HYDRO FLAME 1H2C Hflamefurn04
User Manual: HYDRO FLAME 1H2C
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September 2003 INTRODUCTION The 2004 edition of the Atwood Furnace Service Manual is a resource created to help service technicians identify Atwood product by serial number, diagnose service problems and efficiently and effectively process warranty claims. Changes to the Hydro Flame furnaces include: • Ignition boards in the 79, 85 and 89 series furnaces now have the blower relay incorporated into the PC board. These boards are compatible with previous Hydro Flame furnaces. There is no longer a remote relay. • New boards have a diagnostic ability with 4 fault codes. • Furnaces with no outside access doors (only an exhaust vent) became available in 2003; the initials L/D in the model number identify these models. The gas valve was re-oriented with a longer inlet manifold to make this possible. Each of the manuals within this series offers a general overview of the product as well as more specific product information. For each product within the manual, you will find model identification, recommended tools and equipment, a sequence of operation, warnings, annual maintenance procedures, parts and troubleshooting guides, warranty procedures, flat rate schedules, and replacement part reference charts. Due to the rapidly changing personal computer revolution we have placed troubleshooting information in a variety of places to make sure that the most accurate information is available. The best place to find the current information about Atwood products is our website: www.atwoodmobile.com. At our website brochures may be downloaded, trouble shooting guides reviewed and the latest information bulletins can be read. In addition all Atwood Authorized Service Centers are listed on our site, accessible via an easy-to-use search system. Service for all Atwood products is handled out of our Rockford location. Should you have any questions regarding our products or the information contained in this manual simply dial 1-800-825-4328. Be sure to have the Model and Serial Number when you call. Atwood Service Department Disclaimer: The data presented in this publication is obtained from the most reliable sources, and is believed to be accurate as of the date of publication. Responsibility for typographical errors or omission of data cannot be assumed by the publishers. 1 Recommended Tools and Equipment U-Tube Manometer - P/N 34706 - This is the most accurate device for measuring gas pressure. If you use a dial-type manometer, it should be calibrated periodically with this type of manometer. Slack Tube Manometer - P/N 34880 - A more portable U-Tube Manometer. Multi-meter - This is the most effective meter capable of reading voltage, amperage and continuity. A test light cannot give you specific enough information to trouble-shoot a furnace properly. U-TUBE MANOMETER VOLT OHM-AMP METER with 1/8” pipe nipple Fill here 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 Manometer connection Circuit Board Tester - P/N 32779 - This is a table top device that will test all furnace circuit boards. It will specifically test the following board functions: power, spark, lamp, sense and valve. It will test Fenwal and Channel circuit boards. CIRCUIT BOARD TESTER Air Speed Indicator - P/N 34207 - This hand held device will let you determine air flow out of a heat register. It will help you isolate restricted ducting. Incline Manometer - P/N 34208 - This meter measures the static pressure of the furnace cavity. It provides an x-ray of the total heating system. It will indicate if all of the heat being produced by the furnace is being sufficiently distributed out to the heat registers. Long-handled Allen Wrenches (9/64˝ and 1/8˝) - These two wrenches are necessary to remove the blower wheel and the combustion wheel. Common Hand Tools - 1/4˝ nut drivers, open end wrenches, flat blade and Phillips screw drivers. Leak Test Solution - A solution that bubbles when applied to gas fittings or connections showing where a gas leak is present. 2 hydro flame™ FURNACES TABLE OF CONTENTS Recommended Tools & Equipment ............................................................................................................................................................................................................2 79/80 Series Model Identification ..................................................................................................................................................................................................................................................4 79-II Directional Air Box Insert ......................................................................................................................................................................................................................5 85 Series Model Identification ..................................................................................................................................................................................................................................................6 89 Series & 2-Stage Model Model Identification ..................................................................................................................................................................................................................................................7 Wiring Diagrams 7900-II/8000-II Series ............................................................................................................................................................................................................................................8 8500 Series ..........................................................................................................................................................................................................................................................10-11 8900-III Series & 79 / 85 / 89 with blower control ignition board ..........................................................................................................................12 2-Stage Furnace & Diagnostic Chart ..................................................................................................................................................................................................13 Model 1H2C Digital Thermostat ..................................................................................................................................................................................................................14 Model 2H2C Digital Thermostat ..................................................................................................................................................................................................................15 Sequence of Operation DC Models (standard 1-Stage) ..................................................................................................................................................................................................................16 ™ DC Models (2-Stage Excalibur ) ..............................................................................................................................................................................................................17 Pilot Models ..................................................................................................................................................................................................................................................................18 AC Models ......................................................................................................................................................................................................................................................................19 Safety & Warnings ........................................................................................................................................................................................................................................................20 Annual Preventative Maintenance Inspection ............................................................................................................................................................................21 Furnace Parts Mechanical Thermostat ....................................................................................................................................................................................................................................22 Circuit Breaker & Motor ....................................................................................................................................................................................................................................23 Circuit Boards..............................................................................................................................................................................................................................................................23 Relay ....................................................................................................................................................................................................................................................................................24 Sail Switch ......................................................................................................................................................................................................................................................................24 Limit Switch ..................................................................................................................................................................................................................................................................24 Dual Solenoid Gas Valve ..................................................................................................................................................................................................................................25 Burner Head, Electrode & Valve Assembly ..................................................................................................................................................................................25 The 4 Always (Gas Pressure, Voltage, Ducting, Return Air) ................................................................................................................................26-27 Trouble Shooting Guides Thermostat ....................................................................................................................................................................................................................................................................29 Electronic Ignition Models ....................................................................................................................................................................................................................30-31 Pilot Model ............................................................................................................................................................................................................................................................32-33 Furnace Terminology ......................................................................................................................................................................................................................................34-35 Return Goods Policy (RETURN ADDRESS)..................................................................................................................................................................................................36 Warranty Procedures ................................................................................................................................................................................................................................................36 Warranty ..................................................................................................................................................................................................................................................................................37 Flat Rate Schedule ......................................................................................................................................................................................................................................................38 Furnace Parts Breakdowns 7900-II/8000-II Series ..........................................................................................................................................................................................................................................39 8500-III Series ............................................................................................................................................................................................................................................................40 8500-IV Series ............................................................................................................................................................................................................................................................41 8900-III Series ............................................................................................................................................................................................................................................................42 2-Stage Model 1522 & 2334 ........................................................................................................................................................................................................................43 2-Stage Model 2540 ............................................................................................................................................................................................................................................44 Replacement Part Reference 85-IV 16, 85-IV 20, 85-IV 25, 85-IV 31, 85-IV 35, 1522, 2334 2-STAGE & R-25 ........................................................................................45 7912-II, 7900-II 16 & 20, 8012-II, 85-III 16-20, 85-III 25, 85-III 31-35, 89-III DC, 89-III AC, 2540 2-STAGE ..................48 85-II 16-20, 85-II 25, 82-II 31-35, 89-I DC, 89-I AC, 89-II DC, 89-II AC, FA 79D, FA 79P, HF 80D, HF 80P ..................53 85-I 16-20, 85-I 25, 85-I 31-35, DC82 25-32, DC82 35-41, AC 82, FA 76D, FA 78 25-32, FA 72D, FA 72P ..................56 Atwood Furnace Installation Parts Atwood Training Tapes and Manuals ORDER BLANK 3 79 / 80 Series Model Identification MODEL DESCRIPTION Model & Rate Input 79 -12-II = 12,000 16-II = 16,000 20-II = 18,000 80 -12-II = 12,000 Valve Setting & Power Usage DC = Direct current 12 volts Fitting Size Gas 6 = 3/8˝ flare Venting or Ducting Options A = vent length 4˝ approximate B = vent length 8˝ approximate C = vent length 12˝ approximate 79 I6-II DC 6 A Applications - This unit is typically installed in tent campers, truck campers and small travel trailers due to its small size and lower BTU capacities. It is sometimes used in larger trailers or motor homes for smaller zone heating. Heat Outlets - This furnace is usually set up as a front discharge unit. However, it does have a 4" duct outlet on either side of its casing for soft ducting to remote outlets. To determine the most efficient ducting configuration, refer to Minimum Ducting Configuration. Directional Air Box Insert - If you need to direct heat to the front or rear of a camper and you cannot use soft ducting and registers, an optional diverter plate with 55 degree louvers can be added to the front exhaust box. Serviceability - Practically all of the components of this furnace are accessible by removing the front grille. Therefore, the furnace does not need to be removed for most repairs. The only components that are not accessible without removing the furnace are the blower motor, sail switch and blower and combustion wheels. Power Consumption - The 79 series furnace draws only 3.4 amps. However, there is an 8012 series furnace that has a heating capacity of 12,000 BTU’s and only draws 1.8 amps. This furnace is ideal for dry camping. MINIMUM DUCTING CONFIGURATION 7912-II 7916-II 7920-II - SIDE DISCHARGE UNITS Provides the most air flow and heat to remote heat outlets. The duct runs need to be as short and straight as possible for optimal heating. 7912-II 7916-II 7920-II - SIDE DISCHARGE UNITS with front dischargeThe majority of the heat discharges out the front. A minimal amount of heat will pass through the side ducts. These duct runs need to be as short as possible. An optional air diverter with 55° angle vanes can be added to front discharge opening to direct heat fore or aft in the trailer. 8012-II 7912-II 7916-II 7920-II - FRONT DISCHARGE UNITS no ducts allowed on 8012-II The heat discharges only through the front. The optional air diverter noted above can be added to front discharge opening to direct heat for or aft in the trailer. Duct #1 Front Discharge CLOSED Duct #2 Duct #1 Front Discharge OPEN Duct #2 Front Discharge OPEN RETURN AIR REQUIREMENTS Return air is provided through the front door grill - approximately 33 square inches (213cm2). If the furnace is installed at zero clearance, an additional 16 square inches (103cm2) of return air must be provided to the blower wheel side of the furnace. 4 79-II Directional Air Box Insert (PN 36959) An air discharge diverter is now available for all 79 series furnaces. This insert has fins that are set at a 55 degree angle. This will allow you to direct the heat fore or aft in the camper easier. 