Empire Comfort Systems RB) User Manual

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INSTALLATION INSTRUCTIONS

AND

OWNER'S MANUAL

Installer: Please leave these instructions with the consumer.

Consumer: Please retain these instructions for future use.

WARNING: If not installed, operated and maintained in accordance with the manufacturer's instructions, this product could expose you to substances in fuel or from fuel combustion which can cause death or serious illness.

GRAVITY VENTED DUAL WALL FURNACE

MODEL

GWT-50-2(SG, RB)

EFFECTIVE DATE

JANUARY 2004

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

óDo not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

óWHAT TO DO IF YOU SMELL GAS

ïDo not try to light any appliance.

ïDo not touch any electrical switch; do not use any phone in your building.

ïImmediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

ïIf you cannot reach your gas supplier, call the fire department.

óInstallation and service must be performed by a qualified installer, service agency or the gas supplier.

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TABLE OF CONTENTS

 

SECTION

PAGE

Important Safety Information.................................................................................................

3

Safety Information for Users of LP Gas.................................................................................

4

Introduction ............................................................................................................................

5

Specifications .........................................................................................................................

5

Recommended Vent Configuration ........................................................................................

6

Gas Supply .............................................................................................................................

7

Clearances .............................................................................................................................

8

Ventilation and Combustion Air.............................................................................................

8

Location - All Models ............................................................................................................

8

Rough-InInstructions.........................................................................................................

8-9

Finishing Instructions.......................................................................................................

9-10

Thermostat Location (SG Models).......................................................................................

11

Lighting Instructions ............................................................................................................

12

Vent Safety Shutoff System..................................................................................................

13

Proper Main Burner Flame...................................................................................................

13

Proper Pilot Flame................................................................................................................

13

Troubleshooting....................................................................................................................

14

Parts List...............................................................................................................................

15

How To Order Repair Parts ..................................................................................................

15

Parts View ............................................................................................................................

16

Remote Bulb Control Installation Instructions.....................................................................

17

Optional Blower Installation Instructions .....................................................................

18-19

Service Notes........................................................................................................................

20

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IMPORTANT SAFETY INFORMATION

THIS IS A HEATING APPLIANCE

DO NOT OPERATE THIS APPLIANCE WITHOUT OUTER CASING INSTALLED.

ï Due to high temperatures the appliance should be located

ï

DO NOT put anything around the furnace that will

out of traffic and away from furniture and draperies.

 

obstruct the flow of combustion and ventilation air.

ï Children and adults should be alerted to the hazards of

ï

DO keep the appliance area clear and free from

high surface temperatures and should stay away to avoid

 

combustible material, gasoline and other flammable

burns or clothing ignition.

 

vapors and liquids.

ï Young children should be carefully supervised when they

ï

DO examine venting system periodically and replace

are in the same room as the appliance.

 

damaged parts.

ï Clothingorotherflammablematerialshouldnotbeplaced

ï DO make a periodic visual check of pilot and burners.

on or near the appliance.

 

Clean and replace damaged parts.

ï Any safety screen or guard removed for servicing an

ï DO NOT use this heater if any part has been under water.

appliance must be replaced prior to operating the

 

Immediately call a qualified service technician to inspect

appliance.

 

the heater and to replace any part of the control system

ï Keep burner and control compartment clean.

 

and any gas control which has been under water.

 

 

ï Installation and repair should be done by a QUALIFIED

ï This furnace must not be connected to a chimney flue

SERVICE PERSON. The appliance should be inspected before use and at least annually by a qualified service person. More frequent cleaning may be required due to excessive lint from carpeting, bedding materials, etc. It is imperative that control compartments, burners and circulating air passageways of the appliance be kept clean.

serving a separate solid-fuelburning appliance.

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SAFETY INFORMATION FOR USERS OF LP-GAS

Propane (LP-Gas)is a flammable gas which can cause fires and explosions. In its natural state, propane is odorless and colorless. You may not know all the following safety precautions which can protect both you and your family from an accident. Read them carefully now, then review them point

by point with the members of your household. Someday when there may not be a minute to lose, everyone's safety will depend on knowing exactly what to do. If, after reading the following information, you feel you still need more information, please contact your gas supplier.

LP-GASWARNING ODOR

If a gas leak happens, you should be able to smell the gas because of the odorant put in the LP-Gas.That's your signal to go into immediate action!

ïDo not operate electric switches, light matches, use your phone. Do not do anything that could ignite the gas.

ïGet everyone out of the building, vehicle, trailer, or area. Do that IMMEDIATELY.

