Sterling QVSD User Manual

INSTALLATION INSTRUCTIONS AND SERVICE MANUAL
SEPARATED COMBUSTION
GAS-FIRED INDOOR DUCT FURNACE
ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT POINT OF INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No.(s) IN THE SPACE PROVIDED. RETAIN FOR FUTURE REFERENCE.
SCDFM-5
J30-05393
Unit No.
Serial No.
FOR Y OUR SAFETY
The use and storage of gasoline or other fl ammable v apors and liquids in open containers in the vicinity of this appliance is hazardous.
FOR Y OUR SAFETY
If you smell gas:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open fl ame.
4. Immediately call your gas supplier.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.
APPROVED FOR USE IN CALIFORNIA
Install, operate and maintain unit in accordance with manufacturer's instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness. The state of California has determined that these substances may cause cancer, birth defects, or other reproductive harm.
03/13
INSTALLER'S RESPONSIBILITY
Installer Please Note: This equipment has been test fired and inspected. It has been
shipped free from defects from our factory. However, during shipment and installation, problems such as loose wires, leaks or loose fasteners may occur. It is the installer's
responsibility to inspect and correct any problems that may be found.
RECEIVING INSTRUCTIONS
Inspect shipment immediately when received to determine if any damage has occurred to the unit during shipment. After the unit has been uncrated, check for any visible damage to the unit. If any damage is found, the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with the transportation company.
260 NORTH ELM ST., WESTFIELD, MA 01085
TEL: (413) 568-9571 FAX: (413) 562-8437
www.mestek.com
TABLE OF CONTENTS
GENERAL SAFETY INFORMATION SEPARATED COMBUSTION DUCT FURNACE ...................................1,2,3
SPECIFICA TIONS ........................................................................................................................................4
PERFORMANCE DATA ................................................................................................................................5
CLEARANCES .............................................................................................................................................6
INSTALLATION
Location ...........................................................................................................................................6
Ductwork, Air Flow ........................................................................................................................6,7
Suspension ...................................................................................................................................7,8
Electrical Connections, Wiring Diagrams .......................................................................8,9,10,11,12
Combustion Air Inlet System Piping .........................................................................................12,13
Exhaust Venting ...................................................................................................................13,14,15
Gas Piping .....................................................................................................................................16
Pipe Installation ...................................................................................................................17,18,19
OPERATION
Explanation of Controls .................................................................................................................21
Primary Air Shutter Adjustments ...................................................................................................21
Shut Down .....................................................................................................................................21
MAINTENANCE .........................................................................................................................................22
COMPONENT PARTS ...........................................................................................................................20,23
TROUBLESHOOTING CHART ........................................................................................................................24-28
WARRANTY ...........................................................................................................................................................29
UNIT NUMBER DESCRIPTION .............................................................................................................................30
START UP/INSPECTION SHEET ..........................................................................................................................32
GENERAL SAFETY INFORMATION
The duct furnace design is certifi ed by ETL for use with natural and LP (propane) gases. ANSI and NFPA Standards as well as Canadian installation codes referred to in this manual are the ones that were applicable at the time that the design was certifi ed. In addition, the duct furnace may be installed on the downstream side of a cooling coil, without need of a bypass duct.
If the unit is to be installed at altitudes exceeding 2,000 feet (610m) above sea level, derate the input by 4% for each 1,000 feet (305m) rise above sea level. Special orifi ces are required for installations above 2,000 feet.
When units are installed in Canada, any reference to derations at altitudes in excess of 2,000 f eet (610m) are to be ignored. At altitudes of 2,000 to 4,500 feet (610 to 1372m), the units must be orifi ced for 90% of normal altitude rating, and be so marked in accordance with ETL certifi cation.
The following terms are used throughout this manual, in addition to the ETL requirements to bring attention to the presence of potential hazards, or to important information concerning the product:
Indicates an imminently hazardous situation which, if not av oided, will result in death, serious injury, or substantial property damage.
Indicates an imminently hazard­ous situation which, if not avoided, could result in death, serious injury, or substantial property damage.
Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or property damage.
NOTICE: Used to notify of special instructions on installation, operation, or maintenance which are important to equipment but not related to personal injury.
2
GENERAL SAFETY INFORMATION
Failure to comply with the general safety information may result in extensive property damage, severe personal injury, or death!
This product must be installed by a licensed plumber or gas fi tter when installed within the Commonwealth of Massachusetts.
Installation must be in accordance with local codes, or in absence of local codes, with the latest edition of ANSI Standard Z223.1 (N.F.P.A. No. 54) National Fuel Gas Code. All of the ANSI and NFPA Standards referred to in these installation instructions are those that were applicable at the time the design of this appliance was certified. The ANSI Standards are available from the American National Standards Institute, Inc., 11 West 42nd Street, New York, NY 10036 or www.ansi.org. The NFPA Standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. These duct furnaces are designed for use in airplane hangars when installed in accordance with ANSI/NFPA No. 409, and in public garages when installed in accordance with NFPA No. 88A and NFPA No. 88B.
If installed in Canada, the installation must conform with local building codes, or in the absence of local building codes, with CSA-B149.1 “Installation Codes for Natural Gas Burning Appliances and Equipment” or CSA-B149.2 “Installation Codes for Propane Gas Burning Appliances and Equipment. ” These duct furnaces have been designed and certifi ed to comply with CSA 2.6. Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES.
Do not alter the duct furnace in any way, or damage to the unit and/or severe personal injury or death may occur!
Never service any component without fi rst disconnecting all electrical and gas supplies to the unit, or severe per sonal injury or death may occur!
Ensure that all power sources conform to the requirements of the duct furnace, or damage to the unit will result!
Follow installation instructions CAREFULLY to avoid creating unsafe conditions. All wiring should be done and checked by a qualifi ed electrician, using copper wire only. All external wiring must conform to applicable local codes, and to the latest edition of the National Electric Code, ANSI/NFPA No. 70. All gas connections should be made and leak-tested by a suitably qualifi ed individual, per instructions in this manual.
Also follow procedures listed on the “Gas Equipment Start-Up” sheet located in this manual.
Use only the fuel for which the duct furnace is designed (see rating plate). Using LP gas in a heater that requires natural gas, of vice versa, will create risk of gas leaks, carbon monoxide poisoning, and explosion.
Do not attempt to convert furnace for use with a fuel other than the one intended. Such conversion is dangerous, as it will create the risks previously listed.
Make certain that the power source conforms to the electrical requirements of the furnace.
Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing duct furnace. Always disconnect power at main cir cuit breaker as described above. Failure to do so could result in electrical shock.
Special attention must be given to any grounding information pertaining to this duct furnace. To prevent the risk of electrocution, the furnace must be securely and adequately grounded. This should be accomplished by connecting a ground conductor between the service panel and the furnace. To ensure a proper ground, the grounding means must be tested by a qualifi ed electrician.
Do not insert fi ngers or foreign objects into furnace or its air moving device. Do not b lock or tamper with the heater in any manner while in operation, or just after it has been turned off, as some parts maybe hot enough to cause injury.
This furnace is intended for general heating applications ONLY. It must NOT be used in potentially dangerous locations such as fl ammable, e xplosiv e, chemical-laden, or wet atmospheres.
In cases in which property damage may result from malfunction of the furnace, a back-up system or temperature sensitive alarm should be used.
The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into confi ned spaces UNLESS precautions are taken as follows: (1) by ventilation of the space, (2) control of the purging rate, (3) elimination of all hazardous conditions. All precautions must be taken to perform this operation in a safe manner!
Unless otherwise specifi ed, the following conversions may be used for calculating SI unit measurements: 1 foot = 0.305 m 1 inch = 25.4 mm 1 gallon = 3.785 L 1 pound = 0.453kg 1 psig = 6.894 kPa 1 cubic foot = 0.028m
1000 BTU/cu. ft. = 37.5 MJ/m 1000 BTU per hour = 0.293 kW 1 inch water column = 0.249 kPa liter/second = CFM x 0.472 meter/second = FPM ÷ 196.8
3
3
3
SPECIFICATIONS
Table 1
A B C D (Dia)*† Gas Inlet Weight Unit inches inches inches inches inches lb. Size (mm) (mm) (mm) (mm) Nat LP (kg)
100 17-7/8 15-1/2 17-1/8 4 1/2 1/2 161 (454) (394) (435) (102) (73)
125 20-5/8 18-1/4 19-7/8 4 1/2 1/2 180 (524) (464) (505) (102) (82) 150 20-5/8 18-1/4 19-7/8 4 1/2 1/2 188
(524) (464) (505) (102) (85) 175 23-3/8 21 22-5/8 4 1/2 1/2 207 (594) (533) (575) (102) (93) 200 26-1/8 23-3/4 25-3/8 5 1/2 1/2 227 (664) (603) (645) (127) (103) 225 28-7/8 26-1/2 28-1/8 5 3/4 1/2 or 3/4 246 (733) (673) (714) (127) (116) 250 31-5/8 29-1/4 30-7/8 5 3/4 1/2 or 3/4 266 (803) (743) (784) (127) (121) 300 37-1/8 34-3/4 36-3/8 6 3/4 1/2 or 3/4 305 (943) (883) (924) (152) (138) 350 42-5/8 40-1/4 41-7/8 6 3/4 1/2 or 3/4 344 (1083) (1022) (1064) (152) (156) 400 48-1/8 45-3/4 47-3/8 6 3/4 1/2 or 3/4 383 (1222) (1162) (1203) (152) (174)
†NOTE: “D” diameter equals the air inlet opening and the fl ue discharge opening.