1. Remove the front grill of the furnace. 2. Follow the shutdown procedure instructions affixed to the furnace. 3. Remove the sheet metal screw that holds the circuit board plate to the air box. Retain to fasten the Air Box Insert to the bottom of the air box. 4. Install the Air Box Insert into the air box paying particular attention to the direction where you would like the warm air diverted. Make sure the two holes in the Air Box Insert line up with the existing holes in the air box. 5 5. Fasten the Air Box Insert to the top of the air box using a 1/4˝ long #6 sheet metal screw. Fasten the bottom of the Air Box Insert and the circuit board plate to the bottom of the air box using the screw removed in step 3. 6. Follow the lighting instructions to place the furnace in operation. 7. Replace the front grill on the furnace. 85 Series Model Identification MODEL DESCRIPTION Model 85 I6-II DC LP 6 SB w/o Therm BTU/Hr Rate (Input) 16-IV = 16,000 20-IV = 20,000 25-IV = 25,000 31-IV = 30,000 35-IV = 34,000 Voltage DC Type Gas LP = Propane Gas connection size 6 = 3/8” Flare Options SB = Side/Bottom discharge V = Ventilator SB FIP = SB w/field plug Thermostat with thermostat w/o thermostat NOTE: The new 85-IV series furnace, through some design changes is quieter than the previous 85 series. It incorporates some plastic components in the blower housing area to accomplish this. These components are not retro-fittable to other 85 series furnaces. Applications - This unit is typically installed in travel trailers, 5th wheels and motor homes. Installation - This series of furnace can be installed either vertically or horizontally. If installed vertically, the exhaust port must be located at the bottom. Extra care must also be given in sealing this type of installation. Consult the installation manual for details. Heat Outlets - This furnace can be bottom discharged to a hard duct system, soft ducted out the back to a discharge plate into a hard duct system or completely soft ducted from a combination of the seven outlets located on both sides and back of the furnace. Refer to the installation manual for the ducting requirements of the specific model of furnace. Serviceability - This entire furnace is serviceable without removing it from the RV. Therefore, there is no need to bench test it. All components are accessible by merely opening the access door. We strongly recommend trouble-shooting the furnace while it is installed in the RV. Power Consumption - This furnace is designed to draw between 4.6 and 9.8 amps depending on the model of the furnace. Refer to the furnace specification decal when trouble-shooting its electrical system. 6 89 Series Model Identification 89 35 DC LP 6 MODEL DESCRIPTION Model BTU/Hr Rate (Input) 35 = 35,000 40 - 40,000 Voltage DC = direct current 12 Volts AC = 120 Volts(120 VAC) Type Gas LP = Propane LC = set at factory for propane but field changeable to natural NC = set at factory for natural but field changeable to propane Gas connection size 6 = 3/8” Flare Applications - This unit is typically installed in large travel trailers, 5th wheels, motor homes and park model trailers. Installation - The 89 series furnace must only be installed horizontally. Options - As the chart above indicates, this furnace can be purchased to operate on 12VDC or 120VAC with LP gas or Natural gas. Natural gas option is only available on AC models. Heat Outlets - This furnace can be bottom discharged to a hard duct system, soft ducted out the back to a discharge plate into a hard duct system or completely soft ducted from a combination of the six outlets located on both sides and back of the furnace. Refer to the installation manual for the ducting requirements of the specific model of furnace. Serviceability - This entire furnace is serviceable without removing it from the RV. All components are accessible by merely opening the access door. We strongly recommend trouble-shooting the furnace while it is installed in the RV. Power Consumption - The DC version of this furnace is designed to draw approximately 11.0 amps. This is important when trouble-shooting the motor of this furnace. 2-stage Model Identification 23 34 DC MODEL DESCRIPTION Model BTU/Hr Rate (Input) Low 23 = 23,000 High 34 = 34,000 Voltage DC = direct current 12 Volts Type Gas LP = Propane Gas connection size 6 = 3/8” Flare 8 = 1/2” Flare Packing SP = Single Pack BP = Bulk Pack (layers of 4) 7 LP 6 BP Wiring Diagram for 7900-II / 8000-II IMPORTANT If any original wire has to be replaced, it must be replaced with type 105° C or its equivalent. REMOTE Sense Wiring With Blower Control Ignition Board GROUND GROUND Black Red Black ELECTRODE MOTOR White Red LIMIT Red White VALVE 5179 Yellow Red Black White SAIL SWITCH DSI CONTROL 5179 Yellow Red Red White SWITCH THERMOSTAT Black White Red Blue Black Black High Tension High Tension The ON/OFF switch, located in line with the gas valve, is not used when a combination circuit breaker and ON/OFF switch is used. LOCAL Sense Wiring GROUND Black ELECTRODES Black Red MOTOR White LIMIT VALVE Red SAIL SWITCH 5179 Yellow CIRCUIT BREAKER On/Off Switch Relay Black White NOTE: Red +12V DC Neg. White DSI CONTROL THERMOSTAT Red SWITCH White Red Black High Tension NOTE: The ON/OFF switch, located in line with the gas valve, is not used when a combination circuit breaker and ON/OFF switch is used. 8 CIRCUIT BREAKER On/Off Switch Relay VALVE NEG White PWR BLO DSI CONTROL Red LIMIT +12V DC White Black MOTOR White White SAIL SWITCH ELECTRODES CIRCUIT BREAKER On/Off Switch Black Red Black Red +12V DC Neg. THERMOSTAT BLACK / NOIR WHT / BLANC 115 VAC LINE / Câble 115 VCA 115 VAC NEUTRAL / 115 VCA NEUTRE GRN / VERT 115 VAC GROUND / 115 VCA TERRE GRY / GRIS BLACK / NOIR SENSORS / CAPTEURS BLK NOIR FREEZE / GEL BLK NOIR RED – 12VDC + + / ROUGE – 12VCD + COMPRESSOR COMPRESSEUR GRN VERT GRN VIOLET – AGS / VIOLET – AGS YELLOW – Loadshed / JAUNE – Délestage 2-STG or STD BLUE / BLEU HEAT STRIP BANDE CHAUFFANTE BROWN / MARRON BI-ÉTAGÉ ou STANDARD RJ45 COM VIO / VIO COMPRESSOR / COMPRESSEUR HIGH FAN / VENTILATEUR HAUT LOW FAN / VENTILATEUR BAS MED FAN*/ VENTILATEUR MOY* 115VAC NEUTRAL / 115 VCA NEUTRE GROUND / TERRE AMBIENT / AMBIANT BLACK – 12VDC Ground Terre / NOIR – 12VCD Terre GRY / GRIS CABLE/CÂBLE RJ45 COM CABLE/CÂBLE BLK / NOIR BLK / NOIR RED / ROUGE RED / ROUGE 1 2 3 4 5 6 DOMETIC BANDE CHAUFFANTE RVP DOMETIC ET CARRIER Rev. Valve on DOMETIC Dometic HP and Carrier HP HEAT STRIP 9 1 2 3 4 5 6 RVP DOMETIC AND CARRIER YEL / JAUNE WHT / BLANC 1 2 3 4 5 6 7 8 9 COMPRESSOR HIGH FAN LOW FAN MED FAN* 115VAC NEUTRAL GROUND Fan on * Med. Dometic A/C HEATSTRIP 115V NEUTRAL HEATSTRIP 115V LINE COMPRESSEUR VENTILATEUR HAUT VENTILATEUR BAS VENTILATEUR MOY* 115 VCA NEUTRE TERRE 115 VCA NEUTRE SOUPAPE D’INVERSION COMPRESSEUR BANDE CHAUFFANTE VENTILATEUR HAUT VENTILATEUR BAS TERRE VIDE 115 VCA NEUTRE Soupape d’inversion sur HP Dometic et Carrier BANDE CHAUFFANTE 115V NEUTRE moy sur * Ventilateur climatiseur Dometic CÂBLE DE BANDE CHAUFFANTE 115V 1 2 3 115VAC NEUTRAL REVERSING VALVE COMPRESSOR HEATSTRIP HIGH FAN LOW FAN GROUND BLANK 115 VAC NEUTRAL YEL / JAUNE BLK / NOIR RED / ROUGE WHT / BLANC GRN / VERT REMOTE / A DISTANCE 1 2 3 4 1 2 1 2 REV. VALVE / SOUPAPE D’INVERSIO 2 1 1 4 2 3 COMPRESSOR COMPRESSEUR MOTOR MOTEUR CONNECTS FOR CARRIER PRODUCT 85 Series Wiring Diagrams IMPORTANT: If any original wire has to be replaced, it must be replaced with type 105° C or its equivalent. Terminal Block on 85 Models only. LADDER DIAGRAM WITH DOOR and Blower Control Ignition Board ELECTRODE LS +12v GROUND SS MOTOR BLACK BLACK TH RED CIRCUIT BREAKER BLUE ON/OFF ON SWITCH OFF VALVE 1 4 BLUE 2 5 3 6 BLUE BLUE YELLOW PWR BLUE WHITE BLO 1 4 2 5 3 6 + 12V DC NEG +THERMO THERMO LIMIT SWITCH CB = Circuit Breaker GND = Ground GV = Gas Valve HV = High Voltage EL = Electrode MOT = Blower Motor THERMOSTAT WHITE RED BLACK LADDER DIAGRAM WITHOUT DOOR, but with Blower Control Ignition Board LS +12v GROUND SS ICB +12v GND FS TH Pwr HV Blw VC MOTOR BLACK BLACK SS = Sail Switch TH = Thermostat LS = Limit Switch TR = Thermo Relay VC = Valve Control PS = Power Switch NOTE: In some installations, the Power Switch (PS) may control the air conditioning system thermostat function. HIGH TENSION ELECTRODE VC MOT IGNITION CONTROL RED EL PS CB RED YELLOW SAIL SWITCH GND ICB +12v GND FS TH Pwr HV Blw VC TH CIRCUIT BREAKER/ ON/OFF SWITCH EL VC PS CB RED RED VALVE GND RED MOT + 12V DC NEG +THERMO THERMO YELLOW BLUE BLUE BLUE YELLOW PWR SAIL SWITCH WHITE BLO THERMOSTAT IGNITION CONTROL RED BLUE LIMIT SWITCH WHITE RED GND = Ground GV = Gas Valve HV = High Voltage EL = Electrode MOT = Blower Motor SS = Sail Switch TH = Thermostat LS = Limit Switch TR = Thermo Relay VC = Valve Control PSCB = Power Switch/ Circuit Breaker BLACK NOTE: In some installations, the Power Switch (PS) may control the air conditioning system thermostat function. HIGH TENSION 85-IV Local Sense 85-III Local Sense Ground GROUND ELECTRODE Single Sense Electrode MOTOR Red Yellow BLACK RED RED RELAY VALVE YELLOW ON/OFF ON SWITCH OFF YELLOW BLUE YELLOW IGNITION CONTROL SAIL SWITCH Motor CIRCUIT BREAKER Red Relay Red RED 1 4 BLUE 2 5 3 6 1 4 2 5 3 6 Yellow + 12V DC NEG +THERMO THERMO Yellow Valve Blue THERMOSTAT Ignition control BLUE White Switch Limit switch WHITE Red RED Yellow BLACK High Tension HIGH TENSION 10 1 2 3 4 5 6 1 2 3 4 5 6 +12V DC Neg. Thermostat Yellow Red LIMIT SWITCH Blue White Sail switch RED WHITE Circuit breaker ON/OFF switch White 85 Series Wiring Diagrams IMPORTANT If any original wire has to be replaced, it must be replaced with type 105° C or its equivalent. 85-III Remote Sense Electrode Red Motor Circuit breaker Relay Yellow Red Red Black Yellow Valve Blue Blue Sail switch Ignition control 1 2 3 4 5 6 +12V DC Neg. + Thermo Thermo 1 2 3 4 5 6 Yellow Red White Limit switch Red White Black Yellow NOTE: High Tension 85-I +12 VDC red 12 VDC yellow thermo blue thermo blue 1 2 3 4 5 6 1 2 3 4 5 6 The ON/OFF switch, located in line with the gas valve, is not used when a combination circuit breaker and ON/OFF switch is used. 85-II limit switch 1 2 3 4 5 6 +12 VDC red 12 VDC yellow thermo blue thermo blue sail switch valve 1 2 3 4 5 6 limit switch sail switch circuit breaker relay valve relay power valve sensor motor circuit breaker power valve sensor ground 11 motor Wiring Diagram for 8900-III DC Wiring Diagram WITHOUT DOOR GROUND ELECTRODE IMPORTANT: If any original wire has to be replaced, it must be replaced with type 105° C or its equivalent. MOTOR BLACK YELLOW RED RED CIRCUIT ON/OFF BREAKER SWITCH VALVE RED YELLOW BLUE BLUE SAIL SWITCH YELLOW 1 4 2 5 3 6 PWR BLO + 12V DC NEG +THERMO THERMO 1 4 2 5 3 6 THERMOSTAT IGNITION BOARD RED WHITE LIMIT SWITCH BLUE BLUE RED YELLOW HIGH TENSION DC Wiring Diagram AC Wiring Diagram WITH DOOR WITH DOOR GROUND ELECTRODE GROUND ELECTRODE MOTOR MOTOR BLACK YELLOW GREEN RED RED CIRCUIT BREAKER VALVE ON/OFF SWITCH ON BLUE YELLOW PWR BLO 1 4 2 5 3 6 1 4 2 5 3 6 + 12V DC NEG +THERMO THERMO WHITE YELLOW WHITE THERMOSTAT YELLOW SAIL SWITCH BLUE RED HIGH TENSION +12 VDC red motor Supply LeadsFurnace Wiring (+) 12 volt DCto(+) 12 volt DC (red wire) (-) 12 volt Dto(-) 12 volt DC (yellow wire) thermostattothermostat (blue wires) relay red power blue valve red limit switch sail switch blue red yellow gnd yellow high voltage 1 2 gas 3 4 valve 12 AC CAPACITOR MOTOR RUN BLUE GREEN DC Wiring Diagram +Thermo blue -12 VDC yellow Thermo blue WHITE BLUE LIMIT SWITCH BLUE red yellow blue -THERMO BLUE WHITE WHITE + THERMO BLUE YELLOW Circuit breaker 3 3 120 VAC WHITE IGNITION CONTROL RED HIGH TENSION ON/OFF Switch 1 1 2 2 TRANSFORMER BLUE RED BROWN BLACK OFF ON LIMIT SWITCH CIRCUIT BREAKER BLACK BLACK VALVE IGNITION BOARD RED 120 VAC BLACK GREEN RED BLUE 120 VAC GREEN RELAY OFF YELLOW SAIL SWITCH BLACK YELLOW THERMOSTAT WIRING DIAGRAM FOR 2-STAGE FURNACE DIAGNOSTIC CHART 2-Stage Furnace Diagnostics A diagnostic LED is located inside the exterior access cover on the outside edge of the horizontal (2) stage control board. The following graph defines the codes. NUMBER OF LED FLASHES DIAGNOSTIC INFORMATION 1 2 3 4 5 An Excalibur 2-Stage furnace must use an Atwood Digital Thermostat. Two Stage Furnace Models 1522 & 2334 NOTE: LOCKOUT Low Input voltage Ignition Failure Open High Limit Stuck Sail Switch Module Fault SOFT SOFT SOFT HARD HARD A SOFT lockout is a condition that is timed and will make additional attempts to correct the problem. A HARD lockout requires reset of the thermostat or turning the power switch off then back on. WITH DOOR AND WITHOUT DOOR MOT = Blower Motor SS = Sail Switch LS = Limit Switch PS/CB = Power Switch/ Circuit Breaker NOTE: The Power Switch (PS) does not control the air conditioning system thermostat function. GND = Ground GV = Gas Valve HV = High Voltage EL = Electrode CB = Circuit Breaker MOT = Blower Motor SS = Sail Switch GND = Ground LS = Limit Switch GV = Gas Valve PS = Power Switch HV = High Voltage EL = Electrode NOTE: The Power Switch (PS) does not control the air conditioning system thermostat function. Green Green Black Thermostat Red EL HV Dual Cont. MOT Geen Black Thermostat Red Ignition Control 5ON-12 Blue Blue HV Dual Cont. MOT Geen EL Ignition Control 5ON-12 PS/CB C.B. Red PS 6 54 3 21 Red 1 2 3 4 56 Red 6 54 3 21 Red 1 2 3 4 56 Orange White Orange White Blue Brown Brown Blue Green Green Yellow Yellow –12 VDC SS LS +12 VDC Blue Case Bulkhead Yellow Red White SS LS +12 VDC Blue Yellow Red White Low Valve GND Main Valve GV Redundant Valve Yellow Yellow –12 VDC Main Valve GV Low Valve GND Redundant Valve Two Stage Furnace Model 2540 WITH DOOR AND WITHOUT DOOR GND = Ground GV = Gas Valve HV = High Voltage EL = Electrode MOT = Blower Motor SS = Sail Switch LS = Limit Switch PS = Power Switch CB = Circuit Breaker GND = Ground GV = Gas Valve HV = High Voltage EL = Electrode NOTE: The Power Switch (PS) does not control the air conditioning system thermostat function. NOTE: The Power Switch (PS) does not control the air conditioning system thermostat function. Black Thermostat Black Thermostat Red HV Dual Cont. MOT Geen MOT = Blower Motor SS = Sail Switch LS = Limit Switch PS/CB = Power Switch/Circuit Breaker EL Red Ignition Control 5ON-12 Blue Blue Red 6 54 3 21 Red Red 1 2 3 4 56 6 54 3 21 Red White Blue Yellow Red White Brown LS +12 VDC –12 VDC Yellow Red Brown SS LS +12 VDC SS Blue Green Green Yellow Blue White Blue Case Bulkhead 1 2 3 4 56 Orange Orange White Ignition Control 5ON-12 PS/CB C.B. PS HV Dual Cont. MOT Geen Yellow GND Low Valve Main Valve GV –12 VDC Redundant Valve Yellow Yellow GND 13 Low Valve Main Valve GV Redundant Valve EL MPD 38285 hydro flame TM Model 1H2C Digital Thermostat FOR STANDARD FURNACES & A/C SYSTEMS ENGLISH, FRANCAIS •Installation •Operation (et Canada) Effective 6/19/02 THIS THERMOSTAT HAS BEEN DESIGNED TO OPERATE STANDARD AIR CONDITIONING UNITS IN CONJUNCTION WITH A RV FURNACE. SLIDE SWITCH Display Mode Set Temperature Set LEFT SCROLL ORDER OF DISPLAYED MODES RIGHT COOL OFF Furnace Operation HEAT FAN • COOL OFF M Furnace cycles to satisfy set point. Air Conditioner Operation HEAT FAN • Air conditioner automatically switches compressor and high and low speed fan when cycling to satisfy set point. AU • System Switch SPECIFICATIONS HI • Operating Voltage .............. 9VDC to 18VDC Current Consumption at 12VDC ...... 100mA Operating Temp. .................... -40F to +185F Room Temp. Range ................ +55F to +90F Room Temp. Display Range .... +35F to +99F Thermostat Accuracy ........................ +/- 1F Switching Capability A/C............up to 24 VAC (max. 2 AMPs) LO COOL OFF Air conditioner compressor and low speed fan cycle to satisfy set point. Fan Operation HEAT FAN • • COOL OFF HI Air conditioner fan runs at high speed to circulate air. LO Air conditioner fan runs at low speed to circulate air. Off HEAT FAN • OF No operation occurs. WIRING REQUIREMENTS FOR ATWOOD THERMOSTAT THERMOSTAT INSTALLATION 7.5 VDC ANALOG A/C SYSTEMS (DOMETIC®) 12 VDC ANALOG A/C SYSTEMS (RVP®) 1 2 3&4 5 6 7 8 WIRE FROM FURNACE FUNCTION WIRE FROM A/C FUNCTION -12vdc ground not used +12vdc not used TERMINAL # (L-R) 1 2&4 3 5 6 7 8 Compressor High Fan Low Fan Furnace Control FURNACE WIRE FROM A/C FUNCTION WIRE FROM FURNACE FUNCTION -12vdc ground 7.5 vdc +12vdc Compressor High Fan Low Fan Furnace Control FURNACE 8 8 3 + 5 6 + THERMOSTAT 1 3 1 7 # (L-R) 5 TERMINAL 6 THERMOSTAT Y 14 12 VDC SOURCE LOW FAN GL B 4 TO 3 WITH JUMPER HI FAN GH CONNECT COMPRESSOR LOW FAN 12 VDC SOURCE HI FAN 2 COMPRESSOR Thermostat is very sensitive. HANDLE WITH CARE AT ALL TIMES. Locate thermostat 48˝ to 54˝ above floor on an INTERIOR wall. Pick a dry area where air circulation is good. EXTERIOR wall location must have a 3/4˝ spacer between thermostat and exterior wall. 1. Be sure all electrical power has been disconnected from the air conditioner, furnace and the power supply. 2. Do not install the thermostat where there are unusual heating conditions: such as direct sunlight, heat producing appliances (television, radio, wall lamp, etc.) or a furnace or air conditioner supply register. 3. ATTACHING THE WALL THERMOSTAT. Separate the thermostat body from the sub-base by gently squeezing the top and bottom, connecting wiring per requirements. Attach thermostat sub-base to the wall at desired mounting location. Air conditioner compressor and high speed fan cycle to satisfy set point. 