TO
OUTDOORS
12″MAX
12″MAX 12″MAX
Use any of the following
combinations of openings:
A & B C & D D & E F & G
NOTE:
*Minimum dimensions of 3 in.
CONFINED SPACE
12″
MAX
12″
MAX
OUTDOORS
1 SQ IN.
PER
4000
BTUH*
F
G
—5—

Table 2.) Equipment clearances to the structure shall be
at least 1 in. from the sides and back and 6 in. from the
front of the appliances.
When ducts are used, they must be of the same cross-sectional area
as the free area of the openings to which they connect. The
minimum dimension of ducts must not be less than 3 in. (See Fig.
4.)
AIR DUCTS
I. GENERAL REQUIREMENTS
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA) or
American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE). Or consult factory The Air Systems Design
Guidelines reference tables available from your local distributor.
The duct system should be sized to handle the required system
design CFM at the design static pressure.
When a furnace is installed so that the supply ducts carry air to
areas outside the space containing the furnace, the return air must
also be handled by a duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply- and return-duct connections to furnace with code
approved tape or duct sealer.
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.
II. DUCTWORK ACOUSTICAL TREATMENT
Metal duct systems that do not have a 90 degree elbow and 10 ft
of main duct to the first branch take-off may require internal
acoustical lining. As an alternative, fibrous ductwork may be used
if constructed and installed in accordance with the latest edition of
SMACNA construction standard on fibrous glass ducts. Both
acoustical lining and fibrous ductwork shall comply with NFPA
90B as tested by UL Standard 181 for Class 1 Rigid air ducts.
III. 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.
IV. RETURN AIR CONNECTIONS
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
inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for
airflow requireemnts above 1800 CFM.
A. Upflow Furnaces
The return-air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 1. Bypass humidifier may be attached into
unused side return air portion of the furnace casing. DO NOT
connect any portion of return-air duct to back of furnace casing.
V. FILTER ARRANGEMENT
The air filter arrangement will vary due to application and filter
type. The filter may be installed in an external Filter/Media cabinet
(if provided) or the furnace blower compartment. Factory supplied
washable filters are shipped in the blower compartment.
If a factory-supplied external Filter/Media cabinet is provided,
instructions for its application, assembly, and installation are
packaged with the cabinet. The Filter/Media cabinet can be used
with the factory-supplied washable filter or a factory-specified
high-efficiency disposable filter (see cabinet instructions).
If installing the filter in the furnace blower compartment, deter-
mine location for the filter and relocate filter retaining wire if
necessary. See Fig. 5 for side return application and Fig. 6 for
bottom return application. See Table 3 to determine correct filter
size for desired filter location. Table 3 indicates filter size,
location, and quantity shipped with the furnace.
For bottom air-return applications, filter may need to be cut to fit
some furnace casing widths. A bottom closure panel is factory
installed in the bottom of the furnace. When bottom return inlet is
TABLE 2—FREE AREA OF COMBUSTION AIR OPENING
330AAV
FURNACE
HIGH-FIRE
INPUT
(BTUH)
AIR FROM
UNCONFINED SPACE OUTDOOR AIR THROUGH VERTICAL DUCTS OUTDOOR AIR THROUGH HORIZONTAL DUCTS OUTDOOR AIR THROUGH SINGLE DUCT
Free Area
of Opening
(Sq In.)
Free Area of
Opening and Duct
(Sq In.)
Round
Pipe
(In. Dia)
Free Area of
Opening and Duct
(Sq In.)
Round
Pipe
(In. Dia)
Free Area of
Opening and Duct
(Sq In.)
Round
Pipe
(In. Dia)
40,000 100 10.0 4 20.0 6 13.4 5
60,000 100 15.0 5 30.0 7 20.0 6
80,000 100 20.0 6 40.0 8 26.7 6
100,00 100 25.0 6 50.0 8 33.4 7
120,000 120 30.0 7 60.0 9 40.0 8
133,000 133 33.3 7 66.5 10 44.4 8
WARNING: Do not install furnace on its back. Safety
control operation will be adversely affected. Never con-
nect return-air ducts to back of furnace. Failure to follow
this warning could result in fire, personal injury, or death.
A93043
FRONT
BACK
FRONT
B
A
C
K
—6—
→
→
→

desired, remove and discard the bottom closure panel. Two sets of
hardware are needed for furnaces in 24-1/2-in. wide casings using
2 filters for bottom return. All hardware is provided for filter
installation.
