Tjernlund PAI-1, PAI-2O User Manual

TJERNLUND PRODUCTS, INC.

1601 Ninth Street • White Bear Lake, MN 55110-6794
PHONE [phone] • [phone] • FAX [phone]
Visit our web site • www.tjernlund.com

TM

IN-FORCER

MODELS

PAI-1G & PAI-2G

PAI-10 & PAI-2O

REV. A 5/01

INSTALLATION INSTRUCTIONS

OWNER'S INSTRUCTIONS, DO NOT DESTROY

THIS DEVICE MUST BE INSTALLED BY A

QUALIFIED PERSON.

READ INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION

AND OPERATION OF THE AIR INTAKE SYSTEM.

Copyright © 2001, Tjernlund Products, Inc. All rights reserved. P/N 8504038

TABLE OF CONTENTS

Descriptions and Specifications ......................................................................................................................................1

Installation Restrictions....................................................................................................................................................2

Cautions ..........................................................................................................................................................................2

Safety Inspection of a Previously Used Appliance ......................................................................................................2-3

IN-FORCER Terminology................................................................................................................................................3

Intake Elbow Termination Clearances.............................................................................................................................3

Combustion CFM Necessary For Appliance(s)...............................................................................................................4

Determining IN-FORCER CFM capabilities ....................................................................................................................4

Installation

Tools Required ...............................................................................................................................................................4

Cutting PVC Opening through Wall..............................................................................................................................4-5

IN-FORCER Installation...............................................................................................................................................5-6

Installation of Pipe .......................................................................................................................................................6-7

Confined Space or Closet Installations ...........................................................................................................................7

Installation of Intake Elbow..............................................................................................................................................7

Electrical Wiring

System Operation Check Out........................................................................................................................................13

Maintenance..................................................................................................................................................................13

Trouble Shooting

How to Obtain Service & Warranty ..........................................................................................................................16-17

Replacement Parts List & Isometric IN-FORCER Diagram ..........................................................................................17

PVC Hole Template.......................................................................................................................................................18

Wiring IN-FORCER Models PAI-1O & PAI-2O ............................................................................................8-10

Wiring IN-FORCER Models PAI-1G & PAI-2G ..........................................................................................10-13

Wiring IN-FORCER PAI-G Series With a 24V Furnace/Boiler and Millivolt Water Heater .............................11

Wiring IN-FORCER Models PAI-1G & PAI-2G With Single Zone Gas or Oil Terminal Strip/Fan Center .......13

IN-FORCER Models PAI-1O & PAI-2O ...........................................................................................................14

IN-FORCER Models PAI-1G & PAI-2G......................................................................................................15-16

IN-FORCERTMis a trademark of Tjernlund Products, Inc. for IN-FORCER air intakes.

DESCRIPTION

The IN-FORCER combustion fans are mechanical air intake fans designed and Listed for use with atmospheric or induced combus­tion natural draft gas or oil heating equipment. The IN-FORCER functions as a source of combustion air. Outside intake air is blend­ed with a larger quantity of indoor air so the resulting tempered discharge does not reflect outside temperature extremes. The
IN-FORCER assures intake air is supplied by monitoring the airflow with a Fan Proving Switch. The main burner will be interrupted if
a malfunction occurs.

APPLICATION TABLE

Verify that the total BTU/hr input of the heating appliance(s) fall within the ratings listed below. Check CFM necessary for the BTU/hr
input of the heating appliance(s) on table 1, page 4. CFM delivered depends upon the total length of pipe used. Check CFM capacity
with different inlet and outlet pipe lengths on page 4, Table 2 PAI-1 Series or Table 3 PAI-2 Series.

SPECIFICATIONS

Motor: 115/1/60, 1600 RPM, 80 watts, 1.0 FLA
Fan Prover: Non-adjustable, contacts rated for 3 Amps Inductive @ 120VAC
Relay: 24/115V Switching Relay, PAI-1G & PAI-2G

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GENERAL INFORMATION

These units have been factory tested and rated in accordance with AMCA standard 210, test code for air moving devices.
Each IN-FORCER is electrically factory line tested before shipment.
After opening carton, Inspect thoroughly for hidden damage. Fan wheel should rotate freely. If any damage is found, notify freight
carrier and your distributor immediately and file a concealed damage claim.

INSTALLATION RESTRICTIONS

1. The electrical load controlled through the Fan Proving Switch must not exceed its nameplate ratings.

2. Observe proper location of intake elbow as described on page 3.
WARNING: Improper installation, adjustment, alterations, service or maintenance can cause injury or property damage. Refer to

this manual. For assistance or additional information consult a qualified installer, service agency or the equipment supplier.