ïClose all gas tank or cylinder supply valves.

ïLP-Gasis heavier than air and may settle in low areas such as basements. When you have reason to suspect a gas leak, keep out of basements and other low areas. Stay out until firefighters declare them to be safe.

ïUse your neighbor's phone and call a trained LP-Gasservice person and the fire department. Even though you may not continue to smell gas, do not turn on the gas again. Do notre-enterthe building, vehicle, trailer, or area.

ïFinally, let the service man and firefighters check for escaped gas. Have them air out the area before you return. Properly trainedLP-Gasservice people should repair the leak, then check and relight the gas appliance for you.

NO ODOR DETECTED - ODOR FADE

Some people cannot smell well. Some people cannot smell the odor of the chemical put into the gas. You must find out if you can smell the odorant in propane. Smoking can decrease your ability to smell. Being around an odor for a time can affect your sensitivity or ability to detect that odor. Sometimes other odors in the area mask the gas odor. People may not smell the gas odor or their minds are on something else. Thinking about smelling a gas odor can make it easier to smell.

The odorant in LP-gasis colorless, and it can fade undersome circumstances.For example, if there is an underground leak, the movement of the gas through soil can filter the odorant. Odorants in LP-Gas also are subject to oxidation. This fading can occur if

there is rust inside the storage tank or in iron gas pipes.

The odorant in escaped gas can adsorb or absorb onto or into walls, masonry and other materials and fabrics in a room. That will take some of the odorant out of the gas, reducing its odor intensity.

LP-Gasmay stratify in a closed area, and the odor intensity could vary at different levels. Since it is heavier than air, there may be more odor at lower levels. Always be sensitive to the slightest gas odor. If you detect any odor, treat it as a serious leak. Immediately go into action as instructed earlier.

SOME POINTS TO REMEMBER

ïLearn to recognize the odor of LP-gas.Your local LP-Gas Dealer can give you a "Scratch and Sniff" pamphlet. Use it to find out what the propane odor smells like. If you suspect that your LP-Gas has a weak or abnormal odor, call your LP-Gas Dealer.

ïIf you are not qualified, do not light pilot lights, perform service, or make adjustments to appliances on the LP-Gassystem. If you are qualified, consciously think about the odor ofLP-Gasprior to and while lighting pilot lights or performing service or making adjustments.

ïSometimes a basement or a closed-uphouse has a musty smell that can cover up theLP-Gasodor. Do not try to light pilot lights, perform service, or make adjustments in an area where the conditions are such that you may not detect the odor if there has been a leak ofLP-Gas.

ïOdor fade, due to oxidation by rust or adsorption on walls of new cylinders and tanks, is possible. Therefore, people should be particularly alert and careful when new tanks or cylinders are placed in service. Odor fade can occur in new tanks, or reinstalled old tanks, if they are filled and allowed

to set too long before refilling. Cylinders and tanks which have been out of service for a time may develop internal rust which will cause odor fade. If such conditions are suspected to exist, a periodic sniff test of the gas is advisable. If you have any question about the gas odor, call your LP-gas dealer. A periodic sniff test of the LP-gas is a good safety measure under any condition.

ïIf, at any time, you do not smell the LP-Gasodorant and you think you should, assume you have a leak. Then take the same immediate action recommended above for the occasion when you do detect the odorizedLP-Gas.

ïIf you experience a complete "gas out," (the container is under no vapor pressure), turn the tank valve off immediately. If the container valve is left on, the container may draw in some air through openings such as pilot light orifices. If this occurs, some new internal rusting could occur. If the valve is left open, then treat the container as a new tank. Always be sure your container is under vapor pressure by turning it off at the container before it goes completely empty or having it refilled before it is completely empty.

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INTRODUCTION

Introduction

Vented wall furnace is shipped ready to install in a 2" x 4" stud wall, with studs 16" (406mm) center to center. Always consult your local Building Department regarding regulations, codes or ordinances which apply to the installation of a vented wall furnace.

Instructions to Installer

1.Installer must leave instruction manual with owner after installation.

2.Installer must have owner fill out and mail warranty card supplied with furnace.

3.Installer should show owner how to start and operate furnace and thermostat.

Warning:

Any change to this furnace orits control can be dangerous. This is a heating appliance and any panel, door or guard removed forservicing an appliance must be replaced prior to operating the appliance.

General Information

ThisseriesisdesigncertifiedinaccordancewithAmericanNational Standard / CSA Standard Z21.86 and CSA 2.32 by the Canadian Standards Association, as a Vented Wall Furnace and must be installed according to these instructions.

