Form I-X (12-14) Obsoletes Form I-X (Version E.1) Installation / Operation / Maintenance Applies to: Model X Indoor Duct Furnace T N P M TY UA E RO LITY SYST RA DU CT WA R Q C U S TO M E R CQS STA RT-UP AG C S PROC CY E EN VERGE S N ON ! WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage. Be sure to read and understand the installation, operation, and service instructions in this manual.
Table of Contents 1.0 General................................................................. 2 1.1 Hazard Labels and Notices................................... 2 1.2 General Installation Information............................ 2 1.3 Warranty................................................................ 3 1.4 Installation Codes.................................................. 3 2.0 Furnace Location................................................. 3 2.1 General Recommendations...........................
1.3 Warranty Refer to the limited warranty form in the "Literature Bag". 1.4 Installation Codes WARRANTY: Warranty is void if...... a. Furnaces are used in atmospheres containing flammable vapors or atmospheres containing chlorinated or halogenated hydrocarbons or any contaminant (silicone, aluminium oxide, etc.) that adheres to the spark ignition flame sensing probe. b. Wiring is not in accordance with the diagram furnished with the heater. c.
2.0 Furnace Location (cont'd) 2.2 Combustion Air Requirements for a Heater Located in a Confined Space FIGURE 1 - Confined Space: A space whose volume is less than 50 cubic feet per 1000 BTUH of the installed appliance input rating These duct furnaces are designed to take combustion air from the space in which the furnace is installed. The air that enters into the combustion process is vented to the outdoors.
3.2 Preparing the Furnace for Installation Read this booklet and become familiar with the installation requirements of your particular furnace. If you do not have knowledge of local requirements, check with the local gas company or any other local agencies who might have requirements concerning this installation. Before beginning, make preparations for necessary supplies, tools, and manpower.
4.0 Dimensions and Clearances FIGURE 5 - Model X Dimensions - inches (mm) 4.
5.0 Suspending or Mounting the Furnace 5.1 Weight 5.2 Suspending the Furnace WARNING Unit must be supported level for proper operation. Do not place or add additional weight to the suspended unit. Before installing the furnace, check the supporting structure to be used to verify that it has sufficient load-carrying capacity to support the weight of the unit.
6.0 Mechanical (cont'd) 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 1.4). Gas supply piping installation should conform with good practice and with local codes. 6.1 Gas Piping and Pressures (cont'd) Capacity of Piping Cubic Feet per Hour based on 0.3" w.c. Pressure Drop Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft) Specific Gravity for Propane Gas -- 1.
6.1.2 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" procedure in Paragraph 9.0. The following warnings and instructions apply. WARNING Manifold gas pressure must never exceed 3.5" w.c. for natural gas and 10" w.c. for propane gas. CAUTION: DO NOT bottom out the gas valve regulator adjusting screw.
6.0 Mechanical (cont'd) 6.2 Venting (cont'd) Form I-X, P/N 150491 R10, Page 10 6.2.1 Venting Requirements (cont'd) 2. The unit is equipped with a built-in draft diverter, consequently an external draft diverter MUST NOT be installed in the vent connector or any internal alterations made. Do not install a manual damper or other fixed restriction in the vent connector. 3. Vent pipe should be a minimum of 26-gauge galvanized steel or other noncorrosive material.
Vertical Height of the Vent 6ft (1.8M) 8ft (2.4M) 10ft (3.0M) 15ft (4.6M) 20ft (6.1M) 30ft (9.1M) 6ft (1.8M) 8ft (2.4M) 10ft (3.0M) 15ft (4.6M) 20ft (6.1M) ft 5" M ft 6" M ft 7" M Vent Diameter 8" ft M ft 9" M ft 10" M ft Maximum Horizontal Run for Double-Wall Type B Connector and Double-Wall Type B Vent 6 1.8 6 1.8 6 1.8 6 1.8 6 1.8 8 2.4 8 2.4 16 4.9 16 4.9 16 4.9 10 3 16 4.9 20 6.1 20 6.1 20 6.1 N/A 16 4.9 16 4.9 30 9.1 30 9.1 30 9.1 20 6.1 30 9.1 30 9.1 30 9.1 30 9.1 20 6.1 40 12.
