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Installation & Service Manual DSIM-15

1. 1 1 4 16 5 Bele m 32 HANGING gen A069 S 150 THRU 350 3 5 8 HANGING 925 BLOCKED VENT SWITCH 1 5 16 4 150 THRU 400 a5 5 100 125 100 THRU 125 4 5 8 4 3 8 16UNC ai 17 NUT RETAINERS Sal p FOR HANGING H 1 1 19 AIR FLOW gt 19 Tr KAIR FLOW 32 9 16 483 483 B 36 1 4 483 HI LIMIT 483 s ear AEON OPENING FRONT AND REAR OPENING ACCESS _ OPENING 921 FAR 5 794 ACCESS iJ H H PILOT NUT 55 1 25 FAR SIDE 1 Y FLANGE ALL Y AROUND FRONT 24 E AND REAR 24 610 A 610 26 7 1 16 I 2g 660 79 660 SIDE VIEW FRONT VIEW SIDE VIEW 100 125 MBTU HR UNIT SIZES 100 400 MBTU HR UNIT SIZES 150 400 MBTU HR UNIT SIZES 5 8 Table 1 Natural Vent Duct Furnace UNIT A B 5 GAS INLET WEIGHT So XL T 1 5 5 SIZE in in in in in in Ib F 143 mm mm mm mm mm NAT LP kg 100 17 718 15 1 2 17 178 237 8 6 RV 1 2 1 2 162 454 394 435 606 152 RV 73 L S 125 20 5 8 18 1 4 19 7 8 26 5 8 6 RV 1 2 1 2 175 wm 12 5 524 464 505 676 152 79 150 20 58 18 1 4 19 7 8 26 5 8 7 RH 1 2 1 2 186 A 400 VENT 524 464 505 676 178 RH 84 HORIZONTAL
2. 1 2 3 DUCT FURNACES NATURAL AND POWER VENTED SPECIRIGATIONS LU LESE 4 5 PERFORMANCE BATA ex x vx EN e ra Y aa iN TR o Rea 6 INSTALLATION Location ClearanCces sicci vitto aeia ee i dana Pat up eaa bu rn Cea e a a cg a 7 8 Ductwork Air Flow Ventilation 5 8 jer m 9 Electrical COMMECHONS cio teca iod reo nex raw ga cer 10 i r 11 thru 16 GaS PipINg EE 17 Pipe H 18 OPERATION Natural Vented Units with Standing 19 20 Natural Vented Units with Optional Intermittent 21 23 Power Vented Units with Intermittent 22 23 Adjustments teer ot a E eaa ex E RA e SENSN FE REO E UE 24 25 ens N 24 MAINTENANCE srein a LN 25 COMPONENT PARTS sarietara Eaa Apara NAUENA 26 27 28 TROUBLESHOOTING CHART drna onnon raira Lenan 29 30 31 32 REPLACEMENT PART e ree td Fa aeree tut
3. Where Applicable Tee With di Drip Leg amp Cleanout m amp 04071 Power Venter GAS PIPING A WARNING To avoid equipment damage or possible personal injury do not connect gas piping to this unit until a supply line pressure leak test has been completed Connecting the unit before completing the pressure leak test may damage the unit gas valve and result in a fire hazard Do not rely on a shut off valve to isolate the unit while conducting gas pressure leak tests These valves may not be completely shut off exposing the unit gas valve to excessive pressure and damage PIPE SIZING To provide adequate gas pressure at the gas duct furnace size the gas piping as follows 1 Find the cu ft hr by using the following formula Input Cu ft hr Btu 2 Refer to Table 5 Match Pipe Run in Feet with appropriate Gas Input Cu Ft Hr figure This figure can then be matched to the pipe size at the end of the column Example It is determined that a 67 foot 20 4m run of gas pipe is required to connect a 200 MBTU gas duct furnace to a 1 000 Btu cu ft 0 29 kW natural gas supply 200 000 Btu hr 1 000 Btu cu ft 200 Cu ft hr Using Table 5 a 1 inch nominal diameter pipe is needed NOTICE See General Safety Information section for english SI metric unit conversion
4. DETAIL POSITIONS FRONT REAR RIGHT LEFT DIMENSIONS STANDARD UNITS DIMENSIONS IN PARENTHESIS XX MILLIMETERS Vent Systems Termination Clearance Requirements Minimum Clearances for Structure Termination Locations 4 feet below Door window or any gravity air inlet 4 feet horizontally 1 foot above 3 feet above 6 feet 7 feet above grade Forced air inlet within 10 ft Adjoining building or parapet Adjacent public walkways If the vent terminal is to be installed near ground level the vent terminal must be positioned at least six inches above the maximum anticipated snow depth see below for Canadian requirements FLUE VENT INCREASER ADAPTOR SUPPLIED BY MFR FOR 300 350 400 UNIT SIZES REFER TO SPECIFICATION TABLE AND INSTALLATION MANUAL FOR PROPER USAGE The following instructions apply to Canadian installations 3 in addition to installation and operating instructions 1 Installation must conform with local building codes or in absence of local codes with current CGA B149 1 installation codes for natural gas burning appliances 4 and equipment or CGA B149 2 installation codes for a propane gas burning appliances and equipment 2 Any references to U S standards or codes in these b instructions are to be ignored and the applicable Canadian standards or codes applied If using a metal vent system under positive gauge pressure in Canada a
5. 940 29 3 4 STANDARD VERTICAL VENT POSITION 7562 1 16 E ud 95 1 8 406 a27 C a30 HANGING HANGING zu t at 4 3 8 16UNC NUT RETAINERS FOR HANGING 4 36 4 19 921 482 o 19 OPENING 483 HI LIMIT OPENING ACCESS L 75 m B E 24 7 1 16 D3624C lt 610 gt qua 6 660 FRONT VIEW F 100 400 MBTU HR UNIT SIZES SIDE VIEW CLEARANCE FOR BURNER DRAWER SERVICE 100 125 MBTU HR UNIT SIZES REAR VENT POSITION SHOWN SEE DETAIL G FOR OPTIONAL TOP VENT POSITION 5 D DIA FLUE OPENING AN INCREASER IS SUPPLIED BY THE MFR FUR 300 350 400 UNIT SIZES REDUCER TO BE SUPPLIED BY INSTALLER IF UNE IS REQ 5 16 4 127 406 HANGING KAIR FLOW HI LIMIT ACCESS FAR SIDE 37 3 4 959 19 483 OPENING 19 483 OPENING _ ol ud PILOT H ACCESS FAR SIDED 1 1 8 29 FLANGE ALL AROUND FRONT AND REAR 7 1 16 79 610 26 6600 SIDE VIEW 150 400 MBTU HR UNIT SIZES PERFORMANCE DATA Table 3 INPUT OUTPUT MAX MIN MIN Temp Rise P D in MAX Temp Rise P D in UNIT MBH MBH MBH CFM Deg F of Water CFM Deg F of Water SIZE kW kW kW cu m s Deg C kPa cu m s Deg C Pascals 100 100 50 80 929 80 0 12 2469 30 0 90
6. AWARNING Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5 kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 5 kPa Table 6 Gas Piping Requirements SINGLE STAGE GAS PIPING REQUIREMENTS GasType Natural Gas Propane LP Gas Manifold 3 5 in W C 10 0 in W C Pressure 0 9 kPa 2 5 kPa 14 0 in W C Max 14 0 in W C Max Supply Inlet 3 5 kPa 3 5 kPa 5 0 in W C Min 11 0 in W C Min 1 2 kPa 2 7 kPa single stage application only at normal altitudes TWO STAGE GAS PIPING REQUIREMENTS Gas Type Natural Gas Propane LP Gas Supply Inlet 6 5 in W C Min 11 5 in W C Min Pressure 1 6 kPa 2 9 kPa For two stage applications only at normal altitudes OPERATION NATURAL VENTED UNITS WITH STANDING PILOT Figures 1 and 2 AWARNING It is the installer s responsibility to check all safety controls Check and test the operational functions of all safety devices supplied with this unit and ensure that
7. VENTING FOR NATURAL VENTED CATEGORY I DUCT FURNACES Figures 1 and 2 ALL DUCT FURNACES MUST BE VENTED All venting installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of local building codes See below for Canadian Installations AWARNING CARBON MONOXIDE Your venting system must be blocked by any snow snow drifts or any foreign matter Inspect your venting system to ensure adequate ventilation exists at all times Failure to heed these warnings could result in Carbon Monoxide Poisoning symptoms include grogginess lethargy inappropriate tiredness or flu like symptoms A CAUTION This duct furnace is equipped with a blocked vent spill shutoff switch Before start up push reset button on blocked vent spill shutoff switch If the venting system becomes blocked or there is continuous spillage the vent shutoff switch will shut off the duct furnace Before resetting the switch check to see if the vent system is blocked remove any blockage To reset the switch which is located in the upper corner of the draft diverter push the reset button after the duct furnace has cooled down NOTICE The switch will not reset hot Observe the following precautions when venting the unit 1 Use flue pipe of the same size as the flue connections on the gas duct furnace See Table 1 All heaters s
8. HR 96 40 100 ORIFICE DRILL 42 54 i FT 120 50 125 ORIFICE DRILL 42 54 FT HR 140 60 150 ORIFICE DRILL 42 54 id FT HR 163 70 175 ORIFICE DRILL 42 54 186 80 200 ORIFICE DRILL 42 54 s FT 210 90 225 ORIFICE DRILL 42 54 9 FT HR 233 100 250 ORIFICE DRILL 42 54 10 280 120 300 ORIFICE DRILL 42 54 is FT 326 140 350 ORIFICE DRILL 42 54 14 FT 3 372 160 400 ORIFICE DRILL 42 54 18 This schedule is for units operating at normal altitudes of 2000 ft 610m or less SPECIAL ORIFICES ARE REQUIRED FOR INSTALLATIONS ABOVE 2000 FEET 610M When installed in Canada any references to deration at altitudes in excess of 2000 feet 610m are to be ignored At altitudes of 2000 to 4500 feet 610 to 1372m the unit heaters must be orificed to 90 of the normal altitude rating and be so marked in accordance with the CSA certification PRIMARY AIR SHUTTER ADJUSTMENT After the unit has been operating for at least 15 minutes adjust the primary air flow to the burners Turn the friction locked manually rotated air shutters clockwise to close or counterclockwise to open Forcorrect air adjustment close the air shutter until yellow tips in the flame appear Then open the air shutter to the point just beyond the position where yellow tipping disappears Refer to Figure 20 NOTICE There may be momentary and spasmodic orange flashes in the flame This is caused by the burning of ai
9. 29 3 14 6 23 4 0 438 44 0 03 1 165 17 0 22 125 125 62 5 100 1157 80 0 13 3086 30 0 80 36 6 18 3 29 3 0 546 44 0 03 1 457 17 0 20 150 150 75 120 1389 80 0 15 3704 30 0 75 43 9 22 0 35 1 0 656 44 0 04 1 748 17 0 19 175 175 87 5 140 1620 80 0 14 4321 30 0 75 51 2 25 6 41 0 0 765 44 0 03 2 040 17 0 19 200 200 100 160 1852 80 0 14 4938 30 0 75 58 6 29 3 46 9 0 874 44 0 03 2 331 17 0 19 225 225 112 5 180 2083 80 0 14 5556 30 0 75 65 9 32 9 52 7 0 983 44 0 03 2 622 17 0 19 250 250 125 200 2315 80 0 14 6173 30 0 80 73 2 36 6 58 6 1 093 44 0 03 2 914 17 0 20 300 300 150 240 2778 80 0 13 7407 30 0 90 87 8 43 9 70 3 1 311 44 0 03 3 496 17 0 22 350 350 175 280 3241 80 0 13 8642 30 0 90 102 5 51 2 82 0 1 530 44 0 03 4 079 17 0 22 400 400 200 320 3704 80 0 14 9877 30 0 90 117 1 58 6 93 7 1 748 44 0 03 4 662 17 0 22 Ratings are shown for unit installations at elevations between 0 and 2 000 ft 610m For unit installations in U S A above 2 000 ft 610m the unit input must be derated 4 for each 1 000 ft 305m above sea level refer to local codes or in absence of local codes refer to the latest edition of the National Fuel Gas Code ANSI Standard Z223 1 N F P A No 54 For installations in Canada any references to deration at altitudes in excess of 2 000 ft
10. 3 4 0 824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 21 10 2 7 08 5 66 4 81 4 28 3 91 3 54 3 34 3 11 2 92 2 63 2 38 2 18 2 04 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 27 19 3 13 2 10 6 9 06 8 07 7 36 6 80 6 23 5 80 5 52 4 96 4 53 4 11 3 82 11 4 1 380 1400 950 770 660 580 530 490 460 430 400 360 325 300 280 35 39 6 26 9 21 8 18 7 16 4 15 0 13 9 13 0 12 2 11 3 10 2 9 20 8 50 7 93 11 2 1 610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 41 59 5 41 3 33 4 28 0 25 5 22 9 21 2 19 5 18 4 17 6 15 6 14 2 13 0 12 2 2 2 067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800 53 112 77 9 62 3 53 8 47 6 43 0 39 6 36 8 34 5 32 6 28 9 26 9 24 1 22 7 21 2 2 469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280 63 178 123 99 7 85 0 75 0 68 0 63 7 58 0 55 2 52 4 46 7 42 5 38 8 362 3 3 068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280 78 311 218 177 150 135 122 110 105 97 7 92 0 83 5 75 0 69 4 64 6 4 4 026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600 102 651 447 362 309 275 249 229 212 204 190 170 156 142 130 1 Determine the required Cu Ft Hr by dividing the rated heater input by 1000 3 FOR
