Trane Gas Unit Heaters Installation And Maintenance Manual GMND SVX01B EN 03/16/2012 Installation, Operation, Heater Separated Combustion Indoor Fired Duc

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SAFETY WARNING

Only qualified personnel should install and service the equipment. The installation, starting up, and

servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific

knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could

result in death or serious injury. When working on the equipment, observe all precautions in the literature

and on the tags, stickers, and labels that are attached to the equipment.

Gas Unit Heater

Separated Combustion Indoor Gas-Fired Duct Furnace

March 2012 GMND-SVX01B-EN

Installation, Operation,

and Maintenance

Warnings, Cautions and Notices

Warnings, Cautions and Notices. Note that warnings,

cautions and notices appear at appropriate intervals

throughout this manual. Warnings are provide to alert

installing contractors to potential hazards that could result

in death or personal injury. Cautions are designed to alert

personnel to hazardous situations that could result in

personal injury, while notices indicate a situation that

could result in equipment or property-damage-only

accidents.

Your personal safety and the proper operation of this

machine depend upon the strict observance of these

precautions.

Read this manual thoroughly before operating or servicing

this unit.

Important

Environmental Concerns!

Scientific research has shown that certain man-made

chemicals can affect the earth’s naturally occurring

stratospheric ozone layer when released to the

atmosphere. In particular, several of the identified

chemicals that may affect the ozone layer are refrigerants

that contain Chlorine, Fluorine and Carbon (CFCs) and

those containing Hydrogen, Chlorine, Fluorine and

Carbon (HCFCs). Not all refrigerants containing these

compounds have the same potential impact to the

environment. Trane advocates the responsible handling of

all refrigerants-including industry replacements for CFCs

such as HCFCs and HFCs.

Responsible Refrigerant Practices!

Trane believes that responsible refrigerant practices are

important to the environment, our customers, and the air

conditioning industry. All technicians who handle

refrigerants must be certified. The Federal Clean Air Act

(Section 608) sets forth the requirements for handling,

reclaiming, recovering and recycling of certain

refrigerants and the equipment that is used in these

service procedures. In addition, some states or

municipalities may have additional requirements that

must also be adhered to for responsible management of

refrigerants. Know the applicable laws and follow them.

ATTENTION: READ THIS MANUAL AND ALL LABELS

ATTACHED TO THE UNIT CAREFULLY BEFORE

ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE

UNITS! CHECK UNIT DATA PLATE FOR TYPE OF GAS AND

ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT

THESE AGREE WITH THOSE AT POINT OF INSTALLATION.

RECORD THE UNIT MODEL AND SERIAL No.(s) IN THE

SPACE PROVIDED. RETAIN FOR FUTURE REFERENCE.

ATTE NT ION : Warnings, Cautions and Notices appear at

appropriate sections throughout this literature. Read

these carefully:

WARNING Indicates a potentially hazardous

situation which, if not avoided, could

result in death or serious injury.

CAUTIONsIndicates a potentially hazardous

situation which, if not avoided, could

result in minor or moderate injury. It

could also be used to alert against

unsafe practices.

NOTICE: Indicates a situation that could result in

equipment or property-damage only

WARNING

Proper Field Wiring and Grounding

Required!

All field wiring MUST be performed by qualified

personnel. Improperly installed and grounded field

wiring poses FIRE and ELECTROCUTION hazards. To

avoid these hazards, you MUST follow requirements for

field wiring installation and grounding as described in

NEC and your local/state electrical codes. Failure to

follow code could result in death or serious injury.

WARNING

Personal Protective Equipment (PPE)

Required!

Installing/servicing this unit could result in exposure to

electrical, mechanical and chemical hazards.

• Before installing/servicing this unit, technicians

MUST put on all Personal Protective Equipment (PPE)

recommended for the work being undertaken.

ALWAYS refer to appropriate MSDS sheets and OSHA

guidelines for proper PPE.

• When working with or around hazardous chemicals,

ALWAYS refer to the appropriate MSDS sheets and

OSHA guidelines for information on allowable

personal exposure levels, proper respiratory

protection and handling recommendations.

• If there is a risk of arc or flash, technicians MUST put

on all Personal Protective Equipment (PPE) in

accordance with NFPA 70E or other country-specific

requirements for arc flash protection, PRIOR to

servicing the unit.

Failure to follow recommendations could result in death

or serious injury.

Warnings, Cautions and Notices

GMND-SVX01B-EN 3

Trademarks

Trane and the Trane logo are trademarks of Trane in the

United States and other countries. All trademarks

referenced in this document are the trademarks of their

respective owners.

3M is a trademark of 3M Company; Dow Corning is a

registered trademark of Dow Corning Corporation.

WARNING

Hazardous Service Procedures!

The maintenance and troubleshooting procedures

recommended in this manual could result in exposure

to electrical, mechanical or other potential safety

hazards. Always refer to the safety warnings provided

throughout this manual concerning these procedures.

When possible, disconnect all electrical power

including remote disconnect and discharge all energy

storing devices such as capacitors before servicing.

Follow proper lockout/tagout procedures to ensure the

power can not be inadvertently energized. When

necessary to work with live electrical components,

have a qualified licensed electrician or other individual

who has been trained in handling live electrical

components perform these tasks. Failure to follow all of

the recommended safety warnings provided, could

result in death or serious injury.

WARNING

Overheating or Flooding Could Cause Fire

or Explosion!

Overheating or flooding (where any part of the duct

furnace has been under water) could result in fire or

explosion. Should overheating occur, or the gas supply

fails to shut off, shut off the manual gas valve to the

duct furnace before shutting off the electrical supply.

Do not use the duct furnace if any part has been under

water. Immediately call a qualified service technician to

inspect the duct furnace and replace any gas control

which has been underwater. Failure to follow these

recommendations could result in death or serious

injury.

WARNING

Hazardous Gases and Flammable

Vapors!

Exposure to hazardous gases from fuel substances

have been shown to cause cancer, birth defects or

other reproductive harm. Improper installation,

adjustment, alteration, service or use of this product

could cause flammable mixtures. To avoid hazardous

gases and flammable vapors follow proper

installation and set up of this product and all

warnings as provided in this manual. Failure to follow

all instructions could result in death or serious injury.

4GMND-SVX01B-EN

Introduction

For Your Safety

The use and storage of gasoline or other flammable

vapors and liquids in open containers in the vicinity

of this appliance is hazardous.

If you smell gas:

1. Open windows.

2. Do not touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

Approved For Use in California

Installer’s Responsibility

Installer Please Note: This equipment has been test fired

and inspected. It has been shipped free from defects from

our factory. However, during shipment and installation,

problems such as loose wires, leaks, or loose fasteners

may occur. It is the installer’s responsibility to inspect and

correct any problems that may be found.

Receiving Instructions

Inspect shipment immediately when received to

determine if any damage has occurred to the unit during

shipment. After the unit has been uncrated, check for any

visible damage to the unit. If any damage is found, the

consignee should sign the bill of lading indicating such

damage and immediately file claim for damage with the

transportation company.

Important: It is the equipment owner’s responsibility to

provide any scaffolding or other apparatus

required to perform emergency service or

annual/periodic maintenance to this

equipment.

WARNING

Safety Alert!

You MUST follow all recommendations below. Failure

to do so could result in death or serious injury.

WARNING

Toxic Hazard!

Install, operate and maintain unit in accordance with

manufacturer’s instructions to avoid exposure to fuel

substances or substances from incomplete combustion

which could result in death or serious illness. The state

of California has determined that these substances may

cause cancer, birth defects, or other reproductive harm.

Table of Contents

GMND-SVX01B-EN 5

Warnings, Cautions and Notices . . . . . . . . . . 2

Model Number Descriptions . . . . . . . . . . . . . . 6

Indoor Gas Heating Units . . . . . . . . . . . . . . . 6

Horizontal Blower Assembly . . . . . . . . . . . . 6

General Information . . . . . . . . . . . . . . . . . . . . . 7

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Safety Information . . . . . . . . . . . . . 7

Identification of Parts . . . . . . . . . . . . . . . . . . 8

Unit Dimensions and Weights . . . . . . . . . . . 10

Installation: Mechanical . . . . . . . . . . . . . . . . . 12

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Suspension . . . . . . . . . . . . . . . . . . . . . . . . 14

Nozzle Assembly . . . . . . . . . . . . . . . . . . . 14

Installation: Piping . . . . . . . . . . . . . . . . . . . . . . 16

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pipe Sizing . . . . . . . . . . . . . . . . . . . . . . . . 16

Pipe Installation . . . . . . . . . . . . . . . . . . . . . . 17

Installation: Venting . . . . . . . . . . . . . . . . . . . 18

Combustion Air Venting and Piping . . . . 18

Exhaust Venting . . . . . . . . . . . . . . . . . . . . 19

Installation: Concentric Vent Terminal . . . 21

Horizontal Termination . . . . . . . . . . . . . . 21

Vertical Termination . . . . . . . . . . . . . . . . . 22

Installation: Electrical . . . . . . . . . . . . . . . . . . . 24

Electrical Connections . . . . . . . . . . . . . . . . . 24

Thermostat Wiring and Location . . . . . . 24

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Gas Equipment Start-Up . . . . . . . . . . . . . . . 30

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Periodic Service . . . . . . . . . . . . . . . . . . . . 31

Installation Instructions for Field Replace-

ment of Power Venter Motor . . . . . . . . . . 33

How to Order Replacement Parts . . . . . . 34

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 35

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . .39

6 GMND-SVX01B-EN

Model Number Descriptions

Indoor Gas Heating

Units

Note: All units are AGA approved. For

CGA approved units, contact Air

Handling Product Support.

