Thomas Betts Furnace EEDU User Manual

Model EEDU

and HEEDU

Indoor/Power-Vented

Duct Furnaces

INSTALLATION FORM RGM 421 (Version A)

APPLIES TO:

Installation/Operation/Service

Table of Contents

Paragraph No.

Page No.

Installation and Operation ........................ 1-26.......................... 1-20

Check Installation and Start-Up .............. 27 ............................. 21

Service/Maintenance/Troubleshooting ..... 28-33........................ 22-24

Index by Page Number

Air Flow Requirements ................................. 13

Blower Connections ..................................... 14

Burner Air Adjustment.................................. 21

Burner Rack Removal .................................. 22

Burners .......................................................... 21

Bypass Duct.................................................. 13

Carryover System ......................................... 21

Check Installation and Start-Up ................... 21

CHLORINES .................................................. 5

Cleaning Pilot and Main Burners................. 22

Cleaning the Heat Exchanger ....................... 23

Clearances ...................................................... 4

Combustion Air ............................................... 4

Combustion Air Proving Switch .................. 15

Condensate Drain, Option CS1 .................... 13

Coupling Two, Three, Four or Five

Mounting the Furnace .................................... 6

Pilot and Ignition Systems ........................... 20

Reversing Air Flow ........................................ 6

SERVICE ...................................................... 22

Start-Up ........................................................ 21

Suspending the Furnace ................................. 6

Thermostat .................................................... 15

Troubleshooting ...................................... 23, 24

Optional Two-Stage Operation..................... 19

Uncrating ........................................................ 4

Valve ............................................................. 19

Venter............................................................ 23

Venting ........................................................... 9

Warranty ......................................................... 2

Wiring Diagrams ..................................... 16-17

Furnaces ..................................................... 7

Dimensional Data ........................................... 3

Disconnect Switch ........................................ 15

Duct Connections ......................................... 12

Operating Sequence ...................................... 16

Optional Ductstat ......................................... 19

Electrical Supply and Connections .............. 15

Optional Electronic Modulation .................. 20

Fan Control (Optional) ................................. 18

Gas Piping and Pressures ............................... 8

GENERAL...................................................... 1

HAZARD INTENSITY LEVELS .................. 2

Installation Codes ........................................... 2

Limit Switch ................................................. 17

MAINTENANCE ......................................... 22

Reference: Replacement Parts Form, RGM 735

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. Don't touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

FOR YOUR SAFETY

The use and storage of gasoline or other

flammable vapors and liquids in open

containers in the vicinity of this appliance is

hazardous.

WARNING: Gas-fired appliances are not

designed for use in hazardous atmospheres

containing flammable vapors or combustible

dust, in atmospheres containing chlorinated

or halogenated hydrocarbons, or in

applications with airborne silicone substances.

See Hazard Levels, Page 2.

WARNING: Improper installation, adjustment,

alteration, service, or maintenance can cause

property damage, injury or death. Read the

installation, operation, and maintenance

instructions thoroughly before installing or

servicing this equipment.

GENERAL

Model

EEDU

Characteristics

Indoor, Power-Vented, Standard CFM, 80%

Thermal Efficient

Installation should be done by a qualified agency in accordance

with the instructions in this manual and in compliance with all

codes and requirements of authorities having jurisdiction. The

instructions in this manual apply to the duct furnace models

shown on the right.

Indoor, Power-Vented, High CFM, 80%

Thermal Efficient

HEEDU

RGM Form 421, Mfg No. 150492, Page 1

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3. Dimensions

Figure 1

16"

(centerline of hangers)

(127mm) (406mm)

Electric Supply

6-3/4"

(171mm)

Limit

Keep

clear for

service

18"

(457mm)

Airflow

29"

(737mm)

8-1/8"

(206mm)

3-1/2"

(89mm)

Combustion

Air Opening

4" (102mm)

Minimum unit

spacing

Combustion

Air Opening

View

port

(both

sides)

26"

(660mm)

(Duct width)

G = Gas

Connection

(not supply line)

Front View

Side View

Rear View

Dimensions (inches)

Size

Nat Pro

34-3/8 14-1/4 35-11/16 14-5/8 4-3/8 3-15/16 1/2 1/2

34-3/8 17 35-11/16 17-3/8 4-3/8 3-15/16 1/2 1/2

34-3/8 19-3/4 35-11/16 20-1/8 4-3/8 3-15/16 1/2 1/2

34-3/8 22-1/2 35-11/16 22-7/8 4-3/8 3-15/16 1/2 1/2

5/8

12-1/2 7-1/4 7-7/16 4-5/8

15-1/4 7-1/4 7-7/16

18 7-1/4 7-7/16 7-3/8

20-3/4 7-1/4 7-7/16 8-3/4

75, 100

125, 140

170

200

34-3/8 25-1/4 35-11/16 25-5/8 4-3/8 4-15/16 1/2 1/2 1-3/8 23-1/2 7-1/4 7-7/16 10-1/8

34-3/8 28 35-11/16 28-3/8 7-1/8 4-15/16 1/2 1/2 1-3/8 26-1/4 7-1/4 7-7/16 11-1/2

34-3/8 33-1/2 38-1/8 33-7/8 9-7/8 5-15/16 3/4 1/2 1-3/8 31-3/4 9-9/16 7-5/8 13-7/8

34-3/8 39 38-1/8 39-3/8 12-5/8 5-15/16 3/4 1/2 1-3/8 37-1/4 9-9/16 7-5/8 16-5/8

34-3/8 44-1/2 38-1/8 44-7/8 15-3/8 5-15/16 3/4 1/2 1-3/8 42-3/4 9-9/16 7-5/8 19-3/8

225

250

300

350

400

Dimensions (mm)

Size

Nat Pro

13 13

19 13

873

362

432

502

572

641

711

851

991

1130

906

968

371

441

511

581

651

721

860

1000

1140

111

181

251

321

391

100

125

151

318

387

457

527

597

667

806

946

1086

184

243

189

194

117

152

187

222

257

292

352

422

492

75, 100

125, 140

170

200

225

250

300

350

400

RGM Form 421, Mfg No. 150492, Page 3

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4. Uncrating and Preparation

5. Location, Clearances, and

Combustion Air

This furnace was test operated and inspected at the factory prior to

crating and was in operating condition. If the furnace has incurred any

damage in shipment, file a claim with the transporting agency.

Unit must be installed so that the following clearances are provided for

combustion air space, service and inspection, and for proper spacing

from combustible construction.

CAUTION: Remove the panel from the bottom rear of the

furnace (See Paragraph 28) and check the burner rack as-

sembly. The burner rack "drawer" should be setting level with

each side on a support rail. Check to assure that EXCES-

SIVE shipping vibration has not caused the burner rack as-

sembly to "drop off" the support rails into the bottom pan. If

the burner rack assembly is positioned properly, close the

back panel. If the burner rack has fallen, remove the screws

holding the burner rack assembly and pull out the burner rack

"drawer". Re-assemble by sliding the burner rack "drawer"

into the heater, being sure that both sides are resting on the

support rails. Re-attach to the support brackets underneath

the burners. Re-insert the burner rack screws and close the

back panel.

NOTE: See Figure 5 for service clearance illustration.

REQUIRED CLEARANCES

Front Top Flue Connector Sides Bottom Rear

12"

29"

152mm 152mm

152mm

152mm 305mm 737mm

CAUTION: Do not locate heater where it may

be exposed to liquid spray, rain or dripping

water.

These duct furnaces are designed to take combustion air from the space

in which the furnace is installed. The air that enters into the combus-

tion process is vented to the outdoors. Sufficient air must enter the

equipment location to replace the air exhausted through the vent sys-

tem. Modern construction methods involve the greater use of insula-

tion, improved vapor barriers and weather-stripping, with the result

that buildings generally are much tighter structurally than they have

been in the past. The combustion air supply for gas-fired equipment

can be affected by these construction conditions because infiltration

that would have existed in the past may not be adequate. Extensive use

of exhaust fans aggravates the situation. In the past the filtration of

outside air assumed in heat loss calculations (one air change per hour)

was assumed to be sufficient. However, current construction methods

may now require the introduction of outside air through wall openings

or ducts.

Check the rating plate for the gas specifications and electrical charac-

teristics of the furnace to be sure that they are compatible with the gas

and electric supplies at the installation site. Read this booklet and be-

come familiar with the installation requirements of your particular fur-

nace. If you do not have knowledge of local requirements, check with

the local gas company or any other local agencies who might have

requirements concerning this installation. Before beginning, make

preparations for necessary supplies, tools, and manpower.

Check to see if there are any field-installed options that need to be

assembled to the furnace prior to installation.

Option Parts -- Some gas control options will have parts either shipped

loose with the heater or shipped separately. If your unit is equipped

with any of the following gas control options, be sure these parts are

available at the job site.

WARNING: These furnaces are designed to take

combustion air from the space in which the unit

is installed and are not designed for connection

to outside combustion air intake ducts. Use of

outside air ducts voids the warranty and could

cause hazardous operation. (See Hazard Levels,

page 2.)

Heating -- Gas Option AG7

Control Option Amplifier, P/N 48035

Thermostat, P/N 48033

Makeup Air -- Option AG3

Gas Control

Options

Control Switch, P/N 29054

Gasket, P/N 7726

Requirements for combustion air and ventilation air depend upon

whether the unit is located in a confined or unconfined space. An "un-

confined space" is defined as a space whose volume is not less than 50

cubic feet per 1000 BTUH of the installed appliance. Under all condi-

tions, enough air must be provided to ensure there will not be a nega-

tive pressure condition within the equipment room or space. A posi-

tive seal must be made in all return-air connections and ducts. Even a

slight leak can create a negative pressure condition in a confined space

and affect combustion.

Gasket Retainer Plate, P/N 7727

Option AG8

Temperature Sensor, P/N 48041

Amplifier, P/N 48037

Control Switch, P/N 29054

Option AG9

Remote Temperature Selector, P/N 48042

Temperature Sensor, P/N 48041

Amplifier, P/N 48035

(All of these

options also

require a

shipped-

separate fan

control, Opt

CQ1 (P/N

57960), which

should be

at the job

site.

Installation in a Confined Space

Control Switch, P/N 29054

Option AG15 or AG16

Figure 2 -

Confined Space: A

space whose volume

is less than 50 cubic

feet per 1000 BTUH

of the installed

appliance input

rating

Remote Temperature Selector, P/N 115848

Stage Adder M odule, P/N 115849

Control Switch, P/N 29054

Transformer 115 to 24V, P/N 103055 or

208/230 to 24V, P/N 103497; and 1/2" locknut,

P/N 16222 (for transformer)

Display M odule, P/N 115852 (AG16 only)

Do not install a unit in a confined space without providing wall open-

ings leading to and from the space. Provide openings near the floor

and ceiling for ventilation and air for combustion as shown in Figure

Other shipped-separate options could include a gas shutoff valve, a

condensate drain fitting, a thermostat, a hanger kit, a coupling kit, a fan

control, or high temperature sealing tape.