Any alteration of the original design, installed other than as shown in these instructions or use with a type of gas not shown on the rating plate is the responsibility of the person and company making the change.

Important

All correspondence should refer to complete Model No., Serial No. and type of gas.

Notice: During initial firing of this furnace, its paint will bake out and smoke will occur. To prevent triggering of smoke alarms, ventilate the room in which the furnace is installed.

Installation in Residential Garages

Gas utilization equipment in residential garages shall be installed so that all burners and burner ignition devices are located not less than 18" (457mm) above the floor.

Such equipment shall be located, or protected, so it is not subject to physical damage by a moving vehicle.

Qualified Installing Agency

Installationandreplacementofgaspiping,gasutilizationequipment or accessories and repair and servicing of equipment shall be performed only by a qualified agency. The term "qualified agency" means any individual, firm, corporation or company which either in person or through a representative is engaged in and is responsible for (a) the installation or replacement of gas piping or (b) the connection, installation, repair or servicing of equipment, who is experienced in such work, familiar with all precautions required and has complied with all the requirements of the authority having jurisdiction.

State of Massachusetts: The installation must be made by a licensed plumber or gas fitter in the Commonwealth of Massachusetts.

The installation must conform to local codes or, in the absence of local codes, with the National Fuel Gas Code ANSI Z223.1/NFPA 54* Natural Gas and Propane Installation Code, CSA B149.1.

*Available from the American National Standards Institute, Inc., 11 West 42nd St., New York, N.Y. 10036.

High Altitudes

For altitudes/elevations above 2,000 feet (610m), input ratings should be reduced at the rate of 4 percent for each 1,000 (305m) feetabovesealevel.CanadianHighAltitudesforlocationshaving an elevation above mean sea level between 2,000 feet (610m) and 4,500 feet (1370m), the manifold pressure is to be decreased from 3.5" w.c. (.871kPa) to 3.0" w.c. (.747kPa) for Natural Gas and from 10.0" w.c. (2.49kPa) to 8.0" w.c. (1.992kPa) for Propane Gas.

 

SPECIFICATIONS

 

 

 

 

 

Model

 

GWT-50

 

Input BTU/HR (KW/H)

 

50,000 (14.7)

 

Height

 

66 1/8" (168cm)

 

Width

 

16" (406mm)

 

Depth (Out of wall)

 

6" (152mm)

 

Gas Inlet Pipe

 

1/2"

 

Vent Pipe Type B Oval

 

4" (102mm)

 

Accessory

 

 

 

Blower Package

 

GWTB-2

 

 

 

 

 

GWT-50(SG, RB) is a DUAL WALL Furnace. Warmed air is discharged into two rooms which share a common wall.

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RECOMMENDED VENT CONFIGURATION

Note: No vent equipment supplied with furnace.

4" Oval (all parts purchase locally)

1.Type B-1oval pipe

2.Single story type B-1gas vents require a baseplate and one pair of ceiling plate spacers.

3.Multi-storytypeB-1gas vents require a baseplate, one pair of ceiling

plate spacers at the first floor ceiling and one pair of fire stop spacers at each successive ceiling level.

Type B-Wgas vent pipe is available for single story or multistory installations. TypeB-Wgas vent pipe is to be used with the Listed base plate, ceiling plate spacers and fire stop spacers.

Insulated Vent Enclosure

Gravity vented wall furnaces installed in buildings with flat roofs can have poor venting. The cold vent pipe will have a delay in proper venting and cause the wall furnace to shut "off" by the vent safety switch. To prevent delayed venting as well as condensation of flue products an insulated vent enclosure is recommended.

Use Type B vent pipe and maintain at least a one inch (25mm) clearance to combustibles.

Use metal thimble to protect vent pipe as it passes through combustibles.

Baseplate Gasket is factory installed on header. Baseplate attaches to header with screws. B-ventsnaps into and is attached to baseplate. Minimum height of vent pipe must be six feet (1.8m) above header.

Stud space around gas vents must be free of obstructions and building paper.

Uninsulated Single-WallMetal Pipe shall not be used outdoors in cold climates for venting gas utilization equipment.

Attention: The main burner uses room air for combustion. As the gas/air mixture is injected into the main burner, there is also the flow of dust and lint particles into the main burner.

Dust and lint accumulation inside the main burner will result in a yellow main burner flame and possible sooting inside the combustion chamber and vent pipe. To clean main burner refer to Page 13, "Proper Main Burner Flame."

