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.
I
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-91F)
1) TCA-2 Left Handed Thermocouple Adaptor (CK-91FG)
1) 6 ft. length of 12-2 wire
1) 8 inch jumper wire
2) Flexible conduit connector
2) GSK-3 Spillage Switch
1) 4" MG1 Barometric Draft Control
1) 1/4 inch tubing connector
DO NOT DESTROY
THESE INSTRUCTIONS MUST REMAIN WITH EQUIPMENT
INSTALLATION
M
OUNTING JUNCTION BOX
Typical Vent System Layout
The junction box can be mounted at the venter or remotely mounted away from
the venter. (See Figure 1 & Figure 2)
1. Remove one of the knockouts from the side of the junction 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.
2. Fasten the flexible conduit from the SWG Venter into the 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)
P
RESSURE SWITCH SENSING TUBE INSTALLATION
1. Attach the 1/4 inch tubing connector to the pressure tube on the SWG
Venter. (See Figure 3)
2. Connect the supplied 1/4" aluminum tubing to the tubing 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 1/4" OD copper, aluminum or
plastic tubing and route the tubing to avoid contact with any heat source.
Figure 1
Figure 2
Page 2
Figure 3
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.
C
OLLAR 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.
1. Bend outward the two ears at the front corners of the collar. Bend 90 degrees,
1/4 inch behind the single hole on the straps.
2. Insert clamping screw in ears on collar and bolt the remainder of the collar
Figure 4
together.
3. Hold the collar against the side of the flue in the exact position it is to be installed (shown by dotted lines) and mark
the outline of the collar on the flue.
4. Cut a hole in the flue about 1/2" inside of this outline.
5. Make a series of cuts about 1/2" apart from the edge of this hole to the outline marks.
6. Strap the collar to the flue pipe.
7. Bend the tabs formed by the series of cuts outward against the inside of the collar to make a tight joint.
8. Insert the draft control. (See Draft Control Installation and Adjustment Section.)
D
RAFT 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.
1. Install a vent pipe reducer or increaser into the inner pipe and
fasten using sheet metal screws. (See Figure 5)
2. The opening of the Type B Vent Tee, at the draft control
mounting location, should be sealed with a high temperature
sealant or equivalent.
3. Refer to Draft Control Installation Section.
DRAFT CONTROL INSTALLATION AND ADJUSTMENT
1. Insert the draft control into the collar or tee. The front face of
the control MUST be plumb and the bearing surfaces MUST
be level whether the control is on a horizontal, vertical or
Figure 5
sloping flue pipe.
2. Use a spirit level and level accurately. (See Figure 5) Secure
the control in the collar by tightening the clamping screws. If a
tee is used or a collar is supplied locally, the control may be
held in place by sheet metal screws.
A
DJUSTING 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.
W
HAT DRAFT SETTING TO USE
When adjusting the control, two things are essential;
1. The burner must be operating for at least 10 minutes to obtain
maximum chimney draft.
Figure 6
2. An analysis of the flue gases is necessary to determine the
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 allowable CO levels.
2
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, it's 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.
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ADJUSTMENTS
ROVING SWITCH ADJUSTMENTS
P
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 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
Figure 7
result in a hazardous condition and bodily harm!
T
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 8)
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 9)
3. Install the gas pressure switch into the side of the pipe
Figure 8
Figure 9
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).
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
Figure 10
Figure 11
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 8)
2. Thread the junction block into the thermocouple port and 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
Figure 12
mounted opposite from the vent outlet direction. (See Figure 12)
3. Mount the two spillage switches onto the draft hood and connect inside terminals of
switches with jumper wire. Connect outside terminals to 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.
Figure 13
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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
1. With boilers, locate terminal on spark ignition module or gas valve (if standing pilot) which would 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.
2. With warm air furnaces, locate terminal W in furnace junction box.
3. Remove wire from this terminal and reroute to T1 on CK-91F.
4. With boilers, connect T3 on CK-91F to hot side of gas valve (if standing pilot) or to terminal TH-W, 24 V, THS or T1 if
spark ignition.
NOTE: Remember, the correct terminal is the one that would normally be hot on a call for heat.
5. With warm air furnaces, connect T3 on CK-91F to terminal W in furnace junction box.
6. Connect T2 on CK-91F to a 24 volt neutral where convenient.
LINE VOLTAGE WIRING INSTRUCTIONS
1. Connect 120 volts neutral hot power source wire to terminal L1 on CK-91F.
2. Connect 120 volts neutral power source wire and white wire from venter motor to terminal N on the CK-91F.
3. Connect black wire from venter motor to terminal M on the CK-91F.
Refer to the SWG Venter installation instructions for setting system airflow.
Diagram A
Page 5
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)
1. Thermostat calls for heat.
a. Relay is energized and venter motor starts.
b. Pressure switch closes and burner starts.
c. Thermostat is satisfied, the burner stops.
d. This starts the post purge cycle. Purge time 1 to 2 min.
e. While system is operating, disconnect power to the venter motor. This should open the pressure switch contacts
and stop burner operation.
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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.
b. Check gas pressure switch for continuity across terminals when gas valve is pressurized.
c. Check gas pressure.
2. Flue gas odor:
a. Check system draft.
b. Check for negative pressure in building.
3. Pilot will not stay lit on water heater:
a. Solder all spillage switch wire terminal connections.
b. Check reset buttons on spillage switches.
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
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INSTALLATION INFORMATION
MODEL NO.:____________________________________________________________
INSTALLER'S NAME:_____________________________________________________
INSTALLER'S COMPANY: _________________________________________________
INSTALLER'S PHONE NO.: ________________________________________________
DATE OF INSTALLATION:_________________________________________________
CK-91F/CK-91FG
P/N 46285300 Rev C 10/03
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