Digit 1 — Gas Heating

Equipment

G = Gas Heating Equipment

Digit 2 — Product Type

M = Separated Combustion Indoor

Duct Furnace

Digit 3 — Fuel

N= Natural Gas

P=LP Gas (Propane)

Digit 4 — Development

Sequence

D = Fourth Generation

Digits 5, 6, 7 — Input Capacity

Single Furnace

Digit 8 — Main Power Supply

Digit 9 — Gas Control Option

D = Single-Stage, Intermittent Pilot

Ignition

E = Two-Stage, Intermittent Pilot

Ignition

H = Electronic Modulating with

Room

T-Stat, Intermittent Pilot Ignition

J = Electronic Modulating with

Duct-Stat, Intermittent Pilot

Ignition

L = Electronic Modulating with

External 4–20 mA Input

N = Electronic Modulating with

External 0–10 Vdc Input

T = Single Stage Direct Spark

Ignition

V = Two-Stage, Direct Spark Ignition

Digit 10 — Design Sequence

G = Seventh Design

Digit 11 — Heat Exchanger

Material

1 = Aluminized Steel

3 = #321 Stainless Steel

Digit 12 — Rooftop

Arrangements

0 = None (Indoor Unit)

Digit 13 — Rooftop Heating Unit

Motor Selection

0 = None (Indoor Unit and Rooftop

Duct Furnace)

Digit 14 — Rooftop Fan Section

0 = None (Indoor Unit and Rooftop

Duct Furnace)

Digit 15 — Miscellaneous

Options

0=None

A = #409 Stainless Steel Burners

B = Orifices For Elevation Above

2000 Feet (Specify Elevation)

C = #409 Stainless Steel Draft

Diverter

D = Summer-Winter Switch

F = Horizontal Louvers

G = Horizontal and Vertical Louvers

Horizontal Blower

Assembly

Digit 1, 2, 3 — Horizontal

Blower Assembly

Digit 4 — Development

Sequence

C = Third Generation

Digit 5, 6 — Blower Size

15 = Nominal 1500 cfm

20 = Nominal 2000 cfm

30 = Nominal 3000 cfm

45 = Nominal 4500 cfm

Digit 7 — Transition Size

(Specifies Duct Furnace Size)

Digit 8 — Main Power Supply

Digit 9 — Motor Horsepower

Digit 10 — Design Sequence

D = Fourth Design

Digit 11 — Miscellaneous

Options

0=None

1 = Insulation

3 = Totally Enclosed Motor

010 = 100 MBh 022 = 225 MBh

012 = 125 MBh 025 = 250 MBh

015 = 150 MBh 030 = 300 MBh

017 = 175 MBh 035 = 350 MBh

020 = 200 MBh 040 = 400 MBh

A = 115/60/1 D = 230/60/3

B = 230/60/1 E = 460/60/3

C = 208/60/3 F = 575/60/3

0 = None

A = 100 MBh F = 225 MBh

B = 125 MBh G = 250 MBh

C = 150 MBh H = 300 MBh

D = 175 MBh J = 350 MBh

E=200 MBh K=400 MBh

A = 115/60/1 D = 230/60/3

B = 230/60/1 E = 460/60/3

C = 208/60/3

A = 1/3 hp D = 1 hp

B = 1/2 hp E = 1-1/2 hp

C = 3/4 hp F = 2 hp

GMND-SVX01B-EN 7

General Information

Description

The duct furnace design is certified by ETL for use with

natural and LP (propane) gases. ANSI and NFPA Standards

as well as Canadian installation codes referred to in this

manual are the ones that were applicable at the time that

the design was certified. In addition, the duct furnace may

be installed on the downstream side of a cooling coil,

without need of a bypass duct.

If the unit is to be installed at an altitude exceeding

2,000 feet (610 m) above sea level, derate the input by

4 percent for each 1,000 foot (305 m) rise above sea level.

Special orifices are required for installations above

2,000 feet (610 m).

When units are installed in Canada, any reference to

derations at altitudes in excess of 2000 feet (610 m) are to

be ignored. At altitudes of 2000 to 4500 feet (610 to

1372 m), the units must be orificed to 90 percent of the

normal altitude rating, and be so marked in accordance

with the ETL certification.

General Safety Information

Important: This product must be installed by a licensed

plumber or gas fitter when installed within

the Commonwealth of Massachusetts.

• Installation must be made in accordance with

local codes, or in absence of local codes with the

latest edition of ANSI Standard Z223.1 (N.F.P.A.

No. 54) National Fuel Gas Code.

All of the ANSI and NFPA Standards referred to

in these installation instructions are those that

were applicable at the time the design of this

appliance was certified. The ANSI Standards are

available from the American National Standards

Institute, INC.,11 West 42nd Street, New York,

NY., 10036 or www.ansi.org. The NFPA

Standards are available from the National Fire

Protection Association, Batterymarch Park,

Quincy, MA 02269. These duct furnaces are

designed for use in airplane hangars when

installed in accordance with current ANSI/NFPA

No. 409 and in public garages when installed in

accordance with current NFPA No. 88A and

NFPA No. 88B.

If installed in Canada, the installation must

conform with local building codes, or in absence

of local building codes, with CGA-B149.1

“Installation Codes for Natural Gas Burning

Appliances and Equipment” or CGA-B149.2

“Installation Codes for Propane Gas Burning

Appliances and Equipment”. These duct furnaces

have been designed and certified to comply with

CGA 2.6. Also see sections on installation in

“Aircraft Hangers,” p. 12 and “Public Garages,”

p. 12.

• Do not alter the duct furnace in any way or

damage to the unit and/or severe personal injury

or death could occur!

• Turn off the gas supply and disconnect all

electric power, including remote disconnects

before servicing unit. Follow proper lockout/

tagout procedures to ensure the power can not

be inadvertently energized and the gas can not

be inadvertently turned on. Failure to turn off

gas or disconnect power before servicing could

result in death or serious injury.

• Follow installation instructions CAREFULLY to

avoid creating unsafe conditions. All wiring

should be done and checked by a qualified

electrician, using copper wire only. All external

wiring must conform to applicable local codes

and to the latest edition of the National

Electrical Code ANSI/NFPA No. 70.

• All gas connections should be made and leak-

tested by a suitably qualified individual, per

instructions in this manual. Also follow

procedures listed in “Gas Equipment Start-Up,”

p. 30.

• Use only the fuel for which the duct furnace is

designed (see rating plate). Using LP gas in a

heater that requires natural gas, or vice versa,

will create the risk of gas leaks, carbon

monoxide poisoning and explosion.

Important: Do not attempt to convert the furnace

for use with a fuel other than the one

intended. Such conversion is

dangerous, as it could create the risks

listed previously.

• Make certain that the power source conforms to

the electrical requirements of the furnace.

• All field-installed wiring must be completed by

qualified personnel. All field-installed wiring

must comply with NEC and applicable local

codes. Failure to follow this instruction could

result in death or serious injuries.

• Special attention must be given to any

grounding information pertaining to this duct

furnace. To prevent the risk of electrocution, the

furnace must be securely and adequately

grounded. This should be accomplished by

connecting a grounded conductor between the

service panel and the furnace. To ensure a proper

WARNING

Safety Alert!

You MUST follow all recommendations below. Failure

to do so could result in death or serious injury.

General Information

8 GMND-SVX01B-EN

ground, the grounding means must be tested by

a qualified electrician.

• Do not insert fingers or foreign objects into the

furnace or its air moving device. Do not block or

tamper with the heater in any manner while in

operation or just after it has been turned off, as

some parts may be hot enough to cause injury.

• This furnace is intended for general heating

applications ONL

Y. It must NOT be used in

potentially dangerous locations such as

flammable, explosive, chemical-laden or wet

atmospheres.

• In cases in which property damage may result

from malfunction of the furnace, a backup

system or a temperature sensitive alarm should

be used.

• When connecting to existing gas lines be sure to

valve off the gas supply ahead of connection

point. To avoid explosion or possible fire, always

purge all residual gas from piping before cutting

into existing line or removing threaded fittings.

Failure to remove all gas vapors could result in

death or serious injury or equipment or property-

only-damage.

Unless otherwise specified, the following conversions

may be used for calculating SI unit measurements:

Identification of Parts

1 foot = 0.305 m 1 inch water column = 0.249 kPa

1 inch = 25.4 mm 1 meter/second = FPM ÷ 196.8

1 psig = 6.894 kPa 1 liter/second = CFM x 0.472

1 pound = 0.453 kg 1000 Btu per hour = 0.293 kW

1 gallon = 3.785 L 1000 Btu/Cu. Ft. = 37.5 MJ/m3

1 cubic foot = 0.028 m3

Figure 1. Combustion chamber

1. Gas valve

2. Main burners

3. Retainer spring

4. Air shutters

5. Pilot assy.

6. Manifold

General Information

GMND-SVX01B-EN 9

Figure 2. Internal furnace assembly

1. Flue Collector

2. Heat Exchanger

3. Burner Drawer

10 GMND-SVX01B-EN

Unit Dimensions and Weights

Table 1. Specification data: Separated Combustion Duct Furnace

Unit Size

A B C D (Dia.)(a)

Gas Inlet

in. Weight

in. (mm) in. (mm) in. (mm) in. (mm) Nat. LP lb (kg)

100 17-7/8 15-1/2 17-1/8 4 1/2 1/2 161

(454) (394) (435) (102) (73)

125 20-5/8 18-1/4 19-7/8 4 1/2 1/2 180

(524) (464) (505) (102) (82)

150 20-5/8 18-1/4 19-7/8 4 1/2 1/2 188

(524) (464) (505) (102) (85)

175 23-3/8 21 22-5/8 4 1/2 1/2 207

(594) (533) (575) (102) (93)

200 26-1/8 23-3/4 25-3/8 5 1/2 1/2 227

(664) (603) (645) (127) (103)

225 28-7/8 26-1/2 28-1/8 5 3/4 1/2 or 3/4 246

(733) (673) (714) (127) (116)

250 31-5/8 29-1/4 30-7/8 5 3/4 1/2 or 3/4 266

(803) (743) (784) (127) (121)

300 37-1/8 34-3/4 36-3/8 6 3/4 1/2 or 3/4 305

(943) (883) (924) (152) (138)

350 42-5/8 40-1/4 41-7/8 6 3/4 1/2 or 3/4 344

(1083) (1022) (1064) (152) (156)

400 48-1/8 45-3/4 47-3/8 6 3/4 1/2 or 3/4 383

(1222) (1162) (1203) (152) (174)

(a) “D” dia. equals the air inlet opening and the flue discharge opening.