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GAS SUPPLY

Check all local codes for requirements, especially for the size and type of gas supply line required.

Recommended Gas Pipe Diameter

Pipe Length

Schedule 40 Pipe

Tubing, Type L

(Feet)

Inside

Diameter

Outside

Diameter

 

Nat.

L.P.

Nat.

L.P.

0-10

1/2"

3/8"

1/2"

3/8"

 

1.3 cm

1.0 cm

1.3 cm

1.0 cm

10-40

1/2"

1/2"

5/8"

1/2"

 

1.3 cm

1.3 cm

1.6 cm

1.3 cm

40-100

1/2"

1/2"

3/4"

1/2"

 

1.3 cm

1.3 cm

1.9 cm

1.3 cm

100-150

3/4"

1/2"

7/8"

3/4"

 

1.9 cm

1.3 cm

2.2 cm

1.9 cm

Note: Never use plastic pipe. Check to confirm whether your local codes allow copper tubing or galvanized.

Note: Since some municipalities have additional local codes, it is always best to consult your local authority and installation code.

Check all local codes for requirements, especially for the size and type of gas supply line required. On Natural gas lines less than 15' (4.57m) long, use 1/2" pipe; on longer runs, use 3/4" iron pipe or equal. On LP gas lines please consult LP gas supplier.

Installing a New Main Gas Cock

Each appliance should have its own manual gas cock.

In the state of Massachusetts the gas cock must be a T handle type.

Amanual main gas cock should be located in the vicinity of the unit. Where none exists, or where its size or location is not adequate, contact your local authorized installer for installation or relocation.

Compounds used on threaded joints of gas piping shall be resistant to the action of liquefied petroleum gases. The gas lines must be checked for leaks by the installer. This should be done with a soap solution watching for bubbles on all exposed connections, and if unexposed, a pressure test should be made.

Never use an exposed flame to check for leaks. Appliance must be disconnected from piping at inlet of control valve and pipe capped or plugged for pressure test. Never pressure test with appliance connected; control valve will sustain damage!

A gas valve and ground joint union should be installed in the gas line upstream of the gas control to aid in servicing. It is required by the National Fuel Gas Code that a drip line be installed near the gas inlet. This should consist of a vertical length of pipe tee connected into the gas line that is capped on the bottom in which condensation and foreign particles may collect.

Figure 1

The use of the following gas connectors is recommended:

óANS Z21.24 Appliance Connectors of Corrugated Metal Tubing and Fittings

óANS Z21.45 Assembled Flexible Appliance Connectors of Other Than All-MetalConstruction

The above connectors may be used if acceptable by the authority having jurisdiction. The state of Massachusetts requires that a flexible appliance connector cannot exceed three feet in length.

Pressure Testing of the Gas Supply System

1.To check the inlet pressure to the gas valve, a 1/8" (3.175mm) N.P.T. plugged tapping, accessible for test gauge connection, must be placed immediately upstream of the gas supply connection to the appliance.

2.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).

3.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).

Attention! If one of the procedures results in pressures in excess of 1/2 psig (14" w.c.) (3.5 kPa) on the appliance gas valve, it will result in a hazardous condition.

Checking Manifold Pressure

Both Propane and Natural gas valves have a built-inpressure regulator in the gas valve. Natural gas models will have a manifold pressure of approximately 3.5" w.c. (.871kPa) at the valve outlet with the inlet pressure to the valve from a minimum of 4.5" w.c. (1.120kPa) for the purpose of input adjustment to a maximum of 10.5" w.c. (2.614kPa) Propane gas models will have a manifold pressure approximately 10.0" w.c. (2.49kPa) at the valve outlet with the inlet pressure to the valve from a minimum of 11.0" w.c. (2.739kPa) for the purpose of input adjustment to a maximum of 13.0" w.c. (3.237kPa).

A1/8" (3.175mm) N.P.T. plugged tapping, accessible for test gauge connection, is located on the outlet side of the gas control.

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CLEARANCES

1.In selecting a location for installation, it is necessary to provide adequate accessibility clearances for servicing and proper installation.

2.Clearances to combustible surfaces are 4" (102mm) from sides, 12" (305mm) to top, 1 1/2" (38mm) from floor.

NOTE: Minimum distance of 1 1/2" (38mm) must also be maintained from top surface of carpeting, tile, etc.

