COLEMAN Heater, Kerosene Manual L0601037

User Manual: COLEMAN COLEMAN Heater, Kerosene Manual COLEMAN Heater, Kerosene Owner's Manual, COLEMAN Heater, Kerosene installation guides

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HIGH EFFICIENCY SEALED COMBUSTION
DRUM HEAT EXCHANGER SERIES
MODEL: DFAA/DFAH
(Oil and Gas Conversion
Single Stage Downflow

ISO 9001
Ce4_fied Quality
Managemen_ System

Burner/
Only)

For Installation

66 - 84 MBH INPUT
(19.34 - 24.62 KW) INPUT

1.
2.

Manufactured
Recreational

Modular

In:
(Mobile)
Homes
Vehicles
& Park Models

Homes

& Buildings

LIST OF SECTIONS
SAFETY
................................................
DUCTWORK
............................................
FILTERS
..............................................
OIL PIPING
............................................
ELECTRICAL
POWER
...................................
VENT/COMBUSTION
AIR SYSTEM
.........................

1
5
10
11
13
14

SAFETY
CONTROLS
....................................
START-UP
AND ADJUSTMENTS
...........................
WIRING
DIAGRAM
- OIL-FIRED
FURNACE
..................
GAS GUN BURNER
......................................
START-UP
AND ADJUSTMENTS
...........................
WIRING
DIAGRAM
- GAS CONVERSION
BURNER
............

22
23
27
29
33
38

LIST OF FIGURES
Label Location
...................................................
Dimensions ......................................................
Air Distribution Systems ............................................
Closet To Door Clearance - 6" or Greater ..............................
Furnace To Closet Door Clearance - 1" To 6"
..........................
Furnace To Closet Door Clearance - Less Than 1" . ......................
Duct Connector Dimensions .........................................
Recommended Floor Cut-out ........................................
Duct Connector Depth .............................................
Duct Connector Screw Attachment
...................................
Duct Connector Tab Attachment
.....................................
Anti-Backftow Damper .............................................
Installation of Furnace .............................................
Floor Installation .................................................
Furnace Air Filters ...............................................
Oil Pump .......................................................
One-Pipe System ................................................
Two-Pipe System ................................................
Solenoid Wiring ..................................................
Line Wiring Connections ...........................................
Wiring for Heat Only Thermostat
....................................
Wiring for Electronic Heat-Cool Thermostat ............................
Wiring for Standard Heat-Cool Thermostat
............................

4
5
7
7
7
7
8
8
8
8
9
9
9
10
11
12
13
13
13
14
14
14
14

Wiring for Btend Air Accessory
.....................................
Elbow Assembly
................................................
Combustion Air Inlet Pipe .........................................
Combustion Air Inlet Pipe Alternate ..................................
Flue Shield Installation ............................................
Roof Jack Attachment to Furnace ...................................
Standard Roof Jack ..............................................
Roof Jack With Removable Crowns .................................
Installing Roof Jack Extension ......................................
Ceiling Ring ....................................................
Home Layout ...................................................
Electrode Settings ...............................................
Oit Pump ......................................................
Wiring Diagram for DFAA - Oil-Fired Furnace ..........................
Wiring Diagram for DFAH - Oil Furnace ..............................
Gas Piping .....................................................
ManuaI Shut-off Valve/Gas Piping ...................................
Proper Piping Practice ............................................
Gas VaIve .....................................................
Reading Gas Pressure ...........................................
Electrode Orientation and Gap .....................................
Wiring Diagram for DFAA - Gas Conversion Burner .....................
Wiring Diagram for DFAH - Gas Gun ................................

14
15
16
16
16
16
18
19
20
20
21
23
24
27
28
29
30
30
35
36
37
38
39

LIST OF TABLES
Unit Clearances to Combustibles
.....................................
Minimum Duct Sizing For Proper Airflow
...............................
Round Duct Size .................................................
Externat Static Pressure Range ......................................
Filter Sizes .....................................................
Burner Specifications
.............................................
Burner Rating at Elevation Above Sea Level, gph (I/m) ...................
Ratings & PhysicaI / Electrical Data ..................................
Roof Jack Options
...............................................
Cad CelI Resistance When Sensing Ftame ............................

SECTION

4
6
6
9
10
11
12
13
17
22

Timings and Settings .............................................
Burner Specifications .............................................
Filter Performance - Pressure Drop Inches W.C and (kPa) ...............
Blower Performance CFM .........................................
Replacement Parts - Non Electrical ..................................
Gas Line Piping Size and Length ...................................
Length of Standard Pipe Threads in Inches (ram) .......................
High Altitude Duration Chart .......................................
Gas Burner Settings
.............................................
Inlet Gas Pressure Range .........................................
Nominal Manifold Pressure ........................................

22
23
25
25
26
30
30
32
32
35
35

h SAFETY

This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular
WARNING, or CAUTION.

attention to the signal words DANGER,

DANGER indicates an imminently
hazardous
avoided will result in death or serious injury.

situation, which, if not

WARNING indicates a potentially
hazardous situation, which,
avoided could result in death or serious injury.
CAUTION indicates
avoided may result

,WARNING
Improper
installation
may create
the product could cause personal

a condition
where
injury or property

the operation
damage.

Improper
llTstallation,
adjustment,
alteration,
service
or maintenance can cause injury or property
damage.
Refer to this manual
for assistance
or for additional
information,
consult a qualified
contractor,

installer

or service

agency.

if not

a potentially hazardous situation, which, if not
in minor or moderate iniurv, It is also used to

alert against unsafe practices and hazards involving only property damage.

107272-UIM-A-0905

107272-UIM-A-0905
SPECIFIC
1.

SAFETY

RULES

AND

PRECAUTIONS

The temperature of the return air to the furnace must not be
less than 55 ° F (13 ° C), with no evening setback or furnace
shutdown, to prevent condensation
in the primary heat
exchangers.

The air temperature rise must be within the stated rise range
as indicated on the furnace rating plate, and the firing input
rate must be set to the unit nameplate value.

The external static pressure of the air distribution system
ductwork must be set for heating operation to be at least 0.12
(.03 kPA) to 0.30 (0.7 kPA) inches water column, based on
the input rate of the furnace, with the lower value for input
rates at 66,000 btu/hr and the upper value for units with input
rates at 84,000 btu/hr.

The furnace and ductwork should be thoroughly and completely cleaned prior to occupancy of the dwelling to insure
the proper operation of the furnace and to avoid potential
health concerns.

U.S.....No. 1 or No. 2 heating oil only (ASTM D396),
CANADA.....No.
1 stove oil or No. 2 furnace oil only are approved
for use and can be burned in this furnace. Refer to the furnace rating plate or SECTION IV of these instructions.

Install this furnace only in a location and position as specified
SECTION I of these instructions.

An oil-fired furnace for installation in a residential garage must be
installed as specified in SECTION I of these instructions.

Combustion products must be discharged outdoors. The Roof
Jack vent system is the only approved vent system that can be
installed on this furnace. Install as specified in SECTION VI of
these instructions.

FIRE OR EXPLOSION

HAZARD

Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
Read aft instructions before proceeding. Follow al! instructions completeljz Failure to follow these instructions could result in equipment
malfunction, causing severe personal injury, death, or substantial
property damage.

In Canada refer to the Oil-fired Central Furnace Installation code,
CAN B40.9.3. When installed in a Manufactured (Mobile) Home,
combustion air shall not be supplied from occupied spaces.

10.

The size of the unit should be based on an acceptable heat loss
calculation for the structure. ACCA, Manual J or other approved
methods may be used.

Test for Ieaks in the oil Iine as specified
instructions.

in SECTION VI!I of these

11.

Always install the furnace to operate within the furnace's intended
temperature rise range. Only connect the furnace to a duct system
which has an external static pressure within the allowable range,
as specified on the furnace rating plate.

Manufactured (Mobile) Home and Modular Home Installation:
This appliance must be installed in a (sealed combustion) configuration using a roof jack vent system. A roof jack is the only
approved vent system that can be used to vent this appliance.

12.

Modular Home Definition:
Factory-built home constructed to the
state, local, or regional code where the house will be located. The
home is transported in one or more modules and joined at the
home site.

13.

Manufactured
(Mobile) Home Definition: Factory-built home
constructed, transported and installed under the federal building
code administered by the U.S. Department of Housing and Urban
Development (HUD Code), rather than to building codes at their
destination. The house is built, transported and installed on a nonremovable chassis.

14.

This furnace is approved for installation
vehicles.

The return air duct
turer. This furnace
tem referred to as
specified in these
or regional codes.

It is permitted to use the furnace for heating of buildings or structures under construction. Installation must comply with all manufacturer's installation instructions including:

in trailers or recreational

•

Proper vent installation;

•
•

Furnace operating under thermostatic control;
Return air filter door must be sealed to the furnace;

•
•

Air filters in place;
Set furnace input rate and temperature rise per rating plate
marking;
Means for providing outdoor air required for combustion;

•

Return air temperature
80°F (27°C);

Never attempt to alter or modify this furnace or any of its components.

•

The air filter must be replaced or thoroughly cleaned upon substantial completion of the construction process;

•

Clean furnace, duct work and components upon substantial
completion of the construction process, and verify furnace
operating conditions including ignition, input rate, temperature
rise and venting, according to the manufacturer's instructions.

Never attempt to repair damaged or inoperable components.
Such action could cause unsafe operation, explosion, fire and/
or asphyxiation.
ff a malfunction has occurred, or ff you fee! that the furnace is
not operating as it should, contact a qualified service agency or
oil supplier for assistance.

•

The following

system is not required by the furnace manufacutilizes a sealed combustion air and vent sysa roof jack. The Roof Jack must be installed as
instructions and must conform with state, local,

requirements

maintained

between

SAFETY

55°F (13°C) and

to be met:

Clean, outside combustion air is provided to the furnace to
minimize the impact of corrosive adhesives, sealants, and
other construction materials. Drywall dust is a major concern
during construction, which can be pulled into the combustion
air path, leading to plugged heat exchangers, burners, and
inducer assemblies.

Filter must be installed in the furnace as specified in the
installation instructions, and must be replaced or thoroughly
cleaned prior to occupancy of the home. Again, drywall dust
is the key issue, as that dust can be pulled into the circulating
blower motor, plugging the motor vents, coating the rotors
and stators, etc. which can lead to a potential fire hazard.

•

REQUIREMENTS

•

A manufactured (mobile) home installation must conform with the
Manufactured Home Construction and Safety Standard, Title 24
CFR, Part 3280, Federal Manufactured Home Construction &
Safety Standard (H.U.D., Title 24, Part 3280) or when such standard is not applicable, the standard for Manufactured
Home
Installations (Manufactured Home Sites, Communities, and Setups) NFPA 31 Installation of Oil-Burning Equipment, CANICSA
B139 Installation Codes). This furnace has been certified to the
latest edition of standard UL 727 Standard for Safety for Oil-Burning Equipment, and for Oil-Fired Central Furnaces (Latest Edition), CSA B140.!0 (Latest Edition), and all local codes and
ordinances.

•

Refer to the unit rating plate for the furnace model number, and
then see the dimensions page of these instructions for return air
door dimensions in Figure 2. The filter(s) must be installed
according to the instructions.

Unitary

Products

Group

107272-UIM-A-0905
•

Provide clearances from combustible
Furnace Locations and Clearances.

•

Provide clearances for servicing, ensuring that service access is
allowed for both the burners and blower.

•

These models are ETL listed and approved for installation into a
Modular Home or a Manufactured (Mobile) Home.
Failure to carefully read and follow all instructions
in this
manual can result in furnace malfunction,
death, personal
injury and/or property damage.

•

materials

as listed under

•

Furnaces for installation on combustible flooring shall net be
installed directly on carpeting, tile or other combustible material
other than wood flooring.

•

Check the rating plate and power supply to be sure that the electrical characteristics match. All models use nominal !15 VAC, 1
Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLIANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.

•

Furnace shall be installed so the electrical
tected from water.

components

•

Installing and servicing heating equipment can be hazardous due
to the electrical components and the oil fired components. Only
trained and qualified personnel should install, repair, or service oil
heating equipment. Untrained service personnel can perform
basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precautions in the manuals and on the labels attached to the unit and

SPECIAL

REQIREMENTS

Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
When outdoor air is used for combustion, the combustion air intake duct
system termination must be located external to the building and in an
area where there will be no exposure to the substances listed above.

The furnace area must not be used as a broom closet or for any
other storage purposes, as a fire hazard may be created. Never
store items, such as the following, on, near or in contact with the
furnace.
1. Spray or aerosol cans, rags, brooms,
cleaners or other cleaning tools.
2. Soap powders, bleaches,
pounds; plastic items or

waxes

dust mops, vacuum

or other

cleaning
lighter

com-

fluid, dry

5. Paper bags, boxes or other paper products

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances these
instructions exceed certain local codes and ordinances,
especially
those who have not kept up with changing Modular Home and Manufactured (Mobile) Home construction practices. These instructions are
required as a minimum for a safe installation.
AIR

Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.

4. Paint thinners and other painting compounds.

This equipment must be installed, adjusted, and started only by a
qualified service agency - an individual or agency, licensed and
experienced with all codes and ordinances, who is responsible for
the installation and adjustment of the equipmenL The installation
must comply with all local codes and ordinances and with the latest
revision of the National Fire Protection Association
Standard
NFPA31 (or CSA B139).

(LIST

Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride

3. Containers, gasoline, kerosene, cigarette
cleaning fluids or other volatile fluid.

kDANGER

COMBUSTION

Chlorine based swimming pool chemicals

are pro-

other safety precautions that may apply.
NOTICE

Permanent wave solutions
Chlorinated waxes and cleaners

Never operate the furnace with the blower door removed. To
do so could result in serious personal injury and/or equipment
damage.
INSPECTION
As soon as the furnace and/or accessories are received, it should be
inspected for damage during transit. If damage is evident, the extent of
the damage should be noted on the carrieCs freight bill. A separate
request for inspection by the carrier's agent should be made in writing.
Also, before installation, the furnace and/or accessories should be
checked for screws or bolts which have loosened in transit, or shipping
and spacer brackets that need to be removed.

QUALITY

OF CONTAMINANTS)

The furnace will require OUTDOOR AIR for combustion
nace is located in any of the following environments.
Restricted Environments

when the fur-

CONCEALED DAMAGE - If you discover damage to the burner or
controls during unpacking, notify carrier at once and file the appropriate claim.

Commercial buildings
Buildings with indoor pools
Laundry rooms
Hobby or craft rooms
Near chemical storage areas
Chemical exposure
The furnace will require OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the following substances and / or chemicals.

Unitary

Products

Group

WHEN CONTACTING BECKETT FOR SERVICE INFORMATION Please record the burner serial number (and have available when
calling or writing). You will find the serial number on the Underwriters Laboratories label, located on the left rear of the burner, or
cover mounting plate. See Figure !.

107272-UIM-A-0905

General Model
Information

Model 'APEVC"

MFR'S SETTINGS

Series Oil Burner

R. W, Beckett
ManufactureCs

sE_L,,L
rJUMS_

Serial Number
including Date Code

02092349038

,,J,_, s

=VC201

Rating information

Approval Agency
Symbols

R, W, Beckett Specification
Number and Revision

R00

02g%_23 49038

LIS! ED

o,,, s, o-_/

Can be Customized by
Individual Specification

RW BoXlike11
Corp

Primary Group
and Fuet Oii

Settings

,_/s

State and Locai Approvals

b,,
)

FIGURE 1: Label Location
CHECK
•

CERTIFICATIONS

/ APPROVALS

Do not allow return air temperature to be below 550 F (13 ° C) for
extended periods. To do so may cause condensation to occur in
the main heat exchanger, leading to premature heat exchanger
failure.

Underwriters Laboratories has certified this burner to comply with
ANSI/UL 296 and has listed it for use with #1 or #2 fuel oil as
specifed in ASTM D396. Low sulfur #1 and #2 fuel oils reduce
heat exchanger deposits with all burners compared to the standard fuels. Reduced deposits may extend the service interval for
cleaning and improve the efficiency of the appliance over time.
Low sulfur fuels reduce particulate and oxides of nitrogen emissions as well. The Oil heat Manufacturers' Association recom-

Installation in an ambient below 32°F (0.0 ° C) could create a hazard, resulting in damage, injury or death.

mends these fuels as the preferred fuels for this burner.
•

State and local approvals are shown on burner rating label (See
Figure 1).

•

All oil burners must be installed in accordance with the regulations of the latest revision of the National Fire Protection Associa-

tion Standard NFPA 31 and in complete accordance with all local
codes and authorities having jurisdiction. Regulation of these
authorities take precedence over the general instructions provided in this installation manual.
FURNACE
The furnace

LOCATION

AND

shall be located

Clearances

Twenty-four (24) inches (61 cm) between the front of the furnace
and an adjacent wall or another appliance, when access is
required for servicing and cleaning.

Twenty-four (24) inches (61 cm) at the side where access is
required for passage to the front when servicing or for inspection
or replacement of flue/vent connections.

auidelines:

The furnace should be located where the roof jack can be installed
without major modifications to the roof of the structure.

As centralized

Where there is access to fresh air particularly
accessory will be installed.

Where it will not interfere with proper air circulation in the confined
space.

Where the outdoor section of the roof jack wiII not be blocked or
restricted. Refer to "VENT CLEARANCES" located in SECTION Vl
of these instructions. These minimum clearances must be main-

with the air distribution

as possible.
when the blend air

In all cases, accessibility clearances shall take precedence over clearances for combustible materials where accessibility clearances are
greater.

kWARNING
Check the rating plate and power supply to be sure that the electrical characteristics
match. Al! models use nominal !15 VAC, 1
Phase 60Hz power supply
Furnace shall be installed so the electrical components are protected from water.

tained throughout the installation.
6.

Where the unit will be installed in a level position with no more than
1/4" (0.64 cm) slope side-to-side and front-to-back to provide a
proper roof jack connection and seal.

Installation
1.

in freezina

Furnace

temoeratures:

shall be installed

Installation
1.

in an area where ventilation

facilities

provide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures below 32 ° F (0 ° C) may
result in the vent temperature falling below 260 ° F (127 ° C) at any
point in the vent pipe. Vent temperatures below 260 ° F (127 o C)
will cause the flue products in the vent pipe to condense causing
the vent pipe to deteriorate rapidly.
TABLE 1: Unit Clearances to Combustibles

APPLICATION
CLOSET
ALCOVE

for access:

Ample clearances should be provided to permit easy access to the unit.
The following minimum clearances are recommended:

CLEARANCES

usina the followina

If this furnace is installed in an unconditioned space and an
extended power failure occurs, there will be potential damage to
the internal components. Following a power failure situation, do
not operate the unit until inspection and repairs are performed.

in a residential

aaraoe:

An oil-fired furnace for installation in a residential garage must be
installed so the burner(s) and the ignition source are located not
less than !8 inches (46 cm) above the floor, and the furnace must
be located or protected to avoid physical damage by vehicles.

TOP

FRONT

BACK

SIDES

AIR INLET
PIPING

In. (cm)

In, (cm)

In. (cm)

2 (5.08)
2 (5.08)

6 (15.24)
24 (60.96)

0 (0.0)
0 (0.0)

0 (0.0)
o (0.0)

3 (7.62)
3 (7.62)

0 (0.0)
0 (o.o)

ROOFJACK

DUCT 1

FLOOR/BOTTOM

0 (0.0)
0 (0.0)

1. Approved Duct Connector must be used. Refer to Section II - Ductwork.

Unitary

Products

Group

107272-UIM-A-0905

E
_'F
//

I
I inches

59-1/2"

B-

76 '_

193,0

24.3/4"

62.9

23"

58.4

19-1/2"

49.5

9-3/4 '_

24.8

12"

30.5

G3" Etx.
No Coil

Static

c.m.
151.0

Duct

- Std.

Pressure

Blower

- High

-Speed

DFAH Series

DFAA Series

FIGURE 2: Dimensions

SECTION
DUCTWORK

Ih DUCTWORK
GENERAL

The duct system's

INFORMATION

design and installation

must:

Handle an air volume appropriate for the served space and within
the operating parameters of the furnace specifications.

Be installed in accordance with standards of NFPA (National Fire
Protection Association) as outlined in NFPA pamphlets 90A and
90B (latest editions), in Canada CANiCGA-B149.1-00,
Installation
Code for Oil-Burning Equipment, or applicable national, provincial,
or state, and local fire and safety codes.