7.5V HEAT FAN HI 7 OFF COOL OPERATION CONNECT 4 TO 2 WITH JUMPER LITERATURE NUMBER MPD 38914 hydro flame TM Model 2H2C Two Stage Furnace Digital Thermostat FOR TWO STAGE FURNACE ENGLISH, FRANCAIS •Installation •Operation (et Canada) Effective 2/4/02 THIS THERMOSTAT HAS BEEN DESIGNED TO OPERATE STANDARD AIR CONDITIONING UNITS IN CONJUNCTION WITH AN EXCALIBUR 2-STAGE FURNACE. Screw Mounting Holes THERMOSTAT INSTALLATION Mode Temperature Display Set Set (OFF) OFF (CLIM) COOL HEAT (CHAUFFAGE) FAN (VENTIL.) M System Switch 1 2 3 4 5 6 7 8 12VDC Ground 7.5V +12VDC RELAY COM * A/C COMPRESSOR A/C HI FAN A/C LOW FAN TH FROM FURNACE System Slide Switch LEFT COOL OFF HEAT FAN • • • • • COOL OFF HEAT Scroll Order of Displayed Modes Furnace Operation AU Furnace automatically switches between high and low BTU valve and high and low speed fan when cycling to satisfy set point. Furnace high BTU valve and high speed furnace fan cycle to satisfy set point. LO Furnace low BTU valve and low speed furnace fan cycle to satisfy set point. HF Furnace fan runs at high speed to circulate air. Air conditioner fan does not run. LF FAN Air Conditioner Operation AU Air conditioner automatically switches compressor and high and low speed fan when cycling to satisfy set point. HI Air conditioner compressor and high speed fan operate to satisfy set point. LO Air conditioner compressor and low speed fan operate to satisfy set point. HF Air conditioner fan runs at high speed to circulate air. Furnace fan does not run. LF OFF HEAT FAN OFF HEAT • Specifications FAN Furnace fan runs at low speed to circulate air. Air conditioner fan does not run. Scroll Order of Displayed Modes Scroll Order of Displayed Modes • • COOL OPERATION HI • • • • • COOL SCROLL ORDER OF DISPLAYED MODES RIGHT *Note: Move jumper from positions 3 and 4 to positions 2 and 4 for use with some 7.5V switching analog relay kits. Thermostat is very sensitive. HANDLE WITH CARE AT ALL TIMES. Locate thermostat 48˝ to 54˝ above floor on an INTERIOR wall. Pick a dry area where air circulation is good. EXTERIOR wall location must have a 3/4˝ spacer between thermostat and exterior wall. 1. Be sure all electrical power has been disconnected from the air conditioner, furnace and the power supply. 2. Do not install the thermostat where there are unusual heating conditions: such as direct sunlight, heat producing appliances (television, radio, wall lamp, etc.) or a furnace or air conditioner supply register. 3. ATTACHING THE WALL THERMOSTAT. Separate the thermostat body from the sub-base by gently squeezing the top and bottom. Pull wires through access hole in base plate. Attach thermostat sub-base to the wall at the desired mounting location. Mount the sub-base to the wall before connecting the wires. HI Air conditioner fan runs at low speed to circulate air. Furnace fan does not run. Fan Operation Air conditioner fan and furnace fan run at high speed to circulate air. LO Air conditioner fan and furnace fan run at low speed to circulate air. Scroll Order of Displayed Modes Off OF No operation occurs. Operating Voltage ...................... 9VDC to 18VDC Power Consumption ................................ 100mA Operating Temperature .................. -40F to +185F 15 Room Temperature Range .............. +55F to +90F Room Temperature Display Range .. +35F to +99F Thermostat Accuracy ................................ +/- 1F Sequence of Operation - DC Models (STANDARD ONE-STAGE) The ON/OFF switch allows power to pass to the circuit breaker and the thermostat. FURNACE PRODUCES HIGH TEMPERATURE The thermostat controls the operating circuit to the furnace by reacting to room temperature. When room temperature is below the thermostat set point, the contact closes to allow current to flow to the relay. • Locate furnace out of traffic and away from furniture and draperies. • Do not touch or put combustibles near appliance. Hot surface temperature may occur. • Supervise young children in the same room as the furnace. • Do not place clothing or flammable materials on or near the furnace. WARNING The circuit breaker limits amperage draw of motor. The relay allows current to pass to the motor by closing a switch within the relay. Voltage from the thermostat activates the relay to turn the fan on. This takes 1-25 seconds. +12VDC Current flows to the motor to operate the blower. One end of the motor shaft is for the circulating air wheel and the other side is for the combustion air wheel. Thermostat Circuit Breaker ON/OFF Switch (some furnaces have combination ON/OFF Switch Circuit Breakers) Circulating air blows against the sail switch and closes the contacts, completing the circuit. The sail switch is a safety device that insures air flow before ignition. The limit switch is a safety device that protects the furnace from over heating. The contacts in the limit switch open at a given temperature setting, shutting off power to the electronic ignition system that controls the gas valve. Motor Sail Switch As power is applied to the circuit board, the system does the following: 1. A timing circuit allows the blower to purge the chamber (15-17 seconds) 2. The board supplies current to the gas valve and causes it to open. 3. As the valve opens, the board sends a high voltage spark to the electrode at the burner. The board detects the presence of a flame. If the flame is not sensed after approximately six seconds, the board will lock out (three try for ignition, one hour lockout and then three retry), shutting off power to the valve. 4. If the system does not ignite and the thermostat remains closed, the blower will remain on until the thermostat is reset manually. (Limit and Sail Switch are reversed in 79/80 Series.) Limit Relay Circuit Board (Starting 7/2001 Relay and Circuit Board combined.) Valve When the thermostat senses the desired room air temperature, the contacts open, removing power from the ignition system and shutting off the gas valve. The blower runs until the relay opens the circuit, shutting off current to the motor. Electrode 16 Sequence of Operation - DC Models 2-Stage Excalibur™ Furnace ONLY The digital thermostat controls the operating circuit to the furnace by reacting to room temperature. When the room temperature is below the thermostat set point by 2°F a heat demand signal will be sent to the controller module (see MPD 38463). The ON/OFF switch is an agency safety power shut off to the furnace ignition and gas valve systems. OFF COOL The circuit breaker limits amperage draw of the motor. HEAT FAN M Thermostat Current flows to the controller module and during the first seconds the micro-processor confirms inputs and verifies correct operation of safety redundancies. This module will perform the following diagnostic checks of the system. a. Sail Switch is open b. Internal Microprocessor faults c. Voltage inputs d. Ignition e. Open Limit Switch In the event of a failure an LED on the controller module will flash a code. See chart. The limit switch is a safety device that protects the furnace from over heating. the contacts in the limit switch open at a given temperature setting, shutting off power. This activates the open limit switch diagnostics and makes the LED on the controller module to flash and shuts down the gas valve. See chart. As power is applied to the circuit board, the system does the following: a. timing circuits allows the blower to purge the heat chamber for 15 seconds. b. current is supplied to the gas valve and causes it to open to high burn. (The controller module activates the low burn operation on the valve.) c. as the valve opens, the ignition module sends a high voltage spark to the electrode at the burner. The ignition module detects the presence of a flame. If the flame is not sensed after 7 seconds of sparking a signal is sent to the controller module that there is no ignition and shuts off the valve. After another 25 second purge, it will try again. After a third try, the controller will go into “soft” lockout, timing for one hour and the diagnostic LED will flash a code, see chart. After the timed hour, the controller will initiate (3) more tries for ignition. If there is no ignition, the timing sequence begins again. d. If the system does not ignite and the thermostat is still calling for a heat demand, the blower will run for 90 seconds as a post purge then shut off. 17 Electrical Switch Breaker Controller Module The motor receives current from the controller module and will run at high speed or low speed depending on the demand signal the digital thermostat sends to the controller module. One end of the motor shaft is for the circulating air wheel and the other end is for the combustion air wheel. Circulating air blows against the sail switch and closes the contacts, completing the circuit. The sail switch is a safety device that insures air flow before ignition. - 12VDC +12VDC 10 VDC Motor Sail Switch Limit Switch Circuit Board 2-Stage Valve Electrode When the thermostat senses the desired room air temperature, a signal is sent to the controller module to shut down operation of the gas valve and run the blower for 90 seconds as a post purge of heat from the furnace heat chamber. Sequence of Operation Pilot Models The thermostat controls the operating circuit to the furnace by reacting to room temperature to open and close a set of contact points which allows current to flow to the relay. The relay receives the current and allows current to pass through to the circuit breaker by closing a switch within the relay. This is done by a heater coil within the relay which actuates a bi-metal disc closing the relay circuit. The circuit breaker is placed in line to monitor the Amp draw of the motor. It is an overload and safety protector for the motor. The current then flows to the motor and allows the blower to operate. One end of the motor shaft drives the circulating air wheel and the other end of the motor shaft drives the combustion air wheel that delivers the required air to the burner for combustion. ABCDEFGH- Thermostat Relay Breaker Motor Sail Switch Limit Gas Valve Pilot Assembly A B C As the circulating air wheel comes up to speed, it blows against the sail switch completing the circuit. The sail switch is placed into the system as a safety to prove there is adequate air for combustion. D The limit switch is an in line safety device which protects the furnace from any over heating conditions. The contacts in the limit switch open at a given temperature setting, shutting off power to the valve. F E The next section of operation is controlled by the valve and pilot. Once the power is applied to the valve, the following steps are: 1. Set gas valve knob to the pilot setting to light the pilot. a. light pilot. 2. Set gas valve knob to the ON position for burner operation. 3. While ON stand by, if the pilot goes out and the thermostat closes, the blower will come on, but the valve will remain closed. At this time, the pilot must be relit for burner operation. Note: The blower will remain running until the thermostat contact opens. G H As the thermostat senses the room air temperature, the contacts will open removing power from the valve which will shut off the gas. The blower will remain on until the heater coil within the relay cools and the relay opens and stops the current flow to the motor. 18 Sequence of Operation - AC Models Operating Circuitry 24 VAC The transformer receives 120 VAC which it converts to 24 VAC for the operating circuitry. As power is applied to the electronic ignition circuit board, the system does the following: 1. A timing circuit allows the blower to purge the chamber (15-17 seconds. 2. The board supplies current to the gas valve and causes it to open. There is an electrical switch in line to the valve to allow power to be manually shut off to the valve. This switch must be on for the furnace to operate. (Switch may be separate or combined with circuit breaker). 3. As the valve opens, the board sends a high voltage spark to the electrode at the burner. The board detects the presence of a flame, if the flame is not sensed after seven seconds, the board will lock out, shutting off power to the valve. 4. If the system does not ignite and the thermostat remains closed, the blower will remain on until the thermostat is reset manually. The thermostat controls the operating circuit to the furnace by reacting to room temperature. When room temperature is below the thermostat set point, the contacts close to allow current to flow to the relay. The relay receives 24 VAC and energizes a heater coil within the relay. This activates a bimetal disc which closes the relay circuit. This takes 17-20 seconds. Once the relay circuit is closed, 120 VAC flows to the motor and allows the blower to run. One end of the motor is for the circulating air wheel and the other end is for the combustion air wheel. Circulating air blows against the sail switch and closes the contacts, completing the circuit. The sail switch is a safety device that insures air flow before ignition. When the thermostat senses the desired room air temperature, the contacts open removing power from the ignition system and shutting off the gas valve. The blower runs until the heater in the relay cools and opens the circuit, shutting off current to the motor. The limit switch is a safety device that protects the furnace from overheating. The contacts in the limit switch open at a given temperature setting, shutting off power to the electronic ignition system that controls the gas valve. Operating Circuitry 24 VAC Motor Circuitry 120 VAC 120 volts AC input power Circuit Breaker or Breaker/ Switch Combination Transformer Capacitor Thermostat Black wire 120 VAC Relay Motor Sail Switch Limit Circuit Board WARNING Electrical Switch FURNACE PRODUCES HIGH TEMPERATURE (if applicable) Electrode • Locate furnace out of traffic and away from furniture and draperies. • Do not touch or put combustibles near appliance. Hot surface temperature may occur. • Supervise young children in the same room as the furnace. • Do not place clothing or flammable materials on or near the furnace. 19 WARNING CRITICAL INSTALLATION CRITERIA • Do not install the furnace on material that restricts return air, such as carpet, or any soft material, such as vinyl. • Do not install furnace where clearance to combustibles cannot be maintained. • Do not modify the furnace in any way. • Do not alter the furnace for a positive grounding system. • Do not HI-POT this furnace unless the electronic ignition system (circuit board) has been disconnected. • Do not use a battery charger to supply power to DC model furnace even when testing. • Do not use 120 volt AC current with DC models. • Do not use the furnace cabinet area as a storage compartment. • Do not vent this furnace with a venting system serving any other appliance. • Do not vent this furnace to an outside enclosed porch area. • This furnace is not to be used for temporary heating of buildings or structures under construction. • Locate the furnace in an area that will not be blocked by snow. • Locate the furnace in an area where the flue gases will not cause building materials to degrade over time. • Install furnace so electrical components are protected from water. • Do not use closeable registers when minimum ducting cannot be maintained. • Wire furnace direct to battery when possible. • Use a minimum of 22 gauge wire for the thermostat. • Use a minimum of 18 gauge wire to the furnace from power supply. • Follow wiring color code exactly. • Hold both fittings with a wrench when tightening gas connection. • Always meet or exceed minimum duct requirements. • Always meet minimum return air requirements. • Isolate return air passage from range compartment. WARNING CARBON MONOXIDE POISONING • Furnace must be installed and vented to these instructions. • Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. • Negative pressure produced by the furnace can affect the combustion air or venting of other appliances if installed in an improper location. For assistance or additional information, consult a qualified installer, service agency or gas supplier. 20 ANNUAL PREVENTATIVE MAINTENANCE INSPECTION The following preventive maintenance and safety checks should be performed by a qualified RV technician once a year, or more, depending on the use of the furnace. Failure to properly maintain the furnace may void the furnace warranty and can result in unsafe furnace operation. Preventive maintenance is not covered under warranty. WARNING • Installation, repairs and preventative maintenance should be done by a qualified service person only. • The furnace should be inspected before use and at least annually by a qualified service person. • Frequent cleaning may be required due to excessive lint from carpeting, bedding material, pet hair, etc. It is imperative that control compartments, burners and circulating air passageways of the furnace be kept clean. WARNING • Label all wires prior to disconnection when servicing. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. AIR WHEEL The air wheel should be clean and clear of obstructions. Starting the furnace with something in the blower will damage the wheel, making replacement necessary. GASKETS Inspect all gaskets for tight seals. Do not reuse gaskets - always replace with new. GENERAL Check that the physical support of the furnace is sound and without sagging, cracks, gaps, etc. BURNER The Burner requires no adjustments, but should be inspected annually. Burners should be cleaned with a wire brush to remove debris and corrosion build up. MOTOR The motor is lubricated and permanently sealed. It requires no oiling. Brushes and armatures are not replaceable. COMBUSTION CHAMBER Check the air intake and flue areas of the furnace for internal obstructions, such as wasp or bird nests. The life of the combustion chamber is a function of the amount of time that the furnace has operated. Therefore, it is essential to inspect the chamber for cracks and holes. Have the chamber replaced if it has any cracks or holes - this condition is not field repairable. Chamber should be cleaned if obstructions are present, by removing the chamber and flushing the unit out with water. RETURN AIR The return air passage should be clean and clear of obstructions and meet the minimum square inches as specified in the installation instructions. Make sure combustibles are not stored in the furnace compartment. Filters are not recommended at these air passages. VENTING After checking and clearing, if necessary, the draft cap assembly must have the proper overlap between the exhaust tube and the furnace chamber tube. Any air leakage at these joints may cause improper combustion. Draft cap assembly must overlap no less than 1-1/4˝ (32mm), and be positioned against the door screen for proper function. CONTROL COMPARTMENT Clean the control compartment to remove dirt and lint. DUCTING The heat ducts should be clean and clear of obstructions. Check for proper duct connection. Any ducts disconnected from the furnace or outlets must be reattached. VOLTAGE Voltage should be between 10.5 and 13.5 VDC at the furnace during operation. The power at the furnace needs to be checked with each of the following power sources when applicable: generator, battery, and converter. Low voltage can cause the furnace to overheat and cycle. High voltage can cause unbalanced combustion, and excessive motor wear. Note: To increase motor life the furnace should be wired directly to the battery. GAS PRESSURE Using a U-tube water manometer, with the furnace and all of the gas appliances operating, the pressure should be 11˝ W.C. (27mbar). Improper gas pressure can cause the furnace to work inconsistently and create unbalanced combustion. GAS SUPPLY SYSTEM Perform a pressure-drop test according to current ANSI standards, to insure that there are no gas leaks. WIRE CONNECTIONS Check the furnace for loose or disconnected wires. 