Thomas Betts Furnace RGM 405 User Manual

Model CAUA

Gas-Fired, Indoor, Vertical (Upflow)

Power-Vented Heater

C E R T I F I E D

INSTALLATION FORM RZ 405 (Version B)

Obsoletes Form RGM 405 (Version A)

APPLIESTO:

Installation

Table of Contents

Installation and Operation ...........................Paragraphs 1-18 .... Pages 1-18

Optional Accessories ................................ Paragraphs 19-21 .. Pages 19-21

Check Installation and Start-Up ........................Paragraph 22 .. Pages 22-23

Index

By Page No.

Index

By Page No. Index

By Page No.

Belt Drive ............................................. 15

Blower Motor and Drive ...................... 15

Check/Test/Start-Up ............................. 22

Clearances ................................................ 2

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

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

Concentric Adapter ............................ 2, 5

Condensate Drain .......................... 14

Confined Space Installation .................. 10

Cased Cooling Coil (Model ACU) ..... 2, 19

Control Location Illustration ................. 15

Dimensions ............................................. 3

Discharge Plenum (Optional) ............ 2, 21

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

Electrical Supply and Connections ....... 14

Filter Cabinet (Optional) .................. 2, 20

Gas Piping and Pressures ..................... 13

Gas Valve .............................................. 16

General .................................................... 1

Hazard Intensity Levels ......................... 2

Ignition System ..................................... 16

Inlet Base (Optional) ......................... 2, 21

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

Mixing Cabinet (Optional) .............. 2, 21

Motor Amps ......................................... 16

Mounting the Heater .............................. 2

Start-Up ................................................. 22

Thermostat ........................................... 14

Uncrating and Preparation ...................... 2

Vent and Combustion Air ....................... 4

Determine Type of Vent ........................ 4

Power Vent Only Installation ......... 10-11

Separated-Combustion Installation ... 5-9

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

Wiring Diagrams .............................. 17-19

REFERENCES:

Installation Manual for Optional Filter Cabinet, RZ 405-FC

Installation Manual for Optional Mixing Box, RZ 405-MB

Installation Instructions for Optional Inlet Base, RZ 405-IB

Installation Instructions for Optional Discharge Plenum, RZ 405-DP

Operation/Maintenance/Service Manual, Form RZ 405-OMS

Installation Manual for Model ACU Cooling Coil, RZ 405-CC

Gas Conversion Instructions for Model CAUA, RZ 405-GC

FOR YOUR SAFETY

What to do if you smell gas:

Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any

other appliance.

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

GENERAL

Installation should be done by a qualified agency in accordance with the

instructions in this manual and in compliance with all codes and re-

quirements of authorities having jurisdiction. The instructions in this

manual apply to the heater model shown below.

• Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

Model

CAUA

Description

• If you cannot reach your gas supplier, call

your fire department.

Gas-Fired,

Power-Vented,

Vertical (Upflow)

Heater

WARNING: Improper installation, adjustment,

alteration, service, or maintenance can cause

property damage, injury, or death. Refer to this

manual. For assistance or additional information,

consult a qualified installer, service agency, or the

gas supplier.

Model CAUA heaters are design-certified by the Canadian Standards

Association (CSA) to ANSI Z83.6 and CGA 2.6-M96 for industrial/

commercial installations in the United States and Canada. Heaters are

available for use with either natural or propane gas. The type of gas, the

firing rate, and the electrical characteristics are on the unit rating plate.

A Model CAUA heater requires installation of an inlet air duct or an

optional inlet air base and a supply duct or an optional discharge ple-

num. This heater may be installed as a separated-combustion system

(taking combustion air from outside) or as a power-vented system

(taking combustion air from the space where the heater is installed).

WARNING: Gas-fired appliances are not

designed for use in hazardous atmospheres

containing flammable vapors or combustible dust.

See Hazard Levels, page 2.

Mfg No. 164771, Page 1

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6. Dimensions

Figure 1 - Dimensions of Model CAUA

1” (25mm)

3-5/8” (92mm)

Right

Side

View

13-1/4”

(337mm)

Top View

C Plenum Opening

Alternate

Gas

Connection

Plenum

Opening

Corner indicators for

cutting inlet air opening

16”

(406mm)

Electrical

(supply voltage)

Combustion Air Cutout

Venter Outlet

Gas

150, 200, 250 -

5” (127mm);

300, 350, 400 -

6” (152mm)

150, 200 - 5” (127mm);

250, 300, 350, 400 - 6” (152mm)

6-3/8

(162mm)

4-1/8

(105mm)

2-1/8” (54mm)

1-1/2” (38mm)

2-3/8” (60mm)

Rear

View

24-3/8”

(619mm)

Control Door

46-1/2”

(1181mm)

Corner indicators for cutting

inlet air opening

16”

(406mm)

22-1/4”

(565mm)

Blower Door

2-1/8” (54mm)

2-1/2” (64mm)

1/2” (13mm)

Control Side of Hater

Front View

Corner indicators for

cutting inlet air opening.

NOTE: Composite drawings are

not proportional for all sizes.

Bottom

View

BOTTOM VIEW

Dimensions (inches + or - 1/8")

Size

150 38 34-3/4 36 21 7-1/4 3-3/4 12-1/2

200 38 34-3/4 36 21 7-1/4 3-3/4 12-1/2

250 50 34-3/4 48 21 7-1/4 4-3/8 12-3/4 27-1/4 45 31 16 46 4-3/4

300 50 34-3/4 48 21 7-1/4 4-3/8 12-3/4 27-1/4 45 31 16 46 4-3/4

33 31 19 34 4-5/8

2”

(51mm)

350 50 49-3/4 48 34

400 50 49-3/4 48 34

4-3/8 14-1/8 26-3/4 45 44 32 46 4-7/8

Air Opening Dimensions

Supply Air (Discharge with duct flange) C x D

Dimensions (mm +or- 3)

Inlet Air Opening (location selected by installer)

Right Side of Heater

Left Side* of Heater

Rear of Heater

K x 16" (406mm)

J x 16" (406mm)

Size

150 965 883 914 533 184 95 318 610 838 787 483 864 117

200 965 883 914 533 184 95 318 610 838 787 483 864 117

250 1270 883 1219 533 184 111 324 692 1143 787 406 1168 121

300 1270 883 1219 533 184 111 324 692 1143 787 406 1168 121

350 1270 1238 1219 864 178 111 359 679 1143 1118 813 1168 124

400 1270 1238 1219 864 178 111 359 679 1143 1118 813 1168 124

Bottom of Heater

M x N

*Right side is illustrated; corner indicators for open-

ing are the same on the left side.

Mfg No. 164771, Page 3

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7. Venting and Combustion Air

concentric adapter combustion air/vent system. Flue products must

always be vented to the outdoors.

Installation should be done by a qualified agency in accordance with

these instructions. The qualified service agency installing the vent or

vent/combustion air system is responsible for the installation.

WARNING: The vent must be installed in

accordance with national and local regulations.

Failure to provide proper venting could result in

death, serious injury and/or property damage. This

unit must be installed with a vent to the outside of

the building. Safe operation of any power-vented

gas-fired equipment requires a properly operating

vent system, correct provision for combustion air,

and regular maintenance and inspection.

The venting or venting/combustion air systems illustrated in this manual

are the only ones approved for a Model CAUA heater. However, since

more than one system is approved and requirements vary depending on

the type of installation, the first step must be deciding which vent or

vent/combustion air system is going to be installed. Review the follow-

ing matrix of vent types and installation requirements. If there is any

doubt as to what type of vent is required, contact the equipment dis-

tributor before beginning installation.

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 back pressure effects on the

combustion air proving switch.

Hazards of Chlorines - The presence of chlorine vapors in the com-

bustion air of gas-fired heating equipment presents a potential corro-

sion 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 hydrochloric acid which readily attacks all metals

including 300 grade stainless steel.

Care should be taken to separate these vapors from the combustion

process. This may be done by installing a separated combustion sys-

tem and/or wise location of the furnace with regard to exhausters or

prevailing wind direction. Chlorine is heavier than air. This fact should

be kept in mind when determining installation locations of heating equip-

ment and building exhaust systems.

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. Combustion air for this heater may be

either taken from the space or may be ducted from the outside using the

STEP 1 - Decide which Venting System to Install:

Type of

Installation

Vent Configuration/Options

Required

Type of Vent System

(Description/Instructions)

Type of VENT Pipe* Required

Horizontal Vent / Option CC6

(includes concentric adapter box,

exhaust terminal, and inlet air guard)

Vertical Vent / Option CC2

(includes concentric adapter box,

exhaust terminal, and combustion air

inlet)

Use either vent pipe approved for a Category III

appliance OR single-wall, 26-gauge or heavier

galvanized (or a material of equivalent durability

and corrosion resistance) vent pipe.

COMMERCIAL/ S eparated-Combustion

(uses a power venter to duct

combustion air from outdoors

and exhaust flue products to

INDUS TRIAL

(Harmonized

ANSI Z83.8-1996

and Canadian

Standard

the outdoors) -

(follow

Instructions in Section 7A)

CAN/CGA 2.6-

M96)

(uses a power

Use either vent pipe approved for a Category III

appliance OR appropriately sealed 26-gauge

galvanized steel or equivalent single-wall pipe. If

local code requires, the terminal section may be

double-wall pipe with a single-wall vent run.

Power-Vented

Horizontal Vent / Option CC1

venter to draw combustion air Vent Cap or field-supplied

from the indoor space and

exhaust flue products to the

equivalent (see page 11)

outdoors) -

(follow

Instructions in Section 7B)

Vent pipe listed above for a horizontal power-

vented system may be used, OR 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.

At least 1/2 of the Equivalent

Vent Length is Vertical / Option

Vent Cap or field-supplied

CC1

equivalent (see page 11)

If local code requires, the terminal section may be

double-wall pipe with a single-wall vent run.

STEP 2 - Follow the instructions that apply to the type of vent being

installed

• Separated-Combustion -- requires air inlet pipe, exhaust vent pipe, and concentric adapter kit (Option CC2 or CC6)

Using required pipe (See Table above), FOLLOW INSTRUCTIONS IN SECTION 7A

• Power Vent -- requires vent pipe and vent cap (Option CC1 or field-supplied Type L Breidert Air-x-hauster^®or equivalent vent

cap)

Using required pipe (See Table above), FOLLOW INSTRUCTIONS IN SECTION 7B

Form 405, Page 4

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7A. Venting and Combustion Air Requirements for Separated-Combustion

Installation (must use either Option CC2 or CC6)

Specific Requirements (read all before installing)

Comply with the specific requirements and instructions in the following paragraphs and illustrations.

1. Combustion Air Inlet

Diameter is 5" for Sizes 150 and 200 and 6" for Sizes 250, 300,

350, and 400.

Use tin snips or aviation shears to cut out the hole in the top of

the heater (See Figure 2). Insert the pipe through the hole and

attach it to the collar inside the heater. Seal the joint. (Larger size

heaters have oval collars. If the collar is oval, form the pipe to fit

the collar.)