Figure 3. Dimensions, standard units

Unit Dimensions and Weights

GMND-SVX01B-EN 11

Table 2. Performance data

Unit Size

Input

Output MIN Temp. Rise P.D. MAX Temp. Rise P.D.MAX MIN

MBh (kW) MBh (kW) MBh (kW) cfm (m3/s) °F (°C) in. of H2O (kPa) cfm (m3/s) °F (°C) in. of H2O (kPa)

100 100 50 80 822 90 0.10 3,700 20 2.03

(29.3) (14.6) (23.4) (0.388) (50) (0.02) (1.746) (11) (0.51)

125 125 62.5 100 1,028 90 0.09 4,625 20 1.92

(36.6) (18.3) (29.3) (0.485) (50) (0.02) (2.183) (11) (0.48)

150 150 75 120 1,233 90 0.09 5,550 20 1.81

(43.9) (22.0) (35.1) (0.582) (50) (0.02) (2.620) (11) (0.45)

175 175 87.5 140 1,439 90 0.09 6,475 20 1.86

(51.2) (25.6) (41.0) (0.679) (50) (0.02) (3.056) (11) (0.46)

200 200 100 160 1,645 90 0.09 7,401 20 1.90

(58.6) (29.3) (46.9) (0.776) (50) (0.02) (3.493) (11) (0.47)

225 225 112.5 180 1,850 90 0.09 8,326 20 1.93

(65.9) (32.9) (52.7) (0.873) (50) (0.02) (3.930) (11) (0.48)

250 250 125 200 2,056 90 0.09 9,251 20 1.96

(73.2) (36.6) (58.6) (0.970) (50) (0.02) (4.366) (11) (0.49)

300 300 150 240 2,467 90 0.10 11,101 20 2.00

(87.8) (43.9) (70.3) (1.164) (50) (0.02) (5.240) (11) (0.50)

350 350 175 280 2,878 90 0.10 12,951 20 2.02

(102.5) (51.2) (82.0) (1.358) (50) (0.02) (6.113) (11) (0.50)

400 400 200 320 3,289 90 0.10 14,801 20 2.05

(117.1) (58.6) (93.7) (1.552) (50) (0.02) (6.986) (11) (0.51)

Note: Ratings are shown for elevations up to 2,000 feet (610 m) above sea level. Above 2,000 feet (610 m), input must be derated 4 percent for each

1,000 feet (305 m) above sea level. When units are installed in Canada, any reference to derations at altitudes in excess of 2,000 feet (610 m) are

to be ignored. At altitudes of 2,000 to 4,500 feet (610 to 1,372 m), the units must be orificed to 90 percent of the normal altitude rating, and be so

marked in accordance with the ETL certification.

Figure 4. Temperature rise and pressure drop graph

12 GMND-SVX01B-EN

Installation: Mechanical

Note: Furnace sizing should be based on heat loss

calculations where the furnace output equals or

exceeds heat loss.

Aircraft Hangers. Separated Combustion must be

installed in aircraft hangars as follows: in aircraft hangars,

duct furnaces must be at least 10 feet (3.0 m) above the

upper surface of wings or engine enclosures of the highest

aircraft to be stored in the hangar, and 8 feet (2.4 m) above

the floor in shops, offices and other sections of the hangar

where aircraft are not stored or housed. In Canada,

installation is suitable in aircraft hangars when acceptable

to the enforcing authorities.

Public Garages. In repair garages, duct furnaces must

be installed in a detached building or room separate from

repair areas as specified in the latest edition of NFPA 88B,

Repair Garages.

In parking structures, duct furnaces must be installed so

that the burner flames are located a minimum of 18 inches

(457 mm) above the floor or protected by a partition not

less than 18 inches (457 mm) high. Refer to the latest

edition of NFPA 88A, Parking Structures.

In Canada, installation must be in accordance with the

latest edition of CGA B149 “Installation Codes for Gas

Burning Appliances and Equipment.”

Clearances

Note: Increasing the clearance distances may be

necessary if there is a possibility of distortion or

discoloration of adjacent materials.

Maintain adequate clearances around air openings into

combustion chamber:

NOTICE:

Equipment Damage!

Do not install duct furnaces in corrosive or flammable

atmospheres! Premature failure of, or severe damage to

the unit could result! Avoid locations where extreme

drafts can affect burner operation. Duct furnaces must

not be installed in locations where air for combustion

would contain chlorinated, halogenated or acidic

vapors. If located in such an environment, premature

failure of the unit could occur!

NOTICE:

Maintain Minimum Thermostat Setting!

Separated Combustion Duct Furnaces should not be

installed to maintain low temperatures and/or freeze

protection of buildings. A minimum of 50°F (10°C)

thermostat setting must be maintained. If duct furnaces

are operated to maintain lower than 50°F (10°C), hot

flue gases are cooled inside the heat exchanger to a

point where water condenses onto the heat exchanger

walls. The result is a mildly corrosive acid that

prematurely corrodes the aluminized heat exchanger

and can actually drip water down from the duct furnace

onto the floor surface. Additional duct furnaces should

be installed if a minimum 50°F (10°C) thermostat

setting cannot be maintained. Failure to follow these

recommendations could result in equipment or

property damage.

WARNING

Overheating or Flooding Could Cause Fire

or Explosion!

Overheating or flooding (where any part of the duct

furnace has been under water) could result in fire or

explosion. Should overheating occur, or the gas supply

fails to shut off, shut off the manual gas valve to the

duct furnace before shutting off the electrical supply.

Do not use the duct furnace if any part has been under

water. Immediately call a qualified service technician to

inspect the duct furnace and replace any gas control

which has been underwater. Failure to follow these

recommendations could result in death or serious

injury.

WARNING

Hazardous Gases and Flammable Vapors!

Exposure to hazardous gases from fuel substances

have been shown to cause cancer, birth defects or other

reproductive harm. Improper installation, adjustment,

alteration, service or use of this product could cause

flammable mixtures. To avoid hazardous gases and

flammable vapors follow proper installation and set up

of this product and all warnings as provided in this

manual. Failure to follow all instructions could result in

death or serious injury.

WARNING

Combustible Materials!

Maintain proper clearance between the unit heat

exchanger, vent surfaces, and combustible materials.

Refer to unit nameplate and installation instructions for

proper clearances. Improper clearances could result in a

fire hazard. Failure to maintain proper clearances could

result in death or serious injury or property damage.

Table 3. Minimum clearances

Sides 18” (457 mm)

Top 6” (152 mm)

Bottom 25” (635 mm)

Flue 6” (152 mm)

Note: When the clearances required for accessibility are greater than the

minimum required safety clearances, the accessibility clearances

take precedence.

Installation: Mechanical

GMND-SVX01B-EN 13

Increasing the clearance distances may be necessary if

there is a possibility of distortion or discoloration of

adjacent materials.

Accessibility

The Separated Combustion Duct Furnace is a bottom

service access type. Allow a minimum of 25 inches

(635 mm) at the bottom of the unit to facilitate servicing

the burners and pilot. Provision should also be made to

assure accessibility for recurrent maintenance purposes.

Atmospheres containing commercial solvents or

chlorinated hydrocarbons will produce corrosive acids

when coming in contact with the flames. This will greatly

reduce the life of the gas duct furnace and may void the

warranty. Avoid such areas.

The Separated Combustion Duct Furnace must be

installed on the positive pressure side of the air circulation

blower.

Ductwork

Properly designed and installed ductwork, providing a

uniformly distributed flow of air across the surfaces of the

heat exchanger, is essential to satisfactory unit

performance and life of the equipment.

All duct connection flanges/seams must be sealed to

prevent air leaks. Sealant/tape must be suitable for

temperatures 250°F (121°C) minimum.

If uniform air distribution is not obtained, install additional

baffles and/or turning vanes in the ductwork.

Figure 5 and Figure 6 illustrate recommended ductwork

designs for both the straight-through and elbowed air inlet

arrangements.

Access panels large enough to observe smoke and

reflected light, and to detect the presence of leaks in the

heating equipment, are required both upstream and

downstream from gas duct furnaces. These panels must

be sealed to prevent air leaks. If allowed by local

regulations, install canvas connectors between the

ductwork and fan discharge opening to eliminate the

transmission of sound.

Air Flow

The installation is to be adjusted to obtain an air

throughput within the range specified on the appliance

rating plate.

Bypass

When a gas duct furnace is installed to operate in

conjunction with a summer air conditioning system, the

cfm air delivery of the system blower should be adjusted

to meet the design air volume requirements for cooling. If

this cfm delivery is greater than that required for heating,

resulting in a low air temperature rise, install a damper

WARNING

Fire Hazard!

If the gas duct furnace is to be used in a building

classified as having a hazardous atmosphere, the

installation must comply with the standards set by the

National Board of Fire Underwriters. Consult the

authorities having jurisdiction before starting the job.

Failure to follow recommendations could result in

death or serious injury.

NOTICE:

Use 90° Duct Connection Flanges!

Ducts must be properly connected to duct furnaces for

operation. Do not straighten the 90° duct connection

flanges on the duct furnaces. Straightening the 90° duct

connection flanges will affect the operation of the

furnace and will void the warranty.

Figure 5. Recommended design for field installation of

ductwork for straight-through arrangement

Figure 6. Recommended ductwork design for elbowed

arrangement

Installation: Mechanical

14 GMND-SVX01B-EN

bypass around the gas duct furnace to bypass a portion of

the air.

Suspension

Nozzle Assembly

Use the following procedure for assembling the 30-, 60-, or

90-degree nozzle assembly to your unit heater.

1. Remove the louvers and the cone springs from the unit

heater.

2. Remove the four (4) screws from the upper section of

the front of the unit heater and use these same screws

to temporarily attach the top bracket

(P/N 252-07948-00X).

a. Using the holes in the top bracket as a guide, pre-

drill a 1/8” (0.125”) hole at each location across the

front panel of the unit heater.

b. Using the enclosed screws, permanently attach the

top bracket.

3. Remove the upper two (2) screws from the lower

section on the front of the unit heater. Repeat the

procedure described in Step 2 using the bottom

bracket (P/N 252-07949-00X).