11. 1 Ub 1 05 FAR SIDE Y l bares L FLANGE ALL Y AROUND FRONT 7 1 16 AND REAR V D3622 lt 610 7 7 1 16 610 179 86 26 660 FRONT VIEW 660 E 100 400 MBTU HR UNIT SIZES SIDE VIEW L CLEARANCE FOR BURNER DRAWER SERVICE SIDE VIEW 100 125 MBTU HR UNIT SIZES 4 150 400 MBTU HR UNIT SIZES SPECIFICATIONS Figure 3 Power Vented Furnace Bottom Service Access FIELD INSTALLED ALTERNATE HORIZONTAL VENT D DIA FLUE OPENING AN INCREASER IS SUPPLIED BY THE MFR FOR 300 350 POSITION RIGHT OR LEFT 400 UNIT SIZES STANDARD REDUCER TO BE SUPPLIED BY 29 3 4 VERTICAL VENT POSITION INSTALLER IF ONE IS REQ 756 25 1 8 i 127 cae pai u 4 gt 5 37 HANGING T HANGING i 5 1 eS 42 3 8 16UNC NUT RETAINERS 1 H FOR HANGING Tr 36 1 4 AIR FLOW 19 194 37 3 4 19 19 OPENING 0 483 FRONT AND REAR OPENING HICLIMIT OPENING OPENING out OPENING VER SES E ACCESS L1 H H co H PILOT ACCESS 1 Ceo FAR SIDED 1 H FLANGE ALL 1 AROUND FRONT 24 AND REAR a D3623C 610 A 610 26 7 1 16 26 660 q79 6605 SIDE VIEW FRONT VIEW SIDE V
12. Failure to do so could cause the accumulated gas to ignite rapidly leading to personal injury or death Open the manual valve on the unit heater Turn ON electrical power in accordance with the instructions BON The unit should be under the control of the thermostat Turn the thermostat to the highest point and determine that the power venter motor starts and the pilot and main burners ignite Turn the thermostat to the lowest point and determine that the power venter motor shuts off and pilot and main burners are extinguished If pilot adjustment is required remove the pilot adjustment seal cap and adjust the pilot screw to obtain proper flame Clockwise rotation decreases pilot flame size Replace the cap Turn the thermostat to the desired position Refer to Adjustments section for more specifi cations SHUT DOWN 1 Turn the valve selector knob to the OFF position 2 Turn off the electricity 3 Torelight follow the start up instructions See Figure 19 for parts identification Figure 19 Burner Components Intermittent Pilot Ignition Also refer to Figures 1 thru 4 and 21 thru 25 for component locations Burner Drawer Common Parts NooaPpon gt Main Burners Burner Manifold Air Shutters Burner Springs Main Burner Orifice Transformer Pilot Tubing A eom OF 4 Controls 8A Main Gas Valve Honeywell 8B Main Gas Val
13. Allen Wrench Remove the three Motor Mounting Nuts Item 5 Space Washers Item 11 and Screws Item 12 Do not lose these parts Using caution the motor will disengage from the Mounting Adaptor Plate along with the Relay Junction Box and Pressure Switch Mounting Brackets will also disengage 8 Reverse order to install the new Power Venter Motor 9 TEST FIRE THE UNIT FOR A FEW CYCLES MAKING SURE THAT THE UNIT IS OPERATING SATISFACTORY SI 2 x 28 POSSIBLE CAUSE S Pressure regulator set too high A Flame lifting from burner ports B Flame pops back C Noisy flame Yellow tip flame some yellow tipping on propane gas is permissible Floating flame Gas Odor Delayed ignition H Failure to ignite Troubleshooting Guide Defective Regulator Burner orifice too large Excessive primary air Burner orifice too small Too much primary air Noisy pilot Irregular orifice causing whistle or resonance Excessive gas input Insufficient primary air Clogged main burner ports Misaligned orifices Clogged draft hood Air shutter linted Insufficient combustion air Blocked venting Insufficient combustion air Blocked heat exchanger Air leak into combustion chamber or draft hood Shut off gas supply immediately Blocked heat exchanger venting Drafts around heater Negative Pressure in building Blocked dra
14. BUILDING SEE INSTRUCTIONS 6 INCHES 152MM FIBERGLASS PLUS MAXIMUM SNOW INSULATION DEPTH FOR AREA MIN 2 THICK H VERTICAL PIPE EX 51MM MIN H TENSION OVER 12 305 MUST INSULATED ROOF ROOF PITCHED FLASHING p FROM 0 TO 45 036194 p 2 CLEARANCE 51MM MIN THIMBLE 51MM MIN CALL AROUND gt VENT PIPE DIAMETER SEE GAS PIPE SIZING CHART 14 Figure 13A HORIZONTAL ARRANGEMENT __ _4 6 0 MIN 1 8M MIN APPROVED d VENT CAP ADJACENT BUILDING SEE INSTRUCTIONS 14 6 INCHES 152MM FIBERGLASS PLUS MAXIMUM SNOW INSULATION DEPTH FOR AREA MIN 2 THICK i VERTICAL PIPE EX 51MM MIN TENSION OVER 12 305MM MUST INSULATED ROOF PITCHED 4 FLASHING FROM 0 TO 45 Wn Wu 14 H 8 TD 10 CLEARANCE BE AS SPECIFIED 203 254MM TYPE VENT PIPE MAXIMUM D VENT PIPE DIAMETER SEE GAS PIPE SIZING CHART AJ NC aa JOINT BETWEEN SINGLE WALL VENT AND THF VFNT 15 SINGLE WALL VENT SYSTEM TO DOUBLE WALL TERMINATION BUILDING ADJACENT OVERHANG BUILDING SEAL JOINT BETWEEN SINGLE WALL VENT AND VENT AND THE ANNU
15. Codes for Propane Gas Burning Appliances and Equipment Any reference to U S standards or codes in these instructions are to be ignored and the applicable Canadian standards or codes applied i N Wee ft Min 3 05 Min ef Use Outdoors E Stack Outdoors Thimble ot Min Distance 6 152mm from pipe to ceiling ft Rd 5 ft min 1 52m min Z Min Slope to 1 ft 305mm ft Max 3 05m Not to exceed 75 Vertical Flue Height Use as few elbows as possible Tape flue pipe joints with fireproof paper or material Avoid running vent pipe through unheated spaces When this cannot be avoided insulate the pipe to prevent the condensation of moisture on the inside walls of the pipe Do not damper the flue piping Failure to open such a damper prior to operating the gas duct furnace will result in the spillage of flue gas into the occupied space activating blocked vent spill switch See prior instructions ONO 10 Avoid installing units in areas under negative pressure due to large exhaust fans or air conditioning When required a flue vent fan should be installed in accordance with the instructions included with the fan 11 This optional draftor power venter is designed to operate as a Category I venting system when installed per Installation Instructions to a Category I unit
16. NFPA No 409 and in public garages when installed in accordance with current NFPA No 88A and NFPA No 88B If installed in Canada the installation must conform with local building codes or in absence of local building codes with CGA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CGA B149 8 Installation Codes for Propane Gas Burning Appliances and Equipment These indoor duct furnaces have been designed and certified to comply with CGA 2 6 Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES A WARNING Do not alter the duct furnace in any way or damage to the unit and or severe personal injury or death may occur A WARNING Disconnect all power and gas supplies before installing or servicing the heater If the power disconnect is out of sight lock it in the open position and tag it to prevent unexpected application of power Failure to do so could result in fatal electric shock or severe personal injury CAUTION Insure that all power sources conform to the requirements of the unit heater or damage to the unit will result Follow installation instructions CAREFULLY to avoid creating unsafe conditions All wiring should be done and checked by a qualified electrician using copper wire only All external wiring must conform to applicable local codes and to the latest edition of the National Electric Code ANSI NFPA No 70 All gas conne
17. burners not lighting while ther mostat calls for heat Defective venter relay Incorrect gas input Heater undersized Thermostat malfunction Heater cycling on limit control 5 Check outside dampers if used 31 CORRECTIVE ACTION Check thermocouple connection and replace if defective Eliminate drafts Refer to Installa tion Inspect and correct all wiring Inspect and correct ignition system wiring See symptoms W X amp Y Replace Check and tighten all wiring connec tions per diagrams Thermostat wires tagged W and G must be connected together unless special thermostats are used if so see thermostat wiring diagram See electrical connections Replace motor Check for 24V across 1 and 3 terminals on fan relay If 24V is present jumper terminals numbered 2 and 4 If motor runs the relay is defective and must be replaced If 24V is not present check wiring per diagrams Be sure venter relay heater terminals are connected per diagrams Replace venter relay Check motor amps against motor name plate rating check voltage replace power venter motor if defec Refer to label on motor Check all wiring Refer to amp N symptoms Replace venter relay Refer to Operation This is especially true when the heated space is enlarged Have the heat loss calculated and compare to the heater output 80 of input Your gas supplier or installer ca
18. combustion air inlet openings in bottom panel see Installation Clean heat exchanger Determine cause and repair accordingly Inspect all gas piping and repair Clean heat exchanger flue Eliminate drafts Refer to Installation See Installation Clean draft hood Close air shutter Refer to Operation Clean main burner ports Reset manifold pressure Refer to Operation Supply piping is inadequately sized Refer to Installation Clean pilot orifice Refer to Oper ation Eliminate drafts Refer to Installation Refer to Installation Open all manual gas valves Replace fuse or turn on power supply Turn up thermostat Check limit switch with continuity tester If open replace limit switch Check wiring per diagrams Troubleshooting Guide POSSIBLE CAUSE S CORRECTIVE ACTION 6 Tripped block vent spill switch Check blocked vent spill switch and reset See venting 7 Defective gas valve Replace gas valve 8 Defective thermostat Check thermostat and replace if defective 9 Defective transformer Be sure 115 volts is supplied to the transformer primary then check for 24 volts at secondary terminal before replacing 10 Loose wiring Check and tighten all wiring connec tions per diagrams 11 Defective ignition control Replace if necessary Also see W X amp Y symptoms Refer to Installation Venting Burner won t
19. convert the power venter for horizontal venting remove the shipping support bracket refer to Figures 10 and 24 and follow this procedure 1 Hold power venter motor in position 2 Remove the three Phillips head screws from the motor adaptor plate Remove the three screws which connect the power venter stack to the power venter housing Rotate the power venter housing to the horizontal position Replace screws accordingly 3 4 5 NOTICE The motor pressure switch and junction box bracket MUST remain located as shipped from the factory Rotate only the blower housing If the power venter housing is to be moved to the right horizontal position the junction box must be rotated 90 degrees CCW to clear the connection To do this remove all wires conduit and conduit connector from the junction box noting location of wires Move box using holes provided Move 7 8 plug from bottom of box to side Reconnect all wires according to the unit s wiring diagram Figure 11 FLUE VENT REDUCER Adaptor ADAPTOR Installation D36344 5 127 ADAPTOR ATTACH THE FLUE VENT REDUCER INCREASER ADAPTOR TO THE INSIDE OF THE POWER VENTER BLOWER HOUSING USE 42 8 SHEET METAL SCREWS POWER VENTER ASSY DIMENSIONS XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS MILLIMETERS Figure 10 Optional Top Vent Position Rear Front Right amp Left Flue Positions 03616