21 Mechanical Thermostat WHAT IS A THERMOSTAT? • It is an ON/OFF switch controlled by a bi-metal coil which opens and closes an electrical contact by sensing changes in the ambient temperature. • With its contacts close, it supplies power to the time delay relay which in turn closes a contact that sends power to the blower motor. • Normally, the thermostat contacts are closed if the blower is running. • The hydro flame thermostat is equipped with a heat anticipator which allows one to adjust the length of the heating cycles. A furnace should cycle 5-6 times an hour. a. The anticipator is set at 1.0 on all hydro flame thermostats. If you want to shorten the heating cycle, move anticipator to a lower amp setting. You should not set lower than .48 which is the amperage rating of the gas valve. Setting any lower could burn out the anticipator wire. Note: Heat anticipator adjustments are not covered under warranty. .20 Temperature Setting Level .48 (valve amperage) Mounting Hole Contacts Adjustable Heat Anticipator Off Switch (Optional) 1.0 Anticipator setting Heat/cool thermostats are being used in conjunction with air conditioners and our furnace. The warranty, installation instructions and diagnostic information is provided by the manufacturer of the thermostat. However, if you need to isolate a furnace problem or a dual thermostat problem, by-pass the furnace wires at the thermostat. If the furnace ignites and heats, you have a thermostat problem. If the furnace does not run, the problem is in the furnace, and you should consult the trouble shooting guides in the back of this manual. THERMOSTAT LOCATION • It should be on an inside wall 48˝-54˝ above the floor on an inside wall. • It should not be near areas of extreme heat or cold. • It should not be located directly across from a heat duct. • If installed on an outside wall, a 3/4˝ spacer must be used behind legs of thermostat. This will allow the thermostat to sense the air temperature and not the temperature of the wall. • A minimum of 22 gauge wire should be used to connect the thermostat to the furnace. We recommend 18 gauge stranded wire. 22 Circuit Breaker & Motor The circuit breaker is actually a re-settable heat sensitive device designed to protect the blower motor. In a furnace, this heat evidences itself in the form of an amp draw. Therefore, since there are different size motors, there are different amperage ratings on circuit breakers. When replacing a breaker, do so with similar amperage rated breaker. Thermostat Breaker Relay Motor Sail Switch The breakers used on our furnaces are externally mounted and are of a slow blow style. This means that due to their location on our furnaces, the heat of the furnace cannot affect their operation. Likewise, short amperage spikes will not cause them to trip either. The motor will have to produce an excessive and prolonged amperage draw to trip it. When a circuit breaker trips, it does so because a problem exists. After resetting it, voltage and amperage draws should be taken to determine where the problem is. These readings will determine if you have a power source, breaker or motor problem. On our 79 and 85 series furnaces we have two different types of breakers. The earlier 79 and 85 models and all 89 models used a rectangular slow blow breaker as pictured. Its sole purpose was to protect the motor. On late model 79 and 85 models we started using a finger-size combination breaker and on/off switch. Code required us to be able to shut the gas off at the appliance when servicing it. This switch accomplishes this by shutting off power to the blower motor, which in turn prevents the gas ignition system from coming on. Therefore, it is not only important to use the same amperage rated breaker, but also the same style of breaker. As stated earlier, there are different size motors as well. They are different because they must be compatible with the various BTU capacities. Each BTU of furnace requires a specific motor RPM in order for proper ignition and combustion to take place. Circuit Boards Since it is very important that the proper motor be used for a specific model of furnace, you must identify if you have the correct motor. To help identify a motor, a ‘PF’ number is embossed in the metal housing of the motor. If you look at the parts reference in the back of this manual, not only are the proper hydro flame part numbers for the motor needed on a specific furnace noted, but the corresponding ‘PF’ number is also shown. A new motor has been introduced into all of the 85 and 89 series DC furnaces. This new motor design is hard-wired. As a result the brushes are longer and should increase motor life considerably. As a result, the motor kit will now contain a motor mount bracket, the motor and installation instructions and will add a little more time to the installation process. However, these are the only motors that will be available as replacements in the field. The circuit board has three functions: create a spark, open the gas valve and lock-out when one of the prior two functions do not occur during the ignition cycle. As long as the circuit board is receiving the minimum micro-amps from the electrode assembly, it will not lock out. It has a 15 second ignition delay as well. This delay allows the furnace to purge any unburnt gas in the combustion chamber before ignition occurs. We have used two basic types of circuit boards. The first is the remote sense analog circuit board that we have used for a number of years. It is a single trial ignition board that works in conjunction with a dual or remote sense electrode (an electrode that has a separate porcelain/sensing probe and a separate porcelain/sparking probe). The other board, which we have only used for the past year or so is a micro-processor board. It is a three trial ignition board and operates in conjunction with a single or local sense electrode (an electrode that has only one probe that both sparks and senses). Various versions of the 12VDC analog board have been used. The catalog numbers of those boards are noted below. Fortunately, the local sense micro-processor board is the only one you will have to stock for replacement on a 12VDC furnace. Plastic spacers will be provided CATALOG # ON BOARD ORDER-SERVICE PART NUMBER with the board so that it can be 05-159007-103........FENWAL, old style, uncovered, 12VDC36716 mounted on metal surfaces that 05-309017-153........FENWAL, uncovered, no legs, single try, 12VDC ........................................36716 you may encounter some-times 06-235132-001........FENWAL, single try, uncovered with legs, 12VDC ....................................36716 on various models of our furnace. 05-505650-153........FENWAL, three trial, uncovered, micro-processor, 12VDC ..........36716 The only other circuit board that 05-299004-153........FENWAL, three trial, AC ....................................................................................................................37515 you will have to stock is the AC ............................CHANNEL, 2-Stage ignition board .................................................................................. 37965 version. ............................CHANNEL, 2-Stage motor control board ................................................................ 37966 ............................FENWAL, Relay on board .............................................................................................................. 36716 ............................FENWAL, Relay on board with blower control retrofit kit .............. 38676 23 Relay This component is commonly referred to as a time delay relay. The same relay is used on the 7900, 8500 and 8900 series furnaces. - The relay has one primary function. • to purge the plenum of heat and the chamber of any unburnt gases after each heating cycle. FUNCTION - The motor voltage path of relay is normally open. There should always be voltage from the circuit breaker to the relay terminal of the circuit breaker. There should always be continuity between the thermostat terminal connection and ground terminal connection or the relay. OPERATION Only when the thermostat contacts are closed is voltage supplied to the The sail switch is an air proving device. It is a safety component that will not let ignition occur until it sees 75% of the motor’s rpm’s. It insures that the combustion wheel is rotating fast enough so that there is a proper air and gas mixture for smooth ignition. There are different size sail switches. The noticeable difference is the size of the paddle on the switch. Each switch is matched to the size of motor it must respond to. NOTE: All 85-IV use the same sail switch. thermostat terminal of the relay. This voltage heats a coil in the relay body. In approximately 20 seconds this heated coil causes a bimetal disc to close. Voltage now passes through the relay and on to the motor, which in turn should allow the furnace to ignite and start a heating cycle. When a heating cycle is complete, the contacts of the thermostat open and voltage ceases to the heater coil of the relay. In approximately 45 - 90 seconds, the heater coil cools down, the bi-metal disc opens and voltage ceases to the motor as well. Thermostat Ground (-) Circuit breaker (+) Motor Bimetal Disc Coil AMP Draw - The relay should draw no more than 1 amp. If the relay should draw more than 1 amp, it will burn out the anticipator. Sail Switch When the paddle of the switch is depressed, there should be continuity through the switch. If a sail switch needs to be replaced, it should be replaced with the exact same size. If a larger switch than the original is used, it will probably not close when the motor reaches 75% of its rpm’s and therefore keep ignition from occurring. The most common problems with these switches are bent paddles, loose wire connections or an obstruction between the paddle and switch contact. Limit Switch The limit switch is a very important safety device on a furnace. The function of a limit switch is to protect the furnace from overheating. These switches come in a variety of temperature ratings and are located at critical locations above the heat chamber on the various models of furnaces. Therefore, it is very important that when one of these switches is replaced, you do so with the properly rated switch. 79-II, 89-II, 89-III, 2540 Part # 37021 (was 34781) 3/16˝ / 3/16˝ terminals Markings on Switch L77 or L170 (170°F) Failure to do so could cause an unsafe condition with the heating system. When in doubt as to whether you are using the proper limit switch for a furnace, look at the temperature at the base of the switch and match it to the temperature and related switch noted below. Part Number 36205 is a thermal cut-off and was a specific safety component used on some 89-II furnaces. It was located above the chamber and tripped in the event of a burn through chamber. 85-II, 89-I Part # 35132 1/4˝ terminals 85-III, 85-IV, 1522, 2334 Part # 37022 (was 36176) 1/4˝ terminals L54 (130°F) L190 (190°F) 24 Dual Solenoid Gas Valve We use a White Rodgers dual solenoid gas valve on all of our furnaces. The valve requires a minimum of 10.5VDC in order to open and when open, should draw no more than .48 amps. -12VDC Power from Ignition Control Volt-ohm meter Shut off power before servicing (red wire) +12VDC Valve coil Later model furnaces have an ON/OFF switch on the wire to the gas valve. This replaces the manual shut-off that was used on earlier model furnaces. You can now electrically shut off the gas to the valve with this switch before servicing the furnace. When these valves become inoperative, it is typically one or both of the coils that fail. In order to determine which coil is at fault, you need to conduct a continuity test on both leads of each coil. The resistance on a good coil will be 30-50 ohms. If the resistance is not in this range the coil is defective and must be replaced. The coils on this valve are wired in parallel. Therefore, when replacing the wires on these coils, it is important that they be attached per the diagram. The red 12VDC supply wires must be attached to terminals 1 and 4 and the ground wires must be attached to terminal 2 and 3. If the coils are mistakenly wired in series and there is a marginal supply voltage, there will be a voltage drop from coil to coil and the valve will not open. 30 to 50 OHMS Burner Head, Electrode and Valve Assembly The burner head, electrode and gas valve on the late model 79 series furnace are individually accessible. However, to service these same components on the late model 85 and 89 series, remove the complete assembly. The different models and/or BTU ranges of furnaces use different burner heads. These burners differ by the size of the top gas port holes or the deflector that runs through the throat of the burner. If the wrong one is used, it may cause an ignition, sooting or flame sense problem. 79-II, 85-IV 1522, 2334 When an electrode assembly is installed on a furnace, they will already be in a fixed and predetermined position above the burner. The only adjustment that you may need to do is on the sparking and ground electrode points. This gap should be 1/8˝. However, when the porcelain on an electrode assembly becomes cracked, it will not function properly and will have to be replaced. When doing so, use the proper electrode assembly for the model of furnace being serviced. 89-III 2540 OPEN enclosed DOUBLE MESH, NO DEFLECTOR LARGER PORT HOLES NO DEFLECTOR 8531 & 35-III OPEN There are only two versions of the solenoid valve available for the models of furnaces noted above. These two valves are identical except for the gas inlet porting on them (side or front). As stated earlier in this manual though, the coils are what usually breakdown but they are easily replaceable. The different models and/or BTU ranges of furnaces use different burner heads. These burners differ by the size of the top gas port holes or the deflector that runs through the throat of the burner. If the wrong one is used, it may cause an ignition, sooting or flame sense problem. 85-III -16, 20, 25 OPEN 1/4" Local Sense Electrode 25 1/8" Remote Sense Electrode The 4 Always Remember that you are working on a heating system and not just a furnace. A majority of furnace problems lie outside of the product itself. Therefore, when trouble-shooting a furnace problem, always check the following items before testing or replacing components. #1 - GAS PRESSURE The gas pressure should be set at a minimum of 11˝ W.C. with a minimum of 50% and ideally 100% of the gas fired appliances operating. You should test this pressure with a Utube Manometer only. If you choose to use a dial-type manometer, calibrate it often with a U-tube manometer. #3 - DUCTING Always make sure that the furnace has at least the minimum number of ducts (not including closeable outlets) called out in the installation instructions. Check for proper duct connections at the furnace and heat registers, collapsed ducts and holes in the ducting. The duct runs must be as straight and tight as possible. The heat ducts must also be clean and clear of obstructions. #2 - VOLTAGE Voltage to the furnace should be between 10.5 and 13.5 VDC during operation with the interior lights ON and OFF. This check should be made with the battery, converter or generator when applicable. Use a digital or analog multimeter when taking voltage readings. Do not use a test light. It does not provide enough useful information for proper diagnosis. #4 - RETURN AIR The return air passage should meet the minimum square inches as specified for the particular model of furnace in the installation instructions. This air passage should also be clean and clear of obstructions. Do not put air filters in this passage way. Also make sure that combustibles are not stored in the furnace compartment. #1 - Gas Pressure A furnace is a consumer’s friend when the outside temperature gets colder. Unfortunately though, cold is an enemy of LP gas. The BTU capacity of LP per volume decreases as the outside temperature gets colder. Therefore, based on how full the LP tanks are, the ambient temperature outside and how many BTU’s the furnace is, there may not be enough gas to sustain ignition on the furnace. we use the chart, the vaporization capacity of the tank in these conditions is only 38,500 BTU’s. The furnace is not going to perform very well because there is insufficient BTU capacity in the tank. If you were to put an insulated fire resistant blanket over the tanks and a 75 watt light bulb under that, you would probably raise the temperature of the bottles 10-20 degrees and almost double the BTU capacity of the tank. This in turn would allow the furnace to operate properly. So keep in mind that a furnace problem is not always a component problem. Using the charts below, let’s say that a 40,000 BTU furnace won’t fire up, and we also know that the 65 lb. LP bottle on the RV is 40% full and it is 0 degrees F. outside. One’s first thought might be that the burner or valve is bad. However, if 20 lb. Bottle (*30 lb. bottle multiply X 1.40) % Full 60% 50% 40% 30% 20% 10% +20° 36,000 32,400 28,800 25,200 21,600 16,200 0° 18,000 16,200 14,400 12,600 10,800 8,100 -5° 12,750 12,150 11,400 10,450 8,100 6,075 -10° 8,500 8,100 7,600 7,300 5,400 4,050 -15° 4,250 4,050 3,800 3,150 2,700 2,025 -5° 36,000 32,250 29,250 25,500 21,750 16,200 -10° 23,900 21,500 19,250 17,000 14,500 10,800 -15° 12,100 11,750 9,625 8,500 7,250 5,400 65 lb. Under Mtd. LP Gas Tank BTU available at % Full 60% 50% 40% 30% 20% 10% +20° 95,600 86,000 77,000 68,000 58,000 43,200 0° 47,800 43,000 38,500 34,000 29,000 21,600 26 #2 - Voltage See 4 Always previous page. #3 - Minimum Ducting Requirements The various BTU sizes of 85, 89 and 2-stage series furnaces require a minimum number of square inches of heat ducting. The most common size of soft ducting is 4˝ diameter. Therefore, since a 4˝ duct is equal to 12 square inches, we can call out the minimum number of ducts needed for the models of furnaces noted below. Furnace Model Minimum Ducting Minimum Ducts 8516, 8520 8525. 