Figure 1 - Separated Combustion Duct Furnace
DIMENSIONS XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS (XXX) MILLIMETERS
4
PERFORMANCE DATA
Table 2
Input Output MAX MIN MIN Temp. Rise PD MAX Temp Rise PD Unit MBH MBH MBH CFM °F in. of WC CFM °F in. of WC Size (kW) (kW) (kW) (cu. m/s) (°C) (kPa) (cu. m/s) (°C) (kPa) 100 100 50 80 822 90 0.10 3,700 20 2.03
(29.3) (14.6) (23.4) (0.388) (50) (0.02) (1.746) (11) (0.51) 125 125 62.5 100 1,028 90 0.09 4,625 20 1.92 (36.6) (18.3) (29.3) (0.485) (50) (0.02) (2.183) (11) (0.48) 150 150 75 120 1,233 90 0.09 5,550 20 1.81 (43.9) (22.0) (35.1) (0.582) (50) (0.02) (2.620) (11) (0.45) 175 175 87.5 140 1,439 90 0.09 6,475 20 1.86 (51.2) (25.6) (41.0) (0.679) (50) (0.02) (3.056) (11) (0.46) 200 200 100 160 1,645 90 0.09 7,401 20 1.90 (58.6) (29.3) (46.9) (0.776) (50) (0.02) (3.493) (11) (0.47) 225 225 112.5 180 1,850 90 0.09 8,326 20 1.93 (65.9) (32.9) (52.7) (0.873) (50) (0.02) (3.930) (11) (0.48) 250 250 125 200 2,056 90 0.09 9,251 20 1.96 (73.2) (36.6) (58.6) (0.970) (50) (0.02) (4.366) (11) (0.49) 300 300 150 240 2,467 90 0.10 11,101 20 2.00 (87.8) (43.9) (70.3) (1.164) (50) (0.02) (5.240) (11) (0.50) 350 350 175 280 2,878 90 0.10 12,951 20 2.02 (102.5) (51.2) (82.0) (1.358) (50) (0.02) (6.113) (11) (0.50) 400 400 200 320 3,289 90 0.10 14,801 20 2.05 (117.1) (58.6) (93.7) (1.552) (50) (0.02) (6.986) (11) (0.51)
NOTE:
Ratings are shown for elevations up to 2,000 feet (610M) above sea level. Above 2,000 feet (610M), input must be derated 4% for each 1,000 feet (305M) above sea level. When units are installed in Canada, any reference to derations at altitudes in excess of 2,000 feet (610M) are to be ignored. At altitudes of 2,000 to 4,500 feet (610 to 1372M), the units must be orificed to 90% of the normal altitude rating, and be so marked in accordance with the ETL certifi cation.
TEMPERATURE RISE AND PRESSURE DROP-GRAPH #1
Pa
°C°F
5
CLEARANCES
Under no circumstances should combustible material be located within the clearances specifi ed in T ab le 3. Failure to pr ovide proper clearance could result in personal injury or equipment damage from fi re .
Maintain adequate clearances around air openings into the combustion chamber:
Table 3 - Minimum Clearances
Sides 18" (457mm) Top 6" (152mm) Bottom 25" (635mm) Flue 6" (152mm)
* When clearances required for accessibility are greater than the minimum required safety clearances, the accessibility clearances take precedence.
INSTALLATION
NOTICE: Furnace sizing should be based on heat loss calculations where the furnace output equals or exceeds heat loss.
Do not install duct furnaces in a corrosive or flammable atmosphere! Premature failure of, or severe damage to the unit will result!
Duct furnaces must not be installed in locations where air for combustion would contain chlorinated, halogenated, or acidic vapors. If located in such an envir onment, premature failure of the unit will occur!
ACCESSIBILITY: The Separated Combustion Duct
Furnace is a bottom service access type. Allow a minimum of 25 inches (635mm) at the bottom of the unit to facilitate servicing the burners and pilot. Provision should be made to assure accessibility for recurrent maintenance purposes.
AIRCRAFT HANGARS: Separated Combustion Duct Furnaces must be installed in aircraft hangars as follows: Duct furnaces must be at least 10 feet (3.05m) above the upper surface of wings or engine enclosures of the highest aircraft to be stored in the hangar, and 8 feet (2.44m) above the fl oor in shops, offi ces, and other sections of the hangar where aircraft are not stored or housed. In Canada, installation is suitable in aircraft hangars when acceptable to the enforcing authorities.
PUBLIC GARAGES: In repair garages, duct furnaces must be installed in a detached building or room separated from repair areas as specifi ed in the latest edition of NFP A 88B, Repair Garages.
NOTICE: Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials.
Atmospheres containing commercial solvents or chlorinated hydrocarbons will produce corrosive acids when coming in contact with the fl ames. This will g reatly reduce the life of the duct furnace, and may void the warranty. Avoid such areas.
NOTICE: If the gas duct furnace is to be used in a building classified as having a hazardous atmosphere, the installation must comply with the standards set by the National Board of Fire Underwriters. Consult the authorities having jurisdiction before starting the job.
The Separated Combustion Duct Furnace must be installed on the positive pressure side of the air circulation blower.
In parking structures, duct furnaces must be installed so that the burner fl ames are located a minimum of 18 inches (457mm) above the fl oor or protected by a partion not less than 18 inches (457mm) high. Refer to the latest edition of NFPA 88A, Parking Structures.
In Canada, installation must be in accordance with the latest edition of CSA B149 “Installation Codes for Gas Burning Appliances and Equipment.”
Separated Combustion Duct Furnaces should not be installed to maintain low temperatures and/or freeze protection of buildings. A minimum of 50°F (10°C) thermostat setting must be maintained. If duct furnaces
are operated to maintain lower than 50°F (10°C), hot fl ue gases are cooled inside the heat exchanger to the point where water condenses onto the heat exchanger walls . The result is a mildly corrosive acid which prematurely corrodes the aluminized heat exchanger, and can actually drip water down from the duct furnace onto the floor surface. Additional duct furnaces should be installed if a minimum of 50°F (10°C) thermostat setting cannot be maintained.
DUCTWORK: Properly designed and installed ductwork, providing a uniformly distributed fl ow of air across the surfaces of the heat exchanger , is essential to satisfactory unit performance and life of the equipment.
All duct fl anges/seams must be sealed to prevent air leaks. Sealant/tape must be suitable for temper atures of 250°F (121°C) minimum.
Any attempt to straighten the 90° duct connection fl anges on the duct furnace will affect the operation of the furnace and void the warranty.
6
INSTALLATION (Continued)
If uniform air distribution is not obtained, install additional baffl es and/or turning vanes in the ductwork.
Access panels large enough to observe smoke and refl ected light, and to detect the presence of leaks in the heating equipment, are required both upstream and downstream from the gas duct furnace. These panels must be sealed to prevent air leaks. If allowed by local regulations, install canvas connectors between the ductwork and fan discharge opening to eliminate the transmission of sound.
Figures 2 & 3 illustrate recommended ductwork designs for both the straight-through and elbowed air inlet arrangements.
AIR FLOW: The installation is to be adjusted to obtain an air throughput within the range specifi ed on the appliance rating plate.
Figure 2 - Recommended Design for Field Installation of Ductwork for Straight-through Arrangement
BYPASS: When a gas duct furnace is installed to operate
in conjunction with a summer air conditioning system, the cfm air delivery of the system blower should be adjusted to meet the design air volume requirements for cooling. If this cfm delivery is greater than that required for heating, resulting in a low air temperature rise, install a damper bypass around the gas duct furnace to bypass a portion of the air.
SUSPENSION: Refer to Figure 4 f or typical suspension arrangements.
The Separated Combustion Duct Furnace must be hung level from side to side, and from front to back, from four suspension points provided at the top of the unit. Failure to do so will result in poor performance and or premature failure of the unit. Refer to Figure 4 for typical suspension arrangements. DO NO T mount duct furnaces in series (one in front of another).