Form 421, Page 4

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2, depending on the combustion air source as noted in Items 1, 2, and

3 below the illustration.

Figure 3A - Limit Control Location - When reversing

air flow, the limit control must be re-located. The

limit control MUST be on the discharge end of the

heat exchanger

Add total BTUH of all appliances in the confined space and divide by

figures below for square inch free area size of each (top and bottom)

opening.

1. Air from inside the building -- openings 1 square inch free area per

1000 BTUH. Never less than 100 square inches free area for each open-

ing. See (1) in Figure 2.

2. Air from outside through duct -- openings 1 square inch free area

per 2000 BTUH. See (2) in Figure 2.

3. Air direct from outside -- openings 1 square inch free area per 4000

BTUH. See (3) in Figure 2.

NOTE: For further details on supplying combustion air to a confined

space, see the National Fuel Gas Code ANSI Z223.1a (latest edition ).

Location of

the

factory-

installed

Limit

Control

Bracket on

a Furnace

with

Hazards of Chlorines

The presence of chlorine vapors in the combustion air of gas-fired heat-

ing equipment presents a potential corrosion hazard. Chlorine will,

when exposed to flame, precipitate from the compound, usually freon

or degreaser vapors, and go into solution with any condensation that is

present in the heat exchanger or associated parts. The result is hydro-

chloric acid which readily attacks all metals including 300 grade stain-

less steel.

Standard

Air Flow

Direction

Care should be taken to separate these vapors from the combustion

process. This may be done by wise location of the furnace with regard

to exhausters or prevailing wind direction. Remember, chlorine is

heavier than air. This fact should be kept in mind when determining

installation locations of heating equipment and building exhaust sys-

tems.

NOTE: Actual gas valve

may not be as illustrated.

Figure 3B - Model EEDU has a top and bottom

support assembly and individual baffles.

6. Instructions for Reversing Air Flow

by Changing Directional Air Baffles

in the Heat Exchanger

Duct furnaces are equipped with directional air baffles between the

heat exchanger tubes. Facing the control compartment of the furnace,

the standard direction of air flow is from the rear of the furnace (gas

valve location) toward the front of the furnace. If the installation site

requires air flow from the front to the rear, the unit may be field adapted

by re-locating the limit control and reversing the position of the direc-

tional air baffles.

Instructions:

NOTE: If the unit has optional outer side panels, locate the limit con-

trol and remove the outer panel on that side of the furnace.

1. All Models - Refer to Figure 3A. Remove the screws attaching the

limit control bracket to the side of the furnace. Carefully pull the bracket/

control assembly through the hole. (Do not disconnect wires.)

2. All EEDU Models (see below for high CFM HEEDU Models) -

Refer to Figure 3B and follow Steps a)-d) below to reverse the direc-

tion of the baffles.

a) Remove Screws "A". Individually lift each baffle slightly and slide

forward. Remove all baffles completely from the heat exchanger.

All HEEDU Models (see above for EEDU Models) - Refer to

Figure 3C and follow Steps a) and b) below to move the top

baffle to the entering air end of the heater exchanger.

a) Remove screws B and the baffle.

b) Re-position the baffle on the "entering air" end of the heat exchanger

and attach.

b) Remove Screws B and the top baffle support assembly. Re-position

the assembly on the opposite send of the heat exchanger and attach.

c) Remove Screws C and the assembled bottom baffle support and

brackets. Plug the holes in the heat exchanger bottom by re-insert-

ing the screws in the holes. Position the assembly on the opposite

end of the heat exchanger and attach using field-supplied sheet metal

screws.

d) Re-install all of the individual baffles by reversing procedure in

Step a) above.

RGM Form 421, Mfg No. 150492, Page 5

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Figure 4A - Suspending a Single Furnace

6. Instructions for Reversing Air

Flow (cont'd)

7/16" Diameter

Threaded Rod

15/32"

(12mm)

Diameter

Hole

Figure 3C - Model

HEEDU has only a

top rear heat

Nut for 7/16" Rod

exchanger baffle.

15/32" (12mm)

Diameter Hole

Hanger

Split Ring Lockwasher

Nut for 7/16" Rod

Size

"A"

14-5/8"

Centerline of hangers

75-100

125-140 17-3/8"

371mm

860mm

170

200

225

250

300

350

400

20-1/8"

22-7/8"

25-5/8"

28-3/8"

33-7/8"

3. All Models - Relocate the limit control.

39-3/8" 1000mm

44-7/8" 1140mm

a) At the discharge end on the same side of the heat exchanger, mea-

sure down 4-1/2" and in 1-11/16". Using that point as the center,

punch a 2-1/4" diameter hole in the side panel.

NOTE: It may be necessary to move cable connections. Re-insert

screws to plug all holes in the side panel. After the limit control is

installed, the cable connections may be re-attached using field-sup-

plied sheet metal screws.

Figure 4B - Option

CK3 Hanger Kit (P/N

57959) with four

Free-turning

threaded

socket

b) With the limit control on the heat exchanger side of the bracket,

slide the limit control/bracket assembly into the hole. Attach the

bracket with two sheet metal screws.

threaded sockets

(1" pipe)

c) Cover all of the original factory-made limit control holes with a

field-supplied sheet metal plate. Do not leave any open holes in the

side panel or the heat exchanger bottom.

4. The furnace is now ready for installation with the air flow from front

to rear (gas valve side).

Mounting the Furnace

Change position of the hanger bracket as shown in Figure 5. When the

furnace is mounted on combustible material, a minimum clearance of

12" is required.

7. Suspending or Mounting the

Furnace

Before installing the furnace, check the supporting structure to be used

to verify that it has sufficient load-carrying capacity to support the weight

of the unit.

Figure 5 - Base Mounted Furnace

As shipped location of hanger

support angle

Net Weight

Size 75 100 125 140 170 200 225 250 300 350 400

Limit

Lbs 104 104 126 128 150 172 194 216 262 306 328

Control

Suspending the Furnace

Airflow

Direction

The furnace is provided with four 15/32" diameter holes to provide

four-point suspension. To suspend the unit, cut lengths of 7/16"-16

threaded rod to provide unit height. See Figure 4A for details. NOTE:

A hanger adapter kit Option CK3 is available to facilitate suspension.

See Figure 4B.

Access

Panel

Access

Panel

10"

(254

mm)

Combustion

Air Inlet

Combustion Air Inlet

Keep clean and maintain 29"

(737mm) clearance for burner

rack service

6" (152mm)

minimum

clearance

WARNING: Units must be level for proper

operation. Do not place or add additional weight

to the suspended furnace. See Hazard Levels,

page 2.

12" (305mm)

Hanger Support Angle

Form 421, Page 6

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8. Coupling Two, Three, Four or Five Furnaces using Optional Coupling Kits

Refer to illustrations and follow the instructions below.

Figure 6B - Installing Coupling Kit

Coupling Kit, Option CR1 (P/N

57963), for Two Furnaces

Qty P/N Description

Tie Plate

57964 Filler Plate

57965 Tie Plate

9557 Threaded Socket Assembly

5095 3/8-16 x 1-1/4" lg Hex

Head Bolts

5197 Split Ring Lock Washer

Unit

20 11813 #10 x 1/2" lg Sheetmetal

Screws

Additional Kits:

3 Furnaces - Option CR2 (P/N 82654)

4 Furnaces - Option CR3 (P/N 82655)

5 Furnaces - Option CR4 (P/N 82656)

Item

Description

Socket Assembly

Bolt

Lockwasher

Spotweld Nut

Tie Plate

Figure 6A - Coupling Furnaces

Hanger Angles

Instructions for Coupling Furnaces (Refer to Figures 6A,

6B, 6C and 6D)

1. Attach the tie plate to the first furnace using threaded socket assem-

blies. Tie plate must be positioned below the hanger angles. Secure

fasteners firmly.

2. Move the second furnace into position next to the first furnace. Tie

plate must be below the hanger angle. Secure the tie plate to the

hanger angle using the 3/8-16 bolts, the washers, and the spotweld

nuts on the tie plate.

3. Position the filler plates to furnaces as shown in Figure 6A. Using a

filler plate as a template, drill 1/8" diameter holes. Attach filler plates

using the sheet metal screws provided. Offset of filler plate allows

alignment with unit duct flanges. See Figure 6C.

4. Coupled units require access panels in the top or bottom of the

outlet duct for limit control service. See Figure 6D and Paragraph

11.

Figure 6C - Front View of Coupled Furnaces

Figure 6D - Top View of Coupled Furnaces (NOTE:

Access panel may be in top or bottom of ductwork.)

A + 2"

(51mm)

Limit

Control

Limit

Limit Control

Control

Access panel for

limit control

service and

observation of

coupled unit

Discharge Duct

Size

"A"

14-5/8"

75-100

371mm

860mm

125-140 17-3/8"

170

200

225

250

300

350

400

20-1/8"

22-7/8"

25-5/8"

28-3/8"

33-7/8"

39-3/8" 1000mm

44-7/8" 1140mm

RGM Form 421, Mfg No. 150492, Page 7

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9. Gas Piping and Pressures

WARNING: This appliance is equipped for a

maximum gas supply pressure of 1/2 pound, 8

ounces, or 14 inches water column. Supply

pressure higher than 1/2 pound requires

installation of an additional service regulator

external to the unit.

PRESSURE TESTING SUPPLY PIPING

Test Pressures Above 1/2 PSI: Disconnect the heater and manual valve

from the gas supply line which is to be tested. Cap or plug the supply

line.

NOTE: To permit

burner removal,

this nipple must

extend beyond

edge of heater.

Test Pressures Below 1/2 PSI: Before testing, close the manual valve

on the heater.

All piping must be in accordance with requirements outlined in the

National Fuel Gas Code ANSI/Z223.1a (latest edition), published by

the American Gas Association or CAN/CGA-B149.1 and B149.2, pub-

lished by the Canadian Gas Association (See Paragraph 1). Gas supply

piping installation should conform with good practice and with local

codes.

Figure 7 - Supply Piping Connection

with a minimum 3" drip leg. Local codes may require a minimum drip

leg longer than 3" (typically 6").

Gas connection sizes are included in the Dimensional Tables in Para-

graph 3. After all connections are made, disconnect the pilot supply at

the control valve and bleed the system of air. Reconnect the pilot line

and leak-test all connections by brushing on a soap solution.

Duct furnaces for natural gas are orificed for operation with gas having

a heating value of 1000 (+ or - 50) BTUH per cubic ft. If the gas at the

installation does not meet this specification, consult the factory for

proper orificing.

Gas Connection to Single-Stage Valve

(Not Gas Supply Line Size)

Pipe joint compounds (pipe dope) shall be resistant to the action of

liquefied petroleum gas or any other chemical constituents of the

gas being supplied.

Unit Size

75-250

300-400

Natural Gas

Propane Gas

1/2"

3/4"

1/2"

WARNING: All components of a gas supply

system must be leak tested prior to placing

equipment in service. NEVER TEST FOR

LEAKS WITH AN OPEN FLAME. Failure to

comply could result in personal injury, property

damage or death.

