Installation, Operation, and Maintenance Gas Unit Heater Separated Combustion Indoor Gas-Fired Duct Furnace SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.
Warnings, Cautions and Notices Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at appropriate intervals throughout this manual. Warnings are provide to alert installing contractors to potential hazards that could result in death or personal injury. Cautions are designed to alert personnel to hazardous situations that could result in personal injury, while notices indicate a situation that could result in equipment or property-damage-only accidents.
Warnings, Cautions and Notices WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Introduction WARNING Safety Alert! You MUST follow all recommendations below. Failure to do so could result in death or serious injury. For Your Safety The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. If you smell gas: 1. Open windows. 2. Do not touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
Table of Contents Warnings, Cautions and Notices . . . . . . . . . . 2 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . .39 Model Number Descriptions . . . . . . . . . . . . . . 6 Indoor Gas Heating Units . . . . . . . . . . . . . . . 6 Horizontal Blower Assembly . . . . . . . . . . . . 6 General Information . . . . . . . . . . . . . . . . . . . . . 7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Safety Information . . . . . . . . . . . . .
Model Number Descriptions Indoor Gas Heating Units Digit 13 — Rooftop Heating Unit Motor Selection Note: All units are AGA approved. For CGA approved units, contact Air Handling Product Support.
General Information Description The duct furnace design is certified by ETL for use with natural and LP (propane) gases. ANSI and NFPA Standards as well as Canadian installation codes referred to in this manual are the ones that were applicable at the time that the design was certified. In addition, the duct furnace may be installed on the downstream side of a cooling coil, without need of a bypass duct.
General Information ground, the grounding means must be tested by a qualified electrician. • Do not insert fingers or foreign objects into the furnace or its air moving device. Do not block or tamper with the heater in any manner while in operation or just after it has been turned off, as some parts may be hot enough to cause injury. • This furnace is intended for general heating applications ONLY.
General Information Figure 2. Internal furnace assembly 1 2 3 1. Flue Collector 2. Heat Exchanger 3.
Unit Dimensions and Weights Table 1. Unit Size 100 125 150 175 200 225 250 300 350 400 Specification data: Separated Combustion Duct Furnace A in. (mm) 17-7/8 (454) 20-5/8 (524) 20-5/8 (524) 23-3/8 (594) 26-1/8 (664) 28-7/8 (733) 31-5/8 (803) 37-1/8 (943) 42-5/8 (1083) 48-1/8 (1222) B in. (mm) 15-1/2 (394) 18-1/4 (464) 18-1/4 (464) 21 (533) 23-3/4 (603) 26-1/2 (673) 29-1/4 (743) 34-3/4 (883) 40-1/4 (1022) 45-3/4 (1162) C D (Dia.)(a) in. (mm) in.
Unit Dimensions and Weights Table 2. Performance data Input MAX MIN Output MIN Temp. Rise P.D. MAX Temp. Rise P.D. Unit Size MBh (kW) MBh (kW) MBh (kW) cfm (m3/s) °F (°C) in. of H2O (kPa) cfm (m3/s) °F (°C) in. of H2O (kPa) 100 100 50 80 822 90 0.10 3,700 20 2.03 (29.3) (14.6) (23.4) (0.388) (50) (0.02) (1.746) (11) (0.51) 125 125 62.5 100 1,028 90 0.09 4,625 20 1.92 (36.6) (18.3) (29.3) (0.485) (50) (0.02) (2.183) (11) (0.48) 150 150 75 120 1,233 90 0.09 5,550 20 1.81 (43.9) (22.0) (35.1) (0.
Installation: Mechanical NOTICE: Equipment Damage! Do not install duct furnaces in corrosive or flammable atmospheres! Premature failure of, or severe damage to the unit could result! Avoid locations where extreme drafts can affect burner operation. Duct furnaces must not be installed in locations where air for combustion would contain chlorinated, halogenated or acidic vapors.
Installation: Mechanical Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials. Figure 5. Recommended design for field installation of ductwork for straight-through arrangement Figure 6. Recommended ductwork design for elbowed arrangement Accessibility The Separated Combustion Duct Furnace is a bottom service access type.
Installation: Mechanical bypass around the gas duct furnace to bypass a portion of the air. Suspension Nozzle Assembly Figure 7. Typical four (4) point duct suspending arrangement WARNING Heavy Objects! Ensure that all hardware used in the suspension of each duct furnace is capable of supporting the unit weight. Failure to do so could result in unit falling off its mounting location, which could result in death or serious injury.
