Unitary products group DLAS Series, DGAM Series, DGAT series, DGPT series Use And Care Instruction

Use and Care Instructions
For
Gas Downflow Furnace
035--15875--301 (1198)
DLAS MODELS (No Coil Cabinet)
FORYOURSAFETY--Donotstoreoruseflam­mable liquids, vapors, or materials in the immediate area near the furnace or other heating appliance.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, perĆ sonal injury or loss of life. Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Never attempt to modify this furnace. Fire, exploĆ sion, or asphyxiation may result. If malfunction ocĆ curs, obtain the assistance of a qualified service agent.
DGAM, DGAT & DGPT MODELS (With Built--in Coil Cabinet)
Before placing furnace in service, it must be checked to make sure it is equipped for the type of gas being used. The burner flame must also be observed andadjusted if necesĆ sary. Failure to observe this caution may reĆ sult in unsafe operation, explosion, and/or fire or asphyxiation. See sections Gas SupĆ ply" and Combustion Air".
Use of furnace or air conditioning components that are not included in the Underwriter's LabĆ oratories certification of this appliance may create a hazard, will invalidate the certificaĆ tion, and will in many states make installation illegal. UL listed air conditioning components arespecifiedonthefurnacelabel.
WARRANTY AND RESPONSIBILITIES
It is the sole responsibility of the home owner to make certain that the gas furnace has beencorrectly set upand converted to the proper fuel (Propane or Natural gas) and adjusted to oper­ate properly.
The manufacturer warrants the fur­nace to be free fromdefectsinmateri­al or workmanship for the stated time in the warranty agreement (see war­ranty certificate packed with the fur­nace).
However, the manufacturer will not be responsible for any repair costs to correct problems due to improper set--up, improper installation, furnace adjustments, improper operating pro­cedure by the user, etc.
Some specific examples of service calls which cannot be included in war­ranty payments are:
1. Converting the furnace to use another type of gas.
2. Correcting faulty duct work in the home.
3. Correcting wiring problems in the electrical circuit to the furnace.
4. Resetting circuit breakers or oth­er switches.
5. Adjusting the burner air shutter or service calls made to correct problems caused by improper air adjustment.
6. Correcting problems caused by improper gas supply pressure to the furnace.
7. Instructional training on how to light and operate furnace.
8. Furnace problems caused by in­stallation of air conditioner, heat pump, or other air quality device which is not approved.
9. Problems caused by improper in­stallation of the furnace flue as­sembly (roof jack).
10. Adding a roof jack extension because of unusual wind condi­tions or snow conditions.
11. Adjusting or calibrating the ther­mostat.
12. Construction debris which has fallen into the flue or combustion air openings.
You should establish a firm under­standing of these responsibilities with your manufactured housing dealer, serv ice company or gas supplier so there will be nomisunderstanding at a later time.
GAS SUPPLY
The gas supply to your home will ei­ther be Natural Gas or Propane gas (bottle gas). Your furnace will be fac­tory equipped to operate on only one of these two different gases.
A small metal tag secured to the fur­nace next to the gas valve will specify thetypeofgasyourfurnaceis equipped to use.
If the gas is different from that speci­fied on the metal tag, the furnace can be converted by following the instruc­tions on the furnace safety label inside lower front panel. P arts for con­version are contained in the small cloth bag attached to the gas valve. Be sure the proper size orifice is used, as specified on the furnace name plate.
The furnace must be conĆ verted by a qualified techniĆ cian. Improper conversion can cause unsafe operation, explosion, and/or fire or asĆ phyxiation.
Natural Gas Operation
The furnace is designed for 7” W.C. inlet pressure. Pressure is reduced to 3 1/2” W.C. by the pressure regulator in the gas valve.
Propane Gas Operation
Inlet pressure to the gas valve must be 11”W.C. When properly converted to Propane gas, the pressure is regu­lated at 10” W.C.
SAFETY INFORMATION
For your safety read before lighting.
A. The first lighting of the furnace af-
ter any home setup must be per­formed by a qualified service technician.
B. If this appliance has a pilot that
must be lit by hand, follow these instructions exactly.
C. BEFORE LIGHTING smell all
around the furnace for gas. Be sure to smell next to the floor be­cause some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
D Donottrytolightanyappliance.