NOTE: Furnaces with a 17-1/2-in. wide casing require an addi-
tional procedure when locating the filter for bottom return-air
application. Field fabricate a sheet metal filler strip1X3X24-1/2
in. and install it along side of the filter as shown in Fig. 6. Drive
2 screws through the casing side and into the filler strip to secure
it in place. Filter should rest on the top of the filler strip when
installed.
WARNING: Never operate unit without a filter or with
filter access door removed. Failure to follow this warning
can cause fire, personal injury, or death.
VI. LEVELING LEGS (IF REQUIRED)
When furnace is used with side inlet(s) and leveling legs are
required, refer to Fig. 7 and install field-supplied, corrosion-
resistant 5/16-in. machine bolts and nuts.
NOTE: The length of the bolt should not exceed 1-1/2 in.
1. Lay furnace on its back. Locate and drill 5/16-in. diameter
hole in each bottom corner of furnace as shown in Fig. 7.
2. Install nut on bolt and 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.
Fig. 5—Side Filter Arrangement
(Control Removed for Clarity)
A93045
FILTER
RETAINER
WASHABLE
FILTER
→Fig. 6—Bottom Filter Arrangement
(Control Removed for Clarity)
A00290
WASHABLE
FILTER
FILTER
SUPPORT
FILTER
RETAINER
171⁄2-IN.WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
1″
24 1/2″
3″
21-IN.WIDE
CASINGS ONLY:
SUPPORT RODS (3)
EXTEND 1/4" ON EACH
SIDE OF FILTER AND
REST ON CASING FLANGE
→TABLE 3—FILTER INFORMATION (IN.)
FURNACE
CASING WIDTH FILTER SIZE* FILTER TYPE
Side Return Bottom Return
14-3/16 (1)16X25X1†(1) 14 X 25 X 1 Cleanable
17-1/2 (1)16X25X1†(1)16X25X1†Cleanable
21 (1)16X25X1 (1)20X25X1†Cleanable
24-1/2 (1or2)16X25X1 (1)24X25X1†Cleanable
* Filters may be field modified by cutting filter material and support rods (3) in
filters. Alternate sizes can be ordered from your distributor or dealer.
†Factory provided with the furnace.
Fig. 7—Leveling Leg Installation A89014
1 3⁄4″
1 3⁄4″
1 3⁄4″
1 3⁄4″
5⁄16″
5⁄16″
5⁄16″
5⁄16″
—7—

VII. GAS PIPING
Gas piping must be installed in accordance with national and local
codes. Refer to the NFGC NFPA 54-1999/ANSI Z223.1-1999.
Canadian installations must be installed in accordance with NSC-
NGPIC and all authorities having jurisdiction.
The gas supply line should be a separate line running directly from
the gas meter to the furnace, if possible. Refer to Table 4 for
recommended gas pipe size. Risers must be used to connect to
furnace and meter.
CAUTION: If a flexible connector is required or al-
lowed by the authority having jurisdiction, black iron
pipe shall be installed at the gas valve and extend a
minimum of 2 in. outside the furnace casing.
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before furnace has been attached.
If test pressure exceeds 0.5 psig (14-in. wc), the gas supply pipe
must be disconnected from the 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 before test. (See Fig. 7.) It is
recommended that the ground joint union be loosened before
pressure testing. After all connections have been made, purge lines
and check for leakage with regulated gas supply pressure.
Install a sediment trap in riser leading to furnace. The trap can be
installed by connecting a tee to riser leading from the furnace.
Connect a capped nipple into lower end of the tee. The capped
nipple should extend below level of gas controls. (See Fig. 8.)
Apply joint compound (pipe dope) sparingly and only to male
threads of each joint. The compound must be resistant to action of
propane gas.
Install an accessible manual shutoff valve upstream of furnace gas
controls and within 72 in. of furnace. A 1/8-in. NPT plugged
tapping is provided on the gas valve for test gage connection.
Installation of an additional 1/8-in. NPT plugged tapping, acces-
sible for test gage connection, installed immediately upstream of
gas supply connection to furnace and downstream of manual
shutoff valve, is not required. Place ground joint union between
gas control manifold and manual shutoff valve.
WARNING: Use the proper length of pipes and ad-
equate piping support to avoid stress on the gas control
manifold. A failure to follow this warning can cause a gas
leak resulting in a fire, explosion, personal injury, or
death.
CAUTION: Use a backup wrench at the furnace gas
control when connecting the gas pipe to the furnace to
avoid damaging gas controls or manifold.
WARNING: Never purge a line into a combustion
chamber. Never use matches, candles, flame, or other
sources of ignition for the purpose of checking leakage.
Use a soap-and-water solution to check for leakage. A
failure to follow this warning can cause a fire, explosion,
personal injury, or death.
