Empire Comfort Systems FAW-40-1IP, FAW-40-1SPP User Manual
INSTALLATION INSTRUCTIONS
AND
OWNER'S MANUAL
FAN TYPE
VENTED
WALL FURNACE
MODEL
FAW-40-1SPP
FAW-40-1IP
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.
EFFECTIVE DATE
SEPTEMBER 2003
WARNING: If the information in this
manual is not followed exactly, a fir e or
explosion may result causing property
damage, personal injury or loss of life.
— Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier ,
call the fire department.
— Installation and service must be per-
formed by a qualified installer, service
agency or the gas supplier.
12427-2-0903
Page 1
Introduction
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 or its control can be dangerous. This
is a heating appliance and any panel, door or guard removed
for servicing an appliance must be replaced prior to operating
the appliance.
General Information
This series is design certified in accordance with American National
Standard / CSA Standard Z21.86 and CSA 2.32 by the Canadian
Standards Association, as a Fan Type 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 unit, its paint will bake out and smoke
will occur. To prevent triggering of smoke alarms, ventilate the room in
which the unit is installed.
Installation on Rugs and Tile
If this appliance is installed directly on carpeting, tile or other combustible
material other than wood flooring the appliance shall be installed on a
metal or wood panel extending the full width and depth of the appliance.
The base referred to above does not mean the fire-proof base as used on
wood stoves. The protection is for rugs that are extremely thick and light
colored tile.
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.
Specifications
Model FAW-40SPP FAW-40IP
Input BTU/HR (KW/H) 40,000 (11.7) 40,000 (11.7)
Height 72 1/2" (184.2cm) 72 1/2" (184.2cm)
Width 14 1/8" (35.9mm) 14 1/8" (35.9mm)
Depth 10 3/8" (26.4mm) 10 3/8" (26.4mm)
Gas Inlet Pipe 1/2" (1.27cm) 1/2" (1.27cm)
Vent Collar Type B Oval 4" (10.2cm) 4" (10.2cm)
CFM 275 275
Accessories
Register, side outlet, fixed register SOR-1
Side outlet, 10" (254mm) SOK-1
maximum extension, fixed register
Rear Outlet, 10" (254mm) ROK-1
maximum extension, adjustable register
Vent enclosure, 24" (61cm) FVE-24
[for rooms up to 96 1/2" (245cm) in height]
Vent enclosure, 34" (86cm) FVE-34
[for rooms up to 106 1/2" (270.5cm) in height]
Vent enclosure, 46" (117cm) FVE-46
[for rooms up to 118 1/2" (301cm) in height]
Oval-to-Round flue adapter kit 4" (102mm) DV-648
THIS IS A HEATING APPLIANCE
DO NOT OPERATE THIS APPLIANCE WITHOUT FRONT PANELS INSTALLED.
• Due to high temperatures the appliance should be located out
of traffic and away from furniture and draperies.
• Children and adults should be alerted to the hazards of high
surface temperatures and should stay away to avoid burns or
clothing ignition.
• Young children should be carefully supervised when they are
in the same room as the appliance.
• Clothing or other flammable material should not be placed on
or near the appliance.
• Any safety screen or guard removed for servicing an appliance
must be replaced prior to operating the appliance.
• Keep burner and control compartment clean.
• Installation and repair should be done by a QUALIFIED
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.
• DO NOT put anything around the furnace that will obstruct
Page 2
the flow of combustion and ventilation air.
• DO keep the appliance area clear and free from combustible
material, gasoline and other flammable vapors and liquids.
• DO examine venting system periodically and replace damaged parts.
• DO make a periodic visual check of pilot and burners. Clean
and replace damaged parts.
• CAUTION: Pilot hole cover must be kept tightly closed
during operation.
• DO NOT use this heater if any part has been under water.
Immediately call a qualified service technician to inspect the
heater and to replace any part of the control system and any
gas control which has been under water.
• This furnace must not be connected to a chimney flue serving
a separate solid-fuel burning appliance.
• IMPORTANT: This furnace has a washable permanent
type filter in the door which should be cleaned at least once
per year before the heating season. For dirty or high use
areas more frequent cleaning is required.
12427-2-0903
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
LP-GAS WARNING 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!
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.