For Manufactured (Mobile) Home and Modular Home Return
Duct System Installations:
A return air duct and the return air plenum cannot be installed on
this furnace. The return air is drawn through the louvers on the
blower door. The vent system is a Sealed Combustion Direct Roof
Jack Vent System. This is the ONLY vent system approved for use
on this furnace.

Complete a path for heated or cooled air to circulate through the
air conditioning and heating equipment and from the conditioned
space.

Consideration should be given to the heating capacity required
and also to the air quantity (CFM) required. These factors can be
determined by calculating the heat loss and heat gain of the home
or structure. If these calculations are not performed and the furnace is over-sized, the following may result:
a.

Short cycling of the furnace.

Wide temperature

Reduced overall operating efficiency of the furnace.

fluctuations

from the thermostat setting.

When the furnace is used in conjunction with a cooling coil, the coil
must be installed parallel with, or in the supply air side of the furnace to
avoid condensation in the primary heat exchanger. When a parallel flow
arrangement is used, dampers or other means used to control airflow
must be adequate to prevent chilled air from entering the furnace. If
manually operated, the damper must be equipped with means to prevent the furnace or the air conditioner from operating unless the damper
is in full heat or cool position.

The duct system must be properly sized to obtain the correct airflow
for the furnace size that is being installed.
Refer to Table 8 and the fumace rating plate for the correct rise
range and Table 4 for static pressures.
If the ducts are undersized, the result wil! be high duct static pressures and/or high temperature rises which can result in a heat
exchanger OVERHEATING CONDITION. This condition can result
in premature heat exchanger failure, which can result in personal
injury, property damage, or death.

HAZARD OF ASPHYXIATION,
FLOOR OPENING

DO NOT COVER

OR RESTRICT

The duct system is a very important part of the installation. If the duct
system is improperly
sized, the furnace will not operate properly.
The ducts attached to the furnace duct connector should be of sufficient
size so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.
IMPORTANT: Fabricate and install an inspection door in the plenum
base below the unit to allow an annual inspection of the heat exchangers. The inspection door can be fabricated by following method.
1.

Cut a rectangular opening in the plenum base.

A Sheet metal plate can be made that completely
ing in the base.

The plate must be secured with screws.

This plate must be sealed to prevent leaks.

covers the open-

Table 2 is a guide for determining whether the rectangular duct system
that the furnace is being connected to, is of sufficient size for proper furnace operation.

Unitary

Products

Group

107272-UIM-A-0905

Use the example below to help you in calculating the duct area to determine whether the ducts have sufficient area so that the furnace operates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
Example: The furnace input is 80,000 BTUH, (23.4 kW) 1,200 CFM
(34.0 m3). The recommended duct area is 280 inch 2 (!, there are two 8
in x 14 in (20.3 cm x 35.6 cm) rectangular ducts attached to the plenum
and there are two 7 inch (722 cm 2) round ducts attached to the furnace.
1.

Take 8 in x 14 in (20.3 cm x 35.6 cm), which equals 112 inch 2 X 2
(35.6 cm x 2), which equals 224 inch 2 (1445 cm 2) then go to round
duct size located in Table 3.

The square inch area for 7 inch (!7.8 cm) round pipe is 38.4, multiply by 2 for two round ducts which equals 76.8 inch 2 (495 cm2).

Then take the 224 inch 2 (1445 cm2) from the rectangular duct and
add it to the 76.8 inch 2 (495 cm 2) of round duct. The total square
inch of duct attached to the furnace plenum is 300.8 inch 2 (1,940
cm2). This exceeds the recommended 280 inch 2 (1,806 cm 2) of
duct.

In this example, the duct system attached to the plenum has a sufficient
area so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.

TABLE 2: Minimum Duct Sizing For Proper Airflow
Input
BTU/H

(kW)

Airflow
CFM(m

Return
_)

Rectangular

In = (cm =)

in. x in.(cm

Round

x cm)

in. (cm)

Supply

dia

In 2 (cm 2)

66000

(19.34)

1,050 (29.73)

280 (71!)

14 x 20 (35.6

x 50.8)

18(45.7)

216(549)

84000

(24.62)

1,250 (35.40)

360 (914)

18 x 20 (45.7

x 50.8)

22(55.8)

280(7!1

NOTE: This chart does not replace proper duct sizing calculations
and static pressures.

)

Rectangular

in. x in. (cm x cm)

Round
in. (cm)

2
dia.

12 x 18 (30.5

x 45.7)

!6 (40.6)

14 x 20 (35.6

x 50.8)

18 (45.7)

or take into account static pressure drop for rue length and fittings. Watch out for the temperature

rise

1. Maximum return air velocity in rigid duct @ 700 feet per minute (1982 m3 / minute).
2. Example return main trunk duct minimum dimensions.
3. Maximum supply air veIocity in rigid duct @ 900 feet per minute (2549 ms / minute).

DUCKWORK

TABLE 3: Round Duct Size
Round Duct Size

Calculated

Area For Each Round Duct Size

Air Distribution

Systems

Inches (cm)

Sq. Inch (cm 2)

5 (13)

19.8 (126)

For proper air distribution, the supply duct system shaII be designed so
that the static pressure does not exceed the listed static pressure rating
on the furnace rating plate.

6 (15)

28.2 (!82)

Three typical distribution

7 (18)

38.4 (248)

8 (20)

50.2 (324)

9 (23)

63.6 (410)

10 (25)

78.5 (5O6)

11 (28)

95.0 (613)

12 (30)

113.1 (730)

13 (33)

!32.7 (856)

14 (36)

!53.9 (993)

in Figure 3.

The Air Temperature Rise is to be adjusted to obtain a temperature
within the range(s) specified on the furnace rating plate.
DUCT

DESIGN

rise

- CANADA

Supply duct design shall be in accordance with the latest HRA Digest,
the ASHRAE Handbook Fundamentals, or other good engineering principles.

The Air Temperature Rise is determined by subtracting the Return
Air Temperature Reading from the Supply Air Temperature Reading.

The External Static Pressure is determined
Static Pressure reading.

by the Supply

systems are illustrated

Location, size and number of registers should be selected on the basis
of best air distribution and floor plan of the home.

Duct

TABLES 2 and 3 are to be used as a guide only to help the installer
determine if the duct sizes are large enough to obtain the proper air flow
(CFM) through the furnace. TABLES 2 and 3 ARE NOT to be used to
design ductwork for the building where the furnace is being installed.
There are several variables associated with proper duct sizing that are
not included in the tables. To properly design the ductwork for the building, Refer to the ASHRAE Fundamentals
Handbook, Chapter on
"DUCT DESIGN" or a company that specializes in Residential and Modular Home duct designs.

NOTE: Refer to HRA Digest Residential Air System Design Manual,
Sections 5 and 6, the requirements of which are summarized as follows:
1.

The kilowatt output of each duct register shall not exceed 2.35 kW.

The furnace output should not be more than 20% greater than the
calculated heat loss of the home. If a larger furnace is used, the
duct system shall be capable of the increased air volumes necessary to maintain a maximum air temperature
air passes over the furnace heat exchanger.

The supply air temperature MUST NEVER exceed the Maximum
Supply Air Temperature, specified on the nameplate.
Operating the furnace above the maximum supply air temperature
will cause the heat exchanger to overheat, causing premature heat
exchanger failure. Improper duct sizing, dirty air filters, incorrect oil
pump pressure, incorrect oil orifice and/or a faulty limit switch can
cause the furnace to operate above the maximum supply air temperature. Refer to SECTIONS II, III and VIII for additional information on correcting the problem.

rise of 50o C as the

At least one warm air supply outlet shall be provided in each room.

When rooms are located adjacent to the exterior walls, warm air
outlets shall be located so as to bathe at least one exterior wall
and, where practical, a window area with warm air, except for bathrooms or kitchens where this might not be practical.

INSTALLATION

Where practical, outlets shall be provided
of the home.

CLEARANCE

REQUIREMENTS

near the exterior doors

- CANADA

Supply air ducts from warm air furnaces having a specified minimum
plenum clearance shall maintain this clearance from combustible material for at least the distance specified in CSA Standards C22.2 No. 23 or
B 140.10 or CGA Standard CAN/CGA-2.3.

Unitary

Products

Group

107272-UIM-A-0905

A
Single trunkduct
[

Transition
B*
Dust trunk duct with crossover connector

Transition

C
Duct with Branches

duct

]
Dual trunk duct
_,
Crossover

I
"_3
1,
2.
3.
4.

Crossover Duct must be centered directly under furnace.
Use 12 '_(30,5 cm) Diameter Round or insulated Ftex_duct only.
Terminate Flex-duct (opposite furnace) in the center of the trunk duct.
Flex-duct material must be pulled tight -- No Loops or unnecessary dips -- Air Flow may be impeded.

FIGURE 3: Air Distribution Systems

Furnace to Closet Door Clearance
5 Inches (12.7 cm) or more

Return Air Grille Part No.
79gg-287P/A * White

The closet door MUST have a minimum of 250 Inches2(1613 cm 2)
of free area in the upper half of the doer.
If opening for return air is located in the floor or sidewalls and
below the top of the furnace casing:
1. 6 inches (15,2 cm) minimum clearance must be provided on side
where return is located, and
2. 6 inches (15.2 cm) minimum clearance must be maintMned from

250 IN. 2 (161 cm 2)
MINIMUM
FREE AREA

250 IN.2 (161 cm2)
>MINIMUM
[
FREE AREA

50 IN.2 (322 cm 2)
MINIMUM
FREE AREA

_\
Door
FIGURE

Closet

To Door Clearance

5 in(12.7 cm) or greater * Closet
to Door CI.......
,
Return Air Closet Door Part No.
7900--7771/C* White

- 5" or Greater

Furnace to Closet Door Clearance -Greater than 1 Inch (2.54 cm) and Up to 5 (12.7 cm) Inches
1. "[he closet door MUST have a minimum of 250 Inches 2 (1613 cm 2) of flee
area in the upper half of the door and a minimum of 50 Inches 2 (322 cm 2) of
free area in the lower area of the door. The tower cIoset door grille may be
omitted if an undercut of 2-1/2 inches (16.1 cm) is provided in the door.
2. AfuHy louvered cIoset door MUST have a minimum of
250 Inches 2 (1613 cm 2) of free area in the upper hMf of the door.

FREE AREA
MINIMUM
FREE AREA

J FREE AREA
_i

As an option to the lower grill,
an undercut of 2-1/2" wilt provide
50 inches 2 (322 cm 2) of flee area.

} 260 IN.2(161cm2)

FIGURE 5: Furnace To Closet Door Clearance - 1" To 5"

Furnace to Closet Door Clearance
Less than 1 tnch (2.54 cm}

2501N.2(161
> MINIMUM
FREEAREA

cm 2)

The closet door MUST have three return air grilles, The total free area of the
two upper gdHes must be minimum of 250 Inches 2 (1613 cm _) , The total
Free area of the lower grille MUST be a minimum of 50 tnches 2 (322 cm2).
The grilles MUST BE ALIGNED directly opposite the return air grille of
the furnace door.

501N.2(322 cm 2)
MINIMUM
FREE AREA

FIGURE 6: Furnace To Closet Door Clearance - Less Than 1"

Unitary

Products

Group

107272-UIM-A-0905
DUCT

CONNECTORS
23/8

18-3/4 (47.6 cm)------_

SEE

2-3/8-(6.0 cm)

DUCT

CONNECTOR

DUCT

43/8
--(11.1

4-3/8
(11.1 cm)

DIMENSIONS

DUCTCONNECTOR
PAR]NUMBER

2-3/8---_
(6.0 cm)

DUCT

CONNECTOR
DEPTH

CONNECTOR

DUCTCONNECTOR
PAR]

cm)

DIMENSBONS
DUCT

NUMBER

CONNECTOR
DEPTH

7990-6011

1" (2,5 cm)

7990-6211

1" (25

7990-6021

2" (5.7 cm)

7990-6221

2" (5.7 cm)

cm)

7990-6041

4-1/2"

(11.4 cm

7990-6241

7990-6061

6-1-2"

(16,5

cm)

7990-6261

6-%2"

(16.5

cm)

7990-6071

7-1/2"

(19.0

cm)

7990-6271

7-1/2"

(19.0

cm)

7990-6081

8-1/2"

(21,6

cm)

7990_6281

8-1/2"

(21.6

cm)

7990-6101

10-1/4"

(26.0 cm)

7990-6301

10-1/4"

(26.0

cm)

7990_6121

12-114" (21.1 cm)

7990_6321

12-1/4"

(21.1

cm}

4-1/2"

(11.4 cm

FIGURE 7: Duct Connector Dimensions

Rear Wall
of Enclosure
I

2.3/4 (70 cm)
Min
;

Locator Bracket

Ceiling Cut-Out
For Roof Jack

r_
/

__Nails,
"

_
\/_

Fiat Head Screws

or Staples

F_oor Cut-Out
For Duct

Connector

Floor

t
_"

t [__ I_1"---/381
/

{

ore/*
I __

]--

_.lJ'l

2-1/8 (54 cm)

:: _ 1-3/8

Op_ona_
Ga_
_

or Electric

Entrance

'_l,

Front

Future

_3/fe_r

FIGURE 10:

Pane]

-1-1/8
(29

9-3/4

Refrige_98%4_"

FIGURE 8: Recommended

INSTALLATION

cm)

/-_°fFumace

(508 cm)

_€/_- Fioor

Duct Connector
Depth

OF SCREW

ATTACHMENT

DUCT

Make floor cut out as shown in Figure 8.

Determine the depth of the floor cavity from the surface of the floor
to the top of the supply air duct and select the appropriate duct
connector from the chart.

Place locating bracket (supplied with the duct connector)
back edge of the floor opening. See Figure 10.

Apply a water based duct sealant to the 1/2 in (1.3 cm) supply duct
attachment flange of the duct connector.

Determine which of the four positions the duct connector best centers over the supply duct and insert it through the floor cut-out.

Jo_st

When properly aligned with the supply duct, secure the duct connector to the floor with nails, flat head screws or staples.

Use screws as required to secure the duct connector to the supply
duct.

Cut out the opening to the supply duct. If sealant was not used, the
installer should tape the mating flanges to provide a good air seal.

Supply Duct

FIGURE 9: Duct Connector Depth

Screw Attachment

Floor Cut-out

Duct Connector

CONNECTOR

-- Floor

Line Entrance

Supply Duct

i
\

to the

NOTE: Duct sealant and tape must be classified as meeting HUD Standard 3280.715, U.L. Standard 181A.
If tape is used to provide a better air seal, it should be a type approved
by the applicable national or local codes.

Unitary

Products

Group

107272-UIM-A-0905

For installations with a parallel flow arrangement, the furnace must be
equipped with a damper to prevent cold air from being discharged up
around the heat exchanger. Cold air causes condensation inside the
exchanger and can cause it to rust out which can allow products of
combustion to be circulated into the living area by the furnace blower
resulting in possible asphyxiation. An air flow activated automatic
damper, is available from furnace manufacturer. See Figure 12.

Locator Bracket
Nails, Flat Head Screws
or Staples
Bend "Tabs Under Duct
Opening to Secure to the
Supply Duct
Floor

NOTE: See label on coil panel for conversion and lighting instructions.
Obtain a temperature rise within the ranges specified on the name
plate.
Supply Duct

FIGURE 11: Duct Connector Tab Attachment
INSTALLATION

OF TAB

ATTACHMENT

DUCT

CONNECTORS
1.

Make floor cut out as shown in Figure 8.

Determine the depth of the floor cavity from the surface of the floor
to the top of the supply air duct and select the appropriate duct
connector from the chart.

Place locating bracket

rear of the floor area for the furnace. See Figure 11.
Determine which of the four positions the duct connector best centers over the supply duct and insert it through the floor cut-out.

(supplied

with the duct connector)

to the

Mark cut-out location on the supply duct and remove the duct connector.

Cut out the opening to the supply duct.

Bend tabs down through and back up under the supply duct.

Secure the duct connector to the floor with nails, fiat head screws
or staples.
The duct connector is designed for use on ducts down to 12 in (30.5
cm) width. When using the connector on smaller width ducts, there will
not be sufficient clearance to bend the tabs on two sides of the duct
connector.
In such cases the tabs may be attached to the sides of the duct by
using sheet metal screws or other suitable fasteners. Holes for sheet
metal screws are provided in three (3) tabs on each side of the duct

Furnace
Base
Conneo[or

NOTE: FOR BEST AIR DELIVERY
WiTH BLADES PARALLEL

FIGURE 12: Anti-Backfiow
INSTALLATION

INSTALL DAMPER
TO SUPPLY DUCT,

Damper
THE

FURNACE

connector. If more than 3 tabs need to be used to provide a more
secure and air tight connection, the remaining tabs can also be fastened to the duct with screws after drilling the required screw hole.

Remove the front panels and set the furnace onto the duct connector. Slide it back until the rear of the unit engages the Iocator
bracket.

TABLE 4: External Static Pressure Range

Secure the front of the furnace with two screws at the mounting
holes provided. See Figure 13.

Ext. Static Pressure

Nominal
Input

Output

Air Flow 1

Minimum

Maximum
\

MBH

66000

19.34

53000

15.55 1050 29.73

84000

24.62

67000

19.63 1250 35.40

CFM

cmm

In.W.C

kPa In.W.C

kPa

.!2

.03

.30

.07

.!2

.03

.30

.07

Furnace Seated
Againstthe
Locator Bracket

Std Blower-High Speed-No Coil.
Secure
Furnace
to
° Floor with Two NaiIs

IMPORTANT: The air temperature rise should be taken only after the
furnace has been operating for at least 15 minutes. Temperatures
should be taken 6" (15.2 cm) past the first bend from the furnace in the
supply duct. The return air temperature must be taken at the return air
Iouvered door. Return static pressures can be taken by pushing probe
through the air filter on the Iouvered door.
Furnace

and Air Conditioner

or Screws.

Installations

If an air conditioner is installed which does not use the blower for air distribution and operates completely independent of the furnace, the thermostat system must have an interlock to prevent the furnace and air
conditioner from operating at the same time. This interlock system usually contains a heat-cool switch which must be turned to either HEAT or

FIGURE 13: Installation of Furnace
3.

COOL to activate either heating or cooling operation, or a positive OFF
switch on the cooling thermostat.
When used in connection with a cooling unit the furnace shall be
installed parallel with or on the upstream side of the cooling unit to avoid
condensation in the heat exchanger.
Unitary

Products

Group

Secure the top of the furnace to a structural member using screw
through the strap at the back of the furnace. Strap may be moved
to any of the holes located along the top back of the furnace.
Installer may provide an equivalent method, such as screws
through the casing side.

107272-UIM-A-0905
DFAH

Furnaces:

If a matching cooling coil is used, it may be placed directly on the furnace outlet and sealed to prevent leakage. Follow the coil instructions
for installing the supply plenum. On all installations without a coil, a
removable access panel is recommended in the outlet duct such that
smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This access cover
shall be attached in such a manner as to prevent leaks.
RETURN
Closet

AIR

Flex Duct

REQUIREMENTS

Damper

Installations

Additional

Requirements

Additional requirements for floor and ceiling return system for closet
installed sealed combustion heating appliances are given in the next
paragraph.
Floor or Ceiling
Listed
tured
return
ances
1.

Floor

Return Air System

in the next paragraph are the conditions to be met by ManufacHome Manufacturers to have U.L. acceptance of in-floor or ceiling
air systems of closet installed direct vent forced air heating applifor Manufactured Homes to be sold in the United States.

The return air opening into the closet, regardless of location, is to
be sized not less than !6" X 24" (40.6 cm x 101.6 cm).

If the return air opening is located on the floor of the closet (versus
the vertical front or side wall), the opening is to be provided with
means to prevent its inadvertent closure by a flat object placed
over the opening.

The cross sectional area of the return duct system (when located
in the floor or ceiling of the manufactured home) leading into the
closet is to be not less than 16" X 24" (40.6 cm x 101.6 cm).

At least one register is to be located where likelihood of its being
covered by carpeting, boxes, and other objects is minimized.

Materials located in the return duct system have a flame spread
classification of 200 or less.

Non-combustible
pans having 1" (2.5 cm) upturned flanges are
located beneath openings in the floor return duct system.

