Field Controls B794621 User Manual

24 VAC SYSTEM CONTROL KIT

Model: CK-91F and CK-91FG

Designed for use with the SWG Series Power Venter for controlling Natural Gas or L.P. Gas draft induced
appliances with a 24 VAC Gas Valve and a 30-millivolt controlled Natural or L.P. Gas Water Heater.

ITEMS 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

1- 2 ft. length of

1

1­ 1­ 1-

⁄8" NPT x 3" pipe nipple

1

⁄8" NPT x 1⁄4" OD tubing elbow

1

⁄8" NPT pipe tee

⁄4" aluminum tubing

1- TCA-1 Thermocouple Adaptor (CK-91F)
1- TCA-2 Left Handed Thermocouple Adaptor (CK-91FG)
1- 6 ft. length of 12-2 wire
1- 8" jumper wire
2- Flexible conduit connector
2- GSK-3 Spillage Switch
1- 4" MG1 Barometric Draft Control

1

1-

⁄4" tubing connector

READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY BEFORE PROCEEDING WITH THE INSTALLATION.

This device MUST be installed by a qualified agency in accordance with the manufacturer's 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 HVAC appliances, who is experienced in such work, familiar with all the
precautions required, and has complied with all the requirements of the authority having jurisdiction.

Please retain these instructions after installation.

Installed By: Phone:

www.fieldcontrols.com

Installation Date:

Typical Vent System Layout

MOUNTING JUNCTION BOX

The junction box can be mounted at the venter or remotely mount­ed away from the venter.
(See Figure 1 & Figure 2)

Remove one of the knockouts from the side of the junction 1.
box where the pressure switch is mounted. Install the flexible
conduit connector onto the CK-91F junction box and secure
with fastening nut. If remote mounting the CK-91F junction
box, mount the flexible conduit connector onto a 2" x 4"
installer supplied junction box.

Fasten the flexible conduit from the SWG Venter into the 2.
conduit connector. Mount the CK-91F junction box or installer
supplied junction box onto the wall or floor joist without
straining the flexible conduit. Fasten the CK-91F junction box
through the four dimpled locations on the base of the box.
(See Figure 3)

PRESSURE SWITCH SENSING TUBE INSTALLATION

1

Attach the 1.
SWG Venter. (See Figure 3)

Connect the supplied 2.
connector. Route the tubing to the CK-91F junction box and
connect the tubing to the pressure switch. When routing the
tubing, avoid kinking the tubing by bending the tubing too
sharply.

For remote mounted CK-91F Junction Box, use a
aluminum or plastic tubing and route the tubing to avoid contact
with any heat source.

⁄4" tubing connector to the pressure tube on the

1

⁄4" aluminum tubing to the tubing

1

⁄4" OD copper,

Figure 1

Figure 2

DRAFT CONTROL INSTALLATION
CAUTION: This draft control is shipped as a single acting draft

control. If the draft control is not being used on a gas draft
induced furnace, remove the gate stop on the draft control ring
before installing.

page 2

Figure 3

COLLAR INSTALLATION

This control is shipped with a collar patterned to fit a single wall round
vent pipe. To attach this collar to the flue, See Figure 4 and follow the
instructions below.

Bend outward the two ears at the front corners of the collar. Bend 1.
90 degrees,

1

⁄4" behind the single hole on the straps.
Insert clamping screw in ears on collar and bolt the remainder of 2.
the collar together.
Hold the collar against the side of the flue in the exact position it 3.
is to be installed (shown by dotted lines) and mark the outline of

Figure 4

the collar on the flue.
Cut a hole in the flue about 4.
Make a series of cuts about 5.

1

⁄2" inside of this outline.

1

⁄2" apart from the edge of this hole to the outline marks.
Strap the collar to the flue pipe.6.
Bend the tabs formed by the series of cuts outward against the inside of the collar to make a tight joint.7.
Insert the draft control. (See Draft Control Installation and Adjustment Section.)8.

DRAFT CONTROL INSTALLATION IN TYPE B VENT PIPE
CAUTION: DO NOT use the supplied collar when mounting draft control to Type B Vent Pipe. Install by using a

Type B Vent Pipe Tee.

Install a vent pipe reducer or increaser into the inner pipe and fasten using sheet metal screws. 1.
(See Figure 5)
The opening of the Type B Vent Tee, at the draft control 2.
mounting location, should be sealed with a high
temperature sealant or equivalent.
Refer to Draft Control Installation Section.3.

DRAFT CONTROL INSTALLATION AND ADJUSTMENT

Insert the draft control into the collar or tee. The front face 1.
of the control MUST be plumb and the bearing surfaces
MUST be level whether the control is on a horizontal,
vertical or sloping flue pipe.
Use a spirit level and level accurately. (See Figure 5) 2.
Secure the control in the collar by tightening the clamping

Figure 5

screws. If a tee is used or a collar is supplied locally, the
control may be held in place by sheet metal screws.