Figure 2 - Attach Combustion Air Pipe

Venter

Outlet

Use tin snips

to cut out

hole for

combustion

air pipe

2. Venter Outlet

Collar for

connecting

combustion air

pipe

The venter outlet size is 5" for Sizes 150, 200, and 250 and 6" for

Sizes 300, 350, and 400. A minimum length of 12" of straight

pipe is required at the venter outlet.

3. Concentric Adapter

If installed as a separated-combustion unit, a concentric adapter

is required.

1) Remove door panel.

2) Cut out the hole.

3) Slide pipe down through hole.

4) If collar is oval, form pipe to fit. Attach pipe to collar with

sheetmetal screws and seal the connection.

• Option CC2 and CC6 - The concentric adapter is a

metal box that attaches to the inside of the building. See

the illustrations and dimenstions in Figures 3A and 3B.

Option CC6 is horizontal; Option CC2 is vertical. (Op-

tion kits also include a vent terminal and combustion air

inlet or guard.)

Figure 3A - Concentric Adapter Assembly in Options CC2 and CC6

View of Heater Connection Side

View of Vent Terminal Connection Side

2” (51mm)

Collar for

connecting

indoor portion

of the

6” (152mm)

2” (51mm)

Collar for outside portion of the

combustion air pipe (vent pipe

extends through the box

internally concentric to the

outside portion of the combustion

air pipe)

combustion

air pipe

Install rubber seal

for vent pipe

End View

Figure 3B - Concentric Adapter Box

Dimensions - inches (mm)

Top View of the Concentric Adapter

Box Showing Air Flow

CAUA

150,200

5 (127)

250,300,350,400

6 (152)

= Combustion Air Flow

= Exhaust (Vent) Gas Flow

4 (102)

5 (127)

4 (102)

Field-supplied vent

pipe passes

through the

rubber seal on the

concentric adapter

box, extending out

both sides of the

box

7-1/2 (191)

5 (127)

7-1/2

5 (127)

4 (102)

5 (127)

16-1/2 (419)

8 (203)

16-1/2 (419)

10 (254)

8 (203)

6 (152)

A = Diameter of the

Collar for attaching

the inside

Combustion Air Pipe

from the Heater

= Diameter of the

Side View - Side of the

Adapter Box that Connects

to the Heater

Collar for attaching the

"Outside" Portion of the

Combustion Air Pipe

Mfg No. 164771, Page 5

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7. Venting and Combustion Air (cont'd)

7A. Venting and Combustion Air Requirements for Separated-Combustion

Installation (must use either Option CC2 or CC6) (cont'd)

either tape suitable for 550°F (such as Option FA1, P/N 98266) or

high-temperature (450°F) silicone sealant.

4. Pipe Diameter and Length

Maximum Pipe Length from Heater to Concentric Adapter -

• If using Category III vent pipe, follow the pipe manufacturer's in-

minimum length is five feet (1524mm)

structions for joining pipe sections.

Model

Pipe Diameter

Maximum 90° Elbow 45° Elbow

In Concentric Pipes (outdoor portion) from Concentric Adapter

Box to Air Inlet and Vent Terminal - Follow the installation instruc-

tions for the specific option (CC6 for horizontal vent; CC2 for vertical

vent).

CAUA

150-200

Vent Inlet Air

Length

40 ft

Equals*

5 ft

Equals*

2.5 ft

12.2 M

50 ft

1524 mm

5 ft

762 mm

2.5 ft

250

Joints Requiring Taper-type Connections (See Figure 4) - When

the diameter of the pipe in the vent pipe run is different from the vent

pipe in the terminal section, the joint must be made with a taper-type

pipe connector. Install the connector no more than 6" (152mm) from the

concentric adapter box. A 5" to 4" reducer is required in the vent pipe on

Sizes 150 - 200; a 6" to 5" reducer is required on Sizes 300 - 400.

15.2 M

50 ft

1524 mm

5 ft

762 mm

2.5 ft

300-400

15.2 M

1524 mm

762 mm

*Reduce maximum length by this amount for each elbow.

Concentric Pipes (the vent pipe runs concentric through the out-

door portion of the combustion air pipe) - Sizes 150 and 200 require

a 6" diameter combustion air pipe for outdoor portion and a 4" diam-

eter vent pipe through the concentric adapter to the terminal; Sizes

250-400 require an 8" diameter combustion air pipe for the outdoor

portion and a 5" diameter vent pipe through the concentric adapter to

the terminal.

Figure 4 - When joining different pipe diameters, use taper-

type pipe connectors

Taper-type Connector

Reducer

Either collar

or smaller

diameter pipe

Airflow

Length depends on building construction; specific requirements are

included with the concentric adapter kit instructions.

Secure joints with sheetmetal

screws and seal.

5. Joints

6. Support

Determined by type of pipe - Provide field-supplied vent pipe as

specified in the Table on page 4.

Support horizontal runs every six feet (1829mm); do not rely on the

heater or concentric adapter for support of either horizontal or vertical

pipes.

• If using single wall, 26-gauge or heavier galvanized pipe, secure

slip-fit connections using sheet metal screws or rivets. Seal all

joints. Seal combustion air pipe with pressure sensitive tape ordi-

narily used for warm-air ductwork. Seal flue exhaust pipe with

7. Clearance

Clearance from the vent pipe to combustibles is 6" (152mm). Do not

enclose the vent pipe.

Instructions and Requirements for Installing Horizontal Vent Terminal/Combustion Air Inlet

Option CC6

•

Mounting brackets for concentric adapter box (or box may be

mounted flush, depending on building construction)

Taper-type reducers as required (see requirements above)

Option CC6 Package includes:

Qty Description

150,

200

250, 300,

350, 400

•

Installation Instructions for Option CC6

Complete Horizontal Vent Kit

(Same as Option CC6)

Concentric Box Assembly

(See Figures 3A and 3B)

Screened

157158 82131

155392 68404

155096 53316

1. Determine the location on the outside wall for the vent terminal

(Applies to all horizontal vent kits). In most applications, the terminal

would be on a level with the heater mounting height. Allow 1/4" per foot

downward pitch toward the terminal for draining of condensation.

The distance of the termination of the horizontal vent from adjacent public

walkways, adjacent buildings, openable windows, and building openings

must be in accordance with local codes or, in the absence of local codes,

must conform with National Fuel Gas Code. Local codes supersede all

provisions in these instructions and in the National Fuel Gas Code. Mini-

mum clearances for the horizontal vent terminal are as shown in the table on

page 7.

Exhaust Assy

Inlet

Guard

151755 124940

#10-16x1/2" lg Screws (to

attach the inlet guard)

Rubber seal for vent pipe opening 164492 164493

in concentric adapter

Tube of high temperature (450°F) 53335

silicone sealant

37661

Products of combustion can cause discoloration of some building finishes

and deterioration of masonry materials. Applying a clear silicone sealant

that is normally used to protect concrete driveways can protect masonry

materials. If discoloration is an esthetic problem, relocate the vent or install

a vertical vent.

53335

Field-supplied installation requirements:

•

Thimble (a thimble is not required if wall is of non-combus-

tible construction)

Flashing

Vent pipes (see requirements on pages 4 and 6)

Combustion air pipes (see requirements on pages 4 and 6)

WARNING: All vent terminals must be positioned or

located away from fresh air intakes, doors and

windows to preclude combustion products from

entering occupied space. See Hazard Levels, page 2.

•

Form 405, Page 6

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Minimum Clearances for Vent

Termination Location (all

directions unless specified)

Collar for

combustion

air pipe.

Concentric Adapter Box

Field-supplied

Structure

mounting brackets

Forced air inlet within 10 ft 3 ft (0.9m) above

(3.1m)

Combustion air inlet of

another appliance

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

inlet (any building opening) 4 ft (1.2m) below

1 ft (30cm) above

6 ft (1.8m)

Combustion air pipe

Seal the seam in the vent pipe.

Combustion

Flow

Air

ent Flow

*Do not terminate

the vent directly

Electric meter, gas meter *

and relief equipment

4 ft (1.2m)

horizontally

above a gas meter

or service regulator.

Gas regulator *

3 ft (0.9m)

Install rubber seal in

vent pipe opening.

16” (406mm) minimum

2” (51mm)

ox plus

Adjoining building or parapet 6 ft (1.8m)

Adjacent public walkways

Grade (ground level)

appr

wall thickenss

7 ft (2.1m) above

Vent Pipe - when a taper-type

reducer is required in

the vent pipe; the connection

must be no more than 6”

(152mm) from the box.

2. Prepare clearance hole through the outside wall for a 6"

diameter pipe (Size 150 or 200) or an 8" diameter pipe

(Size 250, 300, 350, or 400). Outside wall construction

thickness should be between 1" (25mm) minimum and 30"

(762mm) maximum. The larger diameter combustion air

pipe serves as clearance for the exhaust pipe on non-com-

bustible construction. A thimble may or may not be re-

quired depending on wall construction and/or local codes.

3. Prepare the concentric adapter box.

3a) Determine whether field-supplied brackets are

required. The box must be positioned so that the

distance from the outside of the wall to the box is a

minimum of 12" (305mm). Maximum distance is 60"

(1524mm). If brackets are used, box should be angled

slightly to allow for downward pitch of pipes. If used,

attach brackets securely; do not leave any unsealed

holes in the adapter box.

Figure 5A. On all Sizes except 250, no more than 6" (152mm) of vent pipe

should extend out the heater side. Any time the pipe is re-positioned, re-check

the seal to be sure that it has not rolled. Adjust the pipe and seal until the pipe is

the correct length on each side of the box and the seal is over the edge of the hole

and tight to the entire circumference of the pipe.

3c) Attach the outside portion of the combustion air pipe to the box. Determine

the length by measuring the bracket length (if brackets are used), plus the wall

thickness, plus 2" (51 mm). The inlet pipe should extend beyond the outside

wall approximately 2" (51mm). Attach the inlet air pipe to the collar of the

concentric adapter with sheetmetal screws being careful not to penetrate the

vent pipe.

4. Attach the concentric adapter box to the wall. Insert

the vent pipe and combustion air pipe through the wall.

Push the concentric adapter box flush against the inside

wall or attach to the wall with the field-supplied brackets.

Caulk or flash inlet air pipe on the outside wall. Flashing is

field supplied.

Flash or caulk

the inlet air pipe

on the outside

If brackets are not used, when the box is installed,

position it tight against the wall.

3b) Install the rubber seal and the vent pipe. Locate the

vent pipe opening (no collar) and place the rubber seal

around and over the edge of the metal.

wall

5. Slide the inlet guard over the end of the vent pipe

and position it on the end of the combustion air pipe. See

Determine the length of the section of vent pipe by

adding the requirements. On the heater side of all Sizes

except CAUA 250, the vent pipe must extend no more

than 6" (152mm) (length limit does not apply to Size

250 because the pipe diameter does not change); plus

6" (152mm) through the box; plus bracket length; plus

the width of the wall; plus a minimum of 18" (457mm)

on the outside (if

Figure 5B. Attach the guard to the inlet air pipe with the

four 1/2" lg screws provided.

