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 Burner/

Single Stage Downflow Only)

66 - 84 MBH INPUT

(19.34 - 24.62 KW) INPUT

LIST OF SECTIONS

SAFETY ................................................ 1 SAFETY CONTROLS .................................... 22

DUCTWORK ............................................ 5 START-UP AND ADJUSTMENTS ........................... 23

FILTERS .............................................. 10 WIRING DIAGRAM - OIL-FIRED FURNACE .................. 27

OIL PIPING ............................................ 11 GAS GUN BURNER ...................................... 29

ELECTRICAL POWER ................................... 13 START-UP AND ADJUSTMENTS ........................... 33

VENT/COMBUSTION AIR SYSTEM ......................... 14 WIRING DIAGRAM - GAS CONVERSION BURNER ............ 38

LIST OF FIGURES

Label Location ................................................... 4

Dimensions ...................................................... 5

Air Distribution Systems ............................................ 7

Closet To Door Clearance - 6" or Greater .............................. 7

Furnace To Closet Door Clearance - 1" To 6" .......................... 7

Furnace To Closet Door Clearance - Less Than 1" . ...................... 7

Duct Connector Dimensions ......................................... 8

Recommended Floor Cut-out ........................................ 8

Duct Connector Depth ............................................. 8

Duct Connector Screw Attachment ................................... 8

Duct Connector Tab Attachment ..................................... 9

Anti-Backftow Damper ............................................. 9

Installation of Furnace ............................................. 9

Floor Installation ................................................. 10

Furnace Air Filters ............................................... 11

Oil Pump ....................................................... 12

One-Pipe System ................................................ 13

Two-Pipe System ................................................ 13

Solenoid Wiring .................................................. 13

Line Wiring Connections ........................................... 14

Wiring for Heat Only Thermostat .................................... 14

Wiring for Electronic Heat-Cool Thermostat ............................ 14

Wiring for Standard Heat-Cool Thermostat ............................ 14

ISO 9001

Ce4_fied Quality

Managemen_ System

For Installation In:

1. Manufactured (Mobile) Homes

2. Recreational Vehicles & Park Models

3. Modular Homes & Buildings

Wiring for Btend Air Accessory ..................................... 14

Elbow Assembly ................................................ 15

Combustion Air Inlet Pipe ......................................... 16

Combustion Air Inlet Pipe Alternate .................................. 16

Flue Shield Installation ............................................ 16

Roof Jack Attachment to Furnace ................................... 16

Standard Roof Jack .............................................. 18

Roof Jack With Removable Crowns ................................. 19

Installing Roof Jack Extension ...................................... 20

Ceiling Ring .................................................... 20

Home Layout ................................................... 21

Electrode Settings ............................................... 23

Oit Pump ...................................................... 24

Wiring Diagram for DFAA - Oil-Fired Furnace .......................... 27

Wiring Diagram for DFAH - Oil Furnace .............................. 28

Gas Piping ..................................................... 29

ManuaI Shut-off Valve/Gas Piping ................................... 30

Proper Piping Practice ............................................ 30

Gas VaIve ..................................................... 35

Reading Gas Pressure ........................................... 36

Electrode Orientation and Gap ..................................... 37

Wiring Diagram for DFAA - Gas Conversion Burner ..................... 38

Wiring Diagram for DFAH - Gas Gun ................................ 39

LIST OF TABLES

Timings and Settings ............................................. 22

Burner Specifications ............................................. 23

Filter Performance - Pressure Drop Inches W.C and (kPa) ............... 25

Blower Performance CFM ......................................... 25

Replacement Parts - Non Electrical .................................. 26

Gas Line Piping Size and Length ................................... 30

Length of Standard Pipe Threads in Inches (ram) ....................... 30

High Altitude Duration Chart ....................................... 32

Gas Burner Settings ............................................. 32

Inlet Gas Pressure Range ......................................... 35

Nominal Manifold Pressure ........................................ 35

Unit Clearances to Combustibles ..................................... 4

Minimum Duct Sizing For Proper Airflow ............................... 6

Round Duct Size ................................................. 6

Externat Static Pressure Range ...................................... 9

Filter Sizes ..................................................... 10

Burner Specifications ............................................. 11

Burner Rating at Elevation Above Sea Level, gph (I/m) ................... 12

Ratings & PhysicaI /Electrical Data .................................. 13

Roof Jack Options ............................................... 17

Cad CelI Resistance When Sensing Ftame ............................ 22

SECTION 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 attention to the signal words DANGER,

WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not

avoided will result in death or serious injury.

WARNING indicates a potentially hazardous situation, which, if not

avoided could result in death or serious injury.

CAUTION indicates a potentially hazardous situation, which, if not

avoided may result in minor or moderate iniurv, It is also used to

alert against unsafe practices and hazards involving only property dam-

age.

,WARNING

Improper installation may create acondition where the operation of

the product could cause personal injury or property damage.

Improper llTstallation, adjustment, alteration, service or mainte-

nance can cause injury or property damage. Refer to this manual

for assistance or for additional information, consult a qualified con-

tractor, installer or service agency.

107272-UIM-A-0905

SPECIFIC SAFETY RULES AND PRECAUTIONS

1. 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 rat-

ing plate or SECTION IV of these instructions.

2. Install this furnace only in a location and position as specified in

SECTION I of these instructions.

3. An oil-fired furnace for installation in a residential garage must be

installed as specified in SECTION I of these instructions.

4. 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 com-

pleteljz Failure to follow these instructions could result in equipment

malfunction, causing severe personal injury, death, or substantial

property damage.

5. Test for Ieaks in the oil Iine as specified in SECTION VI!I of these

instructions.

6. 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.

7. The return air duct system is not required by the furnace manufac-

turer. This furnace utilizes a sealed combustion air and vent sys-

tem referred to as a roof jack. The Roof Jack must be installed as

specified in these instructions and must conform with state, local,

or regional codes.

8. It is permitted to use the furnace for heating of buildings or struc-

tures under construction. Installation must comply with all manu-

facturer's installation instructions including:

• 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 maintained between 55°F (13°C) and

80°F (27°C);

• The air filter must be replaced or thoroughly cleaned upon sub-

stantial 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.

The following requirements to be met:

a. 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.

b. 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.

c. 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.

d. 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.

e. 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.

f. The furnace and ductwork should be thoroughly and com-

pletely cleaned prior to occupancy of the dwelling to insure

the proper operation of the furnace and to avoid potential

health concerns.

9. 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.

11. Manufactured (Mobile) Home and Modular Home Installation:

This appliance must be installed in a (sealed combustion) configu-

ration 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 non-

removable chassis.

14. This furnace is approved for installation in trailers or recreational

vehicles.

SAFETY REQUIREMENTS

•Never attempt to alter or modify this furnace or any of its com-

ponents.

• 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.

•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 stan-

dard is not applicable, the standard for Manufactured Home

Installations (Manufactured Home Sites, Communities, and Set-

ups) 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-Burn-

ing Equipment, and for Oil-Fired Central Furnaces (Latest Edi-

tion), 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.

2 Unitary Products Group

107272-UIM-A-0905

• Provide clearances from combustible materials as listed under

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.

• 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 elec-

trical characteristics match. All models use nominal !15 VAC, 1

Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI-

ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE

130 VOLTS.

• Furnace shall be installed so the electrical components are pro-

tected from water.

• 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 precau-

tions in the manuals and on the labels attached to the unit and

other safety precautions that may apply.

NOTICE SPECIAL REQIREMENTS

kDANGER

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).

These instructions cover minimum requirements and conform to exist-

ing 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 Manu-

factured (Mobile) Home construction practices. These instructions are

required as a minimum for a safe installation.

COMBUSTION AIR QUALITY

(LIST OF CONTAMINANTS)

The furnace will require OUTDOOR AIR for combustion when the fur-

nace is located in any of the following environments.

Restricted Environments

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 fur-

nace is located in an area where the furnace is being exposed to the fol-

lowing substances and /or chemicals.

Permanent wave solutions

Chlorinated waxes and cleaners

Chlorine based swimming pool chemicals

Water softening chemicals

De-icing salts or chemicals

Carbon tetrachloride

Halogen type refrigerants

Cleaning solvents (such as perchloroethylene)

Printing inks, paint removers, varnishes, etc.

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, dust mops, vacuum

cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning com-

pounds; plastic items or

3. Containers, gasoline, kerosene, cigarette lighter fluid, dry

cleaning fluids or other volatile fluid.

4. Paint thinners and other painting compounds.

5. Paper bags, boxes or other paper products

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.

CONCEALED DAMAGE -If you discover damage to the burner or

controls during unpacking, notify carrier at once and file the appro-

priate claim.

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 Underwrit-

ers Laboratories label, located on the left rear of the burner, or

cover mounting plate. See Figure !.

Unitary Products Group 3

107272-UIM-A-0905

General Model

Information

Serial Number

including Date Code

Rating information

Approval Agency b,

Symbols

Primary Group b,,

and Fuet Oii

Model 'APEVC"

Series Oil Burner

sE_L,,LrJUMS_

02092349038

LIS! ED

RW BoXlike11Corp

MFR'S SETTINGS

,,J,_, s ,_/s

=VC201 R00

02g%_23 49038

o,,, s, o-_/

)

R. W, Beckett

ManufactureCs Settings

R,W, Beckett Specification

Number and Revision

Can be Customized by

Individual Specification

State and Locai Approvals

FIGURE 1: Label Location

CHECK CERTIFICATIONS /APPROVALS

• 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 stan-

dard 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 emis-

sions as well. The Oil heat Manufacturers' Association recom-

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 regula-

tions 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 pro-

vided in this installation manual.

FURNACE LOCATION AND CLEARANCES

The furnace shall be located usina the followina auidelines:

1. The furnace should be located where the roof jack can be installed

without major modifications to the roof of the structure.

2. As centralized with the air distribution as possible.

3. Where there is access to fresh air particularly when the blend air

accessory will be installed.

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

space.

5. 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-

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 in freezina temoeratures:

1. Furnace shall be installed in an area where ventilation facilities

provide for safe limits of ambient temperature under normal oper-

ating 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

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.

Installation in an ambient below 32°F (0.0 °C) could create a haz-

ard, resulting in damage, injury or death.

3. 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.

Clearances for access:

Ample clearances should be provided to permit easy access to the unit.

The following minimum clearances are recommended:

1. 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.

2. 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.

In all cases, accessibility clearances shall take precedence over clear-

ances for combustible materials where accessibility clearances are

greater.

kWARNING

Check the rating plate and power supply to be sure that the electri-

cal characteristics match. Al! models use nominal !15 VAC, 1

Phase 60Hz power supply

Furnace shall be installed so the electrical components are pro-

tected from water.

Installation in a residential aaraoe:

1. 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.