NOTICE: When mounting duct furnaces side by side, units must have opposite side gas connections (determined by Digit #6 - Furnace Type in the unit number). Minimum safety clearances must also be maintained; see Table 3. When service/accessibility clearances are greater than minimum safety clearances, service/accessibility clearances take precedence. See “Accessibility” section under “Installation”.
Figure 3 - Recommended Ductwork Design for Elbowed Arrangement
Ensure that all hardware used in the suspension or for duct furnace is more than adequate for the job. Failure to do so may result in extensive property damage, severe personal injury or death!
7
INSTALLATION (Continued)
3/8-16 Treaded Suspension Rod & Jam Nut By Installer
3/8-16 Speed Grip Nut Retainer
Outside Jacket Panel (Duct)
D4285
Section “S-S”
Detail Showing Recommended
Method Of Suspension
(Typical)
“S” “S”
D4284
Figure 4 - Typical Four Point Duct Suspending Arrangement
ELECTRICAL CONNECTIONS
HAZARDOUS VOL TAGE!
disconnect ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.
Standard units are shipped for use on 115 volt, 60 hertz, single phase electric power. The motor name-plate and electrical rating of the transformer should be checked before energizing the duct furnace electrical system. All external wiring must conform to the latest edition of ANSI/ NFPA No. 70, National Electrical Code, and applicable local codes; in Canada, to the Canadian Electrical Code, Part 1, CSA Standard C22.1
Do not use any tools (i.e. screwdriver, pliers, etc.) across the terminals to check for power. Use a voltmeter.
USE COPPER CONDUCTORS ONLY! UNIT TERMINALS ARE NOT DESIGNED TO ACCEPT OTHER TYPES OF CONDUCTORS. Failure to do so may cause damage to the equipment
MAKE CERTAIN THAT THE STRUCTURE TO WHICH THE FURNACE IS TO BE MOUNTED IS CAPABLE OF SAFELY SUPPORTING ITS WEIGHT. UNDER NO CIRCUMSTANCES MUST THE GAS LINES, THE VENTING SYSTEM OR THE ELECTRICAL CONDUIT BE USED TO SUPPORT THE HEATER; OR SHOULD ANY OTHER OBJECTS (I.E. LADDER, PERSON) LEAN AGAINST THE HEATER, GAS LINES, VENTING SYSTEM OR ELECTRICAL CONDUIT FOR SUPPORT. FAILURE TO HEED THESE WARNINGS MAY INJURY OR DEATH.
RESULT IN PROPERTY DAMAGE,
PERSONAL
It is recommended that the electrical power supply to each duct furnace be provided by a separate, fused, and permanently live electrical circuit. A disconnect s witch of suitable electrical rating should be located as close to the gas valve as possible. Each duct furnace must be electrically grounded in accordance with the latest edition of the National Electrical Code, ANSI/NFPA No. 70, or CSA Standard C22.1 Sample wiring diagrams are shown in Figures 6, and 7.
Table 4 - Full Load Current In Amperes
Ampere Values Apply to All Unit Capacities
Amps at 115 Volts 1.9 Amps at 208 Volts 1.1 Amps at 230 Volts 1.0 Amps at 460 Volts 0.5 Amps at 575 Volts 0.4
8
INSTALLATION (Continued)
THERMOSTAT WIRING AND LOCATION NOTICE: The thermostat must be mounted on a
vertical, vibration-free surface, free fr om air currents, and in accordance with the furnished instructions.
Mount the thermostat approximately 5 feet (1.5m) above the fl oor, in an area where it will be exposed to a free circulation of average temperature air. Alwa ys refer to the thermostat instructions, as well as our unit wiring diagram, and wire accordingly. Avoid mounting the thermostat in the following locations:
1. Cold Areas- Outside walls or areas where drafts may affect the operation of the control.
2. Hot Areas- Areas where the sun’s ra ys , radiation, or warm air currents may affect the operation of the control.
3. Dead Areas- Areas where the air cannot circulate freely, such as behind doors or in corners.
NOTICE: Thermostat wires tagged “W” and “G” must be connected together except when using a general purpose “SPDT” 24VAC relay and standard thermostat with a subbase, or when using a Honeywell T834H or T834N thermostat. Also refer to Figure 5 for other wiring connections.
Figure 5 - C1267G
THERMOST A T HEA T ANTICIPAT OR ADJUSTMENTS
The initial heat anticipator setpoint should equal the thermostat’s current amperage draw when the unit is firing. This setpoint should be measured for the best results. Use the recommended ranges f or a guide . If further information is needed, consult your thermostat manufacturer’ s instructions.
Recommended heat anticipator setting ranges:
25 feet (7.6m) T'stat wiring 50 feet T'stat wiring
0.85 to 0.90 A 0.90 to 1.1 A Max. setting on t'stat
9
Figure 6 - Standard Wiring Diagram for Unit with Honeywell Ignition System.
10
Figure 7 - Standard Wiring Diagram for Unit with Johnson Ignition System
11
INSTALLATION (Continued)
FAN TIME DELAY CONTROL (OPTIONAL)
Leads from the fan time delay control are f actory wired to the junction box (when ordered as an optional component). The fan time delay control is a time delay relay (approximately 45 seconds ON, 65 seconds OFF). The fan time delay control is r ated at 17 amps.
NOTICE: The start-up fan delay should not e xceed 90 seconds from a cold start.
IMPORTANT: For all wiring connections, refer to the wiring diagram shipped with your unit (either affi xed to the side jacket or enclosed in the installation instructions envelope). Should any original wire supplied with the heater have to be replaced, it m ust be replaced with wiring material having a temperature rating of at least 105°C.
Should any high limit wires have to be replaced, they must be replaced with wiring material having a temperature rating of 200°C minimum.
POWER VENT POSITION
Units are shipped from the factory set up for horizontal venting. To convert the power venter for vertical or opposite side venting, remove the shipping support bracket, and follow this procedure:
1. Hold power venter motor in position.
2. Remove the three Phillips-head screws from the
motor adaptor plate.
3. Remove the three screws which connect the
power venter stack to the power venter housing.
4. Rotate the power v enter housing to the desired
position.
5. Replace screws accordingly.
NOTICE: The motor, pressure switch, and junction box bracket MUST remain located as shipped from the factory. Rotate only the blower housing! If the power venter housing is to be moved to the right horizontal position, the junction box must be rotated 90 degrees CCW to clear the connection. To do this, remove all wires, conduit and conduit connector from the junction box, noting location of wires. Move box, using holes provided. Move 7/8 inch plug from bottom of box to side. Reconnect all wires according to the unit’s wiring diagram.
COMBUSTION AIR INLET SYSTEM PIPING
Never operate duct furnaces without combustion air and fl ue gas piping in place, or severe personal injury or death may occur!
CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or flu-like symptoms).
1. The combustion air system installation must be in accordance with the latest edition of National Fuel Gas Code-NFP A 54, ANSI Z223.1 National Fuel Gas Code. In Canada, installation must be in accordance with CSA-B149.1 “Installation Code for Natural Gas Burning Appliances and Equipment” or CSA-B149.2 “Installation Code for Propane Burning Appliances and Equipment”.
2. A Breidert Type L or Fields inlet cap furnished by the customer, must be installed at the termination point of the combustion air system, Figures 8 & 9.
NOTICE: The top of the cap is to be no less than 12 inches from the top of the exhaust vent cap. See Figures 8 & 9.
3. Each duct furnace MUST have its own combustion air system. It MUST NOT be connected to other air intake systems.
4. Use single wall pipe constructed of 26 gauge galvanized steel, or material of equivalent durability and corrosion resistance for the combustion air inlet system. For installations in Canada, use pipe constructed from .025 inch thick aluminum or 0.018 inch thick steel.
Never use a pipe of a diameter other than that specifi ed in Table 1, (“D” dia. fl ue opening)! Never use PVC/ABS or other non­metalic pipe for venting! To do so may result in serious damage to the unit, or severe personal injury or death!
12
INSTALLATION (Continued)
5. Long runs of single wall combustion air piping passing through an unheated space may require insulating if condensation becomes noticeable.
6. The combustion air system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21mm/m) toward the inlet cap to facilitate drainage. V ertical combustion air pipes should be arranged as depicted in Figure 9.
7. The equivalent length of the combustion air system must not be less than 5 feet (1.5m) and must not exceed 50 feet (15.2m). Equiv alent length is the total length of straight sections PLUS 15 feet (4.6m) for each 90° elbow and 5 feet (1.5m) f or each 45° elbow .
NOTICE: For optimum performance, keep the combustion air system as straight as possible.
8. Each slip joint must be secured with at least three corrosion resistant screws. T wo full turns of 3M #425 Aluminum Foil Tape or its equivalent must be used to seal each joint. General Electric RTV-108, Dow­Corning RTV-732, or an equivalent, may be used instead of the tape.
9. For horizontal combustion air systems longer than 5 feet (1.5m), the system must be supported from overhead building structures at 3 f eet (1m) intervals.