6. Position the vent cap on the end of the vent pipe. Align the cap so that its baffle

strips are positioned on the horizontal and vertical centerlines (See Figure 5C).

Attach the exhaust cap to the vent pipe with sheetmetal screws.

First, attach the inlet air guard;

Second, attach the exhaust cap

Inlet Air Guard

Worksheet - Determine Length of

the inlet air pipe

extends recom-

Vent Pipe through the Box

inches mm

IMPORTANT: Install

mended

Heater Side (max if +

diameter changes)

152

exhaust cap with baffles

positioned on horizontal and

vertical centerlines as illustrated.

(51mm) beyond

the wall).

Width of Box

Bracket Length

Width of Wall

152

Lubricate the seal

and pipe with liq-

uid soap or a rub-

ber lubricant. (In-

stallation Tip:

Spray cooking oil

__ ___

7. Horizontal vent terminal/combustion air inlet Option CC6 is installed and ready

for connection to the heater.

Terminal Side (min) + 18 457

Length of Pipe

8. Connect the Concentric Adapter Box to the Heater - Use the pipe specified

and joints required for type of pipe. If collar or opening at the heater or adapter are

different diameters from the pipe (use only diameters allowed on page 6), make joint

connection with field-supplied taper-type reducer or enlarger.

A minimum of 12" (305 mm) of straight pipe is required at the venter outlet.

Due to the high temperature, do not enclose the exhaust pipe or place pipe closer

than 6" (152 mm) to combustible material.

Installation of the horizontal vent and combustion air system on your separated-

combustion unit is complete. Refer to Figure 5D and verify that all installation

requirements are met. Continue to Paragraph 8.

works well as a lubricant for this task.)

Being sure the pipe is in the proper flow direction,

slide the end through the box and push it out through

the rubber seal. Push evenly using caution not to dis-

place the seal from its position on the edge of the hole.

If the rubber seal moves, slide the pipe back slightly,

re-position the seal, and slide the pipe through again.

Position the vent pipe so that it will extend a minimum

of 16" past the end of the combustion air pipe. See

Mfg No. 164771, Page 7

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7. Venting and Combustion Air (cont'd)

7A. Venting and Combustion Air Requirements for Separated-Combustion

Installation (must use either Option CC2 or CC6) (cont'd)

60” (1524mm) maximum

12” (305mm) minimum

Figure 5D - Installation of a Typical Separated-

Combustion Unit with Horizontal Vent and Combustion

Air Pipes (Option CC6)

Top

View

Concentric Adapter

Seal Joints

Wall

Combustion Air Pipe

Seal joints; see Require-

ment No. 5 on page 6.

Inlet Air

Guard

Vent (Flue Exhaust) Pipe

Maximum Length (See Requirement

No. 4 on page 6.)

Building Overhang

Screened

Exhaust

Cap

Minimum length is 5 ft (1.5M)

Side View

Vent Pipe

- PITCH

DRAIN

Concentric Adapter Box

6ft (1829mm)

minimum

16”(406mm)

minimum

24”(610mm)

minimum

Thimble

Adjoining

Building

Combustion Air Pipe

(PITCH TO DRAIN)

Wall

"Through-the-Wall" View of a typical

installation of a horizontal vent/inlet air

terminal and concentric adapter

(Option CC6)

IMPORTANT NOTE: Exhaust cap must be installed so the baffles

are positioned on horizontal and vertical centerlines.

Building Projection

Instructions and Requirements for Installing a Vertical Vent Terminal/Combustion Air Inlet

(Requires Concentric Adapter Kit, Option CC2)

Vertical Vent Terminal/Combustion Air Package

Installation Instructions for Option CC2

(Option CC2) includes:

Qty Description

1. Determine the location for the vent terminal on the roof, allowing room for the

150,

200

250,300,

350,400

concentric adapter box inside. A thimble may or may not be required depending

on building construction and/or local codes. Prepare a hole through the roof for

the combustion air pipe (Sizes 150 and 200, pipe is 6"; Sizes 250-400, pipe is 8").

The air inlet pipe must be flashed or sealed to the roof. Flashing is to be supplied

by the installer as required by roof construction and/or codes.

Complete Vertical Vent Kit 157156 54444

(Same as Option CC2)

Concentric Box Assembly

Exhaust

155392 68404

155631 53326

WARNING: All vent terminals must be positioned or

located away from fresh air intakes, doors and windows to

preclude combustion products from entering occupied

space. See Hazard Levels, Page 2.

Terminal

Combustion

Air Inlet

155635 53330

2. Prepare the concentric adapter box.

Rubber seal for vent pipe

opening in concentric adapter

Tube of High Temperature

(450°F) Silicone Sealant

164492 164493

2a) Determine whether field-supplied brackets are required. If used, attach

brackets securely; do not leave any unsealed holes in the adapter box.

If brackets are not used, when in-

53335

Worksheet - Determine Length of

stalled, the box should be tight against

the roof.

2b) Install the rubber seal and the

Vent Pipe through the Box

Field-supplied installation requirements:

inches mm

•

Thimble (a thimble is not required if wall is of non-

combustible construction)

Flashing

Vent pipes (see requirements on pages 4 and 6)

Combustion air pipes (see requirements, pages 4 and 6)

Mounting brackets for concentric adapter box (or box

may be mounted flush, depending on building construc-

tion)

Heater Side (max if +

diameter changes)

152

vent pipe. Locate the vent pipe open-

ing and place the rubber seal around

and over the edge of the metal.

Determine the length of the section of

vent pipe by adding the requirements.

On the heater side of all Sizes except

CAUA 250, the vent pipe must ex-

tend no more than 6" (152mm) (length

limit does not apply to Size 250 be-

•

Width of Box

152

Bracket Length

Width of Roof

Inlet Pipe Height

__ ___

Terminal Side (min) + 22 559

•

Taper-type reducers as required (see requirements on

page 6)

Length of Pipe

Form 405, Page 8

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2c) Attach the outside portion of the com-

bustion air pipe to the box. Determine

the length of the combustion air pipe so

that dimension "X" (Figure 6A) is equal

to the roof thickness, plus snow depth

and ridge or parapet clearance, but does

not exceed 60" (1524 mm). Attach the

combustion air pipe to the collar with

sheetmetal screws being careful not to

penetrate the vent pipe.

3. Attach the concentric adapter. Insert

the vent pipe and combustion air pipe up

through the roof and secure the adapter box.

Flash the combustion air pipe to the outside

of the roof as required.

"X" is the length of combustion air

pipe required through and above

the roof

"X" must equal roof thickness

plus clearance required for

anticipated snow

22"

(559mm)

minimum

Install the vent pipe

by inserting it into the

terminal side of the

box and pushing it out

through the seal on the

heater side.

Seal the seam in

the vent pipe.

plus ridge and/or

parapet clearance

NOTE: Be sure flow

direction is correct.

"X" must not

exceed 60"

(1524mm)

Snow

Clearance

Combustion

air pipe

Field-supplied

mounting brackets

4. Slide the combustion air inlet over the

vent pipe and fasten the collar

to the end of the combustion air

pipe with sheet metal screws

(See Figure 6C). Seal joint at top

between vent pipe and combus-

tion air inlet with silicone seal-

ant to prevent water leakage.

5. Attach the exhaust termi-

nal with sheet metal screws (See

Figure 6D).

1)Slide combustion

air inlet over the

vent pipe

Concentric

Adapter Box

2)Fasten to the end

Collar for combustion

air pipe.

of the combus-

tion air pipe

3)Seal the top joint

with silicone

Vent Pipe - when a taper-type reducer

is required in the vent pipe; it must be no

more than 6” (152mm) from the box.

Install seal

in vent pipe

opening

cause the pipe diameter does not change); plus bracket length;

plus the width of the roof; plus the length of the outer inlet air

pipe; plus a minimum of 22" (559mm).

Install field-supplied

flashing at roof

opening (flashing not

illustrated).

6. Vertical vent terminal/combus-

tion air inlet is installed and ready

for connection to the heater.

7. Connect Concentric Adapter

Lubricate the seal and pipe with liquid soap or a rubber lubri-

cant. (Installation Tip: Spray cooking oil works well as a lubri-

cant for this task.) Being sure the pipe is in the proper flow

direction, slide the end through the box and push it out through

the rubber seal. Push evenly using caution not to displace the

seal from its position on the edge of the hole. If the rubber seal

moves, slide the pipe back slightly, re-position the seal, and

slide the pipe through again.

Position the vent pipe so that it will extend a minimum of 22"

(559mm) past the end of the combustion air pipe. See Figure

6B.

A maximum of 6" (152mm) of vent pipe should extend out the

heater side. Any time the pipe is re-positioned, re-check the

seal to be sure that it has not rolled. Adjust the pipe and seal

until the pipe is the correct length on each side of the box and

the seal is over the edge of the hole and tight to the entire

circumference of the pipe.

Box to the Heater - Use the pipe speci-

fied and joints required for type of pipe.

If collars at the heater or adapter are dif-

ferent diameters from the pipe (use only

diameters allowed on page 6), make con-

nection with field-supplied taper-type re-

ducer or enlarger.

A minimum of 12" (305 mm) of

straight pipe is required at the venter

outlet. Due to the high temperature, do

not enclose the vent pipe or place pipe

closer than 6" (152 mm) to combustible

material.

Exhaust

Terminal

12" (305mm)

minimum

Combustion

Air Inlet

Installation of the vertical vent and combustion air system on your sepa-

rated-combustion unit is complete. Refer to Figure 6E and verify that all

installation requirements are met.

Figure 6E - Installation of Separated-Combustion Unit with Vertical Vent and Combustion Air Pipes (Option CC2)

Vent

Termina

Side View

9-3/8”

(238mm)

6 ft (1829mm)

minimum

12” (305mm)

Seal with high

Flue

Exhaust

(Vent )

Pipe

temperature silicone

rubber sealant supplied

with the kit.

Wall or

Adjoining

Building

11” (279mm)

Combustion

Air Inlet

5 ft (1524mm)

maximum (Size

according to

anticipated

Flashing

(field supplied)

18”(457mm)

minimum

Roof

snow depth.

Flashing

(field supplied)

Roof

Concentric

Adapter

Thimble

Combustion Air Pipe

Rear

View

"Through-the-Roof" View of a typical installation

of a vertical vent/inlet air terminal and concentric

adapter (Option CC2)

Concentric

Adapter

Vent

Pipe

Mfg No. 164771, Page 9

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7. Venting and Combustion Air (cont'd)

7B. Venting and Combustion Air Requirements for Power Vent Drawing

Combustion Air from THE INSIDE SPACE and Venting Flue Products to

the Outdoors (vent cap is required)

If the environment has a positive pressure and is such that it is

not detrimental to combustion air, this system may be installed.

To provide combustion air to the heater sufficient air must enter

the equipment location to replace that exhausted through the

heater vent system. In the past, the infiltration of outside air

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

assumed to be sufficient. However, current construction methods

using more insulation, vapor barriers, tighter fitting and gasketed

doors and windows, weather-stripping, and/or mechanical ex-

haust fans may now require the introduction of outside air through

wall openings or ductwork to the equipment room.