Wiring materials located in the return duct system conform to Article 300-22 (B&C) of the National Electrical Code (NFPA-70).

Fuel piping is not run in or through the return duct system.

The negative pressure in the closet as determined by test with the
air circulating fan operating at high heating speed and the closet
door closed is to be not more negative than minus 0.05 inches (1.2
kPa) water column.

10.

For floor return systems, the manufactured home manufacturer or
installer shall affix a prominent marking on or near the appliance
where it is easily read when the closet door is open. The marking
shall read:

HAZARD OF ASPHYXIATION,
FLOOR OPENING
BLEND

AIR

DO NOT COVER

OR RESTRICT

INSTALLATIONS

If a blend air ventilation system is installed, the 5" (12.7 cm) diameter
knockout in the top cover must be removed. The blend air damper is to
be placed on the top cover and secured with screws as shown in Figure
14. The power wires for the Blend Air Damper are inserted through the
7/8" (2.22 cm) hole in the top cover. The wires to the Blend Air Damper
will be connected as shown in Figure 24. Refer to the Blend Air Installation Manual to complete the installation.

WARM_R_UCl

pKCl c:! t!_r:_g

_ ........................

FIGURE 14: Floor Installation

SECTION
FILTER

IIh

FILTERS

INSTALLATION

All applications require the use of a filter. A standard air filter is located
in the return filter rack on the Iouvered door. The air filter(s) must be
replaced with air filter(s) that are the same size and same type.
Replacement filter size is shown in Table 5.
Downflow

Filters:

There are two types of dewnflow filter racks.
1.
FURNACE FILTER RACK: A return filter rack is with two standard
throwaway type filters are supplied on all models. The return filter
rack is located on the inside of the leuvered door. This type of filter
rack is designed for two standard air filters only. Pleated Media or
Washable Filters cannot be used in this filter rack because they
cause too much pressure drop causing a reduction in airflow.
2.

EXTERNAL RETURN FILTER GRILLE: The second type is an
external return air filter grille that can only be used in applications where the furnace is installed in a closet. This type of filter grille is typically installed in a closet door or wall with the filters
located within 12" (30.5 cm) of the return air opening of the furnace. There must be a minimum clearance of 6" (15.2 cm)
between the front of the furnace and the closet door and/or the furnace and the filter grille to prevent the return air flow from being
obstructed. Refer to Table 1 Unit Clearances to Combustibles.
a.

If the standard throwaway filter are used the external filter
grille must have a minimum area of 540 in2 (3483 cm 2) which
would equal a 15" X 36" (38.! cm x 91.4 cm) filter grille.
If the Pleated Media or Washable Filters are used the external filter grille must have a minimum area of 684 in= (4413
cm=) which would equal a 18" X 38" (38.1 cm x 91.4 cm) filter
grille. The increased area is to reduce the pressure drop
across the air filter.

c.
d.

Consideration

should be given when locating the return filter

grille for maintenance.
Any filter that has a large pressure drop should be checked to
be sure the pressure drop caused by the air filter will not prevent the furnace from operating within the rise range, specified on the rating plate and in Table 8. If the furnace does not
operate within the specified rise range then a larger air filter
or an air filter that has a lower pressure drop must be
installed.

TABLE 5: Filter Sizes
Input / Output

CFM

Top Return

BTU/H (kW)

(m3/mm)

Filter In. (cm)

66/53(19.34/15.53)

!050(29.73)

(2) 14 x 20 (35.56 x 50.8)

64/67(24.62/19.64)

1250(35.40)

(2) 14 x 20 (35.56 x 50.6)

Unitary

Products

Group

107272-UIM-A-0905

IMPORTANT: Air velocity through throwaway
exceed 300 feet per minute (1.52 m/m).

type filters

must

not

TABLE 6: Burner Specifications
Furnace Model
DFAA084BBTA

Burner Spec
EVC - 201

ATC
AF36YHHS

Head
F3

EVC - 202

AF36YHHS

Static Plate

Nozzle

Pump Pressure

Air Boot Setting

3-318 U

0.65 x 70 ° A
Delavan

100 psi
(689.5 kPa)

4.0

3-318 U

0.50 x 70 ° A
Delavan

100 psi
(689.5 kPa)

3.0

DFAH084BBSA
DFAA066BBTA
DFAH066BBSA

Air Filters Can Be
Found On The Inside
Of This Access Panel

The burner fuel unit is shipped without the bypass plug installed.
You must install this plug on two-pipe oi! systems. DO NOT install
the plug in the fuel unit if connected to a one-pipe oil system. Failure to comply could cause fuel unit seal failure, oil leakage, and
potential fire and injury hazard.
Fuel
FIGURE 15: Furnace Air Filters

SECTION
OIL

IV: OIL

PIPING

SAFETY

IMPORTANT INFORMATION: Long or oversized inlet lines may require
the pump to operate dry during initial bleeding period. In such cases,
the priming may be assisted by injecting fuel oil in the pump gearset.
Under lift conditions, lines and fittings must be air tight. To assure this,
"Pipe Dope" may be applied to both the used and unused inlet and both
return fittings. DO NOT USE TEFLON TAPE! DO NOT USE COMPRESSION FITTINGS!
VACUUM CHECK: A vacuum gauge may be installed in either of the 1/
4" NPT inlet ports. The Beckett CleanCut pump should be used where
the vacuum does not exceed 6" hg. (20.3 kPa) single pipe and 12" hg.
(40.6 kPa) two pipe. Remember, running vacuum is the total of all pressure drops (AP) in the system from tank to inlet of pump.
PRESSURE CHECK: When a pressure check is made, use either the
BLEED PORT OR NOZZLE PORT.
CUTOFF CHECK: To check cut-off pressure, dead head a pressure
gauge in nozzle port. Run burner for short period of time. Shut burner
off. The pressure will drop and hold above zero

FUEL

LINES

Carefully follow the fuel unit manufacturer's literature and the latest edition of NFPA 31 for oil supply system specifications. If this information is
unavailable, use the following basic guidelines.

Level

With

or Above

Burner

The oil supply inlet pressure to the fuel unit cannot exceed 3 psi.
(20.7 kPa) Instafl a pressure-limiting
device in accordance with
NFPA 31.
Fuel Supply

Below

the Level

of the Burner

When the fuel supply is below the level of the burner, a two-pipe fuel
supply system is required. Depending on the fuel line diameter and horizontal and vertical length, the installation may also require a two-stage
pump. Consult the fuel unit manufacturer's literature for lift and vacuum
capability.
Fuel Line Installation
•

•

CONNECT

Supply

The burner may be equipped with a single-stage fuel unit for these
installations. Connect the fuel supply to the burner with a single supply
line if you want a one-pipe system (making sure the bypass plug is NOT
installed in the fuel unit). Manual venting of the fuel unit is required on
initial start-up. If connecting a two-pipe fuel supply, install the fuel unit
bypass plug.

Continuous
lengths of heavy wall
mended. Always use flare fittings,
tings.
Always install fittings in accessible
not run against the appliance or the
tion noise).

copper tubing are recomNever use compression fitlocations. Fuel lines should
ceiling joists (to avoid vibra-

Never use Teflon tape on any fue! fitting. Tape fragments can lodge
in fue! line components and the fuel unit, damaging the equipment
and preventing proper operation.

Fuel Line Valve and Filter
Install two high quality shut-off valves in accessible locations on the oil
supply line. Locate one close to the tank and the other close to the
burner, upstream of the filter.

Fuel units with automatic bypass do not require a bypass plug.

Burners equipped with a Beckett CleanCut pump must have a control system that provides a valve-on delay (prepurge).

Some states require these valves to be fusible-handle design for
protection in the event of fire. We recommend this as good industry
practice for all installations.
Install a generous

capacity filter inside the building between the fuel

tank shut-off valve and the burner, locating both the filter and the valve
close to the burner for ease of servicing. The filter should be rated for
50 microns 50 micrometers) or less.

Unitary

Products

Group

107272-UIM-A-0905
NOTICE

SPECIAL

REQUIREMENTS

TABLE 7: Burner Rating at Elevation Above Sea Level, gph (t/m)
Nozzle Size

Elevation
(Above Sea Level)
This equipment must be installed, adjusted, and started only by a
qualified service technician, an individual or agency, licensed and
experienced with al! codes and ordinances, who is responsible for
the installation and adjustment of the equipment. The installation
must comply with all local codes and ordinances and with the
National Fire Protection Standard for Liquid Fuel Equipment, NFPA
3! (or in Canada the installation must comply with CSA B139-M91).

DANGER
This fumace is designed to operate on #! FUEL-OIL or #2 FUELOIL ONLX Do Not burn any other fue! in this furnace. Burning any
fue! except #1 FUEL-OIL or #2 FUEL-OIL in this furnace can cause
premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage, and/or death.
In Canada, the furnace is designed to operate on #1 STOVE OIL or
#2 FURNACE OIL ONLY
THE

EFFECT

ELEVATION

OIL

BURNER

0.60

0.66

gph

I/h

gph

I/h

!52

0.50

! .89

0.65

2.46

1,000

305

0.50

! .89

0.65

2.46

1,500

457

0.50

1.89

0.65

2.46

2,000

610

0.50

1.89

0.65

2.46

2,500

762

0.49

! .86

0.65

2.46

3,000

914

0.48

1.82

0.64

2.42

3,500

1,067

0.48

! .82

0.64

2.42

4,000

1,2!9

0.47

1.79

0.63

2.37

4,500

1,372

0.47

1.79

0.63

2.37

5,000

1,527

0.46

! .76

0.61

2.33

5,500

1,676

0.46

! .76

0.61

2.33

6,000

1,829

0.46

! .72

0.60

2.28

6,500

1,981

0.46

! .72

0.60

2.28

7,000

2,134

0.45

! .69

0.59

2.24

7,500

2,286

0.45

1.69

0.59

2.24

8,000

2,438

0.44

! .66

0.58

2.20

9,000

2,743

0.43

1.63

0.57

2.16

10,000

3,048

0.42

1.60

0.56

2.12

Note: All examples

are for 7000 ft. elevation.

1.84% x 7 (for 7000 ft.) =12.9%

100%- 12.9% =87.1%

ft = feet
m = meters

The elevation of the installation of a modern high-speed flame retention
oil burner affects the performance of the burner, Allowance for elevation
must be taken into consideration when choosing an oil burner and operating it above 2000 ft. (6!0m).

gph = gallons per hour

It is especially important in high elevation installations to adjust air settings to match the burner nozzle firing rate. As elevation increases
above sea level, the ambient air contains less oxygen. Because there is
less available oxygen per cubic foot of air, the burner must deliver a
greater volume flew (cfm) of air to provide the proper amount of oxygen
for the amount of oil being burned, This is the reason that an increase in
the burner air setting may be required.
maxiby the
has a
maxi-

I/h = liters per hour

Re-Rating of the Ma×imum Firing Rate for Burners @ 7000 ft.
Burner
Model
AFG
AF

Maximum

Firing

Elevation

Adjusted

The effect of elevation up to 2000 ft. (610 m) is minimal, so no re-rate is
necessary up to 2000 ft. (610 m) elevation. Above 2000 ft. (610 m), for
every 1000 ft. (305 m) above sea level (including the first 2000 ft. (610
m), there is a 1.84% rate reduction of the burner. To assist you, we have
included the following chart and some examples: Refer to Table 7,

DANGER
The pressure regulator on the fuel pump must not be adjusted
excess of 100 PSIG (689 kPa).

Rate
of Burner
X Re-rate
Factor
=
Maximum
II
@ Sea
Level
@ 7000
ft.
Firing
Rate
3.00 gph (11.4 L/h) X
87.1%
2.61 gph (9.83 Lh)
3.00 gph (1! .4 L/h) X
87.1%
2.61 gph (9.83 Lh)

Nozzle Port
3/16 Flare

By Pass
Solenoid

Inlet Port
Pressure
Adjustment
Screw

mum firing rate of the oil burner decreases as the elevation increases,
because the combustion air contains less oxygen, An increase in the
size of a fixed-type retention head, or even the use of an oil burner with
a higher maximum firing rate may be necessary.

1/4 NPTF
(0.64 cm)

Ptug ForTwo-Pipe System Only
(Use 5/32" Allen Wrench)

FIGURE 16: Oil Pump
in

Pressures exceeding 100 PSIG (689 kPa) may cause an overheating condition which can lead to premature heat exchanger failure,
resulting in a fire or explosion, or cause damage to the furnace of
some of its components that will result in property damage and loss
of life. Refer to Figure 16 for Pressure Regulator Location.

2.460618

500

FIRING

It is also important in high elevation installations to consider the
mum firing rate of the burner, so that the heat input as required
application is maintained. Regardless of elevation, the oil burner
maximum volume flow of air that it can deliver, As a result, the

1.892706

INSTALLATION

AND

CHECKING

OF OIL

PIPING

Location and installation of oil tanks and oil piping must comply with
local codes and regulations. In absence of such codes, follow NFPA 31 :
Standard Floor Installation of Oil Burner Equipment,

Unitary

Products

Group

107272-UIM-A-0905
Follow information provided with the burner, the fuel pump, or the calculation below to determine pipe size and length.

The return line must terminate 3" to 4" above supply line in the oil tank.
Failure to do this may introduce air into the system and could result in
the loss of the prime. Refer to Figure !8.

L = Line Length in feet
H = Head in feet

Outside Tank Fuel Unit
Above Bottom of "Tank

Q = Firing rate in GPH
3/8" (0.95 cm) line L = (6 - 0.75 x H) / 0.0086 x Q)
1/2" (1.27 cm) line

L=H+R
Primary
'Filter

L = (6- 0.75 x H) / (0.00218 x Q)

If tank is above the oil pump, then use the following calculation:
3/8" (0.95 cm) line

L = (6 + 0.75 x H) / (0.0086 x Q)

1/2" (1.27 cm) line

L = (6 + 0.75 x H) / (0.00218 x Q)

IMPORTANT: The recommended piping configuration is a single or two
pipe system that is inserted into the top of the tank as shown in Figure
17 or 18. The two pipe system should be used in applications where the
oil tank is considerably lower than the burner and the oil pump keeps
losing its prime. The oil line should never be connected to the bottom of
the oil tank if the oil tank is outdoors. Water in the bottom of the oil will

"H"

1
Use

PIPE

during the purging.

SOLENOID

PLUG! Connect inlet line to pump inlet.

primary burner control for continuous

operation

wise. Bleed until all air bubbles disap-

rect solenoid wiring. All electrical
with the local codes.

L=H+R

BEFORE

WIRING

TO PRE-

DAMAGE.

wiring must be done in accordance

NOTE: Solenoid power requirements:

Fuet Unit

SUPPLY

SHOCK OR EQUIPMENT

Lead wires on these devices are long enough to reach the junction box
on most burner installations. Refer to Figure 19.
NOTE: Check the burner manufacturer's installation sheets for the cor-

operation of unit. Refer to Figures 16 & 17.

Ven[ _

THE POWER

VENT ELECTRICAL

pear. Tighten bleed valve securely. Hurried bleeding will impair efficient

WIRING

DISCONNECT

Place a clear plastic tube on bleed valve. Open

bleed valve ! turn counterclock

Air

or as

FIGURE 18: Two-Pipe System

BY-PASS

Start burner. Arrange

Ptastic

in Concrete

Locat Codes Require

SYSTEM

DO NOT INSTALL

Protective

Tubing

freeze in the winter causing the oil line to freeze.
ONE

Inlet

1!5 VAC, 0.1 Amp, 60 Hz

Bypass

To Power
Control

----tt-%

Vioiet
White

]

FIGURE 19: Solenoid Wiring
FIGURE 17: One-Pipe System

SECTION

TWO

Electrical

PIPE

SYSTEM

Remove 1/16" (0.16 cm) pipe by-pass plug from plastic bag attached to
the unit. Remove 1/4" (0.635 cm) plug from return port. Insert by-pass
plug into the return port of the oil pump. The oil pump return port location is shown in Figure 16.

V: ELECTRICAL
Power

POWER

Connections

Field wiring to the unit must be grounded. Electric wires that are field
installed shall conform to the temperature limitation for 63°F (35°C) rise
wire when installed in accordance with instructions. Refer to Table 8 in
these instructions for specific furnace electrical data.

Insert a 1/4" MPT x flare adaptor into the by-pass port and the inlet port.
Attach the return and inlet copper lines that go to the oil tank. Start the
burner. DO NOT open the bleed valve. The air in the oil lines will bleed
automatically.
TABLE 8: Ratings & Physical / Electrical Data
Input

Output

Nominal

MBH (kW)

CFM (cm)

Ampe

RPM

Rotation

°F (°C)

66 (19.3)

53 (15.5)

1050 (29.7)

2.1

1/7

3450

CCW

45 - 75 (28 - 47)

0.50 (1.9)

84 (24.6)

67 (19.6)

1250 (35.4)

2.1

1/7

3450

CCW

45 - 75 (28 - 47)

0.65 (2.5)

Input

Max, Outlet
Air Temp

Burner

Blower

Air Temp. Rise

Max Over-current
Size (awg) @

Total
Unit

Input Rate

AFUE

GPH (Liter / H)

DFAA
Min. Wire
One Way

Blower Size

Operation

DFAH
Wgt.

Operation Wgt.

MBH (kW)

°F (°C)

Amps

75 ft. protect

Ampe

In. (cm)

LBS/Kg

66 (19.3)

165 (74)

1/6

8.0

8.3

10 x 8 (25.4 x 20.3)

175/79.4

158/71.7

84 (24.6)

165 (74)

1/4

5.9

7.8

10 x 8 (25.4 x 20.3)

175/79.4

!58/71.7

Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures
Wire size and over current protection must comply with the National Electrical Code (NFPA-70-1atest edition) and all local codes.
The furnace shall be installed so that the electrical components are protected from water
Rotation when facing shaft end

Unitary

Products

Group

107272-UIM-A-0905

NOTE: A burner with an electronic igniter or a PSC motor will have a
lower operating current. The actual load should be determined by a current meter.

Room
Thermosta[

Furnace
Con[rot

NOTE: See appliance manufacturer's burner specifications for required
outlet pressure. Pressure is !00 psig (689 kPa) unless otherwise noted.
SUPPLY
1.

VOLTAGE

CONNECTIONS

FIGURE 21: Wiring for Heat Only Thermostat

Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/national
electrical codes. With the control box switch in the OFF position,
check all wiring against the unit wiring label. Refer to the wiring
diagram in this instruction.

Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction box
with a conduit connector or other proper connection. In the junction
box there will be two wires, a Black Wire, a White Wire and a
Green Screw. Connect the power supply as shown on the unit-wiring label on the coil compartment panel on the DFAA or the onside
of the burner door on the DFAH or the wiring schematic in this section. The black furnace lead must be connected to the L1 (hot) wire
from the power supply. The white furnace lead must be connected
to neutral. Connect the green furnace lead (equipment ground) to
the power supply ground screw.

The furnace's control system requires correct polarity of the power
supply and a proper ground connection. Refer to Figure 20.

Room
Thermostat

Furnace
Control

Condensing
Unit

FIGURE 22: Wiring for Electronic Heat-Cool Thermostat
Room
Thermostat

Furnace
Pigtails

Condensing
Unit

11
11

FIGURE 23: Wiring for Standard Heat-Coo! Thermostat

Nominal
120 Volt

l Control
Blend AirBox

FIGURE 20: Line Wiring Connections
FIGURE 24: Wiring for Blend Air Accessory
LOW

VOLTAGE

CONTROL

WIRING

CONNECTIONS

Insert 24 volt wires through
the control panel.

Connect the thermostat wires to the furnace low voltage pigtails.
See Figure 21 (heating only) and Figure 22 or 23 (heating and
cooling).

Connect low-voltage circuit to the wall thermostat pigtails.