20. factors NOTICE If more than one gas duct furnace is to be served by the same piping arrangement the total cu ft hr input and length of pipe must be considered NOTICE If the gas duct furnace is to be fired with LP gas see below and consult the local LP gas dealer for pipe size information NOTICE HEATER INSTALLATION FOR USE WITH PROPANE BOTTLED GAS MUST BE MADE BY A QUALIFIED L P GAS DEALER OR INSTALLER HE WILL INSURE THAT PROPER JOINT COMPOUNDS ARE USED FOR MAKING PIPE CONNECTIONS THAT AIR IS PURGED FROM LINES THAT A THOROUGH TEST IS MADE FOR LEAKS BEFORE OPERATING HEATER AND THAT IT IS PROPERLY CONNECTED TO PROPANE GAS SUPPLY SYSTEM Before any connection is made to an existing line supplying other gas appliances contact the local gas company to make certain that the existing line is of adequate size to handle the combined load Table 5 GAS PIPE SIZE Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0 5 psig 3 5 kPa or Less and a Pressure Drop of 0 5 Inch Water Column 124 4 Pa Nominal Based on a 0 60 Specific Gravity Gas Iron Internal Pipe Size Dia Length of Pipe ft Meters in in 10 20 30 40 50 60 70 80 90 100 125 150 175 200 mm 3 0 6 1 9 1 12 2 15 2 18 3 21 3 24 4 27 4 30 5 38 1 45 7 53 3 61 0 1 2 0 622 175 120 97 82 78 66 61 57 53 50 44 40 37 35 16 4 96 3 40 2 75 2 32 2 07 1 87 1 73 1 61 1 50 1 42 1 25 1 13 1 05 0 99
21. gas Btu hr input rating see Specifications adjust the gas pressure Adjust the gas pressure as follows 1 NATURAL GAS Best results are obtained when the heater is operating at its full input rating with the manifold pressure of 3 5 inches W C 0 9 kPa Adjustment of the pressure regulator is not normally necessary since it is preset at the factory However field adjustment may be made as follows a Attach manometer at pressure tap plug adjacent to control outlet b Remove regulator adjustment screw cap located on combination gas valve c With small screwdriver rotate the adjustment screw counterclockwise to decrease or clock wise to increase pressure Do not force beyond stop limits d Replace regulator adjustment screw cap PROPANE GAS An exact manifold pressure of 10 0 inches WC 2 5 kPa must be maintained for proper operation of the heater If the unit is equipped with a pressure regulator on the combination gas valve follow steps a through d above If the unit is not so equipped the propane gas supply system pressure must be regulated to attain this manifold operating pressure 24 TABLE 7 MAIN BURNER ORIFICE SCHEDULE TYPE OF GAS NATURAL PROPANE HEATING 1075 BTU F 2500 BTU F INPUT VALUE 40 1 MJ m 93 1 MJ m IN NO OF 1000 MANIFOLD 3 5 10 0 W C BURNER Emi PRESSURE 0 9 kPa 2 5 kPa ORIFICES FT
22. gas duct furnace and may void the warranty Avoid such areas NOTICE If the gas duct furnace is to be used in a building classified as having a hazardous atmosphere the installation must comply with the standards set by the National Board of Fire Underwriters Consult the authorities having jurisdiction before starting the job The duct furnace must be installed on the positive pressure side of the air circulation blower INSTALLATION DUCTWORK Properly designed and installed ductwork providing a uniformly distributed flow of air across the surfaces of the heat exchanger is essential to satisfactory unit performance and life of the equipment All duct connection flanges seams must be sealed to prevent air leaks Sealant tape must be suitable for temperatures 250 F 121 C minimum AWARNING Any attempt to straighten the 90 duct connection flanges on the duct furnaces will affect the operation of the furnace and will void the warranty If uniform air distribution is not obtained install additional baffles and or turning vanes in the ductwork Figures 5 and 6 illustrate recommended ductwork designs for both the straight through and elbowed air inlet arrangements Access panels large enough to observe smoke and reflected light and to detect the presence of leaks in the heating equipment are required both upstream and downstream from gas duct furnaces These panels must be sealed to prevent air leaks If a
23. of the thermostat Turn the thermostat to the highest point and determine that the pilot and main burners ignite Turn the thermostat to the lowest point and determine that the pilot and main burners are extinguished 5 f pilot adjustment is required remove the pilot adjustment seal cap and adjust the pilot screw to obtain proper flame Clockwise rotation decreases pilot flame size Replace the cap 6 Turn the thermostat to the desired position 7 Refer to Adjustments sections for more specifications SHUT DOWN 1 Turn the valve selector knob to the OFF position 2 Turn off the electricity 3 Torelight follow the start up instructions See Figure 19 for parts identification OPERATION POWER VENTED DUCT FURNACES WITH INTERMITTENT SPARK PILOT IGNITION Mandatory Ignition for Power Vented Duct Furnaces Figures 3 and 4 A WARNING It is the installer s responsibility to check all safety controls Check and test the operational functions of all safety devices supplied with this unit and ensure that all are operating effectively Failure to do so could result in unsafe conditions and may result in death serious injury or property damage igiene OF CONTROLS The duct furnace is equipped with a dual automatic gas valve and electric ignition device separate from the gas valve on most models which provide the following functions a The duct furnace is equipped with a power vent System consisting
24. slip fit vent connection must be Secured by at least two corrosion resistant screws or other mechanical locking means The vent shall not terminate Less than 6 feet 1 8m from a combustion air inlet or another appliance Less than 3 feet 1m from any other building opening or any gas service regulator Directly above a gas utility meter or service USA units the reducer must be field supplied for 100 125 150 and 175 MBH unit sizes regulator 13 Figure 12 HORIZONTAL ARRANGEMENT SINGLE WALL VENT SYSTEM TO SINGLE WALL TERMINATION BUILDING OVERHANG ADJACENT a BUILDING XX r VENT PIPE i DIAMETER SEE GAS PIPE SIZING CHART APPROVED m VENT 37 0 MIN SEE INSTRUCTIONS 0 9 MIN 16 MIN e N 2 MIN 406MM MIN Jm CL ARDUNI QUI RENS UA GM MIN ALL AROUN BUILDING MATERIAL DEGRADATION FROM FLUE GASES N N SRK ET PITCH FLUE PIPE N FLASHING DOWN TOWARD DUTLET N Ov 1 4 PER FOOT OF 2 CLEARANCE FIBERGLASS 6MM IN 305MM E INSULATIDN RUN TO ALLOW FOR Scie NEM MIN 2 THICK CONDENSATE DRAINAGE Dee RATE C51MM MIN Figure 12B VERTICAL ARRANGEMENT SINGLE WALL VENT SYSTEM TO SINGLE WALL TERMINATION j 6 0 MIN 1 8M MIN APPROVED 4 VENT f ADJACENT
25. to obtain proper flame Replace the cap NOTICE A proper pilot flame is soft steady flame that envelops 3 8 inch to 1 2 inch 9 5 to 12 7 mm of the thermocouple tip 6 Turn the gas cock dial to the ON position 7 Turn the thermostat to the desired position 8 Check gas input rate see adjustments SHUT DOWN 1 Turn the valve selector knob to the OFF position 2 Turn off the electricity 3 To relight follow the START UP instructions above Figure 18 Burner Components Standing Pilot Components Also refer to Figures 1 2 and 21 thru 25 for component locations Standing Pilot Parts Controls BURNER DRAWER COMMON PARTS 1 Main Burners 5 Main Burner Orifice 2 Burner Manifold 6 Transformer Junction Box 3 Air Shutters 7 Pilot Tubing 4 Burner Springs CONTROLS 9 High Limit Switch 8 Honeywell VR8200 10 Pilot Burner Assembly Gas Valve 11 Blocked Vent Spill Switch 8B Honeywell VR8300 Gas Valve 8C White Rodgers 36C Gas Valve These safety devices are located on the rear header plate of heat exchanger inlet air side TThis safety device is located in the upper right corner of the right side of your unit Bottom access manifold shown P Switch Blocked Vent Spill Honeywell Standing Pilot Gas Valve Honeywell Standing Pilot Gas Valve VR8200 VR8300 A V f U f White
26. with a draft diverter Vent connectors serving Category I heaters shall not be connected into any portion of mechanical draft systems operating under positive pressure VENTING FOR POWER VENTED CATEGORY III DUCT FURNACES Figures 3 and 4 ALL DUCT FURNACES MUST BE VENTED All venting installations shall be in accordance with the latest edition of Part 7 venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of local building codes for natural or power vented units Also see page 13 for additional Canadian installations Horizontal vent systems must be in compliance with UL 1738 for installations in the United States and ULS636 for installations in Canada Power vented units are designed to be used with single wall vent pipe utilizing horizontal or vertical venting arrangements These arrangements must terminate external to the building using either a single wall or double wall Type B vent See Figures 10 thru 16 for special installation requirements regarding these venting conditions A WARNING Do not use a type double wall vent internally within the building on our power vented units If double wall venting is used components which are UL Listed and approved for Category III positive pressure venting systems MUST be used A Briedart Type L Field Starkap or an equivalent vent cap must be supplied by the customer for each power vented unit The vent pipe diameter MUST
27. 12 05 INSTALLATION AND SERVICE MANUAL INDOOR GAS FIRED DUCT FURNACE NATURAL OR POWER VENTED DISM 15 J30 05392 ATTENTION READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE OR SERVICE THESE UNITS CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT THE POINT OF INSTALLATION RECORD THE UNIT MODEL AND SERIAL No s IN THE SPACE PROVIDED RETAIN FOR FUTURE REFERENCE Model No Serial No FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous FOR YOUR SAFETY If you smell gas 1 Open windows 2 Don t touch electrical switches D 3 Extinguish any open flame CERTIFIED 4 Immediately contact your gas supplier AWARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instruction thoroughly before installing or servicing this equipment APPROVED FOR USE IN CALIFORNIA WHEN EQUIPPED WITH SPARK IGNITION AWARNING Install operate and maintain unit in accordance with the manufacturer s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness Th
28. 175 23 38 21 22 5 8 29 3 8 7 RH 1 2 1 2 205 DIMENSIONS STANDARD UNITS 594 533 575 746 178 RH 93 DIMENSIONS IN PARENTHESIS XX MILLIMETERS 200 26 18 23 3 4 25 3 8 32 1 8 8 RH 1 2 1 2 221 664 603 645 816 203 RH 100 225 28 718 26 172 28 1 8 34 7 8 8 RH 3 4 1 2 OR 3 4 243 5 res 733 673 714 886 203 RH 110 75 5 8 250 31 58 29 1 4 30 7 8 37 5 8 8 RH 3 4 1 2 OR 3 4 252 38 ae 803 743 784 956 203 RH 114 T 300 37 1 8 34 3 4 36 3 8 43 1 8 10 OVH 3 4 1 2 OR 3 4 301 943 883 924 1095 254 OVH 137 250 42 58 40 1 4 41 7 8 48 5 8 10 OVH 3 4 1 2 OR 3 4 378 1083 1022 1064 1235 254 OVH 171 I2 400 48 18 45 3 4 47 3 8 54 1 8 12 3 4 1 2 OR 3 4 392 Go 1222 1162 1203 1375 305 OVA 178 A ALTERNATE 400 VENT R Round H Horizontal OV Oval V Vertical VERTICAL Figure 2 Side Service Access Duct Furnace Natural Vent j 1 1 4 Ge MI 5 5 406 127 127 en 3 5 8 EE C HANGING S ARE 350 1 5 164 92 BLOCKED VENT SWITCH 150 THRU 400 33 S mass 100 THRU 125 H 4 578 V 4 3 8 16UNC 17 NUT RETAINERS sil H FOR HANGING 1 H 4 a T F 19 AIR FLOW i 483 483 19 197 ge 1 4 32 9 16 o OPENING 483 483 827 DEENING FONT AND REAR DPENING PLE OPENING 59219 31 1 4 s HI LIMIT FAR SIDED 794 a ACCESS 1 H H e ACCESS