VIII. ELECTRICAL CONNECTIONS
A. 115-v Wiring
Refer to unit rating plate or Table 5 for equipment electrical
requirements. The control system requires an earth ground for
proper operation.
CAUTION: Do not connect aluminum wire between
disconnect switch and furnace. Use only copper wire.
Make all electrical connections in accordance with the National
Electrical Code (NEC) ANSI/NFPA 70-1999 and local codes or
ordinances that might apply. For Canadian installations, all elec-
trical connections must be made in accordance with CSA C22.1
Canadian Electrical Code, or authorities having jurisdiction.
WARNING: The cabinet MUST have an uninterrupted
or unbroken ground according to NEC ANSI/NFPA
70-1999 and Canadian Electrical Code, CSA C22.1 or
local codes to minimize personal injury if an electrical
fault should occur. This may consist of electrical wire or
conduit approved for electrical ground when installed in
accordance with existing electrical codes. Do not use gas
piping as an electrical ground.
TABLE 4—MAXIMUM CAPACITY OF PIPE*
NOMINAL
IRON PIPE
SIZE (IN.)
INTERNAL
DIAMETER
(IN.)
LENGTH OF PIPE (FT)
10 20 30 40 50
1/2 0.622 175 120 97 82 73
3/4 0.824 360 250 200 170 151
11.049 680 465 375 320 285
1-1/4 1.380 1400 950 770 660 580
1-1/2 1.610 2100 1460 1180 990 900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a
supply line pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas).
Ref: Table 10-2, NFPA 54-1999.
Fig. 8—Typical Gas Pipe Arrangement A89417
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
—8—

The junction box can be moved to left-hand side of furnace when
a left-hand side power supply is desired. Remove 2 screws holding
junction box. Mount junction box on left-hand side of furnace. The
blower door interlock switch must also be moved to left-hand side
of furnace due to length of wiring harness. (Holes have been
provided in casing). When moved, tuck wiring harness behind clip
provided to keep extra wire lengths out of the way.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, the furnace control status LED will flash
rapidly and prevent heating operation.
B. 24-v Wiring
Refer to ESD Precautions Procedure before proceeding with 24-v
connections.
Make field 24-v connections at 24-v terminal block. (See Fig. 11.)
Connect terminal Y/Y2 as shown in Fig. 9 or 10 for proper cooling
operation. Use only AWG No. 18 or larger, color-coded copper
thermostat wire.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on main control. Any 24-v electrical shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse. The control will
flash code 24 when fuse needs replacement.
C. Accessories
1. Electronic air cleaner (EAC)
A terminal block (EAC-1 [hot] and EAC-2 [neutral]) is
provided for EAC connection. (See Fig. 11.) The terminals
are energized with 115v, 1-amp maximum during blower
motor operation.
2. Humidifier (HUM)
Screw terminals (HUM and COM) are provided for 24-v
humidifier connection. The terminals are energized with
24v, 0.5-amp maximum when the gas valve is energized.
Fig. 9—Heating and Cooling Application Wiring Diagram 1-Stage Thermostat and Condensing Unit A99071
115-V FUSED
DISCONNECT
SWITCH
(WHEN REQUIRED)
JUNCTION
BOX CONTROL
BOX
24-V
TERMINAL
BLOCK
TWO-WIRE
HEATING-
ONLY
FIVE
WIRE
1-STAGE THERMOSTAT TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
CONDENSING
UNIT
FURNACE
COM
R
WYRG
C
GND GND
GND GND
GND GND
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
208/230- OR
460-V
THREE
PHASE
208/230-V
SINGLE
PHASE
WHT
BLK
WHT
BLK
W/W1
W2
Y/Y2
G
NOTES: 1. Connect Y-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced,
use same type or equivalent wire.
TABLE 5—ELECTRICAL DATA
UNIT SIZE VOLTS— HERTZ—
PHASE
OPERATING
VOLTAGE RANGE MAX
UNIT
AMPS
MIN
WIRE
GAGE
MAX WIRE
LENGTH (FT)‡MAXIMUM FUSE OR CKT BKR AMPS†
Max* Min*
036040 115—60—1 127 104 11.4 14 32 15
024060 115—60—1 127 104 8.2 14 45 15
036060 115—60—1 127 104 10.6 14 34 15
042080 115—60—1 127 104 11.7 14 31 15
048080 115—60—1 127 104 13.4 14 27 15
036100 115—60—1 127 104 10.5 14 35 15
048100 115—60—1 127 104 13.2 14 28 15
060100 115—60—1 127 104 17.7 12 32 20
048120 115—60—1 127 104 13.2 14 28 15
060120 115—60—1 127 104 18.2 12 31 20
060135 115—60—1 127 104 17.4 12 33 20
* Permissible limits of the voltage range at which the unit will operate satisfactorily.