APPLICATION

CLOSET

ALCOVE

TOP

In. (cm)

2 (5.08)

FRONT

In. (cm)

6 (15.24)

24 (60.96)

BACK

In. (cm)

0 (0.0)

SIDES

In. (cm)

0 (0.0)

AIR INLET

PIPING

In. (cm)

0(0.0)

o(0.0)

ROOFJACK

In, (cm)

3 (7.62)

DUCT 1

In. (cm)

0 (0.0)

0 (o.o)

FLOOR/BOTTOM

0 (0.0)

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

4Unitary Products Group

107272-UIM-A-0905

_'F

DFAH Series

__ I inches c.m.

A 59-1/2" 151.0

B- 76 '_ 193,0

C 24.3/4" 62.9

D 23" 58.4

E 19-1/2" 49.5

F 9-3/4 '_ 24.8

G- 12" 30.5

3" Etx. Static Duct Pressure --

No Coil -Std. Blower -High Speed

DFAA Series

FIGURE 2: Dimensions

SECTION Ih DUCTWORK

DUCTWORK GENERAL INFORMATION

The duct system's design and installation must:

1. Handle an air volume appropriate for the served space and within

the operating parameters of the furnace specifications.

2. 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.

3. 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.

4. Complete a path for heated or cooled air to circulate through the

air conditioning and heating equipment and from the conditioned

space.

5. 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 fur-

nace is over-sized, the following may result:

a. Short cycling of the furnace.

b. Wide temperature fluctuations from the thermostat setting.

c. Reduced overall operating efficiency of the furnace.

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 pre-

vent 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 pres-

sures 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, DO NOT COVER OR RESTRICT

FLOOR OPENING

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 pres-

sure 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 exchang-

ers. The inspection door can be fabricated by following method.

1. Cut a rectangular opening in the plenum base.

2. A Sheet metal plate can be made that completely covers the open-

ing in the base.

3. The plate must be secured with screws.

4. This plate must be sealed to prevent leaks.

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 fur-

nace operation.

Unitary Products Group 5

107272-UIM-A-0905

Use the example below to help you in calculating the duct area to deter-

mine whether the ducts have sufficient area so that the furnace oper-

ates 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 2X 2

(35.6 cm x 2), which equals 224 inch 2 (1445 cm 2) then go to round

duct size located in Table 3.

TABLE 2: Minimum Duct Sizing For Proper Airflow

2. The square inch area for 7 inch (!7.8 cm) round pipe is 38.4, mul-

tiply by 2 for two round ducts which equals 76.8 inch 2 (495 cm2).

3. 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 pres-

sure and within the air temperature rise specified on the nameplate.

Input Airflow Return I Rectangular 2 Round 2 Supply 3 Rectangular 2Round 2

BTU/H (kW) CFM(m _) In =(cm =) in. x in.(cm x cm) in. (cm) dia In 2 (cm 2) in. x in. (cm x cm) in. (cm) dia.

66000 (19.34) 1,050 (29.73) 280 (71!) 14 x 20 (35.6 x 50.8) 18(45.7) 216(549) 12 x 18 (30.5 x 45.7) !6 (40.6)

84000 (24.62) 1,250 (35.40) 360 (914) 18 x 20 (45.7 x 50.8) 22(55.8) 280(7!1 ) 14 x 20 (35.6 x 50.8) 18 (45.7)

NOTE: This chart does not replace proper duct sizing calculations or take into account static pressure drop for rue length and fittings. Watch out for the temperature rise

and static pressures.

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).

TABLE 3: Round Duct Size

Round Duct Size Calculated Area For Each Round Duct Size

Inches (cm) Sq. Inch (cm 2)

5 (13) 19.8 (126)

6 (15) 28.2 (!82)

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)

1. The Air Temperature Rise is determined by subtracting the Return

Air Temperature Reading from the Supply Air Temperature Read-

ing.

2. The External Static Pressure is determined by the Supply Duct

Static Pressure reading.

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 build-

ing, Refer to the ASHRAE Fundamentals Handbook, Chapter on

"DUCT DESIGN" or a company that specializes in Residential and Mod-

ular Home duct designs.

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 tem-

perature. Refer to SECTIONS II, III and VIII for additional informa-

tion on correcting the problem.

DUCKWORK INSTALLATION

Air Distribution Systems

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.

Three typical distribution systems are illustrated in Figure 3.

Location, size and number of registers should be selected on the basis

of best air distribution and floor plan of the home.

The Air Temperature Rise is to be adjusted to obtain a temperature rise

within the range(s) specified on the furnace rating plate.

DUCT DESIGN - CANADA

Supply duct design shall be in accordance with the latest HRA Digest,

the ASHRAE Handbook Fundamentals, or other good engineering prin-

ciples.

NOTE: Refer to HRA Digest Residential Air System Design Manual,

Sections 5 and 6, the requirements of which are summarized as fol-

lows:

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

2. 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 neces-

sary to maintain a maximum air temperature rise of 50o C as the

air passes over the furnace heat exchanger.

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

4. 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 bath-

rooms or kitchens where this might not be practical.

5. Where practical, outlets shall be provided near the exterior doors

of the home.

CLEARANCE REQUIREMENTS -CANADA

Supply air ducts from warm air furnaces having a specified minimum

plenum clearance shall maintain this clearance from combustible mate-

rial for at least the distance specified in CSA Standards C22.2 No. 23 or

B 140.10 or CGA Standard CAN/CGA-2.3.

6 Unitary Products Group

107272-UIM-A-0905

Single trunkduct

[

Dust trunk duct with crossover connector

Dual trunk duct

_, Crossover

r"_3

]

Transition Duct with Branches

Transition duct

1, Crossover Duct must be centered directly under furnace.

2. Use 12 '_(30,5 cm) Diameter Round or insulated Ftex_duct only.

3. Terminate Flex-duct (opposite furnace) in the center of the trunk duct.

4. Flex-duct material must be pulled tight -- No Loops or unnecessary dips -- Air Flow may be impeded.

FIGURE 3: Air Distribution Systems

Return Air Grille Part No.

79gg-287P/A * White

250 IN.2 (161 cm 2)

MINIMUM

FREE AREA

50 IN.2 (322 cm 2)

MINIMUM

FREE AREA

Furnace to Closet Door Clearance --

5 Inches (12.7 cm) or more

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 cm2)

>MINIMUM [

FREE AREA

5in(12.7 cm) or greater * Closet

_- to Door CI.......

\ , Return Air Closet Door Part No.

Door 7900--7771/C* White

FIGURE 4: Closet To Door Clearance - 5" or Greater

I FREE AREA

JFREE AREA

As an option to the lower grill,

an undercut of 2-1/2" wilt provide

50 inches 2 (322 cm 2) of flee area.

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.

_i } 260 IN.2(161cm2)

MINIMUM

FREE AREA

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

2501N.2(161 cm 2)

> MINIMUM

FREEAREA

Furnace to Closet Door Clearance --

Less than 1 tnch (2.54 cm}

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

Freearea 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 7

107272-UIM-A-0905

DUCT CONNECTORS

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

2-3/8--

(6.0 cm)

23/8

SEE

4-3/8

(11.1 cm)

DUCT CONNECTOR DIMENSIONS

DUCTCONNECTOR

PAR]NUMBER

7990-6011

7990-6021

7990-6041

7990-6061

7990-6071

7990-6081

7990-6101

7990_6121

DUCT CONNECTOR

DEPTH

1" (2,5 cm)

2" (5.7 cm)

4-1/2" (11.4 cm

6-1-2" (16,5 cm)

7-1/2" (19.0 cm)

8-1/2" (21,6 cm)

10-1/4" (26.0 cm)

12-114" (21.1 cm)

2-3/8---_

(6.0 cm)

DUCT CONNECTOR DIMENSBONS

DUCTCONNECTOR

PAR] NUMBER

7990-6211

7990-6221

7990-6241

7990-6261

7990-6271

7990_6281

7990-6301

7990_6321

43/8

--(11.1 cm)

DUCT CONNECTOR

DEPTH

1" (25 cm)

2" (5.7 cm)

4-1/2" (11.4 cm

6-%2" (16.5 cm)

7-1/2" (19.0 cm)

8-1/2" (21.6 cm)

10-1/4" (26.0 cm)

12-1/4" (21.1 cm}

FIGURE 7: Duct Connector Dimensions

Rear Wall Ceiling Cut-Out

of Enclosure r_ For Roof Jack

2.3/4 (70 cm) I /

Min

; _ F_oor Cut-Out

\/_ For Duct

E I I Connector

_" t) i .. --

t[__ I_1"---/381 ore/*I __ Op_ona_Ga_

/ q I _ I]-- _ or Electric

{ i I _.lJ'l /Entrance

2-1/8 (54 cm) I'_l, Front Pane]

_3/fe_r __ /-_°fFumace

:: _ 1-3/8 -1-1/8

(29 cm)

Future 9-3/4

Refrige_98%4_" -- Floor

Line Entrance (508 cm)

FIGURE 8: Recommended Floor Cut-out

Duct Connector

Depth

Supply Duct

_€/_- Fioor

Jo_st

FIGURE 9: Duct Connector Depth

Locator Bracket

__Nails, Fiat Head Screws

"or Staples

Floor

Supply Duct

FIGURE 10: Duct Connector Screw Attachment

INSTALLATION OF SCREW ATTACHMENT DUCT

CONNECTOR

1. Make floor cut out as shown in Figure 8.

2. 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.

3. Place locating bracket (supplied with the duct connector) to the

back edge of the floor opening. See Figure 10.

4. Apply a water based duct sealant to the 1/2 in (1.3 cm) supply duct

attachment flange of the duct connector.

5. Determine which of the four positions the duct connector best cen-

ters over the supply duct and insert it through the floor cut-out.

6. When properly aligned with the supply duct, secure the duct con-

nector to the floor with nails, flat head screws or staples.

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

duct.

8. 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.

NOTE: Duct sealant and tape must be classified as meeting HUD Stan-

dard 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.

8 Unitary Products Group

107272-UIM-A-0905

Locator Bracket

Nails, Flat Head Screws

or Staples

Bend "Tabs Under Duct

Opening to Secure to the

Supply Duct

Floor

Supply Duct

FIGURE 11: Duct Connector Tab Attachment

INSTALLATION OF TAB ATTACHMENT DUCT

CONNECTORS

1. Make floor cut out as shown in Figure 8.

2. 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.

3. Place locating bracket (supplied with the duct connector) to the

rear of the floor area for the furnace. See Figure 11.

4. Determine which of the four positions the duct connector best cen-

ters over the supply duct and insert it through the floor cut-out.

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

nector.

6. Cut out the opening to the supply duct.

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

8. 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

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 fas-

tened to the duct with screws after drilling the required screw hole.

TABLE 4: External Static Pressure Range

Input

MBH kW

66000 19.34

84000 24.62

Output

MBH kW

53000 15.55

67000 19.63

Nominal

Air Flow 1

CFM cmm

1050 29.73

1250 35.40

Ext. Static Pressure

Minimum Maximum

In.W.C kPa In.W.C kPa

.!2 .03 .30 .07

1 Std Blower-High Speed-No Coil.

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 Installations

If an air conditioner is installed which does not use the blower for air dis-

tribution and operates completely independent of the furnace, the ther-

mostat system must have an interlock to prevent the furnace and air

conditioner from operating at the same time. This interlock system usu-

ally contains a heat-cool switch which must be turned to either HEAT or

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.

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.

NOTE: See label on coil panel for conversion and lighting instructions.

Obtain a temperature rise within the ranges specified on the name

plate.

