24 VAC SYSTEM CONTROL KIT
Model: CK-92FVP and CK-92FGP
Designed for use with the SWG Series Power Venter for controlling
Natural Gas or L.P. Gas appliances equipped with a 24 VAC
automatic vent damper and a 30-millivolt controlled Natural or L.P.
Gas Water Heater.
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TEMS INCLUDED IN KIT:
1) Junction box with mounted pressure switch and post purge timer
1) Fan control gas pressure switch with built in post purge option
1) 2 ft. length of 1/4 inch aluminum tubing
1) 1/8" NPT x 3 inch pipe nipple
1) 1/8" NPT x 1/4 inch OD tubing elbow
1) 1/8" NPT pipe tee
1) TCA-1 Thermocouple Adaptor (CK-92FVP)
1) TCA-2 Left Handed Thermocouple Adaptor (CK-92FGP)
1) 6 ft. length of 12-2 wire
1) 8 inch jumper wire
2) Flexible conduit connector
2) GSK-3 Spillage Switch
1) 1/4 inch tubing connector
WARNING: Installer: if the 24V appliance does not have a blocked vent switch, an
additional GSK-3P spillage switch kit, p/n 46458600, (not included) must be installed
(See Diagram B).
DO NOT DESTROY
THESE INSTRUCTIONS MUST REMAIN WITH EQUIPMENT
INSTALLATION
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OUNTING CONTROL BOX
The control box must be mounted within 6’ of the vent damper, and within
reach of the appliance’s existing damper cable. If the control box must be
mounted out of reach of the power venter’s attached wiring, an additional
installer supplied junction box and wiring (with approves wiring enclosure if
necessary) will be required. (See Figure 1 & 2)
1. Install the flexible conduit connector onto the CK-92* control box and
secure with fastening nut. If additional wiring is required, install the
flexible conduit connector onto the installer supplied junction box.
2. Fasten the flexible conduit from the SWG Venter into the conduit
connector. Mount the CK-92* control box onto a non-heated vertical
surface of the appliance or nearby wall or floor joist through the four
dimpled locations on the base of the box. NOTE: The mounted
pressure switch diaphragm must be mounted with a vertical orientation;
see label on pressure switch. (See Figure 3) If required, run additional
wiring as in figure 2 and connect to CK-92* control box, if required, using
the supplied flexible conduit connector and approved connectors and
anti-short bushings.
Figure 1
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RESSURE SWITCH SENSING TUBE INSTALLATION
1. Attach the 1/4 inch tubing connector to the pressure tube on the SWG
Venter. (See Fig. 3)
2. Connect installer supplied 1/4" O.D. aluminum, copper or stainless steel
tubing to the tubing connector.
3. Route the tubing to the CK control box and connect the tubing to the
pressure switch using supplied plastic nut. When routing the tubing,
avoid kinking the tubing by bending the tubing too sharply. Support the
tubing at 2’ intervals using installer supplied tube clamps.
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Figure 2
Figure 3
ADJUSTMENTS
ROVING SWITCH ADJUSTMENTS
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After proper air flow is established, the pressure switch adjustment is made by
turning the pressure switch adjustment screw clockwise (See Figure 4) until
burner operation stops. Turn the adjustment screw counterclockwise until
burner ignites. Turn the adjustment screw an additional 1/4 to 3/4 turn
counterclockwise to ensure adequate switch adjustment.
WARNING: Failure to properly adjust the pressure switch as specified above
could lead to improper operation of the pressure switch which will result in a
hazardous condition and bodily harm!
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HERMOSTAT HEAT ANTICIPATOR ADJUSTMENT
After venting kit installation and checkout, check the amperage current draw through the
thermostat circuit and adjust the thermostat anticipator accordingly.
INSTALLATION OF GAS PRESSURE SWITCH
CAUTION: Check gas control valve pressure. Pressure MUST NOT exceed 14" WC
pressure.
1. Remove pressure tap plug in gas valve. (See Figure 5) NOTE: If installing on an
existing appliance, shut off gas supply to gas valve before plug removal.
2. Replace the pressure tap plug with the 1/8" pipe nipple and pipe tee. Install pressure
tap plug at the bottom of the pipe tee. (See Figure 6)
3. Install the gas pressure switch into the side of the pipe tee. The gas pressure switch
is supplied with a restrictor orifice in the inlet and outlet ports. With these orifices in
place, the switch does not need to be vented. This feature complies with current
ANSI standards for gas regulators. (See Figure 7).
CAUTION: If for any reason the system has shut down during operation, the cause of
the system failure should be investigated and corrected before resetting the safety
switch and restarting the system.
DRAFT HOOD SAFETY SWITCH INSTALLATION PROCEDURE
NOTE: 12 ga. wire should be used when wiring safety spillage switches, to reduce the
voltage drop in the thermocouple circuit.
1. Remove the thermocouple from the gas control valve. (See Figure 5)
2. Thread the junction block into the thermocouple port and thermocouple into the
bottom of the junction block. (See Figure 8)
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
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NOTE: Draft spillage switches should be mounted 90 degrees apart, and
mounted opposite from the vent outlet direction. (See Figure 9)
3. Mount the two spillage switches onto the draft hood and connect
inside terminals of switches with jumper wire. Connect outside
terminals to 6’ 12ga lead wires which are connected to the
thermocouple junction block. (See Diagram A)
4. Route jacketed lead wires or accepted wiring enclosure on the outside
of the water heater enclosure. Secure them to the enclosure with an
accepted hold down tab. Keep wiring away from any HOT surface
area.