D Do not touch any electric switch
and do not use any phone in your building.
D Immediately call your gas suppli-
er from a neighbor’s phone. Fol­low the gas supplier’s instruc­tions. If you cannot reach your gas supplier, call the fire depart­ment.
D. Use only your hand to push in the
gas control lever. Never use tools. If the lever will not push in by hand, don’t try to repair it. Call a qualified service technician. Force or attemptedrepairmay re­sult in a fire or explosion.
E. Do not use this furnace if any part
has been under water. Immedi­ately call a qualified service tech­nician to inspect the furnace and to replace any part of the control system and any gas control which has been under water.
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INSTRUCTIONS FOR DGPT STANDING PILOT MODELS
LIGHTING INSTRUCTIONS
1. STOP! Read the SAFETY INĆ
FORMATION.
2. Set the thermostat to the lowest setting.
3. Turn off all electrical power to the appliance.
4. Remove the furnace doors.
5. Push in the gas control lever slightly and move right to “OFF”. DO NOT FORCE.
6. Wait ten (10) minutes to clear out any gas. Then smell for gas, in­cluding near the floor. If you smell gas, STOP! Follow “C” in the SAFETY INFORMATION. If you don’t smell gas, go to the next step.
7. Open hinged observation door, the pilot is foundat the end of the pilot shield on the left side of the burner.
8. Slightly depress the gas control lever and move it to the left to the “ON” position and release; then move it to the “PILOT” position.
9. Move the control lever to “SET” and hold. I mmediately light the pi­lot with a match (use match hold­er provided). Continue to hold the control lever for about one (1) minuteafterthepilotislit.Re­lease the lever and it will spring back to the “PILOT””position. Pi­lot should remain lit. If it goes out, repeat steps “5” through “9” above.
D If the lever does not spring back
when released, stopand immedi­ately call your service technician or gas supplier.
D If the pilot will not stay lit after sev-
eral tries, move the gas controlle­ver to “OFF” andcall your service technician or gas supplier.
10. Move the gas control lever to “ON”.
11. Replace the furnace doors.
12. Turn on all electric power to the furnace. Set the thermostat to “HEAT” and/or the desired tem­perature setting. Set the ON-­OFF--FAN switch to “ON”.
In the event of any flashback or exĆ plosion, immediately shut off the furnace and call your servicetechĆ nician.
To Turn off Gas to A ppl i ance
1. Set the thermostat to the lowest setting.
2. Turn off all electric power to the appliance if service is to be per­formed.
3. Remove the furnace doors.
4. Move gas control switch to “OFF” position. DO NOT FOR CE.
5. Replace the furnace doors.
GAS CONTR OLCONTROL LEVER
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PRESSURE REGULATING DEVICE
FIGURE 1 -- ROBERT SHAW
GAS VALVE
SEQUENCE OF OPERATION
1. On a call for heat, the thermostat contacts close, supplying 24 VAC to the gas valve.
2. Whenthegasvalveisenergized it steps open at a reduced flow and opens f ully after approxi­mately 10 seconds.
3. When the call for heat is satisfied the thermostat contacts open, thegasvalveshutoffgasflow.
THE FURNACE CONTROL S AND THEIR FUNCTION
1. “ON--OFF --FAN” switch turns electrical power to the furnace on and off. The switch must be set in the “ON” position for the furnace to operate. To run the blowercon­tinuously without heating, set the swi t ch to “FAN”.
2. Limit Control -- This furnace is protected by two (2) high temper­ature limit switches. The lower limitswitchisanautomaticreset type.
The upper limit switch near left side of blower is a manual reset type limit switch (See Figure 2). If burner does not function, turn system switch to OFF and push reset button in center of limit switch.
Chute to left of blower is hot. Use care when resetting limit switch to avoid burns to hand and arm.
If the upper limit switch trips again soon after resetting, turn the furnace System Switch to the OFF position and call your nearest authorized service techĆ nician.