Furnace

Base

Conneo[or

NOTE: FOR BEST AIR DELIVERY INSTALL DAMPER

WiTH BLADES PARALLEL TO SUPPLY DUCT,

FIGURE 12: Anti-Backfiow Damper

INSTALLATION OF THE FURNACE

1. Remove the front panels and set the furnace onto the duct con-

nector. Slide it back until the rear of the unit engages the Iocator

bracket.

2. Secure the front of the furnace with two screws at the mounting

holes provided. See Figure 13.

\ _

Furnace Seated

Againstthe

Locator Bracket

Secure Furnace to

° Floor with Two NaiIs

or Screws.

FIGURE 13: Installation of Furnace

3. 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.

Unitary Products Group 9

107272-UIM-A-0905

DFAH Furnaces:

If a matching cooling coil is used, it may be placed directly on the fur-

nace 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 indi-

cate the presence of leaks in the heat exchanger. This access cover

shall be attached in such a manner as to prevent leaks.

RETURN AIR REQUIREMENTS

Closet 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 Return Air System

Listed in the next paragraph are the conditions to be met by Manufac-

tured Home Manufacturers to have U.L. acceptance of in-floor or ceiling

return air systems of closet installed direct vent forced air heating appli-

ances for Manufactured Homes to be sold in the United States.

1. 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).

2. 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.

3. 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).

4. At least one register is to be located where likelihood of its being

covered by carpeting, boxes, and other objects is minimized.

5. Materials located in the return duct system have a flame spread

classification of 200 or less.

6. Non-combustible pans having 1" (2.5 cm) upturned flanges are

located beneath openings in the floor return duct system.

7. Wiring materials located in the return duct system conform to Arti-

cle 300-22 (B&C) of the National Electrical Code (NFPA-70).

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

9. 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, DO NOT COVER OR RESTRICT

FLOOR OPENING

BLEND AIR 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 Installa-

tion Manual to complete the installation.

f ,

Flex Duct

Damper

Floor

WARM_R_UCl pKCl c:! t!_r:_g _ ........................

FIGURE 14: Floor Installation

SECTION IIh FILTERS

FILTER 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 applica-

tions where the furnace is installed in a closet. This type of fil-

ter 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 fur-

nace. There must be a minimum clearance of 6" (15.2 cm)

between the front of the furnace and the closet door and/or the fur-

nace 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.

b. If the Pleated Media or Washable Filters are used the exter-

nal 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. Consideration should be given when locating the return filter

grille for maintenance.

d. Any filter that has a large pressure drop should be checked to

be sure the pressure drop caused by the air filter will not pre-

vent the furnace from operating within the rise range, speci-

fied 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)

10 Unitary Products Group

107272-UIM-A-0905

IMPORTANT: Air velocity through throwaway type filters must not

exceed 300 feet per minute (1.52 m/m).

Air Filters Can Be

Found On The Inside

Of This Access Panel

FIGURE 15: Furnace Air Filters

SECTION IV: OIL PIPING

OIL 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 COM-

PRESSION 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 pres-

sure 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

TABLE 6: Burner Specifications

Furnace Model Burner Spec ATC Head

DFAA084BBTA EVC - 201 AF36YHHS F3

DFAH084BBSA

DFAA066BBTA EVC - 202 AF36YHHS F3

DFAH066BBSA

Static Plate Nozzle Pump Pressure Air Boot Setting

3-318 U 0.65 x 70 ° A 100 psi 4.0

Delavan (689.5 kPa)

3-318 U 0.50 x 70 ° A 100 psi 3.0

Delavan (689.5 kPa)

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. Fail-

ure to comply could cause fuel unit seal failure, oil leakage, and

potential fire and injury hazard.

Fuel Supply Level With or Above Burner

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.

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 hor-

izontal 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

• Continuous lengths of heavy wall copper tubing are recom-

mended. Always use flare fittings, Never use compression fit-

tings.

• Always install fittings in accessible locations. Fuel lines should

not run against the appliance or the ceiling joists (to avoid vibra-

tion noise).

CONNECT FUEL LINES

Carefully follow the fuel unit manufacturer's literature and the latest edi-

tion of NFPA 31 for oil supply system specifications. If this information is

unavailable, use the following basic guidelines.

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

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.

Burners equipped with a Beckett CleanCut pump must have a con-

trol 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 11

107272-UIM-A-0905

NOTICE SPECIAL REQUIREMENTS

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 FUEL-

OIL 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 monox-

ide, excessive sooting, a fire hazard, personal injury, property dam-

age, and/or death.

In Canada, the furnace is designed to operate on #1 STOVE OIL or

#2 FURNACE OIL ONLY

THE EFFECT OF ELEVATION ON OIL BURNER

FIRING

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 oper-

ating it above 2000 ft. (6!0m).

It is especially important in high elevation installations to adjust air set-

tings 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.

It is also important in high elevation installations to consider the maxi-

mum firing rate of the burner, so that the heat input as required by the

application is maintained. Regardless of elevation, the oil burner has a

maximum volume flow of air that it can deliver, As a result, the maxi-

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.

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 in

excess of 100 PSIG (689 kPa).

Pressures exceeding 100 PSIG (689 kPa) may cause an overheat-

ing 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.

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

Elevation

(Above Sea Level)

ft m

500 !52

1,000 305

1,500 457

2,000 610

2,500 762

3,000 914

3,500 1,067

4,000 1,2!9

4,500 1,372

5,000 1,527

5,500 1,676

6,000 1,829

6,500 1,981

7,000 2,134

7,500 2,286

8,000 2,438

9,000 2,743

10,000 3,048

Nozzle Size

0.60 1.892706 0.66

gph I/h gph

0.50 ! .89 0.65

0.50 1.89 0.65

0.49 ! .86 0.65

0.48 1.82 0.64

0.48 ! .82 0.64

0.47 1.79 0.63

0.46 ! .76 0.61

0.46 ! .72 0.60

0.45 ! .69 0.59

0.45 1.69 0.59

0.44 ! .66 0.58

0.43 1.63 0.57

0.42 1.60 0.56

2.460618

I/h

2.46

2.42

2.37

2.33

2.28

2.24

2.20

2.16

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

gph = gallons per hour

I/h = liters per hour

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

Maximum Firing Elevation Adjusted I

Burner

Model Rate of Burner X Re-rate Factor = Maximum I

@ Sea Level @ 7000 ft. Firing Rate I

AFG 3.00 gph (11.4 L/h) X 87.1% 2.61 gph (9.83 Lh)

AF 3.00 gph (1! .4 L/h) X 87.1% 2.61 gph (9.83 Lh)

Nozzle Port By Pass

3/16 Flare Solenoid Inlet Port

Pressure

Adjustment

Screw

1/4 NPTF Ptug ForTwo-Pipe System Only

(0.64 cm) (Use 5/32"Allen Wrench)

FIGURE 16: Oil Pump

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,

12 Unitary Products Group

107272-UIM-A-0905

Follow information provided with the burner, the fuel pump, or the calcu-

lation below to determine pipe size and length.

L = Line Length in feet

H = Head in feet

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 = (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

freeze in the winter causing the oil line to freeze.

ONE PIPE SYSTEM

DO NOT INSTALL BY-PASS PLUG! Connect inlet line to pump inlet.

Start burner. Arrange primary burner control for continuous operation

during the purging. Place a clear plastic tube on bleed valve. Open

bleed valve ! turn counterclock wise. Bleed until all air bubbles disap-

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

operation of unit. Refer to Figures 16 & 17.

Air [q L=H+R

Ven[ _ FuetUnit

----tt-%

FIGURE 17: One-Pipe System

TWO 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 loca-

tion is shown in Figure 16.

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.

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.

Outside Tank Fuel Unit

Above Bottom of "Tank L=H+R

Primary

'Filter

_ Inlet

"H"

Use Protective Ptastic

Tubing in Concrete or as

LocatCodes Require

FIGURE 18: Two-Pipe System

SOLENOID WIRING

DISCONNECT THE POWER SUPPLY BEFORE WIRING TO PRE-

VENT ELECTRICAL SHOCK OR EQUIPMENT DAMAGE.

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-

rect solenoid wiring. All electrical wiring must be done in accordance

with the local codes.

NOTE: Solenoid power requirements: 1!5 VAC, 0.1 Amp, 60 Hz

To Power

Control

Bypass _

Vioiet J ]

White

FIGURE 19: Solenoid Wiring

SECTION V: ELECTRICAL POWER

Electrical 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.

TABLE 8: Ratings & Physical /Electrical Data

Input

MBH (kW)

66 (19.3)

84 (24.6)

Input

MBH (kW)

66 (19.3)

84 (24.6)

Output

MBH (kW)

53 (15.5)

67 (19.6)

Max, Outlet

Air Temp

°F (°C)

165 (74)

Nominal

CFM (cm)

1050 (29.7)

1250 (35.4)

Blower

Hp Amps

1/6 8.0

1/4 5.9

Burner Air Temp. Rise

Ampe HP RPM Rotation °F (°C)

2.1 1/7 3450 CCW 45 - 75 (28 - 47)

Max Over-current Total

Size (awg) @ Unit Min. Wire Blower Size

One Way

75 ft. protect Ampe In. (cm)

15 8.3 14 10 x 8 (25.4 x 20.3)

15 7.8 14 10 x 8 (25.4 x 20.3)

AFUE

DFAA

Operation Wgt.

LBS/Kg

175/79.4

Input Rate

GPH (Liter /H)

0.50 (1.9)

0.65 (2.5)

DFAH

Operation Wgt.

LBS/Kg

158/71.7

!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 13

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 cur-

rent meter.

NOTE: See appliance manufacturer's burner specifications for required

outlet pressure. Pressure is !00 psig (689 kPa) unless otherwise noted.

SUPPLY VOLTAGE CONNECTIONS

1. 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.

2. 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-wir-

ing 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 sec-

tion. 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.

3. The furnace's control system requires correct polarity of the power

supply and a proper ground connection. Refer to Figure 20.

Nominal

120 Volt

FIGURE 20: Line Wiring Connections

LOW VOLTAGE CONTROL WIRING CONNECTIONS

1. Insert 24 volt wires through the small plastic bushing just above

the control panel.

2. Connect the thermostat wires to the furnace low voltage pigtails.

See Figure 21 (heating only) and Figure 22 or 23 (heating and

cooling).

3. Connect low-voltage circuit to the wall thermostat pigtails.

NOTE: Five-conductor thermostat cable is recommended for all instal-

lations to allow easy installation of an air conditioning system at a later

time.

Eighteen gauge thermostat wire is highly recommended,

Smaller gauge thermostat wire may be used only if the guideline below

is followed.

Thermostat Wire Length

(Furnace to Thermostat) Thermostat Wire Gauge

0 - 45 feet 22

O - 70 feet 20

Do not use the thermostat wire smaller than 22 gauge. If thermostat

wire small than 18 gauge is used, pay particular attention that the con-

nections 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 represen-

tative of other living areas the thermostat is controlling.

Room Furnace

Thermosta[ Con[rot

FIGURE 21: Wiring for Heat Only Thermostat

Room Furnace Condensing

Thermostat Control Unit 11

FIGURE 22: Wiring for Electronic Heat-Cool Thermostat

Room Furnace Condensing

Thermostat Pigtails Unit 11

FIGURE 23: Wiring for Standard Heat-Coo! Thermostat 11

l Blend Air IControl Box

FIGURE 24: Wiring for Blend Air Accessory

IMPORTANT: Some electronic thermostats do not have adjustable heat

anticipators. They may have other type cycle rate adjustments. Follow

the thermostat manufacturer's instructions.