4. Using the sixteen (16) 5/16-12 x 1/2 screws, attach the

left and right side panel (P/N 251-07944 and 251-07946)

to the unit heater using the holes to which the louvers

were attached.

5. Using the enclosed #8-18 x 1/2 screws and with the top

panel oriented such that the side with the larger holes

WARNING

Heavy Objects!

Ensure that all hardware used in the suspension of each

duct furnace is capable of supporting the unit weight.

Failure to do so could result in unit falling off its

mounting location, which could result in death or

serious injury.

NOTICE:

Equipment Damage!

The Separated Combustion Duct Furnace must be hung

level from side to side and front to back, from four

suspension points provided at the top of the unit.

Failure to do so could result in poor performance and/

or premature failure of the unit. Refer to Figure 7, p. 14

for typical suspension arrangements.

WARNING

Heavy Objects!

Make certain that the lifting methods used to lift the

duct furnace and the method of suspension used in the

field installation of the duct furnace are capable of

uniformly supporting the weight of the furnace at all

times. Make certain that the structure to which the

furnace is mounted is capable of supporting its weight.

Under no circumstances must the heater gas lines, the

venting system or the electrical conduit be used for

support. Failure to follow recommendations could

result in death, serious injury, or property damage.

Figure 7. Typical four (4) point duct suspending

arrangement

“S”

D4284

3/8-16 Treaded

Suspension Rod &

Jam Nut By Installer

3/8-16 Speed Gri p

Nut Retainer

Outside Jacket

Panel (Duct)

D4285

Installation: Mechanical

GMND-SVX01B-EN 15

is facing the unit heater, attach the top panel

(P/N 251-07942-00X) to the top bracket and the two (2)

side panels.

Note: The top panel must be attached so that the side

with the larger holes is facing the unit heater;

this is a requirement for later steps in this

installation procedure.

6. Using the enclosed #8-18 x 1/2 screws and with the

bottom panel oriented such that the side with the larger

holes is facing the unit heater, attach the bottom panel

(P/N 251-07943-00X) to the bottom bracket and the two

(2) side panels.

Note: The bottom panel must be attached so that the

side with the larger holes is facing the unit

heater; this is a requirement for later steps in

this installation procedure.

7. For 30-degree nozzle assemblies: Go to Step 10.

8. For 60- and 90-degree nozzle assemblies: Using the

enclosed #8-18 x 1/2 screws and with the top and

bottom panels oriented such that the sides with the

larger holes are facing the unit heater, create a

sub-assembly by attaching the top panel

(P/N 251-07942-00X) and the bottom panel

(P/N 251-07943-00X) to the left side panel

(P/N 251-07945) and to the right side panel

(P/N 251-07947).

Note: The top and bottom panels must be attached so

that the sides with the larger holes are facing

the unit heater; this makes the assembly easier.

Note: For 90-degree nozzle assemblies, repeat Step 8

to create a second sub-assembly.

9. For 60- and 90-degree nozzle assemblies: Using the

enclosed #8-18 x 1/2 screws, attach the sub-assembly

created in Step 8 to the 30-degree assembly installed to

the unit (in Step 1 through Step 6 of this procedure).

Attach the corresponding panels (i.e., top panel to top

panel, right side panel to right side panel, etc).

Note: For 90-degree nozzle assemblies, install the

second sub-assembly by attaching it to the first

sub-assembly. Attach the corresponding panels

(i.e., top panel to top panel, right side panel to

right side panel, etc).

10. Install the louvers and cone springs.

16 GMND-SVX01B-EN

Installation: Piping

Gas Piping

Pipe Sizing

To provide adequate gas pressure to the gas duct furnace,

size the gas piping as follows:

1. Find the ft3/hr by using the following formula:

2. Refer to Ta b l e 4, p. 17. Match “Length of Pipe” with

appropriate “Gas Input - Ft3/Hr” value. This value can

then be matched to the pipe size at the left of the table.

Example: It is determined that a 67 foot (20.4 m) run of

gas pipe is required to connect a 200 MBtu gas duct

furnace to a 1,000 Btu/ft3 (0.29 kW) natural gas supply.

Using Table 4, p. 17, a 1-inch pipe is needed.

Notes:

•See “General Safety Information,” p. 7 for English/SI

(metric) unit conversion factors.

•If more than one gas duct furnace is to be served by the

same piping arrangement, the total cubic feet per hour

input and length of pipe must be considered.

•If the gas duct furnace is to be fired with LP gas, consult

the local LP gas dealer for pipe size information.

Before any connection is made to an existing line

supplying other gas appliances, contact the local gas

company to make certain that the existing line is of

adequate size to handle the combined load.

WARNING

Flammable Vapors!

When connecting to existing gas lines be sure to valve

off the gas supply ahead of connection point. To avoid

explosion or possible fire, always purge all residual gas

from piping before cutting into existing line or

removing threaded fittings. Failure to remove all gas

vapors could result in death or serious injury or

equipment or property-only damage.

ft3/hr = Input

Btu per ft3

200,000 Btu/hr = 200 ft3/hr

1,000 Btu/ft3

WARNING

Hazard of Explosion and Fire!

Heater installation for use with propane (LP gas) must

be made by a qualified LP Gas Dealer or LP Gas Installer

to ensure that all appropriate codes, installation

procedures, and precautions have been followed.

Failure to follow these instructions could result in death

or serious injury.

Installation: Piping

GMND-SVX01B-EN 17

Pipe Installation

1. Install the gas piping in accordance with applicable

local codes.

2. Check gas supply pressure. Each duct furnace must be

connected to a gas supply capable of supplying its full

rated capacity as specified in Tab l e 5, p. 18. A field LP

tank regulator must be used to limit the supply

pressure to maximum of 14 in. wc (3.5 kPa). All piping

should be sized in accordance with the latest edition of

ANSI Standard Z223.1 National Fuel Gas Code; in

Canada, according to CGA-B149. See Ta b l e 1,

p. 10Ta b l e 4, p. 17, and Ta b l e 5, p. 18 for correct gas

piping size.

If gas pressure is excessive on natural gas applications,

install a pressure regulating valve in the line upstream

from the main shutoff valve.

3. To prevent the mixing of moisture with gas, run the

take-off piping from the top, or side, of the main.

4. Duct furnaces are shipped with a combination valve

which includes:

a. Manual “A” valve

b. Manual “B” valve

c. Solenoid valve

d. Pilot safety

e. Pressure regulator

Table 4. Gas pipe size(a)

Nominal

Iron Pipe

Size, in.

Internal

Diameter,

in. (mm)

Length of Pipe, ft (m)

10 20 30 40 50 60 70 80 90 100 125 150 175 200

(3.0) (6.1) (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0)

1/2 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35

(16) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99)

3/4 0.824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

(21) (10.2) (7.08) (5.66) (4.81) (4.28) (3.91) (3.54) (3.34) (3.11) (2.92) (2.63) (2.38) (2.18) (2.04)

1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135

(27) (19.3) (13.2) (10.6) (9.06) (8.07) (7.36) (6.80) (6.23) (5.80) (5.52) (4.96) (4.53) (4.11) (3.82)

1-1/4 1.380 1400 950 770 660 580 530 490 460 430 400 360 325 300 280

(35) (39.6) (26.9) (21.8) (18.7) (16.4) (15.0) (13.9) (13.0) (12.2) (11.3) (10.2) (9.20) (8.50) (7.93)

1-1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

(41) (59.5) (41.3) (33.4) (28.0) (25.5) (22.9) (21.2) (19.5) (18.4) (17.6) (15.6) (14.2) (13.0) (12.2)

2 2.067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800

(53) (112) (77.9) (62.3) (53.8) (47.6) (43.0) (39.6) (36.8) (34.5) (32.6) (28.9) (26.9) (24.1) (22.7)

2-1/2 2.469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280

(63) (178) (123) (99.7) (85.0) (75.0) (68.0) (63.7) (58.0) (55.2) (52.4) (46.7) (42.5) (38.8) (36.2)

3 3.068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280

(78) (311) (218) (177) (150) (135) (122) (110) (105) (97.7) (92.0) (83.5) (75.0) (69.4) (64.6)

4 4.026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600

(102) (651) (447) (362) (309) (275) (249) (229) (212) (204) (190) (170) (156) (142) (130)

Notes:

1. Determine the required ft3/h by dividing the rated heater input by 1000. For SI / Metric measurements: Convert unit Btu/h to kilowatts. Multiply the

unit input (kW) by 0.0965 to determine m3/h.

2. FOR NATURAL GAS: Select the pipe size directly from the table.

3. FOR PROPANE GAS: Multiply the ft3/h (m3/h) value by 0.633; then use the table.

4. Refer to the metric conversion factors listed in “General Safety Information,” p. 7 for more SI unit measurements/conversions.

(a)Maximum capacity of pipe in cubic feet of gas per hour (cubic meters per hour) for gas pressures of 0.5 psig (3.5 kPa) or less, and a pressure drop of

0.5 inch water column (124.4 Pa) (based on a 0.60 specific gravity gas).

WARNING

Hazard of Explosion!

Adequately support the piping to prevent strain on the

gas manifold and controls. To prevent explosion, fire, or

gas leaks, support piping so that piping does not sag or

put pressure on the burners internal to the unit. Failure

to follow these recommendations could result in death

or serious injury or equipment or property-only-

damage.

Installation: Piping

18 GMND-SVX01B-EN

Pipe directly in to combination valve (see Figure 8,

p. 18).

5. A 1/8 in. N.P.T. plugged tapping, accessible for test

gauge connection, must be installed immediately

upstream of the gas supply connection to the

appliance.

6. Provide a drip leg in the gas piping near the gas duct

furnace. A ground joint union and a manual gas shutoff

valve should be installed ahead of the unit heater

controls to permit servicing. The manual shutoff valve

must be located external to the jacket (see Figure 8,

p. 18).

7. Make certain that all connections have been

adequately doped and tightened.

Note: Use pipe joint sealant resistant to the action of

liquefied petroleum gases regardless of gas

conducted.