29. 610m are to be ignored At altitudes of 2 000 to 4 500 ft 610 to 1372m the unit must be derated 90 of the normal altitude rating and be so marked in accordance with the CSA certification TEMPERATURE RISE AND PRESSURE DROP GRAPH Pressure Drop inches water Temperature Rise 0 2000 4000 6000 8000 10000 12000 14000 16000 Airflow INSTALLATION A CAUTION Do not install duct furnaces in corrosive or flammable atmospheres Premature failure of or severe damage to the unit will result A CAUTION Avoid locations where extreme drafts can affect burner operation Duct furnaces must not be installed in locations where air for combustion would contain chlorinated halogenated or acidic vapors If located in such an environment premature failure of the unit will occur NOTICE Location of duct furnaces is related directly to the selection of sizes Basic rules are as follows ACCESSIBILITY If unit is a bottom service access type allow a minimum of 21 inches 533mm at the bottom of the unit to facilitate servicing the burners and pilot or six inches 152mm if the unit has a side access burner drawer Provision should also be made to assure acces sibility for recurrent maintenance purposes AIRCRAFT HANGARS Duct furnaces must be installed in aircraft hangars and public garages as follows In aircraft hangars duct furnaces must be at least 10 feet 3 05m above the upper surface of wings or e
30. EQUIPMENT START UP Customer Job Name amp Number PRE INSPECTION INFORMATION With power and gas off Type of Equip Indoor Duct Furnace Serial Number Model Number Name Plate Voltage Name Plate Amperage Type of Gas Natural LP Tank Capacity Ibs Rating BTUOG F kg kw X o Are all panels doors vent caps in place o Has the unit suffered any external damage Damage 1 Does the gas piping and electric wiring appear to be installed in professional manner Has the gas and electric been inspected by the local authority having jurisdiction Is the gas supply properly sized for the equipment Were the installation instructions followed when the equipment was installed Have all field installed controls been installed o Do you understand all the controls on this equipment If not contact your wholesaler or rep DO NOT START this equipment unless you fully understand the controls GENERAL GAS HEATING With power and gas off With power and gas on Make certain all packing has been removed 1 Inlet gas pressure in W C or__ kPa 1 Tighten all electrical terminals and connections 1 Pilot amp main burner ignition Check damper linkages for tightness Manifold gas pressure in W C or kPa Check all fans amp blowers for free movement L1 Cycle on HIGH LIMIT Check all controls for proper settings Cycle firestat and or freezestat Check all set screws on
31. IEW 100 125 MBTU HR UNIT SIZES 100 400 MBTU HR UNIT SIZES 150 400 MBTU HR UNIT SIZES REAR VENT POSITION SHOWN SEE DETAIL G FOR OPTIONAL TOP VENT POSITION Table 2 Power Vented Duct Furnace UNIT A B C D Dia F GAS INLET WEIGHT SIZE in in in in in in Ib mm mm mm mm mm NAT LP kg 100 17 7 8 15 1 2 17 1 8 4 23 7 8 1 2 1 2 173 454 394 435 102 606 78 125 20 5 8 18 1 4 19 7 8 4 25 5 8 1 2 1 2 186 12 524 464 505 102 651 84 305 Y 150 20 58 18 14 19 7 8 4 26 5 8 1 2 1 2 197 Au 524 464 505 102 676 89 175 23 3 8 21 22 5 8 4 29 3 8 1 2 1 2 216 ELON AIR FLOW 594 533 575 102 746 98 SS 200 26 1 8 23 3 4 25 3 8 5 32 1 8 1 2 1 2 232 664 603 645 127 816 105 225 28 7 8 26 1 2 28 1 8 5 34 7 8 3 4 1 2 3 4 254 DETAIL 733 673 714 127 886 115 POSITIONS FRONT REAR RIGHT LEFT 250 31 5 8 29 1 4 30 7 8 5 37 5 8 3 4 1 2 OR 3 4 263 den STANDART UNIS 803 743 784 127 956 119 DIMENSIONS IN PARENTHESIS XX MILLIMETERS 300 37 1 8 34 3 4 36 3 8 6 43 1 8 3 4 1 2 OR 3 4 312 943 883 924 152 1095 142 350 42 5 8 40 1 4 41 7 8 6 48 5 8 3 4 1 2 OR 3 4 389 1083 1022 1064 152 1235 176 400 48 1 8 45 3 4 47 3 8 6 54 1 8 3 4 1 2 3 4 403 1222 1162 1203 152 1375 183 Figure 4 Power Vented Duct Furnace Side Service Access FIELD INSTALLED ALTERNATE HORIZONTAL VENT POSITION RIGHT OR LEFT 37
32. LAR SPACE OF THE VENT VENT PIPE DIAMETER APPROVED me SEE GAS PIPE SIZING CHART VENT 3 0 MIN SEE INSTRUCTIONS 0 9 MIN 4 16 MIN um BUILDING MATERIAL 8M MIN DEGRADATION FROM FLUE GASES T1 i L D i PITCH FLUE PIPE pase DOWN TOWARD OUTLET N FLASHING EMM IN 305MM 8 Q WALL 18 INCHES 305 PLUS 803 254MM RUN TO ALLOW FOR MAXIMUM SNOW DEPTH MAXIMUM CONDENSATE DRAINAGE FOR AREA ABOVE GRADE CLEARANCE TO BE AS SPECIFIED ON TYPE B VENT PIPE Figure 13B SINGLE WALL VENT SYSTEM TO DOUBLE WALL TERMINATION VENT AND THE ANNULAR SPACE OF Figure 14 Horizontal Left Vent Position Rear View of Heater Reducer Increaser To Horizontal Flue Where Applicable Vent Termination 1 ower Venter Tee With Drip Leg amp Cleanout Cap At Lowest Point Of Vent System Typ D4072 Figure 15 Horizontal Right Vent Position Rear View of Unit Heater Reducer Increaser To Horizontal Flue Where Applicable Vent Termination Power Venter W Tee With Leg amp Cleanout Cap At Lowest Point Of Vent System Typ gt D4073 Figure 16 Vertical Vent Position Side View of Unit Heater To Vertical Flue Vent Termination D Reducer Increaser
33. NG ASSEMBLY 15 SNAP BUSHING 2 SPEED NUT 16 RELAY 3 MOTOR 17 STRAIGHT CONNECTOR 4 WASHER PLAIN 19 SHIELD PRESSURE SWITCH 5 PLATE ADAPTOR 20 ANTI SHORT 6 BLOWER WHEEL 21 FLEX CONDUIT 23 LONG 7 MOUNTING BRACKET 22 FLEX CONDUIT 24 LONG PRESSURE SWITCH 23 SLOTTED HEAD MACHINE SCREW 8 MOUNTING BRACKET JUNCTION BOX L 7 8 9 SCREW S T 24 DRAFTOR STACK ASSEMBLY 10 SCREW MACHINE L 3 4 25 1 4 ALUMINUM TUBING 11 NUT KEPS EXT LOCKWASHER 26 MALE CONNECTOR 12 AIR PRESSURE SWITCH 27 LOCKNUT 13 DRILL SCREW 28 NUT KEPS EXT LOCKWASHER 14 JUNCTION BOX ASSEMBLY 29 7 8 PLUG SEE FIGURES 3 4 11 14 15 16 AND TABLE 2 FOR USAGE 27 INSTALLATION INSTRUCTIONS FOR FIELD REPLACEMENT OF POWER VENTER MOTOR AWARNING Never service any compartment without first disconnecting all electrical and gas supplies Refer to unit s wiring diagram This replacement must be performed only by a qualified technician Figure 25 Identification of Parts REF NO DESCRIPTION Relay Junction Box Mounting Bracket Assembly 8 Drill Screws 2 required Pressure Mounting Bracket Assembly Mounting Plate Adapter Keps Nut w External Tooth Lockwasher 4 required Motor Support Shipping Bracket Phillips Head Screws 3 required Power Venter Blower Housing Blower Wheel Motor Space Washers 3 required 12 Machine Screw 3 required 13 Sensing Tube 14 Set Screw mk
34. OF SUPPORTING THE WEIGHT OF THE HEATER DURING INSTALLATION FAILURE TO HEED THIS WARNING MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY 3 16 THREADED SUSPENSION ROD amp JAM NUT BY INSTALLER OUTSIDE JACKET PANEL DUCT 3 16 SPEED GRIP SES NUT RETAINER SECTION s s DETAIL SHOWING RECOMMENDED METHOD OF SUSPENDING TYPICAL TYPICAL 4 POINT DUCT SUSPENDING ARRANGEMENT A WARNING MAKE CERTAIN THAT THE STRUCTURE TO WHICH THE FURNACEIS TO BE MOUNTED IS CAPABLE OF SAFELY SUPPORTINGITS WEIGHT UNDER NO CIRCUMSTANCES MUST THE GAS LINES VENTING SYSTEM OR THE ELECTRICAL CONDUIT BE USED TO SUPPORT THE HEATER ANY OTHER OBJECTS LADDER PERSON LEAN AGAINST THE HEATER GAS LINES VENTING SYSTEM OR ELECTRICAL CONDUIT FOR SUPPORT FAILURE TO HEED THESE WARNINGS MAY RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH Figure 7 9 ELECTRICAL CONNECTIONS A WARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING Failure to disconnect power before servicing can cause severe personal injury or death Standard units are shipped for use on 115 volt 60 hertz single phase electric power The motor name plate and electrical rating on the transformer should be checked before energizing the duct furnace electrical system All external wiring must conform to the latest edition of ANSI NFPA No 70 National Electrica
35. PROPANE GAS Multiply the Cu Ft Hr value by 0 633 then use the table from the table 2 FOR NATURAL GAS Select the pipe size directly 4 Refer to the metric conversion factors listed in General Safety section for SI unit measurements conversions 17 PIPE INSTALLATION 1 Install the gas piping in accordance with applicable local codes 2 Check gas supply pressure Each duct furnace must be connected to a manifold pressure and a gas supply capable of supplying its full rated capacity as specified in Table 6 A field LP tank regulator must be used to limit the supply pressure to maximum of 14 W C 3 5 kPa All piping should be sized in accordance with the latest edition of ANSI Standard Z223 1 National Fuel Gas Code Canada according to CGA B149 See Tables 1 2 and 5 for correct gas supply piping size If gas pressure is excessive on natural gas applications install a pressure regulating valve in the line upstream from the main shutoff valve 3 Adequately support the piping to prevent strain on the gas manifold and controls 4 To prevent the mixing of moisture with gas run the take off piping from the top or side of the main 5 Standard gas duct furnaces optional two stage units and hydraulic modulating units are supplied with a combination valve which includes Manual A valve Manual valve Solenoid valve Pilot safety e Pressure regulator Pipe directly in to combination valve see F
36. Rodgers Standing Pilot Gas Valve High Limit Transformer 36C Used with Johnson Control Solenoid Valve 20 OPERATION UNITS WITH INTERMITTENT PILOT IGNITION Optional for Natural Vented Standard Duct Furnaces Figures 1 and 2 AWARNING It is the installer s responsibility to check all safety controls Check and test the operational functions of all safety devices supplied with this unit and ensure that all are operating effectively Failure to do so could result in unsafe conditions and may result in death serious injury or property damage EXPLANATION OF CONTROLS see Figure 19 1 The duct furnace is equipped with a dual automatic gas valve and electric ignition device separate from the gas valve on some models which provide the following functions a Pilot solenoid valve is energized and pilot is electrically ignited when thermostat calls for heat b Electronic circuitry proves that pilot flame is established then energizes main gas solenoid valve c When thermostat is satisfied main gas solenoid valve and pilot solenoid valve are de energized stopping all flow of gas d Pilot solenoid valve also functions as a main gas valve to provide redundancy e Pressure regulator provides proper and steady gas pressure to the main burners f Manual shutoff valve for service and long term shut down Separate from the automatic valve on some models The high limit switch interrupts the flow of elec