8531 8535, 8935, 8940, 1522, 2334, 2540 24 sq. in. 36 sq. in. 48 sq. in. 2 3 4 Ou tsi Du Ducting Locations 85, 89 and 2-Stage Series Furnaces ct de #7 Du ct Du ct of RV Bo op ttom (12enin dis 7m g ch m 5" arg Du x2 x1 e ct 54 0" #1 m m #6 #5 Du ) ct CAUTION - Ducting Installation Du #4 ct 4˝ Flexible Hose #3 • each 90° bend adds the equivalent of 10 feet of ducting • ducting should be securely attached to furnace • each run should be as straight and short as possible Du ct #2 2˝ Flexible Hose • 2 - 2˝ duct runs do not equal one 4˝ duct. A 2˝ duct is only 3 sq/inches • 2˝ duct adapters are available • 2˝ ducts are ideally suited for bathroom and holding tank compartments Closeable Outlets • a closeable outlet does not contribute to the minimum of total outlets recommended for a furnace. Bottom Discharge • furnace must be completely sealed to floor and plenum with a bottom discharge gasket, with no air gaps. • if furnace is installed in middle of run, the main duct run must be a minimum of 24 sq/inches. • if furnace is installed at the end of the run, the main duct must be 48 sq/inches. #4 - Return Air This return air requirement can be met in a couple of ways. The return air grille mounted on an inside wall of the trailer, exposed to the cabinet area of the furnace is the most common mounting used on the 85, 89 and 2-Stage Series furnaces. • Another option is to provide openings at various locations in the furnace cabinet area capable of drawing air from inside the trailer (ie. rowtered holes at bases of sofas or walls, etc.). The total square inches of openings must meet minimum requirements. Do not place any types of air filters in front of or behind the return air door. Blocking this area will substantially decrease the return air causing - less air delivery to the heat registers - short cycle of the furnace - limiting of the furnace. We recommend electrical air filters that can be placed anywhere in the open living area of the recreation vehicle. They can be purchased in most hardware stores. • 33 in2 65 in2 79 Series 85, 1522 an d 2334 Se 80 in2 89 and 2540 Series ries 27 NOTES THIS PAGE INTENTIONALLY LEFT BLANK 28 hydro flame Thermostat TROUBLE SHOOTING GUIDE Effective: 8/10/98 Guides are only intended for use on Atwood® products by service technicians who have successfully completed Atwood® training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the product and any applicable Industry Standards. This is not intended to be a complete list. Please direct questions concerning service of Atwood® products to 800-825-4328 option 5 before proceeding. CAUSE SOLUTION BLOWER DOES NOT RUN Temperature selector out of place --------------------Re-set to desired position Thermostat wires broken or disconnected ----------Not covered under warranty. Heat anticipator burned out --------------------------Dead short (not covered under warranty). Repair short and then replace thermostat. Faulty relay drawing more than 1 amp. Replace relay and thermostat. Covered under warranty. No continuity through thermostat with contacts closed and switch on. ----------------------Replace thermostat. Continuity through thermostat with contacts closed and switch on. ----------------------• Check and reestablish power to thermostat • Reset tripped circuit breaker. • Correct poor ground. • Correct any loose wires. • Replace defective relay. • Replace defective motor. FURNACE DOES NOT CYCLE PROPERLY Furnace cycles too quickly ----------------------------Move anticipator to a higher amp setting to lengthen cycle. NOT covered under warranty. Thermostat located too close to a heat duct. Move thermostat or duct outlet. NOT covered under warranty. High temperature variance ----------------------------Move anticipator to a lower amp setting to shorten cycle. NOT covered under warranty. Note: When the anticipator is set properly and the heating system has operated for a few hours, the furnace should cycle 5-6 time per hour. 29 FURNACE -Electronic Ignition Model TROUBLE SHOOTING GUIDE Effective: 8/10/98 Guides are only intended for use on Atwood® products by service technicians who have successfully completed Atwood® training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the product and any applicable Industry Standards. This is not intended to be a complete list. Please direct questions concerning service of Atwood® products to 800-825-4328 option 5 before proceeding. CAUSE SOLUTION BURNER FAILS TO IGNITE AND - BLOWER FAILS TO RUN No electrical power to the furnace ----------Reconnect or replace power source.* Thermostat defective ----------------------------Replace thermostat Thermostat wires broken or shorted --------Replace wire or wires* Current overload protector device ----------Reset circuit breaker. Check amp draw from motor Defective or tripped (circuit breaker). ------According to furnace’s specifications. Blower relay defective --------------------------Replace relay Wire off motor ------------------------------------Reconnect wire Wire off relay --------------------------------------Reconnect wire Improper ground --------------------------------Clean and secure grounds* Blower motor defective ------------------------Replace motor BLOWER RUNS - BUT FAILS TO IGNITE Low Voltage/High Voltage ----------------------Correct Power Supply* Gas pressure incorrect --------------------------Set pressure to a minimum of 11˝ W.C. with all appliances running. (Replace regulator if not obtainable).* Furnace grounding wires not secure --------Clean and secure grounds established* Air intake restricted ------------------------------Clean air intake.* 12 volt polarity reversed ------------------------Correct polarity* Motor running slow ------------------------------Check voltage first. If 12 VDC while running, replace motor. Exhaust blocked ----------------------------------Clean exhaust.* Combustion air wheel loose ------------------Reposition and tighten. Sail switch defective or wire off --------------Reconnect wire or replace. Limit switch defective or wire off ------------Reconnect wire or replace. Edge connector on circuit board dirty ------Clean with pencil eraser* Circuit Board defective --------------------------Clean plug contacts. If still defective, replace. (check on board tester when possible). Gas valve defective ------------------------------Replace valve or valve coil, depending on problem encountered. Main burner orifice blocked--------------------Clean main burner orifice or replace. High tension lead wire defective --------------Replace wire Electrode out of adjustment ------------------Adjust electrode (take care not to damage porcelain). Electrode defective ------------------------------Replace Obstructed burner head ------------------------Clean burner head* BURNER IGNITES BUT IGNITION SYSTEM “LOCKS OUT” AND TURNS BURNER OFF Low gas pressure --------------------------------Set pressure to a minimum of 11˝ W.C. with all appliances running. Replace regulator if not obtainable.* Exhaust blocked ----------------------------------Clean exhaust.* Combustion air wheel loose ------------------Reposition wheel and tighten Electrodes out of adjustment ------------------Adjust electrode according to furnace specifications. Electrode defective ------------------------------Replace electrode. Circuit Board defective --------------------------Clean plug contacts. If still defective, replace. (Check on board tester when possible). Flame sensor wire between electrode ------Replace wire and circuit board defective Air leakage at gaskets --------------------------Replace gasket Defective heat exchanger ----------------------Replace heat exchanger *indicates NOT covered under warranty. continued backside 30 FURNACE - ELECTRONIC IGNITION Model (continued) Effective: 8/10/98 CAUSE SOLUTION S O O T I N G (caused by lazy yellow flame) Low gas pressure ----------------------------------------------*Set pressure to a minimum of 11˝ W.C. with all appliances running. Replace regulator if not obtainable. Low voltage ------------------------------------------------------Correct power supply* Air leakage at gaskets ----------------------------------------Replace gaskets Combustion wheel installed backwards or loose ------Reposition wheel and tighten. Blockage in heating chamber or burner head ----------Clean or replace Faulty motor ----------------------------------------------------Replace motor Wrong vent kit or draft cap ----------------------------------Replace with correct vent kit or draft cap FAN RUNS CONTINUOUSLY WITH THERMOSTAT “OFF” Defective thermostat ------------------------------------------Replace thermostat Shorted thermostat leads ------------------------------------*Replace wire or wires Defective relay --------------------------------------------------Replace relay LIMITING = BURNER CYCLING ON AND OFF - BLOWER RUNS CONSTANTLY WITH THERMOSTAT ON Restricted or insufficient discharge ducting ------------a. Ducting must meet furnace’s minimum requirements.* b. No excess ducting or unnecessary bends.* c. All closeable registers must be fully open and unrestricted.* Furnace over fired ----------------------------------------------Set gas pressure to a minimum of 11˝ W.C. with all appliances running replace regulator, if not obtainable. Also, check main burner orifice, it must comply with furnace’s specifications.* Restricted return air supply ----------------------------------Make sure return air meets furnace minimum requirements.* Defective limit switch ------------------------------------------Replace limit switch BLOWER SHUTS OFF AT SAME TIME BURNER SHUTS OFF Wired wrong ----------------------------------------------------*Correct wiring Faulty relay ------------------------------------------------------Replace relay. BLOWER VIBRATES OR IS NOISY Motor mount loose --------------------------------------------Tighten motor mounting bracket a. Ducting must meet furnace’s minimum requirements* b. No excess ducting or unnecessary bends.* c. All closeable registers must be fully open and unrestricted. Damaged blower wheel --------------------------------------Replace blower wheel. Motor shaft bent ------------------------------------------------Replace motor INSUFFICIENT HEAT Furnace under fired --------------------------------------------1. Set gas pressure to 11˝ W.C. with all appliances running, replace regulator if not obtainable. Also, check main burner orifice, it must comply with furnace’s specifications. 2. Check ducting and return air according to furnaces specifications.* Furnace improperly sized for coach/or conditions ----Replace furnace with proper size. 31 FURNACE - Pilot Model TROUBLE SHOOTING GUIDE Effective: 8/10/98 Guides are only intended for use on Atwood® products by service technicians who have successfully completed Atwood® training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the product and any applicable Industry Standards. This is not intended to be a complete list. Please direct questions concerning service of Atwood® products to 800-825-4328 option 5 before proceeding. CAUSE SOLUTION BURNER FAILS TO IGNITE AND - BLOWER FAILS TO RUN No electrical power to the furnace --------------Reconnect or replace power source.* Current overload protector device --------------Reset circuit breaker. Check amp draw from motor defective or tripped (circuit breaker).according to furnace’s specifications. Thermostat defective --------------------------------Replace thermostat. Thermostat wires broken --------------------------Replace wire or wires. Thermostat located in high area ------------------Relocate thermostat. Blower motor defective ----------------------------Replace motor. Blower relay defective ------------------------------Replace relay. Wire off motor ----------------------------------------Reconnect wire.* Wire off relay ------------------------------------------Reconnect wire.* Improper ground ------------------------------------Clean and secure grounds.* BLOWER RUNS - BUT FAILS TO IGNITE Low Voltage/High Voltage --------------------------Correct power supply.* 12 volt polarity reversed----------------------------Correct polarity.* Furnace grounding wires not secure ------------Clean and secure grounds established* Gas valve defective ----------------------------------Replace valve or valve coil, depending on problem encountered. Gas pressure incorrect------------------------------*Set pressure to a minimum of 11˝ W.C. with all appliances running. (Replace regulator if not obtainable). Limit switch defective or wire off ----------------Reconnect wire or replace. Sail switch defective or wire off ------------------Reconnect wire or replace. Burner orifice blocked ------------------------------Clean main burner orifice or replace. Combustion air wheel loose ----------------------Reposition and tighten. Burner head adjustment ----------------------------Reposition and tighten. Adjust burner according to furnace specifications. Exhaust blocked --------------------------------------Clean exhaust.* Air intake restricted ----------------------------------Clean air intake.* Broken or loose wire --------------------------------Replace or tighten* Motor running slow --------------------------------Check voltage first. If 12 VDC while running, replace motor.* Pilot orifice plugged --------------------------------Clean or replace orifice Thermocouple defective ----------------------------Replace thermocouple Pilot assembly defective ----------------------------Replace pilot assembly BURNER CYCLING ON AND OFF - BLOWER RUNS CONTINUOUSLY WITH THERMOSTAT “ON” Restricted return air supply ----------------------Make sure return air meets furnace’s minimum requirements. Restricted discharge duct system----------------a. Make sure ducting meets furnace’s minimum requirements.* b. Make sure there is no excess ducting or unnecessary bends.* c. Make sure any closeable registers are fully open and unrestricted. Defective limit switch ------------------------------Replace limit switch.* Furnace over fired ------------------------------------Set gas pressure to a minimum of 11˝ WC with all appliances running. Replace regulator if not obtainable. Also, check main burner orifice, it must comply with furnace’s specifications. *indicates NOT covered under warranty. 32 continued backside FURNACE - Pilot Model (continued) Effective: 8/10/98 CAUSE SOLUTION BLOWER SHUTS OFF AT SAME TIME BURNER SHUTS OFF Faulty relay --------------------------------------------------------Replace relay Thermostat wired wrong --------------------------------------Correct wiring* BURNER FAILS TO IGNITE AND - BLOWER FAILS TO RUN No electrical power to the furnace --------------------------Reconnect or replace power source.* BLOWER VIBRATES OR IS NOISY Damaged blower wheel ----------------------------------------Replace blower wheel. Motor shaft bent--------------------------------------------------Replace motor Loose motor ------------------------------------------------------Tighten motor mounting bracket. Restricted discharge duct system----------------------------a. Make sure ducting meets furnace’s minimum requirements.* b. Make sure there is no excess ducting or unnecessary bends.* c. Make sure any closable registers are fully open and unrestricted.* PILOT FAILS TO IGNITE OR STAY LIT Plugged pilot orifice --------------------------------------------Clean or replace pilot orifice. Electrode out of adjustment ----------------------------------Adjust electrode to furnace’s specifications. Pilot tube defective ----------------------------------------------Replace tube. Piezo sparker defective ----------------------------------------Replace sparker Defective thermocouple ----------------------------------------Replace thermocouple. Defective valve ----------------------------------------------------Replace valve. Vent kit not sealed ----------------------------------------------Seal vent where it meets with the furnace.* MICA window missing ------------------------------------------Replace MICA Combustion air hose plugged or collapsed ----------------Replace combustion hose Water in propane ------------------------------------------------Add alcohol to the propane bottles.