UPPER LIMIT
SWITCH
(MANUAL
RESET)
BLOWER
SYSTEM SWITCH
AUTOMATIC
RESET LOWER
LIMIT SWITCH
HOTHOT
FIGURE 2 -- FURNACE CONTROLS
PILOT
ACCESS
DOOR
GAS VALVE
BURNER AIR
SHUTTER
ADJUSTMENT
ROD
3. Gas Valve -- The gas valve is 100% shut--off type and will fail safe if for some reason the gas is turned off or the pilot goes out. It is also of the modulating or “step-­open” type which means they open to a “low fire” position and after a few seconds “step--open” to “high fire”.
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4. Fan Switch -- This fan switch is a temperature sensing device that turns on theblower when suf­ficient heat has built up within the furnace. It also turns the blower off when the furnace has cooled down sufficiently after burner
is a possibility of the blower com­ing on periodically or operating continuously due to a heat build­up within the furnace by a com­bination of warm weather and heat from the pilot. This is normal operation as long as there is pow-
er to the furnace and the ON-­OFF --FAN switch is at the “ON” position. I F blower operation is not desired, the ON--OFF--FAN switch may be set in the “OFF” position to cut the electrical pow­er to the furnace.
shut-- off. In warm weather, there
INSTRUCTIONS FOR DGAM, DGAT & DLAS AUTOMATIC IGNITION MODELS
LIGHTING INSTRUCTIONS
1. STOP! Read the SAFETY INĆ FORMATION.
2. Set the thermostat to the lowest setting, or OFF.
3. Turn off all electric power to the furnace.
4. This appliance does not have a pilot. It is equipped with an igni­tion device which automatically lights the burner. Do not try to light the burner by hand.
5. Remove upper door panel.
6. Move gas valve control lever to OFF.SeeFigure3.
7. Wait five (5) minutes to clear out any gas. Then smell for gas, in­cluding near the floor. If you smell gas, STOP! Follow “C”, in the SAFETY INFORMATION. If you don’t smell gas, go to the next step.
8. Move gas control control lever to ON.
9. Replace upper door panel.
10. Turn on all electric power to the furnace.
11. Set thermostat to desired setting.
GAS CONTR OL
CONTROL LEVER
FIGURE 3 -- WHITE--ROGERS
GAS VALVE
PRESSURE
REGULATING
DEVICE
SEQUENCE OF OPERATION
This furnace is equipped with an elec­tronic control system which automati­cally supervises burner and fan op­eration. A green indicator light dis­plays during normal operation. T his indicator light also informs the home owner when certain basic services are needed. In response to a call for heat by the room thermostat, the burner is lighted by a hot glowing igni­tor at the beginning of each operation cycle. The burner will continue to op­erate until the thermostat is satisfied at which time all burner flame is extin­guished. During the off cycle no gas is consumed. W ith the room thermostat set belowroomtemperature, andwith the electrical power and gas supply to the furnace on, the normal sequence of operation is as follows:
1. When the room temperature falls below the setting of the room thermostat, the thermostat ener­gizes the furnace control board.
2. When the furnace control board is activated, the combustion air blower is turned on.
3. As the combustion air blower in­creases in speed, the contacts of the pressure switch will close and complete the electrical circuit to the ignition circuit.
4. During the next 40 to50 seconds, the combustion air blower will bring fresh air into the heat ex­changer and the ignitor will begin to glow. At the end of this period, thegasvalvewillopenandthe burner will light.
5. After the burner lights, a separate sensor acts as a flame probe to checkforthepresenceofflame. As long as flame is present, the system will monitor it and hold the gas v alve open.
6. If the burner fails to light within 6--8 seconds after the gas valve opens,thegasvalvewillclose and the ignitor will be turned off. After a short pause, the system will recycle and try again for igni­tion. If the burner fails to light after three tries, the ignition system will lock out. The system will remain in lock--out mode for a period of one hour, then the furnace will try for ignition again.
7. Thelapsedtimefromthemoment the room thermostat closes to when the burner lights may be 45--60 seconds. This delay is caused by
a. Thetimerequiredfortheigni-
tor to heat up and
b. Thetimerequiredforfreshair
to be brought into the heat exchanger.
8. Approximately 90 seconds after the burner lights, furnace air cir­culation blower will run.
9. When room thermostat is satis­fied, the circuit to the furnace con­trol board is opened. T he circuit to the combustion air blower and thegasvalveisopenedandthe burner is extinguished. Then the furnace control board will keep the circulating blower running for a fixed period of time to allow ad­ditional heat to be drawn from the heat exchanger.
