Bryant 352MAV A Series Instructions and recipes

NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
Safety Considerations.....................................................................1
Introduction ....................................................................................3
Codes and Standards......................................................................4
Safety.........................................................................................4
General Installation...................................................................4
Combustion and Ventilation Air..............................................4
Duct Systems ............................................................................4
Acoustical Lining and Fibrous Glass Duct..............................4
Gas Piping and Gas Pipe Pressure Testing..............................4
Electrical Connections..............................................................4
Electrostatic Discharge (ESD) Precautions Procedure..................5
Applications....................................................................................5
General......................................................................................5
Upflow Applications.................................................................5
Downflow Applications............................................................7
Horizontal Left (Supply-Air Discharge)
Applications....................................................................................8
Horizontal Right (Supply-Air Discharge) Applications........10
Location........................................................................................12
General....................................................................................12
Furnace Location Relative to Cooling
Equipment.....................................................................................12
Hazardous Locations...............................................................13
Installation....................................................................................13
Leveling Legs (If Desired).....................................................13
Installation in Upflow and Downflow
Applications..................................................................................13
Installation in Horizontal Applications..................................13
Air Ducts.................................................................................15
Filter Arrangement..................................................................16
Bottom Closure Panel.............................................................16
Gas Piping...............................................................................17
Electrical Connections............................................................18
Direct Venting.........................................................................20
Condensate Drain....................................................................30
Start-Up Adjustment and Safety Check......................................32
General....................................................................................32
Sequence of Operation............................................................33
Start-Up Procedures................................................................35
Adjustments.............................................................................36
Check Safety Controls............................................................42
Checklist..................................................................................43
SAFETY CONSIDERATIONS
Installing and servicing 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 literature, on tags, and
on labels attached to or shipped with unit and other safety
precautions that may apply.
A93040
REGISTERED QUALITY SYSTEM
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I
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E
D
F
I
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M
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9
0
0
1
#
A
2
8
8
3
®
EFFICIENCY
RATING
CERTIFIED
CERTIFIED
Fig. 1—Multipoise Orientations
A93041
UPFLOW
DOWNFLOW
HORIZONTAL
LEFT
AIRFLOW AIRFLOW
AIRFLOW
AIRFLOW
HORIZONTAL
RIGHT
installation, start-up,
and operating instructions
DELUXE 4–WAY MULTIPOISE
2-SPEED, 2-STAGE, DIRECT VENT
CONDENSING GAS FURNACE
Cancels: New II 352M-60-1
3-01
352MAV
Series A
—1—

Fig. 2—Dimensional Drawing
DIMENSIONS (IN.)
UNIT SIZE A D E
036060 17-1/2 15-7/8 16
036080 17-1/2 15-7/8 16
048080 17-1/2 15-7/8 16
048100 21 19-3/8 19-1/2
060100 21 19-3/8 19-1/2
060120 24-1/2 22-7/8 23
A99112
NOTES: 1. Minimum return-air openings at furnace, based on metal duct.If flex duct is used,
see flex duct manufacturer’s recommendations for equivalent diameters.
2. Minimum return-air opening at furnace:
a. For 800 CFM–16-in.round or 14
1/2
x 12-in. rectangle.
b. For 1200 CFM–20-in.round or 14
1/2
x 19
1/2
-in. rectangle.
c. For 1600 CFM–22-in.round or 14
1/2
x 23
1/4
-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.
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. DIA
GAS CONN
2-IN.VENT CONN
1⁄2-IN. DIA THERMOSTAT
ENTRY
22
11
⁄ 16 "
SIDE INLET
23
1
⁄ 4 " TYP
SIDE INLET
1
1
⁄ 4 "
1"
OUTLET
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
THERMOSTAT ENTRY
2-IN.VENT CONN
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
14
1
⁄ 2 "
TYP SIDE INLET
9
7
⁄ 16 "
TYP
26
15
⁄ 16 " TYP
CONDENSATE
DRAIN LOCATION
(UPFLOW)
30
1
⁄ 2 "
9
⁄ 16 "
TYP
CONDENSATE
DRAIN LOCATION
(UPFLOW)
E
INLET
11
/ 16 "
11
/ 16 "
D
13
/ 16 "
13
/ 16 "
OUTLET
A
AIRFLOW 26
1
⁄ 4 "
26
1
⁄ 4 "
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL RIGHT)
OR ALTERNATE
1
⁄ 2 -IN. DIA GAS CONN
—2—