• Do not operate electric switches, light matches, use your
phone. Do not do anything that could ignite the gas.
• Get everyone out of the building, vehicle, trailer, or area. Do
that IMMEDIATELY.
• Close all gas tank or cylinder supply valves.
• LP-Gas is 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
NO ODOR DETECTED - ODOR FADE
Some people cannot smell well. Some people cannot smell
the odor of the chemical stench 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-gas is colorless, and it can fade under
some 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
firefighters declare them to be safe.
• Use your neighbor's phone and call a trained LP-Gas service
person and the fire department. Even though you may not
continue to smell gas, do not turn on the gas again. Do not
re-enter the building, vehicle, trailer, or area.
• Finally, let the service man and firefighters check for
escaped gas. Have them air out the area before you return.
Properly trained LP-Gas service people should repair the
leak, then check and relight the gas appliance for you.
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-Gas may 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
• Learn 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 LPGas Dealer.
• If you are not qualified, do not light pilot lights, perform
service, or make adjustments to appliances on the LP-Gas
system. If you are qualified, consciously think about the odor
of LP-Gas prior to and while lighting pilot lights or performing service or making adjustments.
• Sometimes a basement or a closed-up house has a musty
smell that can cover up the LP-Gas odor. 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 of LP-Gas.
• Odor 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
12427-2-0903
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.
• If, at any time, you do not smell the LP-Gas odorant 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 odorized LP-Gas.
• If 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.
Page 3
Ventilation and Combustion Air
WARNING: Danger of property damage, bodily injury or death,
this furnace and any other fuel burning appliance must be
provided with enough fresh air for proper combustion and
ventilation of flue gases. Most homes will require that outside air
be supplied. Do not draw air from a corrosive environment such
as a workshop or laundry room.
The requirements for providing air for combustion and ventilation are
listed in the National Fuel Gas Codes NFPA 54/ANSI Z223.1 (in
Canada - CAN/CGA B149).
Note: Air requirements for operation of exhaust fans, kitchen ventilation
systems, clothes dryers, fireplace and any other fuel burning or ventilating
equipment used in the space must be considered in determining
combustion air requirements.
Ventilation Air Openings and Ducts
In determining the free area needed consideration must be given to the
blocking effect of louvers, grills or screens protecting openings.
— If a screen is used to cover openings it must not be smaller than 1/4"
mesh.
— Use the free area of a louver or grill to determine the size opening
required to provide the free area specified. If the free area is not
known assume a 20% free area for wood and a 60% free area for a
metal louver or grill.
— Ducts must have the same cross sectional area as the free area of the
openings to which they connect.
— The minimum dimension of air ducts must not be less than 3 inches.
Installation in an Unconfined Space
An unconfined space is an area including all rooms not separated by
doors with a volume greater than 50 cubic feet per 1,000 Btuh of the
combined total input rates of all appliances which draw combustion air
from that space. For example, a space including a water heater rated at
40,000 Btuh input and a furnace rated at 40,000 Btuh requires a volume
of 4,000 cubic feet (50 x (40 + 40) = 4,000) to be considered as
unconfined. If the space has an 8 ft. ceiling, the floor area of the space
must be 500 sq. ft. In general, particularly in older homes, a furnace
installed in an unconfined space will not require outside air for
combustion. However in a "tight" newly constructed home, outside air
may be necessary to insure adequate combustion.
Installation in a Confined Space
A confined space is an area with volume less than 50 cubic feet per 1,000
Btuh of the combined input rates of all appliances drawing combustion
air from that space. Small areas such as equipment rooms are confined
spaces. Furnaces installed in a confined space which supply heated air
to areas outside the space must draw return air from outside the space
through tightly sealed return air ducts. A confined space must have 2
openings into the space for combustion air. One opening must be within
12 inches of the ceiling and the other must be within 12 inches of the
floor. The required sizing of these openings is determined by whether
inside or outside air is used to support combustion, the method by which
the air is brought to the space (vertical or horizontal duct) and by the total
input rate of all appliances in the space. See Figure 1.
All Air From Inside — Confined Space
If combustion air is taken from the heated space the 2 openings must
each have a free area of at least one square inch per 1,000 Btuh of total
input of all appliances in the confined space but not less than 100 square
inches (645cm
For example: for a 40,000 Btuh furnace only in the confined space each
opening must be 100 square inches (645cm
2
) of free area.