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 condi-

tioning unit contactor. DFAA has a separate 24-Volt transformer that

maybe used to provide 24-volt power for air conditioning contactor.

SECTION Vh VENT/COMBUSTION AIR

SYSTEM

VENT AND COMBUSTION AIR SAFETY

This furnace is designed for Manufactured (Mobile) Home and Modular

Home application. It may be installed without modification in an equip-

ment 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 Stan-

dard 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 appli-

ance, 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 appli-

ance 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.

14 Unitary Products Group

107272-UIM-A-0905

EXTERIOR ROOF JACK EXTENSION

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 can result in fire,

asphyxiation, or explosion.

Only use the appropriate roof jack. See Figures 26, 27,

30, & 31 for correct application.

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 safe-

guard 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.

2. 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.

3. Before inserting the roof jack into the furnace top, inspect the fur-

nace flue and combustion air opening for debris or insulation

which might have fallen in during pre-installation steps. Do not pro-

ceed unless all debris has been cleaned out or removed.

4. 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 fur-

nace casing top.

5. 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.

6. 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 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.

The vent and combustion air openings in the top of the furnace

must be free of construction debris before the Roof Jack is

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.

2. 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.

3. Before inserting the vent pipe into the furnace top, inspect the fur-

nace 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.

4. 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 fur-

nace casing top. If necessary to prevent excessive air leakage, the

installer should seal joints in the combustion air tube with alumi-

num type or other suitable sealant.

INSTALLATION 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 accumu-

lation 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.

2. Cut hole in roof. Provide minimum 12" (30.5 cm) vertical separa-

tion between combustion air inlet pipe and roof jack vent cap.

Clearance to combustible materials is not required.

3. Route piping through ceiling and holes. Provide firestop as

required.

4. Insert combustion air inlet coupling into casing. See Figure 26 or

27.

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

pipe to the coupling.

6. Complete piping through roof. Provide flashing at roof penetration.

7. Prepare elbow assembly. See Figure 25. Insert screen into elbow

socket. Secure in place with street elbow (or nipple).

8. 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. Ver-

tical PVC pipe can be up to !0 ft. (3.! m) in length.

90 _'Street

Elbow

Screen

Pipe to Furnace

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 antic-

ipated snow level, but no more than 24" 61.0 cm) above roof.

Unitary Products Group 15

107272-UIM-A-0905

Min.

9" Min.

2" Pipe

Rubber Coupling

with Hose Ctamp

6" Min, or 6" Above

the Snow Line

6" Min,

FIGURE 26: Combustion Air Inlet Pipe

2" Pi

Rubber Coupling

with Hose Clan"

9" Min.

6" Min, or 6" Above

the Snow Line

FIGURE 27: Combustion Air Inlet Pipe Alternate

NOTE: Roof flashing, PVC pipe, PVC 90 ° elbows and fire stop are not

supplied with the furnace.

LOCATING AND CUTTING ROOF JACK 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!.

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).

INSTALLING ROOF JACK IN ROOF

1. Provide protection for Vent Connector and Air-intake Connector

from damage and debris.

2. Mark Roof Jack center line on ceiling. Cut a 5" (1.5 m) radius {10"

(25.4 cm) diameter} hole through ceiling.

3. Mark Roof Jack center line on roof. Cut oblong hole through roof.

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

roof.

Connect Roof Jack to Furnace

1. 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.

Failure to install the Flue Shield may cause premature flue pipe

deterioration. Damaged flue pipe can result in asphyxiation, fire or

equipment malfunction.

Flue Shield

Furnace

Vent

Connector

t//

FIGURE 28: Flue Shield Installation

2. Verify gasket is around outside of Air-Intake Connector. Install new

gasket if missing or damaged.

3. 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.

4. 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.

Bottom of

Roof Jack

Air Intake

Connector

Opening for

CombustionAir

Inlet Grommet

Front of

Furnace

FIGURE 29: Roof Jack Attachment to Furnace

INTERIOR EXTENSIONS

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 Fig-

ures 30 & 31 and Table 9. More than one interior extension may be

used to accommodate "A" dimensions up to 110" (284.5 cm).

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 adjust-

able heights by the amount of the interior extension height.

16 Unitary Products Group

107272-UIM-A-0905

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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 assem-

bly 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 Adjustable Height with a

Roof Jack no Interior Extension 17" Interior Extension

Part Number IN CM IN CM

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

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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 man-

datory 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.

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

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 fur-

nace 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: Under no circumstances shall the connection between

the flue and combustion air pipe assembly of the roof jack and the inte-

rior extension be above the ceiling line.

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.

Secure Roof Jack to Roof

1. Apply caulk or other sealant to underside of Roof Jack flashing.

2. Locate Roof Jack such that pipes are plumb.

3. Secure Roof Jack flashing with nails, screws or staples.

4. Install roofing material over Roof Jack flashing.

5. 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 Installation, as required

1. I nstalI Exterior Roof Jack Extension, if applicable. Refer to installa-

tion instructions provided with Exterior Roof Jack Extension. Refer

to Figure 32.

2. Instali Crown Assembly, if applicable. Refer to installation instruc-

tions provided with Crown Assembly. If Crown Assembly is not

installed, attach warning tags provided with Roof Jack to: Refer to

Figure 32.

Unitary Products Group 17

107272-UIM-A-0905

SWIVEL FLASHING

ADJUSTS FROM

0/12 TO 5/12 PITCH

4000-7101/C

4000-7121/C

4000-7141/C

4000-7151/C

4000-7171/C

SLANT

FLASHING

3/12 PITCH

4000-6101/A

4000-6121/A

4000-6141/A

4000-6151/A

4000-6171/A

DFAH FURNACES

INSTALLATION DIMENSIONS

"A"

ADJUSTABLE HEIGHT

70" to 79"

75" to 86"

83" to 104"

90" to 116"

127" to 157"

DFAA FURNACES

INSTALLATION DIMENSIONS

"B"

ADJUSTABLE HEIGHT

86" to 95"

91" to 102"

99" to 120"

106" to 132"

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.

f Flue

Gases

19 1/2"

Conlbustlon.

Air

Caulk

CarefuIIy Cautk AHAround Swivel Joint with

Sea_ant Supplied by Furnace Manufacturer.

The End of Upper Portion of Roof Jack need

Not extend below the ceiling. -_

Flue

"--_>_ Gases

Cjombusflon

Caulk

Unde[

..... 7_

IMPORTANT

Seal Roof Jack Flashing to the Roof Jack and Roof.

This is the Installer's Responsibility.

59-1/2"

76"

DFAA MODELS

19 1/2"

Roof

DFAH MODEL', i J----_l

Warm Air Duct Duct Connector Duct Connector Warm _,,JrDuct

FIGURE 30: Standard Roof Jack

18 Unitary Products Group

107272-UIM-A-0905

SWIVEL FLASHING

ADJUSTS FROM

0/12 TO 5/12 PITCH

SLANT

FLASHING

3/12 PITCH

4000-8161/C 4000-9161/A

4000-8181/C 4000-9181/A

DFAH FURNACES

INSTALLATION DIMENSIONS

"A"

ADJUSTABLE HEIGHT

85" to 101"

99" to 129"

DFAA FURNACES

INSTALLATION DIMENSIONS

"B"

ADJUSTABLE HEIGHT

101" to 117"

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.

59.1/2 _

76 _

DFAA MODELS

Hf------_-jjDFAHMODELS I __- _1

,_ ---\ Floor /'--" "%

Warm Air Duct Duct Connector Duct Connector Warm Air Duct

FIGURE 31: Roof Jack With Removable Crowns

Unitary Products Group 19

107272-UIM-A-0905

STEP 1:

Remove upper and iower cap.

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.

Upper

Cap

Lower

Cap

Crown

Assembly

Base

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: Make sure that the pipes are

connected.

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.

___ UPPER

cAP

STEP 3: _] LOWER

Reinstall upper and lower cap to extension. _S CAP

Using the three (3) screws removed

in Step 1 attach the tower cap to the I I

extension bracket. Insta,, the upper _j_L_- REXTAENS'ON

cap over the center pipe of the extension. _ .......

Using the two (2) holes located at the

base of the upper cap as guides, drill EXTENSION

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 assembly.

Place these instructions in the customer

packet provided with the furnace.

VENT SYSTEM

This furnace is a sealed combustion (direct vent) unit and is design cer-

tiffed to use only a 4000 Series roof jack. These roof jacks are designed

to exhaust flue products to the outside.

INSTALLING 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 Manufac-

tured Homes and Recreational Vehicles; or in Canada use CANICSA-

Z240 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 sec-

tions 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.

FIGURE 33: Ceiling Ring

VENT CLEARANCES

IMPORTANT: The vent must be installed with the minimum clearances

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

codes and requirements.

FIGURE 32: Installing Roof Jack Extension

20 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 Installations 1 US Installation 2

A. CIearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

12 inches (30 cm) for models <100,000 BTUH

B. CIearance to window or door that may be opened (30 kW), 36 inches (91 cm) for models > 100,000 4 Feet

BTUH (30 kW)

C Clearance to permanently ctosed window 4 Feet 4 Feet

D Vertical clearance to ventilated soffit tocated

above the terminal within a horizontal distance 4 Feet 4 Feet

of 2 feet (61 cm) from the center tine of the terminal

E. CIearance to unventilated soffit 12 Inches 12 Inches

F. Clearance to outside corner 12 Inches 12 Inches

G.Clearance to inside corner 6 Feet 6 Feet

H Clearance to each side of center line extended 3 feet (91 cm) within a height 15 feet (45 m) 3 feet (91 cm) within a height 15 feet (4.5 m)

above the

above meter/regulator assembly meter/regulator assembty above the meter/regulator assembty

I Clearance to service regulator vent outlet 3 feet (91 cm) 3 feet (91 cm)

12 inches (30 cm) for models <100,000 BTUH

J. Clearance to nonmechanical air suppty inlet to buitding (30 kW), 35 inches (91 cm) for models >100,000 4 Feet

or the combustion air inlet to any other appliance BTUH (30 kW)

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

K. CIearance to a mechanical supply inlet 6 feet (1 83 m) horizontally

L CIearance above paved sidewalk or paved driveway located on

public proper_y 7 feet (213 m) € 7 feet (2.13 m) t

M.CIearance under veranda, porch, deck, or balcony 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 In accordance with the current CSA B149 1-00, Natural Gas and Propane Installation Code

2 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 Manufac-

tured 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 21

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.

SECTION VII: SAFETY CONTROLS

CONTROL CIRCUIT FUSE

A 3-amp fuse is provided to protect the 24-volt transformer from over-

load caused by control circuit wiring errors. This is an ATO 3, automo-

tive type fuse and is located in the control box.

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 without the blower

panel in place.

LIMIT CONTROLS

There is a high temperature limit control located on the furnace vesti-

bule 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 SWITCH

The indoor fan motor is an operation controlled by normally open tem-

perature 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).

OIL BURNER PRIMARY 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.