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.
Wear safety glasses and work gloves. Have a 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 unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand these signal words: DANGER, WARNING, and
CAUTION. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which 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
INTRODUCTION
The model 352MAV Series A, 2-Stage, 4-way multipoise, Gas-
Fired , Category IV, direct vent condensing furnace is available in
model sizes ranging in input capacities (high-stage) of 60,000 to
120,000 Btuh. This furnace is C.S.A. (A.G.A. and C.G.A.)
certified for natural and propane gases and for installation in
alcoves, attics, basements, closets, utility rooms, crawlspaces, and
garages. This furnace is factory-shipped for use with natural gas. A
C.S.A. (A.G.A. and C.G.A.) listed gas conversion kit is required to
convert furnace for use with propane gas.
This furnace shall not be installed directly on carpeting, tile, or
any other combustible material other than wood flooring. For
downflow installations, a 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 the
manufacturer’s coil assembly or when the manufacture’s coil box
is used. The design of the 352MAV furnace is not C.S.A. (A.G.A.
and C.G.A.) certified for installation in mobile homes, recreational
vehicles, or outdoors. This furnace is suitable for installation in a
structure built on site or a manufactured building completed at
final site.
This furnace is designed for minimum continuous return-air
temperature of 60 °F db or intermittent operation down to 55°F db.
Return-air temperature must not exceed 85°F db. See Fig. 4.
This furnace is shipped with the drain and pressure tubes con-
nected for UPFLOW applications. Minor modifications are re-
quired when used in DOWNFLOW, HORIZONTAL RIGHT,
or HORIZONTAL LEFT (supply-air discharge direction) appli-
cations as shown in Fig. 1. See details in Applications section.
Fig. 3—Clearances to Combustibles
A01049
This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m).
An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications.
This furnace is 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 kit.
This furnace may be installed on combustible flooring in alcove or closet at minimumclearance from combustible material.
This appliance 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-DWVpipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24
inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
*
Minimum front clearance for service 30 inches (762mm).
For installation on combustible floors only when installed on special base No. KGASB0201ALL, Coil
Assembly, Part No. CD5orCK5, orCoil Casing, Part No. KCAKC.
Line contact is permissible only between lines formedby 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 size furnaces require 1 inch bottom clearance to combustible materials.
ÿ
Clearance in inches
This furnace is approved for UPFLOW, DOWNFLOW and
HORIZONTAL installations.
*
BOTTOM
0"
ÿ
3"
0"
ß
0"
TOP/PLENUM
1"
0"
ß
30
MIN
ALL POSITIONS:
DOWNFLOW POSITIONS:
HORIZONTAL POSITIONS:
SIDE
FRONT
BCK
A
SERVIE
C
FRONTSIDE
U
FRNACE
Clearancearrows do
not change with
furnace orientation.
Ü
Ü
HORIZONTAL
UPFLOW OR
DOWNFLOW
1/2" MAX
FRONT FRONT
1/2" MAX
TO
LEVEL (0")
LEVEL (0")
TO
INSTALLATION
Furnace must be installed level, or pitched forward within 1/2 inch of level for proper
drainage. Failure will result in equipment or property damage. See Installation
Manual for IMPORTANT unit support details on horizontal applications.
ß
326476-201 REV. B (lit-top)
Vent clearance to
combustibles 0".
—3—