37. TOOLS AND PARTS NEEDED Wire Stripper and Crimper Slotted Head and 2 Phillips Head Screwdriver 3 8 Wrench 1 8 Allen Wrench long handle marker 1 1 4 push on terminal for Wire NOTES 1 Remove the cover from the Relay Junction Box Item 1 by removing two screws Item 2 top and bottom Disconnect both wires from the motor lead ends One is connected to terminal 4 on the venter relay and the other is connected with a wire nut to a black wire Remove the sensing tube Item 3 from the Pressure Switch Mounting Bracket Item 3 at motor end only Separated Combustion Units Remove both tubes at motor end only note location Mark locations of the Relay Junction Box and Pressure Switching Mounting Brackets along with the Motor Item 10 mounts on the Mounting Adaptor Plate Item 4 using a marker M NOTICE All hardware screws nuts washers that will be removed from the unit will be reused for this motor replacement DO NOT LOSE ANY OF THESE PARTS 4 Remove nut Item 5 that secures the Motor Support Shipping Bracket Item 6 to the Mounting Adaptor Plate Pull this bracket away from the Motor Mounting Adaptor Plate Remove three phillips head screws Item 7 on the Motor mounting Adaptor Plate Remove the Motor Blower Wheel Adaptor Plate assembly from the Power Venter Blower Housing Item 8 Remove the Blower Wheel Item 9 from the motor shaft by removing the set screw Item 14 using a 1 8
38. all are operating effectively Failure to do so could result in unsafe conditions and may result in death serious injury or property damage EXPLANATION OF CONTROLS see Figure 18 1 The duct furnace is equipped with a combination gas control valve which provides the following functions a Manual main gas valve controls the flow of gas to the unit heater b Pilot gas valve controls flow of gas to the pilot burner c Pilot safety switch interrupts flow of gas completely if pilot is not lit Pressure regulator provides proper and steady gas pressure to the main burners e 24 volt solenoid valve controls flow of gas to main burners and is operated by the wall thermostat The high limit switch interrupts the flow of electric current to the main gas valve in case the heater becomes overheated The optional fan switch delays the operation of the fan until the heater is warmed then keeps the fan running after the gas has been turned off until the useful heat has been removed The startup fan delay must not exceed 90 seconds from a cold start Make sure your fan is functioning properly The wall thermostat is a temperature sensitive switch which turns the main gas valve ON or OFF to control the temperature of the space being heated It must be mounted on vibration free vertical surface away from air currents in accordance with the instructions furnished with the thermostat Not standard equipment Also refer to Electrical Sec
39. andard unit only as Catagory I Unit is overfiring Hi Limit switch tripping 3 Air flow too low 4 Defective switch 32 CORRECTIVE ACTION Replace thermostat Check wiring per diagrams Check operation at valve Look for short such as staples piercing thermostat wiring and correct Replace gas valve Refer to Operation Be sure fan relay heater terminals are connected per diagrams Refer to Operation Check motor voltage with fan running Should be 115 volts AC Refer to Operation Close thermostat contacts Check for 24V across 24V terminals of S8600 Set gap to 0 1 Replace pilot assembly Check all connections terminal PV feeds 24V to pilot valve Check pressure pressure that is either too high or too low may cause a problem Spark should arc from electrode Check pilot line for kinks Ensure there are no drafts Check connections term MV feeds main valve Replace pilot assembly Replace if needed If present replace main valve if not replace S8600 Igniter Lengthen vertical run of flue pipe see venting Manifold pressure is too high adjust Burner orifices may be too large verify replace if req d Increase air flow check fan size Check for proper voltage Replace Indicates units with natural vent only Power vent unit only HOW TO ORDER REPLACEMENT PARTS Please send the f
40. be as specified in the chart on page 5 D Dia Flue Opening A reducer must be field installed for 100 through 175 MBH Unit Sizes All 300 through 400 MBH Unit sizes are factory equipped with the required flue increaser Refer to Figures 11 thru 16 for additional requirements The venting system for these appliances shall terminate at least four feet 1 2m below four feet 1 2m horizontal from or one foot 0 3m above any door window or gravity air inlet into any building Through the wall vents for these appliances shall NOT terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment The vent pipe equivalent length must be 5 ft 1 5m minimum and must not exceed 50 ft 15 2m Equivalent length is the total length of straight sections PLUS 15 ft 4 6m for each 90 degree elbow 8 ft 2 4m for each 45 degree elbow and 10 ft 3 0m for the vent cap Maintain 6 in 152mm between vent pipe and combustible materials A minimum of 12 in 305mm of straight pipe is required from the venter outlet before installing an elbow in the vent system An elbow should never be attached directly to the venter Use single wall pipe constructed of 26 gauge galvanized steel or material of equivalent durability and corrosion resistance for the vent system For installation in Canada use pipe constr
41. blowers and bearings 1 Check electronic modulation Set at 1 Check belt tightness L1 Check mechanical modulation Set at L1 Cycle and check all other controls not listed 1 Check operation of remote panel Entering air temp F or C 1 Discharge air temp high fire F or C 1 External static pressure in W C 1 Cycle by thermostat or operating control Remarks 35
42. ctions should be made and leak tested by a suitably qualified individual per instructions in this manual Also follow procedures listed on the Gas Equipment Start up sheet located in this manual Use only the fuel for which the heater is designed see rating plate Using LP gas in a heater that requires natural gas or vice versa will create the risk of gas leaks carbon monoxide poisoning and explosion A WARNING Do not attempt to convert the heater for use with a fuel other than the one intended Such conversion is dangerous and could create unsafe conditions that result in death serious personal injury or property damage Make certain that the power source conforms to the electrical requirements of the heater A WARNING Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing heater Always disconnect power at main circuit breaker as described above Failure to do so could result in fatal electric shock Special attention must be given to any grounding information pertaining to this heater To prevent the risk of electrocution the heater must be securely and adequately grounded This should be accomplished by connecting a grounded conductor between the service panel and the heater To ensure a proper ground the grounding means must be tested by a qualified electrician Do not insert fingers or foreign objects into the heater or its a
43. damage A WARNING Indicates an imminently hazardous situation which if not avoided could result in death serious injury or substantial property damage A CAUTION Indicates an imminently hazardous situation which if not avoided may result in minor injury or property damage NOTICE Used to notify of special instructions on installation operation or maintenance which are important to equipment but not related to personal injury hazards GENERAL SAFETY INFORMATION A WARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death A WARNING This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts Installation must be made in accordance with local codes or in absence of local codes with the latest edition of ANSI Standard Z223 1 N F P A No 54 National Fuel Gas Code All of the ANSI and NFPA Standards referred to in these installation instructions are those that were applicable at the time the design of this appliance was certified The ANSI Standards are available from the CSA Information Services 1 800 463 6727 The NFPA Standards are available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 These duct furnaces are designed for use in airplane hangars when installed in accordance with current ANSI
44. e Pen vv DE BUDE Fea fec vega d eu dive Ede 33 WARRANTY t ERUNT E 33 START UPANSPECTION SHEET dcr aer do vh eu dau Qu edle ed ua 35 GENERAL SAFETY INFORMATION The duct furnace design is certified by CSA International for use with natural and LP propane gases ANSI and NFPA Standards as well as Canadian installation codes referred to in this manual are the ones that were applicable atthe time the design was certified In addition the ductfurnace may be installed on the downstream side of a cooling unit without need of a bypass duct If the unit is to be installed at an altitude exceeding 2 000 feet 610m above sea level derate the input by 496 for each 1 000 foot 305m rise above sea level Special orifices are required for installations above 2 000 feet 610m When units are installed in Canada any reference to derations at altitudes in excess of 2000 feet 610m are to be ignored At altitudes of 2000 to 4500 feet 610 to 1372m the units must be orificed to 90 of the normal altitude rating and be so marked in accordance with the CSA certification The following terms are used throughout this manual in addition to CSA requirements to bring attention to the presence of potential hazards or to important information concerning the product 0 Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property
45. e state of California has determined that these substances may cause cancer birth defects or other reproductive harm INSTALLER S RESPONSIBILITY Installer Please Note This equipment has been test fired and inspected It has been shipped free from defects from our factory However shipment and installation problems such as loose wires leaks or loose fasteners may occur It is the installer s responsibility to inspect and correct any problem that may be found Look in direction of air flow RECEIVING INSTRUCTIONS to determine if your unit is Inspect shipment immediately when right or left hand accessible received to determine if any damage has occurred to the unit during shipment After the unit has been uncrated check for any visible damage to the unit If any damage is found the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with the transportation company MODEL TYPE DESIGNATION Figure 1 Natural Vented Standard Duct Furnace Bottom Access Standing Pilot Optional Intermittent Pilot Figure 2 Natural Vented Side Service Duct Furnace Side Access Standing Pilot Optional Intermittent Pilot Figure 3 Power Vented Duct Furnace Bottom Access Rear Vent Position Spark Ignition Figure 4 Side Service Power Vented Duct Furnace Side Access Rear Vent Position Spark Ignition TABLE OF CONTENTS GENERAL SAFETY INFORMATION