NOTE:

Five-conductor

the small plastic bushing just above

thermostat cable is recommended

lations to allow easy installation of an air conditioning
time.
Eighteen gauge thermostat

wire is highly recommended,

Thermostat

Wire Gauge

0 - 45 feet

O - 70 feet

Do not use the thermostat wire smaller than 22 gauge. If thermostat
wire small than 18 gauge is used, pay particular attention that the connections between the difference wire sizes are tight.
Operational problems may be caused by loose connections or by the
use of thermostat wire that is too small to carry the required load. Any
such problems are the responsibility of the installer.
A separate 115 V.A.C. supply circuit must be used for the furnace. The
circuit should be protected by a 15 amp fuse or circuit breaker.
Avoid locations where the thermostat could be subject to drafts from
outside, or exposed to direct light from lamps, sun, fireplaces, etc., or
affected by air from a duct register blowing directly on the thermostat.
The walI thermostat should be located 52 to 66 inches above the floor.
The preferred location is on an inside wall situated in an area with good
air circulation, and where the temperature will be reasonably representative of other living areas the thermostat is controlling.

The 24-volt transformer is part of the Electronic Oil Primary Control.The
transformer may not be used to provide 24-Volt power for an air conditioning unit contactor. DFAA has a separate 24-Volt transformer that
maybe used to provide 24-volt power for air conditioning contactor.

for all instal-

system at a later

Smaller gauge thermostat wire may be used only if the guideline below
is followed.
Thermostat Wire Length
(Furnace to Thermostat)

IMPORTANT: Some electronic thermostats do not have adjustable heat
anticipators. They may have other type cycle rate adjustments. Follow
the thermostat manufacturer's instructions.

SECTION
SYSTEM
VENT

AND

Vh VENT/COMBUSTION
COMBUSTION

AIR

SAFETY

This furnace is designed for Manufactured (Mobile) Home and Modular
Home application. It may be installed without modification in an equipment room, alcove, or any other indoor location where all required
clearance to combustibles and other restrictions are met.
The venting system must be installed in accordance with UL311 Standard For Safety for Roof Jacks for Manufactured (Mobile) Homes and
Recreational Vehicles, NFAA 501C and in the Federal Manufactured
Home Construction and Safety Standings, or CANICSA - B139-00
Installation Code for 0il Burning Equipment (latest edition), or applicable
provisions of the local building code and these instructions. The furnace
shall not be connected to any chimney, a flue serving a separate appliance, or any appliance designed to burn solid fuel.
It is recommended

that the appliance

is installed in a location where the

space temperature is 32 °F (0°C) or higher. If the appliance is installed
in a location where the ambient temperature is below 32 °F (0°C), the
combustion by-products could condense causing damage to the appliance heat exchanger and/or the Roof Jack.
IMPORTANT: The "VENT SYSTEM" must be installed as specified in
these instructions for Manufactured
(Mobile) Home and Modular
Homes. This appliance must be vented with an approved manufacturer
supplied roof jack. May not be common vented with another gas-fired or
oil-fired appliance.

Unitary

Products

Group

107272-UIM-A-0905
EXTERIOR

ROOF

JACK

EXTENSION

After unpacking the roof jack, check the rain caps. Insure they are
not damaged, tilted or crooked. Do not twist, crush or sit on the
roof caps during installation.
Damaged roof caps will cause
improper furnace operation. The furnace will not heat properly and
could result in explosion.

Before inserting the vent pipe into the furnace top, inspect the furnace flue and combustion air opening for debris or insulation
which have fallen in during pre-installation steps. Do not proceed
unless all debris have been cleaned out or removed.

After installing roof jack on furnace top collar, check to make sure
there is no gap in back or side between the pipe collar and the furnace casing top. If necessary to prevent excessive air leakage, the
installer should seal joints in the combustion air tube with aluminum type or other suitable sealant.

Application
Available to comply with instances in which the roof jack crown needs to
be raised to meet a roof clearance requirement. One extension will
raise the roof jack crown by 18" 45.7 cm).
ROOF

JACK

Failure to follow aft venting instructions
asphyxiation, or explosion.

can result in fire,

INSTALLATION

Only use the appropriate roof jack. See Figures
30, & 31 for correct application.

26, 27,

Do not exceed the maximum height as determined from
Table 9. Installer should allow an additional 1-1/2" (3.8
cm) travel before the flue pipe assembly is fully extended
against the built-in stop. This provides an additional safeguard against the flue assembly being pulled from the roof
jack during transportation or other stress conditions.
EXISTING

FURNACE

REPLACEMENT

If this furnace replaces an existing furnace, do the following:
1.

If a 2nd roof, roof cap or addition has been made to the existing
roof of the home, remove the old roof jack completely! To avoid the
possibility of an improperly installed pipe or gaps in the old roof
jack, INSTALL A NEW ROOF JACK. Your ceiling and roof height
will determine the correct roof jack to use.

Before inserting the roof jack into the furnace top, inspect the furnace flue and combustion air opening for debris or insulation
which might have fallen in during pre-installation steps. Do not proceed unless all debris has been cleaned out or removed.

After installing roof jack on furnace top collar, check to make sure
there is no gap in back or side between the pipe collar and the furnace casing top.

Use only the pipes provided with the roof jack assembly. Do not
add to or adapt other sheet metal pipes. Do not cut, insert or add
other pipes to this assembly.

In no case should there be a gap between sections of the flue pipe
or the combustion air pipe. If necessary to prevent excessive air
leakage, the installer should seal joints in the combustion air tube
with aluminum type or other suitable sealant.

NEW

HOME

IN SNOW

REGIONS

When the combustion air pipe inlet is covered or blocked with snow, the
furnace will not operate properly due to the depleted combustion air
supply.
Therefore, if the furnace will be located in regions where snow accumulation on the roof exceeds 4" or in H.U.D. Snow Load Zones, a roof jack
extension and PVC combustion air inlet extension is recommended.
Refer to Figure 26 or 27.
COMBUSTION

AIR

INLET

All combustion air pipe and fittings must conform to American National
Standards Institute (ANSI) standards and American Society for Testing
and Materials (ASTM) standards D1785 (Schedule 40 PVC), D2665
(PVC-DWV), F891 (PVC-DWV cellular core). D2241 (SDR-21 and
SDR-26 PVC), D2261 (ABS-DWV), or F628 (Schedule 40 ABS. Pipe
cement and primer must conform to ASTM Standards D2564 (PVC) or
D2235 (ABS).
1.

Mark vertical combustion air inlet centerline on ceiling. Cut hole for
combustion air inlet piping. Clearance to combustible materials is
not required.

Cut hole in roof. Provide minimum 12" (30.5 cm) vertical separation between combustion air inlet pipe and roof jack vent cap.
Clearance to combustible materials is not required.

Route piping
required.

Insert combustion
27.

Slide PVC pipe into coupling. Use a hose clamp to secure the PVC
pipe to the coupling.

Complete piping through roof. Provide flashing at roof penetration.

Prepare elbow assembly. See Figure 25. Insert screen into elbow
socket. Secure in place with street elbow (or nipple).

PVC pipe can be straight through the roof or it can be offset by
using up to 4-90 ° elbows. Horizontal PVC pipe can be up to !0 ft.
(3.1 m) long in any direction from the furnace vent connection. Vertical PVC pipe can be up to !0 ft. (3.! m) in length.

through

ceiling

and

holes.

Provide

firestop

air inlet coupling into casing. See Figure 26 or

90 _'Street
Elbow

INSTALLATION

If this furnace is installed in a new home do the following:
1.

Inspect the furnace top collars for signs of insulation or ceiling
debris which might have fallen in during cutting of the ceiling and
roof holes. Remove all debris before continuing.
Screen

The vent and combustion air openings in the top of the furnace
must be free of construction debris before the Roof Jack is

Pipe to Furnace

installed. Failure to ensure that these openings are free will result in
excessive amounts of CARBON MONOXIDE and elevated heat
exchanger
temperatures
which can lead to premature
heat
exchanger failure, resulting in a fire or explosion or cause damage
to the furnace or some of its components that will result in property
damage and loss of life.

Unitary

Products

Group

FIGURE 25: Elbow Assembly
9.

Attach elbow assembly to combustion air inlet piping. See Figure
26 or 27. Inlet must be minimum 6" (15.2 cm) above highest anticipated snow level, but no more than 24" 61.0 cm) above roof.

107272-UIM-A-0905
Connect
1.

Min.

Roof

Jack

to Furnace

Install Flue Shield inside Vent Connector.

Push Flue Shield down

until in contact with the built-in stop inside the Vent Connector. See
Figures 28 & 29.

T
9" Min.

6" Min, or 6" Above
the Snow Line

Failure to install the Flue Shield may cause premature flue pipe
deterioration. Damaged flue pipe can result in asphyxiation, fire or
equipment malfunction.

2" Pipe
Rubber Coupling
with Hose Ctamp

6" Min,

Flue

Shield
Furnace
Vent

Connector
t//

FIGURE 26: Combustion

Air Inlet Pipe
FIGURE 28:

Flue Shield Installation

Verify gasket is around outside of Air-Intake
gasket if missing or damaged.

9" Min.

6" Min, or 6" Above
the Snow Line

Pull the Roof Jack's telescoping section down onto furnace. Fully
engage Roof Jack onto Vent Connector and Air-Intake Connector
and compress gasket. See Figure 29. Refer to Interior Roof Jack
Extension installation instructions, if applicable.

Align holes in Roof Jack and Air-intake Connector. Secure Roof
Jack to furnace using #10 x 112 - 1-1/2" (#10 x ! .3 - 3.8 cm) Type
AB or Type B sheet metal screw.

2" Pi

Connector. Install new

Bottom of

Rubber Coupling
with Hose Clan"

Roof Jack
Air Intake
Connector
Opening for
CombustionAir
Inlet Grommet

FIGURE 27: Combustion

Air Inlet Pipe Alternate

.J
.J

NOTE: Roof flashing, PVC pipe, PVC 90 ° elbows and fire stop are not
supplied with the furnace.
LOCATING

AND

CUTTING

ROOF

JACK

Front of
Furnace

OPENING

To facilitate the proper installation of the roof jack, it is very important
that the roof jack opening in the ceiling and roof be on the same vertical
center line as the furnace flue collar. See Figures 30 & 3!.

INTERIOR

Mark this location on ceiling and scribe a circle with a 5" (1.5 m) radius
{10" (25.4 cm) diameter} around this mark. Cut opening for roof jack
through ceiling and roof. (if furnace was installed during construction,
cover furnace and flue opening to prevent debris from entering flue
when hole is cut for roof jack).

There is an optional 11" (43.2 cm) long interior extension that can be
used to provide added interior roof jack length, if needed. To choose the
proper length roof jack with or with-out the optional extension see Figures 30 & 31 and Table 9. More than one interior extension may be
used to accommodate "A" dimensions up to 110" (284.5 cm).

INSTALLING

ROOF

JACK

Provide protection for Vent Connector
from damage and debris.

Mark Roof Jack center line on ceiling. Cut a 5" (1.5 m) radius {10"
(25.4 cm) diameter} hole through ceiling.
Mark Roof Jack center line on roof. Cut oblong hole through roof.

to Furnace

EXTENSIONS

ROOF

FIGURE 29: Roof Jack Attachment

and Air-intake

Connector

Insert Roof Jack through roof opening. Do not secure Roof Jack to
roof.

The joint where the optional interior extension connects to the roof
jack must be below the ceiling. Failure to observe this requirement
may result in asphyxiation, fire, or explosion
NOTE: Use of an interior extension will increase the roof jack adjustable heights by the amount of the interior extension height.

Unitary

Products

Group

107272-UIM-A-0905

If using an optional interior extension, place extension down on furnace
top and mate with furnace flue and combustion air collar until it lines up
with screw holes in combustion air collar. Secure the extension to the

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Do not exceed the maximum adjustable height as listed in Table 9.
These maximum heights allow an additional 1 1/2" (3.81 cm) travel
before the flue pipe assembly is fully extended against the built-in
stop. This provides an additional safeguard against the flue assembly being pulled from the roof jack if upward movement should
occur when the home is being transported or subjected to other
stress conditions. Failure to follow these instructions may result in
fire, explosion, or asphyxiation.
TABLE 9: Roof Jack Options
Adjustable Height with
no Interior Extension

Roof Jack
Part Number

Adjustable Height with a
17" Interior Extension
IN

4000B7!41

!4" to 78"

35.6 to 198.1

64" to 95"

!62.6 to 241.3

4000B7!51

66"to90"

165.1 to228.6

83"to !07"

210.8to271.8

4000B8!61

59"to79"

149.9to200.7

76"to96"

193.0to243.8

4000B8181

73" to 103" 185.4 to 261.6

90" to 110" 228.6 to 279.4

Models 4000B8161 and 4000B8181 have removabie crowns

furnace using the pre-punched holes. Use 1/2" (1.27 cm) blunt or sharp
end sheet metal screws to fasten roof jack combustion air pipe to furnace combustion air collar. Screw holes are provided in pipe and collar.
Excessively long screws may extend to flue pipe and puncture, it. if
substitute screws are used. they must not exceed ! 1/2" (3.8a cm) in
length. Pull the roof jack flue and combustion air pipe assembly down
and mate with extension flue and combustion air pipes until the screw
holes line up. See Figure 29. Fasten interior extension to combustion
air pipe assembty with sheet metal screws not exceeding 1 1/2" (3.8
cm) in length.
IMPORTANT:

Secure

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Roof Jack

Group

to Roof

Apply caulk or other sealant to underside of Roof Jack flashing.
Locate Roof Jack such that pipes are plumb.

Secure Roof Jack flashing with nails, screws or staples.

Install roofing material over Roof Jack flashing.

Seal Roof Jack swivel joint with silicone sealant or other sealant
suitable for local weather conditions. Not required for Roof Jacks
with fixed slant flashing.

Complete
1.

Products

between

Installation,

as required

I nstalI Exterior Roof Jack Extension,
tion instructions
to Figure 32.

Unitary

shall the connection

Secure the roof jack to the roof with screws. Non-hardening
mastic
sealer or caulking compound must be used to seal the roof flange to
prevent water leakage. The roof jack swivet joint must also be sealed to
prevent water leakage.

Use 1/2" (1.27 cm) blunt or sharp end sheet metal screws to fasten
roof jack combustion air pipe to furnace combustion air co!lat:
Screw holes are provided in pipe and collar. Excessively long
screws may extend to flue pipe and puncture it. If substitute screws
are used, they must not exceed 1 1/2" (3.81 cm) in length. It is mandatory that the combustion air and flue tube assembly be properly
engaged, and the combustion air pipe fastened to the furnace with
sheet metal screws in the holes provided.

Under no circumstances

the flue and combustion air pipe assembly of the roof jack and the interior extension be above the ceiling line.

if applicable. Refer to installa-

provided with Exterior Roof Jack Extension. Refer

Instali Crown Assembly, if applicable. Refer to installation instructions provided with Crown Assembly. If Crown Assembly is not
installed, attach warning tags provided with Roof Jack to: Refer to
Figure 32.

107272-UIM-A-0905

DFAH FURNACES
SWIVEL FLASHING
ADJUSTS FROM
0/12 TO 5/12 PITCH

SLANT
FLASHING
3/12 PITCH

INSTALLATION
"A"
ADJUSTABLE

DFAA FURNACES

DIMENSIONS

INSTALLATION

DIMENSIONS

"B"
ADJUSTABLE

HEIGHT

4000-7101/C

4000-6101/A

70" to 79"

86" to 95"

4000-7121/C
4000-7141/C

4000-6121/A

75" to 86"

91" to 102"

4000-6141/A

83" to 104"

99" to 120"

4000-7151/C

4000-6151/A

90" to 116"

106" to 132"

4000-7171/C

4000-6171/A

127" to 157"

143" to 173 ....

The 4084-7141

is dimensionally

the same as 4000-7141/C

and is available only in Canada.

2 The 4084-7151

is dimensionally

the same as 4000-7151/C

and is available only in Canada.

CarefuIIy Cautk AH Around Swivel Joint with
Sea_ant Supplied by Furnace Manufacturer.

Flue
Gases

"--_>_

19 1/2"

Gases
Flue

19 1/2"

Cjombusflon
Conlbustlon.
Air
Caulk

Caulk
Unde[
Roof

The End of Upper Portion of Roof Jack need
Not extend below the ceiling. -_

IMPORTANT
Seal Roof Jack Flashing to the Roof Jack and Roof.
This is the Installer's Responsibility.
..... 7_

76"

59-1/2"

DFAA MODELS

DFAH MODEL',

Warm Air Duct

Duct Connector

J----_l

Duct Connector

Warm _,,JrDuct

FIGURE 30: Standard Roof Jack

Unitary

Products

Group

107272-UIM-A-0905

DFAH FURNACES
SWIVEL FLASHING
ADJUSTS FROM
0/12 TO 5/12 PITCH

SLANT
FLASHING
3/12 PITCH

INSTALLATION
"A"
ADJUSTABLE

DFAA FURNACES

DIMENSIONS

INSTALLATION

DIMENSIONS

"B"
ADJUSTABLE

HEIGHT

4000-8161/C

4000-9161/A

85" to 101"

101" to 117"

4000-8181/C

4000-9181/A

99" to 129"

115" to 145"

Carefully Caulk Atl Around Swivei Joint with
Sealant Supplied by Furnace Manufacturer.
/

The End of Upper Portion of Roof Jack need
Not ex_end below the ceiling.

IMPORTANT
Seal Roof Jack Flashing to the Roof Jack and Roof.
This is the InstalleCs Responsibility.

76 _

59.1/2 _

DFAA MODELS

Hf------_jjDFAHMODELS
,

---\

I
Floor

__-

/'--"

_1
"%

Warm Air Duct

FIGURE 31:

Unitary

Duct Connector

Warm Air Duct

Roof Jack With Removable Crowns

Products

Group

107272-UIM-A-0905
VENT
Upper
Cap

This furnace is a sealed combustion (direct vent) unit and is design certiffed to use only a 4000 Series roof jack. These roof jacks are designed
to exhaust flue products to the outside.

Lower
Cap

STEP 1:
Remove upper and iower cap.

SYSTEM

INSTALLING

Remove the two (2) screws
that secure the upper cap to
the crown assembly base and
remove the upper cap. Next,
remove the three (3) screws
that secure the lower cap to
the crown assembly base.
Set bothcaps aside for later use.

Crown
Assembly
Base

CEILING

RING

The ceiling ring is to meet fire stop requirements. Accessory Ceiling
Ring may be installed in Manufactured (mobile) Homes or Modular
Homes.
Refer to the UL 311 Standard for Safety for Roof Jacks for Manufactured Homes and Recreational Vehicles; or in Canada use CANICSAZ240 MH Series - 92 (latest edition) or applicable provisions of the
state, regional or local building codes and these instructions. The
installer must follow approved methods in the above standards and/or
codes for a fire stop. If required, the installer may use up to three sections of the Accessory Ring. Refer to Figure 33.
NOTE: A portion of the outer edge of the ceiling ring may be trimmed so
the ring will fit between the warm air plenum and roof jack.

STEP 2:
Remove upper and lower cap.
Place the roof jack extension on top of the
crown assembly base pushing down firmly
to assure a snug fit.
iMPORTANT:
connected.

Make sure that the pipes are

Using the four (4) holes at the base of the
extension as a guide ddti four (4) hoIes
1/8" diameter into the crown assembly base.
Secure the extension to the crown assembly
base with the four (4) screws provided.
Instalt the tower cap on top of the extension
so that the center pipe sticks through
the hole in the lower cap.

FIGURE 33: Ceiling Ring
VENT

Reinstall
lower cap
to extension.
_S
Using the upper
three and
(3) screws
removed
in Step 1 attach the tower cap to the
I
I
extension bracket. Insta,, the upper
_j_L_cap over the center pipe of the extension.
_
Using the two (2) holes located at the
base of the upper cap as guides, drill
two (2) 1/8" diameter holes into the center pipe.
Finally attach the upper cap to the center
pipe using the two (2) screws removed in
L.
J
step 1 to the center pipe.
[_/

STEP 4:
Complete

The vent must be installed with the minimum clearances

as shown in Figure 34, and must comply with local, state, regional
codes and requirements.

___

STEP 3:

CLEARANCES

IMPORTANT:

UPPER

cAP

LOWER
CAP

REXTA
ENS'ON
.......
EXTENSION

assembly.

Place these instructions in the customer
packet provided with the furnace.