This furnace must be installed with a direct-vent (combustion air
and flue) system and a factory accessory termination kit. In a
direct-vent system, all air for combustion is taken directly from the
outside atmosphere and all flue products are discharged to the
outside atmosphere. See furnace and factory accessory termination
kit instructions for proper installation.
This furnace is shipped with the following materials to assist in
proper furnace installation. These materials are shipped in the main
blower compartment.
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 detail, refer to the applicable instruction
literature.
NOTE: Remove all shipping materials before operating furnace.
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these instructions. The installation must comply with regulations
of the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction in Canada.
In the United States and Canada, follow all codes and standards for
the following:
I. SAFETY
•US: National Fuel Gas Code (NFGC) NFPA 54-1999/ANSI
Z3.1-1999 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B
•CANADA: CAN/CGA-B149.1- and .2-M00 National Standard
of Canada, National Gas and Propane Installation Codes
(NSCNGPIC)
II. GENERAL INSTALLATION
•US: current edition of the NFGC and the NFPA 90B. For
copies, contact the National Fire Protection Association Inc.,
Batterymarch Park, Quincy, MA 02269; or for only the NFGC
contact the American Gas Association, 400 N. Capitol., N.W.,
Washington DC 20001
•CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-
onto), Ontario, M9W 1R3, Canada.
III. COMBUSTION AND VENTILATION AIR
•US: Section 5.3 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-
tractors National Association (SMACNA), or American Soci-
ety of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 1997 Fundamentals Handbook Chapter 32.
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 2,3,4, and 9 and national plumbing codes
•CANADA: NSCNGPIC Part 5
VII. ELECTRICAL CONNECTIONS
•US: National Electrical Code (NEC) ANSI/NFPA 70-1999
•CANADA: Canadian Electrical Code CSA C22.1
Fig. 4—Return-Air Temperature
A93042
Installer Packet includes:
Installation, Startup, and Operating Instructions
Service and Maintenance Instructions
User’s Information Manual
Warranty Certificate
Loose Parts Bag includes Quantity
Pressure tube extension 1
Collector Box or condensate trap extension tube 1
Inducer housing drain tube 1
1/2-in CPVC street elbow 2
Drain tube coupling 1
Drain tube coupling grommet 1
Vent and combustion-air pipe support 2
Condensate trap hole filler plug 3
Vent and combustion-air intake hole filler plug 2
Combustion-air pipe perforated disk assembly 1
Vent Pipe Extension 1*
* ONLY supplied with some furnaces.
—4—

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
Use this procedure for all installed and uninstalled furnaces. An
ESD service kit (available from commercial sources) may be used
to prevent ESD damage.
CAUTION: Electrostatic discharge can affect electronic
components. Follow the Electronic Discharge Precau-
tions Procedure listed below during furnace 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 precau-
tions will help to avoid exposing the control to electro-
static discharge by putting the furnace, the control, and
the person at the same electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S ELECTROSTATIC
CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
hand during grounding will be discharged.
3. You may proceed to service the control or connecting wires
as long as you do nothing to recharge your body (moving or
shuffling feet, touching ungrounded objects, etc.).
4. If you touch ungrounded objects, firmly touch a clean,
unpainted metal surface again before touching control or
wires.
5. Before removing a new control from its container, dis-
charge your body’s charge to ground. If the control is to be
installed in a furnace, follow items 1 through 4 before
bringing the control or yourself in contact with the furnace.
Put all used and new controls into containers before
touching ungrounded objects.
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. 6. See appropriate
application instructions for these procedures.
II. UPFLOW APPLICATIONS
In an upflow application, the blower is located below the burner
section, 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.)
Fig. 5—Condensate Trap
A93026
1⁄2OD
INDUCER HOUSING
DRAIN CONNECTION
1⁄4OD
COLLECTOR BOX TO
TRAP RELIEF PORT
5⁄8OD
COLLECTOR BOX
DRAIN CONNECTION
1⁄2-IN. PVC OR CPVC
SCREW HOLE FOR
UPFLOW OR DOWN-
FLOW APPLICATIONS
(OPTIONAL)
142
78
18
7
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
WIRE TIE
GUIDES
(WHEN USED)
12
1
34
1
34
FRONT VIEW SIDE VIEW
FURNACE
DOOR
FURNACE
DOOR CONDENSATE
TRAP
78
14
26
4
FURNACE
SIDE
FURNACE
SIDE
12
1
14
26
434
534 5
4
SIDE VIEW FRONT VIEW END VIEW FRONT VIEW
34
DOWNFLOW AND ALTERNATE
EXTERNAL UPFLOW APPLICATIONS HORIZONTAL
APPLICATIONS
FIELD
DRAIN
CONN
FIELD
DRAIN
CONN
CONDENSATE
TRAP (INSIDE)
BLOWER SHELF
ALTERNATE DRAIN
TUBE LOCATION
UPFLOW APPLICATIONS
CONDENSATE TRAP
DRAIN TUBE LOCATION
—5—