EXHAUST VENTING - CATEGORY III
Never operate duct furnaces without combustion air and fl ue gas piping in place, or severe personal injury or death may occur!
1. Vent system installation must be in accordance with the latest edition of National Fuel Gas Code-NFPA 54, ANSI Z223.1 National Fuel Gas Code. In Canada, installation must be in accordance with CSA-B149.1 “Installation Code for Natural Gas Burning Appliances and Equipment” or CSA-B149.2 “Installation Code for Propane Burning Appliances and Equipment”.
2. A Breidert Type L or Fields vent cap furnished by the customer, must be installed at the termination point of the vent system, Figures 8 & 9.
3. Each unit MUST have its own vent system. It MUST NOT be connected to other vent systems or to a chimney.
4. Use UL 1738 listed single wall pipe for the vent system. For installation in Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or in the absence of local building codes, with current CSA-B149.1, Installation Codes for Natural Gas Burning Appliances and Equipment or CSA-B149.2, Installation Codes Propane Gas Burning Appliances and Equipment.
for
Never use a pipe of a diameter other than that specifi ed in Table 1, (“D” dia. fl ue opening)! Never use PVC/ABS or other non­metallic pipe for venting! To do so may result in serious damage to the unit or severe personal injury or death!
5. Any run of single wall vent pipe passing through an unheated space must be insulated with an insulation suitable to 550°F.
6. The combustion and exhaust vent air systems must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21mm/m) toward the terminal caps to facilitate drainage (see Figure 8A). Vertical vent pipes should be arranged as depicted in Figure 8.
7. The equivalent length of the vent system must not be less than 5 feet (1.5m) and must not exceed 50 feet (15.2m). Equivalent length is the total length of straight sections PLUS 15 feet (4.6m) for each 90° elbow and 5 feet (1.5m) for each 45° elbow.
8. Each slip joint must be secured with at least three corrosion resistant screws. Two full turns of 3M #425 Aluminum Foil Tape or its equivalent must be used to seal each joint. General Electric RTV-108, Dow­Corning RTV-732, or an equivalent, may be used instead of the tape.
9. For horizontal vent systems longer than 5 feet (1.5m), the system must be supported from overhead building structures at 3 f eet (1m) intervals.
10. The exhaust vent system must remain at a minimum of 6 inches (152mm) from all combustible materials. Any part of the vent system that passes through a combustible material must be properly insulated.
NOTICE: Increasing the clearance distance may be necessary If there is a possibility of distortion or discoloration of adjacent materials.
For a VERTICAL v ent pipe section that passes through a floor or roof, an opening 4 inches (102mm) greater in diameter is required. The opening must be insulated and fl ashed in accordance with applicable installation codes.
A HORIZONTAL section of an exhaust vent system that passes through a combustible wall must be constructed and insulated as shown in Figure 9A.
11. The top of a VER TICALLY VENTED exhaust system must extend at least 3 feet (1m) above the roof surface that it passes through. The point of termination for a HORIZONTALLY VENTED exhaust system must be at least 12 inches (305mm) from the exterior wall that it passes through. See V ent System T ermination Clearance Requirements in T ab le 5. See V ent/Intake Installations in Figures 8 & 8A.
13
INSTALLATION (Continued)
Vent Systems
Termination Clearance Requirements
Minimum Clearance
Structure/Object
Door, window, or gravity vent inlet; combustion air inlet for other appliances
Forced air inlet within 10 feet 3 feet above 6 feet (1.8m) Adjoining Building or parapet 10 feet 10 feet (3.04m)
Adjacent public walkways
Electric, gas meters & regulators
Above grade level* 1 feet 1 feet (0.3m)
*Minimum above maximum snow depth, or per local code, whichever is greater.
for Termination Locations
USA CANADA
9 inches for 10,000 to 50,000 BTU/Hr input; 12 inches for input exceeding 50,000 BTU/Hr.
7 feet above grade
4 feet horizontal
9 inches (230mm) for 10,000 to 50,000 BTU/Hr input; 12 inches (305mm) for input exceeding 50,000 BTU/Hr.
7 feet (2.1m) above grade
3 feet (0.9m) horizontally from meter/regulator asembly. 6 feet (1.8m), any direction, from a gas service regulator vent outlet
Figure 8. Vertical Intake/Vent Installation
CAT-2764C
14
Figure 8A. Horizontal Intake/Vent Locations
Figure 9. Vertical Vent Installation
CAT-2765B
Figure 9A. Horizontal Vent Installation
CAT-2767B
CAT-2766B
15
GAS PIPING
To avoid damage or possible personal injury, do not connect gas piping to this unit until a supply line pressure/leak test has been completed. Connecting the unit before completing the pressure/leak test may damage the gas valve and result in fi re hazard.
Do not rely on a shut-off valve to isolate the unit while conducting gas pressure/ leak tests. These valves may not be completely shut off, exposing the gas valve to excessive pressure and damages.
PIPE SIZING
T o provide adequate gas pressure to the gas duct furnace, size the gas piping as follows:
1. Find cu. ft./hr. by using the following formula: Input
Cu. ft./hr. =
BTU/Cu. ft.
2. Refer to Table 6. Match “Length of Pipe in F eet” with appropriate “Gas Input - Cu. Ft./Hr.” fi gure. This fi gure can then be matched to the pipe size at the top of the column.
Example: It is determined that a 67 foot (20.4m) run of gas pipe is required to connect a 200 MBTU gas duct furnace to a 1,000 BTU/cu. ft. (0.29kW) natural gas supply.
200,000 BTU/Hr 1,000 BTU/Cu. ft.
= 200 Cu. ft./hr.
Using Table 6, a 1 inch pipe is needed.
NOTICE: See General Safety Information section for English/Metric unit conversion factors.
NOTICE: If more than one duct furnace is to be served by the same piping arrangement, the total cu. feet/hr . input and length of pipe must be considered.
NOTICE: If the duct furnace is to be fi red with LP gas, consult your local LP gas dealer for pipe siz e information.
NOTICE: Heater installation for use with propane (bottled) gas must be made by a qualifi ed LP gas dealer or installer. He will insure that proper joint compounds are used for making pipe connections; that air is purged from lines; that a thorough test is made for leaks before operating the heater; and that it is properly connected to the propane gas supply system.
Before any connection is made to the existing line supplying other gas appliances, contact the local gas company to make sure that the existing line is of adequate size to handle the combined load.
Table 6 - Gas Pipe Size
Maximum Capacity of Pipe in Cubic Feet of Gas per Hour (Cubic Meters per Hour) for Gas Pressures of 0.5 psig (3.5 kPa) or Less, and a Pressure Drop of 0.5 Inch Water Column (124.4 Pa) (Based on a 0.60 Specifi c Gravity Gas) Nominal
Iron Internal Length of Pipe, Feet (meters)
Pipe Size Dia. 10 20 30 40 50 60 70 80 90 100 125 150 175 200 inch inch (3.0) (6.1) (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0) 1/2 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35
(4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99) 3/4 0.824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 (10.2) (7.08) (5.66) (4.81) (4.28) (3.91) (3.54) (3.34) (3.11) (2.92) (2.63) (2.38) (2.18) (2.04) 1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 (19.3) (13.2) (10.6) (9.06) (8.07) (7.36) (6.80) (6.23) (5.80) (5.52) (4.96) (4.53) (4.11) (3.82) 1 1/4 1.380 1400 950 770 660 580 530 490 460 430 400 360 325 300 280 (39.6) (26.9) (21.8) (18.7) (16.4) (15.0) (13.9) (13.0) (12.2) (11.3) (10.2) (9.20) (8.50) (7.93) 1 1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 (59.5) (41.3) (33.4) (28.0) (25.5) (22.9) (21.2) (19.5) (18.4) (17.6) (15.6) (14.2) (13.0) (12.2) 2 2.067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800 (112) (77.9) (62.3) (53.8) (47.6) (43.0) (39.6) (36.8) (34.5) (32.6) (28.9) (26.9) (24.1) (22.7) 2 1/2 2.469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280 (178) (123) (99.7) (85.0) (75.0) (68.0) (63.7) (58.0) (55.2) (52.4) (46.7) (42.5) (38.8) (36.2) 3 3.068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280 (311) (218) (177) (150) (135) (122) (110) (105) (97.7) (92.0) (83.5) (75.0) (69.4) (64.6) 4 4.026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600 (651) (447) (362) (309) (275) (249) (229) (212) (204) (190) (170) (156) (142) (130)
1. Determine the required Cu. feet / Hr. by dividing the rated heater input by 1000. For SI / Metric measurements: Convert unit Btu. / Hr. to
kilowatts. Multiply the units input (kW) by 0.0965 to determine Cubic Meters / Hour. 2. FOR NATURAL GAS: Select the pipe size directly from the table. 3. FOR PROPANE GAS: Multiply the Cu. feet / Hr. (Cubic Meters per Hour) value by 0.633; then use the table. 4. Refer to the metric conversion factors listed in General Safety section for more SI unit measurements/conversions.