Install a ground joint union and manual shut-off valve upstream of the

unit control system, as shown in Figure 7. The 1/8" plugged tapping in

the shut-off valve provides connection for supply line pressure test

gauge. The National Fuel Gas Code requires the installation of a trap

Manifold or Orifice Pressure Settings

Measuring manifold gas pressure cannot be done until the heater is in

operation. It is included in the steps of the "Check-Test-Start" proce-

dure in Paragraph 24. The following warnings and instructions apply.

WARNING: Manifold gas pressure must never

exceed 3.5" w.c. for natural gas and 10" w.c. for

propane gas.

Capacity of Piping

Cubic Feet p er Hour based on 0.3" w.c. Pressure Drop

Sp ecific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BT U /Cubic Ft)

Sp ecific Gravity for Prop ane Gas -- 1.6 (Prop ane G as -- 2550 BT U/Cubic Ft)

Length

Diameter of Pipe

1/2"

3/4"

1-1/4"

1-1/2"

Pipe Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane

20'

30'

40'

50'

60'

70'

80'

90'

100'

125'

150'

175'

200'

190

152

130

115

105

116

350

285

245

215

195

180

170

160

150

130

120

110

100

214

174

149

131

119

110

104

730

590

500

440

400

370

350

320

305

275

250

225

210

445

360

305

268

244

226

214

195

186

168

153

137

128

1100

890

760

670

610

560

530

490

460

410

380

350

320

671

543

464

409

372

342

323

299

281

250

232

214

195

2100

1650

1450

1270

1105

1050

990

930

870

780

710

1281

1007

885

775

674

641

604

567

531

476

433

397

372

650

610

Note: When sizing sup p ly lines, consider p ossibilities of future exp ansion and increased requirements.

Refer to National Fuel Gas Code for additional information on line sizing.

Form 421, Page 8

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For Natural Gas: Manifold gas pressure is regulated by

the combination valve to 3.5" w.c. Inlet pressure to the valve

must be a minimum of 5" w.c. or as noted on the rating

plate and a maximum of 14" w.c.

Instructions for Checking Manifold Pressure:

1) With the manual valve (on the combination valve) positioned to prevent flow to

the main burners, connect a manometer to the 1/8" pipe outlet pressure tap in the

valve. NOTE: A manometer (fluid-filled gauge) is recommended rather than a

spring type gauge due to the difficulty of maintaining calibration of a spring type

gauge.

For Propane Gas: Manifold gas pressure is regulated by

the combination valve to 10" w.c. Inlet pressure to the valve

must be a minimum of 11" w.c. and a maximum of 14" w.c.

2) Open the valve and operate the heater. Measure the gas pressure to the mani-

fold. Normally adjustments should not be necessary to the factory preset regulator.

Before attempting to measure or adjust manifold gas pres-

sure, the inlet (supply) pressure must be within the speci-

fied range for the gas being used both when the heater is in

operation and on standby. Incorrect inlet pressure could

cause excessive manifold gas pressure immediately or at

some future time.

If adjustment is necessary, set pressure to correct settings by turning the regulator

screw IN (clockwise) to increase pressure. Turn regulator screw OUT (counter-

clockwise) to decrease pressure.

Consult the valve manufacturer's literature provided with the furnace for more

detailed information.

10. Venting

WARNING: Failure to provide proper venting

could result in death, serious injury, and /or

property damage. Unit must be installed with a

flue connection and proper vent to the outside of

the building. Follow installation codes listed in

Paragraph 1 and all venting instructions. Safe

operation of any gas-fired equipment requires a

properly operating vent system, correct provision

for combustion air (See Paragraph 5) and regular

maintenance and inspection. See Hazard Levels,

page 2.

WARNING: Units installed in multiples require

individual vent pipe runs and vent caps.

Manifolding of vent runs is not permitted due to

possible recirculation of combustion products

into the building and possible back pressure

effects on the combustion air proving switch.

Comply with the specific requirements and instructions in the follow-

ing paragraphs.

Specific Venting Requirements (read all before installing)

1. Venter (Flue) Outlet

Venter Outlet

Diameter

Size

Venting must be in accordance with the National Fuel Gas Code Z223.1

or CAN/CGA B149.1 and B149.2, Installation Code for Gas Burning

Appliances and Equipment, and all local codes. Local requirements

supersede national requirements.

75 - 200

225 - 250

300 - 400

These power-vented units are designed to operate safely and efficiently

with either a horizontal or vertical vent. (Horizontal vent run is recom-

mended for maximum fuel savings.) Use either vent pipe approved for

a Category III heater or appropriately sealed single-wall pipe. Or, if at

least half of the equivalent length of the vent system is vertical, vent

pipe approved for a Category I heater may be used. A vent cap of a type

approved for use with this heater is required. If a vent cap is shipped

with the heater, it is packaged attached to the venter housing. Detach

the vent cap from the housing.

Venter Outlet Attachment Requirements:

o If the pipe used in the vent run is larger than the diameter of the

venter outlet (See Vent Length Table 2), make the transition at the

venter outlet.

o The venter is factory-installed as illustrated in Figure 8A. If re-

quired, the venter housing may be rotated as shown in Figure 8B.

The vent may be run in either of the three directions as indicated by

1, 2, and 3 in the illustrations. Follow the instructions to rotate the

venter housing.

Figure 8A - Factory-Installed Position of the Venter

Housing

Instructions for Rotating Venter Housing

Figure 8B -

1. Remove the three screws that attach the venter

Alternate

housing to the outlet duct (pipe from furnace

to the venter). The assembly will remain in

Position of

the Venter

place.

Housing

2. Remove the three screws holding the motor

plate to the venter housing. Holding the motor,

rotate the venter housing to the alternate posi-

tion (Figure 8B). Re-attach the motor plate to

the housing. (To ensure correct venter wheel

alignment, pre-punched holes are provided in

the motor plate.)

3. Using the holes in the venter housing as a tem-

WARNING: Only the venter housing may be rotated. The

motor and combustion air proving switch MUST remain as

received from the factory. Unsafe or improper operation will

result if the standard position is varied. See Paragraph 16 for

explanation of combustion air proving switch.

plate, drill three 1/8" diameter holes in the out-

let duct. Re-attach the venter housing to the

outlet duct using the three screws removed in

Step 1. Rotation is complete.

RGM Form 421, Mfg No. 150492, Page 9

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4. Vent System Joints - Vent system joints depend on the installa-

tion and the type of pipe being used.

10. Venting (cont'd)

Specific Venting Requirements (read all before installing) (cont'd)

If installed as a Category III heater (required if more than half of

the equivalent length of the vent system is horizontal) and single-

wall vent pipe is being used, use at least two non-corrosive screws

per vent pipe joint and seal all joints to prevent leakage of flue

gases into the building. For sealing joints, the use of Aluminum or

TEFLON^®(trademark of DuPont Corporation) tape suitable for

550^oF is recommended (required in California). Vent tape of this

type is available from the heater manufacturer as P/N 98266.

If installed as a Category III heater (required if more than half of

the equivalent length of the vent system is horizontal) and vent

pipe specifically approved for Category III vent systems is be-

ing used, follow the pipe manufacturer's instructions for proper

sealing.

If installed with a Category I vent system (allowed only if at

least half of the equivalent length of the vent system is vertical),

use at least two non-corrosive screws per vent pipe joint on single-

wall pipe or follow the pipe manufacturer's instructions for joining

double-wall pipe.

5. Vent System Support - Support lateral runs every six feet, us-

ing a non-combustible material such as strap steel or chain. Do not

rely on the heater for support of either horizontal or vertical vent

pipe.

1. Venter (Flue) Outlet (cont'd)

Venter Outlet Attachment Requirements (cont'd):

o A minimum of 12" of straight pipe is required at the venter outlet

(or transition fitting) before installing an elbow in the vent system.

An elbow should never be attached directly to the venter.

2. Vent Pipe

If installed with a horizontal vent run, use either vent pipe approved

for a Category III heater or appropriately sealed 26-gauge galvanized

steel or equivalent single-wall pipe. If at least half of the equivalent

length of the vent system is vertical, vent pipe approved for a Category

I heater may be used. Single-wall pipe or double-wall (Type B) vent

pipe are suitable for use with a Category I heater.

Use only one of the flue pipe diameters listed in the Vent Length Tables

for the furnace size being installed.

3. Vent Length Tables

Table 1: Maximum Permissible Vent Lengths with

S tandard Vent Pipe Diameters

Vent Pipe

Size Diameter

(inches)

Maximum

Vent Length

Equivalent Straight

Length* - ft (M)

90^OEl bo w 4 5 ^OEl bo w

(see Note 1 below)

40 ft (12.2 M)

50 ft (15.2 M)

6 (1.8)

7 (2.1)

9 (2.7)

3 (.9)

6. Condensation - Single wall vent pipe exposed to cold air or run

through unheated areas must be insulated. Where extreme conditions

are anticipated, install a means of condensate disposal.

100

125

140

170

200

225

250

300

350

400

3.5 (1.1)

4.5 (1.4)

7. Vent Terminal (Pipe and Vent Cap) - The vent system must be

terminated with a suitable vent cap that is the same size as the vent run.

Heaters with an A.G.A. rating plate that are ordered with an optional

vent cap and all heaters with a C.G.A. rating plate have a vent cap

packaged with the heater. If the "standard" size (Vent Length Table 1)

of vent pipe is used, install the vent cap provided. If a vent cap is not

included or if a non-standard size (Vent Length Table 2) of vent pipe is

used, a field-provided cap must be used. If the vent cap is field-sup-

plied, use a Type L Breidert Air-x-hauster^®or equivalent vent cap.

(Type L Air-x-hauster^®is a trademark of The G. C. Breidert Com-

pany.) Use of a vent cap supplied by the pipe manufacturer is not

permitted; the vent cap must be the type approved for use with this

heater. A different style vent cap could cause nuisance problems or

unsafe conditions.

11 (3.4) 5.5 (1.7)

*Reduce the maximumvent length by the amount indicated

for each elbow used.

Table 2: Optional Maximum Permissible Vent Lengths

(Requires an increase in vent pipe diameter.)

See the illustrations in Figures 9 and 10 for requirements of both verti-

cal and horizontal vent termination. The vent terminal section may be

either single-wall or double-wall (Type B) vent pipe.

Vent Pipe

Size Diameter

(inches)

Maximum

Vent Length

Equivalent Straight

Length* - ft (M)

90^OEl bo w 4 5 ^OEl bo w

(see Note 1 below)

60 ft (18.3 M)

70 ft (21.3 M)

80 ft (24.3 M)

90 ft (27.4 M)

If double-wall pipe is used in the vent terminal, follow the instructions

below to attach the vent cap and to connect the double-wall pipe to the

single-wall vent pipe run.