The indicator light on the oil primary control provides lockout, recycle,

and cad cell indications as follows:

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

in restricted mode.

2. Flashing at 2 seconds on, 2 seconds off: controi is in recycle

mode.

3. On: cad cell is sensing flame.

4. Off: cad cell is not sensing flame.

Cad Cell Resistance 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.

TABLE 10: Cad Cell Resistance When Sensing Ftame

Flashes Cad Cell Resistance in Ohms

1 Less than 400

2 More than 400 and less than 800

3 More than 800 and less than 1600

4 More than 1600 and less than 5000

Preliminary Steps

1. Check wiring connections and power supply.

2. Make sure power is on to controls.

3. Make sure limit control is closed.

4. Check contacts between ignitor and the electrodes.

5. Check the oil pump pressure.

6. Check the piping to the oil tank.

7. Check the oil nozzle, oil supply and oil filter.

Check Oil Primary Control

If the trouble is not in the burner or ignition hardware, check the oil pri-

mary control by using the following equipment:

1. Screwdriver

2. Voltmeter (0 to 150 VAC range)

3. Insulated jumper wire with both ends stripped

Electrical Shock Hazard

Can cause severe injury, death or property damage.

Be careful to observe all precautions to prevent electrical shock or

equipment damage.

Valve-On Delay

(seconds)

TABLE 11: Timings and Settings

Delay Timings a

Burner Motor-Off Delay

(minutes)

X No Difference or Impact

R7184U

R7184P

0.5

a Specific models may havedifferent 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.

S-1

Off

DIP Switch Settings

S-2

Off

S-3 Enable /Disable

R7184U R7184P

Off

END ViEW

Gap

SiDE VIEW

Nozzle--to-ti

Spacing

5/16 '_Above Nozzte Center

FIGURE 35: Electrode Settings

22 Unitary Products Group

107272-UIM-A-0905

SPECIFICATIONS

Models:

Table 1! lists the major features and the applicable wiring diagram num-

bers for the R7184.

Timing:

1. Safe Start Check: 5 seconds (approximately)

2. Valve-on Delay: 15 seconds.

3. 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.

4. Lockout: 15, 30, or 45 seconds (factory-programmed).

5. Recycle: 60 seconds (fixed).

6. Ignition Carryover: !0 seconds (fixed).

Electrical Ratings:

Inputs:

Outputs:

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

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

Frequency: 60 Hz.

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

amperes (LRA).

b. Valve: 120 VAC, 1A

c. Igniter: 120 VAC, 360 VA

d. Alarm: 30 VAC, 2A

e. Thermostat Current Available: 100mA

F. EnviraCOM TM Current Available: 150mA

TABLE 12: Burner 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.

SECTION Vllh START-UP AND

ADJUSTMENTS

The initial start-up of the furnace requires the following additional

procedures:

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

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 PRI-

MARY CONTROL.

TOOLS AND INFORMATION THAT WILL BE

REQUIRED IN ORDER TO PROPERLY PERFORM THE

FURNACE STARTUP PROCEDURE•

1. You will need a thermometer or portable digital thermometer to

read the supply and return air temperatures.

2. You will need a pressure gauge that has the ability to read pres-

sures between 0 - 100 PSlG (0 - 689 kPa) in order to measure the

oil pump pressures.

3. You will need a 3/32" Allen wrench for the pressure port adjust-

ment screw in the oil pump.

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

(30 cm) in length

5. You will need a clear plastic jug.

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

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

These items are required in order to properly perform the required start-

up procedure.

Furnace Model Burner Spec ATC Head Static Plate Nozzle Pump Pressure Air Boot Setting

DFAA084BBTA 0.65 x 70 ° A

DFAH084BBSA EVC - 20! AF36YHHS F3 3 - 3/8 U Delavan 100 psi (689 kPa) 4.0

DFAA066BBTA 0.50 x 70 ° A

DFAH066BBSA EVC - 202 AF36YHHS F3 3 - 3/8 U Delavan 100 psi (689 kPa) 3.0

START-UP AND ADJUST BURNER

Start-up Burner /Set Combustion

Do not attempt to start the burner when excess fuel or vapor has

accumulated in the appliance. Starting the burner under these con-

ditions could result in a puff back of hot combustion gases, high

smoke levels, or otherwise hazardous operation.

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 above room temperature.

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 pri-

mary control.

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.

• 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.

• 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.

6. Initial air adjustment - Using a smoke tester, adjust the air to obtain

a clean flame. Now the additional combustion tests with instru-

ments can be made. Never drill a hole in the roof jack to take com-

bustion sample or smoke tests.

Unitary Products Group 23

107272-UIM-A-0905

IGNITION SYSTEM SEQUENCE

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

the oil tank.

2. Set the thermostat above room temperature to call for heat.

3. System start-up will occur as follows:

a. The burner motor will start and come up to speed.

b. Shortly after the burner motor starts-up, the ignition trans-

former will provide 10,000 volts through the electrods causing

a spark that will last approximately 15 seconds.

c. The solenoid valve on the oil pump will open providing oil flow

to the nozzle.

d. The oil vapor will ignite. The cad cell flame detector will

detect the flame. The resistance will drop below 1600 ohms.

e. After flame is established, the supply air blower will start

when the fan switch reaches approximately 110 ° F (43.3 ° C).

f. After flame is extinguished, the supply air blower will continue

to operate until the air temperature at the fan switch is below

90° F (32.2 ° C).

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious

injury, death or property damage.

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.

ADJUSTMENT OF OIL PUMP PRESSURE

Nozzle Port By Pass

3/16 Flare Solenoid Inlet Pert

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

The combustion must be adjusted using test instruments. Fail-

ure to do so could result in burner or appliance failure, caus-

ing potential severe personal injury, death, or substantial

property damage.

1. Let the burner run for approximately 5 to 10 minutes.

2. Set the over-fire or stack draft to level specified by appliance man-

ufacturer (usually -0.01" to -0.02" w.c. (-000024 to -0.0050 kPa)

over-fire for natural draft applications).

3. Follow these four steps to properly adjust the burner:

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

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

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 ! .4 to 2.7 per-

centage points).

• Example: Reduce CO 2 from 13.5% to 1!.5%. (2.6% to

5.3% 02).

d. Step 4: Recheck smoke level. It should be zero.

• This procedure provides a margin of reserve air to accom-

modate variable conditions.

• If the draft level has to be changed, recheck the smoke and

CO 2 levels. Adjust the burner air if necessary.

4. Once combustion is set, tighten all fasteners on the air adjustment

and escutcheon plate.

5. 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 OF 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 fur-

nace 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 PERFORMANCE

The airflow capacity data published in Table 14 represents blower per-

formance WITH CLEAN filters.

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 pres-

sure 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)

Airflow Range

CFM Cm/m

1001 -!250 28.35- 35.40

1251 -!500 35.42- 42.47

Minimum

Opening Size

1 Opening

in2 m2

488 45.34

Filter Type

Disposable

1 Opening

inwc kPa

0.1 0.0249

24 Unitary Products Group

107272-UIM-A-0905

APPLYING FILTER PRESSURE DROP TO

DETERMINE SYSTEM AIRFLOW

Example: For a 84,000 BTUH (38.06 kW) furnace with 1 return open-

ings 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, com-

plete the following steps:

Obtain the airflow values at 0.!0 w.c. (125 Pa) & 0.20 w.c. (150 Pa)

ESR

Airflow @ 0.!0": 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)

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.

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

Multiply percentage by airflow difference to obtain airflow reduction.

(0.5) X (-65) = -32.5

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 PROCEDURE

Install 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.

Finish and Trim

Alcove and Closet Installations may now be finished and trimmed as

necessary.

TABLE 14: Blower Performance CFM

Blower Speed

Single Speed - No Coii

Single Speed - With Dry Coil

BLOWER PERFORMANCE CFM - DFAA066

FACTORY EQUIPPED WITH STANDARD BLOWERS AND FILTERS

BTU/H (kW)

Input /Output

66(19.34) /53(15.55)

CFM

(m3/min)

1050(29.73)

!050(29.73)

EXTERNAL STATIC PRESSURE, INCHES WC (kPa)

0.1 (0,025) 0.2 (0,050) 0.3 (0,075) 0.4 (0,099) 0.5 (0,124)

cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m

1175 33.3 1110 3! .4 1050 29.7 1000 28.3 950 26.9

1125 31.9 !070 30.3 !020 28.9 960 27.2 910 25.8

BLOWER PERFORMANCE CFM -DFAA084

Blower Speed

Single Speed - No Coil

Single Speed - With Dry Coil

EXTERNAL STATIC PRESSURE,

BTU/H (kW) CFM 0.1 (0,025) 0.2 (0,050) 0.3 (0,075)

Input /Output (m 3 /min) 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

84(24.62) /67(19.63) !250(35.39) !265 35.8 1195 33.8 1120 31.7

BLOWER PERFORMANCE CFM -DFAH066

INCHES WC (kPa)

0.4 (0,099) 0.5 (0,124)

cfm cm/m cfm cm/m

!175 33.3 !100 31.1

!045 29.6 !015 28.7

Blower Speed

Single Speed - No Coil

EXTERNAL STATIC PRESSURE,

BTU/H (kW) CFM 0.1 (0.025) 0.2 (0.050) 0.3 (0.075)

Input /Output (m 3 /min) cfm cm/m cfm cm/m cfm cm/m

66(!9.34)/53(15.55 1050(29.73) !155 32.7 1111 31.5 1055 29.9

BLOWER PERFORMANCE CFM -DFAH084

INCHES WC (kPa)

0.4 (0.099) 0.5 (0.124)

cfm cm/m cfm cm/m

995 28.2 920 26. !

EXTERNAL STATIC

BTU/H (kW) CFM 0.1 (0.025) 0.2 (0.050) 0.3 (0.075)

Blower Speed Input /Output (m 3 /min) cfm cm/m cfm cm/m

Single Speed - No CoiI 84(24.62) /67(19.63) 1250(35.39) 1127 31.9 1062 30.1

NOTES:

1. Airflow expressed 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

PRESSURE, INCHES WC (kPa)

0.4 (0.099) 0.5 (0.124)

cfm cm/m cfm cm/m cfm cm/m

1005 28.5 952 27.0 887 25.1

Unitary Products Group 25

107272-UIM-A-0905

TABLE 15: Replacement Parts - Non Electrical

DFAA MODEL

ITEM NUMBER DESCRIPTION

1 Limit Switch, Manual (Upper)

2 Thermostat (Heat/Cool)

3 Exchanger, Heat (w/Gaskets)

4 Switch, Rocker (System)

5 Transformer (115 - 24V, 40 VA)

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

7 Panel, Door (Upper)

8 Panel, Door (Lower, Tall)

9 Motor

10 Plug, Connector

11 Capacitor, Run

12 Wheel, Blower

13 Blower, AC Relay

14 Switch, Fan

15 Combustion Chamber Assembly

16 Oil Burner Assembly

17 Switch, Limit (Open 140 - Close !10)

18 Fastener, Door Latch (2 Required)

19 Diagram, Wiring

DFAH MODEL

ITEM NUMBER DESCRIPTION

1 Limit Switch, Manual (Upper)

2 Thermostat (Heat Only)

3 Exchanger, Heat (w/Gaskets)

4 Switch, System

5 Transformer (115 - 24V, 40 VA)

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

7 Panel, Door (Upper)

8 Panel, Door (Lower, Short)

9 Motor

10 Plug, Connector

11 Capacitor, Run

12 Wheel, Blower

13 Blower, AC Relay

14 Switch, Fan

15 Combustion Chamber Assembly

16 Oil Burner Assembly

17 Switch, Limit (Open 140 - Close !10)

18 Fastener, Door Latch (2 Required)

19 Diagram, Wiring

26 Unitary Products Group

"13

¢€

_o.

