Empire Products 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

MARCH 2006

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.

— Do not store or use gasoline or other flam

mable 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.

-

12427-4-0306

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 l eave instruction manual w ith 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" (84.1mm) 72 1/2" (184.1mm)
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" (12.7mm) 1/2" (12.7mm)
Vent Collar Type B Oval 4" (101mm) 4" (101mm)

CFM 275 275
Accessories

Register, side outlet, fixed register
Side outlet, 10" (254mm)

maximum extension, fixed register
Rear outlet, 10" (254mm)

maximum extension, adjustable register
Vent enclosure, 24" (609mm)

[for rooms up to 96 1/2" 2451mm) in height]
Vent enclosure, 34" (86cm)

[for rooms up to 106 1/2" (2705mm) in height]
Vent enclosure, 46" (1168mm)

[for rooms up to 118 1/2" (3009mm) in height]
Oval-to-Round flue adapter kit 4" (102mm) DV-648

SOR-1
SOK-1

ROK-1

FVE-24

FVE-34

FVE-46

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.

12427-4-0306

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 odor

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.

ant. 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-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
LP-Gas 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

12427-4-0306

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.
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 un
der 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.

A periodic sniff test of the LP-gas is a good safety

Page 3

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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 (645cm2) of free area.

For example: for a 40,000 Btuh furnace only in the confined space each
opening must be 100 square inches (645cm2) each of free area.

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.

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
(6.5cm2) 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.

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

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
(6.5cm2) per 2,000 Btuh of total appliance input.

12427-4-0306

4” ROUND

VENT
ENCLOSURE

ADAPTER

BASEPLA

TE

WALL

SIDE

FRONT

A.

4” B-1 OVAL

BRACKET

BASEPLA

TE

B.

4” B-1 OVAL

4” B-1 OVAL

SPACER

BASEPLA

TE

BASEPLA

TE

C.

SPACER

C.

4” 45 DEG.
OVAL ELBOW

S

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.

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.

Note:

Do not place combustible

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

1. Type B-1 round pipe

(all parts purchase locally except Item 2)

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.

Figure 4

.

12427-4-0306

Page 5

Figure 5

Use U.L. listed gas vent equipment when installing the FAW-40. For
vent pipe running through walls, roof, and within one (1) inch (25mm) of
combustible construction, use B-1 or (B-W) [one inch (25mm) clearance
to combustibles] vent pipe. Type B-2 x 4 or Type B-2 x 6 are to be used
in conjunction with a Listed fire stop spacer.

Be sure baseplate is attached to top of furnace before inserting unit into
recessed wall installation.

Installing Optional Side Outlets

Side outlet register,
furnace at the required clearances of 18 inches (457mm) to adjacent wall
or combustible material as shown in Figure 6.

1. Turn "OFF" all electric power to the furnace.

2. Remove the front panel from the furnace.

3. Remove the (2) #8 x 3/8" (9mm) screws that attach the inner shield
cover plate to the inner shield.

4. Scribe a line between the four dimples on the outer casing side to form
a square.

5. Drill a pilot hole within the scribed square on the outer casing. Remove
the sheet metal within the scribed square with a tin snips or comparable
tool. Attention! Do not cut the electrical wires located between the outer
casing and the inner shield.

6. Insert the 5" x 5" (127mm x 127mm) inner boot through the outer cas
ing. Align the clearance holes on the inner boot with the screw holes
on the inner shield. Attach inner boot to inner shield with (2) # 8 x 3/8"
(9mm) screws removed in Step 3.

7. Place the register over the 5 1/2" (140mm) square opening with the
louvers set for the desired direction and mark the mounting holes using
the register as a template.

8. Drill (2) 1/8" diameter holes in cabinet side and attach the register with
(2) #10 x 1" (25mm) provided screws.

9.

Installation of SOR-1 is completed.

Side outlet kit,
warm air discharge into an adjoining room may be installed on either side
of the furnace at the required clearance of 4 inches (102mm) to adjacent
wall as shown in Figure 6.

To install SOK-1, please use Steps 1 through 5 in the SOR-1 instructions
for FAW-40 furnaces. Now, use the following Steps to complete installa
tion of the SOK-1.

1. Using the inner and outer boots as hole templates, mark and drill (4)
1/8" (3mm) diameter holes in the inner shield and (4) 1/8" (3mm)
diameter holes in the cabinet side.