170

200

225

250

300

350

400

9 (2.7)

4.5 (1.4)

11 (3.4) 5.5 (1.7)

12 (3.7) 6 (1.8)

INSTRUCTIONS FOR DOUBLE WALL PIPE INSTALLA-

TION: Material Required: Double wall (Type B) Vent Pipe (Note:

Using only one piece of vent pipe is recommended.); a thimble de-

signed for double wall pipe (if construction is combustible); six

3/4" long sheetmetal screws; the vent cap; and a tube of silicone

sealant

13 (4.0) 6.5 (2.0)

14 (4.3)

7 (2.1)

Instructions to attach VENT CAP to DOUBLE WALL (Type B)

VENT TERMINAL

Look for the "flow" arrow on the vent pipe. Attach the vent cap to

the "exhaust" end of the double wall pipe.

*Reduce the maximumvent length by the amount indicated

for each elbow used.

NOTE 1: If the system contains all vertical pipe or a combination

of vertical and horizontal vent pipe, the Maximum Permissible Vent

Length shown in Tables 1 and 2 may be increased one foot for each

foot of vertical pipe, up to a maximum increase of 10 feet for Model

Sizes 75 - 125 and up to 20 feet for Model Sizes 140 - 400.

1) Slide the vent cap inside the pipe.

2) Drill a hole through the pipe and the vent cap. (Hole should be

slightly smaller than the sheet metal screw being used.) Using a

3/4" long sheet metal screw, attach the cap to the pipe.

3) Repeat Step 2) drilling and inserting two additional screws evenly

spaced (120^°apart) around the pipe.

Form 421, Page 10

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Instructions to connect the SINGLE WALL VENT system to a

DOUBLE WALL (Type B) VENT TERMINAL:

3) Repeat Step 2) drilling and inserting two additional screws evenly

spaced (120^°apart).

1) Slide the single wall pipe inside the inner wall of the double-wall

terminal pipe.

2) Drill a hole through both walls of the double wall pipe and the

single wall pipe. (Hole should be slightly smaller than the sheet

metal screws being used .) Using a 3/4" long sheet metal screw,

attach the two pieces of pipe. Do not overtighten.

4) To seal the annular opening (the gap between the single and double

wall pipe), run a large bead of silicone sealant in the opening. The

bead of sealant must be large enough to seal the opening, but it is

not necessary to fill the full volume of the annular area.

Figure 9 -

Vertical

Vent

Terminal

Figure 10 -

Horizontal

Vent

Terminal

Horizontal Vent Terminal Clearances

Minimum Clearances for Vent Termination

Location (all directions unless specified)

3 ft (0.9m) above

The location of the termination of the hori-

zontal vent system must be in accordance with

National Fuel Gas Code Z223.1. See table for

required minimum clearances.

Structure

Forced air inlet within 10 ft (3.1m)

Combustion air inlet of another appliance

6 ft (1.8m)

If the vent terminal is to be installed near

ground level, position it at least six inches

above maximum anticipated snow depth.

NOTE: Maintain the required clearance

from the wall to the vent terminal cap for

stability under wind conditions and to pro-

tect the building.

Door, window or gravity air inlet (any building 4 ft (1.2m) horizontally

opening)

4 ft (1.2m) below

3 ft (0.9m) above

Electric meter, gas meter * and relief equipment 4 ft (1.2m) horizontally

Gas regulator *

3 ft (0.9m)

Adjoining building or parapet

Grade (ground level)

6 ft (1.8m)

7 ft (2.1m) above

*Do not terminate the vent directly above a gas meter or service regulator.

RGM Form 421, Mfg No. 150492, Page 11

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11. Duct Connections

Figure 12A - Connecting Ductwork to the Furnace

Flanges on the heater turn out as shown.

Shape duct connection as shown -- "U" on top and bottom;

"L" on sides.

Figure 11 - Duct

Connection Dimensions

(inches)

Slide "U" form over heater flange making connection.

Form "U" strips to seal ends. Drill and lock with sheetmetal

screws.

Size

75, 100

125, 140

170

12-1/2" 318

15-1/4" 387

18"

457

20-3/4" 527

23-1/2" 597

26-1/4" 641

31-3/4" 806

37-1/4" 946

42-3/4" 1086

200

225

250

300

350

400

NOTE: If the furnace is equipped with a unit-mounted ductstat (Op-

tion AG3), the sensing bulb must be removed from the mounting bracket

(save the retainer clip) before the ductwork can be attached. See in-

structions in Paragraph 22 for re-mounting the sensor.

Figure 12B -

Attachment

of Duct to

Furnace

Requirements and Suggestions for Connecting

and Installing Ducts

•

Type of Ductwork - The type of duct installation to be used de-

pends in part on the type of construction of the roof (whether wood

joist, steelbar joist, steel truss, pre-cast concrete) and the ceiling

(whether hung, flush, etc.).

•

Ductwork Material - Rectangular duct should be constructed of

not lighter than No. 26 U.S. gauge galvanized iron or No. 24 B & S

gauge aluminum.

Ductwork Structure - All duct sections 24 inches or wider, and

over 48 inches in length, should be cross broken on top and bottom

and should have standing seams or angle-iron braces. Joints should

be S and drive strip, or locked.

•

Through Masonry Walls - No warm air duct should come in con-

tact with masonry walls. Insulate around all air duct through ma-

sonry walls with not less than 1/2" (1" is recommended) of insula-

tion.

Through Unheated Space - Insulate all exposed warm air ducts

passing through an unheated space with at least 1/2" (1" is recom-

mended) of insulation.

•

Duct Supports - Suspend all ducts securely from adjacent build-

ings members. Do not support ducts from unit duct connections.

Duct Sizing - Proper sizing of the supply air ductwork is necessary

to ensure a satisfactory heating installation. The recognized author-

ity for such information is the Air Conditioning Contractors Asso-

ciation, 1228 17th Street N.W., Washington, D.C. 20036. A manual

covering duct sizing in detail may be purchased directly from them.

Figure 12C -The

seals between the

furnace and the

duct must be

mechanical. "U"

channel method is

illustrated here.

•

Removable Panels - The ducts should have removable access pan-

els on both upstream and downstream sides of the furnace. These

openings must be accessible when the furnace is in service and

should be a minimum of 6" x 10" in size so smoke or reflected light

may be observed inside the casing to indicate the presence of leaks

in the heat exchanger. The covers for the openings must be attached

in such a manner as to prevent leakage. See Figure 12A.

Supply Air Duct/Furnace Horizontal Connection - The seal be-

tween the furnace and the duct must be mechanical. Duct connec-

tion should be made with "U" type flanges on the top and bottom of

the connecting duct. Slide the duct over the flanges of the heater

giving an airtight fit. Provide "U" type channels for the other side

flanges to ensure tight joints. Use sheetmetal screws to fasten ducts

and "U" channels to the furnace flange. See Figures 12B and 12C.

CAUTION: Joints where ducts attach to furnace

must be sealed securely to prevent air leakage

into burner rack area. Leakage can cause poor

combustion, pilot problems, shorten heat

exchanger life and cause poor performance. See

Hazard levels, page 2.

Form 421, Page 12

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12. Condensate Drain, Option CS1, for Furnaces Used with

Refrigeration Systems

Figure 13 - Condensate Drain, Option CS1 (P/N 31765)

These furnaces are certified for installation upstream or downstream

from refrigerated units supplying air below the dew point of the ambi-

ent air surrounding the furnace. When installed downstream from a

refrigeration system, condensation will form and therefore, adequate

provision must be made to dispose of the condensate. A drain flange,

Option CS1, may be installed on the furnace casing as shown in Figure

13. When using Option CS1, seal all holes in the bottom pan. Termi-

nate the drain outside of the building. NOTE: A 4-inch minimum clear-

ance is required under the furnace if a 90^ostreet elbow is used.

Seal holes in bottom pan. Terminate drain outside of

building. Periodic cleaning of the condensate collector and

disposal system is required.

Periodic cleaning of the condensate collection and the disposal system

is required.

13. Duct Furnace Air Flow Requirements

The duct furnace must be installed on the positive pressure side of the field supplied blower. The air throughput must be within the CFM range

stated on the heater rating plate. The air distribution must be even over the entire heat exchanger. Turning vanes should be employed in elbows or

turns in the air inlet to ensure proper air distribution (See Paragraph 15). If it is determined that the blower CFM is greater than allowed or desirable,

see Paragraph 14 for instructions on determining the correct size of bypass duct required. To determine temperature rise, the inlet and outlet air

temperatures should be measured at points not affected by heat radiating from the heat exchanger. The following charts show the approved

temperature rise range with the required CFM and the internal pressure drop for each size of unit.

Model EEDU (80% thermal efficient)

Size

100

125

140

170

200

225

250

300

350

400

Temperature

Rise

CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D.

1105 0.24 1475 0.43 1840 0.49 2065 0.65 2505 0.67 2945 0.67 3315 0.69 3685 0.67 4420 0.70 5160 0.75 5895 0.77

920 0.16 1225 0.30 1535 0.33 1720 0.43 2085 0.46 2455 0.46 2765 0.47 3070 0.45 3685 0.47 4300 0.52 4915 0.52

790 0.10 1050 0.21 1315 0.25 1475 0.32 1790 0.33 2105 0.35 2370 0.36 2630 0.34 3160 0.35 3685 0.38 4210 0.38

695 0.07 920 0.16 1150 0.20 1290 0.24 1565 0.25 1840 0.26 2070 0.27 2300 0.26 2765 0.27 3225 0.28 3685 0.28

615 0.05 815 0.12 1020 0.17 1145 0.20 1390 0.19 1635 0.20 1840 0.21 2045 0.20 2455 0.22 2565 0.23 3275 0.22

50°F

60°F

70°F

80°F

90°F

Model HEEDU (80% thermal efficient, high CFM)

Size

100

125

140

170

200

225

250

300

350

400

Temperature

Rise

CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D.

2765 0.60 3685 1.09 4605 1.14 5160 1.50 6265 1.64 7370 1.64 8295 1.69 9215 1.67 11060 1.64 12900 1.64 14745 1.64

1840 0.28 2455 0.50 3070 0.52 3440 0.66 4175 0.73 4915 0.73 5530 0.75 6140 0.72 7370 0.73 8600 0.73 9830 0.73

1380 0.16 1840 0.28 2300 0.27 2580 0.36 3130 0.38 3685 0.39 4145 0.40 4605 0.40 5530 0.39 6450 0.40 7370 0.38

1105 0.12 1475 0.18 1840 0.18 2065 0.22 2505 0.24 2945 0.24 3315 0.26 3685 0.24 4420 0.24 5160 0.25 5895 0.24

920 0.10 1225 0.13 1535 0.14 1720 0.17 2085 0.17 2455 0.17 2765 0.18 3070 0.17 3685 0.17 4300 0.18 4915 0.17

850 0.08 1130 0.11 1415 0.12 1585 0.15 1925 0.14 2265 0.14 2552 0.15 2835 0.14 3400 0.14 3970 0.15 4535 0.15

20°F

30°F

40°F

50°F

60°F

65°F

-- 1790 0.12 2105 0.12 2370 0.13 2630 0.11 3160 0.12 3685 0.13 4210 0.13

70°F

14. Constructing Bypass Duct

Bypass CFM

Pressure Drop through the Furnace

Width 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50

When the CFM of air throughput is greater than desirable or permis-

sible for the unit, a bypass duct may be constructed. Follow these in-

structions to determine the correct size of the bypass duct.