The appliance and its individual shutoff valve must be

disconnected from the gas supply piping system during

any pressure testing of that system in excess of 1/2 psig

(3.5 kPa).

The appliance must be isolated from the gas supply piping

system by closing its individual manual shutoff valve

during any pressure testing of the gas supply piping

system at test pressures equal to or less than 1/2 psig

(3.5 kPa).

Installation: Venting

Combustion Air Venting and Piping

NOTICE:

Overtightening!

Do not overtighten the inlet gas piping into the valve.

This may cause stresses that could crack the valve!

WARNING

Hazard of Explosion!

Never use an open flame to detect gas leaks. Explosive

conditions may occur. Use a leak test solution or other

approved methods for leak testing. Failure to follow

recommended safe leak test procedures could result in

death or serious injury or equipment or property-only-

damage.

Figure 8. Pipe installation, standard controls

D 3 6 31 C

Table 5. Gas piping requirements(a)

(a)

Gas Type Natural Gas Propane (LP) Gas

Manifold Pressure 3.5 in. wc 10.5 in. wc

(0.9 kPa) (2.6 kPa)

Supply Inlet Pressure 14.0 in. wc Max. 14.0 in. wc Max.

(3.5 kPa) (3.5 kPa)

5.5 in wc Min. 13.0 in wc Min.

(1.4 kPa) (3.2 kPa)

WARNING

Exhaust Fumes!

Each duct furnace MUST have its own combustion air

system and MUST NOT be connected to other air intake

systems. To prevent exhaust fumes from being pulled

into the air intake system or improper heating, ensure

that the duct furnace has its own combustion air

system and is not connected to other air intake

systems. Failure to follow these recommendations

could result in death or serious injury or equipment

damage.

WARNING

Carbon Monoxide!

Your venting system must not be blocked by any snow,

snow drifts, or any foreign matter. Inspect your venting

system to ensure adequate ventilation exists at all

times! A blocked venting system could result in carbon

monoxide poisoning. Symptoms of such condition

include grogginess, lethargy, inappropriate tiredness, or

flu-like symptoms. Failure to follow these

recommendations could result in death or serious

injury.

Installation: Piping

GMND-SVX01B-EN 19

1. The combustion air system installation must be in

accordance with the latest edition of (N.F.P.A. 54) ANSI

Z223.1 National Fuel Gas Code. In Canada, installation

must be in accordance with CGA-B149.1 “Installation

Code for Natural Gas Burning Appliances or

Equipment” and CGA-B149.2 “Installation Code for

Propane Burning Appliances and Equipment”.

2. A Breidert Type L or Fields inlet cap, furnished by the

customer, must be installed at the termination point of

the combustion air system (see Figure 9, p. 21 and

Figure 10, p. 21).

Note: The top of the inlet cap is to be no less than

12 inches (305 mm) from the top of the exhaust

vent cap (see Figure 9, p. 21 and Figure 10,

p. 21).

3. Use single wall pipe constructed of 26 gauge

galvanized steel or a material of equivalent durability

and corrosion resistance for the combustion air

system. For installation in Canada, use pipe

constructed from 0.025-inch thick aluminum or 0.018-

inch thick stainless steel.

4. Long runs of single wall combustion air piping passing

through an unheated space may require insulating if

condensation becomes noticeable.

5. The combustion air system must be installed to

prevent collection of condensate. Pitch horizontal

pipes downward 1/4 inch per foot (21 mm/m) toward

the inlet cap to facilitate drainage. Vertical combustion

air pipes should be arranged as depicted in Figure 9,

p. 21.

6. The equivalent length of the combustion air system

must not be less than five feet (1.5 m) and must not

exceed 50 feet (15.2 m). Equivalent length equals the

total length of straight pipe, plus 15 feet (4.6 m) for

each 90-degree elbow and five feet (1.5 m) for each

45-degree elbow.

Note: For optimum performance, keep the

combustion air system as straight as possible.

7. Each slip joint must be secured with at least three

corrosion resistant screws. Two full turns of 3M™ #425

Aluminum Foil Tape or its equivalent must then be

used to seal each joint. General Electric RTV-108, Dow

Corning® RTV-732 or an equivalent may be used

instead of the tape.

8. For horizontal combustion air systems longer than five

feet (1.5 m), the system must be supported from

overhead building structures at three-foot (1-m)

intervals.

Exhaust Venting

1. Vent system installation must be in accordance with

the latest edition of (N.F.P.A. 54) ANSI Z223.1 National

Fuel Gas Code. In Canada installation must be in

accordance with CGA-B149.1 “Installation Code for

Natural Gas Burning Appliances and Equipment” or

CGA-B149.2 “Installation Code for Propane Burning

Appliances and Equipment”.

2. A Breidert Type L or Fields vent cap, furnished by the

customer, must be installed at the termination point of

the vent system (see Figure 9, p. 21 and Figure 10,

p. 21).

3. Use single wall pipe constructed of 26 gauge

galvanized steel or a material of equivalent durability

and corrosion resistance for the vent system. For

installations in Canada, use corrosion resistant and

gas-tight, listed vent pipe conforming with local

building codes, or in the absence of local building

codes, with current CAN/CGA-B149.1, “Installation

Codes for Natural Gas Burning Appliances and

Equipment” or CAN/CGA-B149.2, “Installation Codes

for Propane Gas Burning Appliances and Equipment”.

WARNING

Risk of Fire and Carbon Monoxide

Poisoning with Improper Piping!

Never use pipe of a diameter other than that specified

in Table 1, p. 10 (“D” dia. flue opening)! To prevent pipe

from melting and introducing exhaust fumes into the

air supply, never use PVC, ABS or any other non-

metallic pipe for venting! Failure to follow these

recommendations could result in death or serious

injury or equipment damage. WARNING

Carbon Monoxide!

Never operate duct furnaces without combustion air

and flue gas piping in place. Each unit MUST have its

own combustion air system and MUST NOT be

connected to other vent systems or to a chimney. Your

venting system must not be blocked by any snow, snow

drifts, or any foreign matter. Inspect your venting

system to ensure adequate ventilation exists at all

times! Failure to follow these recommendations could

result in death or serious injury.

WARNING

Risk of Fire and Carbon Monoxide

Poisoning with Improper Piping!

Never use pipe of a diameter other than that specified

in Table 1, p. 10 (“D” dia. flue opening)! To prevent pipe

from melting and introducing exhaust fumes into the

air supply, never use PVC, ABS or any other non-

metallic pipe for venting! Failure to follow

recommendations could result in death or serious

injury or equipment damage.

Installation: Piping

20 GMND-SVX01B-EN

4. Any run of single wall vent pipe passing through an

unheated space must be insulated with an insulation

suitable to 550°F (288°C).

5. The combustion and exhaust vent air systems must be

installed to prevent collection of condensate. Pitch

horizontal pipes downward 1/4 inch per foot (21 mm/

m) toward the terminal cap to facilitate drainage (see

Figure 11 , p . 21). Vertical vent pipes should be

arranged as depicted in Figure 9, p. 21.

6. The equivalent length of the vent system must not be

less than five feet (1.5 m) and must not exceed 50 feet

(15.2 m). Equivalent length equals the total length of

straight pipe plus 15 feet (4.6 m) for each 90-degree

elbow and five feet (1.5 m) for each 45-degree elbow.

7. Each slip joint must be secured with at least three

corrosion resistant screws. Two full turns of 3M™ #425

Aluminum Foil tape or its equivalent must then be

used to seal each joint. General Electric RTV-108, Dow

Corning® RTV-732, or an equivalent may be used

instead of the tape.

8. For horizontal vent systems longer than five feet

(1.5 m), the system must be supported from overhead

building structures at three-foot (1-m) intervals.

9. The exhaust vent system must remain at a minimum of

six inches (152 mm) from all combustible materials.

Any part of the vent system that passes through a

combustible material must be properly insulated.

Note: Increasing the clearance distances may be

necessary if there is a possibility of distortion or

discoloration of adjacent materials.

For a VERTICAL vent pipe section that passes through

a floor or roof, an opening four inches (102 mm)

greater in diameter is required. The opening must be

insulated and flashed in accordance with applicable

installation codes.

A HORIZONTAL section of an exhaust vent system that

passes through a combustible wall must be

constructed and insulated as shown in Figure 12, p. 21.

10. The top of a VERTICALLY VENTED exhaust system

must extend at least three feet (1 m) above the roof

surface that it passes through. The point of termination

for a HORIZONTALLY VENTED exhaust system must be

at least 12 inches (305 mm) from the exterior wall that

it passes through. In addition, the termination point

must be at least three feet (1 m) above the snow line,

more than six feet (2 m) from the combustion air inlet

of another appliance, more than three feet (1 m) from

any building opening, and more than four feet (1.3 m)

from, and not directly above, any electric meter,

regulator, or relief equipment (refer to Figure 10, p. 21

and Figure 12, p. 21).

Installation: Piping

GMND-SVX01B-EN 21

Installation: Concentric Vent

Te rm i n a l

Horizontal Termination

Select a location on an outside wall for the vent terminal.

In most applications, the terminal should be on level with

the flue outlet of the unit, less 1/4 inch per foot pitch for

condensate drainage toward the outside of the building

(see Figure 13, p. 22).

Figure 9. Vertical intake/vent installation

Figure 10. Vertical vent installation

Figure 11. Horizontal intake/vent locations

Figure 12. Horizontal vent installation

WARNING

Hazardous Service Procedures!

The maintenance and troubleshooting procedures

recommended in this manual could result in exposure

to electrical, mechanical or other potential safety

hazards. Always refer to the safety warnings provided

throughout this manual concerning these procedures.

When possible, disconnect all electrical power

including remote disconnect and discharge all energy

storing devices such as capacitors before servicing.

Follow proper lockout/tagout procedures to ensure the

power can not be inadvertently energized. When

necessary to work with live electrical components, have

a qualified licensed electrician or other individual who

has been trained in handling live electrical components

perform these tasks. Failure to follow all of the

recommended safety warnings provided, could result in

death or serious injury.