2. Locate and cut a 6 3/4" (171mm) square opening through wall.

3. Attach furnace to wall (see Attaching Furnace to Wall

4. With furnace in place, after checking alignment of side outlet opening
in wall and furnace, place the 9 3/8" x 9 3/8" (238mm x 238mm) side
outlet wall plate over outer boot, pass the outer boot through the wall

Page 6

SOR-1 may be installed on one or both sides of the

SOK-1, 10" (254mm) boot assembly with register, for

).

and attach side wall plate to furnace side of wall with (2) #10 x 1 1/2"

(38mm) provided screws.

5. Attach outer boot to the cabinet side with (4) #8 x 1/4" (6mm) provided
screws.

6. Position and attach inner boot to inner shield with (4) #8 x 1/4" (6mm)
provided screws.

7. Place the register over the 6 3/4" (171mm) square opening with the louvers
positioned for the desired discharge direction and mark the mounting
holes using the register as a template.

8. Drill (2) 1/8" (3mm) diameter holes in the wall and attach the register
with (2) #10 x 1 1/2" (38mm) provided screws.

9. Installation of SOK-1 is completed.

Figure 6

Installing Optional Rear Outlet

Rear outlet kit, 10" (254mm) boot assembly with register, ROK-1 for warm
air discharge into an adjoining room.

-

Attention: Before furnace is attached to the wall, the wall opening for the
rear outlet must be cut, in addition to removal of the outer and inner casing
knockouts on furnace.

1. The wall opening measurements for the rear outlet are the following.

A. From floor to bottom of wall opening is 10 11/16" (271mm).
B. From bottom of wall opening to top of wall opening is 8 1/2"

(216mm).

C. Wall opening width is 12 1/8" (308mm).

2. Scribe a line between the four dimples on the outer casing back to form

a square. Drill a pilot hole within the scribed square on the outer casing
back. Remove the sheet metal within the scribed square with a tin snips
or comparable tool.

3. Remove the (4) #8 x 3/8" (9mm) screws that attach the inner casing

close off plate to the inner casing.

4. Insert the privacy shield through the outer casing back and the inner

-

casing back. The privacy shield will be in front of the inner casing back
and behind the combustion chamber tubes. Align clearance holes on
privacy shield with screw holes on inner casing back. Attach privacy
shield to inner casing back with (2) #8 x 3/8" (9mm) provided. Attention:

The (2) #8 x 3/8" (9mm) screws must be inserted from the front of
the furnace.

5. Attach furnace to wall.

6. Align clearance holes on 8" x 12" (203mm x 305mm) boot with screw

holes on outer casing back and mark boot to be flush with wall surface.
Remove boot and cut to proper length.

7. Attach 8" x 12" (203mm x 305mm)boot to outer casing back with (6)

12427-4-0306

#8 x 3/8" (9mm) screws provided.

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.

(914mm) plug assembly. Insert 7/8" (22mm) strain relief bushing into
the 7/8" (22mm) hole in the side panel.

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.

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'

12427-4-0306

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).

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.

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

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

12427-4-0306

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.

manual reset vent safety switch continues to "shut off" the gas

If the
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.

12427-4-0306

Figure 13

FAN SWITCH

LIMIT SWITCH

Figure 14

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).

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 leak
age.

-

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
pressure on Natural gas and 10" H20 pressure on LP gas.

O

2

Page 10

Figure 15

12427-4-0306

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. STO P ! R e a d th e sa f e t y in f o rm at io n
above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. Rem o v e c o n t r o l a ccess panel (lower f r o n t
panel).

5. Turn ga s c o n t rol 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 t he 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

• 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.

tubes behind the pilot access cover.

9. Tur n g a s c o n tro l k n o b coun t e r c lo c k w is e

to "PILOT."

10. Pu sh and hold red reset b utto n d own com
pletely 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. Rep l a c e c o n t rol access pane l ( l o w e r 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. Tur n off all e l ectri c po wer to appl i ance if
service is to be performed .

3. Remove con trol acc ess pan el (lo wer front

12427-4-0306

panel).

4. Push in gas control knob slightly and turn
clockwise to "OFF." Do not force.

5. Re plac e cont rol acces s pane l (low er front
panel).

Page 11