"A"

10"

490 530 610 700 780 830 900 960 1010

630 750 870 980 1090 1160 1250 1310 1400

850 1010 1190 1300 1410 1520 1640 1730 1810

1050 1290 1480 1650 1800 1940 2090 2200 2320

1250 1510 1760 1960 2180 2320 2500 2650 2800

1490 1810 2100 2350 2560 2760 2940 3110 3290

1700 2100 2400 2700 2970 3200 3400 3600 3800

1920 2350 2760 3090 3650 4020 4300 4550 4800

2) Subtract the allowable CFM from the actual CFM of the installa-

tion to determine how much air must be diverted through the by-

pass duct.

Example:

Blower CFM 3000

Allowable CFM -1790

Bypass CFM 1210

Figure 13 - Bypass Duct

Directions for Sizing Bypass Duct

1) From the tables in Paragraph 13, find the pressure drop (P.D.) and

3) Go to the column in the Bypass CFM Chart that is closest to the

pressure drop through the heater. Move down in that column until

you find the CFM closest to the answer in Step 2).

the allowable CFM for the furnace that is being installed.

Example:

Standard Size 170 @ 70^oF temperature rise;

P.D. .33; CFM 1790

Example:

P.D. .35

Bypass CFM 1520

RGM Form 421, Mfg No. 150492, Page 13

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15. Furnace Blower Connections

14. Bypass Duct (cont'd)

Requirements: Proper arrangements of blower and duct furnace with respect to

angle of approach of the duct connection and the arrangement of the discharge

opening of the blower are shown. Blowers should be bottom horizontal dis-

charge when coupled to the duct furnace. When a top horizontal discharge blower

is connected to the duct furnace, be sure that sufficient length of duct is pro-

vided to permit even flow of air at the end of the duct. Or, baffles may be in-

serted between the blower and the heater to assure an even flow of air across the

heat exchanger. See illustrations in Figure 14.

4) Move to the left column to find out the required size of

the bypass duct.

Example:

Bypass Duct

Size is 5"

Depth of the bypass duct is 18" on both inlet and outlet ends.

Bypass duct must be located on side opposite controls and 2"

from the heat exchanger side panel.

NOTE: Not all capacities are covered in this chart. If your

installation is not covered, the correct size may be determined

by consulting the factory representative.

WARNING: The furnace must be installed on the

positive pressure side of the air-circulating blower. See

Hazard Levels, page 2.

Figure 14

Form 421, Page 14

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16. Combustion Air Proving

Switch

Figure - 15 - Field Wiring Connections

Connect Field

Wiring in the

Electrical Box

The combustion air proving switch is a pressure sensitive switch

that monitors air pressure to ensure that proper combustion air flow

is available. The switch is a single pole - normally open - device

which closes when a decreasing pressure is sensed in the outlet duct

of the flue gas collection box.

On start-up when the heater is cold, the sensing pressure is at the

most negative level, and as the heater and flue system warm up, the

sensing pressure becomes less negative. After the system has reached

equilibrium (about 20 minutes), the sensing pressure levels off.

If a restriction or excessive flue length or turns cause the sensing

pressure to become less than the switch setpoint, the pressure switch

will function to shut off the main burners. The main burners will

remain off until the system has cooled and/or the flue system resis-

tance is reduced. The Table on the below lists the approximate water

column negative pressure readings and switch setpoints for sea level

operating conditions.

Line Voltage

Connection Tabs

Operating Sequence

1. Set thermostat at lowest setting

2. Turn on the power to the unit.

3. Turn on main and pilot manual gas valve.

4. Set thermostat at desired setting.

Start-Up Cold Equilibrium Set Point "Off" Set Point "On"

5. Thermostat calls for heat energizing the venter motor.

6. Pressure switch closes, energizing the pilot gas valve and spark gap to

produce a pilot flame on each operating cycle. The sensing probe proves

the presence of pilot flame and energizes the safety switch portion of

the control. The switch action de-energizes the spark gap and ener-

gizes the main gas valve.

-1.0" w.c.

-0.60" w.c.

-0.48" w.c.

-0.65" w.c.

DANGER: Safe operation of this unit requires

proper venting flow. NEVER bypass

combustion air proving switch or attempt to

operate the unit without the venter running and

the proper flow in the vent system. Hazardous

conditions could result. See Hazard Levels,

page 2.

7. Fan control (Optional) senses heat exchanger temperature energizing

the fan or blower motor of the air handler.

8. If the pilot flame is extinguished during main burner operation, the

sensing probe detects the absence of the flame and causes the safety

switch to close the main valve. On units with standard intermittent

spark pilot systems, the spark gap recycles. On units with optional

spark ignition with lockout, if the pilot is not established within the

timing cycle (approximately 120 seconds), the unit locks out and must

be reset by interrupting power to the control circuit.

17. Electrical Supply and

Connections

Disconnect Switch

A disconnect switch is a required part of this installation. Switches are

available, as options or parts, or may be purchased locally. When ordered

as an optional component, the disconnect switch is shipped separately.

All electrical wiring and connections, including electrical ground-

ing MUST be made in accordance with the National Electric Code

ANSI/NFPA No. 70 (latest edition) or, in Canada, the Canadian Elec-

trical Code, Part I-C.S.A. Standard C22.1. In addition, the installer

should be aware of any local ordinances or gas company require-

ments that might apply.

The disconnect switch may be fusible or non-fusible. When installing, be

careful that the conduit and switch housing are clear of furnace panels

and inspection plates. Allow at least four feet of service room between

the switch and removable panels.

Check the rating plate on the heater for the supply voltage and cur-

rent requirements. A separate line voltage supply with fused discon-

nect switch should be run directly from the main electrical panel to

the furnace, making connection to leads in the junction box. All

external wiring must be within approved conduit and have a mini-

mum temperature rise of 63^oF. Conduit from the disconnect switch

must be run so as not to interfere with the service panels of the

furnace.

Control Thermostat

A thermostat is not standard equipment but is an installation requirement.

Use either an optional thermostat available with the heater or a field-

supplied thermostat. Install according to the thermostat manufacturer's

instructions.

A 24 volt thermostat must be used to actuate low voltage gas controls. If

line voltage from the thermostat to the unit is desired, consult the factory

representative.

If the heater has field-installed options that require electrical con-

nections, consult the instruction sheet and wiring diagram supplied

in the option package.

Wiring between the thermostat and the heater must be suitable for a tem-

perature rise of 63^oF. Labeled thermostat leads are provided in the heater

junction box for connection of thermostat wiring.

CAUTION: If any of the original wire as

supplied with the appliance must be replaced,

it must be replaced with wiring material having

a temperature rating of at least 105^oC, except

for sensor lead wires which must be 150^oC. See

Hazard Levels, page 2.

Thermostats should be located five feet above the floor on an inside wall,

not in the path of warm or cold air currents, not in corners where air may

be pocketed. Do NOT install on cold air walls. For specific connection

details, refer to instruction packet with the thermostat.

If more than one unit is cycled from one thermostat, separately activated

relays must be substituted at unit thermostat connections.

Specific wiring diagrams that include standard and factory-installed

options are included with the heater. Typical wiring diagrams are

on page 17.

RGM Form 421, Mfg No. 150492, Page 15

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Typical Wiring Diagrams -- Refer to the diagram supplied with the heater for specific

controls or optional equipment.

Single-Stage with Intermittent Spark Pilot System with or without Lockout

W.D. 110920

Field and Replacement Wiring Notes

1. Dotted wiring supplied by others.

2. Thermostat supplied as optional equipment.

3. Use #14 gauge wire for line wiring to unit.

4. Use #18 gauge wire for control wiring.

5. Line and blower motor branch circuit wire sizes should be of a size to

prevent voltage drops beyond 5% of supply line voltage.

6. On 208-230V units, the control transformer has dual voltage primary.

For 208 volt units, use black and red leads (cap yellow).

For 230 volt units, use black and yellow leads (cap red).

On 115 volt units, the control transformer is single voltage primary. Use

black and yellow leads for 115 volt.

Secondary side of transformer (24V), use blue and brown leads.

7. Sizes 75-250, 208 volts, the venter motor wires are black and white (cap

red).

Sizes 75-250, 230 volts, the venter motor wires are red and white (cap

black).

Sizes 75-250, 115 volts, the venter motor wires are black and white.

Sizes 300-400, all voltages, the venter motor wires are black and white.

CAUTION: If any of the original wire as supplied

Field Control Wiring - Length and Gauge

with the appliance must be replaced, it must be

Minimum

Recommended Wire

Gauge

Total Wire

Length

Distance from Unit

to Control

replaced with wiring material having a

temperature rating of at least 105^oC, except for

sensor lead wires which must be 150^oC. See

Hazard Levels, page 2.

150'

250'

350'

75'

125'

175'

#18 gauge

#16 gauge

#14 gauge

Form 421, Page 16

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Two-Stage with Intermittent Spark Pilot System with or without Lockout

W.D. 110824

(HOT)

(COM)

LINE/1/60

OPERATING SEQUENCE

1. SET THERMOSTAT SWITCH AT "OFF" POSITION.

VENTER MOTOR

(SEE NOTE #7

FOR WIRING)

2. TURN ON MAIN AND PILOT MANUAL GAS VALVES.

VENTER RELAY

CONTACTS

3. TURN ON POWER TO UNIT.

4. SET THERMOSTAT SWITCH AT "ON" POSITION.

5. LOW STAGE OF THERMOSTAT CALLS FOR HEAT ENERGIZING THE VENTER MOTOR.

6. PRESSURE SWITCH CLOSED ENERGIZING THE PILOT GAS VALVE AND SPARK GAP

TO PRODUCE A PILOT FLAME ON EACH OPERATING CYCLE. THE SENSING PROBE

PROVES THE PRESENCE OF THE PILOT FLAME AND ENERGIZES THE SAFETY

SWITCH PORTION OF THE CONTROL. THE SWITCH ACTION DE-ENERGIZES THE

SPARK GAP AND ENERGIZES THE LOW STAGE GAS VALVE.

BK OR R

LIMIT CONTROL

BK BK

LINE VOLT

40 VA. CONTROL

TRANSFORMER

7. HIGH STAGE OF THERMOSTAT CALLS FOR HEAT ENERGIZING THE HIGH STAGE

GAS VALVE, FIRING UNIT AT FULL RATE.

8. IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION THE

SAFETY SWITCH CLOSES THE MAIN VALVE AND RECYCLES THE SPARK GAP.