* Burner plate gasket or ----------------------------------------Replace gaskets pilot gasket not sealed LAZY FLAME (yellow) High gas pressure------------------------------------------------*Set pressure to a minimum of 11˝ W.C. with all appliances running. Replace regulator if not obtainable. Burner out of adjustment --------------------------------------Adjust burner according to furnace specification. Combustion wheel installed backwards or loose --------Reposition wheel and tighten. Air leakage at gaskets ------------------------------------------Replace gaskets Low voltage --------------------------------------------------------Correct power supply* FAN RUNS CONTINUOUSLY WITH THERMOSTAT “OFF” Shorted thermostat leads --------------------------------------Replace wire or wires. Defective relay ----------------------------------------------------Replace relay Defective thermostat --------------------------------------------Replace thermostat INSUFFICIENT HEAT Furnace under fired ----------------------------------------------1. Set gas pressure to 11˝ W.C. with all appliances running, replace regulator if not obtainable. Also, check main burner orifice, it must comply with furnace’s specifications.* 2. Check ducting and return air according to furnaces specifications. Furnace limiting --------------------------------------------------Check ducting and return air. It must comply with furnace’s specifications.* *indicates NOT covered under warranty. 33 FURNACE TERMINOLOGY Terminology Definition AC Motor A Motor operating on 120 volts A.C. Adjustable Register A heat outlet capable of being opened and closed. Terminology Definition Fan Switch Air Speed Indicators (Velometer) A tool used to measure the velocity of air movement from a duct outlet. A normally open switch that closes at a set temperature allowing power flow to the motor, and allows the motor to run after the burner shuts down to cool down the combustion chamber. Field Electrical Hook Up The Wiring Harness that connects the furnace to the coach wiring. Ambient Air Temp. Current room air temperature. Flair Fitting Amp Draw The amount of current required to run a given component. Brass fitting used to connect the furnace to the gas supply. Flash Back The time it takes for the furnace Combustion Chamber to burn off all the oils and lubes used in production. A condition when the flame burns on the inside of the burner. Flex Ducting The component in the furnace where combustion occurs creating the main source of heat within the Combustion Chamber. A round, collapsible, wire reinforced product used to deliver the heated air from the furnace to the living area. Forced Combustion A type of combustion when a second air wheel is used to force air into the burner to increase the air to gas mixture. Burn Off Burner Burner Flame Lift Off When the flame lifts off the Burner. Candling A small flame at the Main Burner Orifice when the Valve is in a closed position. Gas Pressure The amount of gas being supplied to the furnace, measured in column inches. Circuit Breaker A normally closed switch that automatically interrupts an electrical circuit under abnormal AMP loads. Gas Valve A mechanical device by which the flow of gas is started or stopped by an electrical signal. Circulating Air Air drawn into the furnace by the Main Air Wheel then heated and forced out the heat outlets. Gravity Combustion A type of combustion using no other source but gravity to supply combustion air for the proper air to gas mixture at the burner. Combustion Air Air supplied to the Burner specifically for combustion. Hard Ducting (See Floor Ducting) Combustion Chamber The component where combustion occurs and transfers heat to circulating air. Heat Anticipator Component of a Thermostat that can be adjusted to increase or decrease the length of the heating cycle. Converter Component that is used to change 120 VAC to 12 VDC. Available in linear, pharo-resonant and switching styles. Heating Element (See Combustion Chamber) High Tension Lead Wire The wire carrying the high tension spark from Circuit Board to Electrode. Cycling The normal on and off operation of the furnace controlled by the thermostat. Incline Manometer Tool used to measure Static Pressure of the furnace plenum. DC Motor Motor operating on 12 VDC. Junction Box Circuit Board A Circuit Board in the furnace controlling the ignition sequence and proves a flame has been established. A box inside or outside of the furnace where electrical connections are made. Limit Switch A normally closed switch that opens at a set temperature which does not allow the furnace to over heat. Limiting A condition caused by over-heating the Limit Switch The burner turns on and off during a heating cycle. Electrode Both a conductor establishing an electrical spark at the Burner to ignite the air to gas mixture, and a sensor to signal the circuit board the flame is established. 34 Terminology Definition Loud Ignition A condition where the air to gas mixture is off and the burner lights with a loud noise. Main Burner Orifice Manifold Terminology Definition Sooting The Orifice regulating the amount of gas delivered to the Burner. A black powder that builds up around the Burner in the Combustion Chamber normally caused by an improper air to gas mixture. Start Capacitor The tube delivering gas from the Gas Valve to the Main Burner Orifice. A device giving an electrical boost to start an A/C motor. Static Pressure Amount of pressure inside the Furnace Plenum or Duct caused by the ability to dispel air out the duct outlets. Thermocouple Safety device used to generate an electrical signal sent to the Gas Valve to hold the Pilot Flame on. Thermopile Safety device much like a Thermocouple. It gives a much higher electrical output, also used to open the Main Valve with a Thermostat. Manual Reset Switch A Limit Switch manually reset after reaching it’s set temperature. MicroAmps: Amps sent back to the Circuit Board to establish a flame is present. Millivolts Voltage created by a Thermocouple or Thermopile. Multi-Try Circuit Board Circuit Board providing 2 or 3 trials for ignition. OEM A manufacture of recreational vehicle, “Original Equipment Manufacture”. Thermostat Device used with the Furnace to regulate the room air temperature. Pig Tail (see Field Electrical Hook Up) Time Delay Relay A normally open Relay. When activated closes, sending power to the Blower Motor. When deactivated allows Blower to run for a period of time to cool the Combustion Chamber. Transformer Device reducing 120 VAC to 24 VAC. Pilot Light Assembly An assembly used to light the burner. Plenum The metal box enclosing the Combustion Chamber directing the heated air to the duct outlets. Power Supply A source of electrical power, usually a converter, inverter or battery. U-Tube Tool measuring gas pressure in inches of water. Primary Air A portion of the combustion air mixing directly in the Burner at the Main Burner Orifice. VOM Meter reading voltages and OHMs resistance. Valve Coil Resonating A whining noise created by a Burner with an improper air to gas mixture. Electromagnetic Coil on the Gas Valve holding and releasing a plunger to start and stop the flow of gas. Return Air Air pulled into the furnace, heated, force through duct outlets back to the living area. Safety Lockout Circuit Board not sensing a flame, cutting power to the Gas Valve. Sail Switch Air prover switch that will engage when the Blower Motor reaches 75% of the rated RPM. Secondary Air Combustion Air that helps complete the combustion after the Burner is on. Sensor Wire Wire carrying an electrical signal from the Electrode back to the Circuit Board on a remote sense system. Slope Gauge (see Incline Manometer) 35 FOR EFFICIENT PROCESSING OF CLAIM FURNACE/LP DETECTORS Atwood Mobile Products Salt Lake City Operations 1874 South Pioneer Road Salt Lake City, UT 84104 1. Call for a RGN number. 2. Fill Warranty Service Report form out completely. 3. Using tape or a tag mark the returning part with the RGN #. 4. Package part including the Warranty Service Report in the box. 5. On the outside of the package clearly mark the RGN number. 6. Return part to the correct Division of Atwood Mobile Products. CO DETECTOR KIDDE Safety (1-800-880-6788) 1394 South Third Street Mebane, NC 27302 RANGE/COOK TOPS/DROP-INS/SOL-A-VENTS Atwood Mobile Products Wedgewood Operations 6320 Kelly Willis Road Greenbrier, TN 37073 Return Goods Policy Effective August 7, 1995, all Atwood defective returns will no longer be repaired at the warehouses and returned to customers. Defective returns will be shipped back to the respective manufacturing facility for problem cause analysis within 30 days of sales. Full credit will be issued if the cause analysis determines Atwood is responsible. If the cause analysis determines the customer is responsible, partial or no credit will be issued. Warranty Returns - the warranty policy, must return policy and approved labor rates provide the framework for warranty returns by product line. Non-Defective Returns - A restocking fee of 20% will be charged for handling of overstock returns or standard stock items ordered incorrectly by the customer providing the product is received in resalable condition. Product that has been specifically designed at a customers request is non-returnable. Obsolete or out dated product will not be accepted for credit. Shipping Damage - Once the product has been accepted at its final destination it is the customers responsibility to file a damage claim with the carrier. Follow Warranty Procedures for Atwood returns. Return Parts When returning parts, there are three divisions responsible for specific product and their claims. Prior to returning parts, a Return Goods Number (RGN) must be obtained by calling the Atwood Mobile Product Service Department at 800-825-4328. Shipping - Reasonable shipping charges are reimbursed on defective and warranty parts if the analysis determines Atwood is responsible for the disposition. All products not shipped via Atwood trucks should be shipped prepaid via UPS ground unless negotiated at the time the RGN is given. No collect shipments will be accepted. Packaging - The RGN must be identified on each container & all packing information. Product returned must be properly packaged to prevent shipping damage. Full credit will not be issued on product sent back on an open skid or improperly packaged. Additional product boxes are available upon request. Submit claims to the correct division. Failure to do so makes claim processing a more difficult and lengthy process delaying payment of your claims. Together we can maintain a speedy and efficient warranty program. WATER HEATERS//HARDWARE (jacks, couplers, 5th wheel & braking systems) Atwood Mobile Products 4750 Hiawatha Drive Rockford, IL 60013 36 Must Return Parts List Under Atwood’s Warranty Administration Program we require, with the return of warranty claims, the specific parts noted below. Failure to accompany your claims with these parts will result in the non-shipment of a replacement part, or the non-processing of the appropriate credit until such time as the part is received by Atwood. Before returning the part, a RGN (Return Goods Number) must be obtained. This number can be acquired for all products except seating, by calling the Atwood Mobile Products Service Department at 1-800-825-4328. To obtain RGN’s for seating components, please call 1-219-522-7891. Without this RGN appearing on the outside of the shipping carton, the shipment will be refused at our receiving department. FURNACE All parts HARDWARE Couplers Jacks Actuators Master cylinders Shock absorbers Foundation brakes Power jacks Power jack motors All 5th Wheel items RANGE & OVENS Regulators Oven thermostats Safety pilot valves Burner valves Manifolds Top pilot valves 12v ignition module Burners w/ignition electrode Complete ranges (BY APPROVAL ONLY) SEATING COMPONENTS All parts WATER HEATER Complete water heaters Inner tanks Gas thermostat valves Circuit boards Gas solenoid valves Electric thermostats Heating elements Pilot assemblies Spark probe assemblies E.C.O. & T-stat kits Thermal cut-offs Pressure-Temperature Relief Valves ATWOOD MOBILE PRODUCTS ATWOOD MOBILE PRODUCTS hydro flame FURNACE LIMITED WARRANTY hydro flame TM TM FURNACE EXTENDED SERVICE CONTRACT Atwood Mobile Products warrants to the original owner and subject to the below mentioned conditions, that this product will be free of defects in material or workmanship for a period of two years from the original date of purchase. Atwood’s liability hereunder is limited to the replacement of the product, repair of the product, or replacement of the product with a reconditioned product at the discretion of Atwood Mobile Products. This warranty is void if the product has been damaged by accident, unreasonable use, neglect, tampering or other causes not arising from defects in material workmanship. This warranty extends to the original owner of the product only and is subject to the following conditions: 1. For two years from the date of purchase, Atwood will repair or replace any part defective in material or workmanship. This warranty includes reasonable labor charges required to remove and replace the part. Service calls to customer’s location are not considered part of these charges and are, therefore, the responsibility of the owner. 2. This warranty does not cover the following items classified as normal maintenance: ADJUSTING - gas pressure, voltage, loose wire connections, and/or thermostat heat anticipator CLEANING - air wheels, burner and/or burner orifice CLEANING OR ADJUSTING - heat chamber, heat ducting, return air opening, and/or exhaust tubes 3. In the event of a warranty claim, the owner must contact, in advance, either an authorized Atwood Service Center or the Atwood Service Department. Warranty claim service must be performed at an authorized Atwood Service Center (a list will be provided at no charge) or as approved by the Consumer Service Department, Atwood Mobile Products, 4750 Hiawatha Drive, Rockford, IL 61103-1298 USA. Phone: 815-877-5700 4. RETURN PARTS MUST BE SHIPPED TO ATWOOD “PREPAID”. Credit for shipping costs will be included with the warranty claim. The defective parts become the property of Atwood Mobile Products and must be returned to the Quality Assurance Dept., Salt Lake City Operations, 1874 South Pioneer Road, Salt Lake City, Utah 84104 USA. 5. This warranty applies only if the unit is installed according to the installation instructions provided and complies with local and state codes. 6. The warranty period on replacement parts is the unused portion of the original warranty period. 7. Damage or failure resulting from misuse (including failure to seek proper repair service), misapplication, alterations, water damage, freezing or not using genuine Atwood parts are the owner’s responsibility. 8. Atwood does not assume responsibility for any loss of use of vehicle, loss of time, inconvenience, expense for gasoline, telephone, travel, lodging, loss or damage to personal property or revenues. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. 9 Any implied warranties are limited to (2) two years. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 10. Replacement parts purchased outside of the original furnace warranty carry a 90 day warranty. This includes the part at no charge and reasonable labor charges to replace it. This hydro flame furnace is designed for use in recreation vehicles for the purpose of heating air as stated in the “data plate” attached to furnace. Any other use, unless authorized in writing by the Atwood Engineering Department, voids this warranty. 9/03 TERMS AND PROVISIONS: 1. Written approval by Atwood must be obtained prior to having any repairs made or parts replaced under these Warranties at other than an Atwood Authorized Service Center. A list can be obtained by calling 1-815-877-5700. Any such unauthorized charges will not be paid by Atwood. 2. Air freight or postage charges shall be borne by party claiming under Warranties. The Original Purchaser shall have the full responsibility of making the furnace or RV available for repair or replacement at Atwood Mobile Products, Salt Lake Operations or at an Atwood Authorized Service Center. Service calls are not covered under the normal two year warranty. 3. Atwood’s Authorized Service Centers are neither agents nor employees of Atwood and at all times will be acting as independent contractors with the Original Purchaser. Atwood will reimburse service centers for warranty service rendered on a direct basis only. 4. Repairs, replacement parts and or furnace replacement authorized by Atwood shall be subject to the remainder of the warranty, if any of the aforesaid two year period. Exclusions (specifically excluded from the warranties) 1. Incidental or consequential damages. 2. Damaged caused by shipment. 3. Damage resulting from improper installation, misuse, neglect, accident or use in violation of instructions furnished by Atwood Mobile Products. 4. Equipment and parts which have been altered in any way whatsoever without written authorization from Atwood Mobile Products. 5. All repairs and replacement parts not authorized by Atwood Mobile Products. 6. Preventative maintenance. Limitations 1. The maximum liability of Atwood Mobile Products in connection with this limited warranty shall not in any event exceed the original price paid for the furnace claimed to be defective or unsuitable. 2. Components manufactured by any supplier other than Atwood Mobile Products shall bear only that warranty made by the manufacturer or supplier of that product. 3/97 37 hydro flame Furnaces AND Detectors TM TIME ALLOWANCE SCHEDULE Flat Rate Schedule July 19, 2001 in hours 85 II, III & IV 1522 & 2334 DC89 I & II & III 2540 AC89 I & II & III 8012 I & II 79 I & II Air Box Extension .....................................................................................................................................................................................................................70 .......................................70 ............ Air Wheel (Circulating) .........................................75 .........................................75 .......................................75 ....................................1.00 ..................................1.00 ............ Air Wheel (Combustion) ..............................1.00 ..................................1.00 ..................................1.00 ....................................1.00 ..................................1.00 ............ Blower Housing .................................................................50 .........................................50 .......................................50 .................................................................................................................. Burner...................................................................................................60 .........................................60 .......................................60 .........................................80 .......................................80 ............ Burner Box .................................................................................70 .........................................70 .......................................70 .................................................................................................................. Burner Plate .........................................................................................................................................................................................................................................80 .......................................80 ............ Burner Plate Gasket.............................................................................................................................................................................................................75 .......................................75 ............ Casing ............................................................................................1.00 ..................................1.00 ..................................1.00 ....................................1.50 ..................................1.50 ............ Circuit Breaker.....................................................................40 .........................................40 .......................................40 .........................................80 .......................................80 ............ Combustion Chamber ....................................1.50 ..................................1.50 ..................................1.50 ....................................1.50 ..................................1.50 ............ Door .........................................................................................................70 .........................................70 .......................................70 .........................................30 .......................................30 ............ Draft Cap .......................................................................................30 .........................................30 .......................................30 .................................................................................................................. Circuit Board ...........................................................................70 .........................................70 .......................................70 .........................................70 .......................................70 ............ Circuit Board Bracket ...........................................70 .........................................70 .......................................70 .........................................70 .......................................70 ............ Electrode.........................................................................................60 .........................................60 .......................................60 .........................................70 .......................................70 ............ Exhaust Tube .....................................................................................................................................................................................................................................70 .......................................70 ............ Gasket Comb. Chamber............................1.50 ..................................1.50 ..................................1.50 .................................................................................................................. Gasket Electrode ...........................................................60 .........................................60 .......................................60 .........................................70 .......................................70 ............ High Tension Lead .......................................................50 .........................................50 .......................................50 .........................................50 .......................................50 ............ Limit Switch .............................................................................90 .........................................90 .......................................90 .........................................60 .......................................60 ............ Manifold Inlet .........................................................................75 .........................................75 .......................................75 .................................................................................................................. Manifold Outlet...................................................................75 .........................................75 .......................................75 ....................................1.00 ..................................1.00 ............ Motor ................................................................................................1.00 ..................................1.00 ..................................1.15 ....................................1.15 ..................................1.15 ............ Motor Bracket ................................................................1.15 ..................................1.15 ..................................1.15 .................................................................................................................. Motor Capacitor .....................................................................................................................................................................50 .................................................................................................................. Motor Mounting Wall ........................................1.50 ..................................1.50 ..................................1.50 .................................................................................................................. Orifice (Burner) ...................................................................60 .........................................60 .......................................60 .........................................80 .......................................80 ............ Relay .......................................................................................................50 .........................................50 .......................................50 .........................................60 .......................................60 ............ Sail Switch...................................................................................60 .........................................60 .......................................60 ....................................1.00 ..................................1.00 ............ Thermostat .................................................................................50 .........................................50 .......................................50 .........................................50 .......................................50 ............ Transformer .......................................................................................................................................................................................60 .................................................................................................................. Valve .......................................................................................................80 .........................................80 .......................................80 ....................................1.00 ..................................1.00 ............ Valve Bracket .........................................................................80 .........................................80 .......................................80 ....................................1.00 ..................................1.00 ............ Valve Coil .......................................................................................70 .........................................70 .......................................70 .........................................50 .......................................50 ............ Wiring Harness ............................................................1.00 ..................................1.00 ..................................1.00 ....................................1.00 ..................................1.00 ............ DETECTORS ...........................................................................25 38 NOTE: If more than one repair is done minus .40 for each additional repair. NOTE: All flat rates include diagnostic time and when applicable, gas leak test. 38 MPD 38137 hydro flame TM 7900-II / 8000-II Series Furnace Technical Installation Manual ENGLISH, FRANCAIS •Installation (et Canada) Effective 7/01/00 29 28 30 8 11 6 12 24 23 5 13 4 3 27 7 2 1 16 26 17 14 18 10 15 30 25 31 9 21 19 20 22 Item # 1 2 3 4 5 6 7 8 9 10 10 11 11 Description of Parts Front Door Electronic Ignition Board Valve Front Discharge Cover Plate Electrode Cover Plate Electrode Electrode Gasket Heat Exchanger Burner Plate Gasket Sail Switch (79-II) Sail Switch (80-II) Blower Wheel (79-II) Blower Wheel (80-II) Item # Description of Parts 12 12 13 14 15 16 17 18 19 20 21 22 23 Motor (79-II) Motor (80-II) Combustion Wheel Duct Adapter Duct Cover Plate Air Hose Thermostat -SPECIFY COLOR Limit Switch (L-170) Relay On/Off Circuit Breaker Burner Head Manifold Motor Gasket 39 Item # Description of Parts 24 25 25 26 27 28 29 Motor Spacer Small Burner Air Baffle - SPECIFY RATE Large Burner Air Baffle - SPECIFY RATE Electronic Ignition Mounting Plate Valve Bracket Vent Kit Specify Length Exhaust Tube Assembly - SPECIFY LENGTH & MATERIAL 30 31 Air Box Assembly - SPECIFY LENGTH Orifice - SPECIFY RATE EXCALIBUR 8500-III October 1997 26 7 18 42 20 32 41 4 1 36 15 43 40 8 46 30 23 27 28 22 35 6 46 10 14 9 45 17 37 24 12 19 13 45-49 Atwood Furnace Installation Parts SEE PARTS MATRIX PAGES Drawing # Description of Parts 1 4 6 7 8 9 10 12 13 14 15 17 18 19 20 22 23 8516 Blower Wheel Asmbly, Plate & Gasket Burner Asmbly Casing Extension Box Circuit Breaker Replacement Coil Combustion Wheel Door Hinges Door Asmbly ◆ Slide Plate Thermostat Valve Wiring Harness Draft Cap Asmbly Electronic Ignition Board (05-30) Duct Adapters Duct Cover Plate 8520 ◆ 8525 ◆ 8531 ◆ 8535 Drawing # Description of Parts 24 25 26 27 28 30 32 35 36 37 40 41 42 43 45 ◆ 40 Electrode Electrode Gasket Flex Adapter Plate Asmbly Gas Inlet Plug High Tension Lead Bottom Plenum Plate Limit Switch Motor Gasket Motor Kit Orifice Relay Sail Switch Element Asmbly Exhaust Wall Gasket Recess Pan Asmbly 8516 8520 8525 ◆ ◆ ◆ 8531 8535 ◆ ◆ ◆ Order by Color LITERATURE NUMBER MPD 33940 hydro flame TM 8500-IV Series Furnace MODELS 8516, 8520, 8525, 8531, 8535 Technical Installation Manual ENGLISH, FRANCAIS •Installation •Maintenance (et Canada) Effective 9/1/03 30 26 52 7 18 42 32 20 1 47 54 41 3 57 36 49 15 43 46 51 8 35 28 27 50 48 4 22 23 6 56 46 10 14 45 9 17 37 24 11 19 13 12 DRAWING 1 3 4 6 7 8 9 10 11 12 13 14 15 17 # DESCRIPTION Blower Wheel Motor Clamp Gasket/Plenum Plate Kit- Top & Bottom Burner Assembly Extension Box ON/OFF Switch Replacement Coil Combustion Wheel Door Hinges Door, Standard ORDER BY COLOR Door, Deluxe -SPECIFY COLOR Slide Plate Thermostat - specify color Valve 18 19 20 22 23 24 26 27 28 30 32 35 36 37 41 Field Wiring Harness Draft Cap Assembly - Specity model Electronic Ignition Board Duct Adapters Duct Cover Plate Electrode Flex Adapter Plate Assembly Kit Gas Inlet Plug High Tension Lead Top/Bottom/Side Cover Limit Switch Motor Gasket Motor - specify rate Orifice - specify rate Sail Switch 41 42 43 45 46 47 48 49 50 51 52 54 56 57 N/S Element Assembly - specify model Exhaust Wall Gasket Recess Pan Assembly-SPECIFY COLOR Mounting Bracket Venturi Blower Housing Back Blower Housing Motor/Combustion Wall Circuit Breaker Control Board Mounting Bracket Plenum Plate, Extension Boot Door Fastener Kit Double Housing Field Harness High Voltage Lead - noise suppresion LITERATURE NUMBER MPD 33941 hydro flame TM 8500-IV-LD Series Furnace 8516, 8520, 8525, 8531, 8535 MODELS Technical Installation Manual ENGLISH, FRANCAIS •Installation •Maintenance (et Canada) Effective 9/1/03 57 30 26 58 52 7 8 42 32 20 1 54 41 3 30 36 49 15 43 4 35 28 22 50 48 23 6 10 17 24 37 9 19 DRAWING 1 3 4 6 7 8 9 10 15 17 19 # DESCRIPTION Blower Wheel Motor Clamp Gasket & Plenum Plate Kit Burner Assembly Extension Box ON/OFF Switch / Circuit Breaker - Specify Model Replacement Coil Combustion Wheel Thermostat - specify color Valve Vent Assembly - Specity Model 20 22 23 24 26 28 30 32 35 36 37 41 Electronic Ignition Board Duct Adapters Duct Cover Plate Electrode Flex Adapter Plate Assembly Kit High Tension Lead Cover Top/Bottom/Side Plate Limit Switch Motor Gasket Motor - specify rate Orifice - specify rate Sail Switch 42 59 56 42 43 48 49 50 52 54 56 57 58 59 Element Assembly - specify model Exhaust Wall Gasket Blower Housing Back Blower Housing Motor/Combustion Wall Control Board Mounting Bracket Plenum Plate Extension Box Assembly Combustion Cover (specify) Extended Manifold Gas Line Gasket Vent Ring LITERATURE NUMBER MPD 33938 hydro flame TM 8900-III Series Furnace MODELS 8935, 8940 Technical Installation Manual ENGLISH, FRANCAIS •Installation (et Canada) Effective 9/1/03 33 31 35 23 4 13 34 29 17 3 25 36 37 2 18 14 20 7 24 1 11 43 40 10 6 44 32 30 45 28 8 9 16 5 42 38 19 39 41 DRAWING 1 2 3 4 5 6 7 8 9 10 11 13 14 16 # DESCRIPTION OF PARTS Relay Thermostat - specify color Duct Cover Plate Duct Adapter Orifice — SPECIFY GAS & BTU Combustion Wheel Motor Gasket Valve DC Valve Repl Coil DC Gas Inlet Plug Slide Plate Electronic Ignition Board DC Kit Recessed Pan (MUST ORDER BY COLOR) Valve AC 17 18 19 20 23 24 25 28 29 30 31 32 33 34 35 Motor DC Sail Switch Draft Cap Assembly DC/AC35 Circuit Breaker DC Junction Box Asmbly AC Motor Capacitor AC Element Exhaust Wall Gasket Valve Replacement Coil AC Blower Wheel Electrode Limit Switch Burner Assembly Element Assembly Electronic Ignition Board AC Kit Transformer Assembly AC 43 43 36 37 38 39 40 41 42 43 44 45 Motor AC High Voltage Wire Deluxe Door & Bezel Assembly (MUST ORDER BY COLOR) Draft Cap Assembly AC/DC 40 Gasket & Plate Assembly Standard Door & Bezel Assembly (MUST ORDER BY COLOR) Combustion Cover Door Fastener Kit Recess Pan Bracket Rain Shield LITERATURE NUMBER MPD 33939 hydro flame TM 8500-IV 2 Stage Series Furnace 1522, 2334 Technical Installation Manual MODELS Patent No US 6,464,000 Other Patents Pending ENGLISH, FRANCAIS •Installation •Maintenance (et Canada) Effective 9/1/03 30 53 26 7 18 42 52 32 20 1 47 54 41 3 36 49 15 HEAT FAN OFF COOL 43 M 46 51 8 35 28 27 50 48 4 22 23 6 55 46 10 14 45 9 17 37 24 11 19 15 13 12 DRAWING 1 3 4 6 7 8 9 10 11 12 13 14 15 17 # DESCRIPTION Blower Wheel Motor Clamp Gasket & Plenum Plate Kit Burner Assembly Extension Box ON/OFF Switch Mounting Bracket Valve Combustion Wheel Door Hinges Door, Standard ORDER BY COLOR Door, Deluxe -SPECIFY COLOR Slide Plate Dual Thermostat Valves - (1522 = ORANGE) (2334 = WHITE) 18 19 20 22 23 24 26 27 28 30 32 35 36 37 41 Field Wiring Harness Draft Cap Assembly Electronic Ignition Board Duct Adapters Duct Cover Plate Electrode Flex Adapter Plate Assembly Kit Gas Inlet Plug/Seal High Tension Lead Top/Bottom/Side Cover Plate Limit Switch Motor Gasket 10 VDC Motor - Specify Model Orifices - (1522 = #54) (2334 = #51) Sail Switch 44 44 42 43 45 46 47 48 49 50 51 52 53 54 55 NS Element Assembly - Specify Model Exhaust Wall Gasket Recess Pan Assembly-SPECIFY COLOR Mounting Bracket Venturi Blower Housing Back Blower Housing Motor/Combustion Wall Circuit Breaker Control Board Mounting Bracket Speed Control Board Adapter Plate Door Fastener Kit High Tension Lead Noise Supression LITERATURE NUMBER MPD 33943 hydro flame TM 8900-III-LD 2 Stage Series Furnace 2540 Technical Installation Manual MODEL Patent No US 6,464,000 Other Patents Pending ENGLISH, FRANCAIS •Installation (et Canada) Effective 9/1/03 42 8 32 53 56 52 20 22 1 15 OFF COOL HEAT FAN 49 41 28 23 43 58 36 M 35 6 48 50 26 54 10 37 17 24 9 12 19 57 DRAWING 1 4 6 8 9 10 15 17 19 20 22 # DESCRIPTION Blower Wheel Gasket & Plenum Plate Kit Burner Assembly ON/OFF Switch / Circit Breaker Valve Coil Replacement (DC) Combustion Wheel Dual Thermostat Valve Vent Assembly Electronic Ignition Board Duct Adapters 23 24 26 28 32 35 36 37 41 42 43 48 Duct Cover Plate Electrode Adapter Plate Assembly High Tension Lead Limit Switch Motor Gasket Motor Orifice - #49 Sail Switch Element Assembly Exhaust Wall Gasket Blower Housing Back 45 55 49 50 52 53 54 55 56 57 58 Blower Housing Motor/Combustion Wall Control Board Mounting Bracket Motor Speed Control Board Adapter Plate Combustion Cover (specify) Extended Manifold Vent Ring Gas Line Gasket 46 85-IV 31 85-IV 35 1522 2-stage 2334 2-stage R-25 Blowers Wheels & Covers 37605 Blower cover - back (outside) ✗ ✗ 37606 Blower cover - front (inside) ✗ ✗ 37607 Blower Venturi Ring ✗ ✗ 33126 Blower Wheel Kit ✗ ✗ Burner 36043 Burner Head ✗ ✗ 35491 Burner Head Burner Orifices 31257 #56 16,000 BTU ✗ 31265 1.25MM 18,000 BTU ✗ 31267 #54 22,000 BTU 37580 1.45MM 25,000 BTU 31280 #52 31,000 BTU 32285 #51 35,000 BTU 34004 Burner Orifice 42 (Nat) Circuit Board 37966 Controller Module Motor Speed 37984 Controller Module Bracket 38676 Ignition Board Retrofit Kit (w/fan control) ✗ ✗ 36716 Ignition Board Kit (3 Trial) ✗ ✗ 33686 Ignition Board bracket ✗ ✗ 37965 Ignition Module 38224 Ignition Module with Motor Control Circuit Breakers 33751 7 AMP (with door) ✗ ✗ 33752 10 AMP (with door) 34034 15 AMP (with door) 34011 7 AMP (without door circuit breaker/on/off) ✗ ✗ 34012 10 AMP (without door circuit breaker/on/off) 34013 15 AMP (without door circuit breaker/on/off) 34015 20 AMP (without door circuit breaker/on/off) Combustion 37084 Combustion Air Restrictor 1-1/4” ✗ 37085 Combustion Air Restrictor 1-3/4” NLA 33128 Combustion Wheel Kit ✗ ✗ Draft Cap 37620 Draft Cap (5/8” Baffle) (before S/N 1260456) ✗ ✗ 37619 Draft Cap (3/8” Baffle) (before S/N 1260456) 38141 Draft Cap (3/8” Baffle).