2
) each of free area.
furnace
confined
space
opening
Figure 1
Outdoor Air
Outlet and inlet air can be brought into the confined space via openings
into a ventilated attic and ventilated crawl space.
attic ventilation louvers
furnace
crawl space ventilation louvers
outlet air
inlet air
Figure 2
Confined Space
Outdoor Air Using Vertical or Horizontal Ducts
If combustion air is taken from outdoors through vertical ducts, the
openings and ducts must have a minimum free area of one square inch
2
(6.5cm
) per 4,000 Btuh of total appliance input. In installations
drawing combustion air from a ventilated attic both air ducts must
extend above the attic insulation.
outlet air
furnace
inlet air ends one foot above floor
furnace
vertical
outlet air duct
inlet air duct
WARNING: Combustion air must not be drawn from a heated
space which includes exhaust fans, fireplaces or other devices that
may produce a negative pressure in the space.
Page 4
horizontal
Figure 3
If combustion air is taken from outdoors through horizontal ducts the
openings and ducts must have a minimum free area of one square inch
2
(6.5cm
) per 2,000 Btuh of total appliance input.
12427-2-0903
Qualified Installing Agency
Installation and replacement of gas piping, gas utilization equipment 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.
The installation must conform with local codes or, in the absence of local
codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54*
Natural and Propane Installation Code, CSA B149.1.
*Available from the American National Standards Institute, Inc., 11 West 42nd St., New
York, N.Y. 10036.
Clearances
1. In selecting a location for installation, it is necessary to provide
adequate accessibility clearances for servicing and proper installation.
2. The FAW-40 can be attached to the wall or recessed into the wall up
to 9 1/2 inches (24.1cm) in depth. Note:
Do not place combustible
header or material on top of unit when installed in wall.
Maintain 3/4" minimum spacing above heater.
3. The wall in which the furnace is recessed has (0) zero (0mm)
clearance to the furnace sides.
4. When using side discharge registers, SOR-1 or SOK-1, the furnace
cannot be recessed into the wall.
5. Clearance to sidewall or combustible material is 4 inches (10.2cm).
6. Ceiling clearance is 4 inches (10.2cm).
7. Floor and rear wall clearance is (0) zero inches (0mm).
8. Clearance of 18 inches (46cm) is required to adjacent wall or
combustible material when flush mounted SOR-1, side outlet register
is used.
Before Installing Consider The Following Venting
1. A chimney for residential-type or low-heat gas utilization equipment
shall extend at least 3 feet (914mm) above the highest point where
it passes through a roof of a building and at least 2 feet (610mm)
higher than any portion of building within a horizontal distance of 10
feet (3m).
2. This furnace must not be connected to a chimney flue serving a
separate solid-fuel burning appliance.
3. Uninsulated Single-Wall Metal Pipe shall not be used outdoors
in cold climates for venting gas utilization equipment.
4. Attention! This Fan Type Vented Wall Furnace is equipped with a
vent safety switch. In the event of spillage of flue products due to
improper venting the vent safety switch will open, which results in
the main burners to "shut off".
Model No. FAW-40 may be vented as shown in Figure 4. The vent
cap termination must be at least 12 feet (3.7m) above the floor and
must exhaust to the outdoors.. Clearance to combustible construction
is held by the fixed spacers at 1 inch (25mm) with B-1 or (B-W) vent
pipe. Installation must conform to local codes.
A. 4" (102mm) Round (all parts purchase locally except Item 2)
1. Type B-1 round pipe
2. Part No. DV-648, 4" (102mm) oval-to-round flue adapter kit
(see accessories)
3. Single story type B-1 gas vents require a baseplate and one
pair of ceiling plate spacers.
4. Multi-story type B-1 gas 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.
B. 4" (102mm) Oval (all parts purchase locally)
1. Type B-1 oval pipe or B-W vent pipe
2. Single story type B-1 or (B-W) gas vents require a baseplate
and one pair of ceiling plate spacers.
3. Multi-story type B-1 or (B-W) gas 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.
C. 4" (102mm) Oval In-The-Wall (all parts purchase locally)
1. Type B-1 oval pipe or B-W vent pipe
2. Type B-1 oval elbows or B-W oval elbows
3. Single story type B-1 or (B-W) gas vents require a baseplate
and one pair of ceiling plate spacers.