FIGURE 32: Installing Roof Jack Extension

Unitary

Products

Group

107272-UIM-A-0905

Comer

Detail

[]

Vent lerminal

Air Supply

[]

Area

Where

Terminal

is Not Permitted

Fixed
Closed
Operable

FIGURE

34:

Home

Layout
Canadian

A. CIearance

above grade, veranda,

porch, deck, or balcony

Installations

12 inches (30 cm)

12 inches (30 cm)
4 Feet

B. CIearance

to window or door that may be opened

12 inches (30 cm) for models <100,000 BTUH
(30 kW), 36 inches (91 cm) for models > 100,000
BTUH (30 kW)

C Clearance

to permanently

4 Feet

D Vertical clearance to ventilated soffit tocated
above the terminal within a horizontal distance
of 2 feet (61 cm) from the center tine of the terminal

4 Feet

E. CIearance

to unventilated

12 Inches

F. Clearance

to outside corner

12 Inches

G. Clearance

to inside corner

6 Feet

H Clearance

to each side of center line extended

3 feet (91 cm) within a height 15 feet (45 m)
above the
meter/regulator assembty

3 feet (91 cm) within a height 15 feet (4.5 m)

3 feet (91 cm)

J. Clearance to nonmechanical air suppty inlet to buitding
or the combustion air inlet to any other appliance

12 inches (30 cm) for models <100,000 BTUH
(30 kW), 35 inches (91 cm) for models >100,000
BTUH (30 kW)

4 Feet

K. CIearance

6 feet (1 83 m)

3 feet (91 cm) above if within 10 feet (3 cm)
horizontally

7 feet (213 m) €

7 feet (2.13 m) t

above meter/regulator
I Clearance

soffit

assembly

to service regulator vent outlet

to a mechanical

L CIearance above paved
public proper_y
M.CIearance

ctosed window

US Installation

supply inlet
sidewalk

or paved

driveway

under veranda, porch, deck, or balcony

located

above the meter/regulator

assembty

on
12 inches (30.4 cm)

12 inches (304 cm)

Vent Termination from any Building Surface

12" (30.4 cm)

12" (304 cm)

Above anticipated snow depth

12" (30.4 cm)

12" (304 cm)

1
2

In accordance with the current CSA B149 1-00, Natural Gas and Propane Installation Code
In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code. In accordance with the current UL 311 Standard for Safety for Roof Jacks for Manufactured Homes and Recreational VeMctes.
1- A vent shalI not terminate directty above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
$ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor For clearance not specified in UL 311 Standard for
Safety for Roof Jacks for Manufactured Homes and RecreationaI Vehicles
CIearance in accordance with Iocal installation codes and the Manufacturer's Installation ManuaI
Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.
Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.
A terminus of a vent shall be either:
Fitted with a cap in accordance with the vent manufacturer's
installation instructions, or In accordance with the installation instructions for a special venting system
* Does not apply to muttipte installations of this furnace mode_ Refer to "VENTING MULTIPLE UNITS" in this section of these instructions
IMPORTANT: Consideration must be given for degradation of buiIding materials by flue gases. Sidewatt termination may require sealing or shielding of buitding surfaces
with a corrosion resistant materiai to protect against combustion product corrosion. Consideration must be given to wind direction in order to prevent flue
products and/or condensate from being blown against the buitding surfaces If a metal shieId is used it must be a stainless steet matedai at a minimum
dimension of 20" (508 cm) tt is recommended that a retaining type collar be used that is attached to the buitding surface to prevent movement of the vent
pipe.
Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer
Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent
Also in accordance with the current UL 727 Standard for safety for oil-fired central furnaces.

Unitary

Products

Group

107272-UIM-A-0905
FAN-ASSISTED

COMBUSTION

SYSTEM

An appliance equipped with an integral mechanical means to either
draw or force products of combustion through the combustion chamber
and/or heat exchanger.

Flashing
mode.

On: cad cell is sensing flame.

Off: cad cell is not sensing flame.

SECTION

Cad Cell

VII:

CONTROL

SAFETY

CIRCUIT

CONTROLS

at 2 seconds on, 2 seconds

Resistance

off: controi is in recycle

Check

For proper operation, it is important that the cad cell resistance is below
1600 ohms. During a normal call for heat, once the controI has entered
the Run mode, press and release the reset button. See Table !0 for
equivalent cad cell resistance.

FUSE

A 3-amp fuse is provided to protect the 24-volt transformer from overload caused by control circuit wiring errors. This is an ATO 3, automotive type fuse and is located in the control box.

TABLE 10: Cad Cell Resistance When Sensing Ftame
Flashes

without

the blower

More than 400 and less than 800

More than 800 and less than 1600

More than 1600 and less than 5000

Preliminary
LIMIT

CONTROLS

in Ohms

Less than 400

Main power to the unit must still be interrupted at the main power
disconnect switch before any service or repair work is to be done to
the unit.
Blower and burner must never be operated
panel in place.

Cad Cell Resistance

Steps

Check wiring connections

Make sure power is on to controls.

Make sure limit control is closed.

Check contacts between ignitor and the electrodes.

Check the oil pump pressure.

Check the piping to the oil tank.

The indoor fan motor is an operation controlled by normally open temperature actuated switch located above the limit control which is set to
close at 110° F (43.3 ° C) and open at 90 ° F (32.2 ° C).

Check the oil nozzle, oil supply and oil filter.

OIL

If the trouble is not in the burner or ignition hardware, check the oil primary control by using the following equipment:

There is a high temperature limit control located on the furnace vestibule panel near the control box. This is an automatic reset control that
provides over temperature protection due to reduced airflow, that may
be caused by a dirty filter, or if the indoor fan motor should fail.
INDOOR

FAN

BURNER

SWITCH

PRIMARY

Check

CONTROL

The R7184A, B, P, U Interrupted Electronic Oil Primary is a line voltage,
safety rated, interrupted ignition oil primary control for residential oil
fired burners used in forced air furnaces. The R7184A, B, P, U used
with a cad cell flame sensor operates an oil burner and optional oil
valve. The primary controls fuel oil, senses flame, controls ignition
spark and notifies a remote alarm circuit when in lockout.

Control

Screwdriver

Voltmeter

Insulated jumper wire with both ends stripped

The indicator light on the oil primary control provides lockout, recycle,
and cad cell indications as follows:
1.

Oil Primary

and power supply.

(0 to 150 VAC range)

Electrical Shock Hazard
Can cause severe injury, death or property damage.
Be careful to observe all precautions to prevent electrical shock or
equipment damage.

Flashing at 1/2 second on, 1/2 second off: system is locked out or
in restricted mode.

TABLE 11: Timings and Settings
Delay Timings a
Burner Motor-Off
(minutes)

Valve-On Delay
(seconds)

R7184U

DIP Switch
Delay

S-3 Enable / Disable
S-1

S-2

R7184P

Settings

R7184U

0.5

Off

R7184P

Off
b

X No Difference or Impact

a Specific models may have different timings. Be sure to check device labet.
b S-3 not provided on R7184P models.
Check

/ Adjust

Electrodes

Check the electrode tip settings. Adjust, if necessary, to comply with the
dimensions shown in Figure 35. To adjust, loosen the electrode clamp
screw and slide/rotate the electrodes as necessary. Securely tighten the
clamp screw when finished.

END

Gap

ViEW

SiDE VIEW
Nozzle--to-ti
Spacing

5/16 '_Above Nozzte Center

FIGURE 35: Electrode Settings

Unitary

Products

Group

107272-UIM-A-0905

SPECIFICATIONS

NOTE: Reduce burner FLA rating by igniter load. For example, if the
igniter draws 3A (120 VAC, 360 VA), reduce the burner motor FLA to
7A.

Models:
Table 1! lists the major features and the applicable wiring diagram numbers for the R7184.
Timing:
Safe Start Check: 5 seconds (approximately)

Valve-on Delay: 15 seconds.

Burner motor-off Delay: 0, 2, 4, or 6 minutes. Field seIectable
using dual in-line programmable (DIP) switch positions 1 and 2.
Select models have 0.5, 2, 4, or 8 minute delays.

NOTE: Valve-on delay and burner motor-off delay timings can be
enabled (values as listed) or disabled (values are zero) in the field,
using DiP switch position 3.
Lockout: 15, 30, or 45 seconds (factory-programmed).

Recycle: 60 seconds (fixed).

Ignition Carryover:

Electrical

START-UP

AND

The initial start-up of the furnace requires the following additional
procedures:
IMPORTANT: All electrical connections made in the field and in the fac-

SECTION
Vllh
ADJUSTMENTS

!0 seconds (fixed).

tory should be checked for proper tightness.
When the oil line is initially connected to the furnace, the tubing may be
full of air. In order to purge this air, it is recommended that the bleed
valve be loosened until no air bubbles are detected in the plastic tubing.
If burner does not light, press the reset button on the primary control
once only and bleed oil pump again. If burner still does not light, turn off
the power to the furnace and call a qualified service technician. DO
NOT CONTINUE TO PRESS THE RESET BUTTON ON THE PRIMARY CONTROL.
TOOLS

Ratings:

AND

REQUIRED
FURNACE

Inputs:
a.

Voltage: 102 to 132 VAC, !20 VAC nominal.

Current: 100 mA plus burner motor, valve and igniter loads.

INFORMATION

IN ORDER
STARTUP

THAT

WILL

TO PROPERLY
PROCEDURE•

PERFORM

THE

You will need a thermometer or portable digital thermometer
read the supply and return air temperatures.

Frequency: 60 Hz.

Burner: 120 VAC, 10 full load amperes (FLA), 60 locked rotor
amperes (LRA).

You will need a pressure gauge that has the ability to read pressures between 0 - 100 PSlG (0 - 689 kPa) in order to measure the
oil pump pressures.

Valve: 120 VAC, 1A

You will need a 3/32" Allen wrench for the pressure port adjustment screw in the oil pump.

Igniter: 120 VAC, 360 VA

d.
e.

Alarm: 30 VAC, 2A
Thermostat Current Available: 100mA

You will need 1 piece of 1/4" (0.63 cm) ID flexible tubing that is 12"
(30 cm) in length

You will need a clear plastic jug.

You will need a 7/16" open end or box wrench.

You will need a 1/4" brass NPT x flare fitting.

Outputs:

EnviraCOM

Current Available: 150mA

These items are required in order to properly perform the required startup procedure.
TABLE 12: Burner Specifications
Furnace Model

Burner Spec

DFAA084BBTA
DFAH084BBSA

EVC - 20!

DFAA066BBTA
DFAH066BBSA

START-UP

AF36YHHS

EVC - 202

AND ADJUST

ATC

AF36YHHS

Head
F3
F3

Static Plate

Nozzle

Pump Pressure

Air Boot Setting

3 - 3/8 U

0.65 x 70 ° A
Delavan

100 psi (689 kPa)

4.0

3 - 3/8 U

0.50 x 70 ° A
Delavan

100 psi (689 kPa)

3.0

BURNER

•

Start-up Burner / Set Combustion

If the burner locks out on safety during venting, quickly close the
vent plug, reset the safety switch, open the vent ptug when the
motor starts rotation, and complete the venting procedure.

NOTE: Electronic safety switches can be reset immediately; others may
require a 3 to 5 minute wait.
Do not attempt to start the burner when excess fuel or vapor has
accumulated in the appliance. Starting the burner under these conditions could result in a puff back of hot combustion gases, high
smoke levels, or otherwise hazardous operation.
1.

Open the shut-off valves in the oil supply line to the burner.

Set the air boot adjustment to the setting stated in Table !2. This is
an initial air setting. Additional adjustments must be made with
instruments.

Set the thermostat substantially

Close the line voltage switch to start the burner. If the burner does
not start, you may have to reset the safety switch of the burner primary control.

above room temperature.

•

If the burner stops after flame is established, additional venting is
probably required. Repeat the venting procedure until the pump
is primed and a flame is established when the vent plug is closed.

•

For R7184 primary controls, see Technician's Quick Reference
Guide, Beckett part number 61351, for special pump priming
sequence.
Prepare for combustion tests by taking a sample in the flue pipe.
A combustion sample should be taken with a 114" (0.4 km) tube
placed in the center of the vent pipe outside beneath the crown
assembly.

•

Initial air adjustment - Using a smoke tester, adjust the air to obtain
a clean flame. Now the additional combustion tests with instruments can be made. Never drill a hole in the roof jack to take combustion sample or smoke tests.

Vent air from fuel pump as soon as burner motor starts rotating.
To vent the fuel pump, attach a clear plastic hose over the vent
plug. Loosen the plug and catch the oil in an empty container.
Tighten the plug when all air has been purged from the oil supply
system.

Unitary

Products

Group

107272-UIM-A-0905

IGNITION

SYSTEM

SEQUENCE

Set the over-fire or stack draft to level specified by appliance manufacturer (usually -0.01" to -0.02" w.c. (-000024 to -0.0050 kPa)
over-fire for natural draft applications).

Follow these four steps to properly adjust the burner:

Turn the oil supply ON at external valve on the oil pump, and/or at
the oil tank.

Set the thermostat above room temperature

System start-up will occur as follows:

Step 1: Adjust the air until a trace of smoke level is achieved.

The burner motor will start and come up to speed.

Step 2: At the trace of smoke level, measure the CO 2 (or 02).

Shortly after the burner motor starts-up, the ignition transformer will provide 10,000 volts through the electrods causing
a spark that will last approximately 15 seconds.
The solenoid valve on the oil pump will open providing oil flow
to the nozzle.

c.
d.
e.
f.

to call for heat.

This is the vital reference point for further adjustments.
• Example: 13.5% CO2 (2.6% 02).
c.

Step 3: Increase the air to reduce CO 2 by 1 to 2 percentage
points. (02 will be increased by approximately

The oil vapor will ignite. The cad cell flame detector will
detect the flame. The resistance will drop below 1600 ohms.
After flame is established, the supply air blower will start
when the fan switch reaches approximately 110 ° F (43.3 ° C).
After flame is extinguished, the supply air blower will continue
to operate until the air temperature at the fan switch is below

• Example:

HAZARD

Pressing the reset button repeatedly could cause a pool of oil to
form in the bottom of the chamber. If ignited, could result in a very
dangerous situation which could result in personal injury, property
damage, and/or death.
IMPORTANT: Burner ignition may not be satisfactory on first start-up
due to residual air in the oil line or until pump pressure is adjusted. The
ignition control will make 3 attempts to light before locking out.
The furnace should have a safety or fire shut-off valve connected to the
inlet part of the oil pump to shut off the flow of oil in an emergency.
Refer to Figure 36 for inlet port location.

Nozzle Port
3/16 Flare

CO 2 from

13.5% to 1!.5%.

(2.6% to

Step 4: Recheck smoke level. It should be zero.
• This procedure provides a margin of reserve air to accommodate variable conditions.
• If the draft level has to be changed, recheck the smoke and
CO 2 levels. Adjust the burner air if necessary.

Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.

ADJUSTMENT

Reduce

5.3% 02).

90° F (32.2 ° C).

FIRE OR EXPLOSION

! .4 to 2.7 per-

centage points).

OIL

PUMP

By Pass
Solenoid

PRESSURE

Inlet Pert

Once combustion is set, tighten all fasteners on the air adjustment
and escutcheon plate.

Start and stop the burner several times to ensure satisfactory
operation. Test the primary control and all other appliance safety
controls to verify that they function according to the manufacturer's
specifications.

ADJUSTMENT

TEMPERATURE

RISE

kDANGER
The temperature rise, or temperature difference between the return
air and the supply (heated) air from the furnace, must be within the
range shown on the furnace rating plate and within the application
limitations shown in Table 8 "ELECTRICAL AND PERFORMANCE
DATA".
The supply air temperature cannot exceed the "Maximum Supply
Air Temperature"
specified in these instructions and on the furnace rating plate. Under NO circumstances can the furnace be
allowed to operate above the Maximum Supply Air Temperature.
Operating the furnace above the Maximum Supply Air Temperature
will cause premature heat exchanger failure, high levels of Carbon
Monoxide, a fire hazard, personal injury, property damage, and/or
death.
After about 20 minutes of operation, determine the furnace temperature
rise. Take readings of both the return air and the heated air in the ducts,
about six feet (1.83 m) from the furnace where they will not be affected
by radiant heat.
FILTER

1/4 NPTF
(0.64 cm)

Plug For Two-Pipe System Only
(Use 5/32" Alien Wrench)

FIGURE 36: Oil Pump
SET

COMBUSTION

WITH

INSTRUMENTS

kWARNING

PERFORMANCE

The airflow capacity data published
formance WITH CLEAN filters.

in Table 14 represents

blower per-

The filter pressure drop values in Table 13 are typical values for the
type of filter listed and should only be used as a guideline. Actual pressure drop ratings for each filter type vary between filter manufacturers.
DO NOT USE Pleated Media or Hogs Hair filters on this furnace.
Be sure to check for leaks in the oil line and fittings. A leak wiii cause oil
pump to loose it's prime. Repair leaks before continuing with the final
adjustments to the oil burner.
TABLE 13: Filter Performance - Pressure Drop Inches W.C. and (kPa)

The combustion
must be adjusted using test instruments.
Failure to do so could result in burner or appliance failure, causing potential
severe personal
injury, death, or substantial
property damage.
1.

Let the burner run for approximately

5 to 10 minutes.

Minimum
Airflow

Range

Opening Size
1 Opening

CFM

Cm/m

in2

Filter Type
Disposable
1 Opening
inwc

kPa

1001 -!250

28.35-

35.40

488

45.34

0.1

0.0249

1251 -!500

35.42-

42.47

488

45.34

0.1

0.0249

Unitary

Products

Group

107272-UIM-A-0905
APPLYING
DETERMINE

FILTER
PRESSURE
SYSTEM
AIRFLOW

DROP

Multiply percentage by airflow difference to obtain airflow reduction.
(0.5) X (-65) = -32.5

Example: For a 84,000 BTUH (38.06 kW) furnace with 1 return openings and operating on high-speed blower, it is found that total system
static is 0.30" w.c. (0.075 kPa). To determine the system airflow, complete the following steps:
Obtain the airflow values at 0.!0
ESR
Airflow @ 0.!0":

w.c. (125 Pa) & 0.20 w.c. (150 Pa)

Subtract airflow reduction value to airflow @ 0.10 w.c. (125 Pa) to
obtain actual airflow @ 0.30 wc (144 Pa) ESP.
1050 - 32.5 = 1017.5
FINAL
Install

1175 CFM (60.17 m3/min)

Airflow @ 0.20": !110 CFM (57.62 m3/min)
Subtract the airflow @ 0.10 w.c. (!25 Pa) from the airflow @ 0.20 w.c.
(150 Pa) to obtain airflow difference.
1175 - 11!0 = -65 CFM (2.55 m3/min)

PROCEDURE
Furnace

Doors

Install the lower door first by sliding the bottom of the door down until
the tabs on the casing base engage the slots in the bottom door end
cap. Then push the top of the lower door in until the door clips snap into
place. Install the upper door in a similar manner, first engaging the slots
in the top of the upper door on the tabs on the casing top. Then snap
the bottom of the upper door into place against the casing.

Subtract the total system static from 0.10 w.c. (125 Pa) and divide this
difference by the difference in ESP values in the table, 0.20 w.c.
(150 Pa) - 0.10 w.c. (125 Pa), to obtain a percentage.

Alcove and Closet Installations

(0.30 - 0.10) / (0.20 - 0.10) = 0.5

necessary.