6.0 Mechanical (cont'd) 6.3 Duct Furnace Airflow (cont'd) 6.3.1 Pressure Drop and Temperature Rise by Size (cont'd) Model X - Pressure Drop Table for 80% Thermal Efficient Duct Furnace Size 75 100 125 150 175 200 225 250 300 350 400 Temp Rise CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. CFM P.D. 50°F 1105 0.2 1475 0.4 0.5 2210 0.4 2580 0.5 2945 3315 0.5 3685 0.4 4420 0.6 5160 0.7 5895 0.7 1840 0.
of air at the end of the duct. Or, baffles may be inserted between the blower and the heater to assure an even flow of air across the heat exchanger. WARNING The furnace MUST be installed on the positive pressure side of the aircirculating blower. See Hazard Levels, Page 2. 6.3.3 Constructing Bypass Duct When the CFM of air throughput is greater than desirable or permissible for the unit, a bypass duct may be constructed. Follow these instructions to determine the correct size of the bypass duct.
6.0 Mechanical (cont'd) 6.3.4 Duct Connections (cont'd) 6.3 Duct Furnace Airflow (cont'd) • Through Masonry Walls - No warm air duct should come in contact with masonry walls. Insulate around all air duct through masonry walls with not less than 1/2" (1" is recommended) of insulation. • Through Unheated Space - Insulate all exposed warm air ducts passing through an unheated space with at least 1/2" (1" is recommended) of insulation. • Duct Supports - Suspend all ducts securely from building members.
6.3.5 Discharge Air Sensor for Makeup Air Application Makeup air Option AG3 has a unit mounted ductstat with a capillary sensor that is factory-installed in the unit discharge (See Paragraph 8.4.3). Makeup air Options AG8, AG9, and AG15 require field installation of the sensor in the discharge ductwork. Option AG15 uses the box and sensor holder in FIGURE 15A. Options AG8 and AG9 include a sensor and mixing tube as illustrated in FIGURE 15B.
7.0 Electrical Supply and Wiring 7.1 General 7.2 Supply Voltage and Wiring Check the rating plate on the heater for the supply voltage and current requirements. Run a separate line voltage supply with fused disconnect switch directly from the main electrical panel to the furnace, making connection to leads in the junction box.
7.4 Typical Wiring Diagrams NOTE: If a wiring diagram is needed for a Model X with a match lit pilot (manufactured prior to 10/03), see APPENDIX, page 30. FIGURE 16 - Typical Wiring Diagram for Model X Furnace with Spark Pilot and Single-Stage Gas Valve OPERATING SEQUENCE NOTES - SET THERMOSTAT AT LOWEST SETTING. - TURN ON POWER, MAIN AND PILOT MANUAL GAS VALVES. - SET THERMOSTAT AT DESIRED TEMPERATURE. - THERMOSTAT CALLS FOR HEAT. - BLOWER MOTOR OPERATES FROM FAN TIME DELAY.
7.0 Electrical Supply and Wiring (cont'd) 7.4 Typical Wiring Diagrams (cont'd) FIGURE 17 - Wiring Diagram for Model X Furnace with Spark Pilot and Two-Stage Gas Valve OPERATING SEQUENCE - SET THERMOSTAT SWITCH AT "OFF" POSITION. - TURN ON POWER, MAIN AND PILOT MANUAL GAS VALVES. - SET THERMOSTAT SWITCH AT "AUTO" POSITION. - ON A CALL FOR HEAT, THE BLOWER MOTOR OPERATES FROM FAN TIME DELAY. - LOW STAGE OF THERMOSTAT CALLS FOR HEAT. - ENERGIZING THE IGNITION CONTROLLER AND PILOT GAS VALVE, LIGHTING PILOT.
8.0 Controls WARNING If you turn off the power supply, turn off the gas. See Hazard Levels, Page 2. 8.1 Fan Control 1. A fan control provides for the following control of the field-supplied blower. (a) After the gas valve opens, there is a time delay of blower operation to prevent the discharge of cold air. (b) Blower operation continues after the thermostat is satisfied as determined by the fan time delay. 2.
8.0 Controls (cont'd) 8.4 Gas Controls (cont'd) 8.4.3 Optional TwoStage Operation for Makeup Air (cont'd) Makeup air applications are usually adjusted to discharge an outlet air temperature between 65°F and 75°F. In all applications, the allowable temperature rise of the furnace in the installation dictates the limits of the ductstat temperature setting.