4. Multi-story type B-1 or (B-W) gas 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.
Stud space around gas vents must be free of obstructions and
building paper.
4" ROUND
VENT
ENCLOSURE
WALL
ADAPTER
BASEPLATE
A.
SIDE
4" B-1 OVAL
BRACKET
BASEPLATE
FRONT
B.
4" B-1 OVAL
4" 45 DEG.
OVAL ELBOWS
SPACER
BASEPLATE
C.
4" B-1 OVAL
SPACER
C.
BASEPLATE
Figure 4
12427-2-0903
Page 5
Page 6
12427-2-0903
8. Align clearance holes on 6" x 10" (152mm x 254mm) duct with
screw holes on inner casing back and mark duct to be 2 1/4" (57mm)
shorter than 8" x 12" (203mm x 305mm) boot. Remove duct and cut
to proper length.
9. Attach 6" x 10" (152mm x 254mm) duct to inner casing back with (4)
#8 x 3/8" (9mm)screws removed in Step 3, 2 on top and 2 on bottom.
10. Insert rear register into 8" x 12" (203mm x 305mm) boot. Attach
rear register to wall with (2) #10 x 1"(25mm) screws provided.
11. Installation of ROK-1 is completed.
Locating Furnace On Wall
The furnace is to be located on a wall. The furnace is 14 1/8" (35.9cm)
in width and can be recessed into the wall with typical stud spacing.
A template is provided in furnace carton for locating gas line connection.
Also, refer to Figure 7 for positioning the furnace on wall and for
locating gas line connection.
Locating Gas Supply
The gas line can enter the furnace either through the floor or wall. The
gas line opening should be made at this time. Location of the opening
will be determined by the position of floor joists and the valve and union
used for servicing. See Figure 7.
72 3/4"
14 3/8"
CUT OUT OPENING FOR RECESSED MOUNTING
Attention! The 7/8" (22mm) strain relief bushing is located within the
same yellow envelope as the Installation Instructions and Owner's
Manual.
Attaching Furnace to Wall
When attaching furnace to the wall remove that portion of baseboard and
molding on the wall which is behind the furnace. Attach furnace to wall,
at the outer casing top, with (2) toggle bolts provided and to floor, at the
outer casing bottom, with (2) #10 x 1 1/2" (38mm) screws provided.
Gas Supply
Check all local codes for requirements, especially for the size and type
of gas supply line required. On Natural gas lines less than 75' (22.9m)
long, use 1/2" (13mm) pipe; on longer runs, use 3/4" (19mm) 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.
A manual 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.
GAS LINE
HOLE 1 1/4"
2 1/8"
4"
4"
GAS LINE/ELECTRICAL OPENINGS FOR
RECESSED AND SURFACE MOUNT
ELECTRICAL WIRING HOLE
RECESSED MOUNTING
LOCATION
8"
Figure 7
Locating Electric Supply
A 7/8" (22mm) diameter knockout is provided at the bottom of the left
and right side panels. A three-prong (grounding) plug assembly is
located within the control compartment (bottom) of the furnace. Please
remove 7/8" (22mm) knockout from appropriate side panel when
routing plug assembly to an electrical outlet.
Installation of Three-prong (Grounding) Plug Assembly
1. Disconnect nylon cap on 3' (914mm) plug assembly from nylon plug
on wiring harness. Remove 3' (914mm) plug assembly from control
compartment (bottom) of the furnace.
2. Remove 7/8" (22mm) knockout from appropriate side panel.
3. Insert nylon cap on 3' (914mm) plug assembly into the 7/8" (22mm)
hole in the side panel.
4. Connect nylon cap on 3' (914mm) plug assembly to nylon plug on the
wiring harness.
5. Place 7/8" (22mm) strain relief bushing around the cord of the 3'
(914mm) plug assembly. Insert 7/8" (22mm) strain relief bushing
into the 7/8" (22mm) hole in the side panel.