B. Condensate Trap Tubing (Factory-Shipped
Orientation)
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 or side Filter/Media Cabinet is used, drain
tube should be located to opposite side of casing of 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 condensate 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 follow-
ing:
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.
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.
Fig. 6—Factory-Shipped Upflow Tube Configuration
(Shown with Blower Access Panel Removed)
A01030
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
DRAIN TUBE (BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
1⁄2-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
PLUG
CONDENSATE
TRAP
Fig. 7—Alternate Upflow Configuration and Trap
Location
A01031
COLLECTOR BOX
TUBE (PINK)
CONDENSATE
TRAP
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
PLUG
—6—

5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
D. Condensate Trap Tubing (Alternate Upflow Orienta-
tion)
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 High Pressure Switch and should not require any
modification.
NOTE: See Fig. 6 or 7 or tube routing label on main furnace door
to check for proper connections.
G. Upper Collector Box and Inducer Housing (Unused)
Drain Connections
1. 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.
2. 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 connec-
tion is capped.
NOTE: See Fig. 6 or 7 or tube routing label on main furnace door
to check for proper connections.
H. Condensate Trap Freeze Protection
Refer to Condensate Drain Protection section for recommenda-
tions and procedures.
III. DOWNFLOW APPLICATIONS
In a downflow furnace application, the blower is located above the
burner section, 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.
Fig. 8—Downflow Tube Configuration
Left-Hand Trap Installation)
A01023
PLUG
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
EXTENSION TUBE
CONDENSATE
TRAP
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE)
Fig. 9—Downflow Tube Configuration
(Right-Hand Trap Installation)
A01024
PLUG
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
EXTENSION
DRAIN TUBE
CONDENSATE
TRAP
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
COLLECTOR BOX
EXTENSION TUBE
DRAIN TUBE
COUPLING
COLLECTOR BOX
DRAIN TUBE (BLUE)
CAP
COLLECTOR BOX
EXTENSION TUBE
—7—

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,
7, or 8.)
4. Install casing hole filler cap into blower shelf hole where
trap was removed.
5. Install condensate trap into desired casing hole by inserting
tube connection stubs through casing hole and rotating until
tabs snap into locking position.
B. Condensate Trap Tubing
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. 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 collector 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
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 tube (violet label and factory-
supplied in loose parts bag) to connect LOWER inducer
housing drain connection to the condensate trap.
e. Connect inducer housing drain connection to condensate
trap.
(1.) Condensate Trap Located on Left Side of Casing
(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 High 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
High 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.
1. Disconnect collector box pressure tube (pink label) attached
to High 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. Connect collector box pressure tube (green label) to High
Pressure Switch connection labeled COLLECTOR BOX.
4. Extend collector box pressure tube (pink label) which was
previously connected to High 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
In a horizontal left furnace application, the blower is located to the
right of the burner section, and conditioned air is discharged to the
left.
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.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
—8—

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. 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.
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 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. 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 Attachments
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 High Pressure Switch for use when furnace is
installed in UPFLOW applications. This tube MUST be discon-
Fig. 10—Horizontal Left Tube Configuration
A01029
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
040, 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
—9—