10. Diagnostic Light
If furnace does not maintain home temperature as set, check the light in­dicator, located behind the upper front door of the furnace.
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The electronic furnace control is equipped with a diagnostic light which flashes when there is a service prob­lem. T he diagnostic codes are:
Steady on Normal operation.
ONE flash: Ignition failure.
TWO flashes: Pressure switch failed closed.
THREE flashes: Pressure switch failed open.
FOUR flashes: Limit switch open.
FIVE flashes: Gas valve energized with no call for heat
SIX flashes or Rapid flash: Reversed polarity
If a problem is indicated, contact your authorized service person.
THE FURNACE CONTROL S AND THEIR FUNCTION
1. System Switch -- This system switch turns ON or OFF the 120 volt electrical circuit that powers the furnace controls and the blower motor. The system switch must be turned ON for the fur­nace to operate. Turn the switch to OFF when cleaning the blower, etc.SeeFigure2.
2. Limit Control -- This furnace is protected by two high tempera­ture safety limit switches. The auxiliary (upper) limit switch and the high temperature (lower) limit switch are automatic reset types. If either limit trips, the burner will shut off. If either limit switch trips off again soon after resetting, set the furnace ON--OFF switch to the “OFF” position and call your authorized technician.
3. Gas Valve -- The gas valve for the gas furnaces are a 100% shut--off typeandwillfailsafeifforsome reason the gas is turned off.
UPPER
LIMIT
SWITCH
BLOWER
DIAGNOSTIC
LIGHT
COMBUSTION
FAN MOTOR
SYSTEM
SWITCH
LIMIT
SWITCH
BURNER
OBSERVATION
WINDOW
GAS VALVE
BURNER AIR
SHUTTER
ADJUSTMENT
ROD
FIGURE 4 -- FURNACE CONTROLS
GENERAL INFORMATION FOR ALL MODELS
Gas Shutoff
Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the furnace and allow blower to run until furnace cools down and blower shuts off before shutting off the electrical supply.
The furnace gas valve is equipped with a manual gas shutoff. Figure 2 shows the location of the manual shutoff valve. Toturn off gas to the fur­nace, move the lever on the gas valve to the OFF position.
The furnace installation should also have a manual shutoff valve in the gas piping to the furnace, similar to whatisshowninFigure5.Toturnoff the gas to the furnace, use a wrench and turn the knob or lever so that it is pointing 90 degrees from the gas pipe, as shown in Figure 5.
OFF ON
OFF ON
FIGURE 5 -- MANUAL GAS
SHUTOFF VALVE
Set the room thermostat at the de­sired room temperature. Greatest comfort will be achieved when the setting is not changed frequently.
For energy conservation and econ­omy it is recommended that the ther­mostat be set at 68_for heating and 80_for cooling.
For Heating with Air Conditioning Applications -- Set HEAT/COOL switch to HEAT position andset FAN switch to AUTO position.
Observing Burner Operation
1. Observe burner to make sure it ignites. Observe color of flame. On natural gas the flame will burn blue with appreciably yellow tips. On Propane gas a yellow flame may be expected. If flame is not the proper color call a qualified serviceman for service. See Fig­ure 6 and 7.
2. Let furnace heat until blower cycles on.
3. Turn thermostat down.
4. Observe burner to make sure it shuts off.
5. Let the furnace cool and blower cycle off
If any abnormalities are observed when checking for correct operation, such as burner failing to ignite or to turn off, sooty flame, etc., call your nearest authorized service technician as shown in the Service Center List includedinthe home ownerenvelope.
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In order for the burner flame to burn efficiently, it must receive adequate combustion air.
The amount of combustion air can be changedbyoperatingthe combustion air adjustment rod located beneath thegasvalve.SeeFigure2.
Theadjustmentrodissetatan“aver­age” position at the factory and may be properly set for many applications.
However, the amount of combustion air required will vary depending on al­titude, actual BTU. content of the gas being used, gas pressure, conversion to another gas, and other variable fac­tors.