Installation: Piping

22 GMND-SVX01B-EN

The location of the vent terminal must be in accordance

with the National Fuel Gas Code ANSI Z223.1 in the U.S. or

the National Gas Installation Code CAN/CGA-B149.1 or the

Propane Gas Installation Code CAN/CGA-149.2 in Canada.

Minimum clearance are as follows:

In Canada, a vent shall not terminate above a meter/

regulator assembly within 3 feet horizontally of the

vertical center line of the regulator nor within 6 feet of any

gas service regulator vent outlet.

Cut a hole through the wall for an 8-inch combustion air

pipe. Install thimble if required by local codes or type of

wall construction (see Figure 14, p. 22, Step 1).

Fasten a length of 5-inch pipe to the exhaust connection of

the concentric adapter with sheet metal screws. Use at

least three corrosion-resistant screws per joint. Seal all

joints with high temperature silicone sealant. The

concentric adapter box may be fastened directly to the wall

or spaced away from the wall using suitable brackets

(field-supplied). Before mounting the box, cut a length of

8-inch pipe so that it will protrude 2 inches through the

wall when the box is mounted in position. Fasten the

8-inch pipe to the combustion air inlet connection of the

concentric adapter and seal the joint. Add an additional 5-

inch pipe, if necessary, so that the base of the exhaust cap

will be 16 to 24 inches from the combustion air inlet (see

Figure 14, p. 22, Step 2).

Insert the pipes through the wall and fasten the adapter

box in place. Flash and/or caulk 8-inch pipe on outside wall

(see Figure 14, p. 22, Step 3).

Install the inlet air screen on the 8-inch pipe and fasten with

sheet metal screws. Install the flue terminal on the 5-inch

pipe and fasten in place (see Figure 14, p. 22, Step 4).

Connect the flue pipe and the combustion air pipe from the

concentric adapter to the unit. The pipe must be single wall

26-gauge or heavier galvanized steel or a material of

equivalent durability and corrosion resistance. The pipe

diameter must be listed under inlet and flue size in Table 1,

p. 10. The equivalent length of the exhaust vent pipe must

be a minimum of 5 feet and a maximum of 50 feet. The

equivalent length equals the total length of straight pipe

plus 15 feet for each 90-degree elbow and 5 feet for each

45-degree elbow. Secure each joint with a minimum of

three corrosion resistant screws. Seal all joints of the

exhaust vent pipe with two full turns of 3M #425

Aluminum Foil Tape or its equivalent suitable for 550°F or

high temperature silicone sealant. Seal all joints of the

combustion air inlet pipe with two full turns of duct tape or

aluminum foil tape or silicone sealant.

Vertical Termination

Select a location on the roof for the vent terminal, ensuring

adequate space inside for the concentric vent box. The

terminal must be at least 6 feet from any wall or adjoining

building (see Figure 15, p. 23).

Figure 13. Horizontal concentric venting

Table 6. Horizontal concentric venting—minimum

clearance

Object

Minimum Clearance

U.S. Canada

Forced air inlet within

10 feet 3 feet above 6 feet

Door, window or gravity

air inlet or combustion air

inlet for other appliance

4 feet below

4 feet horizontally

1 foot above

12 inches for

100,000 Btu/h input

or less. 3 feet for

input exceeding

100,000 Btu/h.

Adjacent public walkways 7 feet above grade 7 feet above grade

Above grade level 1 foot 1 foot

Size pipes

according to

Table 1, p. 10.

Figure 14. Horizontal concentric venting—installation

Installation: Piping

GMND-SVX01B-EN 23

Cut a hole through the roof for an 8-inch combustion air

pipe. Fasten a length of 5-inch pipe to the exhaust

connection of the concentric adapter with sheet metal

screws. Use at least three screws per joint. Seal all joints

with high temperature silicone sealant. The concentric

adapter box is to be suspended from the underside of the

roof using suitable brackets (field-supplied). Before

mounting the box, cut a length of 8-inch pipe so that

dimension A (see Figure 16, p. 23, Step 1), is equal to the

roof thickness plus 18 inches or the roof thickness plus the

expected snow depth, whichever is greater. Fasten the

8-inch pipe to the combustion air inlet connection of the

concentric adapter and seal the joint. Add an additional

5-inch pipe to extend at least 20 inches above the top of the

8-inch pipe.

Insert the pipe through the roof and fasten the adapter box

in place (see Figure 16, p. 23, Step 2).

Flash and/or caulk the 8-inch pipe to the roof (see

Figure 16, p. 23, Step 3).

Install the inlet air cap on the 8-inch pipe and fasten with

sheet metal screws. Install the flue terminal on the 5-inch

pipe and fasten in place. Seal the joint between the 5-inch

pipe and the inlet air cap with silicone sealant to prevent

the entry of water (see Figure 16, p. 23, Step 4).

Connect the flue pipe and the combustion air pipe from the

concentric adapter to the unit. Pipe must be single wall

26-gauge or heavier galvanized steel or a material of

equivalent durability and corrosion resistance. Pipe

diameter must be as listed under inlet and flue size in

Table 1, p. 10. The equivalent length of the exhaust vent

pipe must be a minimum of 5 feet and a maximum of

50 feet. The equivalent length equals the total length of

straight pipe plus 15 feet for each 90-degree elbow and

5 feet for each 45-degree elbow. Secure each joint with a

minimum of three corrosion-resistant screws. Seal all

joints of the exhaust vent pipe with two full turns of 3M

#425 Aluminum Foil Tape or its equivalent suitable for

550°F or high temperature silicone sealant. Seal all joints

of the combustion air inlet pipe with two full turns of duct

tape or aluminum foil tape or silicone sealant. Do not

enclose the exhaust vent pipe or run the pipe within

6 inches of combustible material.

Figure 15. Vertical concentric venting

Size pipes

according to

Table 1, p. 10.

Figure 16. Vertical concentric venting—installation

24 GMND-SVX01B-EN

Installation: Electrical

Electrical Connections

Standard units are shipped for use on 115 volt, 60 hertz

single phase electric power. The motor nameplate and

electrical rating of the transformer should be checked

before energizing the duct furnace electrical system. All

external wiring must conform to the latest edition of ANSI/

NFPA No. 70 National Electrical Code and applicable local

codes; in Canada, to the Canadian Electrical Code, Part 1

CSA Standard C22.1.

It is recommended that the electrical power supply to each

duct furnace be provided by a separate, fused, and

permanently live electrical circuit. A disconnect switch of

suitable electrical rating should be located as close to the

gas valve as possible. Each duct furnace must be

electrically grounded in accordance with the latest edition

of the National Electric Code, ANSI/NFPA No. 70 or CSA

Standard C22.1. Sample wiring connections are depicted

in Figure 22, p. 39 and Figure 23, p. 40.

Thermostat Wiring and Location

Note: The thermostat must be mounted on a vertical,

vibration-free surface, free from air currents, and in

accordance with the furnished instructions.

Mount the thermostat approximately 5 feet (1.5 m) above

the floor in an area where it will be exposed to a free

circulation of average temperature air. Always refer to the

thermostat instructions as well as our unit wiring diagram,

and wire accordingly. Avoid mounting the thermostat in

the following locations:

1. Cold areas—Outside walls or areas where drafts may

affect the operation of the control.

2. Hot areas—Areas where the sun’s rays, radiation, or

warm air currents may affect control operation.

3. Dead areas—Areas where air cannot circulate freely,

such as behind doors or in corners.

Note: Thermostat wires tagged “W” and “G” must be

connected together except when using a general

purpose “SPDT” 24 Vac relay and a standard

thermostat with subbase, or when using

Honeywell T834H or T834N thermostats. Also refer

to Figure 17, p. 24 for other wiring connections.

Thermostat Heat Anticipator Adjustments. The

initial heat anticipator setpoint should equal the

thermostat’s current amperage draw when the unit is

WARNING

Hazardous Service Procedures!

The maintenance and troubleshooting procedures

recommended in this section of the manual could result

in exposure to electrical, mechanical or other potential

safety hazards. Always refer to the safety warnings

provided throughout this manual concerning these

procedures. When possible, disconnect all electrical

power including remote disconnect and discharge all

energy storing devices such as capacitors before

servicing. Follow proper lockout/tagout procedures to

ensure the power can not be inadvertently energized.

When necessary to work with live electrical

components, have a qualified licensed electrician or

other individual who has been trained in handling live

electrical components perform these tasks. Failure to

follow all of the recommended safety warnings

provided, could result in death or serious injury.

WARNING

Hazardous Voltage and Gas!

Turn off the gas supply and disconnect all electric

power, including remote disconnects before servicing

unit. Follow proper lockout/tagout procedures to

ensure the power can not be inadvertently energized

and the gas can not be inadvertently turned on. Failure

to turn off gas or disconnect power before servicing

could result in death or serious injury.

WARNING

Proper Field Wiring and Grounding

Required!

All field wiring MUST be performed by qualified

personnel. Improperly installed and grounded field

wiring poses FIRE & ELECTROCUTION hazards. To

avoid these hazards, you MUST follow requirements for

field wiring installation and grounding as described in

NEC and your local/state electrical codes. Failure to

follow these requirements could result in death or

serious injury.

NOTICE:

Use Copper Conductors Only!

Unit terminals are not designed to accept other types

of conductors. Failure to use copper conductors could

result in equipment damage.

Figure 17. C1267G, thermostat wiring diagram

Installation: Electrical

GMND-SVX01B-EN 25

firing. This setpoint should be measured for the best

results. Use the recommended ranges as a guide. If further

information is needed, consult your thermostat

manufacturer’s instructions.

Recommended Heat Anticipator Setting Ranges:

Fan Time Delay Control

Leads from the fan time delay controls are factory wired to

the junction box. The fan control is a time delay relay

(approximately 45 seconds ON, 65 seconds OFF). The fan

control is rated at 17 amps.

Notes:

•The start-up fan delay should not exceed 90 seconds

from a cold start.

•For all wiring connections, refer to the wiring diagram

shipped with your unit (either affixed to the side jacket

or enclosed in your unit’s installation instruction

envelope). Should any original wire supplied with the

heater have to be replaced, it must be replaced with

wiring material having a temperature rating of at least

105°C.

