Field Controls 46477500 User Manual

DRAFT INDUCER KIT WITH PRE-WIRED CONTROL AND

THERMAL SAFETY SWITCHES

Model: DI PAK 24

Kit Includes:

• DI-2 Draft Inducer with pre-wired
power cable

• CK-41P control box with pre­wired power cable

• FTS Thermal Safety Switches,
pre-wired to CK-41P

• 5’ of ¼” Aluminum tubing

• Miscellaneous mounting and

connection hardware

This draft inducer kit is designed for installation on vent systems serving gas-fired
appliances having a 24V automatic damper and draft hood. The control and thermal
safety switches are pre-wired for easy field installation via the modular damper
control harness connector.

DO NOT DESTROY

THESE INSTRUCTIONS MUST REMAIN WITH EQUIPMENT

CAUTION:

This device is NOT designed for sidewall venting applications. The vent to which the inducer is to be mounted is to be
installed in accordance with NFPA 54 or other local codes.

This device MUST be installed by a qualified agency in accordance with the manufacturers installation
instructions.

The definition of a qualified agency is: any individual, firm, corporation or company which either in person or through a
representative is engaged in, and is responsible for, the installation and operation of gas appliances, who is experienced
in such work, familiar with all the precautions required, and has complied with the requirements of the authority having
jurisdiction.

Appliances should have a maximum measure flue gas temperature of 750°F at the desired location of the draft inducer.
The installer MUST write or imprint his name, phone number, and date of installation on the tag provided with this device.
The tag MUST be attached to the draft inducer. Recording burner and draft inducer operation information (draft level,
efficiency, etc) is recommended as a guide for future service.

Draft inducers are designed to increase draft in venting applications where inadequate natural draft exists.

WARNING

instructions, before placing the appliance into service.

: The fan proving pressure switch MUST be adjusted according to the procedure, given in these

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I. MOUNTING THE CONTROL BOX (Figure 1)

1. Remove the kit from the packaging and inspect for
shipping damage.

2. Place the pre-wired control box/thermal safety
switch assembly on top of the water heater.

3. Select a location for mounting the control box, so
that the water heater’s damper cable will reach the
socket provided inside the control box, and the
control box damper cable will reach the damper
motor. NOTE: The pressure switch on the control
box must be mounted vertically, see the warning on
the pressure switch.

WARNING:

WARNINGS OR OTHER IMPORTANT LABLES ON
THE WATER HEATER!

4. Mount the control box onto the water heater in the
location selected, using installer-supplied sheet metal screws though the four dimpled holes in the base of the
control box.

WARNING: DO NOT INSTALL SCREWS INTO A RACEWAY OR OTHER ENCLOSURE CONTAINING WIRING OR
ELECTRICALLY LIVE PARTS!

II. MOUNT THE THERMAL SAFETY SWITCHES (Figure

2)

1. Select locations for the two pre-wired thermal safety
switches on the draft hood. The thermal safety
switches should be mounted at right angles to each
other, and on the side of the draft hood that is
nearest to any potential source of depressurization
of the structure (vent fans, oven hoods etc.).

2. Mark the locations of the thermal safety switches,
and drill holes for the #10-24 mounting screws
provided.

3. Mount the switches onto the draft hood using the
screws, flat and serrated washers, and nuts
provided. Adjust the position of each switch such
that the edges of the sensors are 1/8” from the edge
of the draft hood.

4. Secure any excess cable with the cable clamps
provided.

III. CONNECT TO APPLIANCE CONTROL AND

DAMPER (Figure 3)

3. Disconnect power to the water heater.

4. Remove a knockout from the control box for the
water heater damper cable, and install the supplied
plastic bushing into the knockout as shown.

5. Insert the water heater damper cable into the
control box through the bushing, and plug it into the
socket provided in the control box. BE SURE TO
ALIGN THE GROOVE IN THE PLUG WITH THE
SPLINE IN THE SOCKET WHEN INSERTING!

6. Connect the control box damper cable to the
automatic damper. BE SURE TO ALIGN THE
GROOVE IN THE PLUG WITH THE SPLINE IN
THE SOCKET WHEN INSERTING!