Finish

and Trim
may now be finished and trimmed as

TABLE 14: Blower Performance CFM
BLOWER PERFORMANCE CFM - DFAA066
FACTORY EQUIPPED WITH STANDARD BLOWERS AND FILTERS
EXTERNAL
CFM

Blower Speed

BTU/H (kW)
Input / Output

Single Speed - No Coii

66(19.34) / 53(15.55)

0.1 (0,025)

STATIC PRESSURE,

0.2 (0,050)

INCHES WC (kPa)

0.3 (0,075)

0.4 (0,099)

0.5 (0,124)

(m3/min)

cfm

cm/m

cfm

cm/m

cfm

cm/m

cfm

cm/m

cfm

cm/m

1050(29.73)

1175

33.3

1110

3! .4

1050

29.7

1000

28.3

950

26.9

1125
31.9
!070
30.3
Single Speed - With Dry Coil 66(19.34) / 53(15.55) !050(29.73)
BLOWER PERFORMANCE CFM - DFAA084

!020

28.9

960

27.2

910

25.8

EXTERNAL
Blower Speed
Single Speed - No Coil

STATIC PRESSURE,

BTU/H (kW)

CFM

0.3 (0,075)

0.4 (0,099)

Input / Output

(m 3 / min)

cfm

cm/m

cfm

cm/m

cfm

cm/m

cfm

cm/m

cfm

cm/m

84(24.62) / 67(19.63)

1250(35.39)

1370

38.8

1305

37.0

1245

35.3

!175

33.3

!100

31.1

31.7

!045

29.6

!015

28.7

0.1 (0,025)

0.2 (0,050)

Single Speed - With Dry Coil 84(24.62) / 67(19.63) !250(35.39)
!265
35.8
1195
33.8
BLOWER PERFORMANCE CFM - DFAH066
EXTERNAL
Blower Speed

BTU/H (kW)

CFM

Input / Output
Single Speed - No Coil

66(!9.34)/53(15.55

(m 3 / min)

0.1 (0.025)
cfm

cm/m

cfm

Single Speed - No CoiI
NOTES:
1. Airflow expressed

cm/m

1050(29.73)
!155
32.7
1111
31.5
BLOWER PERFORMANCE CFM - DFAH084

BTU/H (kW)

CFM

0.1 (0.025)

Input / Output

(m 3 / min)

cfm

cm/m

cfm

84(24.62) / 67(19.63)

1250(35.39)

1127

31.9

1062

1120

STATIC PRESSURE,

0.2 (0.050)

EXTERNAL

Blower Speed

INCHES WC (kPa)
0.5 (0,124)

INCHES WC (kPa)

0.3 (0.075)

0.4 (0.099)

cfm

cm/m

cfm

cm/m

cfm

cm/m

1055

29.9

995

28.2

920

26. !

STATIC PRESSURE,

0.5 (0.124)

INCHES WC (kPa)

0.3 (0.075)

0.4 (0.099)

cm/m

cfm

cm/m

cfm

cm/m

cfm

cm/m

30.1

1005

28.5

952

27.0

887

25.1

0.2 (0.050)

0.5 (0.124)

in standard cubic feet per minute (cfm) and in cubic meters per minute (cm!m)

2. Return air is through Iouvered filter door only.
3. Motor voltage at 1!5V

Unitary

Products

Group

107272-UIM-A-0905

TABLE 15: Replacement Parts - Non Electrical
DFAA MODEL
ITEM NUMBER
1
2
3

DESCRIPTION
Limit Switch, Manual (Upper)
Thermostat

(Heat/Cool)

Exchanger, Heat (w/Gaskets)

Switch, Rocker (System)

Transformer (115 - 24V, 40 VA)

Filter (16 x 20 x !) (2Required)

Panel, Door (Upper)

Panel, Door (Lower, Tall)

Motor

Plug, Connector

Capacitor,

Run

Wheel, Blower

Blower, AC Relay

14
15

Switch, Fan
Combustion

Chamber Assembly

Oil Burner Assembly

Switch, Limit (Open 140 - Close !10)

Fastener, Door Latch (2 Required)

Diagram, Wiring

DFAH MODEL
ITEM NUMBER

DESCRIPTION

Limit Switch, Manual (Upper)

2
3

(Heat Only)

Switch, System

Transformer (115 - 24V, 40 VA)

Filter (!6 x 20 x !) (2 Required)

Panel, Door (Upper)

Panel, Door (Lower, Short)

Motor

Plug, Connector

Capacitor,

Wheel, Blower

Blower, AC Relay

14
15

Thermostat

Exchanger, Heat (w/Gaskets)

Run

Switch, Fan
Combustion

Chamber Assembly

Oil Burner Assembly

Switch, Limit (Open 140 - Close !10)

Fastener, Door Latch (2 Required)

Diagram, Wiring

Unitary

Products

Group

"13

C
nl
¢€

BLOWER SPEED CHART
(CHARTE DE VITEBBE
DE LA BOUFFLERIE]

LADDER
(DIADRAMME

DIAGRAM
ELEMENTAZRE)

CONNECTION
{DIAGRAMME

e+ BLACK

DIAGRAM
DE

RACCORDEMENT)

ON MOTORS WITHOUT CAPACITOR

g
3

_>
i

_o.
377

77
C

3
o

o
OZL BURNER
z_
0

24v CONNECTIONROOMTHERMOSTAT
FIELD CONNECTION
FACTORYWIRING ANO OEVICES
FIELO WIRING AND OEWCES

z_
0

2€v RACCOROEMENT
OU THERMOSTATDE PIECE
RACCOROEMENT
DE CHANTIER
FILAGE OE L'USINE ET APPAREILS
FILAGE DE CHANTIER ET APPAREILS

,>
o

'1rll

5
C_

m
O0

BLOWER

SPEED

CHARTE
DE

LADDER

CHART

DIAGRAM

(DIAGRAMME

VITESSE

IF
IT

ELEMENTAIRE)

SOUFFLERIE)

ANY
MUST

OF
THE
ORIGINAL
BE
REPLACED

WIRE
WITH

TYPE

SUPPLIED
IOB'C

WITH
THIS
THERMQPLASTIC

UNIT
OR

MUST
ITS

BE
REPLACED,
EQUIVALENT.

CAPACITOR

SWITCH
BLACK
SYSTEM

WIRE

COLOR

POWER SUPPLY
IALIMENTATION

115 I 60
115 I 60

SEE NOTE
I
VO[R
NOTE
I]

MOTORS

WITHOUT

g
o

CAPACITOR

@FS

KEY

(CODE DE COULEUR
DU FILAGE)

ORG

BLACK

CNOIR]
BLUE
(BLEU)

VCqT

[BLEU]
RED

(ROUGE)

I
_T

WHITE

(BLANC)
BRN
(BRUN)

(BLANC)
BRO_N
[BRUN}

8RN
(VERT)

FAN
SWITCH

GREEN
(VERT]

PRP
(POURPRE)
ORN

WHT

YELLOW
(JAUNE)

(JAUN]

ORG
PRP

PURPLE
(POURPRE)
ORANGE

(ORA)

ALL

DISCONNECTS

SERVICING

--J

HEAT/COOL
ITHERMOSTAT

CAUTION
OPEN

AUTO
RESET

IORANBE)
THERWOSTAT
CL[MA/CHAUF)

BLU

BEFORE

THIS

UNIT

PRECAUTION
OUVREZ
DE

LES

DISJONCTEURS

PROC£DER

AVEC

AVANT

NOTES=

SERVICE

80+

ALL

FIELD

WIRING

PER:

[A)

DOWNFLOW FURNACE

(B)
[C)
2,

(FOURNAISE
80X
VENTILEE
PAR LE HAUTI

ANY

THE

REPLACED,
IT
TEMPERATURE
3

CONNECTORS

ALL

NOTES=

ORIGINAL

WIRE

SUPPLIED

COBE
CODE
GODE_
WITH

[NEC}
{CEC)

THE

AND/OR/
AND/OR/

FURNACE

MUST
BE REPLACED
WITH _R]NG
MATERIAL
RATING
OF AT LEAST
Z21"F
{105"C)
SUITABLE

REPLACEMENT

PROVIDE

NATIONAL
ELEC,
CANADIAN
ELEC
LOCAL
OR CITY

FOR

COPPER

COMPONENTS

DISCONNECTS

FOR

CONDUCTORS

MUST

ALL

POWER

WALL

[
MUST

HAVING

NEU_

ONLY

PROPERLY

GROUNDED,

SYSTEM

SUPPLIES,

SWZTCH

_. MOTORS
ARE_NHERENTLY
PROTECTED.
INCOMING

TOUT

F[LAGE

CHANT]ER

SELON,

(A}

CODE

ELEC,,NAT[ONAL

(GEN}

ET/OU/

S( LE
L'ETRE
D'AU

F[LAGE
AVEC
MO[N5

SEULEMENT

€,

TOUTE

FOURN[£SEZ

LES

DOIT
ET_E
REMPLACE
UN MATERIAUX
POUVANT
Z21"F
(lOS"C).

DES

MARETTES

COMPOSANTE

LES

MOTEURS

POUR

REMPLACEMENT

D[SJONCTEURS

SONT

FIE

EN P_TRIE
RESISTER

PROTEGES'

POUR
DE PAR

LES

PRIMARY
IGNITION

RELAY

DOIT

LEUR

[ETRE

BIEN

M[SE

TERRE,

CONCEPTION,

LE'GENDE
BM

CONTROL

TRANSFORMER

MOTEUR

DU BRU_EUR

CONTR_LE

RELA]£

VALVE

SOUPE

CONTROL

CONTROLE

LSI

PRIMARY

LS2

LIMIT

& SOCKET

LIMIT

ON BLO_R

IT
(_

RUN

£W]TGH

SWITCH

IDENTIFIED

CAPACITOR
ROOM

THERMOSTAT

CONNECT(ON

FACTORY
_N_

WIRING

DEVICES

SOLENO[DE
PRIMA(RE

MOTEUR

DE LA

SOUFFLER[E

COMMUTATEUR
GOMMUTATEUR

DE LIM[TE

COMMUTATEUR

CENTRIF[QUE

DE L[M[TE

OOUILLE

BOUCHON

A 9

P[GES

BUR

PR[NGIPALE

COOZNG.
SUIVEZ

(_
_

CAPAC[TEUR

DE FONCT[ONNEMENT

CAPACITEUR

FONCT[ONNEMENT

RACCOROEMENT

RACCORDEMENT
FILA_E
F]LAGE

DE
BE

JUNCTION
_OX

BURNER

(DENT(FIE

TRANSFORMEUR

Z4V

wHT
OIL

FUSIBLE

O
AND

_EV[CES

COLOR

POLARIBEE."

PRP
DU

LS2

IT
RUN

D'IGN[T]ON

LSI

IRC

CONNECT(ON

FIELD

1_2_1_!_

_
CAPACITOR

TRANSFORMER

Z4V

PI/SI

£W[TCH

CENTRIFICAL
FUSE

IRC

MOTOR

OPSV

PRIMAIRE

TRANSFORMATEUR

PRIMARY

PLUG

OBSERVE
E_RE

COULEURB.

L'AL[MENTA]TON

SOL[NO[D

DOIT

WHT

PC
9

POLARIZED.

PI/SI

CODES

BE
COURANT

CU[VRE,

MOTOR

MUST
DU

OU EN TOUT,
Ih DOIT
A DES TEMPERATURES

LEGEND
BURNER

POWER

L'ALIMENTATION

/_/COOL
CANAO_E.
COEC_
ET/OU/
CODES ELEC
LOCAUX
ET MUN[CIPAUX,
Z,

WHT

L'USINE
CHANT[ER

THERMOSTAT

I[3ENTIFIE
DE PIECE

CHANTER
ET
ET

APPAREILS
APPARE[LS

1589_1

UWD

IBM

107272-UIM-A-0905

SECTION

X: GAS

GUN

BURNER

These instructions were prepared for the guidance of those installing
this particular gas conversion burner. While they apply in principle to all
installations, they should not be interpreted as meaning the only safe
and economical way to install a conversion burner. It may be necessary
to deviate from these instructions in some instances in order to comply
with local gas company rules or codes in effect in the area in which the
installation is made. It is recommended that the installer confer with the
local gas company and with the proper municipal officials regarding any
specific code or regulation governing the installation of gas conversion
burners, the installation must conform with local codes or, in the
absence of local codes, with the American National Standard Installation of Domestic Gas Conversion Burners, Z21.8 latest edition, and the
National Fuel Gas Code, ANSI Z223. l-latest edition.

ADANGER
An overpressure protection device, such as a pressure regulator,
must be installed in the gas piping system upstream of the fumace
and must act to limit the downstream pressure to the gas valve so it
does not exceed 0.5 PSI (!4" w.c. (3.48 kPa). Pressures exceeding
0.5 PSI (14" w.c. (3.48 kPa) at the gas valve wil! cause damage to
the gas valve, resulting in a fire or explosion or cause damage to
the furnace or some of its components that will result in property
damage and loss of life.
GAS

PIPING

Installation

and Checking

of Gas Line

Safe and economical operation of the burner throughout its service life
is dependent to a large extent upon its proper installation in the heating
appliance. Therefore, we may impress upon the installer that good
clean workmanlike installations mean satisfied customers.

Gas Supply piping must be sized in accordance with the recommendations contained in National Fuel Gas Code (ANSI-Z223.1, NFPA-54)
unless local codes or regulations state otherwise.
Materials used and pipe sizing for U.S. manufactured (mobile) homes

PREPARATION

must comply with requirements contained in Manufactured
Homes
Al19.1, Recreational Vehicles A!19.2 and H.U.D. Title 24, Section

OF COMBUSTION

CHAMBER

The power gas burner is designed for "inshot" firing into a refactory
lined combustion
chamber constructed
in the furnace originally
designed for oil firing.
When converting
same combustion

oil designed furnaces, it is recommended that the
chamber be used with the oil burner. If the blast tube

3280.705 and any local or state codes.
NOTE: The gas line inlet on the gas valve is 1/2-14 N.P.T. The gas line
may be installed through the furnace floor or either side of the furnace
to the gas valve.

opening into the combustion chamber is larger than the 4" (101.6 mm)
diameter, high temperature cement should be used to reduce the opening to 4" (101.6 mm) diameter.
IN NO CASE SHOULD THE TUBE BE ALLOWED TO EXTEND INTO
THE CHAMBER, IT MUST BE AT LEAST 1/8" (3,175mm) SHORT OF
THE INSIDE SURFACE OF THE COMBUSTION CHAMBER.
COMBUSTION

CHAMBER

The chamber is very fragile. DO NOT come in contact with the chamber
with the vacuum cleaner hose. The suction from the hose will create a
hole in the chamber. Hold hose at an angle when vacuuming
INSTALLATION

OF BURNER

AND

MANUAL
,_/SHUT-OFF
VALVE

chamber.

CONTROLS

The inshot power gas burner was designed especially for converting
gun fired oil designed furnaces. Due consideration was given to making
it as simple and easy to install and service as possible without weakening its durability or efficiency. The burner is supplied as a completely
assembled package unit.

MANUAL
SHUT-OFF
VALVE

LEG
DRIP
LEG

GAS
BURNER

NOTE: The burner must be installed in such a manner that the unit and
all controls will be readily accessible
ment, and repairs.

for inspection,

cleaning,

adjust-

This conversion burner is designed to operate on NATURAL GAS
or PROPANE GAS ONLX Do Not Burn any other Fue! in this furnace. Burning any fue! except NATURAL GAS or PROPANE GAS
can cause premature heat exchanger burnout, high levels of carbon
monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death.

FIGURE 39: Gas Piping

CAUTt0
]
The gas valve body is a very thin casting that cannot take any
external pressure. Never apply a pipe wrench to the body of the gas
valve when installing piping. A wrench must be placed on the octagon hub located on the gas inlet side of the valve. Placing a wrench
to the body of the gas valve wil! damage the valve causing improper
operation and/or the valve to leak. Refer to Figure 42.
The gas line should be a separate supply direct from the meter to the
gas valve. It is recommended that new pipe be used and located so that
a minimum amount of work will be required in future servicing. The piping should be so installed as to be durable, substantial and gas tight. It
should be clear and free from cutting burrs and defects in structure or
threading. Cast iron fittings or aluminum tubing should not be used for
the main gas circuit. Joint compounds (pipe dope) should be used sparingly on male threads only and be approved for all gases. Refer to Figures 39, 40 & 41.
It is recommended

that the pipe diameter in Table 16 be used to deter-

mine the size pipe to use from the meter to the burner.

Unitary

Products

Group

107272-UIM-A-0905

TABLE 16: Gas Line Piping Size and Length
Nominal
Length of Pipe in
Feet (Meter)

3/4 (!9.05)

1 (25.4)

Capacity-Cu.

Diameter

of Pipe in Inches (mm)

!-1/4 (31.75)

Ft. (m 3) Per Hr. with a 0.6 Sp. Gr. Gas and Pressure

!-1/2 (38.1)

2 (50.8)

Drop of 0.3 in. (74.72 Pa) Water Col.

15 (4.572)

172 (4.87)

345 (9.77)

750 (21.24

30 (9.!44)

120 (3.4)

24! (6.82)

535 (15.15)

850 (24.07)

45 (!3.72)

99 (2.8)

!99 (5.64)

435 (!2.32)

700 (!9.82)

60 (18.29)

86 (2.44)

173 (4.90)

380 (10.76)

610 (17.27)

75 (22.86)

77 (2.!8)

155 (4.34)

345 (9.77)

545 (15.43)

105 (32)

65 (1.84)

13! (3.71)

285 (8.07)

450 (12.74)

920 (26.05)

120 (36.58)

120 (3.4)

270 (7.65)

420 (!1.89)

860 (24.35)

180 (54.86)

100 (2.83)

225 (6.37)

350 (10.76)

720 (20.39)

The building structure should not be weak end by installation for the gas
piping. The piping should not be supported by the other piping, but
should be firmly supported with pipe hooks, straps, bands, or hanger.

Some utility companies or local codes require pipe sizes larger than the
minimum sizes listed in these instructions and in the codes. The furnace

Butt or lap welded pipe should not be bent.

approved for this furnace - only use those approved

The gas piping should be so installed so as to prevent an accumulation

IMPORTANT:

of condensation and it must be protected against freezing. A horizontal
pipe should be pitched so that it grades toward the meter and is free
from sags. The pipe can not be run through or in an air duct or clothes
chute.

upstream of the furnace gas valve and within 6 feet (1.8 m) of the furRace.

The appliance

and its individual shut-off

valve must be disconnected

from the gas supply piping system during any pressure testing of the
system at test pressure in excess of 1/2 (3447 PaG) psig.
The appliance must be isolated from the gas supply piping system by
closing its individual manual shut-off valve during any pressure testing
of the gas supply piping system at test pressures equal to or Iess than
1/2 (3447 PaG) psig. Refer to Figure 40.

TESTING

An accessible

PIPING

FOR

in this section specify the type of gas

manual

gases.

shut-off valve must be installed

LEAKS

Before turning on gas under pressure into piping, atl openings from
which gas can escape should be closed. Immediately after turning on
gas, the system should be checked for leaks. This can be done by
watching the 1/2 cubic feet (0.14 m 3) test dial and allowing 5 minutes to
show any movement, or by soaping each pipe connection and watching
for bubbles. If a Ieak is found, make the necessary repairs and repeat
the above test.
DEFFECTIVE PIPES OR FITTINGS SHOULD BE REPLACED AND
NOT REPAIRED. NEVER USE A FLAME OR FIRE IN ANY FORM TO

ManuaI
Shutoff Valve
(Close this valve during pressure
testing of the gas line)
Gas Line
Shutoff,
Valve

rating plate and the instructions

1/8" NPT Plugged
Pressure
Gauge Port
Direction
of Flow

Union

Black

LOCATE GAS LEAKS, USE A SOAP SOLUTION.
TABLE 17: Length of Standard Pipe Threads in Inches (mm)
PIPE SIZE

EFFECTIVE LENGTH
OF THREAD

OVERALL LENGTH
OF THREAD

3/8 (9.53)

9/16 (!4.29)

1/2 (12.7)

3/4 (19.05)

3/4 (!9.05)

1/2 - 9/16 (14.29)

13/16 (20.64)

1 (25.4)

9/16 (14.29)

1 (25.4)

To Gas
Valve
2 Imprerfect
Threads

t
3.00 Min.

Leave 2 End I/
Threads Bare J

Pipe
LOCATION OF UNION AND DRiP LEG FOR
CONNECTING BURNER TO HOUSING PiPiNG

FIGURE 40:
GAS

PIPING

Manual Shut-offValve/Gas

Piping

INSTALLATION

Properly sized wrought iron, approved flexible or steel pipe must be
used when making gas connections to the unit. If local codes allow the
use of a flexible gas appliance connection, always use a new listed connector. Do not use a connector that has previously serviced another gas
appliance.

FIGURE 41:

Proper Piping Practice

........
If the gas input to the furnace is too great because of excessive
gas pressure, wrong size orifice, high altitude, etc., the burner
flame will be sooty and may produce carbon monoxide, which
could result in unsafe operation, explosion, and/or fire or
asphyxiation.