16
PIPE INSTALLATION
D3631C
1. Install the gas piping in accordance with applicable local codes.
2. Check gas supply pressure. Each duct furnace must be connected to a manifold pressure and a gas supply capable of supplying its full rated capacity as specifi ed in Table 7. A fi eld LP tank regulator must be used to limit the supply pressure to a maximum of 14 inches WC (3.5 kPa). All piping should be sized in accordance with the latest edition of ANSI Standard Z223.1 (NFPA 54), National Fuel Gas Code; in Canada, according to CSA B149. See Tables 1, 6 & 7 (of this manual) for correct gas piping size. If gas pressure is excessive on natural gas applications, install a pressure regulating valve in the line upstream from the main shutoff valve.
3. Adequately support the piping to prevent strain on the gas manifold and controls.
4. To prevent the mixing of moisture with gas, run the take-off piping from the top, or side, of the main.
5. Duct furnaces are shipped with a combination valve which includes: a. Manual "A" valve b. Manual "B" valve c. Solenoid valve d. Pilot safety e. Pressure regulator
Pipe directly into the combination valve (see Figure
10).
6. A 1/8 inch N.P.T . plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the appliance.
7. Provide a drip leg in the gas piping near the gas duct furnace. A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing. The manual shutoff valve must be located exter nal to the jacket (See Figure 10).
8. Make certain that all connections have been adequately doped and tightened.
NOTICE: Use pipe joint sealant resistant to the action of liquefied petroleum gases regardless of gas conducted.
Check all pipe joints for leakage using a soap solution or other approved method. Never use an open fl ame or severe personal injury or death may occur!
Figure 10- Pipe Installation, Standard Controls
Never use an open fl ame to detect gas leaks. Explosive conditions may exist which will result in personal injury or death.
The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system in excess of 1/2 psig (3.5 kPa).
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).
Do not over tighten the inlet gas piping into the valve. This ma y cause stresses that will crack the valve!
17
PIPE INSTALLATION (Continued)
Table 7 - Gas Supply Pressure Requirements
Natural Gas Propane Gas
Heating V alue
Manifold Pressure
Single Stage Application 3.5 in. WC 10.0 in. WC
Two Stage Application - High Fire 3.5 in. WC 10.0 in. WC
Two Stage Application - Low Fire 1.1 in. WC 3.8 in. WC
Modulating Application - High Fire 3.5 in. WC 10.0 in. WC
Modulating Application - Low Fire 0.9 in. WC 3.5 in. WC
Minimum Supply Pressure
Single Stage Application 5.0 in. WC 11.0 in. WC
Two Stage Application 6.5 in. WC 11.5 in. WC
Modulating Application 6.5 in. WC 11.5 in. WC
Maximum Supply Pressure 14.0 in. WC 14.0 in. WC
1075 Btu/Ft3 2500 Btu/Ft (40.1 MJ/m3) (93.1 MJ/m3)
(0.87 kPa) (2.49 kPa)
(0.87 kPa) (2.49 kPa)
(0.27 kPa) (0.95 kPa)
(0.87 kPa) (2.49 kPa)
(0.22 kPa) (0.87 kPa)
(1.24 kPa) (2.74 kPa)
(1.62 kPa) (2.86 kPa)
(1.62 kPa) (2.86 kPa)
(3.49 kPa) (3.49 kPa)
3
18
GAS INPUT RATE
Table 8 - Main Burner Orifi ce Schedule*
Never overfi re the duct furnace, as this may cause unsatisfactory operation, or shorten the life of the heater.
Check the gas input rate as follows (Refer to General Safety Information section for metric conversions).
1. Turn off all gas appliances that use gas through the
same meter as the unit heater.
2. Turn the gas on to the unit heater.
3. Clock the time in seconds required to burn 1 cubic ft.
of gas by checking the gas meter.
4. Insert the time required to burn one cubic foot of gas
into the following f ormula and compute the input rate
3600 (Sec. per Hr.) x BTU/Cu./Ft.
= Input Rate Time (Sec.)
For example , assume the BTU content of one cubic foot of gas is 1000, and that it takes 18 seconds to burn one cubic foot of gas. 3600 x 1000
= 200,000 18
NOTICE: If the computation exceeds, or is less than 95% of the gas BTU/hr. input rating (see Table 2), adjust the gas pressure.
Adjust the gas pressure as follows:
1. NATURAL GAS: Best results are obtained when
the duct furnace is operating at its full rated input with the manifold pressure of 3.5 inch WC (0.9 kP a). Adjustment of the pressure regulator is not normally necessary since it is preset at the factory. However, fi eld adjustment may be made as follows: a. Attach manometer at the pressure tap
plug below the control outlet.
b. Remove the regulator adjustment screw cap ,
located on the combination gas valve.
c. With a small screwdriver, rotate the adjustment
screw clockwise to increase pressure.
d. Replace regulator adjustment screw cap.
2. PROPANE GAS: An exact manif old pressure of 10.0
inch WC (2.5 kPa) must be maintained for proper operation of the duct furnace. If the unit is equipped with a pressure regulator on the combination gas valve, f ollo w steps “a” through “d” abov e. If the unit is not so equipped, the propane gas supply system pressure must be regulated to attain this manifold operating pressure.
*
INPUT
IN
1000
BTU
100 125 150 175 200 225 250 300 350 400
* This schedule is for units operating at normal altitudes of 2000 feet (610m) or less. Special orifi ces are required for installations above 2000 f eet (610m).
When installed in Canada, any references to deration at altitudes in excess of 2000 feet (610m) are to be ignored. At altitudes of 2000 to 4500 feet (610 to 1372m), the unit heaters must be orifi ced to 90% of the normal altitude rating, and be so marked in accordance with the ETL certifi cation.
HEATING
VALUE
MANIFOLD
PRESSURE
3
FT
/HR
ORIFICE DRILL
3
/HR
FT
ORIFICE DRILL
3
FT
/HR
ORIFICE DRILL
FT 3/HR
ORIFICE DRILL
3
/HR
FT
ORIFICE DRILL
3
/HR
FT
ORIFICE DRILL
3
/HR
FT
ORIFICE DRILL
FT 3/HR
ORIFICE DRILL
FT 3/HR
ORIFICE DRILL
3
/HR
FT
ORIFICE DRILL
1075 BTU/Ft
(40.1 MJ/m3)
3.5 Inch WC (0.9 kPa)
96 42
120
42
140
42
163
42
186
42
210
42
233
42
280
42
326
42
372
42
3
2500 BTU/Ft
(93.1 MJ/m3)
10.5 Inch WC
PROPANETYPE OF GAS NATURAL
(2.6 kPa)
40 54 50 54 60 54 70 54 80 54 90 54
100
54
120
54
140
54
160
54
3
NO. OF
BURNER
ORIFICES
4 5 6 7 8
9 10 12 14 16
PILOT ADJUSTMENT
1. Remove the PILOT ADJUSTMENT CAP.
2. Adjust the pilot screw to provide a properly sized fl ame.
3. A proper fl ame is a soft, steady fl ame that envelops 3/8 to 1/2 inches (9.5 to 12.7mm) of the fl ame sensor.
4. Replace the pilot adjustment cap.
MANIFOLD PRESSURE ADJUSTMENT
If the manifold pressure requires adjustment, remove the cap from the pressure regulator and turn the adjustment screw clockwise to increase the pressure, and counterclockwise to decrease the pressure. The adjusted manifold pressure should not vary more than 10% from the pressures specifi ed in Table 8.
19
10
11
7
12
13
Figure 11 - Burner Components – Intermittent Pilot Ignition
BURNER DRAWER COMMON PARTS:
1. MAIN BURNERS
2. BURNER MANIFOLD
3. AIR SHUTTERS
4. BURNER SPRINGS
5. MAIN BURNER ORIFICE
6. TRANSFORMER
7. PILOT TUBING
1
2
3
1
6
5
4
CONTROLS: 8A. MAIN GAS VALVE (HONEYWELL) 8B. MAIN GAS VALVE (WHITE RODGERS)
9. HONEYWELL IGNITOR
10. PILOT BURNER
11. PILOT ORIFICE
12. ELECTRODE/SENSOR LEAD
13. HIGH LIMIT (LOCATED ON THE REAR HEADER PLATE OF THE HEAT EXCHANGER - AIR INLET SIDE).
8A
O
F
F
O
N
8B
W
ARNING
V
M
1
Honeywell
S
8
C
6
0
ONTI
0M
N
UOUS
1
0
0
R
%
9
E-T
SHU
0
SEC.