46. eads from time delay controls are factory wired to the junction box when ordered as an optional component The fan control is a time delay relay approximately 45 seconds ON 65 seconds OFF The fan control is rated at 17 amps NOTICE The start up fan delay must not exceed 90 seconds from a cold start NOTICE For all wiring connections refer to the wiring diagram that your unit is equipped with either affixed to the side jacket or enclosed in your unit s installation instruction envelope Should any original wire supplied with the heater have to be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Should any high limit or blocked vent spill switch wires have to be replaced they must be replaced with wiring material having a temperature rating of 200 minimum VENTING ANSI now organizes vented Category I Category III appliances into four categories Includes non condensing Appliances are non condensing appliances with negative vent and operate with a positive vent Venting Categories pressure like the traditional pressure c Non atmospheric unit heater Category IV ondensing Condensing 1 Negative Category II Covers condensing appliances Vent I I the Si condensing appliances with positive vent pressure Pressure with negative vent pressure NOTICE Category and IV do 2 not apply to equipment specified within this manual ressure
47. ft hood Excessive primary air Main burner ports clogged near pilot Pressure regulator set too low Pilot decreases in size when main burners come on Pilot flame too small Drafts around heater Improper venting Main gas off Lack of power at unit Thermostat not calling for heat Defective limit switch Improper thermostat or transformer wiring at gas valve ON sperm oc Table 8 CORRECTIVE ACTION Reset manifold pressure Refer to Operation Replace regulator section of combin ation gas valve or complete valve Check with local gas supplier for proper orifice size and replace Refer to Operation Close air shutter Refer to Operation Check with local gas supplier for proper orifice size and replace Refer to Operation Close air shutter Reduce pilot gas Refer to Operation Replace orifice Reset manifold pressure Refer to Operation Replace regulator section of combination gas valve or complete valve or Check with local gas supplier for proper orifice size and replace Refer to Operation Open air shutters Refer to Oper ation Clean main burner ports Replace manifold assembly Clean draft hood Check for dust or lint at air mixer opening and around the air shutter Clean combustion air inlet openings in bottom panel see Installation Clean flue Refer to Installation Clean
48. hould be vented with a UL Listed Type B vent a factory built chimney or a lined brick and mortar chimney that has been constructed in accordance with the National Building Code 2 Where two or more gas duct furnaces vent into a common flue the cross sectional area of the common flue must be equal to the largest vent connection plus 50 of the area of each additional vent connection 3 Provide as long a vertical run of flue at the gas duct furnace as possible A minimum of five feet 1 52m of vertical flue is required The top of the vent pipe should extend at least two feet 61 m above the highest point on the roof Install a weather cap over the vent opening 4 Slope horizontal runs upward from the gas duct furnace at least 1 4 inch per foot 21mm m Horizontal runs should not exceed 75 of the vertical height of the vent pipe or chimney above the flue pipe connection up to a maximum length of 10 feet 8m Horizontal portions of the venting system shall be supported at maximum intervals of four feet 1 22m to prevent sagging See Figure 9 Figure 9 Rogf 5 ft min 1 52 The following instructions apply to Canadian installations in addition to installation and operating instructions Installation must conform with local building codes or in absence of local codes with current CGA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CGA B149 2 Installation
49. igure 17 6 A 1 8 N P T plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the appliance 7 Provide a drip leg in the gas piping near the gas duct furnace A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing The manual main shutoff valve must be located external to the jacket See Figure 17 8 Make certain that all connections have been adequately doped and tightened A CAUTION Do not over tighten the inlet gas piping into the valve This may cause stresses that would crack the valve NOTICE Use pipe joint sealant resistant to the action of liquefied petroleum gases regardless of gas conducted A WARNING Check all pipe joints for leakage using a soap solution or other approved method Never use an open flame or severe personal injury or death may occur A manual shut off valve with 1 8 In plugged tapping accessible for test gage con nection must be installed immediately upstream of the gas supply connection to the appliance When installed within the Commonwealth of Massachusetts a handle gas cock must be used Gas Supply Ground Joint Union To Controls lugged 1 8 In Test Gage Connection 76MM Min 036318 Drip Pocket Figure 17 Pipe Installation Standard controls
50. inguishing the pilot flame Within one minute the automatic gas valve should close extinguishing the flame on the main burners 12 Inspect and service the blower section of the system 13 Check and test the operational functions of all safety devices supplied with your unit DUCT FURNACE COMPONENTS Natural and Power Vented FLUE COLLECTOR POWER VENTED DUCTS ONLY DRAFT DIVERTER STANDARD DUCTS ONLY BAFFLE HEAT EXCHANGER BURNER DRAWER lt BOTTOM ACCESS SHOWN Figure 21 Duct Furnace Components MAIN BURNER MANIFOLD AIR BURNER SHUTTERS RETAINING PILOT 0 BURNER TUBI 4 GAS VALVE Se PILOT OBSERVATION PORT PILOT BURNER ASSEMBLY PARTS BURNER DRAWER FLAME MAIN BURNER CARRYOVER Figure 22 Burners Controls preh i q m THERMOCOUPLE OR ELECTRODE SENSING LEAD LOCATION r i Figure 23 Burner Assembly Parts POWER VENTER ASSEMBLY Power Vented Duct Furnaces Only USE THIS ASSEMBLY FOR ALT HORIZONTAL RIGHT VENT POSITION os CEA Sp ue SERI ep EET e a o MEOS USE THIS ASSEMBLY FOR i 4 14 STD VERTICAL VENT AND CN 3 HORIZONTAL LEFT VENT POSITIONS x B amp O NOTE i _ HAND TIGHTEN ONLY DO NOT USE TOOLS Figure 24 REF REF NO DESCRIPTION NO DESCRIPTION 1 BLOWER HOUSI
51. ir moving device Do not block or tamper with the heater in any manner while in operation or just after it has been turned off as some parts may be hot enough to cause injury This heater is intended for general heating applications ONLY It must NOT be used in potentially dangerous locations such as flammable explosive chemical laden or wet atmospheres In cases in which property damage may result from malfunction of the heater a backup system or a temperature sensitive alarm should be used CAUTION The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into confined spaces UNLESS precautions are taken as follows 1 By ventilation of the space 2 control of purging rate 3 elimination of all hazardous conditions All precautions must be taken to perform this operation in a safe manner Unless otherwise specified the following conversions may be used for calculating SI unit measurements 1 foot 0 305 m 1000 Btu per hour 0 293 kW 1 inch 25 4 mm 1 inch water column 0 249 kPa 1 gallon 3 785L 1000 Btu Cu Ft 37 5 MJ m 1 pound 0 453 kg liter second CFM x 0 472 1psig 6 894 kPa meter second FPM 196 8 1 cubic foot 2 0 028 m SPECIFICATIONS Figure 1 Standard Duct Furnace Natural Vent Bottom Service Access
52. l Code and applicable local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 CAUTION Do not use any tools i e screwdriver pliers etc across the terminals to check for power Use a voltmeter A CAUTION USE COPPER CONDUCTORS ONLY UNIT TERMINALS ARE NOT DESIGNED TO ACCEPT OTHER TYPES OF CONDUCTORS Failure to do so may cause damage to the equipment It is recommended that the electrical power supply to each duct furnace be provided by a separate fused and permanently live electrical circuit A disconnect switch of suitable electrical rating for each duct furnace should be located as close to the gas valve and controls as possible Each duct furnace must be electrically grounded in accordance with the latest edition of the National Electric Code ANSI NFPA No 70 or CSA Standard C22 1 THERMOSTAT WIRING AND LOCATION NOTICE The thermostat must be mounted on a vertical vibration free surface free from air currents and in accordance with the furnished instructions Mount the thermostat approximately 5 feet 1 5 m above the floor in an area where it will be exposed to a free circulation of average temperature air Always refer to the thermostat instructions as well as our unit wiring diagram and wire accordingly Avoid mounting the thermostat in the following locations 1 Cold areas Outside walls or areas where drafts may affect the operation of the control 2 Hot a
53. let side of the combination control and connect a manometer to that tapping Turn the manual valve on to apply pressure to the combination control Note the pressure reading on the manometer then turn the valve off A loss of pressure indicates a leak If a leak is detected use a soap solution to check all threaded connections If no leak is found combination control is faulty and must be replaced before putting appliance back in service NOTICE The heater and vent system should be checked once a year by a qualified technician A WARNING it is the service technician s responsibility to check all safety controls Check and test the operational functions of all safety devices supplied with this unit and ensure that all are operating effectively Failure to do so could result in unsafe conditions and may result in death serious injury or property damage All Maintenance Service info should be recorded accordingly on the Inspection Sheet provided on back cover of this manual Should maintenance be required perform the following inspection and service routine 1 Inspect the area near the unit to be sure that there is no combustible material located within the minimum clearance requirements listed in the Installation section and in Table 4 25 A WARNING Under no circumstances should combustible material be located within the clearances specified in this manual Failure to provide proper clearance could resu
54. llowed by local regulations install canvas connectors between the ductwork and fan discharge opening to eliminate the transmission of mechanical vibration AIR FLOW The installation is to be adjusted to obtain an air throughput within the range specified on the appliance rating plate AIR BAFFLE CANVAS CONNECTOR FAN WHEEL ET B E d LZ Ri MIN GAS DUCT A FURNACE DIMENSION A 1 1 2 X DIMENSION B COMBUSTION INLET AIR VENTILATION Inlet Air From Another Room If the duct furnace is installed in a tightly constructed room or compartment provide two inlet air openings The size of each vent opening should be no less than one square inch 6 452 square centimeters of free area for each 1000 Btu hr 293 W input Each opening must not be less than 100 square inches 645 square centimeters Inlet Air From Outdoors If the enclosed space is to have inlet combustion air from the outside the vent opening must not be smaller than one square inch 6 452 square centimeters of free area for each 2500 3000 Btu hr 733 879 W input Each opening must not be less than 100 square inches 645 square centimeters BYPASS When a gas duct furnace is installed to operate in conjunction with a summer air conditioning system the cfm air delivery of the system blower should be adjusted to meet the design air volume requirements for cooling If thi