Figure 8 - Alternate

Vent in any

Vent Directions

position above

horizontal

A minimum of 12" of

straight pipe is required

before an elbow

The requirements for combustion and ventilation air depend upon

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

"unconfined space" is defined as a space whose volume is not less

than 50 cubic feet per 1000 BTUH of the installed appliance.

Under all conditions, enough air must be provided to ensure

there will not be a negative pressure condition within the equip-

ment room or space. Follow the specific requirements below for

a confined space installation.

Confined Space Installation - Do not install a unit in a con-

fined space without providing wall openings leading to and from

the space. Provide openings near the floor and ceiling for ventila-

tion and air for combustion as shown in Figure 7, depending on

the combustion air source as noted in Items 1, 2, and 3 below.

•

Do not install dampers or any other type of flue restrictor device.

2) Vent Pipe Diameter and Length

Maximum Vent Length - minimum length is 5 ft (1.5M)

CAUA

Pipe

Diameter

Maximum

Length

90° Elbow

Equals*

45° Elbow

Equals*

150-250

300-400

50 ft (15.2M) 5 ft (1.5M)

2.5 ft (.8M)

*Reduce by this amount for each elbow.

Note: If the system contains all vertical pipe or a combination of horizontal

and vertical vent pipe, the Maximum Permissible Vent Length may be in-

creased one foot (305mm) for each foot (305mm) of vertical rise up to a

maximum increase of ten feet (3M).

Figure 7 - Confined Space:

A space whose

3) Vent Pipe and Joints

volume is less than

50 cubic feet per

1000 BTUH of the

installed appliance

input rating

Provide field-supplied vent pipe as specified in the Table on page 4.

•

If using single wall, 26-gauge or heavier galvanized pipe, secure slip-fit

connections using sheet metal screws or rivets. Seal pipe joints either with

tape suitable for 550°F (such as Option FA1, P/N 98266) or high-tem-

perature silicone sealant.

If using Category III vent pipe, follow pipe manufacturer's instructions

for joining pipe sections. When attaching Category III pipe to the venter

outlet or the vent cap, make secure, sealed joints following a procedure

that best suits the style of Category III pipe being used.

If using double-wall (Type B) vent pipe (at least 1/2 of the equivalent vent

length must be vertical), follow pipe manufacturer's instructions for join-

ing pipe sections. For joining double-wall pipe to the venter outlet collar,

single-wall pipe, and/or the vent cap, follow the instructions below:

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 opening. See (1) in Figure 7.

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

area per 2000 BTUH. See (2) in Figure 7.

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

4000 BTUH. See (3) in Figure 7.

Instructions for attaching double-wall (Type B) vent pipe to the ven-

ter outlet, a single-wall pipe run, or to the vent cap (use these in-

structions for either full length double-wall or terminal only):

Hardware and Sealant Required: 3/4" long sheetmetal screws; and a tube of

high temperature silicone sealant

1) Look for the "flow" arrow on the vent pipe; attach according to the

arrow. Slide the pipe so that the venter outlet, the single-wall pipe, or the

vent cap is inside the double-wall pipe.

2) Drill a hole through the pipe into the outlet collar, the single-wall pipe,

or 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 pipe.

Do not overtighten. Repeat, drilling and inserting two additional screws

evenly spaced (120° apart) around the pipe.

3) Use silicone sealant to seal any gaps. If there is an annular opening, run

a large bead of 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.

NOTE: For further details on supplying combustion air to a

confined space, see the National Fuel Gas Code ANSI Z223.1a

(latest edition).

Specific Venting Requirements (read all

before installing)

1) Venter (Flue) Outlet

Venter

Model Size

150, 200, 250 300, 350, 400

5" 6"

Outlet

Size:

Outlet Diameter

Venter Outlet Attachment Requirements:

•

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

outlet before installing an elbow in the vent system. An elbow

should never be attached directly to the venter. An elbow

attached to the straight pipe can be in any position at or above

horizontal. See Figure 8.

4) Vent System Support

Lateral runs should be supported every six feet (1.8M) using a non-combus-

tible material, such as strap steel or chain. Do not rely on the heater for

support of either horizontal or vertical vent pipe.

Form 405, Page 10

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heater manufacturer (Option CC1) or a field-supplied cap. If the vent cap is

field-supplied, 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 Company.) 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.

See the illustrations in Figures 9A and 9B for requirements of vertical and

horizontal vent termination. The vent terminal pipe may be either single-

wall or double-wall (Type B). If double-wall pipe is used in the vent termi-

nal with a single-wall vent run, follow the instructions on page 10 to attach

the vent cap and to connect the double-wall pipe to the single-wall vent pipe

run.

5) Condensation

Any length of single-wall vent pipe exposed to cold air or run

through an unheated area or an area with an ambient temperature

of 45°F or less must be insulated along its entire length with a

minimum of 1/2" foil-faced fiberglass, 1-1/2# density insulation.

Where extreme conditions are anticipated, install a means of con-

densate disposal.

6) Vent Terminal (Pipe and Vent Cap)

The vent system must be terminated with the type of vent cap

approved for use with this heater. The vent cap must be the same

size as the vent pipe. Use either a vent cap available from the

Figure 8 - Horizontal Vent Terminals

Single-Wall Vent

Single-Wall

Vent Run

and Double-

Wall

Terminal

Roof or Building Overhang

Run and Single-

Wall Terminal

12”

(305mm)

minimum

6’ (2M)

(305mm)

minimum

6’ (2M)

minimum

Wall

Note position of

vent cap openings.

Note position of vent

Approved clearance

thimble for single-wall

vent pipe is required

when flue pipe extends

through combustible

materials.

cap openings.

Approved clearance

thimble for single-wall

vent pipe is required

when flue pipe extends

through combustible

materials. Follow

Pitch flue pipe down toward

outlet 1/4” per foot for con-

densate drainage.

(NOTE: Applies to entire

horizontal vent run.)

Pitch flue pipe down toward outlet

1/4” per foot for condensate drainage.

(NOTE: Applies to entire horizontal

vent run.)

the requirements

of the double-wall

pipe manufacturer.

Follow instructions on page 10 to join single

and double-wall pipe and to seal the connection.

Horizontal Vent Terminal Clearances

Structure

Minimum Clearances for Vent Termination

Location (all directions unless specified)

3 ft (0.9m) above

6 ft (1.8m)

4 ft (1.2m) horizontally

4 ft (1.2m) below

A vent cap is required. Maintain a clearance

of 12" from the wall to the vent terminal cap

for stability under wind conditions.

Forced air inlet within 10 ft (3.1m)

Combustion air inlet of another appliance

Door, window, or gravity air inlet

(any building opening)

Products of combustion can cause discolora-

tion of some building finishes and deteriora-

tion of masonry materials. Applying a clear

silicone sealant that is normally used to pro-

tect concrete driveways can protect masonry

materials. If discoloration is an esthetic prob-

lem, relocate the vent or install a vertical vent.

1 ft (30cm) above

Electric meter, gas meter* and relief

equipment

Gas regulator*

Adjoining building or parapet

Adjacent public walkways

Grade (ground level)

4 ft (1.2m)

*Do not terminate the vent

horizontally directly above a gas meter

3 ft (0.9m)

6 ft (1.8m)

or service regulator.

7 ft (2.1m) above

Figure 9 - Vertical Vent Terminals

Single-Wall Vent

Run and Single-

Wall Terminal

Single-Wall Vent

Run and Double-

Wall Terminal

6’ (2M) minimum

Vertical flue extension

to be 6” (152mm) higher

than anticipated snow

depth but no less than

2 feet (610mm) above the

roof.

Vertical flue extension to

be 6” (152mm) higher than

anticipated snow depth but

no less than 2 feet (610mm)

above the roof.

Vertical pipe extension

must be insulated.

6’ (2M) minimum

Roof Flashing

Roof - pitched

from 0 to 45°

Roof - pitched

from 0 to 45°

6” (152mm) minimum

Approved clearance thimble

for single-wall vent pipe is

Approved clearance thimble

for single-wall vent pipe is

required when flue pipe

extends through

required when flue pipe extends

through combustible materials.

Follow the requirements of the

double-wall pipe manufacturer.

Follow instructions on page 10

to join single and double-wall

pipe and to seal the connection.

combustible materials.

Mfg No. 164771, Page 11

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The cut edges of the metal will be sharp.

8. Duct Connections and

Ductwork

If installing an optional filter or filter/mixing cabinet shipped with the

heater, attach the cabinet at the "cutout" opening (See Optional Acces-

sories, Paragraph 18 or 19). Depending on the cabinet and how it is

installed, the inlet opening may be horizontal or vertical.

Attach the ductwork to the heater or to the inlet cabinet.

Both inlet air ductwork and supply air discharge ductwork are required

unless the heater is equipped with an optional inlet base and/or an

optional discharge plenum. IMPORTANT NOTE: If a Model ACU

cased cooling coil is part of the installation, it must be installed before

attaching discharge ductwork. Installation of a filter cabinet is rec-

ommended when a cooling coil is installed.

Figure 12 - Duct Opening for Connecting the Inlet Air

Duct to the field-installed Filter or Mixing Cabinet

Depending on the heater size and whether the cabinet is on the side

or the rear, the inlet opening may be either vertical (on the top of the

filter cabinet) or horizontal (on the side of the filter cabinet.)

Discharge Duct Connection - The discharge duct connects to the top

of the heater or to the outlet of the optional cooling coil cabinet. See

Figures 10 and 11. Connect the ductwork plenum to the duct flange as

illustrated in Figure 11.

1) The duct connection on the top of the heater has a 90° flange.

2) The duct may either have no flange or a 90° flange.

Filter Cabinet Inlet Opening

150, 200 - Rear or Side Filter Cabinet - 32” (813mm)

250, 300 - Side Filter Cabinet - 32” (313mm)

3) Position ductwork around the outside of the heater flange.

250, 300 - Rear Filter Cabinet - 45-1/8” (1146mm)

350, 400 - Rear or Side Filter Cabinet = 45-1/8 (1146mm)

4) If the ductwork has a flange, drill holes vertically through duct

flange into the top of the heater and secure with sheetmetal

screws. If the ductwork does not have a flange, drill holes hori-

zontally through the ductwork and the heater flange; secure with

sheetmetal screws.

16”

(406mm)

Inlet

Opening

Figure 10 - Top View showing Discharge Duct

Connection Dimensions (inches)

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 building.

• 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.

Electrical

Combustion Air Knockout

Venter Outlet

Gas

• 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.

6-3/8”

(162mm)

4-1/8”

(105mm)

2-3/8” (60mm)

• 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 buildings mem-

bers. Do not support ducts from unit duct connections.