CAUTIONS

1. Failure to install, maintain and/or operate the IN-FORCER in accordance with manufacturer’s instructions may result in conditions
that can produce bodily injury and property damage.

2. The IN-FORCER must be installed by a qualified installer (an individual properly licensed and/or trained) in accordance with all
local codes or in their absence, in accordance with the appropriate National Fire Protection Association #31, #54, #211 and the
National Electric Code.

3. The IN-FORCER motor shaft must be mounted horizontally and with discharge facing down to prevent motor bearing wear and
ensure proper operation of the Fan Proving Switch.

4. The IN-FORCER must be installed level to ensure proper damper operation.

5. Disconnect power supply when making wire connections and servicing the IN-FORCER. Failure to do so may result in personal
injury and/or equipment damage.

6. Make certain the power source is adequate for the IN-FORCER requirements. Do not add the IN-FORCER to a circuit where the
total electrical load is unknown.

WARNING: The IN-FORCER CFM outputs are estimates that will assure adequate combustion air is supplied if the appliance is
functioning properly. However, in the event that there is an appliance malfunction, such as a cracked heat exchanger or clogged
flue, there is no guarantee that additional combustion air will eliminate carbon monoxide spillage into the home.

SAFETY INSPECTION OF A PREVIOUSLY USED OIL APPLIANCE

(Perform prior to IN-FORCER installation)

The following procedure is intended as a guide to aid in determining that an appliance is properly installed and is in safe condition for
continuing use. This procedure is based on central furnace and boiler installations and it should be recognized that generalized pro­cedures cannot anticipate all situations. Accordingly, in some cases deviation from this procedure may be necessary to determine
safe operation of the equipment.

A. This procedure should be performed prior to any attempt at modifications of the appliance or installation of the IN-FORCER.
B. If it is determined there is a condition which could result in unsafe operation, the appliance should be shut off and the owner

advised of the unsafe condition.

The following steps should be followed in making the safety inspection:

1. Visually inspect the venting system and determine there is no blockage or restriction, leakage, corrosion or other deficiencies
which could cause an unsafe condition.

2. Inspect burner and primary control for proper operation.

3. Applicable only to furnaces: Inspect heat exchanger for cracks, openings or excessive corrosion. Check both the limit control
and fan control for proper operation.

4. Applicable only to boilers: Inspect for evidence of water or combustion product leaks. Determine that the water pumps are in
operating condition. Test low water cutoffs, automatic feed controls, pressure and temperature limit controls and relief valves in
accordance with the manufacturer's recommendations to determine that they are in operating order.

SAFETY INSPECTION OF A PREVIOUSLY USED GAS APPLIANCE

(Perform prior to IN-FORCER installation)

The following procedure is intended as a guide to aid in determining that an appliance is properly installed and is in safe condition for
continuing use. This procedure is based on central furnace and boiler installations and it should be recognized that generalized pro­cedures cannot anticipate all situations. Accordingly, in some cases deviation from this procedure may be necessary to determine
safe operation of the equipment.

A. This procedure should be performed prior to any attempt at modifications of the appliance or installation of the IN-FORCER.

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B.

If it is determined there is a condition which could result in unsafe operation, the appliance should be shut off and the owner

advised of the unsafe condition.

The following steps should be followed in making the safety inspection:

1. Conduct a gas leakage test of the appliance piping and control system downstream of the shutoff valve in the supply line to the
appliance.

2. Visually inspect the venting system and determine there is no blockage or restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.

3. Shut off all gas to the appliance(s).

4. Inspect burners and crossovers for blockage and corrosion.

5. Applicable only to furnaces: Inspect heat exchanger for cracks, openings or excessive corrosion. Check both the limit control
and fan control for proper operation.

6. Applicable only to boilers: Inspect for evidence of water or combustion product leaks. Determine that the water pumps are in
operating condition. Test low water cutoffs, automatic feed controls, pressure and temperature limit controls and relief valves in
accordance with the manufacturer's recommendations to determine that they are in operating order.

* Excerpts from the National Fuel Gas Code (ANSI Z223.1/NFPA #54), Appendix H.

IN-FORCER TERMINOLOGY

INTAKE ELBOW TERMINATION CLEARANCES

The IN-FORCER has been Listed in accordance with the 1990 BOCA national Mechanical Codes M-306.1 and M-306.1.1 as follows,
(See Diagram A).

M-306.1 LOCATION: Outside air exhaust and intake openings shall be located a minimum of 10 feet (3048mm) from lot lines or build­ings on the same lot. When openings front on a street or public way, the distance shall be measured to the centerline of the street or
public way.