Installation: Mechanical is facing the unit heater, attach the top panel (P/N 251-07942-00X) to the top bracket and the two (2) side panels. Note: The top panel must be attached so that the side with the larger holes is facing the unit heater; this is a requirement for later steps in this installation procedure. 6.
Installation: Piping Gas Piping WARNING Flammable Vapors! When connecting to existing gas lines be sure to valve off the gas supply ahead of connection point. To avoid explosion or possible fire, always purge all residual gas from piping before cutting into existing line or removing threaded fittings. Failure to remove all gas vapors could result in death or serious injury or equipment or property-only damage.
Installation: Piping Table 4. Gas pipe size(a) Nominal Internal 10 Iron Pipe Diameter, Size, in. in. (mm) (3.0) 1/2 Length of Pipe, ft (m) 20 (6.1) 30 40 50 60 70 80 90 100 125 150 175 200 (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0) 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35 (16) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99) 0.
Installation: Piping Pipe directly in to combination valve (see Figure 8, p. 18). 5. A 1/8 in. N.P.T. plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the appliance. 6. Provide a drip leg in the gas piping near the gas duct furnace. A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing.
Installation: Piping WARNING Risk of Fire and Carbon Monoxide Poisoning with Improper Piping! Never use pipe of a diameter other than that specified in Table 1, p. 10 (“D” dia. flue opening)! To prevent pipe from melting and introducing exhaust fumes into the air supply, never use PVC, ABS or any other nonmetallic pipe for venting! Failure to follow these recommendations could result in death or serious injury or equipment damage. 1.
Installation: Piping 4. Any run of single wall vent pipe passing through an unheated space must be insulated with an insulation suitable to 550°F (288°C). 5. The combustion and exhaust vent air systems must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21 mm/ m) toward the terminal cap to facilitate drainage (see Figure 11, p. 21). Vertical vent pipes should be arranged as depicted in Figure 9, p. 21. 6.
Installation: Piping Figure 9. Vertical intake/vent installation Figure 12. Horizontal vent installation Installation: Concentric Vent Terminal WARNING Hazardous Service Procedures! Figure 10. Vertical vent installation The maintenance and troubleshooting procedures recommended in this manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures.
Installation: Piping Figure 13. Horizontal concentric venting Size pipes according to Table 1, p. 10. Insert the pipes through the wall and fasten the adapter box in place. Flash and/or caulk 8-inch pipe on outside wall (see Figure 14, p. 22, Step 3). Install the inlet air screen on the 8-inch pipe and fasten with sheet metal screws. Install the flue terminal on the 5-inch pipe and fasten in place (see Figure 14, p. 22, Step 4). Figure 14.
Installation: Piping Figure 15. Vertical concentric venting Figure 16. Vertical concentric venting—installation Size pipes according to Table 1, p. 10. Cut a hole through the roof for an 8-inch combustion air pipe. Fasten a length of 5-inch pipe to the exhaust connection of the concentric adapter with sheet metal screws. Use at least three screws per joint. Seal all joints with high temperature silicone sealant.
Installation: Electrical Electrical Connections WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Installation: Electrical firing. This setpoint should be measured for the best results. Use the recommended ranges as a guide. If further information is needed, consult your thermostat manufacturer’s instructions. Recommended Heat Anticipator Setting Ranges: 25 ft. (7.6 m) T’stat Wiring 0.85 to 0.90 A 50 ft. (15.2 m) T’stat Wiring 0.90 to 1.1 A Max. Setting on T’stat Fan Time Delay Control Leads from the fan time delay controls are factory wired to the junction box.
Start-Up Operation Explanation of Controls WARNING Carbon Monoxide! Never operate duct furnaces if the power venter is not operable. Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to follow these recommendations could result in death or serious injury due to Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or flu-like symptoms). 1.
Start-Up Figure 18. Burner components (intermittent pilot ignition) Burner Drawer Common Parts: 1. 2. 3. 4. 5. 6. 7. Main Burners Burner Manifold Air Shutters Burner Springs Main Burner Orifice Transformer Pilot Tubing 1 Controls: 8A. Main Gas Valve (Honeywell) 8B. Main Gas Valve (White-Rodgers) 9. Honeywell Ignitor 10. Honeywell Pilot Burner 11. Honeywell Pilot Orifice 12. Honeywell Electrode/Sensor Lead 13.