• Duct Sizing - Proper sizing of the supply air ductwork is neces-

sary to ensure a satisfactory heating installation. The recognized

authority for such information is the Air Conditioning Contractors

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

manual covering duct sizing in detail may be purchased directly

Size

150, 200

250, 300

350, 400

36" (914mm) 48" (1219mm) 48" (1219mm)

21" (533mm) 21" (533mm) 34" (864mm)

Figure 11 - Connecting Discharge Ductwork

Removable

Access Panel in

the Ductwork -

6" x 10"

(152mm x

254mm)

minimum

from them.

CAUTION: An external duct system static pressure

not within the limits shown on the rating plate, or

improper motor pulley or belt adjustment, may

overload the motor. See Hazard Levels, page 2.

Attach to Duct

Flange

Heater

• 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 11.

Inlet Air Ductwork - The location of the inlet air duct connection

depends on the installation. Corner indicators for the opening are pro-

vided on the right side, the left side, and the rear of the heater. (See

Dimensions in Figure 1, page 3.) Determine where the inlet air opening(s)

should be and cut out using tin snips or aviation shears. CAUTION:

Form 405, Page 12

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From Gas Supply

Immediately upstream of the gas

supply connection, install a manual

shutoff valve with a 1/8” NPT

plugged tap accessible for test

gauge connection.

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 lockup-type service

regulator external to the unit.

To Controls

From

Gas

Supply

Manual

Gas Valve

Ground Joint Union

NOTE:

PRESSURETESTINGSUPPLYPIPING

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.

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

valve on the heater.

Connections

shown are by

the installer.

6” Drip Leg

Figure 13 -

Supply Piping

Connection

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.

All piping must be in accordance with requirements outlined in the

National Fuel Gas Code ANSI Z223.1a (latest edition) or CAN/CGA-

B149.1 and B149.2 (See Paragraph 1). Gas supply piping installation

should conform with good practice and with local codes.

Unit heaters are orificed for operation with natural gas having a heating

value of 1000 (± 50) BTUH per cubic ft or propane gas with a heating

value of 2550 BTUH per cubic ft. If the gas at the installation site does

not meet these specifications, consult the factory for proper orificing.

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.

Install a ground joint union and manual shutoff valve upstream of the

unit control system as shown in Figure 13. The 1/8" plugged tapping in

the shutoff valve provides connection for a supply line pressure test

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

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

leg longer than 3" (typically 6"). Bleed gas lines of trapped air.

Gas connection is either 1/2" or 3/4" depending on size and type of gas.

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 22. The following warnings and instructions apply.

WARNING: Manifold gas pressure must never

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

propane gas.

For Natural Gas: Manifold gas pressure is regulated by the combina-

tion 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.

Size

Gas

Gas Connection

150-200

250-400

150-400

Natural

Propane

1/2"

3/4"

1/2"

For Propane Gas: Manifold gas pressure is regulated by the combina-

tion 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.

Leak-test all connections by brushing on a leak-detecting solution.

Before attempting to measure or adjust manifold gas pressure, the inlet

Sizing a Gas Supply Line

- Cubic Feet per Hour based on 0.3" w.c. Pressure Drop

Capacity of Piping

Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft)

Specific Gravity for Propane Gas -- 1.6 (Propane Gas -- 2550 BTU/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 supply lines, consider possibilities of future expansion and increased requirements.

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

Mfg No. 164771, Page 13

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Figure 14 - Burner Condensate Drain Connection

9. Gas Piping and

Pressures (cont'd)

Manifold Pressure Settings (cont'd)

(supply) pressure must be within the specified range for the

gas being used both when the heater is in operation and on

standby. Incorrect inlet pressure could cause excessive mani-

fold gas pressure immediately or at some future time.

! Hex Locknut (silver)

Instructions to Check Manifold

Pressure (when unit is operating):

1) With the manual 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.

—Burner Bottom Pan—

" Sealing Washer

# Brass Nut

$ 90° Nylon Fitting

2) Open the valve and operate the heater. Measure the gas

pressure to the manifold. Normally adjustments should not

be necessary to the factory preset regulator.

1) Assemble the brass nut, the sealing washer, and the 90° fitting.

2) Position the threaded fitting up through the hole so that the hose barb is

toward the bushing in the side of the cabinet. Attach using the silver-colored

locknut.

If adjustment is necessary, set pressure to correct settings

by turning the regulator screw IN (clockwise) to increase

pressure. Turn regulator screw OUT (counterclockwise) to

decrease pressure.

3) Under the burner, push the tubing onto the hose barb, being sure that it is

secure. Maintaining a downward slope, extend the hose out through the

cabinet side.

4) Just after exiting the cabinet, create a trap in the line by making a loop in

the hose. Secure the loop with the wire ties.

5) Continue downward with the tubing, connecting it into the coil drain pipe.

10. Burner Condensate

Drain

11. Electrical Supply and Connections

All electrical wiring and connections, including electrical grounding, MUST be

made in accordance with the National Electric Code ANSI/NFPA No. 70 (latest

edition) or, in Canada, the Canadian Electrical Code, Part I-C.S.A. Standard C22.1.

In addition, the installer should be aware of and comply with any local ordinances

or gas company requirements.

If an optional cooling coil is installed on a Model CAUA

heater (either now or at a later time), a burner condensate

drain line must be installed.

The following parts to install the drain line are packaged and

shipped with all Model CAUA heaters.

Check the rating plate on the heater for the supply voltage and current require-

ments. A separate line voltage supply with fused disconnect switch should be run

directly from the main electrical panel to the heater. All external wiring must be

within approved conduit and have a minimum temperature rise rating of 60°C.

Conduit from the disconnect switch must be run so as not to interfere with the

service panels of the heater.

The electrical supply and control wiring enter at the top of the heater (See Figure

1, page 3) and connect to the terminal strip behind the gas valve (See Figure 15).

Consult the wiring diagram supplied with your heater. Typical wiring diagrams are

on pages 17 and 18.

Qty

P/N

165955

165952

Description

6-ft length of 3/8" I.D. Tubing

90° Nylon Fitting, 1/4" NPT x 3/8"

tubing

110628

171527

165953

20913

1/4" NPT Brass Nut

1/4" Locknut, Hex, T& B 139

Sealing Washer

Nylon Wire Ties, T&B #TY-24M

Snap Bushing, Heyco SB 625-8

87556

Instructions for Installing the Burner

Condensate Drain (Figure 14)

1. Remove the burner compartment door.

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°C,

except for sensor lead wires which must be 150°C. See

Hazard Levels, page 2.

2. The burner box cover is in two sections. On the left side

of the burner box cover, disconnect the flame sensor wire

and the flame rollout switch wires. Disconnect the sili-

cone tubing from the static tap. Remove the left section

of the burner box cover.

12. Thermostat and Connections

3. Determine which side of the cabinet will be most conve-

nient for the drain line. Remove the hole plug on that side

and insert the snap bushing from the package.

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

either an optional thermostat available with the heater or a field-supplied 24-volt

thermostat. Install according to the thermostat manufacturer's instructions. Con-

trol wiring enters on the right side of the heater and connects to the terminal strip

in the control compartment; see Figure 15.

4. Locate the hole in the bottom center of the burner pan

and remove the plug. Follow the instructions in Figure 14

to install the drain. Complete all steps as listed in the

illustration.

Make sure that the heat anticipator setting on the thermostat is in accordance with

the amperage value noted on the wiring diagram of your heater.

When installation of the burner condensate drain is com-

plete, re-assemble the heater.

WARNING: If you turn off the power supply, turn off the

gas. See Hazard Levels, page 2.

Form 405, Page 14

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Figure 15 - Control

Locations

Venter

Limit Control

Supply Wiring Terminal Block

(behind the gas valve)

(Line voltage enters the control

compartment through a hole in

the top of the heater cabinet.)

Pressure Switch

Transformer

Gas

Valve

Thermostat

Terminal Strip

(Thermostat wires enter

the control compartment

through a hole in the right

side of the heater cabinet.)

Terminal Strip

Contactors

Ignition Control

Module

14. Blower Motor and Drive

13. Combustion Air Proving

Switch

Model CAUA units are equipped with either direct drive motor(s) and

blower(s) or adjustable belt-drive blower(s) and motor.

The combustion air proving switch is a pressure sensitive switch

that monitors air pressure to ensure that proper combustion air is

available.

Direct Drive

All direct drive blower motors are 1 horsepower. Sizes 150-200 have a

single motor. Size 150 has a 12-9 blower; Size 200 has a 12-12 blower.

Sizes 250-400 have dual motors with dual 12-9 blowers.

The switch is single pole/double throw with the normally open

contacts closing when the proper airflow is sensed in the system.

Belt Drive

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.

The motor horsepower on a belt drive unit is whatever was specified on

the order ranging in size from 1/4 HP to 5 HP. Check the heater rating plate

and the motor rating plate.

As part of the start-up procedure, check belt tension. Proper belt tension

is important to the long life of the belt and motor. A loose belt will cause

wear and slippage. Too much tension will cause excessive motor and blower

bearing wear. Adjust the belt tension by turning the adjusting screw on the

motor base until the belt can be depressed 3/4". (See Figure 16.) After

correct tension is achieved, re-tighten the locknut on the adjustment screw.

Be sure that the belt is aligned in the pulleys.

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

pressure to be outside 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 resistance is

reduced. The table below lists the approximate water column nega-

tive pressure readings and switch setpoints for sea level operating

conditions.

Model Start-Up Equilibrium Set Point Set Point

Size

150

200

250

300

350

400

Cold

1.45

1.50

1.55

1.60

1.30

1.20

“OFF”

.75

“ON”

.90

1.05

1.10

1.15

1.05

1.00

Figure 16 -

Check Belt

Tension

3/4” (19mm)

.75

.90

Most blower motors are equipped with thermal overload protection of the

automatic, reset type. If the motor is not equipped with thermal overload

protection, the unit will be equipped with a starter. The adjustable setting

on the starter will be factory set to match the amp draw of the motor and

sealed. No change should be made to the starter setting unless the original

motor is replaced. Starters are equipped with a manual reset. If an overload

condition is experienced, the condition must be corrected and the starter

must be manually reset.

After the installation is complete including all ductwork, the amp draw of

the motor should be checked with an amp meter to verify that the motor

amp rating on the motor nameplate is not being exceeded. Amps may be

adjusted downward by reducing the blower speed or by increasing the duct

system static pressure. The temperature rise must be within the range

specified on the unit rating plate.

DANGER: Safe operation of this unit requires

proper venting flow. NEVER bypass the com-

bustion 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

Mfg No. 164771, Page 15

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motor specifications. At final adjustment, amperes should not ex-

ceed motor nameplate amp rating. The installation must be ad-

justed to obtain a temperature rise within the range specified on

the heater rating plate.

14. Blower Motor and Drive

(cont'd)

Adjusting Blower Speed

Full Load Amps - Blower Motors (Open)

The blower speed may be adjusted to achieve the desired outlet tem-

perature, as long as the adjustment is within the temperature rise and

the static pressure limits shown on the heater rating plate. Direct drive

motors are factory set at medium speed for heating and high speed for

cooling (if ordered). Belt drive motors are factory set between maxi-

mum and minimum blower speeds.