IV. INSTALL THE DI CONTROL KIT ADAPTER KIT ON THE DRAFT INDUCER

1. Refer to the included instructions with the kit for this procedure.

DO NOT OBSCURE ANY EXISTING

Figure 1

Figure 2

Figure 3

(Pressure sensing port)

Page 2

V. INSTALL THE DI-SERIES DRAFT INDUCER ON THE VENT

N

PIPE (Figure 4)

1. Refer to the included DI instruction manual for this
procedure. Set the draft adjustment plate on the draft
inducer to maximum setting before installing

NOTE: The draft inducer proving switch (DIP-1) is not required;
a proving switch is provided on the control box.

2. Connect the DI pressure sensing port as installed under step
IV to the pressure switch mounted on the control box, using
the supplied ¼” aluminum tubing and the supplied white
plastic nut on the pressure switch port.

Pressure
Sensing
Port

VI. CONNECT DRAFT INDUCER POWER CABLE TO CONTROL

BOX (Figure 5)

1. Remove a knockout from the control box, and connect the
conduit connector on the end of the draft inducer pre-wired
power cable to the control box.

2. Connect the green ground wire from the draft inducer to
the stripped green ground wire riveted to the control box,
using the supplied wire nut.

3. Connect the black wire from the draft inducer to the “M”
terminal on the control box.

4. Connect the white wire from the draft inducer to the “N”
terminal on the control box.

VII. CONNECT TO POWER SOURCE:

1. CAUTION:
for the control box and draft inducer.

2. If local wiring codes allow, plug the 115V power cord from the control box into a 115V outlet having at least a 15
Amp Rating. If local wiring codes require that the unit be permanently wired into a power source, follow
guidelines to connect the power source to the L1(hot) and N (neutral) terminals on the control box and ground.
Wire the venter motor and controls in accordance with the National Electrical Code, manufacturer's
recommendations and/or applicable local codes. Units must be grounded. Check ground circuit to make certain
that the unit has been properly grounded. The wiring should be protected by an overcurrent circuit device rated at
15 amperes. CAUTION must be taken to ensure that the wiring does not come into contact with any heat source.
All line voltage and safety control circuits, between the venter and the appliance, must be wired in accordance
with the National Electrical Code for class one wiring or equivalent methods.

VIII. SET PRESSURE SWITCH AND PERFORM CHECK-OUT PROCEDURE:

Disconnect power to the intended power source

White
Plastic

ut

Figure 4

Adjusting
Screw

Figure 5

WARNING

service.

1. Reconnect power to the water heater and control box source(s).

2. Disable all ventilation and other equipment that may affect the air pressure in the area of the water heater, and
open a nearby door or window if possible, to ensure that the air pressure in the water heater area is neutral.

3. Create a call for heat from the water heater if necessary, by running hot water or temporarily resetting the
thermostat. The automatic damper should begin opening, and after a short delay, the draft inducer should begin
running and the burner should fire. If the burner does not fire with the damper open and the draft inducer running,
turn the pressure switch adjusting screw counterclockwise until the burner fires.

4. Allow burner to operate 5 minutes, then while the burner is still firing turn the pressure switch adjusting screw
clockwise until the burner shuts off. Now, back the screw out just until the burner fires, then back the screw out
an additional 1/8 to 1/4 turn.

5. Tighten the locknut on the adjusting screw.

6. While the burner is firing, disconnect power to the control box. The burner should shut off within a few seconds,
after the draft inducer motor shaft stops turning.

7. While the burner is firing, hold a match or other low-temperature heat source (do NOT use a propane torch or
similar device) up to the sensing disk on either of the thermal safety switches. When the disk is heated to

: The adjustment screw on the pressure switch MUST be set before putting the appliance into

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approximately 140°F, the switch should activate and shut the burner off. Allow to cool and manually reset the
thermal safety switch. Repeat this procedure for the other thermal safety switch.

IX. INTERNAL WIRING DIAGRAM

X. REPLACE MENT PA RTS

Description Part Number

DI-2 46075300
FTS-4 01170004
Pressure Switch 46273100
RJR-5 46080200

P/N 46477500 Rev B 10/06

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