VENTILATION AND COMBUSTION AIR

Wall furnaces shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas and proper venting under normal conditions. In buildings of conventional frame, brick, or stone construction without tight storm windows and doors, infiltration is normally adequate to provide air for combustion and draft hood dilution.

Where appliances are installed in confined and unconfined spaces withinabuilding,thebuildingbeingofunusuallytightconstruction, air for combustion and ventilation must be obtained directly from outdoors or from such spaces that freely communicate with the outdoors. Under these conditions, the confined and unconfined spaces shall be provided with two permanent openings, one near the top of the enclosure and one near the bottom; each opening shall have a free area of not less than one square inch (6.45cm2) per 2,000 BTU (.6KW/H) per hour of total input.

LOCATION - ALL MODELS

Select a location near the center of the space to be heated. Overflow heat will circulate through doorways into adjacent rooms.

For large homes or spread-outfloor plans, two or more furnaces are recommended. Do not locate furnace where a door could swing over the outer casing, or where circulation could be retarded by furniture or cabinets.

Do not install in a closet, alcove or small hallway where the furnace

could be isolated by closing doors to the heated space.

When location is selected, check the walls, attic and roof to make sure there are no obstructions such as pipes, electric wiring, etc., which would interfere with the installation of the furnace or vent pipe.

NOTE: If Optional Blower is to be used, hard wiring must be completed for the optional blower prior to installation of header plate.

ROUGH-ININSTRUCTIONS

Provide an opening in the wall 14 1/2" (368mm) wide and 66 1/8" (168cm) high measured from top of floor plate (See Figure 2 and Figure 3). Wall depth is to be 2" x 4" framing with 1/4" (6.5mm) to 5/8" (16mm) sheeting. Attach baseplate (not supplied with furnace) to header plate with sheet metal screws at each end. Attach 4" (102mm) oval, double wall vent pipe to baseplate.Attach enough vent pipe so that when installed in wall opening the vent pipe will extend above the ceiling plate by at least 6" (152mm). Install ceiling spacers according to manufacturer's instructions. Two header extensions are attached to the header plate. One header extension is welded to the header plate and one header extension is screwed to the header plate. To install header plate into wall

Page 8

opening remove the header extension that is screwed to the header plate (2 screws). Insert header plate with attached 4" oval, double wall vent pipe into wall opening. Position header plate at height shown in Figure 2. Locate rear edge of nailing flange at the back of the 2" x 4" stud which will center the vent collar in the wall. Locate the angled edge of header plate flush with the top of the wall opening. Nail header plate to the wall studs. Replace and attach header extension onto header plate with 2 screws.

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Figure 2

FINISHING INSTRUCTIONS

Plastering (Figure 4)

In new construction use only plain (not perforated) gypsum lath around furnace and vent pipe so that plaster "Keys" will not project into wall space.

Use wood strips nailed to inside of studs and top of bottom plate. These must be removed before installation of furnace. Lath and plaster against top projection of Header Plate.

Do not allow wall finish materials to project into furnace recess..

Cleartherecessofalldebris,andremoveanywoodplaster-grounds.Stand the furnace on floor in front of wall opening.

Insert furnace flue into rectangular opening in header plate and raise furnace carefully (see Figure 5). Swing bottom of furnace into wall opening with back of legs flush with rear of floor plate. Secure furnace support legs to the floor plate.

Figure 4

Installing Furnace (Figure 5)

Figure 5

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FINISHING INSTRUCTIONS (continued)

IMPORTANT ó Avoid securing too tightly and disturbing the inner casing. Do not try to force furnace into a wall opening which is smaller than specified dimension.

OUTER CASING (Figure 6)

1.Align 1 3/4" slot on casing bracket with bottom screw hole on inner casing.Attach casing bracket to inner casing with one (1) 10 x 1/2" screws for each casing bracket. Do not completely tighten screws at this time.

2.Place outer casing onto header.

Attention: Use center clearance hole on outer casing top for attachment to header with one (1) 8 x 3/8" Phillips screwwhen optional blower is not installed.

Attention: Use outside clearance holes on outer casing top for attachment to header with two (2) 8 x 3/8" Phillips screwswhen optional blower is installed.

3.Align clearance holes on outer casing bottom with screw holes on casing brackets by adjusting slots on casing brackets.

4.Complete tightening casing bracket screws from Step 1 to inner casing at this time.

5.Attach outer casing to casing brackets with two (2) 10 x 1-1/2"screws.

INSTALLING CONTROL DOOR

Attach two washers supplied in hardware package to pivot pins located at bottom of control door. Install control door to outer casing assembly.

Figure 6

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