BLOWER SPEED CHART

(CHARTE DE VITEBBE

DE LA BOUFFLERIE]

z_ 24v CONNECTIONROOMTHERMOSTAT

0 FIELD CONNECTION

FACTORYWIRING ANO OEVICES

FIELO WIRING AND OEWCES

LADDER DIAGRAM

(DIADRAMME ELEMENTAZRE)

z_ 2€v RACCOROEMENTOU THERMOSTATDE PIECE

0 RACCOROEMENTDE CHANTIER

FILAGE OE L'USINE ET APPAREILS

FILAGE DE CHANTIER ET APPAREILS

CONNECTION DIAGRAM

{DIAGRAMME DE RACCORDEMENT)

e+ BLACK ON MOTORS WITHOUT CAPACITOR

OZL BURNER

'1rll

BLOWER SPEED CHART

CHARTE DE VITESSE

DE LA SOUFFLERIE)

WIRE COLOR KEY

(CODE DE COULEUR

DU FILAGE)

BLACK

CNOIR]

BLUE

(BLEU) [BLEU]

RED

(ROUGE)

YELLOW

(JAUN] (JAUNE)

_T WHITE

(BLANC) (BLANC)

BRN BRO_N

(BRUN) [BRUN}

8RN GREEN

(VERT) (VERT]

PRP PURPLE

(POURPRE) (POURPRE)

ORN ORANGE

(ORA) IORANBE)

CAUTION

OPEN ALL DISCONNECTS BEFORE

SERVICING THIS UNIT

PRECAUTION

OUVREZ LES DISJONCTEURS AVANT

DE PROC£DER AVEC LE SERVICE

80+ DOWNFLOW FURNACE

(FOURNAISE 80X

VENTILEE PAR LE HAUTI

LADDER DIAGRAM

(DIAGRAMME ELEMENTAIRE)

SYSTEM _ POWER SUPPLY 115 I 60 SEE NOTE I _ I

SWITCH

IALIMENTATION 115 I 60 VO[R NOTE I]

@FS

L --J

HEAT/COOL THERWOSTAT

ITHERMOSTAT CL[MA/CHAUF)

NOTES=

I, ALL FIELD WIRING PER: [A) NATIONAL ELEC, COBE [NEC} AND/OR/

(B) CANADIAN ELEC CODE {CEC) AND/OR/

[C) LOCAL OR CITY GODE_

2, [F ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE

REPLACED, IT MUST BE REPLACED WITH _R]NG MATERIAL HAVING A

TEMPERATURE RATING OF AT LEAST Z21"F {105"C)

3 CONNECTORS SUITABLE FOR COPPER CONDUCTORS ONLY

4 ALL REPLACEMENT COMPONENTS MUST BE PROPERLY GROUNDED,

5, PROVIDE DISCONNECTS FOR ALL POWER SUPPLIES,

NOTES= _. MOTORSARE_NHERENTLYPROTECTED.

I, TOUT F[LAGE EN CHANT]ER SELON, (A} CODE ELEC,,NAT[ONAL (GEN} ET/OU/

/_/COOLELECCANAO_E.COEC_ET/OU/

CODES LOCAUX ET MUN[CIPAUX,

Z, S( LE F[LAGE DOIT ET_E REMPLACE EN P_TRIE OU EN TOUT, Ih DOIT

L'ETRE AVEC UN MATERIAUX POUVANT RESISTER A DES TEMPERATURES

D'AU MO[N5 Z21"F (lOS"C).

5, SEULEMENT DES MARETTES POUR FIE DE CU[VRE,

€, TOUTE COMPOSANTE DE REMPLACEMENT DOIT [ETRE BIEN M[SE EN TERRE,

B, FOURN[£SEZ LES D[SJONCTEURS POUR L'AL[MENTA]TON

6, LES MOTEURS SONT PROTEGES' DE PAR LEUR CONCEPTION,

IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE IOB'C THERMQPLASTIC OR ITS EQUIVALENT.

CAPACITOR

BLACK ON MOTORS WITHOUT CAPACITOR

WALL

ORG

VCqT

WHT

[

NEU_ WHT

SYSTEM

SWZTCH

INCOMING POWER MUST BE POLARIZED. OBSERVE COLOR COOZNG.

L'ALIMENTATION DU COURANT DOIT E_RE POLARIBEE." SUIVEZ

LES CODES DE COULEURB.

WHT

LEGEND LE'GENDE

BM BURNER MOTOR BM MOTEUR DU BRU_EUR OPSV

PC PRIMARY CONTROL PC CONTR_LE PRIMAIRE

[T IGNITION TRANSFORMER [T TRANSFORMATEUR D'IGN[T]ON

RI RELAY RI RELA]£

SV SOL[NO[D VALVE SV SOUPE DU SOLENO[DE

PC PRIMARY CONTROL PC CONTROLE PRIMA(RE

PI/SI 9 PIN PLUG & SOCKET ON BLO_R MOTOR PI/SI LE MOTEUR DE LA SOUFFLER[E OOUILLE ET BOUCHON A 9 P[GES BUR

LSI PRIMARY LIMIT £W]TGH LSI COMMUTATEUR DE L[M[TE PR[NGIPALE

LS2 LIMIT £W[TCH LS2 GOMMUTATEUR DE LIM[TE

CS CENTRIFICAL SWITCH CS COMMUTATEUR CENTRIF[QUE

FUSE _ FUSIBLE

IRC RUN CAPACITOR IRC CAPAC[TEUR DE FONCT[ONNEMENT (DENT(FIE

IT TRANSFORMER IT TRANSFORMEUR

(_ IDENTIFIED RUN CAPACITOR (_ CAPACITEUR DE FONCT[ONNEMENT I[3ENTIFIE

Z4V CONNECT(ON ROOM THERMOSTAT _ Z4V RACCOROEMENT DU THERMOSTAT DE PIECE

O FIELD CONNECT(ON O RACCORDEMENT DE CHANTER

FACTORY WIRING AND DEVICES FILA_E DE L'USINE ET APPAREILS

wHT

PRP

OIL BURNER

JUNCTION

_OX

_ IBM

FAN

SWITCH

ORG

PRP AUTO

RESET

BLU _ _H

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 Installa-

tion of Domestic Gas Conversion Burners, Z21.8 latest edition, and the

National Fuel Gas Code, ANSI Z223. l-latest edition.

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.

PREPARATION 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 oil designed furnaces, it is recommended that the

same combustion chamber be used with the oil burner. If the blast tube

opening into the combustion chamber is larger than the 4" (101.6 mm)

diameter, high temperature cement should be used to reduce the open-

ing 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 chamber.

INSTALLATION OF BURNER AND 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 weaken-

ing its durability or efficiency. The burner is supplied as a completely

assembled package unit.

NOTE: The burner must be installed in such a manner that the unit and

all controls will be readily accessible for inspection, cleaning, adjust-

ment, and repairs.

This conversion burner is designed to operate on NATURAL GAS

or PROPANE GAS ONLX Do Not Burn any other Fue! in this fur-

nace. 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, prop-

erty damage and/or death.

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

Gas Supply piping must be sized in accordance with the recommenda-

tions 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

must comply with requirements contained in Manufactured Homes

Al19.1, Recreational Vehicles A!19.2 and H.U.D. Title 24, Section

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.

MANUAL

SHUT-OFF

VALVE

LEG

DRIP GAS

LEG BURNER

MANUAL

,_/SHUT-OFF

VALVE

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 octa-

gon 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 pip-

ing 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 spar-

ingly on male threads only and be approved for all gases. Refer to Fig-

ures 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 29

107272-UIM-A-0905

TABLE 16: Gas Line Piping Size and Length

Nominal Diameter of Pipe in Inches (mm)

Length of Pipe in 3/4 (!9.05) 1 (25.4) !-1/4 (31.75) !-1/2 (38.1) 2 (50.8)

Feet (Meter) Capacity-Cu. Ft. (m3) Per Hr. with a 0.6 Sp. Gr. Gas and Pressure 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.

Butt or lap welded pipe should not be bent.

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

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.

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.

Gas Line

Shutoff,

Valve

ManuaI

Shutoff Valve

(Close this valve during pressure

testing of the gas line)

1/8" NPT Plugged

Pressure

Gauge Port

Direction

of Flow Union

Black

3.00 Min.

Pipe

To Gas

Valve

LOCATION OF UNION AND DRiP LEG FOR

CONNECTING BURNER TO HOUSING PiPiNG

Some utility companies or local codes require pipe sizes larger than the

minimum sizes listed in these instructions and in the codes. The furnace

rating plate and the instructions in this section specify the type of gas

approved for this furnace - only use those approved gases.

IMPORTANT: An accessible manual shut-off valve must be installed

upstream of the furnace gas valve and within 6 feet (1.8 m) of the fur-

Race.

TESTING PIPING FOR 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

LOCATE GAS LEAKS, USE A SOAP SOLUTION.

TABLE 17: Length of Standard Pipe Threads in Inches (mm)

EFFECTIVE LENGTH OVERALL LENGTH

PIPE SIZE OF THREAD OF THREAD

3/8 (9.53) 3/8 (9.53) 9/16 (!4.29)

1/2 (12.7) 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)

2 Imprerfect

Threads

FIGURE 41: Proper Piping Practice

Leave2 End I/

Threads Bare J

FIGURE 40: Manual Shut-offValve/Gas Piping

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 con-

nector. Do not use a connector that has previously serviced another gas

appliance.

........

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.

30 Unitary Products Group

107272-UIM-A-0905

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 asphyxia-

tion. Also, pipe sealant must be resistant to Propane gas.

A main shut-off valve shaft be installed externally of furnace cas-

ing. 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 asphyxia-

tion.

A drip leg is required by some local codes to trap moisture and contam-

inations. 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 equal to or less

than 1/2 psig (3.5 kPa).

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)

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

but may be converted to operate on propane (LP) gas by using a fac-

tory-supplied LP conversion kit. Follow the instructions supplied with

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

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 pres-

sure in excess of 4.0 in w.c (0.99 kPa) can cause premature heat

exchanger failure. High levels of carbon monoxide, excessive soot-

ing, a fire hazard, personal injury, property damage, and/or death.

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.

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 CAN/CGA-B149.1-00 Natural Gas and Propane Installation

Code.

HIGH ALTITUDE PRESSURE SWITCH 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 Acces-

sory 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 con-

vetted wil! create an extremely dangerous condition resulting in pre-

mature heat exchanger failure, excessive sooting, high levels of

carbon monoxide, personal injury, property damage, a fire hazard

and/or death.

High altitude and propane (LP) conversions are required in order

for the appliance to satisfactory meet the application.

An authorized 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.