Figure 8
Method of Installing a Tee Fitting Sediment Trap
The use of the following gas connectors is recommended:
— ANS Z21.24 Appliance Connectors of Corrugated Metal Tubing
and Fittings
— ANS Z21.45 Assembled Flexible Appliance Connectors of Other
Than All-Metal Construction
The above connectors may be used if acceptable by the authority having
jurisdiction.
Pressure Testing of the Gas Supply System
1. To check the inlet pressure to the gas valve, a 1/8" (3mm) 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).
12427-2-0903
Page 7
Attention! If one of the above 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-in pressure regulator
in the gas valve. Natural gas models will have a manifold pressure of
approximately 4.0" w.c. (.996kPa) at the valve outlet with the inlet
pressure to the valve from a minimum of 5.0" w.c. (1.24kPa) for the
purpose of input adjustment to a maximum of 10.5" w.c. (2.615kPa).
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).
A 1/8" (3mm) N.P.T. plugged tapping, accessible for test gauge
connection, is located on the outlet side of the gas control.
The built-in regulator comes on at approximately 1/4th pressure and full
on in 10 seconds.
from the burner box, remove each main burner. Pilot mounting bracket
will need to be unscrewed and moved out of the way to remove all
burners. Burners can be blown out using compressed air or by blowing
through them. Be sure there is no lint or foreign debris blocking the
burner ports. Reassemble using the same screws earlier removed and
locate pilot in the same position as before and noted above.
THERMOCOUPLE
BURNER
SPARK
ELECTRODE
PILOT
STANDING PILOT
Figure 9
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 feet (305m) above sea
level. For Canadian high altitude applications, this appliance is suitable
for installation at elevations between 0 feet (0m) and 4,500 feet (1,372m)
without change.
Piezo Pilot Ignitor Instructions
Depressing the red button completely causes a spark to occur at the pilot.
This is a substitute for a match which requires opening the pilot hole
cover.
To light the pilot, it is important that the electrode be 1/8" (3mm) from
the thermocouple. The spark must occur at the point the burner flame
hits the thermocouple. The end of the electrode will be red hot with the
pilot on.
On a new installation with air in the gas line, it is suggested that a match
be used. The match will light the pilot faster than the piezo under this
condition.
Proper Pilot Flame
The correct pilot flame (Figure 10) will be blue, extending past the
thermocouple. The flame will surround the thermocouple just below the
tip.
Natural gas pilots require adjusting when the inlet gas pressure is above
5" w.c. (1.245kPa). Remove the pilot cover screw on the control valve
(Figure 9), and turn the adjustment screw clockwise to reduce flame.
Replace pilot cover screw to eliminate gas leakage.
LP gas (propane) will not require adjustment.
After use, cleaning may be required for the proper flame.
Proper Main Burner Flame
The correct flame will be a short, blue inner flame with a much larger,
light blue, outer flame. The burner does not have a primary air adjustment.
The flame will be correct if the factory-set pressure and orifice opening
are used. After the furnace has been operating, the burner ports may be
blocked by foreign matter carried in by combustion air. Therefore,
cleaning of the burner may be needed for proper flame.
To clean burner port disconnect the gas supply to the valve, and remove
the screws fastening the burner door. After removing the burner door
THERMOCOUPLE
SPARK
ELECTRODE
PILOT LOCATION END VIEW
STANDING PILOT SHOWN
3/8" TO 1/2"
PILOT FLAME
PILOT
HOT SURFACE
IGNITOR
IP-MODEL PILOT
FLAME
ROD
PILOT SHIELD
GROUND
ELECTRODE
BURNER
Figure 10
Figure 11
Cleaning Combustion (Exchanger) Assembly
A QUALIFIED SERVICE PERSON should remove the combustion
(exchanger) assembly and flue baffles. Apply air pressure to the inside
of the combustion (exchanger) assembly and flue baffles in order to
clear all passageways.
Page 8
12427-2-0903
Oiling the Motor
The fan motor should be cleaned and oiled once each heating season. Oil
holes are located on the top at each end of the motor. Use a few drops of
#10 motor oil. To clean the motor, blow air through its ventilation
openings with a vacuum cleaner or low pressure air source.