nected, extended, rerouted, and then reconnected to the pressure
switch in HORIZONTAL LEFT applications for 060 and 080
heating input furnaces.
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 High Pressure Switch.
2. Use smaller diameter tube (factory-supplied in loose parts
bag) to extend tube disconnected in item 1.
3. Route extended tube:
a. Behind inducer housing.
b. Between blower shelf and inducer housing.
4. Determine appropriate length, cut, and reconnect tube to
High Pressure Switch connection labeled COLLECTOR
BOX.
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.
NOTE: Combustion-air and vent pipes are restricted to a mini-
mum length of 5 ft. (See Table 6.)
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 35.)
V. HORIZONTAL RIGHT (SUPPLY-AIR DISCHARGE)
APPLICATIONS
In a horizontal right furnace application, the blower is located to
the left of the burner section, 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 in attic application or over a finished
ceiling.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC Installation Codes and/or local codes.
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.
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 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
Fig. 11—Attic Location and Working Platform
A93031
COMBUSTION –AIR
INTAKE VENT
MANUAL
SHUTOFF
GAS VALVE
SEDIMENT
TRAP CONDENSATE
TRAP
DRAIN
ACCESS OPENING
FOR TRAP
30″MIN
WORK AREA
A 12-IN. MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT) VENT SYSTEMS
TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
5 3⁄4″
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
—10—

3. Install casing hole filler cap (factory-supplied in loose parts
bag) into blower shelf hole where trap was removed.
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. Tube does not
need to be cut.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube:
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
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.
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 High 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
High Pressure switch in DOWNFLOW or HORIZONTAL RIGHT
applications.
NOTE: See Fig. 12 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 High 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. Connect collector box pressure tube (green label) to High
Pressure Switch connection labeled COLLECTOR BOX.
4. Use remaining smaller diameter tube (factory-supplied in
loose parts bag) to extend collector box pressure tube (pink
label) which was previously connected to High Pressure
Switch. Route this extended tube (pink label) to condensate
trap relief port connection.
Fig. 12—Horizontal Right Tube Configuration
A01028
PLUG
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX TUBE (GREEN)
CAP COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (PINK)
CONDENSATE
TRAP
COLLECTOR BOX EXTENSION TUBE
AUXILARY “J”BOX RELOCATED HERE
—11—

5. Determine appropriate length, cut, and connect tube.
6. 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
connection to condensate trap must also be properly
sloped to an open drain.
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. 10 or 35.)
LOCATION
I. GENERAL
This furnace must
•be installed so the electrical components are protected from
water.
•not be installed directly on any combustible material other than
wood flooring (refer to INTRODUCTION).
•be located so combustion-air and vent pipe maximum lengths
are not exceeded. Refer to Table 7.
•be located where available electric power and gas supplies meet
specifications on the furnace rating plate.
•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 rating plate.
This furnace may be located in a confined space without special
provisions for dilution or ventilation air.
NOTE: For proper furnace operation, install furnace so that it is
level or pitched forward within 1/2-in. to ensure proper condensate
drainage from secondary heat exchangers. (See Fig. 13.)
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 ducts sealed to furnace casing. The ducts terminate
outside the space containing the furnace to ensure there will not be
a negative pressure condition within equipment room or space.
WARNING: Do not install furnace on its back. (See Fig.
14.) Safety control operation will be adversely affected.
Never connect return-air ducts to back of furnace. Failure
to follow this warning could result in fire, personal injury,
or death.
CAUTION: Do not operate this furnace during con-
struction. If the furnace is required, use clean outside air
free of chlorine and fluorine compounds for combustion
and ventilation. These compounds form acids that cor-
rode the heat exchangers. These compounds are found in
paneling and dry wall adhesives, paints, thinners, ma-
sonry cleaning materials, and many other materials.
CAUTION: If this furnace is installed in an uncondi-
tioned space where the ambient temperatures may be
32°F or lower, freeze protection measures must be taken.
(See Fig. 15.)
Fig. 13—Proper Condensate Drainage
A93025
UPFLOW OR DOWNFLOW HORIZONTAL
FRONT
LEVEL (0″)
TO
1⁄2″MAX LEVEL (0″)
TO
1⁄2″MAX
FRONT
Fig. 14—Prohibit Installation on Back
A93043
FRONT
BACK
FRONT
B
A
C
K
Fig. 15—Freeze Protection
A93058
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
—12—