(after S/N 1260455) 38139 Draft Cap (5/8” Baffle).(after S/N 1260455) ✗ ✗ Electrodes 37057 Electrode ✗ ✗ Gaskets 38261 Exhaust Box Gasket No Longer Available 32926 Exhaust Wall Gasket (before S/N 1260456) ✗ ✗ 37956 Exhaust Wall Gasket (after S/N 1260455) ✗ ✗ 38286 Exhaust Tube Gasket No Longer Available 37713 Motor Gasket No Longer Available 37600 Motor Gasket ✗ ✗ 85-IV 25 85-IV 20 85-IV 16 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 47 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ R-25 2334 2-stage 85-IV 35 1522 2-stage 85-IV 31 Heating Elements 37960 Htg Element Kit* 16, 20 (before S/N 1260456) ✗ ✗ 37961 Htg Element Kit* 25 (before S/N 1260456) 37962 Htg Element Kit* 31, 35 (before S/N 1260456) 37958 Htg Element 16, 20, 25 (after S/N 1260455) ✗ ✗ 37959 Htg Element 31, 35 (after S/N 1260455) 38282 Htg Element No Longer Available *Kit includes draft cap & element gasket Switches 37022 Limit Switch 190˚ ✗ ✗ 36121 ON/OFF Switch ✗ ✗ 38279 Pressure Switch 36680 Sail Switch Use 37716 ✗ ✗ Motor 34039 Capacitor 38223 Motor AC 37696 Motor PF 20076Q ✗ ✗ 37697 Motor PF 23199Q 37698 Motor PF 26157Q 37964 Motor PF 26170Q 38554 Motor PF 23211Q 37646 Motor Clamp ✗ ✗ 37602 Motor Lock Bracket 37603 Motor Lock Bracket 37604 Motor Lock Bracket ✗ ✗ 37801 Motor Mounting Wall Kit ✗ ✗ Relay 31017 Klixon Relay ✗ ✗ Thermostats 38453 Thermostat (white) Heat only HFH-2000 ✗ ✗ 38452 Thermostat (brown) Heat only HFH-2000 ✗ ✗ 38535 Thermostat, Digital, 2-Stage 2H2C 38555 Thermostat, Digital, Single Stage 1H2C ✗ ✗ 38291 Thermostat Valves 37383 Valve, W/R 25M16V-711 ✗ ✗ 37384 Valve W/R 25M18-711 37973 2-Stage Valve W/R 25M05V-701 38564 2-Stage Valve W/R 25M05V-702 37613 Valve Bracket ✗ ✗ 33475 White Rodgers Coil ✗ ✗ Wires 37987 Field Plug Assembly 36290 Field Plug Assembly ✗ ✗ 36327 Field Plug Asbly Special (Holiday Rambler) ✗ ✗ 37419 High Tension Wire ✗ ✗ 37773 Shielded High Tension Wire (optional) No Longer Available 85-IV 25 85-IV 20 85-IV 16 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 85-IV 35 1522 2-stage 2334 2-stage ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ R-25 85-IV 31 85-IV 20 No Longer Available ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 85-IV 25 Miscellaneous 37844 Air Intake Tube 32882 Door Screen 31474 Duct Adapter 4” 36688 Duct Adapter 2” 31361 Duct Cover Plate 37410 Gas Inlet Plug 37411 Slide Plate 38248 Transformer 85-IV 16 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ 48 49 ✗ ✗ ✗ ✗ ✗ 2540 2-Stage ✗ 89-III AC 85-III 31-35 ✗ 89-III DC 85-III 25 Blower 33580 Blower Cover 34014 Blower Cover 35881 Blower Wheel ✗ ✗ 33431 Blower Wheel ✗ 34550 Blower Wheel 33126 Blower Wheel Kit Burner 36043 Burner ✗ ✗ ✗ 32811 Burner 33842 Burner 35491 Burner 36147 Secondary Air Baffle 7920 & 7916 (after S/N 0651157) ✗ 36438 Secondary Air Baffle 7916 (before S/N 0651156) ✗ 36258 Secondary Air Baffle 7912, 8012 ✗ ✗ Burner Orifices 31257 #56 16,000 BTU ✗ 31265 1.25 MM 18,000 BTU ✗ 36218 #60 12,000 BTU (before S/N 0651156) No Longer Available 37389 #62 12,000 BTU (after S/N 0651155) ✗ ✗ 31267 #54 25,000 BTU 31280 #52 31,000 BTU 32285 #51 35,000 BTU 34004 #49 40,000 BTU 34092 #30 40,000 BTU NAT. 34093 #32 35,000 BTU NAT. Circuit Board 37966 Controller Module 37984 Controller Module Bracket 37515 Ignition Board Kit (AC) 36716 Ignition Board Kit (DC) ✗ ✗ ✗ 38676 Ignition Board Retrofit Kit (with fan control) ✗ ✗ ✗ 33686 Ignition Bracket 37965 Ignition Module 36119 Ign. Plate Metal (before S/N 1165563) ✗ ✗ ✗ 37951 Ign. Plate Plastic (after S/N 1165562) ✗ ✗ ✗ Circuit Breakers 35791 Breaker 5 AMP ✗ ✗ ✗ 37049 Combination Breaker-ON/OFF Switch 5 AMP USE 35791 32331 Breaker 7 AMP Use 33751 33780 Breaker Kit 7 AMP 33590 Breaker 10 AMP 33781 Breaker Kit 10 AMP 34034 Breaker 15 AMP 33782 Breaker Kit 15 AMP 38507 Breaker 20 AMP 34015 Breaker 20 AMP (without door circuit breaker on/off) 85-III 16-20 8012-II 7900-II 16 & 20 7912-II hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 50 85-III 16-20 85-III 25 85-III 31-35 89-III DC 89-III AC 2540 2-Stage Combustion 35892 Combustion Air Hose ✗ ✗ 33128 Combustion Wheel Kit 33124 Combustion Wheel Kit ✗ ✗ 36216 Metal Combustion Wheel 8535-III Use 37107 Door 37912 1/4 Turn Nylatch ✗ ✗ 36644 Access Grill (Screw-In) No Longer Available 37520 Access Grill (1/4 turn fastener) ✗ ✗ 37864 Access Grill (1/4 turn Artic White) No Longer Available 37760 Clip on Receptacle ✗ ✗ 31145 Roller Door Catch ✗ ✗ Draft Cap 33650 Draft Cap Assembly Adjustable NLA USE 37619 38141 Draft Cap 3/8” baffle 38139 Draft Cap 5/8” baffle Electrodes 37517 Electrode - single sense ✗ ✗ 37176 Electrode - single sense (or sub 36999) 37057 Electrode - single sense 36998 Electrode - dual sense ✗ ✗ 36999 Electrode - dual sense 36997 Electrode - dual sense 37079 Electrode Cover Plate (Single Sense) ✗ ✗ 36044 Electrode Cover Plate (Dual Sense) ✗ ✗ Gaskets 35890 Burner Plate Gasket (use 2) ✗ ✗ 32172 Electrode Gasket Dual Sense ✗ ✗ 37100 Electrode Gasket Single Sense ✗ ✗ 34053 Element Wall Gasket (before SN1259907) 37956 Element Wall Gasket (after SN1259906) 32926 Heating Element Gasket 32841 Motor Gasket 37661 Motor Gasket ✗ ✗ Heating Element 35903 Heating Element ✗ ✗ 37960 Heating Element Kit* 16, 20, 37961 Heating Element Kit* 25 37962 Heating Element Kit* 31, 35 34976 Heating Element *Kit includes draft cap & element gasket Manifolds 33565 Inlet Manifold (before S/N 0654748) 37392 Outlet Manifold (after S/N 0654747) 36376 Inlet Manifold (before S/N 0657716) 37392 Outlet Manifold (after S/N 0657715) 37391 Outlet Manifold (after S/N 0651155) ✗ ✗ 8012-II 7900-II 16 & 20 7912-II hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 8940 8935 8940 8935 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 51 ✗ ✗ ✗ ✗ ✗ ✗ ✗ 2540 2-Stage ✗ 89-III AC 85-III 31-35 ✗ 89-III DC 85-III 25 ✗ 85-III 16-20 33566 Outlet Manifold (before S/N 0654748) 35936 Outlet Manifold (before S/N 0651156) No Longer Available 31043 Brass Inlet Fitting ✗ ✗ Use with Part #’s 37392/37391 32173 Brass Inlet Elbow (before S/N 0654748) Motor 35122 Motor AC 34039 Motor Capacitor AC 36122 Motor PF20066Q 31036 Motor PF20040Q ✗ ✗ 37964 Motor PF26170Q 37360 Motor Bracket Kit 35879 Motor Bracket ✗ ✗ 37359 Motor Kit PF20076Q 37358 Motor Kit PF23190Q 37357 Motor Kit PF26157Q Relay 31017 Klixon Relay ✗ ✗ Switches 37021 Limit Switch L77 / 170° ✗ ✗ 37022 Limit Switch L190° 36121 ON-OFF Switch ✗ ✗ 36133 Sail Switch ✗ ✗ 36134 Sail Switch 36680 Sail Switch (May Use 37716) NLA USE 37716 35054 Sail Switch 35050 Sail Switch 35137 Sail Switch (May Use 37716) NLA USE 37716 36040 Sail Switch Bracket ✗ ✗ Thermostats 38452 Thermostat (brown) Heat Only HFH-2000 ✗ ✗ 38453 Thermostat (white) Heat Only HFH 2000 ✗ ✗ 38535 Thermostat, Digital, 2 Stage 2H2C 38555 Thermostat, Digital, Single Stage 1H2C ✗ ✗ Valve 36035 White Rodgers 25M16-503 Side Port ✗ ✗ (before S/N 0651156) 37383 White Rodgers Side Outlet ✗ ✗ (after S/N 0651155) 25M16V-711 33475 White Rodgers Coil (DC) ✗ ✗ 36036 White Rodgers Valve Bracket ✗ ✗ (Use with Part #’s 36035) 37390 White Rodgers Valve Bracket ✗ ✗ (Use with Part #’s 37383) 33337 White Rodgers (before S/N 0654748-85 series) 25M16V-701 (before S/N 0657716-89 series) 37383 White Rodgers Side Outlet (After Serial #0654747) 25M16V-711 33586 White Rodgers Valve Bracket (Use with Part # 33337) 37426 White Rodgers Valve Bracket (Use with Part # 37383) 8012-II 7900-II 16 & 20 7912-II hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 37383 White Rodgers Valve (DC) (After Serial #0657715) 34006 White Rodgers Valve (AC) (Before Serial #0657716) 25M18V-701 37384 White Rodgers Valve (AC) (After Serial #0657715) 25M18V-711 34515 White Rodgers Coil (AC) 37973 2-Stage Gas Valve W/R 25M05V-701 Vent Kit 35955 79A-II 4 inch ✗ ✗ ✗ 35956 79B-II 8 inch ✗ ✗ ✗ 35957 79C-II 12 inch ✗ ✗ ✗ Wires 37987 Field Plug Assembly 36290 Field Plug Assembly 34116 High Tension Lead ✗ ✗ ✗ 35193 High Tension Lead (before S/N 0654748) 37419 High Tension Lead (after S/N 0654747) 35193 High Tension Lead (before S/N 0657716) 37419 High Tension Lead (after S/N 0657715)) 37773 Optional Shielded (before S/N 0654747) No Longer Available 37773 Optional Shielded (after S/N 0657715) No Longer Available 36180 Wiring Harness Complete (internal) 36875 Wiring Harness Complete DC 37443 Wiring Harness Complete AC Miscellaneous 35121 24 VAC Transformer 36412 Casing Assembly ✗ ✗ 36175 Control Box (Before Serial #0654748) No Longer Available 37427 Control Box (After Serial #0654747) No Longer Available 35912 Control Box ✗ ✗ ✗ 37431 Control Box 36959 Directional Air Box Insert ✗ ✗ ✗ 31474 Duct Adapter 4” ✗ ✗ ✗ 36688 Duct Adapter 2” ✗ ✗ ✗ 31361 Duct Cover Plate ✗ ✗ ✗ 33567 Gas Inlet Plug (Before Serial #0654748) 37410 Gas Inlet Plug (After Serial #0654747) 33567 Gas Inlet Plug (Before Serial #0657716) 37410 Gas Inlet Plug (After Serial #0657715) 33729 Slide Plate (Before Serial #0654748) 37411 Slide Plate (After Serial #0654747) 33729 Slide Plate (Before Serial #0657716) 37442 Slide Plate (After Serial #0657715) 52 2540 2-Stage 89-III AC 89-III DC 85-III 31-35 85-III 25 85-III 16-20 8012-II 7900-II 16 & 20 7912-II hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 53 89-II AC ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ HF 80P ✗ ✗ HF 80D ✗ ✗ FA79P ✗ 89-II DC 89-I AC ✗ FA 79D Blower 33580 Blower Cover ✗ ✗ ✗ 33431 Blower Wheel 33618 Blower Wheel ✗ ✗ 33619 Blower Wheel ✗ 34550 Blower Wheel Burner 32149 Burner No Longer Available 32811 Burner ✗ 33842 Burner ✗ ✗ 34000 Burner (Use Kit 38548) 35491 Burner Burner Orifice 31268 #59 12,000 BTU 31257 #56 16,000 BTU ✗ 31265 1.25 MM 20,000 BTU 31267 #54 25,000 BTU ✗ 31280 #52 31 & 32,000 BTU ✗ 32285 #51 35,000 BTU ✗ 34004 #49 40,000 BTU 34093 #32 35,000 BTU NAT 34092 #30 40,000 BTU NAT Circuit Board 33686 Ignition Board Bracket ✗ ✗ ✗ 37515 Ignition Board Kit (AC) 36716 Ignition Board Kit (DC) ✗ ✗ ✗ Circuit Breaker 31028 Breaker 5 AMP ✗ 32331 Breaker 7 AMP (Use 33751) ✗ 33590 Breaker 10 AMP ✗ 34034 Breaker 15 AMP Combustion 31881 Combustion Air Hose 33124 Combustion Wheel Kit 33128 Combustion Wheel Kit ✗ ✗ ✗ Door 33753 Deluxe Door 01 White ✗ ✗ ✗ 33754 Deluxe Door 02 Colonial White ✗ ✗ ✗ 33756 Deluxe Door 04 White ✗ ✗ ✗ 33763 Deluxe Door 11 White ✗ ✗ ✗ 33764 Deluxe Door 12 Beige No Longer Available ✗ ✗ ✗ 35001 Deluxe Door 18 Grey ✗ ✗ ✗ 35057 Deluxe Door 20 Grey ✗ ✗ ✗ 35101 Deluxe Door 22 White ✗ ✗ ✗ 35102 Deluxe Door 23 White ✗ ✗ ✗ 89-I DC 85-II 31-35 85-II 25 85-II 16-20 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 89-II DC 89-II AC ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ HF 80P 89-I AC ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ HF 80D 89-I DC ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ FA79P 85-II 31-35 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ FA 79D 85-II 25 33853 Recess Pan 01 White 33854 Recess Pan 02 Colonial White 33856 Recess Pan 04 White 33863 Recess Pan 11 White 35063 Recess Pan 12 Grey 35104 Recess Pan 22 White 35105 Recess Pan 23 White 33847 Door Catch Screw Type (set) 33620 Door Hinge - inner (set) 31145 Roller Door Catch Draft Cap 34032 Draft Cap Assembly - AC NLA (Use 37890) 34030 Draft Cap Assembly - DC NLA (Use 37890) 36980 Draft Cap Assembly NLA (USE 37619) Electrodes 33234 Electrode 36999 Electrode 34001 Electrode (Use 38548) 36997 Electrode 36998 Electrode Exhaust Tube Extensions 31680 79/80A (0˝ - 3-1/2˝) NLA Gaskets 34451 Bottom Discharge Gasket 34553 Bottom Discharge Gasket 31842 Burner Plate Gasket 31843 Burner Plate Gasket 33485 Combustion Gasket Set 32172 Electronic Ignition Electrode Gasket 32926 Element Gasket 34053 Element Wall Gasket 32841 Motor Gasket Heating Elements 34976 Heating Element 37960 Heating Element Kit* 37961 Heating Element Kit* 37962 Heating Element Kit* *Kit includes draft cap & element gasket Motor 34039 Motor Capacitor AC 35122 Motor 7162-2839E AC 31035 Motor PF2041Q 31036 Motor PF2040Q 32774 Motor PF23175Q 33219 Motor PF2055Q 33589 Motor PF23144Q 32870 Motor Bracket 37357 Motor Kit 85-II 16-20 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 54 ✗ FA 79D FA79P HF 80D HF 80P 89-II AC 89-II DC 89-I AC 89-I DC 85-II 31-35 85-II 25 85-II 16-20 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ Pilot 32466 1/4 x 7 Pilot Tube w/ fittings 33830 Jade Orifice .008 31307 Jade Thermal Couple 14˝ 33831 Jade Pilot Assembly J721013CLP (Use 31299) 36038 Piezo Igniter Kit Relay 31017 Klixon Relay ✗ ✗ ✗ Switches 31023 Limit Switch L170 35132 Limit 130 Switch ✗ ✗ ✗ 37021 Limit Switch L77-C 35047 Sail Switch 35050 Sail Switch ✗ 36680 Sail Switch (Use 37716) ✗ 35054 Sail Switch ✗ 35137 Sail Switch (Use 37716) 36205 Thermal Cut-Off 8900-II Thermostat 38452 Thermostat (brown) heat only ✗ ✗ ✗ 38453 Thermostat (white) heat only ✗ ✗ ✗ Valve 33716 ITT Valve Retrofit Kit (pilot) 33796 ITT/FEN Valve Retrofit Kit (Electronic Ignition) 32697 Robertshaw Valve 7000 ERLC-LP 33337 White Rodgers Valve 25M16-701 (DC) ✗ ✗ ✗ 33475 White Rodgers Coil (DC) ✗ ✗ ✗ 34006 White Rodgers Valve 25M18-701 (AC) 34515 White Rodgers Coil (AC) Wires 31090 High Tension Lead No Longer Available 33661 High Tension Lead No Longer Available 35193 High Tension Lead 35235 Wiring Harness Blower AC Miscellaneous 35121 24 VAC Transformer 31361 Duct Cover Plate ✗ ✗ ✗ 31474 Duct Adapter ✗ ✗ ✗ 33567 Gas Inlet Plug ✗ ✗ ✗ 33729 Slide Plate ✗ ✗ ✗ 55 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 56 ✗ ✗ FA 72P ✗ FA 72D ✗ FA 78 25-32 AC 82 ✗ FA 76D DC82 35-41 Blower 31135 Blower Wheel NLA 31139 Blower Wheel 32775 Blower Wheel ✗ ✗ 32776 Blower Wheel ✗ Burner 32002 Burner 32112 Burner 32149 Burner No Longer Available 32811 Burner ✗ ✗ ✗ Burner Orifice 31270 #66 Orifice 31268 #59 Orifice 31257 #56 16,000 BTU ✗ 31265 1.25mm 18,000 BTU ✗ 31267 #54 25,000 BTU ✗ 31280 #52 31 &32,000 BTU ✗ 32285 #51 35,000 BTU ✗ 31256 #50 41,000 BTU 32284 #40 35,000 BTU NAT 32238 #36 41,000 BTU NAT Circuit Breaker 31028 Breaker 5 AMP ✗ 32331 Breaker 7 AMP (Use 33751) ✗ 33590 Breaker 10 AMP ✗ Circuit Board 36716 Ignition Board Kit (DC) ✗ ✗ ✗ 37515 Ignition Board Kit (AC) Combustion 33124 Combustion Wheel Kit ✗ ✗ 31138 Combustion Wheel No Longer Available 32777 Combustion Wheel NLA (Use 37107) ✗ Electrodes 33234 Electrode 33235 Electrode 33625 Electrode Kit ✗ ✗ ✗ 36999 Electrode Only ✗ ✗ ✗ Gaskets 34551 Bottom Discharge Gasket 34553 Bottom Discharge Gasket ✗ ✗ ✗ 31838 Burner Plate Gasket 32762 Burner Plate Gasket 33485 Combustion Gasket Set 32172 Electronic Ignition Electrode Gasket ✗ ✗ ✗ 32926 Element Gasket ✗ ✗ ✗ 31841 Manifold Gasket 32841 Motor Gasket ✗ ✗ ✗ Heating Elements 32118 Heating Element Assembly 32119 Heating Element Assembly DC82 25-32 85-I 31-35 85-I 25 85-1 16-20 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ 57 FA 72P FA 78 25-32 FA 76D AC 82 DC82 35-41 FA 72D Motor 31039 Motor JA25065N (AC) 31036 Motor PF2040Q 31037 Motor PE2423Q 31038 Motor PE2627Q 32330 Motor PF23129Q 32774 Motor PF23175Q ✗ ✗ 33219 Motor PF2055Q ✗ 32870 Motor Bracket ✗ ✗ ✗ Pilot 31292 ITT Pilot Assembly 26C1762 33829 ITT TV Orifice .010 32417 ITT TV Orifice .008 31299 Jade Pilot Assembly J72C2426CL 32416 Jade Orifice .010 31307 Jade Thermocouple 14˝ 32480 Jade Thermocouple 18˝ Relay 31017 Klixon Relay ✗ ✗ ✗ Switch 31023 Limit 170 Switch 31025 Limit 190 Switch w/plate 32927 Limit 190 Switch ✗ ✗ ✗ 35282 Sail Switch ✗ ✗ ✗ 33697 Sail Switch Thermostat 38452 Thermostat (brown) heat only ✗ ✗ ✗ 38453 Thermostat (white) heat only ✗ ✗ ✗ Valves 33717 ITT Valve Retrofit Kit (pilot 33688 ITT/FEN Valve Retrofit Kit (DSI) 33797 ITT/FEN Valve Retrofit Kit (DSI) 33806 ITT/FEN Valve Retrofit Kit (DSI) 36728 Johnson Valve Retrofit Kit (DSI) (AC) 33475 White Rodgers Coil ✗ ✗ ✗ 33337 White Rodgers Valve 25M16-701 ✗ ✗ ✗ Wire 32139 Field Hookup 32140 Field Hookup Miscellaneous 32475 12 VDC Converter 31480 24 VAC Transformer (Use 33784) 31831 Door Interior 33774 Door Catch Assemblies No Longer Available 31474 Duct Adapter ✗ ✗ ✗ 31361 Duct Cover Plate ✗ ✗ ✗ 32137 Exhaust Tube Ext. 82F (6.5˝-8.5˝) 32133 Vent Shell (only) 82BE (3.5˝-6.5˝) 32134 Vent Shell (only) 82AD (0˝-3.5˝) DC82 25-32 85-I 31-35 85-I 25 85-1 16-20 hydro flame Furnace REPLACEMENT PART REFERENCE September 2002 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ Atwood Furnace Installation Parts Series 85 and 2-Stage Furnaces Part # Appearance Description 34438 Floor plate and (3) adapters for 4" ducts to rear of furnace. 36278 Adapter plate for bottom discharge - with foam seals on both sides. 36277 Adapter plate for bottom discharge - no seals but with alignment tabs. Use with gasket 34551. 37745 Adapter plate for bottom discharge - same as 36277 except includes foam seals on both sides. 37878 Extension plenum, rear discharge to floor duct with two seals. 33150 Extension plenum, rear discharge to floor duct with one seal. 37868 Adapter plate for bottom discharge from extension plenum. No seals but with alignment tabs. Use with extension plenum 33150 or 37878. 58
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