T
OFF IP
TRIAL FOR
)
D
MV/PV
V
P
GN
2
3
4
IGNITION
)
24V
(GND
(BURNER
24V
5
TH-W
(OPT.)
6
7
9
R
Y
8
SPARK 9
20
OPERATION
NORMAL
(HARD FLAME)
LIFTING
(TOO MUCH AIR)
YELLOW TIPPING
(MARGINAL)
YELLOW FLAME
(TOO LITTLE AIR)
Never operate the unit beyond the specified limits or severe damage to, and/or premature failure of, the unit will result!
EXPLANATION OF CONTROLS
1. Each Separated Combustion Duct Furnace comes
equipped with a power vent system that consists of a power ventor motor and b lower , pressure switch, and sealed fl ue collector. (See Figure 15)
The addition of external draft hoods or power ventors is not permitted. Addition of such devices may cause serious unit malfunction or failure.
2. The power ventor is energized by the room thermostat
when a demand for heat is sensed. The pressure switch measures the differential pressure between the air inlet and the exhaust vent systems. If the differential is correct, the indirect spark ignition system is energized.
Under no circumstances is the unit to be fi red if the power ventor is not operable, or severe personal injury or death may occur!
3. The indirect spar k ignition system consists of an ignition module, a dual combination gas valve , and a spark-ignited pilot burner. When the pressure switch is closed, the pilot valve opens as a spark is generated to light the pilot. When the fl ame is sensed by the fl ame sensing circuit, the spark ceases, and the main gas valve opens to supply gas to the main burners. Once the thermostat is satisfi ed, the vent system and gas valve are simultaneously de-energiz ed, stopping all gas fl ow to the unit.
4. The high limit switch interrupts the fl ow of electrical current to the main gas valve if the duct furnace becomes overheated.
5. The optional fan switch delays the operation of the fan for appro ximately 45 seconds once the thermostat is closed, and continues fan operation for approximately 65 seconds after the thermostat opens. The start-up fan delay must not exceed 90 seconds from a cold start.
6. The wall thermostat, supplied optionally, is a temperature sensitive switch that operates the vent and ignition systems to control the temperature of the space being heated.
INITIAL LIGHTING
1. Open the manual gas valve, in the gas supply line to the duct furnace. Loosen the union in the gas supply line to purge it of air. Tighten the union, and check f or leaks.
NOTICE: Check all pipe joints for leakage using a soap solution or other approved method.
Never use an open fl ame to detect gas leaks. Explosive conditions may e xist which could result in property damage, personal injury or death.
Before attempting to light or relight the pilot, wait 5 minutes to allow gas which may have accumulated in the burner compartment to escape. Failure to heed this warning could result in property damage, personal injury or death!
2. T urn on electrical power. The duct furnace should now be under the control of the thermostat. Set the thermostat to it's highest setting, the power ventor motor should start, and burner ignition occur. Tur n the thermostat to the lowest setting. The burners and power ventor should stop operating immediately. Reset the thermostat to the desired operational setting.
PRIMARY AIR SHUTTER ADJUSTMENT
After the unit has been operating for at least 15 minutes, adjust the primary air flow to the burners. Turn the friction-locked, manually-rotated air shutters clockwise to close, and counterclockwise to open.
For correct air adjustment, close the shutter until yellow tips in the fl ame appear. Then, open the air shutter to the point just beyond where the yellow tipping disappears. Refer to Figure 12.
NOTICE: There may be momentary and spasmodic orange fl ashes in the fl ame . This is caused by the burning of airborne dust particles, and should not be confused with yellow tipping, whic h is a stable, or permanent, situation when there is insufficient primary air.
Figure 12 - Main Burner Flames
NOTICE: The thermostat must be mounted on a vertical, vibration-free surface, free fr om air currents, and in accordance with the furnished instructions.
SHUT DOWN
1. Turn the valve selector knob to the "OFF" position.
2. Turn off the electricity.
3. To relight, follow "Initial Lighting" instructions.
21
MAINTENANCE
PERIODIC SERVICE
Open all disconnect switches and secure in that position before servicing unit. Failure to do so may result in personal injury or death from electrical shock!
Gas tightness of the safety shut­off valves must be chec ked on at least an annual basis.
To check gas tightness of the safety shut-off valv es, turn off the manual valve upstream of the appliance combination control. Remo ve the 1/8 inch pipe plug on the inlet side of the combination control and connect a manometer to that tapping. Turn the manual valve on to apply pressure to the combination control. Note the pressure reading on the manometer, then turn the valv e off. A loss of pressure indicates a leak. If a leak is detected, use a soap solution to check all threaded connections. If no leak is found, combination control is faulty and m ust be replaced before putting appliance back in service.
NOTICE: The heater and vent system should be checked once a year by a qualifi ed technician.
Should maintenance be required, perform the following inspection and service routine:
1. Inspect the area near the unit to be sure that there is no combustible material located within the minimum clearance requirements listed in Table 3.
2. T urn off the manual gas v alve and electrical power to the duct furnace.
3. T o clean or replace the main burners, open the bottom panel and compress the spring by moving the burner toward the manifold. Slide the opposite end of the burner downward from the locating slot while retaining spring is still compressed. Pull the burners aw ay from the heater.
4. With the burners removed, wire brush the inside surfaces of the heat exchanger.
5. Remove any dirt, dust, or other foreign matter from the burners using a wire brush and/or compressed air. Ensure that all par ts are unobstructed. Inspect and clean the pilot burner if necessary.
6. Reassemble the gas duct furnace by replacing all parts in reverse order.
7. Complete the appropriate unit start-up procedure as given in the “Operation” section of this manual (see unit lighting instruction plate and the unit nameplate).
8. Check the burner adjustment. See “Primary Air Shutter Adjustment” section in this manual.
9. Check all gas control valves and pipe connections for leaks.
10. Check the operation of the automatic gas valve by lowering the setting of the thermostat, stopping the operation of the gas duct furnace. The gas valve should close tightly, completely extinguishing the fl ame on the main burners.
11.
Inspect and service the blower section of the system.
12. Check and test the operational functions of all saf ety devices supplied with your unit.
GAS VALVE
MAIN BURNERS
Under no circumstances should combustible material be located within the clearances specifi ed in T able 3. Failure to pr ovide proper clearances could result in personal injury or equipment damage from fi re!
Figure 13 - Combustion Chamber
MANIFOLD
PILOT ASSY.
RETAINER SPRING
AIR SHUTTERS
Figure 14 - Internal Furnace Assembly
22
Figure 15 - Power Venter Assembly
Ref. No. Description
1 Blower Housing Assembly 2 Speed Nut 3 Motor 4 Washer, Plain 5 Plate Adapter 6 Blower Wheel 7 Mounting Bracket (Pressure Switch) 8 Mounting Bracket (Junction Box) 9 Screw, S.T. 10 Screw, Machine (L = 3/4 inch) 11 Nut, Keps (Ext. Lock Washer) 12 Air Pressure Switch*
Ref. No. Description
14 Junction Box Cover 15 Snap Bushing 16 Relay (Motor) 17 Draftor Stack Assembly 18 Tubing (Aluminum) Formation 19 Male Connector 20 Locknut 21 Hole Plug 22 Pressure Switch Cover 23 Drill Screw 24 Junction Box Base 25 Relay (Purge)
13 Drill Screw
NOTES: *1) For item No. 6 use counter-clockwise rotation.
2) DO NOT OVERTIGHTEN CELCON NUT! HAND TIGHTEN ONLY! DO NOT USE TOOLS! Approximate 1/3 turn maximum or 8 inch pounds is suffi cient from the point where the tube does not slip in or out.
3) Flue Sizes: 100/175 units: 4 inch diameter fl ue outlet Reducer required – To be supplied by installer. 200/250 units: 5 inch diameter fl ue outlet (no adaptor required on fl ue). 300/400 units: 6 inch diameter fl ue outlet Increaser required – To be supplied by manufacturer.
4) See “Power Vent Position” in Installation section for instructions on how to adjust vent position from factory installed position.
23
Table 9 - Troubleshooting Guide
SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION
A. Flame lifting from burner ports.
B. Flame pops back.
C. Noisy fl ame.
1. Pressure regulator set too high.
2. Defective regulator.
3. Burner orifi ce too large.
1. Excessive primary air.
2. Burner orifi ce too small.
1. Too much primary air.
2. Noisy pilot.
3. Irregular orifi ce causing whistle or resonance.
4. Excessive gas input.
1. Reset manifold Pressure. Refer to “Operation”.
2. Replace regulator section of combination gas valve or complete valve.
3. Check with local gas supplier for proper orifi ce size, and replace. Refer to “Operation”.
1. Close air shutter. Refer to “Operation”.
2. Check with local gas supplier for proper orifi ce size and replace. Refer to “Operation”.
1. Close air shutter.
2. Reduce pilot gas. Refer to “Operation”.
3. Replace orifi ce.
4. Reset manifold pressure. Refer to “Operation”: Replace regulator section of combination gas valve or complete valve; or Check with local gas supplier for proper orifi ce size, and replace. Refer to “Operation”.