ON UNIT EQUIPPED WITH G77ONGC-4 LOCKOUT CONTROL, IF PILOT IS

NOT ESTABLISHED WITHIN 120 SECONDS (APPROX.) UNIT LOCKS OUT

AND MUST BE REST BY INTERRUPTING POWER TO CONTROL CIRCUIT.

(SEE LIGHTING INSTRUCTIONS)

24V

VENTER

RELAY COIL

NOTES

1. DOTTED WIRING SUPPLIED AND INSTALLED BY OTHERS.

2. CAUTION: IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE

MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING

A TEMPERATURE RATING OF A LEAST 105 DEGREES C., EXCEPT FOR ENERGY

CUT-OFF OR SENSOR LEAD WIRE WHICH MUST BE 150 DEGREES C.

3. LIMIT WIRE TO BE #18 GA. 200 C. SF-1 OF SEW-1.

4. USE #14 GA. WIRE FOR LINE WIRING TO UNIT.

5. LINE AND BLOWER MOTOR BRANCH CIRCUIT WIRE SIZES SHOULD BE OF A SIZE

TO PREVENT VOLTAGE DROP BEYOND FIVE PERCENT OF SUPPLY LINE VOLTAGE.

6. ON 208/230V. UNITS THE CONTROL TRANSFORMER HAS A DUAL VOLTAGE PRIMARY.

FOR 208V. UNITS USE BLACK AND RED LEADS (CAP YELLOW).

GRND.

STRIP

FOR 230V. UNITS USE BLACK AND YELLOW LEADS (CAP RED).

ON 115V. UNITS THE CONTROL TRANSFORMER IS SINGLE VOLTAGE PRIMARY.

USE BLACK AND YELLOW LEADS FOR 115V.

SECONDARY SIDE OF TRANSFORMER (24V.) USE BLUE AND BROWN LEADS.

O7.N 75-250 208V UNITS, THE VENTER MOTOR WIRES ARE BLACK AND WHITE (CAP RED)

ON 75-250 230V UNITS, THE VENTER MOTOR WIRES ARE RED AND WHITE (CAP BLACK)

ON 75-250 115V UNITS AND 300-400 UNITS ALL VOLTAGES, THE VENTER MOTOR WIRES

ARE BLACK AND WHITE.

G67BG-5

W.R. TWO STAGE

REDUNDANT

GAS VALVE

RECYCLE

G770NGC-4

LOCKOUT

IGNITION

CONTROLLER

FLAME SENSING

PROBE

FIELD CONTROL WIRING

TOTAL WIRE MINIMUM RECOMMENDED

LENGTH

150 FEET

250 FEET

350 FEET

WIRE SIZE

#18 GA.

#16 GA.

#14 GA.

PRESSURE

SWITCH

IGNITOR

GRND

CHASSIS GRND.

18. Limit Switch

Figure 16 - Access

to the limit switch

depends on the

installation

A non-adjustable high limit switch mounted at the outlet air side of the

heat exchanger acts to shut off the gas supply in the event of air handler

motor failure, lack of correct air flow (See Paragraph 13), or restriction

due to filters and/or duct design. See Figure 16 for mounting and ser-

vice.

Depending on accessibility, the limit switch may be serviced from ei-

ther the outside of the unit or from the inside through the access panel

in the discharge duct. When units are installed side by side, the service

access panel must be in either the top or bottom of the ductwork for

limit switch service. (See Paragraphs 8 and 11.)

View of limit

switch from

"inside" the

furnace

WARNING: If you turn off the power supply,

turn off the gas. See Hazard Levels, page 2.

Access to

limit switch

from

"outside"

the furnace

RGM Form 421, Mfg No. 150492, Page 17

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19. Fan Control (Optional,

Field Installed)

NOTE: Required with makeup air gas control options; see

Paragraphs 22 and 23.

Figure 17 - Installation of Optional Fan Control

Kit, Option CQ1 (P/N 57960)

1. Fan control provides the following: a) Delay of fan op-

eration preventing circulation of cold air, and b) Fan op-

eration as long as the unit is hot.

2. The fan control provides additional safety by keeping the

fan in operation in the event that the gas valve fails to

close when the thermostat is satisfied.

3. To be sure that the fan can continue to operate, the power

supply to the heater MUST NOT be interrupted except

when servicing the heater.

4. If the customer wants the heater off at night, the gas valve

circuit SHOULD BE OPENED by a single pole switch

wired in series with the thermostat. Some thermostats are

provided with this feature. Multiple units controlled from

a single thermostat are shut off in the same manner. For

proper operation, be sure fan control wiring is observed.

See Figure 17 for installation of fan control and wiring.

WARNING: If you turn off the power

supply, turn off the gas. See Hazard

Levels, page 2.

Location of the Fan

Control Mounting Holes

Typical Fan Control

Wiring (W.D. 145977)

Install the gasket supplied in

the option kit between the

fan control and the duct.

Drill 13/16" diameter hole for element

Drill four 1/8" diameter holes for screws

(102mm)

Fan Control P/N 147611,

Honeywell Model

L4064A1347

(76mm)

3/4"

(19mm)

(76mm)

Heater

2-3/8"

(60mm)

Discharge Duct

Recommended dial setting for most

conditions 130^oF ON and 100^oF OFF

DP-ST Control Switch (Used with Options

AG3, AG8, AG9, AG15, and AG16)

Form 421, Page 18

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20. Gas Valve

Figure 18 - Ductstat/Sensing Bulb Locations for

Furnace with Option AG3

All furnaces are equipped with a 24-volt combination valve which

includes the automatic electric on-off valve controlled by the room

thermostat, the pressure regulator, the safety pilot valve, and the

manual shutoff valve. The standard gas valve allows for single-stage

control from a single-stage, 24-volt thermostat.

The ductstat provided with Op-

tion AG3 is attached to the side

of the furnace at the factory.

The sensor is mounted on a

bracket on the inner part of

the furnace duct side.

WARNING: The operating valve is the prime

safety shutoff. All gas supply lines must be free

of dirt or scale before connecting the unit to

ensure positive closure. See Hazard Levels, page

Side

View

Ductstat

Front

View

Bulb

Retaining

Clip

Ductstat

Bracket

21. Optional Two-Stage Operation -

Heating Only Application

Sensing

Bulb

Rear

View

NOTE: This option is not available on Size 75 using propane gas.

The standard combination control valve is replaced with a two-stage

combination gas control valve providing for low fire or high fire

operation controlled by a two-stage thermostat. First stage (low fire)

is factory set (not field adjustable). Both high and low stages are

controlled by a Servo regulator, maintaining constant gas input un-

der wide variations in gas supply pressure. See instructions packed

with the unit for specific gas valve specifications, wiring, and oper-

ating instructions.

Ductstat

Sensing Bulb

Bracket

The Sensor and the ductstat are connected by a permanently attached

capillary tubing. In order to attach the discharge ductwork, the sensor

must be removed form the bracket (save the retaining clip) and the

capillary tubing moved out of the way. After the ductwork is attached

to the furnace (See Paragraph 12), a hole must be made in the duct-

work to allow for the sensor to be re-installed on the bracket (capil-

lary tubing with sensor will run through the hole). A removable ac-

cess panel must be provided in the ductwork as shown in Figure 12A,

Paragraph 12.

22. Optional Two-Stage Operation -

Makeup Air Application

NOTES: Requires field installed fan control, see Paragraph 19. This

option is not available on Size 75 using propane gas.

Two-stage makeup air units are equipped with a two-stage gas valve,

but instead of control from a two-stage room thermostat, the outlet

air temperature is monitored and controlled by a two-stage ductstat.

When the discharge air temperature drops to the setpoint, low fire is

energized. If low fire cannot satisfy the ductstat setting, high fire is

energized.

Parts Required and Instructions:

Since the sensor is larger than

Qty P/N

Description

the tubing, a gasket and gasket

retainer plate are needed to plug

the hole and protect the capillary

tubing where it passes through

7726 Gasket

7727 Gasket Retainer Plate

Makeup air applications are usually adjusted to discharge an outlet

air temperature between 65^oF and 75^oF. In all applications, the al-

lowable temperature rise of the furnace in the installation dictates the

limits of the ductstat temperature setting.

the ductwork. These parts were shipped loose with the furnace. Two

field-supplied sheet metal screws will be needed to attach the plate.

1) Drill the Holes - Refer to the illustration below and select a loca-

tion on the ductwork so that a minimum length of capillary tubing

will be inside the ductwork. Following the pattern, drill holes in

the ductwork.

Depending on the option selection, the factory-installed sensor is

either field-connected by capillary tubing to the unit-mounted ductstat

(Option AG3), Figures 18 and 19, or electrically connected to a re-

mote electronic remote temperature selector (Options AG15 or AG16,

Figure 20). The remote temperature selector is available with or with-

out a display module.

Optional Ductstat with Capillary Tubing (Option AG3) -- The

ductstat is attached to the side of furnace and is connected by capil-

lary tubing to the sensor which is mounted on a bracket on the inner

part of the furnace duct side (See Figure 18). In order to attach the

discharge ductwork to the furnace, the sensor must be removed from

the bracket and the capillary tubing moved out of the way. Follow

the illustrated instructions in Figure 18 for re-connecting the ductstat

after the ductwork is attached.

2) Re-Mount the Sensor on the Bracket - Push the sensor through

the hole. Remove the ductwork access plate. Reaching through

the access hole, use the retaining clip to re-mount the sensor on

the bracket.

3) Install the Gasket - Slide the gasket and hole retainer plate over

the capillary tubing. With the gasket next to the ductwork, attach

the hole retaining plate with field-supplied sheet metal screws (as

illustrated above). Close the ductwork access panel.

The ductstat dial is illustrated in Figure 19. The dial has an adjust-

able range from 60^oF to 100^oF with a fixed differential of 2-1/2^oF.

Due to different CFM settings and outside air temperatures, the aver-

age downstream outlet air temperature may not match the ductstat

exactly. After the installation is complete, adjust the ductstat setpoint

to achieve the desired average outlet air temperature.

RGM Form 421, Mfg No. 150492, Page 19

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els. Electronic modulation control systems for makeup air applications

controlled by a duct sensor and temperature selector (55-90^oF) are iden-

tified as either Option AG8 or Option AG9. The temperature selector

setting for Option AG8 is on the amplifier; Option AG9 has a remote

temperature selector. Both systems are available with an override ther-

mostat. Options AG8 and AG9 for makeup air applications apply to

duct furnace and packaged systems.

22. Optional 2-Stage Operation (cont'd)

Dial has no temperature markings. Pin on adjustment

screw pointing to "B" equals approximately 70^oF.