Wiring
The appliance, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with the
National Electrical Code, ANSI/NFPA 70 or Canadian Electrical Code,
CSA C22.1, if an external electrical source is utilized. This appliance
is equipped with a three-prong [grounding] plug for your protection
against shock hazard and should be plugged directly into a properly
grounded three-prong receptacle. Do not cut or remove the
grounding prong from this plug. For an ungrounded receptacle, an
adapter, which has two prongs and a wire for grounding, can be
purchased, plugged into the ungrounded receptacle and its wire connected
to the receptacle mounting screw. With this wire completing the ground,
the appliance cord plug can be plugged into the adapter and be electrically
grounded. A 7/8" (22mm) hole is provided in the junction box for use
with a conduit connector if local codes require this type of protection.
Thermostat Installation
The thermostat should be installed in the same room as the furnace 4'
(1.2m) to 5' (1.5m) above the floor and away from another heat source
(cooking stove, hot water heater, etc.) including walls and doorways
with a heat source in an adjoining room. Do Not Install Thermostat on
Outside Wall.
Insulated Vent Enclosure
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.
To reset the manual reset vent safety switch:
1. Remove front panel.
2. Depress manual reset button. The manual reset vent safety switch is
located on the draft diverter.
3. Replace front panel.
If the manual reset vent safety switch continues to "shut off" the gas flow
to the main burners a qualified service person must be contacted to
inspect for improper venting, blockage in the vent pipe or the manual
reset vent safety switch for being defective.
Figure 12
Vent Safety Shutoff System
This appliance must be properly connected to a venting system. This
appliance is equipped with a vent safety shutoff system.
Warning: Operation of this wall furnace when not connected to
a properly installed and maintained venting system or tampering
with the vent safety shutoff system can result in carbon monoxide
(CO) poisoning and possible death.
This furnace is equipped with a manual reset vent safety switch. The
manual reset vent safety switch will cause gas flow to the main burners
to "shut off" due to improper venting or a blocked flue.
12427-2-0903
PIEZO
IGNITOR
Figure 13
FLUE CONNECTOR
Figure 14
VENT LIMIT SWITCH
DRAFT DIVERTER
FAN
FAN SWITCH
LIMIT SWITCH
LIMIT SWITCH
FAN SWITCH
BURNER BOX
GAS VALVE
JUNCTION BOXTRANSFORMER
Page 9
SERVICE AND MAINTENANCE SUGGESTIONS
CALL SERVICEMAN
GENERAL: All furnaces have been fire-tested to check for proper
operation. This includes, main burner flame, pilot flame, fan operation,
fan control, limit control and automatic valve operation. If the furnace
fails to function on initial installation, it is advisable to re-check the
following:
1. 115 volts to the junction box.
2. Inlet gas pressure.
3. The 24 volt system.
4. Type of gas being used and that shown on the rating label.
The Service Department at Empire Comfort Systems, Inc. may be
contacted to assist in servicing furnace.
Standing Pilot Model
Servicing the Pilot and Main Burners, Pilot Orifice, Thermocouple,
and Main Burner Orifices: Disconnect the gas supply at the inlet to the
control valve. Then remove the burner door to gain access to the above
listed components.
Spark Igniter Does Not Light Pilot: With air in the gas line, such as
when the furnace is first installed or was off all summer, the pilot flame
may be too lean to ignite on the first few trials. Turn the control valve
knob to pilot position and depress the red reset button. Holding the
button down continually to bleed the line;.
1. Use lighter rod to light pilot with a match.
2. Use the piezo ignitor at 30 second intervals until it lights.
If Electrode Does Not Produce Spark:
1. Check wire connections.
2. Check gap for pilot burner to the electrode tip. Should be between
1/8" (3mm) and 3/16" (5mm). Electrode wire and tip must be more
than 1/4" (6mm) away from all other metal components.
If Pilot Does Not Light By Any Means:
1. Check valve knob for being in the "Pilot" position.
2. Check pilot adjustment for being full open (counterclockwise to
open).
3. If gas is available in the supply tubing, the pilot orifice and/or pilot
burner is probably restricted by a spider web. Clean pilot assembly
and relight.
If Pilot Does Not Remain On After Releasing Knob:
1. Follow instructions and hold button down longer and harder.
2. Determine if pilot flame extends past thermocouple; if not, adjust
input or clean pilot burner.