D. Yellow tip fl ame (some yellow tipping on propane gas is permissible).
E. Floating fl ame.
F. Gas odor.
1. Insuffi cient primary air.
2. Clogged burner ports.
3. Misaligned orifi ces.
4. Clogged draft hood.
5. Air shutter.
6. Insuffi cient combustion air.
1. Blocked Venting.
2. Insuffi cient combustion air.
3. Blocked heat exchanger
4. Air leak into combustion chamber or draft hood.
1. Shut off gas immediately.
2. Blocked heat exchanger/venting.
3. Drafts around heater.
4. Negative pressure in building.
5. Blocked draft hood.
1. Open air shutter. Refer to “Operation”.
2. Clean main burner ports.
3. Replace manifold assembly.
4. Clean draft hood.
5. Check for dust or lint at air mixer opening and around air shutter.
6. Check for obstruction in combustion air inlet cap and piping. See “Installation”.
1. Clean fl ue. Refer to “Installation”.
2. Check for obstruction in combustion air inlet cap and piping. See “Installation”.
3. Clean heater.
4. Determine cause and repair accordingly.
1. Inspect all gas piping and
repair.
2. Clean heat exchanger/fl ue.
3. Eliminate drafts. Refer to “Installation”.
4. See “Installation”.
5. Clean draft hood.
24
Table 9 - Troubleshooting Guide
SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION
G. Delayed ignition.
H. Failure to ignite.
1. Excessive primary air.
2. Main burner ports clogged near pilot.
3. Pressure regulator set too low.
4. Pilot decreases in size when main burners come on.
5. Pilot fl ame too small.
6. Drafts around ventor.
7. Improper venting.
1. Main gas valve off.
2. Lack of power at unit.
3. Thermostat not calling for heat.
4. Defective limit switch.
5. Improper thermostat or transformer wiring at gas valve.
6. Defective gas valve.
7. Defective thermostat.
8. Defective transformer.
9. Loose wiring.
10. Defective ignition control.
1. Close air shutter. Refer to “Operation”.
2. Clean main burner ports.
3. Reset manifold pressure. Refer to “Operation”.
4. Supply piping is inadequately sized. Refer to “Installation”.
5. Clean pilot orifi ce. Refer to “Operation”.
6. Eliminate drafts. Refer to “Installation”.
7. Refer to ˆ“Installation”.
1. Open all manual gas valves.
2. Replace fuse or turn on power supply.
3. Turn up thermostat.
4. Check limit switch with continuity tester. If open, replace high limit.
5. Check wiring per wiring diagrams.
6. Replace gas valve.
7. Check thermostat and replace if defective.
8. Be sure 115 volts is supplied to the transformer primary, then check for 24 volts at secondary terminal before replacing.
9. Check and tighten all wiring connections per diagrams.
10. Replace, if necessary. Also see W, X, & Y symptoms.
J. Condensation of water vapor.
K. Burner won't turn off.
1. Condensation of water vapor.
1. Poor thermostat location.
2. Defective thermostat.
3. Improper thermostat or transformer wiring at gas valve.
4. Short circuit.
5. Defective or sticking gas valve.
6. Excessive gas supply pressure.
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1. Refer to “Installation, Venting”.
1. Relocate thermostat away from drafts.
2. Replace thermostat.
3. Check wiring diagrams.
4. Check operation at valve. Look for short (such as staples piercing thermostat wiring) and correct.
5. Replace gas valve.
6. Refer to “Operation”.
Table 9 - Troubleshooting Guide
SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION
L. Rapid burner cycling.
M. Noisy power ventor.
N.
Pilot will not light or will not stay lit.
1. Loose wire connections at gas valve or thermostat.
2. Excessive thermostat heat anticipator.
3. Unit cycling on high limit.
4. Poor thermostat location.
5. Draft on pilot.
6. Defective ignitor control.
7. Defective high limit.
1. Power ventor wheel loose.
2. Power ventor wheel dirty.
3. Power ventor wheel rubbing housing.
4. Bearings are dry.
1. Main gas valve off.
2. Pilot adjustment screw turned too low on combination main gas valve.
3. Air in gas line.
4. Incorrect lighting procedure.
5. Dirt in pilot orifi ce.
6. Extremely high or low gas pressure.
7. Drafts around unit.
8. Pilot valve not opening (faulty wiring).
9. No spark (faulty wiring).
10. Defective gas valve.
1. Tighten all connections.
2. Adjust thermostat for longer cycles. Refer to “Operation”.
3. Check for proper air supply across heat exchanger.
4. Relocate thermostat (do not mount thermostat on unit).
5. Eliminate drafts. Refer to “Installation”.
6. Replace ignitor.
7. Jumper high limit switch terminals 1 and 2. If burner operates normally, replace switch.
1. Replace or tighten.
2. Clean power ventor wheel.
3. Realign power ventor wheel.
4. Oil bearings on power ventor motor. Refer to label on motor.
1. Open all manual gas valves.
2. Refer to “Operation”.
3. Purge air from gas line.
4. Follow lighting instruction label adjacent to gas valve.
5. Remove pilot orifi ce. Clean with compressed air or solvent. Do not ream.
6. Refer to “Operation”.
7. Eliminate drafts. Refer to “Installation”.
8. Inspect and correct wiring.
9. Inspect and correct ignition system wiring. See symptoms W, X & Y.
10. Replace gas valve.
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Table 9 - Troubleshooting Guide
SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION
O. Power ventor will not run.
P. Power ventor motor turns on and off while burners are operating.
1. Loose wiring.
2. Defective motor overload protector or defective motor.
3. Defective power ventor relay.
1. Fan relay heater element improperly wired.
2. Defective ventor relay switch.
3. Motor protector cycling on and off.
4. Motor not properly oiled.
1. Check and tighten all wiring connections per diagrams. Thermostat wires tagged “W” and “G” must be connected together (unless special thermostats are used; if so, see thermostat wiring
diagram). See “Electrical
Connections”.
2. Replace motor.
3. Check 24V across 1 and 3 terminals on fan relay. If 24V is present, jumper terminals numbered 2 and 4. If motor runs, the relay is defective and must be replaced. If 24V in not present, check wiring per wiring diagrams.
1. Be sure ventor relay heater terminals are connected per diagrams.
2. Replace ventor motor.
3. Check motor amps against motor name plate rating, check voltage, replace power ventor motor if defective.
4. Refer to label on motor.
Q. Power ventor motor will not stop.
R. Not enough heat.
T. Too much heat.
1. Improperly wired ventor relay.
2. Main burners not lighting while thermostat calls for heat.
3. Defective ventor relay.
1. Incorrect gas input.
2. Heater undersized.
3. Thermostat malfunction.
4. Heater cycling on high limit.
5. Check outside dampers if used.
1. Thermostat malfunction.
2. Heater runs continuously.
1. Check all wiring.
2. Refer to H & N Symptoms.
3. Replace ventor relay.
1. Refer to “Operation”.
2. This is especially true when heated space is enlarged. Have heat loss calculated and compare to heater output (80% of input). Your gas supplier or installer can furnish this information. If heater is undersized, add additional heaters.
3. Replace thermostat.
4. Check air movement through heat exchanger. Check voltage to fan motor. Clean power ventor motor.
5. Adjust dampers accordingly.
1. Replace thermostat.
2. Check wiring diagrams; Check operation at valve. Look for short (such as staples piercing thermo- stat wiring) and correct: Replace gas valve; Refer to “Operation”.
U. Cold air is delivered on start-up
1. Fan relay heater element improperly wired.
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1. Be sure fan relay heater terminal are connected per diagrams.
Table 9 - Troubleshooting Guide
SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION
V. Cold air is delivered during heater operation.
W. No spark.
X. Spark present but pilot does not light.
Y. Pilot lights — Main valve does not energize.
1. Incorrect manifold pressure or input.
2. Voltage to unit too high.
3. Air through put too high.
1. Thermostat not calling for heat.
2. No low voltage.
3. Spark gap closed or too wide.
4. Broken or cracked ceramic on spark electrode.
1. Loose S8600 connections.
2. Improper gas pressure.
3. Is spark in pilot gas stream?
4. No pilot gas — do not use match to test - presence of gas is easily detected by the odor.
1. Loose S8600 connections.
2.
Cracked or broken sensor ceramic.