Therefore, it is essential that the burn­er flame be observed and any neces­sary adjustments are made before the furnace is put into service at the fi­nal home site. Adjustingthe burner air is considered part of the normal home set--upprocedureandis theresponsi-
bility of either the home seller or buy­er, depending on their agreement. Adjustments of this type are not cov­ered by the warranty.
Combustion air adjustments must be made only by a qualiĆ fied technician. Improper air adjustment may cause unĆ safe operation, explosion or asphyxiation.
To adjust the combustion air:
1. To light and operate furnace see label inside lower furnace door.
2. Allow the burner to burn for about 1MINUTE.
3. Look through the observation window and observ e the appear­ance of the flame.
4. On natural gas, the base of the flameshouldbebluebutthetips of the flame will be yellow. See Figure 6.
5. On Propane gas, almost all of the flame will be yellow although some blue should still be present at the base of the flame next to the end of the burner. See Figure
7.
6. If the flame is too yellow, the com­bustionair shouldbe increased. If the flame is excessively blue (no yellow) the combustion air should be decreased.
7. To adjust the combustion air, loosen the lock screw holding the combustion air rod in place. Push in on the rodto increase the com­bustion air. Pull out on the com­bustion air rod to decrease the combustion air. Tighten lock screw after adjustment is made.
View of Burner Through the Observation Window
LIGHT BLUE WITH YELLOW TIPS
DARK BLUE
BLUE TIPS JUST STARTING TO BECOME PRONOUNCED.
CORRECT AMOUNT OF
PRIMARY AIR
TOO LITTLE PRIMARY AIR PUSH SHUTTER R OD IN
FIGURE 6 -- NATURAL GAS FLAME APPEARANCE
WHTISH Y ELLOW TO LIGHT Y ELLOW
LIGHT BLUE
BLUE TIPS JUST STARTING TO BECOME P RONOUNC ED
CORRECT AMOUNT OF
PRIMARY AIR
TOO LITTLE PRIMARY AIR PUSH SHUTTER R OD IN
FIGURE 7 -- PROPANE GAS FLAME APPEARANCE
YELLOW WITH ORA NGE TIPS
LIGHT BLUE
NO BLUE TIPS EXTENDING FROM THE END OF THE BURNER
DARK YELLOW TO ORANGISH YELLOW
MAIN FLAME IS A WHITISH YELLOW REFLECTIVE COL­OR. VERY LITTLE BLUE EXTENDING FROM THE END OF THE BURNER.
TOO MUCH PR IMARY AIR PULL SHUTTER ROD OUT
TOO MUCH PR IMARY AIR PULL SHUTTER ROD OUT
DARK BLUE
DARK BLUE
LONG AND EXTREMELY PRONOUNCED BLUE TIPS EXTENDING FROM THE END OF THE BURNER
WHITISH YELLOW
LIGHT BLUE
LONG AND EXTREMELY PRONOUNCED BLUE TIPS EXTENDING FROM THE END OF THE BURNER
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If Furnace Fails to Operate Properly
1. Check settingof thermostat -- and position of HEAT/COOL switch if air conditioning is installed. If a set--back type thermostat is em­ployed be sure that the thermo­stat is in the correct operating mode.
2. Check to see that electrical power is ON.
3. Check tosee that the lever on the gas control valve is in the full ON position.
4. Make sure filters are clean, return grilles are not obstructed, and supply registers are open.
5. Be sure that furnace flue pipingis open and unobstructed.
If the cause for the failure to operĆ ate is not obvious, do not attempt to service the furnace yourself. Call a qualified service agency or your gas supplier.
PERIODIC INSPECTION AND MAINTENANCE BY HOMEOWNER
It is recommended that the home­ownerorusermakeaninspectionof the furnace at least every 90 days, or more often if desired. It is also recom­mended that a qualified service agency inspect the furnace before each operating season the furnace is used, both heating and air condition­ing, andat any time that there is an in­dication of malfunction. The owner/ user should not attempt to disassem­ble the furnace unless experienced and qualified to do so.
FOR SAFETY -- Turn off electriĆ cal power to furnace before perĆ forming service such as cleaning filters.
Filters
It is very important that filters in your furnace or air conditioning system be replaced frequently. Clean filters not only provide added comfort and a more healthful environment, but also allow the system to operate more effi-
ciently. Check filters every two or three weeks.