Start-Up Gas Input Rate pressure must be regulated to attain this manifold operating pressure. NOTICE: Table 7. Main burner orifice schedule(a) Overfiring! Type of Gas Natural Never overfire the duct furnace, as this could cause unsatisfactory operation, or shorten the life of the heater. Heating Value 1075 BTU/ft3 (40.1 MJ/m3) 2500 BTU/ft3 (93.1 MJ/m3) Check the gas input rate as follows: 1. Turn off all gas appliances that utilize gas through the same gas meter as the unit heater. 2.
Start-Up Figure 19. Main burner flames NORMAL (HARD FLAME) YELLOW TIPPING (MARGINAL) LIFTING (TOO MUCH AIR) YELLOW FLAME (TOO LITTLE AIR) Pilot Adjustment 1. Remove the pilot adjustment cap. 2. Adjust the pilot screw to provide a properly sized flame. 3. A proper pilot flame is a soft steady flame that envelops 3/8- to 1/2-inch (9.5 to 12.7 mm) of the flame sensor. 4. Replace the pilot adjustment cap.
Start-Up Gas Equipment Start-Up Customer _____________________________________________ Job Name & Number _________________________ Pre-Inspection Information with Power and Gas Off Type of Equip: Duct Furnace Serial Number: _________________________ Model Number: _____________________________ Name Plate Voltage: ____________________ Name Plate Amperage: ______________________ Type of Gas: Tank Capacity: Natural LP _______ lb Rating: _______ kg _______ Btu @ ____ °F ________ kW @ ____ °C
Maintenance WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Maintenance Figure 20. Power venter assembly Ref. No. Description Ref. No. Description 1 Blower Housing Assembly 15 Snap Bushing 2 Speed Nut 16 Relay (Motor) 3 Motor 17 Draftor Stack Assembly 4 Washer, Plain 18 Tubing (Aluminum) Formation 5 Plate Adapter 19 Male Connector 6 Blower Wheel (see Note 1) 20 Locknut 7 Mounting Bracket (Pressure Switch) 21 Hole Plug 8 Mounting Bracket (Junction Box) 22 Pressure Switch Cover 9 Screw, S.T.
Maintenance Installation Instructions for Field Replacement of Power Venter Motor Important: This replacement must be performed only by a qualified technician. Note: All hardware (screws, nuts, washers) that will be removed from the unit will be reused for this motor replacement. DO NOT LOSE ANY OF THESE PARTS. Figure 21. Identification of parts Ref. No. Tools and Parts Needed Wire Stripper and Crimper; Slotted Head and #2 Phillips Head Screwdriver; 3/8-in. Wrench; 1/8-in.
Maintenance How to Order Replacement Parts Please send the following information to your local Parts center; If further assistance is needed, contact the manufacturer’s customer service department. • Model number • Serial Number • Part description and Number as shown in the Replacement Parts Catalog.
Diagnostics Troubleshooting WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Diagnostics Table 8. Troubleshooting guide (continued) Symptoms Possible Cause(s) Corrective Action F. 1. Shut off gas immediately! 1. Inspect all gas piping and repair. 2. Blocked heat exchanger/venting. 2. Clean heat exchanger/flue. 3. Drafts around heater. 3. Eliminate drafts. Refer to “Installation: Mechanical,” p. 12. 4. Negative pressure in building. 4. See “Installation: Piping,” p. 16. Gas Odor. G. Delayed ignition. H. Failure to ignite. 5. Blocked draft hood. 5.
Diagnostics Table 8. Troubleshooting guide (continued) Symptoms N. Power venter will not run. O. Power venter motor turns on and off while burners are operating. P. Power venter motor will not stop. Q. Not enough heat. R. Too much heat. Possible Cause(s) Corrective Action 2. 2. Increase size of pilot flame. Refer to “Operation,” p. 26. Pilot adjustment screw turned too low on combination main gas valve. 3. Air in gas line. 3. Purge air from line. 4. Incorrect lighting procedure. 4.
Diagnostics Table 8. Troubleshooting guide (continued) Symptoms Possible Cause(s) U. No Spark. 1. Thermostat not calling for heat. 1. Close thermostat contacts. 2. No low voltage. 2. Check for 24V across 24V terminals of S8600. 3. Spark gap closed or too wide. 3. Set gap to 0.1. 4. Broken or cracked ceramic on spark electrode. 4. Replace pilot assembly. 1. Loose S8600 connections. 1. Check all connections, term. PV feeds 24V to pilot valve. 2. Improper gas pressure. 2.
Wiring Diagrams Figure 22.
Wiring Diagrams Figure 23.
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