†Time-delay type is recommended.
‡Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
—9—

IX. VENTING
Refer to the enclosed Installation Instructions, (Vent Tables For 1-
and 2-Stage Category I Fan-Assisted Furnaces) for quick, easy
reference, and national or local installation code such as National
Fuel Gas Code NFPA 54-1999/ANSI Z223.1-1999 in the United
States, or the National Standard of Canada Natural and Propane
Installation Codes CAN/CGA-B149.1- and .2-M95 in Canada, for
proper vent sizing and installation requirements.
After fully assembling the vent connector to the furnace flue
collar, securely fasten the vent connector to the collar with 2
field-supplied, corrosion-resistant, sheet metal screws located
180 degrees apart and midway up the collar.
The horizontal portion of the venting system shall maintain a
minimum of 1/4-in. upward slope per linear ft, and it shall be
rigidly supported every 5 ft or less with hangers or straps to
ensure that there will be no movement after installation.
X. START-UP, ADJUSTMENT, AND SAFETY CHECK
A. General
The furnace must have a 115-v power supply properly connected
and grounded. Correct polarity must be maintained to enable gas
heating operation.
The gas service pressure must not exceed 0.5 psig (14-in. wc), and
no less than 0.16 psig (4.5-in. wc).
Thermostat wire connections at R and W/W1 are the minimum
required for gas heating operation. W2 must be connected for
2-stage heating thermostats. COM, Y/Y2, and G are required for
cooling, heat pumps, and some clock thermostats. These must be
made at the 24-v terminal block on the control. (See Fig. 11.)
This furnace can be installed with either a single-stage heating or
a 2-stage heating thermostat.
For single-stage thermostats, connect thermostat W to W/W1 at
furnace control terminal block. (See Fig. 9.) For single-stage
thermostats, the control will determine, based on length of previ-
ous heating on and off cycles, when to operate in low- and
high-gas heat for optimum comfort. Setup switch-2 (SW-2) must
be in the factory-shipped OFF position. See Fig. 12 and Tables 6
and 7 for setup switch information.
If a 2-stage heating thermostat is to be used, move SW-2 to ON
position at end of furnace installation. This overrides built-in
control process for selecting high and low fire and allows the
Fig. 10—Heating and Cooling Application Wiring Diagram 2-Stage Thermostat and Condensing Unit A99072
115-V FUSED
DISCONNECT
SWITCH
(WHEN REQUIRED)
JUNCTION
BOX CONTROL
BOX
24-V
TERMINAL
BLOCK
THREE-WIRE
HEATING-
ONLY
SEVEN
WIRE
2-STAGE THERMOSTAT TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
2-SPEED
CONDENSING
UNIT
FURNACE
G
R
W2 Y2 G Y1 C
GND GND
GND GND
GND GND
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
208/230- OR
460-V
THREE
PHASE
208/230-V
SINGLE
PHASE
Y2
Y1
C
WHT
BLK
WHT
BLK
W1 R
W2
COM
W/W1
Y/Y2
NOTES: 1. Connect Y-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced,
use same type or equivalent wire.
TABLE 6—SETUP SWITCH DESCRIPTION
SETUP
SWITCH NO. NORMAL POSITION DESCRIPTION OF USE
SW-1
Only High-Gas Heat OFF (Staged Gas Heat) Turn switch on to obtain only high-gas-heat operation on any call
for heat regardless of whether R-W/W1, or R-W/W1, -W2 is
closed. SW-1 overrides SW-2.
SW-2
Low-Gas Heat (Adaptive Mode) OFF (Single-Stage Thermostat)
Turn switch off for installations with single-stage thermostats; con-
trol selects low-gas-heat or high-gas-heat operation based on pre-
vious cycles. Turn switch on for installations with 2-stage thermo-
stats to permit only low-gas-heat operation in response to closing
R-W/W1. High-gas heat is supplied only when R to W/W1 and W2
are closed.
SW-3 and SW4 ON, OFF Switches control gas heating mode blower off delay. (See Table
7.)
TABLE 7—BLOWER OFF DELAY SETUP
SWITCH (SW) POSITION
DESIRED HEATING
MODE BLOWER OFF
DELAY (SEC)
SETUP SWITCH
SW-3 SW-4
90 OFF OFF
135 OFF ON
180 ON OFF
225 ON ON
—10—