1/4 1/3 1/2 3/4

Direct-Drive Motors

-- --

6.3

Optional Belt Drive Motors

1-1/2

230V 1PH --

208V 1 PH 2.1 3.2 5.1 6.3 7.5 8.3 10.0

230V 1PH 2.3 2.8 4.4 5.5 6.5 7.5 10.2

If the duct resistance is low, the blower may deliver too high an air

volume. If the resistance is very low, the blower may deliver excess air

to overload the motor, causing the overload protector to activate. Re-

ducing the blower speed will correct these conditions. If ductwork is

added to an installation, it may be necessary to increase the blower

speed.

208V 3 PH 1.1 1.4 3.0 2.9 3.7 5.6 7.0 9.0 13.4

230V 3PH 1.4 1.6 2.5 2.6 3.2 5.0 6.6 8.6 13.2

460V 3PH 0.75 0.8 1.0 1.3 1.6 2.7 3.5 4.3 6.6

575V 3PH --

1.1 1.6 2.1 3.6 5.4

Direct drive motors have multi-speed taps for speed adjustment. If

your installation requires an adjustment of the blower speed, the motor

may be re-wired to an alternate tap by following these instructions.

1. Turn off the gas and electric power.

CAUTION: An external duct system static

pressure not within the limits shown on the rating

plate, or improper motor pulley or belt adjustment,

may overload the motor or cause the limit control

to activate. See Hazard Levels, page 2.

2. Remove the blower door panel.

3. Consult the wiring diagram on the heater and follow the chart below

to choose the wiring for the desired adjustment. Units are wired at

high speed for cooling (if ordered) and medium speed for heating.

15. Gas Valve

Model Sizes

Speed

Use these two motor wires:

The main operating gas valve is powered by the 24-volt control circuit

through the thermostat and safety controls. The main control valve is

of the diaphragm type providing regulated gas flow preset at the fac-

tory.

150, 200, 250, 350

High

White and Black

Medium

Low

White and Blue

White and Red

300 and 400

High

White and Black

Medium White and Blue

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 2.

4. Cut the crimped cap for the end of the wire that you intend to use

and strip the insulation.

5. Disconnect the factory-wired connection and re-wire, using the newly

stripped wire.

6. Put a wire nut on the end of the blower motor wire that was discon-

nected.

16. Ignition System

7. Replace the heater door panel. Turn on the gas and electric. Check

for proper operation.

This heater is equipped with a direct spark integrated control system.

The system monitors the safety devices and controls the operation of

the blower and venter motors and the gas valve.

Belt drives have an adjustable pulley which permits adjustment of the

blower speed. Follow these instructions to adjust blower speed.

1. Turn off the gas and the electric power.

Ignition System Operating Sequence

On a call for heat from the thermostat, the system energizes the venter

motor and goes through a 10-second prepurge. The system verifies that

the pressure switch has changed states closing the normally open con-

tactor and that the high limit is in the closed state.

The gas valve is then energized, and the ignition system provides the

high voltage spark to the electrode to ignite the main burner gas. Burner

flame is electronically sensed by the control (minimum 1.0 microamps)

upon carryover of all burners. (A separate solid metal probe is used as

the flame sensing function. A low voltage electrical signal is imposed on

the metal probe which is electrically isolated from ground. When the

flame impinges on the flame sensing probe, the flame acts as a conduc-

tion path to ground. The flame rectifies and completes the DC circuit,

and the ignition system acknowledges the flame.)

2. Loosen belt tension and remove the belt.

3. Loosen the set screw on the side of the pulley away from the motor.

4. To increase the blower speed, turn the adjustable half of the pul-

ley inward. To decrease the blower speed, turn the adjustable half

of the pulley outward. One turn of the pulley will change the speed

8-10%.

5. Tighten the set screw on the flat portion of the pulley shaft.

6. Replace the belt and adjust the belt tension. Adjust tension by

turning the adjusting screw on the motor base until the belt can be

depressed 3/4". (See Figure 16.) Re-tighten the lock nut on the

adjusting screw. Be sure that the belts are aligned in the pulley

grooves properly and are not angled from pulley to pulley.

7. Turn on the gas and electric. Light the heater following the instruc-

tions on the lighting instruction plate.

The blower motor is energized by the system after 30 seconds of flame

sensing.

8. Check the motor amps with an amp meter. The maximum motor

amp rating on the motor nameplate must not be exceeded.

When service is complete, check for proper operation.

After the thermostat has been satisfied, the system de-energizes the gas

valve, the venter motor goes through a 45-second post-purge, and the

blower motor remains energized for an additional 135 seconds.

NOTE: This is a three trial system. The unit will lockout for one hour

before initiating another trial for ignition. If the unit fails after one

recycle interval, the unit will go into hard lockout and must be reset by

interrupting power or resetting the thermostat. To initiate another trial

for ignition before the one hour interval, either reset the thermostat or

interrupt power to the unit for 30 seconds.

Motor Amps

Use an amp meter to check motor amps. The chart lists full load amps

for various HP's and voltages. Amps may be adjusted downward by

reducing blower RPM or increasing duct system static pressure.

The chart below can be used for sizing line wiring but should not be

interpreted as the exact motor amps. See the motor rating plate for exact

Form 405, Page 16

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TYPICAL WIRING DIAGRAMS

Figure 17 - Typical Wiring Diagram for Model CAUA with Direct-Drive Blower Motor(s)

GRD

OPTIONAL DISCONNECT SWITCH

(SEE NOTE)

INHERENTLY

PROTECTED

BLOWER

MOTOR

HEAT SPEED

CONTACTS

INHERENTLY

PROTECTED

BLOWER

MOTOR

(SEE NOTE #7)

COOL SPEED CONTACTS

MOTOR WIRE COLORS

WHITE - NEUTRAL

BLACK - HIGH SPEED

BLUE - MEDIUM SPEED

RED - LOW SPEED

GRD

(DO NOT USE WITH 208V)

VENTER MOTOR

(SEE NOTE #8)

DSI CONTROL

BK OR BR

HEAT SPEED

BK OR BL

LINE

CMB

BLWR AUX

VAC HOT

CONTACTOR COIL

24VAC

HOT

ACB HEAT

ACB COOL

GROUND

WIRING CODE

BLACK - BK

BROWN - BR

RED - R

ORANGE - O

YELLOW - Y

GREEN - G

BLUE - BL

FLAME

ROLLOUT SWITCH

COOL SPEED

CONTACTOR COIL

ROLLOUT

CUSTOMER'S

COOL RELAY COIL

PURPLE - PR

WHITE - W

IGNITOR

BURNER GROUND

HV LEAD

THERMOSTAT

TERMINAL STRIP

FLAME SENSING

PROBE

HIGH

LIMIT

FLAME SENSE

PSW

PRESSURE SWITCH

HI LIMIT

OUT

TR OR

PV-MV

LED

VALVE

TH OR

FACTORY WIRING

FIELD WIRING

CHASSIS GRND.

OPTIONAL FACTORY WIRING

TH-TR

OR PV

DOOR SWITCH

24V

MAIN TERMINAL BLOCK

UNIT TERMINAL STRIP

40 VA. CONTROL

TRANSFORMER

LINE VOLT

OPERATING SEQUENCE

THERMOSTAT TERMINAL STRIP

1. SET THERMOSTAT SYSTEM SWITCH AT "OFF" POSITION, FAN SWITCH AT "AUTO" POSITION.

2. TURN ON MANUAL GAS VALVE.

3. TURN ON POWER TO UNIT.

4. SET THERMOSTAT SYSTEM SWITCH AT "HEAT" POSITION; FAN SWITCH AT "AUTO" POSITION.

5. THERMOSTAT CALLS FOR HEAT, ENERGIZING THE VENTER MOTOR.

6. VENTER PRESSURE SWITCH CLOSES, FIRING UNIT.

7. BURNER FLAME IS SENSED, AND IN 30 SECONDS THE BLOWER MOTOR IS ENERGIZED.

LED CODES

8. IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION, THE INTEGRATED CONTROL SYSTEM

SLOW FLASH NORMAL OPERATION - NO CALL FOR HEAT

FAST FLASH NORMAL OPERATION - CALL FOR HEAT

2 FLASHES SYSTEM LOCKOUT - FAILED TO DETECT OR SUSTAIN FLAME

3 FLASHES PRESSURE SWITCH OPEN OR CLOSED

4 FLASHES HIGH LIMIT OPEN

5 FLASHES FLAME SENSED AND GAS VALVE NOT ENERGIZED

STEADY ON INTERNAL FAILURE (MICRO-CONTROLLER FAILURE: SELF CHECK)

CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT

(SEE LIGHTING INSTRUCTIONS).

9. SET THERMOSTAT SYSTEM SWITCH AT "COOL" POSITION, FAN SWITCH AT "AUTO" POSITION.

(A) ON A CALL FOR COOLING, BLOWER MOTOR IS ENERGIZED AT HIGH SPEED AND COOLING

CIRCUIT IS ENERGIZED.

10. WHEN BLOWER DOOR IS OPENED, THE UNIT IS SHUTDOWN.

11. SET THERMOSTAT SYSTEM SWITCH AT "OFF" POSITION, FAN SWITCH AT "AUTO" POSITION, FOR SHUTDOWN..

NOTES

1. THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS: THERMOSTAT

2. DOTTED WIRING AND COOL RELAY COIL INSTALLED BY OTHERS.

3. CAUTION: IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE

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

HAVING A TEMPERATURE RATING OF AT LEAST 105° C. EXCEPT FOR SENSOR

LEAD WIRE WHICH MUST BE 150° C.

FIELD CONTROL WIRING

TOTAL WIRE

LENGTH

DISTANCE FROM

UNIT TO CONTROL

MIN. RECOMMENDED

WIRE GUAGE

#18 GA. WIRE

#16 GA. WIRE

#14 GA. WIRE

150'

250'

350'

75'

125'

175'

4. USE 18 GA. WIRE FOR CONTROL WIRING ON THE UNIT.

5. USE 14 GA. WIRE FOR LINE AND MOTOR WIRING ON UNIT.

6. LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT

VOLTAGE DROPS BEYOND 5% OF SUPPLY LINE VOLTAGE.

7. SECOND BLOWER MOTOR ON 250-400 UNITS ONLY.

8. VENTER MOTOR ON 350-400 UNITS HAS BROWN AND BLUE WIRES.

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

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

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

10. WHEN PROVIDING OR REPLACING FUSES IN THE FUSIBLE DISCONNECT SWITCH

USE DUAL ELEMENTS TIME DELAY FUSES AND SIZE ACCORDING TO

TIMES THE MAXIMUM TOTAL INPUT AMPS.