Should any high limit wires have to be replaced, they

must be replaced with wiring material having a

temperature rating of 200°C minimum.

25 ft. (7.6 m) T’stat

Wiring 50 ft. (15.2 m) T’stat Wiring

0.85 to 0.90 A 0.90 to 1.1 A Max. Setting on T’stat

26 GMND-SVX01B-EN

Start-Up

Operation

Explanation of Controls

1. Each Separated Combustion Duct Furnace comes

equipped with a power vent system that consists of a

power venter motor and blower, pressure switch, and

sealed flue collector (Figure 20, p. 32).

2. The power venter motor is energized by the room

thermostat when a demand for heat is sensed. The

pressure switch measures the pressure differential

between the air inlet and exhaust vent systems. If the

differential is correct, the indirect spark ignition system

is energized.

3. The indirect spark ignition system consists of an

ignition module, a dual combination valve, and a

spark-ignited pilot burner. When the pressure switch is

closed, the pilot valve opens as a spark is generated to

light the pilot. When the flame is sensed by the flame

sensing circuit, the spark ceases, and the main gas

valve is opened to supply gas to the main burners.

Once the thermostat has been satisfied, the vent

system and gas valve are simultaneously de-

energized, stopping all gas flow to the unit.

4. The high limit switch interrupts the flow of electric

current to the main gas valve if the duct furnace

becomes overheated.

5. The optional fan switch delays the operation of the fan

is delayed for approximately 45 seconds once the

thermostat is closed, and continues fan operation for

approximately 65 seconds after the thermostat opens.

Note: The start-up fan delay must not exceed 90

seconds from a cold start.

6. The wall thermostat, supplied optionally, is a

temperature sensitive switch that operates the vent

and ignition systems to control the temperature of the

space being heated.

Note: The thermostat must be mounted on a vertical,

vibration-free surface, free from air currents,

and in accordance with the furnished

instructions.

Initial Lighting

1. Open the manual gas valve, in the gas supply line to the

duct furnace. Loosen the union in the gas supply line to

purge it of air. Tighten the union and check for leaks.

2. Turn on the electrical power. The duct furnace should

now be under the control of the thermostat. Set the

thermostat to its highest setting; the power venter

motor should start and burner ignition occur. Turn the

thermostat to its lowest setting. The burners and

power venter should stop operating immediately.

Reset the thermostat to the desired operational setting.

Shut-Down

1. Turn the valve selector knob to the OFF position.

2. Turn off the electricity.

3. To relight, follow the instructions in “Initial Lighting,”

p. 26 (preceding section).

WARNING

Carbon Monoxide!

Never operate duct furnaces if the power venter is not

operable. Your venting system must not be blocked by

any snow, snow drifts, or any foreign matter. Inspect

your venting system to ensure adequate ventilation

exists at all times! Failure to follow these

recommendations could result in death or serious

injury due to Carbon Monoxide Poisoning (symptoms

include grogginess, lethargy, inappropriate tiredness, or

flu-like symptoms).

NOTICE:

Additional Devices!

The addition of external draft hoods or power venters is

not permitted. Addition of such devices could cause

severe unit malfunction or failure!

WARNING

Hazard of Explosion!

Never use an open flame to detect gas leaks. Explosive

conditions may occur. Use a leak test solution or other

approved methods for leak testing. Before attempting

to light or relight the pilot, wait 5 minutes to allow gas

which may have accumulated in the burner

compartment to escape. Failure to follow

recommended safe leak test procedures or pilot

lighting/relighting instructions could result in death or

serious injury or equipment or property-only-damage.

Start-Up

GMND-SVX01B-EN 27

Figure 18. Burner components (intermittent pilot ignition)

Burner Drawer Common Parts:

1. Main Burners

2. Burner Manifold

3. Air Shutters

4. Burner Springs

5. Main Burner Orifice

6. Transformer

7. Pilot Tubing

Controls:

8A.Main Gas Valve (Honeywell)

8B.Main Gas Valve (White-Rodgers)

9. Honeywell Ignitor

10. Honeywell Pilot Burner

11. Honeywell Pilot Orifice

12. Honeywell Electrode/Sensor Lead

13. Hi Limit Switch (Located on Rear Header

Plate of Heat Exchanger, Air Inlet Side)

SPARK

MV/PV

GND

(BURNER)

24V

(GND

)

24V

TH-W

(OPT.)

Honeywell

WARNING

S8600M

CONTINUOUS RE-TRY

100% SHUTOFF IP

90 SEC. TRIAL FOR IGNITION

Start-Up

28 GMND-SVX01B-EN

Gas Input Rate

Check the gas input rate as follows:

1. Turn off all gas appliances that utilize gas through the

same gas meter as the unit heater.

2. Turn gas on to the unit heater.

3. Using the gas meter, clock the time that it takes to burn

one cubic foot of gas (Heating Value).

4. Insert the time, in seconds, into the formula below:

Example: If the heating value = 1000 BTU/ft3 and the time/

ft3 = 18 s/ft3 then

Input Rate = 200,000 BTU/hr

(Refer to “General Safety Information,” p. 7 for metric

conversions.)

Note: If the computation exceeds, or is less than 95

percent of the gas Btu/h input rating (see “Unit

Dimensions and Weights,” p. 10), adjust the gas

pressure:.

Gas Pressure Adjustments

Adjust the gas pressure as follows:

1. NATURAL GAS: Best results are obtained when the

duct furnace is operating at its full input rating with the

manifold pressure of 3.5 inches wc (0.9 kPa).

Adjustment of the pressure regulator is not normally

necessary since it is preset at the factory.

However, field adjustment may be made as follows:

a. Attach manometer at pressure tap plug below the

control outlet.

b. Remove the regulator adjustment screw cap,

located on the combination gas valve.

c. With a small screwdriver, rotate the adjustment

screw clockwise to increase pressure.

d. Replace regulator adjustment screw cap.

2. PROPANE GAS: An exact manifold pressure of

10.0 inches wc (2.5 kPa) must be maintained for proper

operation of the duct furnace. If the unit is equipped

with a pressure regulator on the combination gas

valve, follow Step a through Step d (above). If the unit

is not so equipped, the propane gas supply system

pressure must be regulated to attain this manifold

operating pressure.

Primary Air Shutter Adjustment

After the unit has been operating for at least 15 minutes,

adjust the primary air flow to the burners. Turn the friction-

locked, manually-rotated air shutters clockwise to close, or

counterclockwise to open.

For correct air adjustment, close the air shutter until yellow

tips in the flame appear. Then open the air shutter to the

point just beyond the position where yellow tipping

disappears. Refer to Figure 19.

Note: There may be momentary and spasmodic orange

flashes in the flame. This is caused by the burning

of airborne dust particles, and should not be

confused with the yellow tipping, which is a stable

or permanent situation when there is insufficient

primary air.

NOTICE:

Overfiring!

Never overfire the duct furnace, as this could cause

unsatisfactory operation, or shorten the life of the

heater.

Input Rate = Heating Value (Btu/ft3) (3600 s/hr)

Time (s/ft3)

Input Rate = (1000 BTU/ft3) (3600 s/hr)

18 s/ft3

Table 7. Main burner orifice schedule(a)

(a) This schedule is for units operating at normal altitudes of 2000 feet

(610 m) or less. SPECIAL ORIFICES ARE REQUIRED FOR INSTALLA-

TIONS ABOVE 2,000 FEET (610 m).

Input in

1000

BTU(a)

Type of Gas Natural Propane

No. of

Burner

Orifices

Heating

Value

1075 BTU/ft3

(40.1 MJ/m3)

2500 BTU/ft3

(93.1 MJ/m3)

Manifold

Pressure 3.5” wc (0.9 kPA) 10.5” wc (2.6 kPA)

100 ft3/hr 96 40 4

Orifice Drill 42 54

125 ft3/hr 120 50 5

Orifice Drill 42 54

150 ft3/hr 140 60 6

Orifice Drill 42 54

175 ft3/hr 163 70 7

Orifice Drill 42 54

200 ft3/hr 186 80 8

Orifice Drill 42 54

225 ft3/hr 210 90 9

Orifice Drill 42 54

250 ft3/hr 233 100 10

Orifice Drill 42 54

300 ft3/hr 280 120 12

Orifice Drill 42 54

350 ft3/hr 326 140 14

Orifice Drill 42 54

400 ft3/hr 372 160 16

Orifice Drill 42 54

Note: When installed in Canada, any references to deration at altitudes in

excess of 2000 feet (610 m) are to be ignored. At altitudes of 2000

to 4500 feet (610 to 1372 m), the unit heaters must be orificed to

90 percent of the normal altitude rating, and be so marked in

accordance with the CSA certification.

Start-Up

GMND-SVX01B-EN 29

Pilot Adjustment

1. Remove the pilot adjustment cap.

2. Adjust the pilot screw to provide a properly sized

flame.

3. A proper pilot flame is a soft steady flame that

envelops 3/8- to 1/2-inch (9.5 to 12.7 mm) of the flame

sensor.

4. Replace the pilot adjustment cap.

Manifold Pressure Adjustment

If the manifold pressure requires adjustment, remove the

cap from the pressure regulator and turn the adjustment

screw clockwise to increase the pressure, or

counterclockwise to decrease the pressure. The adjusted

manifold pressure should not vary more than 10 percent

from the pressures specified in Table 7, p. 28.

Figure 19. Main burner flames

LIFTING

(TOO MUCH AIR)

NORMAL

(HARD FLAME)

YELLOW TIPPING

(MARGINAL)

YELLOW FLAME

(TOO LITTLE AIR)

Start-Up

30 GMND-SVX01B-EN

Gas Equipment Start-Up

Customer _____________________________________________ Job Name & Number _________________________

Pre-Inspection Information with Power and Gas Off

Type of Equip: Duct Furnace

Serial Number: _________________________ Model Number: _____________________________

Name Plate Voltage: ____________________ Name Plate Amperage: ______________________

Type of Gas: Natural LP Tank Capacity: _______ lb Rating: _______ Btu @ ____ °F

_______ kg ________ kW @ ____ °C

Are all panels, doors, vent caps in place?