Computer Controlled Electronic Modulation between 50% and

100% Firing Rate (Option AG21) - With this

option the furnace is equipped with a Maxitrol A200

Figure 19 -

Ductstat

Control in

Option AG3

(Mounted in

inverted

signal conditioner which operates much the same

way as the amplifier above to control the regulator

valve. The conditioner accepts an input signal of

either 4-20 milliamps or 0-10 volts from a customer-

supplied control device such as a computer. With the dip switches on

the conditioner in the "on" positions, the conditioner accepts a 4-20

milliamp signal. In the "off" positions, the conditioner accepts a 0-10V

signal. The conditioner converts the signal to the 0 to 20 volt DC cur-

rent required to control the modulating valve.

position)

Optional Ductstat with Electronic Remote Setpoint Module (Op-

tions AG15 and AG16) -- The field-installed sensing probe is field-

wired to a remote temperature selector with a temperature operating

range to 130^oF. The remote modules and a required transformer are

shipped separately for field installation. (Do not wire the remote mod-

ule to the control transformer on the furnace.) Follow the wiring dia-

gram with the unit and the manufacturer's instructions for wiring and

installation. There will be one module for selecting temperature and

one-stage adder module. Option AG16 includes the digital display

module. See Figure 20.

24. Pilot and Ignition Systems

A gas-fired intermittent pilot is standard. The vertical pilot is located

under the aeration panel on the control end of the burner tray and is

accessible only after the burner rack has been removed. Remove the

pilot for maintenance or service, such as checking the wiring and clean-

ing. (See Paragraph 30.) All pilots are target type with lint-free feature.

Pilot gas pressure should be the same as supply line pressure. (See

Paragraph 9.) If required, adjust the pilot flame length to approximately

1-1/4" with the pilot adjustment screw in the control valve body.

CAUTION: The remote temperature selector

heat/cool selector switch is factory-set in cool

position. To function properly, set switch to heat

position.

NOTE: This model furnace manufactured prior to 11/95 had a hori-

zontal pilot with a spark gap of 7/64".

Intermittent Spark Ignition Safety Pilot Systems -- There are two

types of intermittent spark pilots -- one type shuts off the pilot gas flow

between the cycles and the other not only shuts off the pilot gas flow

between cycles but also has a lockout device that stops the gas flow to

the pilot if the pilot fails to light in 120 seconds. This lockout feature

requires manual reset by interruption of the thermostat circuit. Pro-

pane units require the spark ignition system with the lockout device.

Figure 20 - Remote

Temperature

Selector, Stage-

Adder Module, and

Optional Display

Module for Ductstat

in Two-Stage

Ignition Controller -- As part of the intermittent safety pilot systems,

the ignition controller provides the high voltage spark to ignite the

pilot gas and also acts as the flame safety device. After ignition of the

pilot gas, the ignition controller electronically senses the pilot flame. A

low voltage DC electrical signal is imposed on the separate metal probe

in the pilot assembly. The metal probe is electrically insulated from

ground. The pilot flame acts as a conduction path to ground complet-

ing the DC circuit and proving pilot flame. With pilot flame proven,

the ignition controller energizes the main gas valve.

Makeup Air Control

Options (Option

AG15 or AG16)

23. Optional Electronic Modulation

Note: Requires field-installed fan control.

The type and capability of the electronic modulation system, depends

on the option selected. Electronic modulation options are identified by

a suffix to the Serial No. printed on the heater rating plate. AG7 is

identified as MV-1; AG8 is identified as MV-3; AG9 is identified as

MV-4; and AG21 is identified as MV-A.

If no spark occurs, check the following:

a) Voltage between blue and white terminals (non-lockout type pilot)

and Terminals 2 and 5 (lockout type pilot) on the ignition controller

should be at least 20 volts and no higher than 32 volts. Refer to

Troubleshooting (Paragraph 32) if no voltage is observed.

b) Short to ground in the high tension lead and/or ceramic insulator.

c) Pilot spark gap should be approximately .100". (NOTE: This model

furnace manufactured prior to 11/95 had a horizontal pilot with a

spark gap of 7/64".)

Electronic Modulation between 50% and 100% Firing Rate (Op-

tions AG7, AG8, AG9) - Depending on the heat requirements as es-

tablished by the thermistor sensor, the burner modulates between 100%

and 50% firing. The thermistor is a resistor that is temperature sensi-

tive in that as the surrounding temperature changes, the Ohms resis-

tance changes through the thermistor. This change is monitored by the

solid state control center (amplifier) which furnishes varying DC cur-

rent to the modulating valve to adjust the gas input.

NOTE: When checking for spark with the pilot burner assembly re-

moved from the burner rack, the pilot assembly must be grounded to

the heater for proper spark.

Each modulating valve is basically a regulator with electrical means of

raising and lowering the discharge pressure. When no DC current is

fed to this device, it functions as a gas pressure regulator, supplying

3.5" w.c. pressure to the main operating valve.

If the above conditions are normal and no spark occurs, replace the

ignition controller.

If the main gas valve fails to open with a normal full size pilot flame

established, check for the following:

a) Voltage between black and brown leads on the main gas valve is 20

to 32 VAC and there is no main gas flow with the built-in manual

valve in FULL OPEN position -- the main valve is defective.

Refer to the wiring diagram supplied with the furnace for proper wir-

ing connections. Electronic modulation for heating controlled by a spe-

cially designed room thermostat (60^o-85^oF) is identified as Option AG7

and is available on unit heater, duct furnace and packaged heater mod-

Form 421, Page 20

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b) No voltage between black and brown leads on the main

gas valve -- check for disconnected or shorted flame sen-

sor lead or flame sensor probe.

26. Burner Air Adjustment

Burner air shutters are not normally required on natural gas furnaces. Air shut-

ters are supplied on propane gas units and may require adjustment.

When the above conditions are normal and the main gas flow

is still off, the ignition controller is probably defective.

Before making any adjustments to the air shutters, allow the heater to operate for

about fifteen minutes with the air shutters open. The slotted screw on the end

manifold bracket moves the air shutters and adjusts all burners simultaneously.

Turning the screw clockwise opens the shutters; counterclockwise closes the

shutters. After the furnace has been in operation for 15 minutes, close the air

shutters observing the flame for yellow-tipping. Open the shutters until the yel-

low disappears. A limited amount of yellow-tipping is permissible for propane

gas. Other fuels should not display any yellow-tipping.

25. Burners and Carryover

System

These duct furnaces have individually formed steel burners

with accurately die-formed ports to give controlled flame

stability without lifting or flashback with either natural or

propane gas. The burners are lightweight and factory mounted

in an assembly which permits them to be removed as a unit

for inspection or service.

When making the adjustment, close the air shutters no more than is necessary to

eliminate the problem condition.

DANGER: Failure to install and/or adjust air shutters

according to directions could cause property damage,

personal injury, and or death.

All burners are equipped with two flash carryover systems

that receive a supply of gas simultaneously with the main

burner. During regular service, check the main burner ports,

the carryover assemblies, and the orifices for cleanliness.

27. Check Installation and Start-Up

Check the installation prior to start-up:

Start-Up

oCheck suspension. Unit must be secure and level.

oTurn electric and gas supply on to the furnace. Adjust the thermo-

stat or ductstat so that a call for heat exists. Observe for complete

sequencing of safety pilot and ignition.

oBe certain the electrical supply matches voltage rating of the fur-

nace. (Refer to the rating plate.)

Check installation after start-up:

oWith the unit in operation, measure manifold gas pressure. Mani-

fold pressure for natural gas should be 3.5" w.c. and 10" w.c. for

propane gas. See Paragraph 9.

oCheck all field wiring against the wiring diagram. Be sure wire

gauges are as required for the electrical load. Verify that fuses or

circuit breakers are in place and sized correctly.

oCheck clearances from combustibles. Requirements are shown in

oTurn the unit off and on, pausing two minutes between each cycle.

Paragraph 5.

Observe for smooth ignition. On two-stage or modulating burner

systems, manipulate temperature adjustment slowly up and down to

see if control is sequencing or modulating properly. Raising tem-

perature setting drives burner on or to full fire.

oIf installed in a confined space, verify that the furnace has adequate

combustion air supply. See Paragraph 5.

oCheck vent system to be sure that it is installed according to the

instructions in Paragraph 10. Be sure to have used an approved

vent terminal.

oObserve burner flame at full fire. Natural gas flame should be about

1-1/2" in height with blue coloring. Propane gas flame should be

approximately the same length with blue coloring. Yellow tipping

may appear on propane gas. If yellow extends beyond 1/2 to 3/4",

adjust air shutters. See Paragraph 26 .

oCheck piping for leaks and proper gas line pressure. Bleed gas

lines of trapped air. See Paragraph 9.

a) Turn manual shutoff valve to off position.

b) Turn gas supply on.

oChecked the limit control. With the heater on, completely block off

distribution air. The limit control should open within a few minutes,

shutting off the gas supply to the main burners.

c) Observe gas meter for movement, or

d) Attach pressure gauge readable to .1" w.c. and after turning gas on

for ten seconds, turn gas supply off. No change in pressure should

occur over a three-minute period.

oPlace "Owner's Envelope" containing Limited Warranty Card, this

e) If either c) or d) above indicate a leak, locate leak by brushing a

leak-detecting solution on all fittings. Bubbles will appear at a leak.

Repair and repeat tests.

booklet, and any optional information in an accessible location near

the heater. Follow the instructions on the envelope.

DANGER: The gas burner in this gas-fired equipment is designed and equipped to provide safe and

economically controlled complete combustion. However, if the installation does not permit the burner

to receive the proper supply of combustion air, complete combustion may not occur. The result is

incomplete combustion which produces carbon monoxide, a poisonous gas that can cause death. Safe

operation of indirect-fired gas burning equipment requires a properly operating vent system which

vents all flue products to the outside atmosphere. FAILURE TO PROVIDE PROPER VENTING

WILL RESULT IN A HEALTH HAZARD WHICH COULD CAUSE SERIOUS PERSONAL INJURY

OR DEATH.

Always comply with the combustion air requirements in the installation codes and in Paragraph 5.

Combustion air at the burner should be regulated only by manufacturer-provided equipment. NEVER

RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER.

Indoor units installed in a confined space must be supplied with air for combustion as required by

Code and in Paragraph 5 of this heater installation manual. MAINTAIN THE VENT SYSTEM IN

STRUCTURALLY SOUND AND PROPERLY OPERATING CONDITION.

RGM Form 421, Mfg No. 150492, Page 21

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SERVICE AND MAINTENANCE

WARNING: If you turn off the power supply,

turn off the gas. See Hazard Levels, page 2.

CAUTION: When cleaning, wearing eye

protection is recommended.

Maintenance Requirements -- Like all quality equipment, this unit

will operate with a minimum of maintenance. However, to ensure long

life and satisfactory performance, the following service schedule is rec-

ommended. When servicing, follow standard safety procedures and

those specific instructions and warnings in this manual.

Figure 22 --

Vertical Spark

Pilot

Furnaces should be inspected at the beginning of each heating season

and then once every four (4) months where the equipment is working

under normal conditions. If the furnace is located where an unusual

amount of dust or soot or other impurities are contained in the air,

more frequent inspection is recommended. Clean the heat exchanger

(inside and outside) annually.

When re-installing

the pilot, be sure to

include the pilot

hole cover plate.