CAUA SERIES 150 - 400 DWG. # B-164607 REV #1

AG1 - AK2 OR AK3 - CL10 - DIRECT DRIVE

BABS

Mfg No. 164771, Page 17

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TYPICAL WIRING DIAGRAMS (cont'd)

Figure 18 - Typical Wiring Diagram for Models CAUA with Belt-Drive Blower Motor

OPTIONAL DISCONNECT SWITCH

GRD

(SEE NOTE)

INHERENTLY

PROTECTED

BLOWER

MOTOR

CONTACTOR

MAIN TERMINAL BLOCK

UNIT TERMINAL STRIP

THERMOSTAT TERMINAL STRIP

GRD

VENTER MOTOR

(SEE NOTE #8)

DSI CONTROL

BK OR BR

WIRING CODE

BLACK - BK

BROWN - BR

RED - R

ORANGE - O

YELLOW - Y

GREEN - G

BLUE - BL

BK OR BL

MOTOR

LINE

CMB

VAC HOT

BLWR AUX

CONTACTOR COIL

24VAC

HOT

ACB HEAT

FLAME

ROLLOUT SWITCH

ROLLOUT

ACB COOL

GROUND

PURPLE - PR

WHITE - W

CUSTOMER'S

COOL RELAY COIL

IGNITOR

BURNER GROUND

HV LEAD

THERMOSTAT

TERMINAL STRIP

FLAME SENSING

PROBE

FLAME SENSE

FACTORY WIRING

FIELD WIRING

OPTIONAL FACTORY

WIRING

PRESSURE SWITCH

HIGH

LIMIT

PSW

HI LIMIT

OUT

TR OR

PV-MV

LED

VALVE

TH OR

CHASSIS GRND.

TH-TR

OR PV

DOOR SWITCH

24V

40 VA. CONTROL

TRANSFORMER

LINE VOLT

OPERATING SEQUENCE

LED CODES

1. SET THERMOSTAT SYSTEM SWITCH AT "OFF" POSITION; FAN SWITCH AT "AUTO" POSITION.

2. TURN ON MANUAL GAS VALVE.

3. TURN ON POWER TO UNIT.

4. SET THERMOSTAT SYSTEM SWITCH AT "HEAT" POSITION; FAN SWITCH AT "AUTO" POSITION.

5. THERMOSTAT CALLS FOR HEAT, ENERGIZING THE VENTER MOTOR.

6. VENTER PRESSURE SWITCH CLOSES, FIRING UNIT.

7. BURNER FLAME IS SENSED, AND IN 30 SECONDS THE BLOWER

MOTOR IS ENERGIZED.

SLOW FLASH NORMAL OPERATION - NO CALL FOR HEAT

FAST FLASH NORMAL OPERATION - CALL FOR HEAT

2 FLASHES SYSTEM LOCKOUT - FAILED TO DETECT OR SUSTAIN FLAME

3 FLASHES PRESSURE SWITCH OPEN OR CLOSED

4 FLASHES HIGH LIMIT OPEN

5 FLASHES FLAME SENSED AND GAS VALVE NOT ENERGIZED

STEADY ON INTERNAL FAILURE (MICRO-CONTROLLER FAILURE: SELF CHECK)

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

THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND

MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT

(SEE LIGHTING INSTRUCTIONS).

9. SET THERMOSTAT SYSTEM SWITCH AT "COOL" POSITION, FAN SWITCH AT "AUTO" POSITION.

(A) ON A CALL FOR COOLING, BLOWER MOTOR IS ENERGIZED AND COOLING

CIRCUIT IS ENERGIZED.

FIELD CONTROL WIRING

10. WHEN BLOWER DOOR IS OPENED, THE UNIT IS SHUTDOWN.

TOTAL WIRE

LENGTH

DISTANCE FROM

UNIT TO CONTROL

MIN. RECOMMENDED

WIRE GUAGE

#18 GA. WIRE

#16 GA. WIRE

#14 GA. WIRE

11. SET THERMOSTAT SYSTEM SWITCH AT "OFF" POSITION, FAN SWITCH AT "AUTO" POSITION, FOR SHUTDOWN.

NOTES

150'

250'

350'

75'

125'

175'

1. THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS: THERMOSTAT

2. DOTTED WIRING AND COOL RELAY COIL INSTALLED BY OTHERS.

3. CAUTION: IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE

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

HAVING A TEMPERATURE RATING OF AT LEAST 105° C. EXCEPT FOR SENSOR

LEAD WIRE WHICH MUST BE 150° C.

4. USE 18 GA. WIRE FOR CONTROL WIRING ON THE UNIT.

5. USE 14 GA. WIRE FOR LINE AND MOTOR WIRING ON UNIT.

6. LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT

VOLTAGE DROPS BEYOND 5% OF SUPPLY LINE VOLTAGE.

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

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

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

8. VENTER MOTOR ON 350-400 UNITS HAS BROWN AND BLUE WIRES.

9. WHEN PROVIDING OR REPLACING FUSES IN THE FUSIBLE DISCONNECT SWITCH

USE DUAL ELEMENTS TIME DELAY FUSES AND SIZE ACCORDING TO 1.25

TIMES THE MAXIMUM TOTAL INPUT AMPS.

Form 405, Page 18

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OPTIONAL ACCESSORIES

17. Optional Cased Cooling Coil, Model ACUA, ACUB, or ACUC

This cased cooling coil is designed for use with the Model CAUA upflow heater. It is shipped separately for field installation over the discharge

opening of the heater. Before installing, verify that the coil cabinet is the same size as the heater cabinet.

Follow the installation instructions shipped with the cooling coil (Installation Form RZ 405-CC), the wiring diagram, and the instructions provided

by the compressor manufacturer.

Model

Size

ACUA

060 072 090

ACUB

090 120 150

90 120 150

ACUC

120 150 180

Heater/Coil Cross-Reference

Table by Cabinet Size

Heater Model CAUA

Nominal Cooling Capacity (MBH) 60

Refrigerant Type

Thermal Expansion Valves*

Approximate Weight (lbs)

No. of Intertwining Circuits

Face Area (sq ft)

Rows-Fins/Inch

Airflow (cfm) Low

Nominal

R-22 R-22 R-22 R-22 R-22 R-22 R-22 R-22 R-22

150 200

250 300 350

400

86 105

110 122 140

12 12 18

176 180 188

12 16 18

ACUA

060

ACUB

090

ACUC

120

7.79 7.79 9.38 14.04 11.67 13.70 17.13 15.38 17.13

2-10 2-12 3-10 2-12 3-10 3-12 2-12 3-10 3-10

072

090

120

150

180

1800

2400

3000

4000

5000

High

3000**

5000**

6000**

* - TXV's are factory supplied. Models with two TXV's have intertwined circuiting.

** - Airflow in excess of maximum values shown may result in blow-off of condensation.

Figure 19 - A Model ACU cooling coil installed on a Model CAUA heater and the line connection sizes

Model Size

Connections

Suction Line

ACUA 060/072

Connection(s)

(1) 7/8" Suction Line

(1) 3/8" Liquid Line

(1) 1/2" Liquid Line

(2) 7/8" Suction Lines

(2) 3/8" Liquid Lines

(2) 7/8" Suction Lines

(2) 3/8" Liquid Lines

(2) 1/2" Liquid Lines

(2) 7/8" Suction Lines

(2) 3/8" Liquid Lines

(2) 1/2" Liquid Lines

ModelACU

Cased

Cooling Coil

060

Liquid Line

Connection(s)

3/4" Drain Line

Connection

072

090

ACUB 090/120/150

090/120

Hole for Burner

Condensate Drain

Tube (use this hole

or the one on the

opposite side) - see

Paragraph 10, page

ModelCAUA

Heater

150

ACUC 120/150/180

120

150/180

Drain line connection is 3/4" for all sizes.

Burner Condensate Drain

When a system includes a cooling coil, a burner condensate drain must be installed. The parts required for the drain are shipped with the heater.

Instructions for installing the drain are in Paragraph 10, page 14.

Electrical Connections

Figure 20 - Typical

Heater Terminal Strip

Thermostat

Connections

(Read thermostat

manufacturer’s

installation

Condensing Unit

Connections

(Read

Low Voltage Wiring

(field-supplied)

24V Supply *

Common

manufacturer’s

installation

Common

instructions

before wiring.)

1st Stage Cooling

2nd Stage Cooling

1st Stage Heating

1st stage cooling

24V control relay

2nd stage cooling

24V control relay

for Sizes 090, 120,

150, and 180

Optional 2-Stage Heating

Fan

* A separate 24V control transformer may

Legend (field-supplied 24V wiring)

be required for the condensing equipment controls

Install a jumper wire between RH and RC terminals

on the thermostat for single transformer operation.

Consult the thermostat manufacturer’s instructions.

Thermostat wiring - 24V

Field control wiring - 24V

Mfg No. 164771, Page 19

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OPTIONAL ACCESSORIES (cont'd)

18. Optional Filter Cabinet (return air only)

A filter cabinet designed for 2" pleated disposable or permanent metal filters is shipped separately for field assembly and installation. Depending on

the option selected, filters are either shipped with the cabinet or are field-supplied.

To adapt to a variety of applications, the heater cabinet is designed so that the filter cabinet can attach on either the right side, the left side, or the rear

of the heater. The larger filter cabinets (left two tables below) are uniquely designed so that the same cabinet can be field-assembled and installed with

either a horizontal or vertical air inlet. The smaller filter cabinet in the table on the right is limited to Sizes 150 and 200 and is available with a

horizontal inlet only. All cabinets have door panels for easy filter removal for changing or cleaning.

All of the filter cabinets have a duct flange for attaching the inlet air duct. For inlet duct dimensions, see Paragraph 8.

Follow the step-by-step instructions included with the filter cabinet package to assemble and attach it to the heater.

Figure 21 - Filter Cabinets with Filter Arrangements and Filter Sizes

Option CW8 with 2" Pleated Filters

Option CW4 with 2" Pleated Filters

Option CW5 with 2" Permanent Filters

Option CW6 for Field-Supplied Filters

Option CW7 with 2" Pleated Filters

Option CW12 with 2" Permanent Filters

Option CW11 for Field-Supplied Filters

Option CW9 with 2" Permanent

Filters

Option CW10 for Field-Supplied

Filters

•

Attaches on Either Side of the Heater

Vertical (Top) or Horizontal Inlet Opening

"V" Filter Rack Arrangement

•

Attaches on the Rear of the Heater

Vertical (Top) or Horizontal Inlet

Opening

•

Attaches on either Side or the Rear

of a Size 150 or 200 Heater

Horizontal Inlet Opening

•

"V" Filter Rack Arrangement

•

"V" Filter Rack Arrangement

Figure 21B -

Assembled

with

Horizontal

Air Inlet

Opening

Figure 21A -

Assembled with

Vertical Air

Figure 21C -

Small Filter

Cabinet for Sizes

150 and 200 only

-- Horizontal Air

Inlet Only

Inlet Opening

Sizes of Permanent or Pleated 2"

Filters for Options CW4, CW5, or CW6

Sizes of Permanent or Pleated 2"

Filters for Options CW7, CW12, or

CW11

Filters for Options CW8, CW9, CW10

Size

150

CFM

1800

2400

3000

2400

3000

*4000

FPM

281

375

469

375

469

625

Filters

(4) 16 x 16

(6) 16 x 16

Size

CFM

1800

2400

3000

2400

3000

4000

5000

3000

4000

5000

4300

5000

*6000

4300

5000

*6000

FPM

281

375

469

375

469

313

417

521

313

417

521

448

521

625

448

521

625

Filters

SizeCFM FPM

2" Filters

150

(4) 16 x 16

(6) 16 x 16

Pleated Permanent

150 1800 375 (2) 12 x 32 (4) 12 x 16

200

250

2400 500 (2) 12 x 32 (4) 12 x 16

200

250

*3000 625

200 2400 500 (2) 12 x 32 (4) 12 x 16

*3000 625 -- (4) 12 x 16

(4) 12 x 16

**5000 781

300

3000

*4000

**5000 781

469

625

300

350

400

350

400

4300

5000

*6000

4300

5000

*6000

448

521

625

448

521

625

NOTES:

* Requires 2" permanent filters.