II. 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 must 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 the damper is in
full-heat or full-cool position.
III. HAZARDOUS LOCATIONS
WARNING: When the furnace is installed in a residen-
tial garage, the burners and ignition sources must be
located at least 18 in. above the floor. The furnace must
be located or protected to avoid physical damage by
vehicles. When the furnace is installed in a public garage,
airplane hangar, or other building having a hazardous
atmosphere, the furnace must be installed in accordance
with the National Fire Protection Association, Inc. re-
quirements. (See Fig. 16.)
INSTALLATION
I. 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.
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 in each bottom corner of furnace. (See Fig.
17.) 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 are used.
See Bottom Closure Panel section.
II. INSTALLATION IN UPFLOW AND DOWNFLOW
APPLICATIONS
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when special base (available from
manufacturer) Part No. KGASB0201 ALL is used. Special base is
not required when this furnace is installed on manufacturer’s Coil
Assembly Part No. CD5 or CK5, 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 Part No. CD5 or CK5 or Coil Box
Part No. KCAKC is used, install as shown in Fig. 21.
NOTE: Remove furnace perforated, supply-air duct flanges when
they interfere with mating flanges on coil or downflow subbase. To
remove perforated, supply-air duct flanges, use wide duct pliers,
duct flange tool, or hand seamers to bend flange back and forth
until it breaks off. Be careful of sharp edges. (See Fig. 21.)
Fig. 16—Installation in a Garage
A93044
18-IN. MINIMUM
TO BURNERS
Fig. 17—Leveling Legs
A89014
1 3⁄4″
1 3⁄4″
1 3⁄4″
1 3⁄4″
5⁄16″
5⁄16″
5⁄16″
5⁄16″
Fig. 18—Floor and Plenum Opening Dimensions
A96283
PLENUM
OPENING
C
A
BD
FLOOR
OPENING
—13—

TABLE 1—OPENING DIMENSIONS (IN.)
FURNACE
CASING
WIDTH APPLICATION PLENUM OPENING FLOOR OPENING
ABCD
17-1/2
Upflow Applications 16 24–1/8 16–5/8 24–3/4
Downflow Applications on Non-Combustible Flooring 15-7/8 19 16-1/2 19-5/8
Downflow Applications on Combustible Flooring Using
KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box 15-1/8 19 16-3/4 20-3/8
Downflow Applications on Combustible Flooring NOT Using
KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box 15-1/2 19 16-1/2 20
21
Upflow Applications 19-1/2 24-1/8 20-1/8 24-3/4
Downflow Applications on Non-Combustible Flooring 19-3/8 19 20 19-5/8
Downflow Applications on Combustible Flooring Using
KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box 18-5/8 19 20-1/4 20-3/8
Downflow Applications on Combustible Flooring NOT Using
KGASB Subbase
Furnace with or without 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 23-3/4 20-3/8
Downflow Applications on Combustible Flooring NOT Using
KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or
KCAKC Coil Box 22-1/2 19 23-1/2 20
Fig. 19—Furnace, Plenum, and Subbase Installed
on a Combustible Floor
A96285
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
FLOORING
Fig. 20—Furnace, Plenum, and Coil Assembly or Coil
Box Installed on a Combustible Floor
A96284
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
FURNACE
SHEET METAL
PLENUM
FLOOR
OPENING
COMBUSTIBLE
FLOORING
—14—

WARNING: Do not bend duct flanges inward as shown
in Fig. 20. 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.
III. INSTALLATION IN HORIZONTAL APPLICATIONS
These furnaces can be installed horizontally in either horizontal
left or right discharge position. In a crawlspace, the 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 desired length. Use 1 X 3/8-in. flat
washers, 3/8-in. lock washers, and 3/8-in. nuts on hanger rods as
shown in Fig. 22. Dimples are provided for hole locations. (See
Fig. 2.)
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.
IV. AIR DUCTS
A. General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA) or
American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE), or consult The Air Systems Design 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.
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.
B. 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.
C. Supply Air Connections
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 accessory 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. Supply air
opening duct flanges must be modified per Fig. 21.
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.
D. Return Air Connections
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.
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. 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.
DOWNFLOW AND HORIZONTAL FURNACES
The return-air duct must be connected to return-air opening
provided. DO NOT cut into casing sides or back to attach any
portion of return-air duct. Bypass humidifier connections should
be made at ductwork or coil casing sides exterior to furnace.
Fig. 21—Duct Flanges
A93029
NO
YES
YES
PERFORATED
DISCHARGE DUCT
FLANGE
210°
MIN
—15—