Motor Lubrication
The circulating air blower motor and vent blower are permanently lubri­cated and do not require periodic lu­brication.
Return Air
On some closet installations, the re­turn air opening to the furnace may be on the floor, and/or on the door and/or on the side wall of the closet. The up­per grille on the front of the furnace admits return air to the blower. Return air must be providedback to the circu­lating blower in order to provide air distribution.
Do not obstruct these openings including the grille on the furĆ nace.TodosowillcausethefurĆ nace to activate the high limit and shut down or it may cause asphyxiation.
While you are away
Your f urnace is equipped with a safety device which will shut off the supply of gas to the burner in case of malfunc­tion. F or this reason it is never practi­cal to assume that the furnace will op­erate unattended for a long period of time, especially if there is a possibility of damage to your property because of freezing. So, if you plan to be away from home, arrange for someone to check your house every day.
SEASONAL SERVICE INFORMATION
Duringextreme coldweather, ice may form on the furnace roof jack crown. Small amounts of ice forming on the roof jack will present no problem to proper furnace operation. However, excessive ice formation could restrict the combustion air supply to the burn­er causing inefficient burner opera­tion.
When the temperature is very cold, near zero or below, it is recom­mended that the roof jack be in­spected every day or more frequently if required. If ice has started to collect on the roof jack crown, it should be carefully broken off.
Your Serviceman
Your furnace’s best friend is your qu­alified serviceman. If the unit gives any indication of improper operation, call your serviceman. If the service­man is allowed to perform the normal routine care of your furnace, he can many times detect potential difficul­ties and make corrections before trouble develops. Preventative main­tenance of this type will allow you to operate the unit with a minimum of concern, and at the same time will pay for itself in added years of comfort.
When You Call For Service Assistance
Very often time can be saved if you will give the service agency the MODEL and SERIAL NUMBER of your furnace. This will enable him to determine the specific components used, and perhaps to better identify the possible problem and be better prepared if a service call is required.
To Contact You r Serviceman
(fi ll in)
COMPANY:___________________
ADDRESS:____________________
TELEPHONE:_________________
All appliances need maintenance by serviceman at the beginning of each heating season. Call your nearest au­thorized service technician to:
1. Replace filters. Clean all lint and dust from around furnace.
2. Removefanandcleanalldust and lint from unit with stiff bristle brush.
3. Inspect combustionchamber,the transition into the blower com­partment, flue collar, and roof jack.
4. Check the gas valve and line con­nections for leaks.
5. Make any adjustments neces­sary for good operation.
NOTE: T he coil panel provides a
good removable access for inspecting inside the furnace casing. Smoke or reflected light inside the casing indicates the presence of leaks in the heat exchanger.
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. As an owner of a new furnace you need to know the following information:
If your home is located at an elevation above 2,000 feet, the burner orifice in your furnace will need to be derated. Please contact the nearest authorized Service Center to have this procedure performed properly.
Your dealer or gas company may have already applied the proper deration for your unit. If so, they should be able to advise you as such. If not, you need to have the deration made to insure continued use of your furnace. Not having the unit derated properly will eventually render the furnace inoperable.
Deration of the orifice for furnaces installed in homes at elevations above 2,000 feet is not covered by the warranty. This procedure is considered a part of the installation process and is required to make the furnace operate properly.
These furnaces are shipped from the factory with a natural gas orifice. If you will be operating this furnace on LP (liquid propane gas), it will also be necessary to have the furnace converted. The correct LP orifice is supplied with the furnace to allow operation at elevations below 2,000 feet. If the furnace will be operatingon LP gas at elevations above 2,000 feet, the orifice supplied will be too large to allow proper operation. You should contact your LP supplier for assistance in getting the derated orifice installed.
We hope you follow these instructions and enjoy many years of trouble free service. If you have any questions, please feel free to contact the technical assistance hot line at 316/832--6450.
Subject to change without notice. Printed in U.S.A. Copyright E by Unitary Products Group 1997. All rights reserved.
Unitary Products Group
Post Office Box 19014
8
035--15875--301 (1198) P.I.
Wichita KS. 67204
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