Unitary

Products

Group

107272-UIM-A-0905
HIGH

ALTITUDE

GAS

ORIFICE

CONVERSION

This furnace is constructed at the factory for natural gas-fired operation
at 0 - 2,000 ft. (0 m - 610 m) above sea level.
To install gas line and to connect it to the gas valve, care must
be taken to hold gas valve firmly to prevent misalignment of the
burner orifice, or to damage gas valve which could result in
improper heating, explosion, fire or asphyxiation.
DO NOT USE EXCESSIVE PIPE SEALANT ON PIPE JOINTS.
Pipe sealant, metal chips or other foreign material that could be
deposited in the inlet of the gas valve, when gas pipe is installed
or carried through the gas piping into the gas valve inlet after
installation, may cause the gas valve to malfunction and could
result in possible improper heating, explosion, fire or asphyxiation. Also, pipe sealant must be resistant to Propane gas.
A main shut-off valve shaft be installed externally of furnace casing. After piping has been installed, turn gas on and check all
connections with a leak detector or soap solution.
Never use open flame to test for gas leaks as fire or explosion
could occur.
Do not test the fuel system at more than !4" W. C. after furnace
has been connected to fuel line. Such testing could void the
warranty. Any test run above !4" tAZC. may damage furnace
control valve which could cause an explosion, fire or asphyxiation.
A drip leg is required by some local codes to trap moisture and contaminations. Refer to Figure 39 or 40.
For natural gas operation, the furnace is designed for 7" W.C. inlet gas
pressure. Pressure to main burner is then reduced to 3 1/2" W.C at the
gas valve.
Refer to Figure 42 for location of Gas Valve Main Regulator Adjustment.
The furnace must be isolated from the gas supply piping system by
closing its individual external manual shut-oft valve during any pressure
testing of the gas supply piping system at pressures
than 1/2 psig (3.5 kPa).

equal to or less

Gas piping may be connected from either side of the furnace using any
of the gas pipe entry knockouts on both sides of the furnace. Refer to
Figure 39 Gas Piping.
GAS

ORIFICE

CONVERSION

FOR

PROPANE

(LP)

The gas orifices on this furnace must be changed in order to maintain
proper and safe operation, when the furnace is installed in a location
where the altitude is greater than 2,000 ft. (616 m) above sea level on
natural gas or the altitude is greater than 4,000 ft. (1219 m) above sea
level on propane (LP) gas. Refer to Table 18 or the instructions in the
high altitude conversion kit for the proper gas orifice size.
For Propane gas operation, the furnace is designed for 11" w.c. (2.74
kPa) inlet gas pressure. Pressure to main burner is then reduced to 3.5"
w.c. (0.87 kPa).
The unit may also be converted for altitudes up to 10,000 ft. (3048 m)
on natural and propane (LP) gas with additional derate as shown in
Table 18 or refer to ANSI Z223.1 NFPA 54 National Fuel Gas Code or in
Canada
Code.
HIGH

CAN/CGA-B149.1-00

ALTITUDE

Natural

PRESSURE

Gas and Propane

SWITCH

Installation

CONVERSION

For installation in locations where the altitude is less than 4,500 feet
(1372 m), it is not required that the pressure switch be changed, For
altitudes above 4,500 feet (137 m), refer to Instructions in the Accessory High Altitude Kit.

A.DANGER
PROPANE AND HIGH ALTITUDE

CONVERSION

KITS

It is very important to choose the correct kit and/or gas orifices for
the altitude and the type of gas for which the furnace is being
installed.
Only use natural gas in furnaces designed for natural gas. Only use
propane (LP) gas for furnaces that have been properly converted to
use propane (LP) gas. Do not use this furnace with butane gas.
Incorrect gas orifices or a furnace that has been improperly convetted wil! create an extremely dangerous condition resulting in premature heat exchanger failure, excessive sooting, high levels of
carbon monoxide, personal injury, property damage, a fire hazard
and/or death.

This burner is constructed at the factory for natural gas-fired operation,

High altitude and propane (LP) conversions are required in order
for the appliance to satisfactory meet the application.

but may be converted to operate on propane (LP) gas by using a factory-supplied LP conversion kit. Follow the instructions supplied with

An authorized

the LP kit. Refer to Table 18 or the instructions

in the propane (LP) con-

version kit for the proper gas orifice size.
IMPORTANT: When converting gas valve from or to Propane gas, it will
be necessary to change main burner orifice to prevent an underfired or
overfired condition. Refer to furnace rating plate or to Table 18 for
proper orifice size.

,&DANGER

distributor or dealer must make all gas conversions.

In Canada, a certified conversion station or other qualified agency,
using factory specified and/or approved parts, must perform the
conversion.
The installer must take every precaution to insure that the furnace
has been converted to the proper gas orifice size when the furnace
is installed. Do not attempt to drill out any orifices to obtain the
proper orifice size. Drilling out a gas orifice will cause misalignment
of the burner flames, causing premature heat exchanger burnout,
high levels of carbon monoxide, excessive sooting, a fire hazard,
personal llW04 property damage and/or death.

The manifold pressure does not change when converting to Natural
or Propane Gas. The manifold pressure is 3.5 in w.c. (0.87 kPa) on
both Natural and Propane Gas. Change only the gas orifice when
converting this burner to Natural or Propane Gas. Manifold pressure in excess of 4.0 in w.c (0.99 kPa) can cause premature heat
exchanger failure. High levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage, and/or death.

Unitary

Products

Group

107272-UIM-A-0905
TABLE 18: High Attitude Duration Chart
NATURAL
Elevation
Feet

56,000 -- Input
Meters

Sea Level

Orifice
Dia.

Drill
Size

0.136

GAS

70,000 -- Input
Part #

77,000 -- Input

Orifice
Dia.

Drill
Size

Part #

Orifice
Dia.

Drill
Size

9951--1361

0.!54

9951--1541

0.161

90,000 -- Input

Part #

Orifice
Dia.

Drill
Size

Part #

9951--16!1

0.180

9951--1801

2,000

618

0.136

9951--1361

0.149

9951--1491

0.157

995!--157!

0.177

9951--1771

3,000

914

0.128

9951--1281

0.!49

9951--1491

0.157

995!--!57!

0.173

9951--1731

4,000

1219

0.128

9951--!281

0.147

9951--1471

0.154

9951--1541

0.173

9951--173!

5,000

1524

0.128

9951--1281

0.!44

9951--1441

0.152

995!--!52!

0.169

9951--1691

6,000

1829

0.128

9951--1281

0.144

9951--1441

0.149

995!--149!

0.166

9951--1661

7,000

2134

0.120

9951--1201

0.!40

9951--1401

0.147

995!--!47!

0.161

9951--161!

8,000

2438

0.120

9951--1201

0.!36

9951--1361

0.144

995!--!44!

0.161

9951--161!

9,000

2743

0.120

9951--1201

0.136

9951--1361

0.140

995!--140!

0.157

9951--1571

10,000

3048

0.116

9951--116!

0.!28

9951--1281

0.136

995!--!36!

0.152

9951--1521

PROPANE
Elevation
Feet

56,000 -- Input
Meters

Sea Level
2,000

Orifice
Dia.

Drill
Size

GAS

70,000 -- Input
Part #

77,000 -- Input

90,000 -- Input

Orifice
Dia.

Drill
Size

Part #

Orifice
Dia.

Drill
Size

Part #

Orifice
Dia.

Drill
Size

Part #

0.082

9951--0821

0.093

9951--0931

0.098

9951--0981

0.106

9951--1061

618

0.081

9951--081!

0.093

9951--0931

0.096

995!--096!

0.104

9951--1041

3,000

914

0.078

9951--0781

0.089

9951--0891

0.093

995!--093!

0.101

9951--101!

4,000

1219

0.078

9951--0781

0.089

9951--0891

0.093

9951--0931

0.101

9951--1011

5,000

1524

0.078

9951--0781

0.089

9951--0891

0.093

995!--093!

0.099

9951--0991

6,000

1829

0.076

9951--0761

0.086

9951--0861

0.089

995!--089!

0.098

9951--0981

7,000

2134

0.076

9951--0761

0.086

9951--0861

0.089

995!--089!

0.096

9951--0961

8,000

2438

0.073

9951--0731

0.082

9951--0821

0.086

9951--0861

0.096

9951--0961

9,000

2743

0.073

9951--0731

0.081

9951--0811

0.086

995!--086!

0.093

9951--0931

10,000

3048

0.070

9951--0731

0.078

9951--0781

0.082

995!--082!

0.089

9951--0891

Tabte shows 4% Input Reduction per 1,000 ft (3048 m) Elevation Reference Source: NFPA No. 54, ANSI Z 2231, National Fuet Gas Code.
For Canadian high aItitude {2000 - 4500 ft (6096 - 1,371.6)}, reduce gas manifotd pressure to 3.0" w.c. (0.75 kPa) for Natural gas and for Propane gas

SIZING

FURNACE

INPUT

The orifice spud supplied with all burners is the size for the minimum
BTU input of the burner for the type gas shown on the rating plate.
Table 18 shows the correct drill size for various inputs.
The correct manifold pressure for natural and LP gas is 3.5" w.c (0.87
kPa). Only minor adjustments in the input rate should be made by
adjusting the pressure regulator. The minimum manifold pressure
should be 3.0" w.c. (0.75 kPa) and the maximum pressure should be
3.5 w.c. (0.87 kPa) the next size larger or smaller orifice size should be
used if the desired input rating cannot be obtained within the above
manifold pressure adjustment range.

TABLE 19: Gas Burner Settings
Gas

Firing Rate

Orifice

Air Shutter

(@ 3.5" W.C.)

BTU/Hr (kw)

Size

Setting

Natural

66,000 (19.3)

0.142" (3.61mm)

! .0

Natural

84,000 (24.6)

0.166" (4.22 mm)

3.5

66,000 (19.3)

0.!16" (2.95 ram)

2.0

84,000 (24.6)

0.100" (2.54 mm)

3.5

NOTE: The BTU input valves in the above table show the approximate
hourly input of the burner for the various drill sizes shown. To determine
the actual input of the burner, turn off all other gas appliances.

Unitary

Products

Group

107272-UIM-A-0905

CARBON MONOXIDE

POISONING

HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon
monoxide poisoning or death.
The following steps shaft be followed for each appliance connected to the venting system being placed into operation, while aft other appliances
connected to the venting system are not in operation:
1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or other
deficiencies, which could cause an unsafe condition
2. Close all building doors and windows and all doors.
3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum
speed. Open the fireplace dampers. Do not operate a summer exhaust fan.
4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance
uously.
5. Test each appliance

shall operate contin-

(such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening

after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to the
appliance as possible. Use a combustion analyzer to check the CO2 and CO levels of each appliance. Use a draft gauge to check for a
downdraft or inadequate draft condition.
6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their normal condition.
7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not
have enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can
function safely.
NOTE: An unsafe condition exists when the CO reading at the furnace vent exceeds 40 ppm and the draft reading is not in excess of - 0.! in.
W.C. (-0.025 kPa) with all of the appliance(s) operating at the same time.
8. Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National FueI Gas Code
Z223.1 or CAN/CGA B149.1-00 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the
appropriate tables in Appendix G of the above codes or for this appliance.

SECTION
Xh
ADJUSTMENTS

START-UP

The initial start-up of the furnace
procedures:
IMPORTANT:

AND
requires

After the gas line to the conversion

the following

additional

All electrical connections made in the field and in the fac-

burner has been fully purged, the

gas supply at other pilot burners located on other gas appliances which
were extinguished as the result of interrupted service will need to be
reignited. Check all appliances to make sure the pilots are ignited.
CALCULATING

THE

FURNACE

INPUT

tory should be checked for proper tightness.

(NATURAL

When the gas supply is initially connected to the furnace, the gas piping
may be full of air. In order to purge this air, it is recommended that the
ground union be loosened until the odor of gas is detected. When gas is

NOTE: Front door of burner box must be secured when checking gas
input.

detected, immediately retighten the union and check for leaks. Allow
five minutes for any gas to dissipate before continuing with the start-up
procedure. Be sure proper ventilation is available to dilute and carry
away any vented gas.
PURGING
After the piping has been checked, all piping and appIiances receiving
gas through the meter shall be fully purged. A suggested method for
purging the gas Iine to the burner is to allow the burner to cycle until
burner ignites. Do not purge by loosening gas lines. Under no circumstances shall the Iine be purged into the combustion chamber.

Unitary

Products

Group

GAS)

NOTE: Burner orifices are sized to provide proper input rate using natural gas with a heating value of 1030 BTU/Ft 3 (3.6 mj/m 3. If the heating
value of your gas is significantly
replace the orifices.

different,

it may be necessary

Turn off all other gas appliances connected to the gas meter.

At the gas meter, measure the time (with a stop watch) it takes to
use 2 cubic ft. (0.0566 m3) of gas.

Calculate the furnace
tions.

input by using one of the following

equa-

107272-UIM-A-0905

In the USA use the following

formula

to calculate

the furnace

input,

For natural gas multiply the heat content of the gas BTU/SCF or Default 1030 BTU/SCF (38.4 M j/m3), times 2 cubic ft. (0.056 m) of gas measured at
the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (in seconds) it took to
measure 2 cubic ft. (0.056 m) of gas from the gas meter.
For propane (LP) gas multiply the heat content of the gas BTU/SCF or Default 2500 BTU/SCF (93. !5 Mj/m3), times 1 cubic ft. (0.028 m) of gas measured at the gas meter, times a barometric pressure and temperature
took to measure
The formula

1 cubic ft. (0.028

for US input

m) of gas from

calculation

using

a cubic

foot

gas

BTU/ft 3 x 2 cu.ft, x 0.960 x 3600
Seconds it took to measure the 2 cu.ft, of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
1030 x 2 x 0960 x 3600
905
Natural Gas
1030 BTU/SCF

In Canada you will use the following

formula

For Natural Gas multiply the Heat content

correction factor of 0.960; times 3600, then divided by the time (In seconds) it

the gas meter.
meter:
BTU/H

BTU/ft 3 x 1 cuft x 0960 x 3600
Seconds it took to measure the 1 cuft of gas
PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
2500 x 1 x 0960 x 3600
108
Propane Gas
2500 BTU/SCF

78,666.90

to calculate the furnace

BTU/H

80,000 00

input if you are using a cubic foot gas meter.

of the gas MJ/m 3 (or Default 38.4), times 2 cubic ft. of gas x 0.028 to convert from cubic feet to cubic

meters measured at the gas meter, times a barometric pressure and temperature
took to measure 2 cubic ft. (0.056 m) of gas from the gas meter.

correction factor of 0.960; times 3600, then divided by the time it

For Propane (LP) Gas multiply the Heat content of the gas MJ/m 3 (or Default 93.15), times 1 cu. ft. of gas x 0.028 to convert from cubic feet to cubic
meters measured at the gas meter, times a barometric pressure and temperature
took to measure ! cubic ft. (0.028 m) of gas from the gas meter.
The formula

for metric input calculation

using a cubic foot gas meter:

MJ/m 3 x 2 cu.ff, x 0.028 x 0.960 x 3600
Seconds it took to measure the 2 cu ft of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
384 x 2 x 0.028 x 0.960 x 3600
90.5
Natural Gas
1030 BTU/SCF

In Canada use the following

formula

MJ/H

02777

3412.14

8212

02777

2280

3412.14

8346

02777

2318

3412.14

BTU/H

77,79680

= 38.4 MJ/m 3

PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
93.15 x 1 x 0028 x 0.960 x 3600
108
Propane Gas
2500 BTU/SCF

correction factor of 0.960; times 3600, then divided by the time it

79,0934

= 93.15 MJ/m 3

to calculate the furnace

input if you are using a gas meter that measures

cubic meters.

For Natural Gas multiply the Heat content of the gas MJ/m 3 (or Default 38.4), times 0.10 m3 of gas measured at the gas meter, times a barometric
pressure and temperature

correction factor of 0.960; times 3600, then divided by the time it took to measure 0.10 m3 of gas from the gas meter.

For Propane (LP) Gas multiply the Heat content of the gas M Jim 3 (or Default 93.!5),
metric pressure and temperature
meter.
The formula

times 0.10 m 3 of gas measured at the gas meter, times a baro-

correction factor of 0.960; times 3600, then divided by the time it took to measure 0.10 m3 of gas from the gas

for metric input calculation
MJ/m 3 x m 3 x 0960

using a cubic meter gas meter:
x 3600

Seconds it took to measure the 0.10 m
NATURAL GAS INPUT CALCULATION
EXAMPLE:
384 x 0.1 x 0960 x 3600
160
Natural Gas
1030 BTU/SCF = 38.4 MJ/m 3

of gas

PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
9315 x 01 x 0.960 x 3600
387
Propane Gas
2500 BTU/SCF = 93.15 MJ/m 3

MJ/H

02777

341214

BTU/H

8294

02777

2303

341214

78,581.60

8319

02777

2310

341214

78,826.3

DO NOT ADJUST the manifold pressure regulator if the actual input is equal to or within 8% less than the furnace input specified on the rating plate
or if the furnace rise is above the specified rise range on the rating plate.
If the actual input is significantly
higher than the furnace
of the proper size for the type of gas you are using.

input specified

For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED.
ALTITUDES IN SECTION IV for information on high altitude conversions.

on the rating

plate then replace the gas orifices with the gas orifices

Refer to the GAS CONVERSION

FOR PROPANE (LP) AND HIGH

Unitary

Products

Group

107272-UIM-A-0905
INITIAL

START

ADJUSTMENT

Read the applicable sequence of gas control operation
Operation and Troubleshooting section before proceeding.

Move the gas valve control switch to the "OFF" position.

Adjust the primary air. Set the damper to the start up settings.

On new gas line installations, air may be trapped in the line, the
burner may experience several lockouts until all the air is purged
from the lines.

Turn on the main electrical power and set the thermostat to call for
heat. Allow the burner to run a MINIMUM of 5 minutes to purge
combustion chamber and appliance heat exchanger.

Set the thermostat
"OFF".

Move the gas valve control switch to the "ON" position.

Set the thermostat or operating control to call for heat. The burner
will start and go through the applicable sequence of burner/primary gas control operation, refer to step 1.

below room temperature,

in the

shutting the burner

THE

GAS

MANIFOLD

GAS

PRESSURE

Manifold gas pressure may be measured at the gas valve.
Turn gas off at the ball

valve

or gas cock

before the gas valve.
Find the
valve marked
OUT and INLET.

pressure

on gas supply
ports

line

on the gas

IMPORTANT: The cap for the pressure regulator must be removed
entirely to gain access to the adjustment screw. Loosening or tightening
the cap does not adjust the flow of gas.
1.

Refer to Figure 42 for location of pressure regulator
cap and adjustment screw on main gas valve.

Adjust manifold pressure by adjusting gas valve regulator
for the appropriate gas per the following:

adjustment
screw

TABLE 21: Nominal Manifold Pressure
NOMINAL

Once burner is running, adjust the orifice manifold pressure regulator as described in Pressure Regulator Adjustment.

CHECKING

MANIFOLD

PRESSURE

Natural Gas

35" w.c (087 kPa)

Propane (LP) Gas

35" w.c. (0.87 kPa)

PRESSURES

The pressure ports on the gas valve are marked OUT and INLET.

The manifold pressure must be taken at the port marked OUT.

The inlet gas supply pressure must be taken at the port marked IN
LET.

Using a 3/32" (0.2 cm) Alien wrench, loosen the set screw by turning it 1 turn counter clockwise. DO NOT REMOVE THE SET
SCREW FROM THE PRESSURE PORT.

IMPORTANT: If gas valve regulator is turned in (clockwise), manifold
pressure is increased. If screw is turned out (counter clockwise), manifold pressure will decrease.

Use the 4" (10.2 cm) piece of 3/8" (0.9 cm) tubing to connect the
positive side of the manometer to the gas valve pressure reference port. Refer to Figure 43 for connection details.

Electrical Terminals

FIGURE 42: Gas Valve

Minimum
Maximum

RANGE

Natural Gas

Propane (LP)

45" WC (1 12 kPa)
105 _W.C (261 kPa)

80 _W.C (199 kPa)
130" (3.24 kPa) W.C.

IMPORTANT: The inlet gas pressure operating
the minimum and maximum gas line pressures
nace operation.

range table specifies
required for safe fur-

After the manifold pressure has been adjusted, re-calculate the
furnace input to make sure you have not exceeded the specified
input on the rating plate. Refer to "CALCULATING
INPUT (NATURAL GAS)".

TABLE 20: inlet Gas Pressure Range
INLET GAS PRESSURE

(Shown in ON position)

THE FURNACE

Once the correct BTU (kW) input has been established,

turn the

gas valve to OFF and turn the electrical supply switch to OFF; then
remove the flexible tubing and fittings from the gas valve pressure
tap and tighten the pressure tap plug using the 3/32" Allen wrench.
5.