V. FILTER ARRANGEMENT
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.
The air filter arrangement will vary due to application, furnace
orientation, and filter type. The filter may be installed in an
external Filter/Media cabinet (if provided) or the furnace blower
compartment. Factory supplied washable filters are shipped in the
blower compartment.
If a factory-supplied external Filter/Media cabinet is provided,
instructions for its application, assembly, and installation are
packaged with the cabinet. The Filter/Media cabinet can be used
with the factory-supplied washable filter or a factory-specified
high-efficiency disposable filter (see cabinet instructions).
If installing the filter in the furnace blower compartment, deter-
mine 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 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
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.
Fig. 22—Crawlspace Horizontal Application
A93304
NOTES:
ANGLE
IRON OR
EQUIVALENT
(B)
(A) ROD LOCATION
USING DIMPLE
LOCATORS
(SEE DIMENSIONAL
DWG FOR
LOCATIONS)
13/16-IN. MAX
ALTERNATE SUPPORT
LOCATION FROM BACK
ALTERNATE SUPPORT
LOCATION 4-IN. MIN
8-IN. MAX
3⁄8-IN. ROD
(A) (B)
(A)
(B)
(B)
(A)
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.
(A) PREFERRED ROD LOCATION
(B) ALTERNATE ROD LOCATION
DRAIN
5 3⁄4″
3/8-IN. HEX NUT
& WASHER (4)
REQD PER ROD
TABLE 2—FILTER INFORMATION
AIR FILTER LOCATED IN BLOWER COMPARTMENT
FURNACE
CASING
WIDTH (IN.)
FILTER SIZE (IN.)* FILTER
TYPE
Side Return Bottom Return
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 and additional filters may be ordered from your dealer.
†Factory-provided with furnace.
—16—

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.
NOTE: Remove and discard bottom closure panel when bottom
inlet is used.
VI. BOTTOM CLOSURE PANEL
This furnace is 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 the 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.
VII. 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.
CAUTION: Connect gas pipe to furnace using a backup
wrench to avoid damaging gas controls.
WARNING: Gas valve shutoff switch MUST be facing
forward or tilted upward. Failure to follow this warning
could result in property damage or death.
Fig. 23—Filter Installed for Side Inlet
A93045
FILTER
RETAINER
WASHABLE
FILTER
Fig. 24—Bottom Filter Arrangement
A00213
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″
Fig. 25—Removing Bottom Closure Panel
A93047
BOTTOM
CLOSURE
PANEL
FRONT FILLER
PANEL
—17—

WARNING: Never purge a gas line into a combustion
chamber. Never use matches, candles, flame, or other
sources of ignition for purpose of checking leakage. Use
a soap-and-water solution to check for leakage. Failure to
follow this warning could result in fire, explosion, per-
sonal 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.
Install a sediment trap in riser leading to furnace. Trap can be
installed by connecting a tee to riser leading to furnace so
straight-through section of tee is vertical. Then connect a capped
nipple into lower end of tee. Capped nipple should extend below
level of gas controls. Place a ground joint union between gas
control manifold and manual gas shutoff valve. (See Fig. 26.)
CAUTION: If a flexible connector is required or al-
lowed by authority having jurisdiction, black iron pipe
shall be installed at gas valve and extend a minimum of
2 in. outside furnace casing.
An accessible manual shutoff valve MUST be installed upstream
of furnace gas controls 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.
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before the furnace has been
connected. If the pressure exceeds 0.5 psig (14-in. wc), 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 located on gas valve before
test. 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.
NOTE: The gas valve inlet press tap connection is suitable to use
as test gage connection providing test pressure DOES NOT exceed
maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 53.)
Piping should be pressure tested in accordance with NFGC local
and national plumbing and gas codes before furnace is attached. In
Canada, refer to current edition of NSCNGPIC.
VIII. ELECTRICAL CONNECTIONS
See Fig. 27 and 28 for field wiring diagram showing typical field
115-v and 24-v wiring. Check all factory and field electrical
connections for tightness.
WARNING: Blower access panel door switch opens
115-v 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 wire routed to gas valve and
burner box screw.
A. 115-V Wiring
Before proceeding with electrical connections, make certain that
voltage, frequency, and phase correspond to that specified on the
furnace rating plate. Also, check to be sure that service provided
by utility 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 70-1999 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.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control LED status indicator light will flash
rapidly and furnace will NOT operate.
CAUTION: Do not connect aluminum wire between
disconnect switch and furnace. Use only copper wire.
(See Fig. 29.)
TABLE 3—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 pressure drop of 0.5–in wc (based on a 0.60 specific gravity gas).
Ref: NFGC.
Fig. 26—Typical Gas Pipe Arrangement
A93324
UNION
SEDIMENT
TRAP
MANUAL
SHUTOFF
VALVE
(REQUIRED)
GAS
SUPPLY
—18—