ADJUSTING THE DRAFT CONTROL WITH 4” MG1

The control MUST be adjusted to the desired draft setting by
adding or removing the washer-type weights supported by the
two chains on the side of the draft control. (See Figure 6) DO
NOT move the weight attached directly to the gate, this is used
only for balancing at the factory.

WHAT DRAFT SETTING TO USE

When adjusting the control, two things are essential;

The burner must be operating for at least 10 minutes to 1.
obtain maximum chimney draft.

Figure 6

An analysis of the flue gases is necessary to determine the 2.
percentage of CO

Refer to the appliance instructions and/or to the local gas company for the proper CO

and check for presence of CO.

2

readings and

2

allowable CO levels. A rule of thumb for draft setting is between .01” to .03” of water column draft at the
appliance outlet. (Check equipment requirement.)

Changes in the adjustment of the 4” MG1 control should be made by adding or removing the washer-like
weights (supplied with the control) to or from the weight holder chain assembly. After the control is adjusted,
its action will be entirely automatic, the gate will open or close by itself to correct for changes in the draft that
occur in the chimney.

page 3

ADJUSTMENTS
PROVING SWITCH ADJUSTMENTS

After proper airflow is established, the pressure switch adjustment is made
by turning the pressure switch adjustment screw clockwise (See Figure 7)
until burner operation stops. Turn the adjustment screw counterclockwise

1

until burner ignites. Turn the adjustment screw an additional

⁄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!

THERMOSTAT 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.

Remove pressure tap plug in gas valve. (See Figure 1.

8) NOTE: If installing on an existing appliance, shut
off gas supply to gas valve before plug removal.

1

Replace the pressure tap plug with the 2.

⁄8" pipe
nipple and pipe tee. Install pressure tap plug at the
bottom of the pipe tee. (See Figure 9)
Install the gas pressure switch into the side of the 3.
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 10).

Figure 8

Figure 10

Figure 7

Figure 9

Figure 11

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.

Remove the thermocouple from the gas control valve. (See Figure 8)1.
Thread the junction block into the thermocouple port and 2.
thermocouple into the bottom of the junction block. Connect lead wire
from the junction block to the jacketed lead wires or wire enclosed in
an accepted wiring enclosure. (See Figure 11)

NOTE: Draft spillage switches should be mounted 90 degrees apart, and
mounted opposite from the vent outlet direction. (See Figure 12)

Mount the two spillage switches onto the draft hood and connect 3.
inside terminals of switches with jumper wire. Connect outside
terminals to lead wires which are connected to the thermocouple
junction block. (See Diagram A)
Route jacketed lead wires or accepted wiring enclosure on the 4.
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.

Figure 12

Figure 13

page 4

WIRING
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.

LOW VOLTAGE WIRING INSTRUCTIONS FOR BOILERS AND WARM AIR FURNACES

With boilers, locate terminal on spark ignition module or gas valve (if standing pilot) which would 1.
normally be 24 volts hot on a call for heat. With spark ignition systems, this terminal could be TH-W, 24
V, THS or T1 depending on the spark ignition control.
With warm air furnaces, locate terminal W in furnace junction box.2.
Remove wire from this terminal and reroute to T1 on CK-91F.3.
With boilers, connect T3 on CK-91F to hot side of gas valve (if standing pilot) or to terminal TH-W, 24 V, 4.
THS or T1 if spark ignition.

NOTE: Remember, the correct terminal is the one that would normally be hot on a call for heat.

With warm air furnaces, connect T3 on CK-91F to terminal W in furnace junction box.5.
Connect T2 on CK-91F to a 24 volt neutral where convenient.6.

LINE VOLTAGE WIRING INSTRUCTIONS

Connect 120 volts neutral hot power source wire to terminal L1 on CK-91F.1.
Connect 120 volts neutral power source wire and white wire from venter motor to terminal N on the 2.
CK -91F.
Connect black wire from venter motor to terminal M on the CK-91F.3.

Refer to the SWG Venter installation instructions for setting system airflow.

page 5

Diagram A

Diagram B

INTERNAL WIRING FOR CK-CONTROL KIT: DIAGRAM A & B

L1 to 1 on timer T2 to timer relay base
M to 3 on timer T3 to N/O on pressure switch

T1 to common on pressure switch Timer base to common on pressure switch

SYSTEM CONTROL CHECK OUT PROCEDURES

For furnaces or boilers, adjust the thermostat to call for heat and observe the power venting system for proper
operation sequence. (Repeat if necessary)

Thermostat calls for heat.1.