3. Check sensor/spark lead for continuity.
4. Measure 24 volts from term. MV to term. MV/PV.
1. Refer to "Operation".
2. Check motor voltage with fan running. Should be 115 volts AC.
3. Refer to "Operation".
1. Close thermostat contacts.
2. Check for 24V across 24V terminals of S8600.
3. Set gap to 0.1".
4. Replace pilot assembly.
1. Check all connections, term. PV feeds 24V to pilot valve.
2. Check pressure — pressure that is either too high or too low may cause a problem.
3. Spark should arc from electrode.
4. Check pilot line for kinks. Ensure there are no drafts.
1. Check connections-term. MV feeds main valve.
2. Replace pilot assembly.
3. Replace if needed.
4. If present, replace main valve; if not, replace S8600 Igniter.
Z. Hi-Limit switch tripping.
1. Unit is overfi ring.
2. Air fl ow too low
3. Defective switch.
1. Manifold pressure too high; adjust. Burner orifi ces may be too large: verify/replace if req'd.
2. Increase air fl ow; check fan size. Check for proper voltage.
3. Replace.
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HOW TO ORDER REPLACEMENT PARTS
Please send the following information to your local representative; If further assistance is needed, contact the manufacturer's customer service department.
• Unit number
• Serial Number (if any)
• Part description and Number as shown in the Replacement Parts Catalog.
LIMITED WARRANTY
SEPARATED COMBUSTION DUCT FURNACE
1. The “Manuf acturer” warrants to the original owner at original installation site that our Separated Combustion Duct Furnace (“the Product”) will be free from defects in material or workmanship for one (1) year from the date of shipment from the factory. If upon examination by the Man uf acturer the Product is sho wn to ha v e a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective.
2. This limited warranty does not apply: (a) if the Product has been subjected to misuse or neglect, has been accidentally or intentionally
damaged, has not been installed, maintained or operated in accordance with the furnished written
instructions, or has been altered or modifi ed in any way by any unauthorized person. (b) to any expenses, including labor or material, incurred during removal or reinstallation of the Product. (c) to any damage due to corrosion by chemicals, including halogenated hydrocarbons, precipitated in
the air. (d) to any workmanship of the installer of the Product.
3. This limited warranty is conditional upon: (a) advising the installing contractor, who will in turn notify the distributor or manufacturer. (b) shipment to the Manufacturer of that part of the Product thought to be defective . Goods can only be
returned with prior written approval of the Manufacturer . All returns must be freight prepaid.
(c) determination in the reasonable opinion of the Manufacturer that there exists a def ect in material or
workmanship.
4. Repair or replacement of any part under this Limited W arranty shall not extend the duration of the w arranty
with respect to such repaired or replaced part beyond the stated warranty period.
5. THIS LIMITED W ARRANTY IS IN LIEU OF ALL O THER W ARRANTIES, EITHER EXPRESS OR IMPLIED,
AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY . IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. Y OU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION.
In the interest of product improvement, we reserve the right to make changes without notice.
29
SEPARATED COMBUSTION INDOOR DUCT FURNACE
UNIT NUMBER DESCRIPTION
Digit X X X X — 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 + Item
Prefi x UT CA FT FM GT IC AL GC SV MT MS AS
(Internal use Only)
Digit #1, 2 - Unit Type [UT]
D6 - Separated Combustion Duct Furnace
Digit #3, 4, 5 - Capacity [CA]
100 - 100,000 BTU/HR 125 - 125,000 BTU/HR 150 - 150,000 BTU/HR 175 - 175,000 BTU/HR 200 - 200,000 BTU/HR 225 - 225,000 BTU/HR 250 - 250,000 BTU/HR 300 - 300,000 BTU/HR 350 - 350,000 BTU/HR 400 - 400,000 BTU/HR
Digit #6 - Furnace Type [FT]
A - Right Side Access (Optional) B - Left Side Access (Standard)
Digit #7 - Heat Exchanger Construction Material [FM]
1 - Aluminized Steel 2 - 409 Stainless Steel 3 - 321 Stainless Steel
Digit #8 - Gas Type [GT]
N - Natural Gas P - Propane Gas (LP) K - Natural Gas w/100% Shutoff
Digit #9 - Ignition Control [IC]
2 - Spark Ignition
Digit #10 - Altitude [AL]
A - 0–1,999 ft. J - 8,000–8,999 ft. B - 2,000–2,999 ft. K - 9,000–9,999 ft. C - 3,000–3,999 ft. L - 10,000–10,999 ft. D - 4,000–4,999 ft. M - 11,000–11,999 ft. F - 5,000–5,999 ft. N - Local Gas Supplier Derate G - 6,000–6,999 ft. P - Canadian High Altitude 2,000–4,500 ft. H - 7,000–7,999 ft.
Digit #11 - Gas Control [GC]
A - Single Stage B - T wo Stage H - Electronic Modulation w/Room Sensing J - Electronic Modulation w/Duct Sensing K - Electronic Modulation w/Duct Sensing & Room Ovrd. Stat L - Electronic Modulation w/External 4-20 mA Input N - Electronic Modulation w/External 0-10 VDC Input
Digit #13 - Motor Type [MT]
0 - None/Not Applicable
Digit #14 - Motor Sizes [MS]
0 - None/Not Applicable
Digit #15 - Accessories [AS] FACTORY INSTALLED
A8 - Input Derate P4 - Terminal Block Wiring P6 - Summer/Winter Switch K4 - Fan Time Delay K5 - Air Flow Prove Switch S1 - 409 Stainless Steel Burners S3 - 409 Stainless Steel Flue Collector
† FIELD INSTALLED (AS-____ )
† Field Installed Accessories are not included in the Unit Number. All Field Installed Accessories are entered as a separate line item using the catalog number which utilizes “AS” as a prefi x. i.e: A7 becomes AS-A7.
A7 - Pressure Regulator 1/2-2 psi H5 - Low Ambient Control F1 - 1-Stage T675A Ductstat M2-1 -
F2 - 2-Stage T678A Ductstat M2-2 ­ M2-3 ­G1 - 1-Stage T87K Mercury Free Thermostat M3-1 ­ w/Subbase Kit M4 - Vertical Combustion Air Inlet Kit G2 - 1-Stage T87K Mercury Free Thermostat M5 - Horizontal Combustion Air Inlet Kit
w/TG511A Guard Kit G3 - 1-Stage T834N Mercury Free Thermostat P2 - Adjustable High Limit Switch w/Fan Switch P3 - Adjustable Fan Switch
G6 - Locking Thermostat Cover P5 - 24V SPST Relay-Specify Purpose G8 - 1-Stage T6169C Line Voltage Stat w/Subbase Q7 - Horizontal/Vertical Louvers G9 - 1-Stage T822K Mercury Free
Thermostat
Vent Caps (4 inch) (Unit Capacity 100-175) Vent Caps (5 inch) (Unit Capacity 200-250) Vent Caps (6 inch) (Unit Capacity 300-400)
Adaptors (5-4 inch) (Unit Capacity 100-175)
Digit #12 - Supply Voltage [SV]
1 - 115/1/60 5 - 230/3/60 2 - 208/1/60 6 - 460/3/60 3 - 230/1/60 7 - 575/3/60 4 - 208/3/60 Z - Special
Note: Supply Voltages [SV] 2-7 include fi eld mounted step down transformer.
30
31
GAS EQUIPMENT
START-UP
Customer ____________________________________ Job Name & Number _________________________
PRE-INSPECTION INFORMATION
With power and gas off.
Type of Equip:
Serial Number _________________________ Model Number __________________________ Name Plate Voltage: _____________ Name Plate Amperage: _____________ Type of Gas: Natural LP Tank Capacity _______ lbs Rating: _ _____ BTU @ ____ °F
_______ kg _ _____ kw @ ____ °C
Duct Furnace
Are all panels, doors, vent caps in place? ❐ Has the unit suffered any external damage? Damage ______________________________ ❐ Does the gas piping and electric wiring appear to be installed in a professional manner? ❐ Has the gas and electric been inspected by the local authority having jurisdiction? ❐ Is the gas supply properly sized for the equipment? ❐ Were the installation instructions followed when the equipment was installed? ❐ Have all fi eld installed controls been installed? ❐ Do you understand all the controls on this equipment? If not, contact your wholesaler or rep.
(DO NOT START this equipment unless you fully understand the controls.)
With power and gas off.
GENERAL
Make certain all packing has been removed. Tighten all electrical terminals and connections. Check all controls for proper settings.
Inlet gas pressure. ____ in. WC or ____ kPa Pilot & main burner ignition. Manifold gas pressure. ____ in. WC or ____ kPa
GAS HEATING
With power and gas on.
Check electronic modulation. Set at: __________ Cycle and check all other controls not listed. Entering air temp. _____ °F or ____ °C Discharge air temp. (high fi re) ____ °F or ____ °C External static pressure _________ in. WC Cycle by thermostat or operating control. Combustion Reading:
Carbon Monoxide: ____ PPM Carbon Dioxide: ____ %
Remarks: _____________________________________________
__________________________________________________ __________________________________________________
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