Figure 23 - Pilot Location

Burner

28. Burner Rack Removal Instructions

1. Turn off the gas supply.

Rear

2. Turn off the electric supply.

Support

3. Remove bottom rear panel (located on the manifold side of the fur-

nace) by removing the two screws from each side.

4. Mark and disconnect electric valve leads.

6. Uncouple the union in the gas supply.

7. Remove two sheet metal screws in the bottom of the burner rack

assembly.

of burner

3/4"

(+ or - 1/32")

of pilot and

sensor

8. Pull "drawer-type" burner rack out of the furnace.

To disassemble the burner rack:

1. Remove flash carryover system (screws located at rear of burner

drawer).

2. Remove burner hold down clamp (located inside burner drawer un-

derneath the pilot).

3. Pull main burners horizontally away from injection opening and

lift out.

disassemble the ignition controller. There are no field replaceable com-

ponents in the control enclosure.

Follow the instructions in Paragraph 29 to clean. To re-assemble and

replace, reverse the above procedures being careful not to create any

unsafe conditions.

CAUTION: Due to high voltage on pilot spark

wire and pilot electrode, do not touch when

energized. See Hazard Levels, page 2.

Burners - Normally it is unnecessary to clean the main burners but

during the annual cleaning of the heat exchanger tubes it is wise to

inspect the burners for plugged ports. Main burners may be cleaned

using air pressure. Use an air nozzle to blow out scale and dust accu-

mulation from the burner ports. Alternately blow through the burner

ports and the venturi. Use a fine wire to dislodge any stubborn par-

ticles. Do not use anything that might change the port size.

29. Cleaning Pilot and Main Burners

Pilot - The pilot is located under the aeration panel on the control end

of the burner tray and is accessible only after the burner rack assembly

has been removed. In the event the pilot flame is short and/or yellow,

check the pilot orifice for blockage caused by lint or dust accumula-

tion. Remove the pilot orifice and clean with air pressure. DO NOT

REAM THE ORIFICE. Check and clean the aeration slot in the pilot

burner.

Clean the metal sensing probe and the pilot hood with an emery cloth

and wipe off the ceramic insulator. Check the spark gap; spark gap

should be maintained

Clean the burner rack flash carryover systems with air pressure.

Burner Orifices for Sea Level Operation

to .100". After the

Size

Qty Natural Gas

Propane Gas

pilot is cleaned, blow

any dirt away with

compressed air. The

combination valve

includes a pilot ad-

justment screw. To

adjust, remove cap

screw and adjust the

Drill Size P/N Drill Size P/N

38678 1.2 mm 63003

11792 1.45 mm 61652

45870 1.55 mm 61653

45871 1.55 mm 61653

100

125

140

170

200

225

250

300

350

400

Figure 21 - Pilot Burner Spark Gap

pilot flame to ap-

proximately 1-1/4".

Pilot System - No periodic maintenance of the ignition control box

is required. However, each season the lead wires should be checked for

insulation deterioration and good connections. Proper operation of the

electronic spark ignition system requires a minimum flame signal of

0.2 microamps as measured by a microampmeter. Do not attempt to

45871

9789

9879

NOTE: Use only factory-authorized replacement parts.

Form 421, Page 22

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All Sizes 75, 100 and 125 (do not have heat exchanger "V" baffles)

and Sizes 140-400 manufactured prior to 11/95 (do not have heat

exchanger "V" baffles) -- Remove the burner rack assembly. Use a

furnace brush (or a piece of heavy wire to which a piece of steel wool

is attached). Brush up and down within the tubes until all soot is re-

moved. With an air hose or brush, clean the outside space between the

lower portions of the heat exchanger tubes to remove any accumulated

dust or light deposits.

30. Cleaning the Heat Exchanger

CAUTION: When cleaning, wearing eye

protection is recommended.

Outer Surfaces (circulating air side) - To clean the outer sur-

faces of the heat exchanger, gain access by removing the inspection

panels in the ductwork or remove the ductwork. Depending on whether

or not the furnace is designed for high CFM (Model prefix "H"), there

may be directional baffles between the heat exchanger tubes. The stan-

dard furnace has baffles between the heat exchanger tubes as shown in

Figure 3B, page 5. (High CFM furnaces have only the top baffle sup-

port which does not need to be removed for cleaning.)

Sizes 140 - 400 manufactured beginning 11/95 (have heat exchanger

"V" baffles) -- Remove the burner rack assembly. Make sure that the

flue pipe is supported. Remove the three screws that attach the venter

housing to the outlet duct (pipe from furnace to venter). The venter

assembly will remain in place. Remove the six screws used to attach

the flue collection box to the top of the furnace. Remove the flue col-

lection box exposing the heat exchanger tubes. The V-shaped tube

baffles can now be removed.

To remove the baffles, remove the screws marked "A" in Figure 3B,

and slide each baffle forward. Use a brush and/or an air hose to remove

accumulated dust and grease deposits from the heat exchanger tubes

and the baffles. Re-install the baffles by sliding them into the rear slot

and replacing the screw. Secure ductwork as necessary.

All Sizes -- After cleaning is complete, reverse the procedure to re-

assemble the furnace. Use extreme care so that no unsafe conditions

are created. Check the furnace for proper operation.

Inner Surfaces (combustion gas side) - The inner surfaces of the

heat exchanger can be reached for cleaning with the burner rack re-

moved (See Paragraph 28.) An air hose; a long (18 to 24-inch), 1/2"

diameter stiff brush; a flashlight; and a mirror are needed. The required

procedure depends on the size of the furnace and the date of manufac-

ture. Follow these instructions to clean the inner surfaces of the heat

exchanger.

31. Venter

Motor - Remove dirt from the outer surface. The venter motor is per-

manently lubricated; no oiling is required.

Venter Relay - The venter relay controls the venter motor. If relay

contacts fail to "make", the venter motor will not run. If relay contacts

fail to "open, the venter motor will not shut off.

32. Troubleshooting

TROUBLE

PROBABLE CAUS E

REMEDY

No power to unit.

Turn on power, check supply fuses, or circuit breaker.

Turn up thermostat; check control transformer output. Check for loose wire connections.

Replace relay.

Replace motor or capacitor.

Open manual valve.

Venter

motor will

not start

No 24 volt power to venter relay.

Venter relay defective.

Defective motor or capacitor.

Manual valve not open.

Air in gas line.

Dirt in pilot orifice.

Gas pressure too high or too low.

Kinked pilot tubing.

Pilot valve does not open.

No spark:

Loose wire connections

Transformer failure.

Pilot will

not light

(venter

Bleed gas line.

Remove and clean with compressed air or solvent (do not ream).

Adjust supply pressure. (See Paragraph 9).

Replace tubing.

operating)

If 24 volt available at valve, replace valve.

Be certain all wires connections are solid.

Be certain 24 volts is available.

Maintain spark gap at .100".

Replace worn or grounded spark cable.

Replace pilot if ceramic spark electrode is cracked or grounded.

Make sure all panels are in place and tightly secured to prevent drafts at pilot.

Make certain ignition control is grounded to furnace chassis

If 24 volt is available to ignition controller and all other causes have been eliminated,

Incorrect spark gap.

Spark cable shorted to ground.

Spark electrode shorted to ground.

Drafts affecting pilot.

Ignition control not grounded.

Faulty ignition controller.

replace ignition control.

Optional lockout device interrupting Reset lockout by interrupting control at thermostat.

Faulty combustion air proving

Manual valve not open.

Main valve not operating.

Defective valve.

Replace combustion air proving switch.

Open manual valve.

Pilot lights, 1.

main valve 2.

will not open a)

If 24 volt is measured at valve connections and valve remains closed, replace valve.

Check and tighten all wiring connections.

Loose wire connections.

(Troubleshooting is continued on page 24.)

RGM Form 421, Mfg No. 150492, Page 23

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32. Troubleshooting (cont'd)

TROUBLE (cont'd) PROBABLE CAUSE (cont'd)

REMEDY (cont'd)

Ignition control does not power main valve.

Pilot lights, main

valve will not open

(cont'd)

Loose wire connections.

Flame sensor grounded. (Pilot lights - spark

Check and tighten all wiring connections.

Be certain flame sensor lead is not grounded or insulation or

continues)

ceramic is not cracked. Replace as required.

Set supply pressure at 5" w.c. to 14" w.c. for natural gas and

Gas pressure incorrect.

11" w.c. to 14" w.c. for propane gas.

Cracked ceramic at sensor.

Faulty ignition controller.

Replace sensor.

If all checks indicate no other cause, replace ignition

controller. Do not attempt to repair ignition controller; it has no

field replaceable components.

Dirty Filters

Incorrect manifold pressure or orifices.

Clean or replace filters.

Check manifold pressure (See Paragraph 9).

No heat (Heater

Operating)

Cycling on limit control.

Improper thermostat location or adjustment. See thermostat manufacturer's instructions.

Belt slipping on blower.

Fan control improperly located or adjusted.

Defective fan control.

Blower set for too low temprrature rise.

Incorrect manifold pressure.

Circuit open.

Check air throughput (See Paragraph 15).

Adjust belt tension.

Relocate or adjust fan control (See Paragraph 19).

Replace fan control.

Slow down blower or increase static pressure..

Check manifold line pressure (See Paragraph 9).

Check wiring and connections.

Replace fan control.

Replace motor or capacitor.

Relocate or adjust fan control (See Paragraph 19).

Replace fan control.

Check motor load against motor rating plate. Replace motor

Cold air delivered 1.

On Start-up 2.

During Operation 3.

Motor will not run 1.

Fan control inoperative.

Defective motor or capacitor.

Fan control improperly located or adjusted.

Defective fan control.

Motor turns on and 1.

off while burner is 2.

Motor overload device cycling on and off.

operating (See

if needed.

"Motor... " below)

3 phase motor rotating in opposite

Improper motor pulley and/or adjustment.

Interchange 2 legs on supply connections.

See instructions on air throughput.

Blower motor cuts 1.

Improper static pressure in the duct system. Adjust duct system dampers.

out on overload

Low voltage.

Check power supply.

FOR SERVICE OR REPAIR, FOLLOW THESE STEPS IN ORDER:

FIRST:

Contact the installer.

Name

_______________________________________________________________________________________

Address ________________________________________________________________________________________

________________________________________________________________________________________

Phone ________________________________________________________________________________________

SECOND:

THIRD:

Contact the nearest distributor (See telephone Yellow Pages.)

Contact:

REZNOR^®, Thomas & Betts Corporation

150 McKinley Avenue

Mercer, PA 16137

Phone: (724) 662-4400

Model No. _______________________________________

Unit Serial No. ___________________________________

Date of Installation ________________________________

Printed in the U.S.A.

MANUFACTURER OF GAS, OIL, ELECTRIC HEATING AND VENTILATING SYSTEMS

Trademark Note: Reznor^®is registered in the United States and other countries.

3/00 YL Form 421-A.5

Form 421, Page 24

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