M-306.1.1 INTAKE OPENINGS: Outside air intake openings shall be located a minimum of 10 feet (3048mm) from any hazard or
noxious contaminant such as vents, chimneys, plumbing vents, streets, alleys, parking lots and loading docks. When a source conta­minant is located within 10 feet (3048mm) of an intake opening, such opening shall be located a minimum of 2 feet (610mm) below
the contaminant source.

IN ADDITION TO THESE CODES THE MANUFACTURER RECOMMENDS THAT:

• The intake elbow should be a minimum of 1 foot above grade or anticipated snow line.

DIAGRAM A

* IF TERMINATING BELOW GRADE

OR ANTICIPATED SNOW LINE, USE
EXTENSION PROCEDURE AS
SHOWN IN TABLE 2 OR TABLE 3.

If possible, terminate the IN-FORCER on a wall that does not face the direction of prevailing
winds. This will diminish the possibility of wind induced damper fluctuation noise.

3

COMBUSTION CFM NECESSARY FOR APPLIANCE

The type of appliance the IN-FORCER is being interlocked with will have to be considered when determining the minimum CFM for
combustion purposes. Consult chart for recommended minimum CFM needed to fulfill combustion air requirements, (See Table 1).

TABLE 1

Note:

The PAI-1 Series maximum
capacity is 59 CFM.

The PAI-2 Series maximum
capacity is 80 CFM.

DETERMINING CFM CAPABILITIES

Reference the chart of the correct model selecting either the PAI-1 or PAI-2 series. The readings for CFM are determined with vari­ous inlet and outlet pipe lengths. The charts are read the same way except the right hand chart takes into consideration an intake
elbow that is extended up to 4’ above exterior penetration for below grade applications or to extend above anticipated snow line. The
top row of the chart has inlet 3” diameter PVC pipe lengths from 2 to 20 feet. The left hand column has outlet 6” diameter pipe
lengths from 0 to 20 feet. Pipe lengths must be calculated in equivalent feet, (See Diagram H, Page 6). With correct model selected,
determine pipe lengths and read intersection of inlet and outlet pipe lengths to determine CFM. Consult Tjernlund Products for infor­mation on CFM data with pipe runs longer than those indicated on the charts.

TABLE 2

TABLE 3

PAI-1 SERIES

PAI-2 SERIES

INSTALLATION (TOOLS REQUIRED)

• 3-1/2” hole saw or reciprocating saw • 5/16”, 1/4” nut runner or socket • Wire cutter/stripper

• Drill and 1/2” bit • Blade screwdriver

CUTTING PVC OPENING THROUGH WALL

Note: Before cutting opening through wall, consider layout of PVC pipe runs and consult performance charts above to make sure

CFM necessary for equipment is achieved with pipe run lengths.

4

1.

A) Attach template to the rim joist in between the floor joists ensuring that it is snug against the subfloor and joist that IN-FORCER

will be mounted to, (See Diagram B). If unit is to be installed on floor trusses, the template should be adjusted to compensate
for the thickness of the added plywood as described in truss mounting section below, (See Diagram C).

B) If IN-FORCER is not being installed between floor joists or trusses, attach the template to the wall it will be exiting, ensuring

IN-FORCER will be level.
DIAGRAM B

2. Using 1/2” bit, drill pilot holes noted on the template from inside through rim joist, wall board, siding, etc., keeping drill bit
perpendicular to the wall. 1/2” bit must be long enough to penetrate through exterior.

3. Remove template from rim joist and attach to building exterior, aligning pilot hole markings on template with holes previously
created in Step #2.

4. Using 3-1/2” hole saw or a reciprocating saw and appropriate blade, cut opening through rim joist, wall board, siding, etc., following
the template outline for the pipe, (See Diagram D).

5. Knock out material exposing hole through the wall.

DIAGRAM D

DIAGRAM C

TRUSS MOUNTING

If IN-FORCER will be mounted on a floor truss instead of a joist follow this section, otherwise, skip to installation of IN-FORCER.

1. Cut a piece of plywood measuring 22” x 9”.

2. Position 22” side of plywood flush against sub floor.

3. Secure plywood to trusses with a minimum of 4-8 penny nails or 1-1/2” wood screws.

INSTALLATION OF IN-FORCER

A minimum two foot length of PVC intake pipe is recommended so the IN-FORCER can be easily serviced. If intake PVC pipe
lengths are relatively short, the pipe can be cemented to the IN-FORCER coupler and fed through exterior opening before securing to
the wall. If PVC pipe run is extended, first secure IN-FORCER to joist/truss, then extend PVC pipe run through exterior opening and
cement to PVC coupler.

Note: Before cutting opening through wall, consider layout of PVC pipe runs and consult performance charts on page 4 to make sure
CFM necessary for equipment is achieved with pipe run lengths.

1. Assemble vibration mount brackets on IN-FORCER as shown below in diagram E.

DIAGRAM E

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