FIGURE 20B - Signal Conditioner in Option AG21 8.5 Pilot and Ignition Systems Computer Controlled Electronic Modulation between 50% and 100% Firing Rate (Option AG21) - With this option the furnace is equipped with a Maxitrol signal conditioner which operates much the same way as the amplifier above to control the regulator valve. The conditioner accepts an input signal of either 4-20 milliamps or 0-10 volts from a customer-supplied control device such as a computer.
8.0 Controls (cont'd) 8.5 Pilot and Ignition Systems (cont'd) NOTE: When checking for spark with the pilot burner assembly removed from the burner rack, the pilot assembly must be grounded to the heater for proper spark. FIGURE 23 - Spark Pilot -- Maintain a spark gap of 7/64" CAUTION: Due to high voltage on pilot spark wire and pilot electrode, do not touch when energized. See Hazard Levels, page 2.
When making the adjustment, close the air shutters no more than is necessary to eliminate the problem condition. DANGER: Failure to install and/or adjust air shutters according to directions could cause property damage, personal injury, and or death. 9.0 Commissioning 9.1 Check the installation prior to startup and Startup Check suspension. Unit must be secure and level. Be certain the electrical supply matches voltage rating of the furnace. (Refer to the rating plate.
9.0 Commissioning and Startup (cont'd) 9.3 Check installation after startup (cont'd) Close all panels tightly. With the heater on, check limit control by completely blocking off distribution air. The limit control should open within a few minutes, shutting off the gas supply to the main burners. Place "Literature Bag" containing Limited Warranty Card, this booklet, and any optional information in an accessible location near the heater.
10.2 Maintenance Procedures 10.2.1 Operating Gas Valve WARNING The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting to the unit to ensure positive closure. See Hazard Levels, page 2. NOTE: Operational pressure settings and instructions for checking pressure settings are in Paragraph 6.1. CAUTION: DO NOT bottom out the gas valve regulator adjusting screw.
10.0 Maintenance and Service (cont'd) 10.2.3 Cleaning Pilot and Main Burners 10.2.4 Cleaning the Heat Exchanger Outer Surfaces - To clean the outer surfaces (circulating air side) of the heat exchanger, gain access by removing the inspection panels in the ductwork or remove the ductwork. There are baffles between the heat exchanger tubes as shown in FIGURE 25. (NOTE: If the heater has been converted to high CFM (see APPENDIX, page 28, and Label on the unit), these baffles will have already been removed.
air hose, an 18-24" long, 1/2" diameter furnace brush (or heavy wire with steel wool securely attached), a flashlight, and a mirror are needed. The furnace has "V" shaped baffles in the top of each heat exchanger tube. Follow the instructions in FIGURE 26 to remove the "V" baffles when cleaning the inner surfaces of the heat exchanger. NOTE: Furnaces manufactured prior to 3/95 may not have heat exchanger "V" baffles.
APPENDIX Converting Model X Duct Furnace for Lower Temperature Rise and Higher CFM Application WARNING This conversion shall be done by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire, explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life.
Baffles (Remove with the supports as an assembly.) FIGURE 28 - Discharge Air End of the Heat Exchanger showing the Baffle Assembly to be Removed Remove the support bracket screws and slide the baffle assembly out of the heat exchanger. Replace the screws to plug the holes. Conversion is complete for Sizes 75-100; skip to Step 4. 3.
Wiring Diagrams for Match-Lit Pilot Discontinued in 2003 APPENDIX (cont'd) FIGURE 30 - For Reference Only, W. D. 113235 for Model X with Standard Match-Lit Pilot and Standard Single-Stage Gas Valve - APPLIES ONLY TO UNITS MANUFACTURED PRIOR TO 10/03.
INDEX A I B L Air Baffles 5 Duct Furnace Airflow 11 Air shutters 23 Heat Exchanger Baffles 28 Blocked Vent Switch 19 Blower Connections 12 Burner Air Adjustment 22 Burner Carryover 22 Burner Rack Removal 25 Bypass Duct 13 C Higher CFM 28 Chlorine 4 Clearances 6 Combustion Air Requirements 4 Commissioning and Startup 23, 24 Condensate Drain 5 Confined Space 4 Supply Piping Connection 8 Contact 32 Control Wiring 16 Conversion Label 28 Converting Model X for Lower Temperature Rise and Higher CFM Applica
INSTALLATION RECORD - to be completed by the installer: Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ ________________________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Company _______________