Unitary Products Group 31

107272-UIM-A-0905

TABLE 18: High Attitude Duration Chart

NATURAL GAS

56,000 -- Input 70,000 -- Input 77,000 -- Input 90,000 -- Input

Elevation

Feet Meters Orifice Drill Part # Orifice Drill Part # Orifice Drill Part # Orifice Drill Part #

Dia. Size Dia. Size Dia. Size Dia. Size

Sea Level 0.136 29 9951--1361 0.!54 23 9951--1541 0.161 20 9951--16!1 0.180 !5 9951--1801

2,000 618 0.136 29 9951--1361 0.149 25 9951--1491 0.157 22 995!--157! 0.177 16 9951--1771

3,000 914 0.128 30 9951--1281 0.!49 25 9951--1491 0.157 22 995!--!57! 0.173 !7 9951--1731

4,000 1219 0.128 30 9951--!281 0.147 26 9951--1471 0.154 23 9951--1541 0.173 17 9951--173!

5,000 1524 0.128 30 9951--1281 0.!44 27 9951--1441 0.152 24 995!--!52! 0.169 !8 9951--1691

6,000 1829 0.128 30 9951--1281 0.144 27 9951--1441 0.149 25 995!--149! 0.166 19 9951--1661

7,000 2134 0.120 31 9951--1201 0.!40 28 9951--1401 0.147 26 995!--!47! 0.161 20 9951--161!

8,000 2438 0.120 31 9951--1201 0.!36 29 9951--1361 0.144 27 995!--!44! 0.161 20 9951--161!

9,000 2743 0.120 31 9951--1201 0.136 29 9951--1361 0.140 28 995!--140! 0.157 22 9951--1571

10,000 3048 0.116 32 9951--116! 0.!28 30 9951--1281 0.136 29 995!--!36! 0.152 24 9951--1521

PROPANE GAS

56,000 -- Input 70,000 -- Input 77,000 -- Input 90,000 -- Input

Elevation

Feet Meters Orifice Drill Part # Orifice Drill Part # Orifice Drill Part # Orifice Drill Part #

Dia. Size Dia. Size Dia. Size Dia. Size

Sea Level 0.082 45 9951--0821 0.093 42 9951--0931 0.098 40 9951--0981 0.106 36 9951--1061

2,000 618 0.081 46 9951--081! 0.093 42 9951--0931 0.096 41 995!--096! 0.104 37 9951--1041

3,000 914 0.078 47 9951--0781 0.089 43 9951--0891 0.093 42 995!--093! 0.101 38 9951--101!

4,000 1219 0.078 47 9951--0781 0.089 43 9951--0891 0.093 42 9951--0931 0.101 38 9951--1011

5,000 1524 0.078 47 9951--0781 0.089 43 9951--0891 0.093 42 995!--093! 0.099 39 9951--0991

6,000 1829 0.076 48 9951--0761 0.086 44 9951--0861 0.089 43 995!--089! 0.098 40 9951--0981

7,000 2134 0.076 48 9951--0761 0.086 44 9951--0861 0.089 43 995!--089! 0.096 41 9951--0961

8,000 2438 0.073 49 9951--0731 0.082 45 9951--0821 0.086 44 9951--0861 0.096 41 9951--0961

9,000 2743 0.073 49 9951--0731 0.081 46 9951--0811 0.086 44 995!--086! 0.093 42 9951--0931

10,000 3048 0.070 50 9951--0731 0.078 47 9951--0781 0.082 45 995!--082! 0.089 43 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

LP 66,000 (19.3) 0.!16" (2.95 ram) 2.0

LP 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.

32 Unitary Products Group

CARBON MONOXIDE POISONING HAZARD

107272-UIM-A-0905

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 shall operate contin-

uously.

5. Test each appliance (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, fire-

place 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 START-UP AND

ADJUSTMENTS

The initial start-up of the furnace requires the following additional

procedures:

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

tory should be checked for proper tightness.

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

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 circum-

stances shall the Iine be purged into the combustion chamber.

After the gas line to the conversion 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

(NATURAL GAS)

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

input.

NOTE: Burner orifices are sized to provide proper input rate using natu-

ral gas with a heating value of 1030 BTU/Ft 3 (3.6 mj/m 3. If the heating

value of your gas is significantly different, it may be necessary to

replace the orifices.

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

2. At the gas meter, measure the time (with a stop watch) it takes to

use 2 cubic ft. (0.0566 m3) of gas.

3. Calculate the furnace input by using one of the following equa-

tions.

Unitary Products Group 33

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 mea-

sured 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 1 cubic ft. (0.028 m) of gas from the gas meter.

The formula for US input calculation using a cubic foot gas meter:

BTU/ft 3 x 2 cu.ft, x 0.960 x 3600 BTU/H

Seconds it took to measure the 2 cu.ft, of gas

NATURAL GAS INPUT CALCULATION

EXAMPLE:

1030 x 2 x 0960 x 3600

905 78,666.90

Natural Gas

1030 BTU/SCF

I BTU/ft 3 x 1 cuft x 0960 x 3600 = BTU/H

Seconds it took to measure the 1 cuft of gas

PROPANE (LP) GAS INPUT CALCULATION

EXAMPLE:

2500 x 1 x 0960 x 3600

108 = 80,000 00

Propane Gas

2500 BTU/SCF

In Canada you will use the following formula to calculate the furnace input if you are using acubic foot gas meter.

For Natural Gas multiply the Heat content 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 correction factor of 0.960; times 3600, then divided by the time 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 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 correction factor of 0.960; times 3600, then divided by the time it

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 = MJ/H x

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 = 8212 x

90.5

Natural Gas

1030 BTU/SCF = 38.4 MJ/m 3

PROPANE (LP) GAS INPUT CALCULATION

EXAMPLE:

93.15 x 1 x 0028 x 0.960 x 3600 = 8346 x

108

Propane Gas

2500 BTU/SCF = 93.15 MJ/m 3

02777 kW 3412.14

02777 2280 3412.14

02777 2318 3412.14

BTU/H

77,79680

79,0934

In Canada use the following formula to calculate the furnace input if you are using agas 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), times 0.10 m 3of gas measured at the gas meter, times a baro-

metric 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.

The formula for metric input calculation using a cubic meter gas meter:

MJ/m 3 x m 3x 0960 x 3600 3 MJ/H

Seconds it took to measure the 0.10 m of gas

NATURAL GAS INPUT CALCULATION

EXAMPLE:

384 x 0.1 x 0960 x 3600 8294

160

Natural Gas

1030 BTU/SCF = 38.4 MJ/m 3

PROPANE (LP) GAS INPUT CALCULATION

EXAMPLE:

9315 x 01 x 0.960 x 3600 8319

387

Propane Gas

2500 BTU/SCF = 93.15 MJ/m 3

02777 kW 341214

02777 2303 341214

02777 2310 341214

BTU/H

78,581.60

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 input specified on the rating plate then replace the gas orifices with the gas orifices

of the proper size for the type of gas you are using.

For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED. Refer to the GAS CONVERSION FOR PROPANE (LP) AND HIGH

ALTITUDES IN SECTION IV for information on high altitude conversions.

34 Unitary Products Group

107272-UIM-A-0905

INITIAL START UP

1. Read the applicable sequence of gas control operation in the

Operation and Troubleshooting section before proceeding.

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

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

4. 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.

5. 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.

6. Set the thermostat below room temperature, shutting the burner

"OFF".

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

8. Set the thermostat or operating control to call for heat. The burner

will start and go through the applicable sequence of burner/pri-

mary gas control operation, refer to step 1.

9. Once burner is running, adjust the orifice manifold pressure regu-

lator as described in Pressure Regulator Adjustment.

ADJUSTMENT OF MANIFOLD GAS PRESSURE

Manifold gas pressure may be measured at the gas valve.

Turn gas off at the ball valve or gas cock on gas supply line

before the gas valve. Find the pressure ports on the gas

valve marked OUT and INLET.

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 adjustment

cap and adjustment screw on main gas valve.

2. Adjust manifold pressure by adjusting gas valve regulator screw

for the appropriate gas per the following:

TABLE 21: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

Natural Gas _ 35" w.c (087 kPa)

Propane (LP) Gas T35" w.c. (0.87 kPa)

CHECKING THE GAS PRESSURES

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

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

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

LET.

4. Using a 3/32" (0.2 cm) Alien wrench, loosen the set screw by turn-

ing it 1 turn counter clockwise. DO NOT REMOVE THE SET

SCREW FROM THE PRESSURE PORT.

5. 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 refer-

ence port. Refer to Figure 43 for connection details.

TABLE 20: inlet Gas Pressure Range

INLET GAS PRESSURE RANGE

Natural Gas Propane (LP)

Minimum 45" WC (112 kPa) 80 _W.C (199 kPa)

Maximum 105 _W.C (261 kPa) 130" (3.24 kPa) W.C.

IMPORTANT: The inlet gas pressure operating range table specifies

the minimum and maximum gas line pressures required for safe fur-

nace operation.

The minimum inlet gas pressure required to obtain the BTU input speci-

fied 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

Electrical Terminals (Shown in ON position)

FIGURE 42: Gas Valve

IMPORTANT: If gas valve regulator is turned in (clockwise), manifold

pressure is increased. If screw is turned out (counter clockwise), mani-

fold pressure will decrease.

3. 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 THE FURNACE

INPUT (NATURAL GAS)".

4. 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 manifold pressure must be checked with the screw-off cap for

the gas valve pressure regulator in place. If not, the manifold pres-

sure setting could result in an over-fire condition. A high manifold

pressure will cause an over-fire condition, which could cause pre-

mature 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.

Unitary Products Group 35

107272-UIM-A-0905

MAINFOLD PRESSURE "U" TUBE CONNECTION

Outlet

Pressure

Tap

Tubing

Gas Valve

3.5 IN (0.87 kPa)

Water

Cotumn

Gas

Pressure

Shown

FIGURE 43: Reading Gas Pressure

Observing Burner Operation

1. 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. Let furnace heat until blower cycles on.

3. Turn thermostat down.

4. Observe burner to make sure it shuts off.

5. Let the furnace cool and blower cycle off.

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

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

List included in the home owner envelope with the furnace.

If Furnace Fails to Operate Properly

1. 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.

2. Check to see that electrical power is ON.

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

ON position.

4. Make sure filters are clean, return grilles are not obstructed, and

supply registers are open.

5. Be sure that furnace flue piping is open and unobstructed.

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.

ADJUSTMENT OF TEMPERATURE RISE

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 fur-

nace 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.

The temperature rise, or temperature difference between the return air

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.

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 CHECK

1. 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

tips for propane gas.

2. 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.

All adjustments below must be made with the following instructions:

a. Draft Gauge

b. 02 or CO 2 Analyzer

c. CO Tester

d. Water Column Gauge

NOTE: ALWAYS USE RELIABLE COMBUSTION TEST INSTRU-

MENTS. BEING PROFICIENT IN THE USE OF THESE INSTRU-

MENTS AND INTERPRETING THE DATA IS NECESSARY FOR

SAFE, RELIABLE AND EFFICIENT BURNER OPERATION

IT IS ESSENTIAL TO MAKE CERTAIN THAT THE PRODUCTS OF

COMBUSTION DO NOT CONTAIN CARBON MONOXIDE, CO.