3. Replace thermocouple if millivolts read less than 15 millivolts.
Main Gas Valve Does Not Open When Thermostat Is Turned To On:
1. Check for 24 volts to valve by removing one wire and touching to
the SAME TERMINAL it was on. Terminal should have a light
spark. DO NOT SHORT ACROSS TERMINALS, AS IT WILL
BURN OUT THE WALL THERMOSTAT.
2. Thermostat wires at the wall may be shorted, so check for a faulty
thermostat.
3. To check for line voltage to furnace, remove front panel and short
across two-terminal fan control to allow fan to operate (Figure 14).
CAUTION: Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.
IP-Model Pilot
This heater is using a Honeywell "Smart Valve" system for intermittent
pilot ignition.
On a call for heat by the thermostat this control turns on a 24 volt mini
hot surface ignitor which lights a pilot that in turn lights the main burner.
The gas valve used in this system is a step opening which opens at a
lower pressure for ignition and then steps to a full inlet pressure of 4"
H
O pressure on Natural gas and 10" H20 pressure on LP gas.
2
Pilot Flame Adjustment
The pilot flame should envelop 3/8 to 1/2 inch (10 to 13mm) of the tip
of the flame rod. See Figure 10.
To adjust:
1. Remove the pilot adjustment cover screw.
2. Turn the inner adjustment screw clockwise
or counterclockwise
to increase pilot flame. Pilot adjust-
to decrease
ment is shipped at full flow rate. Turn the inner adjustment screw
clockwise
if the inlet pressure is too high.
3. Replace the cover screw after the adjustment to prevent gas
leakage.
PRESSURE REGULATOR
ADJUSTMENT-UNDER CAP
SCREW
INLET PRESSURE TAP
TO 24 V."HOT" ON TRANSFORMER
VALVE CONTROL
CONNECTOR
HONEYWELL IP
SMART VALVE
GAS FLOW
IGNITOR
ON
OFF
CONTROL
IGNITOR
CONTROL
I P-MODEL GAS VALVE AND WIRING
L2 NEUTRAL
LADDER WIRING DIAGRAM-IP VALVE
120 VAC
MOTOR
120VAC
24 VAC
THERMOSTAT
OUTLET PRESSURE TAP
PILOT ADJUSTMENTUNDER CAP SCREW
IGNITOR-PILOT ASSY.
TO 24 V. THERMOSTAT
TO 24 V. COMMON ON TRANSFORMER
L1 "HOT"
FAN
SWITCH
40 VA TRANSFORMER
VENT SAFETY
LIMIT
PILOT OUTLET
WIRING
LIMIT
CONTROL
Figure 15
Page 10
12427-2-0903
STANDING PILOT MODEL
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these instructions
exactly.
B. BEFORE LIGHTING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. Remove control access panel (lower front panel).
5. Turn gas control knob clockwise to "OFF."
6. Wait ten (10) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas,
STOP! Follow "B" in the safety information above. If
you don't smell gas, go to the next step.
7. Remove the pilot access cover located on the combustion chamber.
8. Find pilot - follow metal tube
from gas control. The pilot is
located between the two burner
tubes behind the pilot access cover.
• If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in
or turn by hand, don't try to repair it; call a
qualified service technician. Force or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to inspect the appliance and to replace any part
of the control system and any gas control which has
been under water.
9. Turn gas control knob counterclockwise
to "PILOT."
10. Push and hold red reset button down completely and
repeatedly push the ignitor button until the pilot burner
is lit. Pilot may also be lit with a match. Continue to
hold the red reset button down for about one (1)
minute after the pilot is lit. Release button and it will
pop back up. Pilot should remain lit. If it goes out,
repeat steps 5 through 10.
• If button does not pop up when released, stop and
immediately call a qualified service technician or
gas supplier.
• If the pilot will not stay lit after several tries, turn
the gas control knob to "OFF" and call your
service technician or gas supplier.
11. Replace pilot access cover.
12. Turn gas control knob counterclockwise
to "ON."
13. Replace control access panel (lower front panel).
14. Turn on all electric power to the appliance.
15. Set thermostat to desired setting.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to appliance if service is
to be performed .
3. Remove control access panel (lower front panel).
12427-2-0903
4. Push in gas control knob slightly and turn clockwise to "OFF." Do not force.
5. Replace control access panel (lower front panel).
Page 11
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