WIRING
Figure 9
CAUTION: Disconnect electrical power when wiring power venter.
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. Route the venter motor and control wiring with an appropriate wiring method. Refer to
Wiring Diagrams A and B.
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NTERNAL WIRING FOR CK-CONTROL KIT
Diagram A
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Diagram B
L1 to 1 on post purge timer T2 to timer relay base
M to 3 on post purge timer T3 to N/O on pressure switch
T1 to common on pressure switch Timer base to common on pressure switch
LOW VOLTAGE WIRING INSTRUCTIONS FOR
BOILERS:
1. Route the appliance’s vent damper cable to
the CK-92*. Plug the cable into the
receptacle located inside the CK-92* using
the supplied plastic knockout grommet (if the
cable does not have a conduit connector).
(See Diagram A)
2. Connect the CK-92*’s pre-wired damper
cable to the vent damper (See Diagram A).
Snap the end of the flexible conduit into
place on the vent damper conduit bracket. If
the damper has a round type motor
assembly and does not have a conduit bracket (See Diagram A), install the supplied
conduit bracket using the supplied #6 screws and nuts (See Figure 10). If it has a
rectangular or “box-like” motor assembly, refer to Fig. 11 for cable attachments.
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INE VOLTAGE WIRING INSTRUCTIONS
1. Connect 120 volts hot power source wire to terminal L1 on CK-92*.
2. Connect 120 volts neutral power source wire and white wire from venter motor to terminal N on the CK-92*.
3. Connect black wire from venter motor to terminal M on the CK-92*.
4. Wire gas pressure switch terminals COM and NO to L1 and M respectively, per local and national electrical code
requirements.
Refer to the SWG Venter installation instructions for setting system airflow.
Figure 10
Figure 11
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SYSTEM CONTROL CHECK OUT PROCEDURES
1. Adjust the thermostat and/or aquastat to call for heat and observe the power venting system for proper operation
sequence. (Repeat if necessary)
a. Aquastat calls for heat.
b. After a short delay, the relay is energized, the venter motor starts and the vent damper begins opening.
c. Pressure switch closes, the vent damper reaches the open position and the burner starts.
d. Aquastat is satisfied, the burner stops and the vent damper begins closing.
e. This starts the post purge cycle. Purge time 1 to 2 min.
2. While system is operating, disconnect power to the venter motor. This should open the pressure switch contacts and
stop burner operation.
GAS PRESSURE SWITCH FOR WATER HEATER
1. Follow water heater manufacturer's instructions to light pilot. Turn the gas control valve to the ON position. Then
adjust the thermostat to call for heat, which will energize the venter motor. (May see a 1 to 8 sec. delay of venter
motor)
2. Turn gas control valve to the PILOT position, which will start a 1 to 3 min. post purge of the venter motor.
3. Repeat Step 1 and 2 to ensure proper operation.
SPILLAGE SWITCHES
1. Allow the water heater to heat up to operating temperature, then disconnect the power to the gas pressure switch.
2. Adjust the thermostat to call for heat with the venter inoperative. Allow approximately 2 minutes of flue gas spillage for
the spillage switches to sense the spillage and disrupt the thermocouple circuit, halting the gas flow to the pilot and
burner.
3. Wait 2 to 3 minutes. Reset the spillage switches and light the pilot, then perform a second safety spillage test (Steps 1
and 2).
CAUTION: If for any reason the system has shut down during operation, the cause of the system failure should be
investigated and corrected before resetting the safety switch and restarting the system.
TROUBLE SHOOTING HINTS
1. Venter does not activate when thermostat calls for heat.
a. Check wiring: 115 VAC from L1 to ground; N connected to a neutral.
b. Check for 24V from orange to black wires on base of timer relay. If no other voltage, the appliance is not calling
for heat to the CK-92*. If there is 24 volts continuously for at least 45 second, there should be 115 volts from N to
M. If not, the time relay is defective, or L1 and N are not properly wired.
c. Check gas pressure switch for continuity across terminals when water heater burner is lit.
2. Flue gas odor:
a. Check system draft. Adjust power venter’s airflow adjustment damper if necessary.
b. Check for negative pressure in building.
3. Venter activates but burner does not fire after a minimum of 45 second continuous call for heat:
a. Check wiring.
c. Check pressure switch adjustment.
d. Make sure the vent damper is in open position.
e. Check for 24 volts from both yellow wires on pressure switch to black wire on base of timer relay. If neither yellow
wire has 24 volts, the vent damper is defective, has loose wiring, or is not receiving call for heat on the orange
wire. If one yellow wire has 24 volts but the other does not, the pressure switch is not closing.
4. Pilot will not stay lit on water heater:
a. Solder all spillage switch wire terminal connections.
b. Check reset buttons on spillage switches.
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REPAIR AND REPLACEMENT PARTS LIST
Gas Pressure Switch 46284200
GSK-3 Spillage Switch 46086400
Post Purge Timer 46282800
Pressure Switch 46273100
TCA-1 Thermocouple Adaptor 46082700
TCA-2 Left Handed Thermocouple Adaptor 46429900
Wire Harness 46457200
MODEL PART NUMBER
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INSTALLATION INFORMATION
MODEL NO.:____________________________________________________________
CK-92FVP/CK-92FGP
INSTALLER'S NAME:_____________________________________________________
INSTALLER'S COMPANY: _________________________________________________
INSTALLER'S PHONE NO.: ________________________________________________
DATE OF INSTALLATION:_________________________________________________
Page 8
P/N 46490500 05/05
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