Fig. 27—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.
Fig. 28—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.
—19—

WARNING: The furnace casing MUST have an unin-
terrupted 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 electri-
cal 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. 30.)
2. Rotate J-box 180°and attach box to left side, using holes
provided.
CAUTION: If manual disconnect switch is to be
mounted on furnace, select a location where a drill or
fastener will not contact electrical or gas components.
B. 24-V Wiring
Make field 24-v connections at 24-v terminal block. (See Fig. 31.)
Connect terminal Y/Y2 as shown in Fig. 27 and 28 for proper
cooling operation. Use only 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.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on control (See Fig. 31.) Any direct shorts of 24-v wiring during
installation, service, or maintenance could cause this fuse to blow.
If fuse replacement is required, use ONLY a 3-amp fuse of
identical size/type. The control will flash code 24 when fuse needs
replacement.
C. Accessories
1. Electronic Air Cleaner (EAC)
Two male quick-connect terminals marked EAC-1 and
EAC-2 are provided for EAC connection. (See Fig. 32.)
These terminals are energized with 115-v (1.0-amp maxi-
mum) during blower motor operation.
2. Humidifier (HUM)
Screw terminals HUM and COM 24V are provided for 24-v
humidifier connection. (See Fig. 31.) The HUM terminal is
energized with 24-v (0.5-amp maximum) after inducer
pressure switch closes.
NOTE: A field-supplied, 115–v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
WARNING: DO NOT connect furnace control HUM
terminal to HUM (humidifier) terminal on Thermidis-
tat™, Zone Controller or similar device. See Thermidis-
tat™, Zone Controller, thermostat, or controller manufac-
turer’s instructions for proper connection. A failure to
follow this warning could result in fire.
IX. DIRECT VENTING
The 352MAV furnaces require a dedicated (one 352MAV furnace
only) direct-vent system. In a direct-vent system, all air for
combustion is taken directly from outside atmosphere, and all flue
products are discharged to outside atmosphere.
TABLE 4—ELECTRICAL DATA
UNIT
SIZE
VOLTS—
HERTZ—
PHASE
OPERATING
VOLTAGE RANGE MAX
UNIT
AMPS
UNIT
AMPACITY†
MIN
WIRE
SIZE
MAX WIRE
LENGTH
(FT)‡
MAX FUSE
OR CKT BKR
AMPS**
Max* Min*
036060 115-60-1 127 104 8.4 11.3 14 33 15
036080 115-60-1 127 104 8.1 10.8 14 34 15
048080 115-60-1 127 104 11.6 15.3 12 37 20
048100 115-60-1 127 104 11.6 15.4 12 37 20
060100 115-60-1 127 104 13.3 17.5 12 33 20
060120 115-60-1 127 104 12.9 16.8 12 34 20
* Permissible limits of voltage range at which unit will operate satisfactorily.
†Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’(EAC, humidifier, etc.) full load
amps.
‡Length shown is a measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
** Time-delay type is recommended.
Fig. 29—Disconnect Switch and Furnace
A93033
COPPER
WIRE ONLY
ELECTRIC
DISCONNECT
SWITCH
ALUMINUM
WIRE
Fig. 30—Relocating J-Box
A00212
FACTORY
INSTALLED
LOCATION
ALTERNATE
FIELD
LOCATION
—20—