55. lt in personal injury or equipment damage from fire 2 Turn off the manual gas valve and electrical power to the gas duct furnace 3 To clean or replace the main burners remove the bottom panel or slide out the pullout drawer and compress the spring by moving the burner toward the manifold Slide the opposite end of the burner downward from the locating slot while retaining spring is still compressed Pull the burners away from the manifold 4 With the burners removed wire brush the inside surfaces of the heat exchanger 5 Remove any dirt dust or other foreign matter from the burners using a wire brush and or compressed air Ensure that all parts are unobstructed Inspect and clean pilot burner if necessary 6 Reassemble the gas duct furnace by replacing all parts in reverse order 7 Complete the appropriate unit start up procedure as given in the Operation section of this manual see lighting instruction plate on the access side of the unit 8 Check the burner adjustment See the Primary Air Shutter Adjustment section of this manual 9 Check all gas control valves and pipe connections for leaks 10 Check the operation of the automatic gas valve by lowering the setting of the thermostat stopping the operation of the gas duct furnace The gas valve should close tightly completely extinguishing the flame on the main burners 11 Check the operation of the pilot safety device by closing the pilot line valve ext
56. motor N Pilot will not light or will not Main gas off Open all manual gas valves stay lit Pilot adjustment screw turned too low Increase size of pilot flame Refer to on combination automatic main gas Operation valve Air in gas line Purge air from gas supply Incorrect lighting procedure Follow lighting instruction label adjacent to gas valve Dirt in pilot orifice Remove pilot orifice Clean with compressed air or solvent Do not ream 6 Extremely high or low gas pressure 6 Refer to Operation Indicates units with intermittent pilot spark ignition only Indicates units with natural vent only Power vent unit only 30 POSSIBLE CAUSE S O Power venter will not run P Power venter motor turns on and off while burner is operating Q Power Venter motor will not stop R Not enough heat Indicates units with intermittent pilot spark ignition only Troubleshooting Guide Defective thermocouple Standing pilot units only Drafts around unit Pilot valve not opening faulty wiring No spark if applicable faulty wiring Defective gas valve Loose wiring Defective motor overload protector or defective motor Defective power venter relay Fan relay heater element improperly wired Defective venter relay switch Motor overload protector cycling on and off Motor not properly oiled Improperly wired venter relay Main
57. n furnish this information If heater is undersized add additional heaters Replace thermostat Check air movement through heat exchanger Check voltage to fan motor Clean power venter blade and heat exchanger and oil power venter motor Adjust dampers accordingly Indicates units with natural vent only Power vent unit only Indicates units with intermittent pilot spark ignition only Troubleshooting Guide T Too much heat 1 Thermostat malfunction 2 Heater runs continuously Cold air is delivered on start 1 Fan relay heater element improperly up wired Cold air is delivered during 1 Incorrect manifold pressure or input heater operation Voltage to unit too high Air through put too high Thermostat not calling for heat No low voltage NO Spark if applicable Spark gap closed or too wide Broken or cracked ceramic on spark electrode Spark present but pilot does Loose S8600 connections not light If spark is applicable Improper gas pressure Is spark in pilot gas stream No pilot gas do not use match to test presence of gas is easily detected by the odor Pilot lights Main valve Loose S8600 connections does not energize Spark units only Cracked or broken sensor ceramic Check sensor spark lead for continuity Measure 24 volts from terminal MV to terminal MV PV Vertical run of flue is too short St
58. ngine enclosures of the highest aircraft to be stored in the hangar and 8 feet 2 4m above the floor in shops offices and other sections of the hangar where aircraft are not stored or housed Refer to current ANSI NFPA No 409 Aircraft Hangars In Canada installation is suitable in aircraft hangars when acceptable to the enforcing authorities PUBLIC GARAGES In repair garages duct furnaces must be installed in a detached building or room separated from repair areas as specified in the latest edition of NFPA 88B Repair Garages In parking structures duct furnaces must be installed so that the burner flames are located a minimum of 18 inches 457mm above the floor or protected by a partition not less than 18 inches 457mm high Refer to the latest edition of NFPA 88A Parking Structures In Canada installation must be in accordance with the latest edition of CGA B149 Installation Codes for Gas Burning Appliances and Equipment When the unit is equipped with an automatic gas ignition system the duct furnace must be installed such that the gas ignition control system is not directly exposed to water spray rain or dripping water Duct furnaces should not be installed to maintain low temperatures and or freeze protection of buildings A minimum of 50 F 10 C thermostat setting must be maintained If duct furnaces are operated to maintain lower than 50 F 10 C hot flue gases are cooled inside the heat exchanger to the
59. oduct This limited warranty is conditional upon a advising the installing contractor who will in turn notify the distributor or manufacturer b shipment to the Manufacturer of that part of the Product thought to be defective Goods can only be returned with prior written approval of the Manufacturer All returns must be freight prepaid determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship c Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED AND ALL SUCH OTHER WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL SPECIAL OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION In the interest of product improvement we reserve the right to make changes without notice 33 NOTES 34 GAS
60. of a power venter motor and blower pressure switch and sealed flue collector in place of the conventional draft diverter A CAUTION Never operate the unit beyond the specified limits severe damage to and or premature failure of the unit will result b The power venter motor is energized by the room thermostat on a call for heat The pressure switch measures the flow through the vent system and energizes the indirect spark ignition system when the flow is correct A WARNING The pressure switch MUST NOT be bypassed The unit MUST NOT be fired unless the power venter is operating An unsafe condition could result A CAUTION The addition of external draft hoods or power venters is not permitted Addition of such devices may cause serious unit malfunction or failure or possible personal injury c The indirect spark ignition system consists of an ignition control module a dual combination valve and a spark ignited pilot burner When the pressure switch closes the pilot valve opens and a spark is generated to light the pilot burner When the flame sensing circuit senses that pilot flame is established the main gas valve is opened to supply gas to the main burners When the thermostat is satisfied the vent system is de energized and both valves are closed to stop all flow of gas to the unit Pilot solenoid valve also functions as a main gas valve to provide redundancy Pressure
61. ollowing information to your local representative If further assistance is needed contact the manufacturer s customer service department Model number Serial Number if any Part description and Number as shown in the Replacement Parts Catalog LIMITED WARRANTY Gas Fired Duct Furnaces The Manufacturer warrants to the original owner at original installation site that the above models of the Duct Furnaces the Product will be free from defects in material or workmanship for a period not to exceed one 1 year from startup or eighteen 18 months from the date of shipment from the factory whichever occurs first If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period the Manufacturer will repair or replace at its option that part of the Product which is shown to be defective This limited warranty does not apply a ifthe Product has been subjected to misuse or neglect has been accidentally or intentionally damaged has not been installed maintained or operated in accordance with the furnished written instructions or has been altered or modified in any way b to any expenses including labor or material incurred during removal or reinstallation of the defective Product or parts thereof c to any damage due to corrosion by chemicals including halogenated hydrocarbons precipitated in the air d to any workmanship of the installer of the Pr
62. point where water vapor a flue gas by product condenses onto the heat exchanger walls The result is a mildly corrosive acid that prematurely corrodes the aluminized heat exchanger and can actually drip water down from the duct furnace onto floor surface Additional duct furnaces should be installed if a minimum 50 F 10 C thermostat setting cannot be maintained CLEARANCES A WARNING Under no circumstances should combustible material be located within the clearances specified in Table 4 Failureto provide proper clearance could result in personal injury or equipment damage from fire Maintain adequate clearances around air openings into combustion chamber Table 4 Minimum Clearances SIDES 6 152 mm when the clearances required TOP e 1 52 mm for accessibility are greater than the minimum safety clearances BOTTOM 6 152 mm theaccessibility clearances take FLUE 6 152 mm Precedence 21 533 mm is required for accessibility on furnaces with bottom access burner compartments DRAFTS Avoid installing the duct furnace in an extremely drafty location Strong drafts may cause pilot outage Units with intermittent pilot ignition may be preferable in areas where drafts cannot be avoided Atmospheres containing commercial solvents or chlorinated hydrocarbons will produce corrosive acids when coming in contact with the flames This will greatly reduce the life of the
63. rborne dust particles and not to be confused with the yellow tipping which is a stable or permanent situation when there is insufficient primary air Figure 20 Main Burner Flames E LIFTING TOO MUCH AIR 4 4 i Co YS YELLOW FLAME TOO LITTLE AIR NORMAL HARD FLAME YELLOW TIPPING MARGINAL PILOT ADJUSTMENT 1 Remove the pilot adjustment 2 Adjust the pilot screw to provide a properly sized flame 3 A proper pilot flame is a soft steady flame that envelops 3 8 to 1 2 inch 9 5 to 12 7 mm of the flame sensor tip 4 Replace the pilot adjustment cap MANIFOLD PRESSURE ADJUSTMENT If the manifold pressure requires minor adjustment remove the cap from the pressure regulator and turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure The adjusted manifold pressure should not vary more than 10 from the pressures specified in Table 6 MAINTENANCE PERIODIC SERVICE A WARNING Open all disconnect switches and secure in that position before servicing unit Failure to do so may result in personal injury or death from electrical shock A WARNING Gas tightness of the safety shut off valves must be checked on at least an annual basis To check gas tightness of the safety shut off valves turn off the manual valve upstream of the appliance combination control Remove the 1 8 inch pipe plug on the in