Relay is energized and venter motor starts.a.
Pressure switch closes and burner starts.b.
Thermostat is satisfied, the burner stops.c.
This starts the post purge cycle. Purge time 1 to 2 min.d.
While system is operating, disconnect power to the venter motor. This should open the pressure switch e.

contacts and stop burner operation.

page 6

PRESSURE SWITCH FOR WATER HEATER

Follow water heater manufacturer’s instructions to light pilot. Turn the gas control valve to the ON 1.
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)

Turn gas control valve to the PILOT position, which will start a 1 to 3 min. post purge of the venter motor.2.
Repeat Step 1 and 2 to ensure proper operation.3.

SPILLAGE SWITCHES

Allow the water heater to heat up to operating temperature, then disconnect the power to the gas 1.
pressure switch.

Adjust the thermostat to call for heat with the venter inoperative. Allow approximately 2 minutes of flue 2.
gas spillage for the spillage switches to sense the spillage and disrupt the thermocouple circuit, halting
the gas flow to the pilot and burner.

Wait 2 to 3 minutes. Reset the spillage switches and light the pilot, then perform a second safety spillage 3.
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

Venter does not activate when thermostat calls for heat.1.

Check wiring.a.
Check gas pressure switch for continuity across terminals when gas valve is pressurized.b.
Check gas pressure.c.

Flue gas odor:2.

Check system draft.a.
Check for negative pressure in building.b.

Pilot will not stay lit on water heater:3.

Solder all spillage switch wire terminal connections.a.
Check reset buttons on spillage switches.b.

REPAIR AND REPLACEMENT PARTS

MODEL PART NUMBER

Gas Pressure Switch 46284200

GSK-3 Spillage Switch 46086400

Post Purge Timer 46282800

Pressure Switch 46083000

TCA-1 Thermocouple Adaptor 46082700

TCA-2 Left Handed Thermocouple Adaptor 46429900

page 7

LIMITED WARRANTY

Field Controls, LLC (“Company”) warrants that its products shall be free from defects in material and workmanship
under normal use for the limited period indicated, from the date of manufacture, subject to the provisions 1-8 below.

Eighteen (18) months

All Field Controls Products (except for those listed below as 5 years or 90 days).

Five (5) years

Field Controls Direct Vent Systems (FDVS), Field Oil Vent Kits (FOVP), and ComboVents (CV).

Field Controls warrants that the products listed below shall be free from defects in material and workmanship under
normal use for the limited period indicated, from the date of purchase by the consumer, subject to the provisions

1-8 below.

Ninety (90) days
UV lamps/bulbs

Provisions:

1. During the limited warranty period, Company, or its authorized service representative, will repair or replace, at Company’s
option, without charge, a defective Product. Product that is repaired may be repaired with new or refurbished replacement
parts. Product that is replaced may be replaced with a new or refurbished product of the same or similar design. Company
will return repaired or replacement Product to customer in working condition. Labor charges are not covered as part of the
limited warranty.

2. With regard to UV lamps/bulbs, customer shall be required to include a "valid proof of purchase" (sales receipt) identifying
the Product purchased (Product model or accurate date code information) and the date the Product(s) was purchased.

3. Product whose warranty/quality stickers, Product serial number plates or electronic serial numbers have been removed,
altered or rendered illegible shall not be covered under the limited warranty.

4. Defective Product must be returned to Company, postage prepaid.

5. IN NO EVENT SHALL COMPANY BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR SIMILAR
DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS OR REVENUE, INABILITY TO USE PRODUCT, OR OTHER
ASSOCIATED EQUIPMENT, THE COST OF SUBSTITUTE EQUIPMENT, AND CLAIMS BY THIRD PARTIES) RESULTING FROM
THE USE OF PRODUCT. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.

6. THIS WARRANTY AND REMEDIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, REMEDIES AND
CONDITIONS, WHETHER ORAL, WRITTEN, EXPRESS, STATUTORY OR IMPLIED. TO THE EXTENT PERMITTED BY LAW,
COMPANY DISCLAIMS ALL IMPLIED AND STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE.

7. Company makes no warranty of any kind in regard to other manufacturer’s products distributed by Company. Company will
pass on all warranties made by the manufacturer and where possible, will expedite the claim on behalf of the customer, but
ultimately, responsibility for disposition of the warranty claim lies with the manufacturer.

8. Product that has been subjected to misuse, accident, shipping or other physical damage, improper installation or application,
abnormal operation or handling, neglect, fire, water or other liquid intrusion are not covered by the warranty.

© Field Controls, LLC P/N 46285300 Rev D 08/09

Phone: [phone] • Fax: [phone]

www.fieldcontrols.com