** If using side inlets, two cabinets must be

installed, one on each side.

19. Mixing Cabinet (Outside and Return Air)

The optional mixing box for the Reznor^®Model CAUA heater is designed

to provide the system with a supply air mixture of return air and outside

air. Any percentage of outside air can be supplied to the unit as long as the

air temperature entering the blower is 35°F or above. The mixing box is

available in an assortment of configurations with a selection of actuators

and controls. All mixing boxes are completely assembled at the factory for

field attachment to the rear of a Model CAUA heater.

instructions for routing the damper motor wires, and connect the

wires according to the wiring diagram. If there are both return air and

outside air dampers, follow the directions to adjust the damper

linkage.

All mixing box inlet air openings have duct flanges for attachment of

ductwork. Ductwork must be attached to the outside air opening.

Removable door panels provide for filter access from either end of

the cabinet. If the box was ordered with optional filters, it is shipped

with the filters installed.

Follow the instructions packed with the mixing box to cut out the opening

and attach the mixing box. If the mixing box has dampers, follow the

Form 405, Page 20

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Option Configuration

Top Outside Air Opening with Dampers/

GA1

GA2

GA3

GA4

GA5

GA6

GA7

GA8

GA9

Rear or Bottom Return Air Opening without Dampers

Rear Outside Air Opening with Dampers/

Top or Bottom Return Air Opening without Dampers

Figure 22 -

Optional

Outside Air

and Return

Air Mixing

Box

Bottom Outside Air Opening with Dampers/

Top or Rear Return Air Opening without Dampers

Bottom Outside Air Opening with Dampers/

Rear Return Air Opening with Dampers

Bottom Outside Air Opening with Dampers/

Top Return Air Opening with Dampers

Rear Outside Air Opening with Dampers/

Top Return Air Opening with Dampers

Configurations/Accessories

Rear Outside Air Opening with Dampers/

Bottom Return Air Opening with Dampers

Before installing, check to be sure that the configuration of the mixing

box matches the order and that any accessories ordered are part of the

cabinet. Factory-installed optional accessories could include a damper

motor, potentiometer, return air controller, mixed air controller, and/or

filters. NOTE: If the potentiometer is to be field-installed, it is shipped

in a separate carton.

Top Outside Air Opening with Dampers/

Rear Return Air Opening with Dampers

Top Outside Air Opening with Dampers/

Bottom Return Air Opening with Dampers

Figure 23 - Dimensions of Optional

Mixing Box - inches (mm)

150-200

38 (965)

250-400

50 (1270)

22-3/4 (578)

7-5/8 (194)

36-1/2 (927)

6-3/4 (171)

Note: Damper frame fits in the inlet opening.

21. Inlet Base (Sizes 350 and 400 only)

20. Discharge Plenum (Sizes 350

The optional mounting base is designed to support a Model CAUA 350

or 400 heater while providing an inlet for return air. The mounting base

is designed to be used with an optional discharge plenum (Paragraph 20)

creating a "packaged stand-alone" heating or heating/cooling upflow

system which can be used in an air turnover application.

However, if the installation requires it, the mounting base may also be

used with discharge ductwork.

and 400 only)

The optional discharge plenum is designed to be used with a screened

mounting base (Paragraph 21) to create a "packaged stand-alone" upflow

system that circulates building air. However, the discharge plenum

may also be used in place of ductwork in applications that do not have

an optional mounting base.

The discharge plenum is available in three types. Option CD60 and

CD61 are for a heater without a cooling coil; Option CD60 is designed

for an open area and Option CD61 includes field-installed blockoff

plates to block off one or two sides. Option CD62 can only be ordered

with a cooling coil and includes blockoff plates to provide higher veloc-

ity required for cooling.

The mounting base has guarded openings on all four sides and is avail-

able with optional 1" flat disposable, 1" permanent aluminum, or 1"

pleated disposable filters.

The base is designed for a fairly open area and must have at least three

of the four sides open.

The base adds 36-1/2" (927mm) to the overall height.

A discharge plenum adds 49-15/16" (1268mm) to the height of the

heater. (If installing Option CD62, this height includes the cooling

coil.)

Mfg No. 164771, Page 21

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Check/Test/Start-Up

22. Check Installation & Start-Up

Check the installation prior to start-up:

replace any part of the control system and any

gas control which has been under water.

%Check clearances from combustibles. Requirements are shown in

Operating Instructions and Operating Sequence

1. Set thermostat at lowest setting.

Paragraph 4.

%If installed as a separated-combustion unit, check vent/combustion

air system to be sure that it is installed according to the instructions

in Paragraph 7A.

2. Turn off all electric power to the appliance.

3. This appliance is equipped with an ignition device which

automatically lights the burner. Do not try to light the burner

by hand. Open the access door and locate the gas valve.

%Check piping for leaks and proper gas line pressure. Bleed gas lines

of trapped air. See Paragraph 9.

4. Models CAUA 150 and 200 - Locate the gas control (ON/OFF)

knob on the gas valve. Turn the gas control knob clockwise

to "OFF".

%Check the blower compartment to be sure that all shipping sup-

ports have been removed. Close the blower compartment door se-

curely. Heater will not operate if the blower compartment door is

not closed.

Models CAUA 250, 300, 350, and 400 - Locate the gas con-

trol (ON/OFF) knob on the gas valve. Turn knob clockwise to

align the line on the knob with the position indicator. Depress

knob and continue rotation to the "OFF" position.

%Check electrical wiring. Be sure all wire gauges are as recommended.

A service disconnect switch should be used. Verify that fusing or

circuit breakers are adequate for the load use.

Top View of Gas Valve used on

Control Knob on Top of

Start-Up

CAUA 150 and 200

Gas Valve used on CAUA

250 - 400

WARNINGS: For your safety, read before

operating. If you do not follow these instructions

exactly, a fire or explosion may result causing

property damage, personal injury, or loss of life.

• This appliance does not have a pilot. It is

equipped with an ignition device which auto-

matically lights the burner. Do not try to light

the burner by hand.

5. Wait five (5) minutes to clear out any gas. Then smell for gas,

including near the floor. If you smell gas, STOP! and follow

the steps in the WARNINGS printed in the right column or

on the Operating Label on the heater. If you do not smell gas,

proceed to the next step.

• Before operating, smell all around the appliance

area for gas. Be sure to smell next to the floor

because some gas is heavier than air and will

settle on the floor.

6. Models CAUA 150 and 200 - Turn the gas control knob coun-

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

terclockwise to "ON".

Models CAUA 250, 300, 350, and 400 - Turn knob counter-

clockwise to align the line on the knob with the position indi-

cator. Allow knob to "pop up", and continue rotation to the

"ON" position.

• Do not touch any electrical switch; do not

use any phone in your building.

• Immediately call your gas supplier from a

neighbor's phone. Follow the gas

supplier's instructions.

7. Close the access door.

8. Turn on the electric power to the heater.

9. Set the thermostat to the desired setting.

• If you cannot reach your gas supplier, call

your fire department.

NOTE: If the appliance does not operate, follow the instructions

"To Turn Off Gas to the Appliance" printed below (and on the

Operating Label on the heater). Call your service technician.

• Use only your hand to turn the gas control ON/

OFF knob on the gas valve. Never use tools. If

the valve ON/OFF knob will not turn by hand,

do not try to repair it. Call a qualified service

technician. Force or attempted repair may re-

sult in a fire or explosion.

10. Thermostat calls for heat, energizing the venter motor.

11. Venter pressure switch closes, allowing the unit to fire.

12. Burner flame is sensed and in 30 seconds, the blower motor

is energized.

13. If the flame is extinguished during the main burner operation,

the integrated control system closes the main valve and must

be reset by interrupting power to the control circuit. (See

lighting instructions on the heater.).

• Do not use this appliance if any part has been

under water. Immediately call a qualified ser-

vice technician to inspect the appliance and to

Form 405, Page 22

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TO TURN OFF GAS TO THE APPLIANCE

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.

1) Set thermostat to lowest setting

2) If service is to be performed, turn off all electric power

to the appliance.

3) Open the access door.

4) Turn the gas control knob to "OFF" (follow instruc-

tions in No. 4 above). Do not force control knob.

5) Close the access door.

Check installation after start-up:

%&Vent System Testing Procedure - Power Vent

Units (does not apply to separated-combustion

installation)

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal

pitch, as required in the National Fuel Gas Code, ANSI

Z223.1 or CAN/CGA B149.1 and B149.2, Installation Code

for Gas Burning Appliances and Equipment, and this

manual. Determine that there is no blockage or restric-

tion, leakage, corrosion and other deficiencies which could

cause an unsafe condition.

If installed as a separated-combustion unit, install

either the horizontal or vertical combustion air/

vent system illustrated in Paragraph 7A using the

concentric adapter supplied. Always comply with

the combustion air requirements in the installation

codes and instructions. 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.

CHECK THE VENT SYSTEM FOR

SOUNDNESS AND FUNCTION; MAINTAIN IT

IN PROPER OPERATING CONDITION.

3. In so far as practical, close all building doors and win-

dows and all doors between the space where the heater is

and other spaces of the building. Turn on clothes dryers

and exhaust fans, such as range hoods and bathroom

exhausts, so they shall operate at maximum speed. Do not

operate a summer exhaust fan. Close fireplace dampers.

4. Light the heater following the lighting instructions. Ad-

just the thermostat for continued operation. Verify that

combustion products are venting properly. After deter-

mining that the heater vents properly, return doors, win-

dows, exhaust fans, and fireplace dampers to their previ-

ous conditions. If improper venting is observed, the vent-

ing system must be corrected.

%With the unit in operation, measure manifold gas pressure.

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

w.c. for propane gas. See Paragraph 9.

%Turn the unit off and on, pausing two minutes between each

cycle. Observe for smooth ignition.

%Place the "Owner's Envelope" containing the Limited War-

ranty, this booklet, the operation/maintenance/service manual,

and any control or optional information in an accessible loca-

tion near the heater. Follow the instructions on the envelope.

Mfg No. 164771, Page 23

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Printed in the U.S.A.

MANUFACTURER OF HEATING, COOLING, AND VENTILATING SYSTEMS

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

(800) 695-1901; www.ReznorOnLine.com

2/01 YL Form RZ 405 (Version B)

Form 405, Page 24

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