64. reas Areas where the sun s rays radiation or warm air currents may affect control operation 3 Dead areas Areas where air cannot circulate freely such as behind doors or in corners Thermostat wires tagged W and G must be connected together except when using a general purpose SPDT 24VAC relay and a standard thermostat with subbase or when using Honeywell T834H 1009 or T834H 1017 thermostats Also refer to figure 8 for other wiring connections Figure 8 C1267G LOW VOLTAGE THERMOSTAT TO UNIT HEATER gt BLACK gt BLUE RED FOR LOW VOLTAGE THERMOSTAT WIRING WITHOUT SUMMER FAN SWITCH OPERATION W G bosco R THERMOSTATHEAT ANTICIPATOR ADJUSTMENTS The initial heat anticipator setpoint should equal the heater control circuit s current amperage draw when the unit is firing This current should be measured for the best results Use the recommended ranges as a guide If further information is needed consult your thermostat manufacturer s instructions Recommended Heat Anticipator Setting Ranges 25 ft 7 6m 50 ft 15 2m Gas Ignition Type T stat Wiring T stat Wiring For Natural Vent Units Standing Pilot 0 68 to 0 75 A 0 73 to 0 81 A Intermittent Spark 0 76 to 0 81 A 0 81 to 0 91 For Power Vented Units Intermittent Spark 0 85 to 0 90 A 0 90 to 1 1A Max Setting on T stat FAN TIME DELAY CONTROL OPTIONAL L
65. regulator provides proper and steady gas pressure to the main burners f Manual shutoff valve for service and long term shut down Separate from the automatic valve on some models 22 2 The high limit switch interrupts the flow of electric current to the main gas valve in case the heater becomes overheated The fan switch delays the operation of the fan until the heater is warmed then keeps the fan running after the gas has been turned off until the useful heat has been removed The start up fan delay must not exceed 90 seconds from a cold start The wall thermostat supplied optionally is a temperature sensitive switch which operates the vent system and ignition system it turns the main gas valve ON or OFF to control the temperature of the space being heated It must be mounted on a vibration free vertical surface away from air currents furnished with the thermostat also refer to Electrical Section START UP 1 Open the manual valve supplying gas to the unit heater and with the union connection loose purge air from the gas line Tighten the union and check for gas leaks using a soapy water solution only A WARNING Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death AWARNING Before attempting to light or relight pilot wait 5 minutes to allow gas which may have accumulated in the burner compart ment to escape
66. s cfm delivery is greater than that required for heating resulting in a low air temperature rise install a damper bypass around the gas duct furnace to bypass a portion of the air AWARNING Insure that all hardware used in the suspension or each unit heater is more than adequate for the job Failure to do so may result in extensive property damage personal injury or death TURNING VANES Y AIR BAFFLE s ea CANVAS V CONNECTOR T GAS DUCT FURNACE n d ee pt E 610MM i MIN VN s y SYSTEM FAN wo 7 Figure 5 Recommended Design for Field Installation of Ductwork for Straight Through Arrangement Figure 6 Recommended Ductwork Design for Elbowed Arrangement A CAUTION suspension po SUSPENSION The duct furnace must be hung level from side to side and front to back from four ints provided at the top of the unit Failure to do so will result in poor performance and or premature failure of the unit Refer to Figure 7 for typical suspension arrangements TYPICAL SIDE BY SIDE 8 POINT DUCT SUSPENDING ARRANGEMENT NOTE WHEN TWO UNITS ARE JOINED SIDE BY SIDE IN THE FIELD A SOLID PIECE OF SHEET METAL MUST BE PROVIDED BY THE INSTALLER AT THE BACK OF ADJACENT CENTER FLANGES FRONT amp REAR AWARNING MAKE CERTAIN THAT THE LIFTING METHODS USED TO LIFT THE UNIT HEATER ARE CAPABLE
67. tion d A WARNING Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death START UP Open the manual shutoff gas valve to the duct furnace and with the union connection loose purge air from the gas line Tighten the union and check for leaks using a soapy water solution only A WARNING Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death Light the pilot as follows 1 2 Close the main and pilot gas supply by depressing and turning gas cock dial to OFF Refer to Figure 18 for burner component identification Turn the thermostat to the OFF position or lowest temperature setting on the dial Before attempting to light or relight the pilot wait five minutes to allow gas which may have accumulated in the burner compartment to escape Failure to do so could cause the accumulated gas to ignite rapidly leading to personal injury or death Turn the gas cock dial to PILOT position Depress and hold the gas cock or red bottom dial while lighting the pilot burner Allow the pilot to burn for approximately 30 seconds before releasing Ifthe pilot does not remain lit repeat the operation allowing a longer period of time before releasing If pilot adjustment is required remove the pilot adjustment cap and adjust the pilot key
68. tric current to the main gas valve in case the heater becomes overheated The optional fan switch delays the operation of the fan until the heater is warmed then keeps the fan running after the gas has been turned off until the useful heat has been removed The start up fan delay must not exceed 90 seconds from a cold start Make sure your fan is functioning properly The wall thermostat is a temperature sensitive switch which turns the main gas valve ON or OFF to control the temperature of the space being heated It must be mounted on a vibration free vertical surface away from air currents in accordance with the instructions furnished with the thermostat also refer to Electrical Section 21 START UP 1 Open the manual valve supplying gas to the duct furnace and with the union connection loose purge air from the gas line Tighten the union and check for gas leaks using a soapy water solution only A WARNING Never use an open flame to detect gas leaks Explosive conditions may exist which would result in personal injury or death AWARNING Before attempting to light or relight pilot wait 5 minutes to allow gas which may have accumulated in the burner compartment to escape Failure to do so could cause the accumulated gas to ignite rapidly leading to personal injury or death 2 Open the manual valve on the unit heater 3 Turn on electrical power 4 The unit should be under the control
69. turn off 1 Poor thermostat location Relocate thermostat away from drafts 2 Defective thermostat Replace thermostat 3 Improper thermostat or transformer Check wiring per diagrams wiring at gas valve Short circuit Check operation at valve Look for short such as staples piercing thermostat wiring and correct Defective or sticking gas valve Replace gas valve Excessive gas supply pressure Refer to Operation L Rapid burner cycling Loose electrical connections at gas Tighten all electrical connections valve or thermostat Excessive thermostat heat anticipator Adjust thermostat heat anticipator for longer cycles Refer to Operation Unit cycling on high limit Check for proper air supply across heat exchanger Poor thermostat location Relocate thermostat Do not mount thermostat on unit Draft on Pilot Eliminate drafts Refer to Installation Defective ignitor control if applicable Replace ignitor Unit cycling on high limit Check for proper air supply across heat exchanger Defective high limit switch Jumper limit switch terminals 1 and 2 If burner operates normally replace Switch M Noisy power venter Power venter wheel loose Replace or tighten Power venter wheel dirty Clean power venter wheel Power venter wheel rubbing housing Realign power venter wheel Bearings are dry Oil bearings on power venter motor Refer to label on
70. ucted from 0 025 inch thick aluminum or 0 018 inch thick stainless steel AWARNING Never use a pipe of a diameter other than that specified in Tables 1 or 2 Never use pvc or other nonmetallic pipe for venting To do so may result in serious damage to the unit or severe personal injury or death Any run of single wall vent pipe passing through an unheated space must be insulated with an insulation suitable to 550 F The vent terminal must be installed with a minimum clearance of four feet 1 2m from electric meters gas meters regulators and relief equipment Seal ALL vent pipe joints and seams to prevent leakage Use General Electric RTV 108 or Dow Corning RTV 732 silicone sealant or 3M 425 aluminum foil tape The vent system must be installed to prevent collection of condensate Vertical vent pipes should be equipped with condensate drains Pitch horizontal pipes downward 1 4 in per foot 21mm m toward outlet for condensate drainage Horizontal portions of the venting system shall be supported at maximum intervals of four feet 1 2m to prevent sagging in Canada support at 3 feet 1m maximum intervals Insulate single wall vent pipe exposed to cold air or running through unheated areas Each unit must have an individual vent pipe and vent terminal per furnace section Each unit MUST NOT be connected to other vent systems or to a chimney Units are shipped from the factory set up for vertical venting To
71. ve White Rodgers 9 10 11 13 Honeywell Ignitor Honeywell Pilot Burner HoneywellL Pilot Orifice High Limit Located on the Rear Header Plate of the Heat Exchanger Air Inlet Side Blocked Vent Spill Switch Located in the Upper Right Corner of the Unit Access Side NOTE Manifold shown for duct furnaces with bottom service access Figures 1 and 3 gt 10 69 9 11 FT Sun p pe 1 E 23 GAS INPUT RATE A CAUTION Never overfire the duct furnace as this may cause unsatisfactory operation or shorten the life of the heater Check the gas input rate as follows Refer to general safety section for metric conversions SI units 1 Turn off all gas appliances that use gas through the same meter as the heater 2 Turn gas on to the heater 3 Clockthe time in seconds required to burn one cubic foot of gas by checking the gas meter 4 Insert the time required to burn one cubic foot of gas into the following formula and compute the input rate 3600 Sec Per Hr x Btu Cu Ft Input Rate Time Sec For example assume the Btu content of one cubic foot of gas equalled 1000 and that it takes 18 seconds to burn one cubic foot of gas 3600 x 1000 18 200 000 NOTICE If the computation exceeds or is less than 95 percent of the

Installation & Service Manual DSIM-15

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Installation &amp; Service Manual DSIM-15

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Installation & Service Manual DSIM-15