The most common causes of CO are flame impingement on cool sur-

face 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 pri-

mary air.

36 Unitary Products Group

107272-UIM-A-0905

Combustion efficiency is determined by the percent CO 2 and the tem-

perature 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.

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.

Refer to your local gas company and codes for assistance.

3. Perform the following combustion analysis. All adjustments below

must be made with the following 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 natu-

ral 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 -- SC80-C GAS BURNER UTI-

LIZING HONEYWELL S87K GAS PRIMARY WITH BUILT IN

30 SECOND PREPURGE

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 pres-

sure is sensed by the air proving switch and closes the switch contacts

energizing the $89F gas primary control.

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 com-

pleted, 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.

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 pri-

mary 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 sec-

ond 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-ener-

gized 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.

<-.13 Igniter Gap

..13 FIame Sense

Rod Gap

FIGURE 44: Electrode Orientation and Gap

Unitary Products Group 37

BLOWER SPEED CHART

(CHARTE DE VITESSE

DE LA SOUFFLERIE)

WIRE COLOR KEY

(CODE DE COULEUR

DU FILAGE)

BLACK

(NOIR)

BLUE

[BLEU) [BLEU)

RED RED

IROUG} [ROUGE)

YELLOW

{JAUNE}

WHITE

[BLANC) [BLANC)

BRN BROWN

[BRUN} [BRUN)

GRN GREEN

(VERT} {VERT)

PRP PURPLE

{POURPRE] {POURPRE[

ORN ORANGE

(ORA} {ORANGE)

CAUTION

OPEN ALL DISCONNECTS BEFORE

SERVICING THIS UNIT

PRE'CAUTION

OUVREZ LES DISJONCTEURS AVANT

DE PROCEDER AVEC LE SERVICE

80+ DOWNFLOW FURNACE

(FOURNAISE BOX

VENTILEE PAR LE HAUTI

NOTES=

I TOUT F[LAGE EN CHANTIER SELON: CA[ CODE ELEC .NATIONAL (CEN[ ET/OU/

/_/CODEELECCA.ADENCOEC_ET_OUJ

CODES LOCAUX ET MUNIC[PAUX

Z. S[ LE F[LABE DOlT ET_E REMPLACE EN P_TRIE OU EN TOUT, [L DOIT

L'ETRE AVEC UN MATER[AUX POUVANT RESISTER A DES TEMPERATURES

D'AU MO[NS ZZI"F (105"C).

3, SEULEMENT DES MARETTES POUR FIE DE CUIVRE

#. TOUTE COMPOSANTE DE REMPLACEMENT DOlT [ETRE BEN M[SE EN TERRE.

5 FOURN[SSEZ LE£ D[SJONCTEURS POUR L'AL[MENTAITON.

6, LES MOTEURS SONT PROTE,GES DE PAR LEUR CONCEPTION.

LADDER DIAGRAM

(DIAGRAMME ELEMENTAIRE) IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE IO5'C THERMOPLASTIC OR ITS EQUIVALENT.

ee BLACK ON MOTORS WITHOUT CAPACITOR

ORG

LI L2

R2 LSZ MV 1_24v ÷ *.T

GNU GND

II(EN TERRE) F BLEND AIR

(IF EQUIPPED) LSI

_ SEC _1@1@1_1 • •

Ic_k_ i I i i

L __ :3 liarN

HEAT/COOL THERMOSTAT I [_ RED

(THERMOSTAT CLIMA/CHAUF)

NOTES: I III _1 BLK

I. ALL FIELD _[R[NG PER: (A) NATIONAL ELEC. CODE [NEC} AND/OR/

{B) CANADIAN ELEC. CODE (CEC) AND/OR/ I'

[C} LOCAL OR CITY CODESI I I L_ _/_

2. IF ANY OF THE OR[SINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE i II CONDENSING

UNITREPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A I i I

TEMPERATURE RATING OF AT LEAST 221"F (lOS"C). ICONTACTORi

3. CONNECTORS SUITABLE FOR COPPER CONDUCTORS ONLY. I r_i

_I z I a •_F EQUIPPED

41 ALL REPLACEMENT COMPONENTS MUST BE PROPERLY 8ROUNDED. _z _ m m

5. PROVIDE D[SgONNEgT5 FOR ALL POWER SUPPLIES _"

6. MOTORS ARE INHERENTLY PROTECTED

WALL

THERMOSTAT

ORG U

FORIER

BLK

GRaUND

INCOMING POWER MUST BE POLARIZEOI OBSERVE COLOR COOINGI

L'ALIMENTATION DU COURANT DOIT E_RE POLARISEE[ SUIVEZ

LES CODES DE COULEURS.

SYSTEM

SWITCH

LEGEND

BM BURNER MOTOR

PC PRIMARY CONTROL

IT IGNITION TRANSFORMER

R2 RELAY

PC PRIMARY CONTROL

PI/SI 9 PIN PLUG &SOCKET ON BLOWER MOTOR

LSI PRIMARY LIMIT S_ITCH

LS2 LIMIT SWITCH

CS CENTR[FICAL SWITCH

FUSE

IRC RUN CAPACITOR

IT TRANSFORMER

@ IDENTIFIED RUN CAPACITOR

2#V CONNECTION ROOM THERMOSTAT

0 FIELD CONNECTION

FACTORY WIRING AND DEVICES

FIELD WIRING AND DEVICES

LE'GENBE

BM MOTEUR DU BRU_EUR

pC CONTRO_LE pRIMA[RE

PI/SI

L£1

LS2

IRC

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 UWO A 0705

WR GAS VALVE

BLK

_o.

BLOWER SPEED CHART

(CHARTE DE VITESSE

DE LA SOUFFLERIE)

WIRE COLOR KEY

{CODE DE COULEUR

DU FILAGE)

BLACK

(NOIR}

BLUE

(BLEU) (BLEU)

RED

(ROUGE}

YELLOW

(JAUN) (JAUNE)

WHT WHITE

(BLANC) (BLANC)

BROWN

{BRUN)

GREEN

! VpER_T) (VERT)

PURPLE

:POURPRE) (POURPRE)

ORN ORANBE

CORAl CORANGEI

CAUTION

OPEN ALL DISCONNECTS BEFORE

SERVICINB THIS UNIT

PRE'CAUTION

OUVREZ LES DISJONCTEURS AVANT

DE PROCEDER AVEC LE SERVICE

80+ DOWNFLOW FURNACE

(FOURNAISE 80X

VENTILEE PAR LE HAUT I

NOTES=

LADDER DIAGRAM

(DIAGRAMME ELEMENTAIRE)

FSYSTEM POWER SUPPLY 115 I 6O SEE NOTE I

S_]TCH

_" (ALIMENTATIeN 115 I 60 VOIR NOTE I)

L I L2

M_ GV

IX24v

8ND IIGNo

4_} SENSOR

L 3

HEAT/COOL THERMOSTAT

[THERMOSTAT CLIMA/CHAUF)

NOTES:

I. aLL FIELD WIRING PER, (a) NATIONAL ELEC. CODE (NEC) aND/OR/

(B) CANAO[AN ELEC. COOE (CEC) ANO/OR/

2 IF ANY OF THE ORIGINAL WIRE AS SUPPLED WITH THE FURNACE MUST BE

REPLACEO, IT MUST BE REPLACEO WITH WIRING MATERIAL HAVING A

TEMPERATUREaATINGOr ATLEAST221"F (105'C)

5 CONNECTORS £UITABLE FOR COPPER CONDUCTORS ONLY

4 ALL REPLACEMENTCOMPONENTSMUSTBE PnOPERLYGROUNOED.

5. PROVIDE D[SCONNECT£ FOR ALL POWER SUPPLIES

GNO

(EN TERRE)

IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED•

CAPACITOR

BLACK ON MOTORS WITHOUT CAPACITOR

ORG

WHT

BLK

GROUND SYSTEM

EARTH GROUND _SCREw SWITCH

& MOTORSARE iNHERENTLY PROTECTED.

INCOMING POWER MUST BE POLARIZED. OBSERVE COLOR CODING.

I. TOUT F[LAGE EN CHANT[ER 5ELON: (A) CODE ELEC. NATIONAL (FEN} ET/OU/ L'ALIMENTATION DU COURANT DOIT ET_RE POLARISEE. SUIVEZ

LES CODES DE COULEURG.

CENTRIFUGAL SWITCH

REO _L

BL_

LE'GENDE _

MOTEUR DU BRU_EUR

CONTR_LE PRIMA{RE

TRANSFORMATEUR D'[BNITION _ TRANS

RELAIS YEL FORMER WV 7

SOUPE DU SOLENOIDE /

CONTROLE PRIMAIRE

LE MOTEUR DE LA SOUFFLERIE DOU[LLE ET BOUCHON A 9 P[GES SUR

CAPACITEuRCOMMUTATEuRCOMMUTATEURFus[BLEDECENTRIF[QuEDEFoNCTIONNEMENTL[MITEIDENT[FE _ _D:i W_3662¢G_ ......206

TRANSFORMEUR

CAPACITEUR DE FONCT[ONNEMENT iDENTIFIE

2€V RACCORDEMENT DU THERMOSTAT DE PIECE

RACCOROEMENT DE CHANTER

F[LAGE DE L'US[NE ET APPAREILS

F[LAGE DE CHANTIER ET APPAREILS 125525 UWD A 0705

B CODE ELEC CANADIEN (CEC) ET/OU/

14........................

• Sl _E rILA_E DGIT ET_E _M_ _ _ _ _ _, _ _

_ET_E A_EC U_ _ATE_AU× POU_A_T RE_TE_ _ DE_ TE_PE_ATU_E_

D_AU M_ _ I_CI_

_ _EU_EME_T DE_ _ETTE_ _U_ _ DE _U_E_

_ TOUTE COMPO_A_TE DE _EM_ACEME_T _O_T [ET_E _E_ M_E E_ TER_E_

_U_E_ _E_ O_TEU_ _OUR _A_E_T_T_

_ _E_ _OTEUR_ _O_T P_OTE_E_ _ _E PA_ _EU_ CO_CE_T_O_

LEGEND

BM BURNER MOTOR BM

PC PRIMARY CONTROL PC

[T IGNITION TRANSFORMER IT

RI RELAY RI

SV SBLINO[D VALVE SV

PC PRIMARY CONTROL PC

PI/SI 9 PIN PLUG & SOCKET ON BLO_R MOTOR PI/SI

LSI PRIMARY LiMiT SWITCH LSI

LS2 L[_[T SWITCH LS2

CS CENTR[F[CAL SWITCH CS

FUSE

IRC RUN CAPACITOR IRC

IT TRANSFORMER IT

IDENTIFIED RUN CAPACITOR

24V CONNECT{ON ROOM THERMOSTAT

0 FIELD CONNECT{ON 0

FACTORY WIRING AND DEVICES

FAN

SWITCH

ORB

PRP AUTO

RESET

LIM

BLU _SW[1

,12

NOTES

Subject to change without notice. Printed in U.S.A.

Unitary

Product

Group

5OO5

York

Drive

107272-UIM-A-0905

Supersedes: 035-16393-001 Rev. B (0304)

Norman

73069

COLEMAN Heater, Kerosene Manual L0601037

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