Turn the electrical and gas supplies back on, and with the burners
in operation, check for gas leakage around the gas valve pressure
port for leakage using an approved gas detector, a non-corrosive
leak detection fluid, or other leak detection methods.

The minimum inlet gas pressure required to obtain the BTU input specified on the rating plate and in these instructions is shown below:
•

7.0" w.c. (1.74 kPa) for Natural Gas

•

11.0" w.c. (2.74 kPa) for Propane (LP) Gas

Unitary

Products

Group

The manifold pressure must be checked with the screw-off cap for
the gas valve pressure regulator in place. If not, the manifold pressure setting could result in an over-fire condition. A high manifold
pressure will cause an over-fire condition, which could cause premature heat exchanger failure. If the manifold pressure is too low,
sooting and eventual clogging of the heat exchanger could occur.
Be sure that gas valve regulator cap is in place.

107272-UIM-A-0905

MAINFOLD PRESSURE

ADJUSTMENT

"U" TUBE CONNECTION

TEMPERATURE

RISE

F_
Outlet
Pressure
Tap

The temperature rise, or temperature difference between the return
air and the supply (heated) air from the furnace, must be within the
range shown on the furnace rating plate and within the application
limitations shown in Table 8 "ELECTRICAL AND PERFORMANCE
DATA".

Tubing

Gas
3.5 IN (0.87
Water

The supply air temperature cannot exceed the "Maximum Supply
Air Temperature"
specified in these instructions and on the furnace rating plate. Under NO circumstances can the furnace be
allowed to operate above the Maximum Supply Air Temperature.
Operating the furnace above the Maximum Supply Air Temperature
will cause premature heat exchanger failure, high levels of Carbon
Monoxide, a fire hazard, personal injury, property damage, and/or
death.

Valve

kPa)

Cotumn
Gas
Pressure
Shown

FIGURE 43:
Observing

The temperature

Reading Gas Pressure
Burner

rise, or temperature

Operation

Observe burner to make sure it ignites. Observe color of flame. On
natural gas the flame will burn blue with appreciably yellow tips.
On Propane gas a yellow flame may be expected. If flame is not
the proper color call a qualified service technician for service.

2.
3.

Let furnace heat until blower cycles on.
Turn thermostat down.

Observe burner to make sure it shuts off.

Let the furnace cool and blower cycle off.

After the desired input has been obtained, re-adjust the primary air
damper open or closed to visually obtain a blue flame with welt
defined orange or yellow tips for natural gas, or well defined yellow

After the burner has been in operation for at least 20 minutes,
assuring combustion chamber and heat exchanger are fully
warmed, take combustion analysis flue gas samples in the flue
pipe.

tips for propane gas.

shutting off the electrical supply.
If any abnormalities are observed when checking for correct operation,
such as burner failing to ignite or to turn off, sooty flame, etc., call your
nearest authorized service technician as shown in the Service Center

All adjustments below must be made with the following instructions:
a.
Draft Gauge

List included in the home owner envelope with the furnace.
Fails

to Operate

CHECK

1.
Should overheating occur, or the gas supply fail to shut off,
shut off the manual gas valve to the furnace and allow burner
to run until furnace cools down and blower shuts off before

between the return air

After about 20 minutes of operation, determine the furnace temperature
rise. Take readings of both the return air and the heated air in the ducts.
Increase the blower speed to decrease the temperature rise; decrease
the blower speed to increase the rise.

PERFORMANCE

If Furnace

difference

and the heated supply air from the furnace, must be within the range
shown on the furnace rating plate and within the application limitations
as shown in Table 8.

Properly

Check setting of thermostat - and position of HEAT/COOL switch if
air conditioning
is installed. If a set-back type thermostat is
employed be sure that the thermostat is in the correct operating
mode.

b.
c.

02 or CO 2 Analyzer
CO Tester

d.
Water Column Gauge
NOTE: ALWAYS USE RELIABLE COMBUSTION
TEST INSTRUMENTS. BEING PROFICIENT
IN THE USE OF THESE INSTRUMENTS AND INTERPRETING
THE DATA IS NECESSARY FOR

Check to see that electrical power is ON.

Check to see that the switch on the gas control valve is in the full
ON position.

SAFE, RELIABLE

AND EFFICIENT BURNER OPERATION

IT IS ESSENTIAL

TO MAKE CERTAIN THAT THE PRODUCTS

Make sure filters are clean, return grilles are not obstructed,
supply registers are open.

COMBUSTION

Be sure that furnace flue piping is open and unobstructed.

and

If the cause for the failure to operate is not obvious, do not attempt to
service the furnace yourself. Call a qualified service agency or your gas
supplier.

DO NOT CONTAIN CARBON

MONOXIDE, CO.

The most common causes of CO are flame impingement on cool surface and insufficient primary air, both of which could be caused by over
firing. The only answer is to reduce the firing rate or increase the primary air.

Unitary

Products

Group

107272-UIM-A-0905

Combustion efficiency is determined by the percent CO 2 and the temperature of the flue gases. These two measurements are taken on the
vent. Combustion efficiency and stack loss calculators are available
from several manufacturers of combustion test equipment.

On a call for heat, voltage (24V) is applied to motor start relay and air
switch. Once the fan motor reaches operating rpm, combustion air pressure is sensed by the air proving switch and closes the switch contacts
energizing the $89F gas primary control.

IMPORTANT: DRAFT - When installing Wayne power conversion gas
burners in oil fired furnaces a minimum negative draft of .01" w.c.
(0.0025 kPa) over fire must be maintained.

The S87K gas primary control has an internal 30 second prepurge
timer. After the initial 30 second prepurge, an internal 8 second safe
start check of the S89F will commence. Once this is successfully completed, the S87K simultaneously energizes the gas valve and ignition
transformer. Gas flows and the transformer produces an approximate
7300 volt spark end point grounded at the burner head establishing
main burner flame.

Refer to your local gas company and codes for assistance.
3.

Perform the following combustion
must be made with the following

analysis. All adjustments below
instruments: draft gauge, 02 or

CO 2 analyzer and CO tester.
a.

Adjust the primary air damper to provide about 25% excess
combustion air. Confirm this by checking the flue gas for its
FREE

OXYGEN

(02)

or CARBON

DIOXIDE

(CO2) PER-

CENTAGES with a test instrument. Free oxygen should be
about 4.5%, or carbon dioxide should be about 9.5% for natural gas, 12.1% for propane gas.
b.

CARBON MONOXIDE - Should be checked for its presence
in the flue gas. This percentage should not exceed .04% (or
400 PPM).

NOTE: Check overfire draft and adjust to NEGATIVE -.01 (0.0025 kPa)
to -.02 (4.982 pa) inches w.c. during burner operation.
OPERATION

AND

TROUBLESHOOTING

SEQUENCE
OF OPERATION
LIZING HONEYWELL
S87K
30 SECOND
PREPURGE

-- SC80-C GAS BURNER
UTIGAS PRIMARY
WITH BUILT IN

<-.13

At the start of each heat cycle, there is a trial for an ignition period of a
four (4) second duration. Normally, burner flame will be established
before the end of this period. Once the flame is established, sparking
will cease and the flame rod will provide flame monitoring to the $87K
gas control primary for the remainder of the heat cycle. If the flame
should be extinguished during the heat cycle, the $87K gas control primary will go into the 30 second prepurge and 8 second safe start check,
then re-energize the gas valve and ignition transformer in an attempt to
establish the main burner flame. If this does not occur within the 4 second trial for ignition period, the S87K gas primary control will go into
lockout de-energizing the gas valve and ignition transformer.
To restart the system, the main power or thermostat must be de-energized momentarily, then re-energized. If, at any time during the heat
cycle, there is an insufficient supply of combustion air to the burner, the
air switch will open, putting the system into lockout, closing the gas
valve.

Igniter Gap

. .13 FIame Sense
Rod Gap

FIGURE 44:

Unitary

Electrode Orientation

Products

Group

and Gap

6_
C

m
01

BLOWER

SPEED

(CHARTE
DE

LADDER

CHART

DIAGRAM

(DIAGRAMME

VITESSE

ELEMENTAIRE)

IF
IT

ANY
MUST

OF
THE
ORIGINAL
WIRE
SUPPLIED
BE
REPLACED
WITH
TYPE
IO5'C

WITH
THIS
THERMOPLASTIC

UNIT

MUST
BE
REPLACED,
OR
ITS EQUIVALENT.

SOUFFLERIE)
ee

BLACK

ON MOTORS WITHOUT

CAPACITOR

g
o

ORG

WIRE

COLOR

KEY

(CODE DE COULEUR
DU FILAGE)
BLACK
(NOIR)
BLUE

[BLEU)
RED

IROUG}

[ROUGE)
YELLOW
{JAUNE}

LSZ

1_24v
GNU

WHITE

[BLANC)
BRN
[BRUN}

[BLANC)
BROWN
[BRUN)

GRN
(VERT}

GREEN
{VERT)

GND
II(EN TERRE)

÷ *.T
F

BLEND

(IF

PRP
{POURPRE]
ORN

PURPLE
{POURPRE[
ORANGE

(ORA}

{ORANGE)

_ SEC

AIR

EQUIPPED)

LSI

_1@1@1_1

•

•
FORIER

CAUTION

OPEN

Ic_k_

ALL
DISCONNECTS
SERVICING
THIS

BEFORE
UNIT

i I i i

L __

PRE'CAUTION

HEAT/COOL

THERMOSTAT

(THERMOSTAT
OUVREZ
DE

LES

DISJONCTEURS

PROCEDER

AVEC

SERVICE
_[R[NG

PER:

DOWNFLOW FURNACE

(A) NATIONAL
{B)
CANADIAN
[C}

(FOURNAISE
BOX
VENTILEE
PAR LE HAUTI

NOTES=
TOUT

6.
F[LAGE

CHANTIER

SELON:

CA[ CODE

ELEC

LOCAL

ELEC.
ELEC.
CITY

CODE [NEC}
CODE (CEC)

AND/OR/
AND/OR/

CONNECTORS

SUITABLE

REPLACEMENT

PROVIDE
MOTORS
.NATIONAL

FOR

ARE

FOR

INHERENTLY

(CEN[

COPPER

COMPONENTS

D[SgONNEgT5

ALL

CONDUCTORS

MUST

ONLY.

BE PROPERLY

POWER

8ROUNDED.

SUPPLIES

S[ LE F[LABE
L'ETRE
AVEC
D'AU
MO[NS

SEULEMENT

TOUTE

FOURN[SSEZ

LES

DOlT
ET_E
REMPLACE
UN MATER[AUX
POUVANT
ZZI"F
(105"C).
DES

MARETTES

COMPOSANTE
LE£

MOTEURS

POUR

REMPLACEMENT

D[SJONCTEURS

SONT

FIE

EN P_TRIE
RESISTER

PROTE,GES

POUR
DE PAR

[ETRE

BEN

M[SE

BURNER

PRIMARY

IGNITION

R2
PC
PI/SI
LSI
LS2
CS

pC
IT
R2

CONTROL

LIMIT

& SOCKET

LIMIT

BLOWER

S_ITCH

MOTOR

PI/SI
L£1

SWITCH

LS2

CENTR[FICAL

SWITCH

FUSE
IRC
IT
@

RUN

IRC

TRANSFORMER

2#V
0

CAPACITOR

IDENTIFIED

FIELD

CAPACITOR

WIRING

AND

ROOM THERMOSTAT

CONNECTION

FACTORY
FIELD

IT
RUN

CONNECTION

CONTACTOR
r_i
•_F

EQUIPPED

GRaUND

SYSTEM
SWITCH

LE'GENBE
BM

TRANSFORMER

PRIMARY

CONDENSING
UNIT

BLK

TERRE.

CONTROL

PLUG

I
I
i

_/_

CONCEPTION.

MOTOR

PRIMARY

INCOMING POWER MUST BE POLARIZEOI
OBSERVE
COLOR COOINGI
L'ALIMENTATION
DU COURANT DOIT E_RE POLARISEE[
SUIVEZ
LES CODES DE COULEURS.

RELAY

i
i

BLK
'

WALL

LEGEND
BM

THERMOSTAT

OU EN TOUT,
[L DOIT
A DES
TEMPERATURES

L'AL[MENTAITON.
LEUR

PROTECTED

CUIVRE

DOlT

III

ET/OU/

/_/CODE
CA.ADEN
COEC_
ET_OUJ
CODES ELEC
LOCAUX
ET MUNIC[PAUX
Z.

CODESI

IF ANY OF THE
OR[SINAL
WIRE AS SUPPLIED
WITH THE
FURNACE
MUST
REPLACED,
IT MUST
BE REPLACED
WITH
WIRING
MATERIAL
HAVING
A
TEMPERATURE
RATING
OF AT LEAST
221"F
(lOS"C).

41 ALL

RED

AVANT

NOTES:
I. ALL
FIELD
80+

liarN

I [_

CLIMA/CHAUF)

0
AND

DEVICES

MOTEUR

CONTRO_LE

BRU_EUR
pRIMA[RE

TRANSFORMATEUR D'[GNITION
RELA[S
CONTROLE PR[MAIRE
LE MOTEURDE LA SOUFFLER[E DOUILLE ET BOUCHONA 9 P[OES BUR
COMMUTATEURDE LIM[TE PR[NC[PALE
COMMUTATEURDE LIM[TE
COMMUTATEURCENTRIF[QUE
FUSIBLE
CAPACITEUR DE FONCT[ONNEMENT [DENT[FIE
TRANSFORMEUR
CAPACITEUR DE FONCT[ONNEMENT [DENTIFIE
2¢V RAgCORDEMENT DU THERMOSTAT DE PIECE
RACCORDEMENTDE CHANTER
F[LABE DE L'USiNE ET APPARE[LS
FILAGE DE CHANTIER ET APPARE[LS

107#67

BLK

UWO A 0705

GAS

VALVE

5
C
m

BLOWER

SPEED

(CHARTE
DE LA

DE VITESSE
SOUFFLERIE)

LADDER

CHART

DIAGRAM

(DIAGRAMME

ELEMENTAIRE)

ANY

MUST

THE

ORIGINAL

WIRE

REPLACED

WITH

SUPPLIED
TYPE

WITH

I©5_6

THIS

THERMOPLASTIC

UNIT

MUST
OR

ITS

REPLACED•

EQUIVALENT.

CAPACITOR
S_]TCH
FSYSTEM

POWER SUPPLY
(ALIMENTATIeN

BLACK

115 I I 60
6O VOIR
SEE NOTE
115
NOTE I I)

MOTORS

WITHOUT

CAPACITOR

4
tQ

_o.
WIRE COLOR

KEY

{CODE DE COULEUR
DU FILAGE)

GNO
(EN TERRE)

ORG

BLACK

(NOIR}
BLUE
(BLEU)

L I

(ROUGE}
YELLOW
(JAUNE)

:I
(JAUN)

WHT

(BLEU)
RED

WHT

WHITE

(BLANC)

(BLANC)
BROWN

IX24v

WHT

FAN
8ND

IIGNo

SWITCH

{BRUN)
GREEN

(VERT)
PURPLE

:POURPRE)
ORN

ORB
PRP

(POURPRE)
ORANBE

CORAl

CORANGEI

4_}

LIM

CAUTION
OPEN

ALL

BLU

DISCONNECTS

SERVICINB

UNIT
L

LES

AVEC

HEAT/COOL
[THERMOSTAT

DISJONCTEURS

PROCEDER

THERMOSTAT
CLIMA/CHAUF)

AVANT

NOTES:

SERVICE

80+

DOWNFLOW

aLL

FIELD

WIRING

PER,

(a)

FURNACE

(B)

NATIONAL
CANAO[AN

(FOURNAISE
VENTILEE
PAR

80X
HAUT

ANY

REPLACEO,

THE
IT

ORIGINAL
MUST

LOCAL

WIRE

REPLACEO

ELEC.
ELEC.

CODE
COOE

CiTY

SUPPLED
WITH

(NEC)
(CEC)

WIRING

THE

FURNACE

MATERIAL

TEMPERATURE
aATINGOr ATLEAST221"F (105'C)

CONNECTORS

£UITABLE

FOR

COPPER

aND/OR/
ANO/OR/

CODES,
WITH

CONDUCTORS

MUST

HAVING

BLK

ONLY

4 ALL REPLACEMENT
COMPONENTS
MUSTBE PnOPERLY
GROUNOED.
NOTES=

PROVIDE

D[SCONNECT£

FOR

ALL

POWER

MOTORS ARE iNHERENTLY PROTECTED.
INCOMING
POWER
L'ALIMENTATION

14........................
B

•

Sl _E
_ET_E
D_AU

DGIT
ET_E
_M_
U_ _ATE_AU×
POU_A_T
_
I_CI_

_EU_EME_T

TOUTE

COMPO_A_TE

_U_E_

_E_

DE_

_ETTE_

_U_

CODE

ELEC

_
_
RE_TE_

CANADIEN

_
_
_ DE_

(CEC)

GROUND
EARTH

SUPPLIES

I. TOUT F[LAGE EN CHANT[ER 5ELON: (A) CODE ELEC. NATIONAL (FEN} ET/OU/

rILA_E
A_EC
M_

ET/OU/

LES

CODES

GROUND

MUST
BE
POLARIZED.
DU
COURANT
DOIT

_E_

_OTEUR_

_EM_ACEME_T

O_TEU_

SWITCH

OBSERVE
COLOR
ET_RE
POLARISEE.

_O_T

P_OTE_E_

_ _E

PA_

COULEURG.

_,
_
_
TE_PE_ATU_E_

[ET_E

_E_

M_E

_EU_

BURNER

PRIMARY

IGNITION

RELAY

REO

CO_CE_T_O_

PC
PI/SI

LE'GENDE

LSI
LS2
CS

TRANSFORMER

IT
RI

VALVE

CONTROL

PLUG

PRIMARY
L[_[T

CONTROL

PRIMARY
9

& SOCKET

LiMiT

ON BLO_R

SWITCH

MOTOR

PI/SI

PRIMA{RE

TRANSFORMATEUR

D'[BNITION

_
YEL

MOTEUR

DE LA

WV 7
/

SOUFFLERIE

DOU[LLE

BOUCHON

A 9

P[GES

SUR

RUN

CAPACITOR

2€V
0

AND

DEVICES

FONCT[ONNEMENT

RACCORDEMENT

RACCOROEMENT
F[LAGE
F[LAGE

DE
DE

_D:i

W_3662¢G_ ......
206

TRANSFORMEUR
CAPACITEUR

ROOM THERMOSTAT

CONNECT{ON
WIRING

IRC
IT

CONNECT{ON

FACTORY

FORMER

SOUPE DU SOLENOIDE
CONTROLE
PRIMAIRE

CAPACITEuRCOMMUTATEuRCOMMUTATEURFus[BLE
DECENTRIF[QuEDEFoNCTIONNEMENTL[MITE
IDENT[FE

FIELD

TRANS

RELAIS

CAPACITOR

IDENTIFIED

CONTR_LE

BRU_EUR

LS2
SWITCH

TRANSFORMER

24V

LSI

SWITCH

CENTR[F[CAL

RUN

MOTEUR

FUSE
IRC

BL_

MOTOR

SBLINO[D

SWITCH

TER_E_

_A_E_T_T_

LEGEND
BM

CODING.
SUIVEZ

_U_E_

_O_T
_OUR

SYSTEM

_SCREw

CENTRIFUGAL

_SW[1

BEFORE

THIS

PRE'CAUTION
OUVREZ

AUTO
RESET

SENSOR

DU
DE

L'US[NE
CHANTIER

THERMOSTAT

iDENTIFIE
DE

PIECE

,12

CHANTER
ET
ET

APPAREILS
APPAREILS

125525

UWD

0705

,>
g

NOTES

107272-UIM-A-0905
Supersedes: 035-16393-001 Rev. B (0304)

Unitary
Product
Group

5OO5
York
Drive

Norman
OK
73069

Source Exif Data:

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File Type Extension             : pdf
MIME Type                       : application/pdf
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Page Count                      : 40
Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 3, 2, 1, 4
Create Date                     : Fri Apr 20 13:44:33 2007
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COLEMAN Heater, Kerosene Manual L0601037

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