Has the unit suffered any external damage? Damage ______________________________

Does the gas piping and electric wiring appear to be installed in a professional manner?

Has the gas and electric been inspected by the local authority having jurisdiction?

Is the gas supply properly sized for the equipment?

Were the installation instructions followed when the equipment was installed?

Have all field installed controls been installed?

Do you understand all the controls on this equipment? If not, contact your wholesaler or rep. (DO NOT START

this equipment unless you fully understand the controls.)

Remarks: _____________________________________________________________________________________________________

_______________________________________________________________________________________________________________

GENERAL

With power and gas off.

Make certain all packing has been removed.

Tighten all electrical terminals and connections.

Check all fans and blowers for free movement.

Check all controls for proper settings.

Check all set screws on blowers and bearings.

Check belt tightness.

BLOWER

With power on and gas off.

Check voltage L1 _____ L2 _____ L3 _____

Check rotation of main .

Check motor amps L1 _____ L2 _____ L3 _____

Blower RPM _____________

Check air filters. (Record quantity & size.)

GAS HEATING

With power and gas on.

Inlet gas pressure. ____ in. wc or ____ kPa

Pilot and main burner ignition.

Manifold gas pressure. ____ in. wc or ____ kPa

Cycle firestat and/or freezestat.

Check electronic modulation. Set at: __________

Cycle and check all other controls not listed.

Check operation of remote panel.

Entering air temp. _____ °F or ____ °C

Discharge air temp. (high fire) ____ °F. or ____ °C

External static pressure _________ in. wc

GMND-SVX01B-EN 31

Maintenance

Periodic Service

All Maintenance/Service information should be recorded

accordingly on the inspection sheet provided in this

manual (see “Gas Equipment Start-Up,” p. 30).

Note: The heater and vent system should be checked

once a year by a qualified technician.

Important: Gas tightness of the safety shut-off valves

must be checked on at least an annual basis.

To check gas tightness of the safety shut-off valves, turn off

the manual valve upstream of the appliance combination

control. Remove the 1/8-inch pipe plug on the inlet side of

the combination control and connect a manometer to that

tapping. Turn the manual valve on to apply pressure to the

combination control. Note the pressure reading on the

manometer, then turn the valve off. A loss of pressure

indicates a leak. If a leak is detected, use a soap solution to

check all threaded connections. If no leak is found,

combination control is faulty and must be replaced before

putting appliance back in service.

Should maintenance be required, perform the following

inspection and service routine:

1. Inspect the area near the unit to be sure that there is no

combustible material located within the minimum

clearance requirements listed in this manual (see

Table 3, p. 12).

2. Turn off the manual gas valve and electrical power to

the gas duct furnace.

3. To clean or replace the main burners, remove the

bottom panel and compress the spring by moving the

burner toward the manifold. Slide the opposite end of

the burner downward from the locating slot while

retaining spring is still compressed. Pull the burners

away from the heater.

4. With the burners removed, wire brush the inside

surfaces of the heat exchanger.

5. Remove any dirt, dust, or other foreign matter from the

burners using a wire brush and/or compressed air.

Ensure that all parts are unobstructed. Inspect and

clean pilot burner if necessary.

6. Reassemble the gas duct furnace by replacing all parts

in reverse order.

7. Complete the appropriate unit start-up procedure as

given in “Operation,” p. 26 (see unit lighting instruction

plate and the unit nameplate).

8. Check the burner adjustment (see “Primary Air Shutter

Adjustment,” p. 28).

9. Check all gas control valves and pipe connections for

leaks.

10. Check the operation of the automatic gas valve by

lowering the setting of the thermostat, stopping the

operation of the gas duct furnace. The gas valve should

close tightly, completely extinguishing the flame on

the main burners.

11. Inspect and service the blower section of the system.

Check and test the operational functions of all safety

devices supplied with your unit.

WARNING

Hazardous Service Procedures!

The maintenance and troubleshooting procedures

recommended in this section of the manual could

result in exposure to electrical, mechanical or other

potential safety hazards. Always refer to the safety

warnings provided throughout this manual concerning

these procedures. When possible, disconnect all

electrical power including remote disconnect and

discharge all energy storing devices such as capacitors

before servicing. Follow proper lockout/tagout

procedures to ensure the power can not be

inadvertently energized. When necessary to work with

live electrical components, have a qualified licensed

electrician or other individual who has been trained in

handling live electrical components perform these

tasks. Failure to follow all of the recommended safety

warnings provided, could result in death or serious

injury.

WARNING

Hazardous Voltage and Gas!

Turn off the gas supply and disconnect all electric

power, including remote disconnects before servicing

unit. Follow proper lockout/tagout procedures to

ensure the power can not be inadvertently energized

and the gas can not be inadvertently turned on. Failure

to turn off gas or disconnect power before servicing

could result in death or serious injury.

WARNING

Hazard of Explosion!

Never use an open flame to detect gas leaks. Explosive

conditions may occur. Use a leak test solution or other

approved methods for leak testing. Failure to follow

recommended safe leak test procedures could result in

death or serious injury or equipment or property-only-

damage.

WARNING

Combustible Materials!

Maintain proper clearance between the unit heat

exchanger, vent surfaces and combustible materials.

Refer to unit nameplate and installation instructions for

proper clearances. Improper clearances could result in a

fire hazard. Failure to maintain proper clearances could

result in death or serious injury or property damage.

Maintenance

32 GMND-SVX01B-EN

Figure 20. Power venter assembly

Notes:

1. For item No. 6, use counter-clockwise rotation.

2. DO NOT OVERTIGHTEN CELCON NUT! HAND TIGHTEN ONLY! DO NOT USE TOOLS! Approximate 1/3 turn maximum or 8 inch pounds is sufficient from

the point where the tube does not slip in or out.

3. Flue Sizes:

100/175 units: 4” dia. flue outlet Reducer required—to be supplied by installer.

200/250 units: 5” dia. flue outlet (no adapter required).

300/400 units: 6” dia. flue outlet Increaser required—to be supplied by manufacturer.

Ref. No. Description

1 Blower Housing Assembly

2Speed Nut

3 Motor

4 Washer, Plain

5 Plate Adapter

6 Blower Wheel (see Note 1)

7 Mounting Bracket (Pressure Switch)

8 Mounting Bracket (Junction Box)

9Screw, S.T.

10 Screw, Machine (L = 3/4”)

11 Nut, Keps (Ext. Lock Washer)

12 Air Pressure Switch

13 Drill Screw

14 Junction Box Cover

Ref. No. Description

15 Snap Bushing

16 Relay (Motor)

17 Draftor Stack Assembly

18 Tubing (Aluminum) Formation

19 Male Connector

20 Locknut

21 Hole Plug

22 Pressure Switch Cover

23 Drill Screw

24 Junction Box Base

25 Purge Relay

Maintenance

GMND-SVX01B-EN 33

Installation Instructions for Field

Replacement of Power Venter Motor

Important: This replacement must be performed only

by a qualified technician.

Note: All hardware (screws, nuts, washers) that will be

removed from the unit will be reused for this motor

replacement. DO NOT LOSE ANY OF THESE

PARTS.

Tools and Parts Needed

Wire Stripper and Crimper; Slotted Head and #2 Phillips

Head Screwdriver; 3/8-in. Wrench; 1/8-in. Allen Wrench

(long handle); marker; (1) 1/4-in. push on terminal for Wire.

Notes:

•Remove the cover from the Relay Junction Box (Item 1)

by removing two screws (Item 2) top and bottom.

Disconnect both wires from the motor lead ends. One

is connected to terminal #4 on the venter relay, and the

other is connected with a wire nut to a black wire.

•Remove the sensing tube (Item 3) from the Pressure

Switch/Mounting Bracket (Item 3) at motor end only.

Separated Combustion Units: Remove both tubes at

motor end only—note location.

•Mark locations of the Relay Junction Box and Pressure

Switch Mounting Brackets along with the Motor (Item

10) mounts on the Mounting Adapter Plate (Item 4)—

using a marker.

•Remove nut (Item 5) that secures the Motor Support

Shipping Bracket (Item 6) to the Mounting Adapter

Plate. Pull this bracket away from the Motor Mounting

Adapter Plate.

•Remove three phillips head screws (Item 7) on the

Motor mounting Adapter Plate. Remove the Motor/

Blower Wheel/Adapter Plate assembly from the Power

Venter Blower Housing (Item 8).

•Remove the Blower Wheel (Item 9) from the motor

shaft by removing the set screw (Item 14) using a 1/8-in.

Allen Wrench.

•Remove the three Motor Mounting Nuts (Item 5),

Space Washers (Item 11), and Screws (Item 12). Do not

lose these parts! Using caution—the motor will

disengage from the Mounting Adapter Plate, along

with the Relay Junction Box and Pressure Switch

Mounting Brackets will also disengage.

•Reverse order to install the new Power Venter Motor.

•TEST FIRE THE UNIT FOR A FEW CYCLES, MAKING

SURE THAT THE UNIT IS OPERATING

SATISFACTORILY.

Figure 21. Identification of parts

Ref. No. Description

1 Relay Junction Box/Mounting

Bracket Assembly

2 #8 Drill Screws (2 required)

3 Pressure/Mounting Bracket

Assembly

4 Mounting Plate Adapter

5 Keps Nut w/External Tooth

Lockwasher (4 required)

6 Motor Support Shipping Bracket

7 Phillips Head Screws (3 required)

8 Power Venter Blower Housing

9Blower Wheel

10 Motor

11 Space Washers (3 required)

12 Machine Screw (3 required)

13 Sensing Tube

14 Set Screw

Maintenance

34 GMND-SVX01B-EN

How to Order Replacement Parts

Please send the following information to your local Parts

center; If further assistance is needed, contact the

manufacturer’s customer service department.

•Model number

• Serial Number

• Part description and Number as shown in the

Replacement Parts Catalog.

GMND-SVX01B-EN 35

Diagnostics

Troubleshooting

WARNING

Hazardous Service Procedures!

The maintenance and troubleshooting procedures

recommended in this section of the manual could result

in exposure to electrical, mechanical or other potential

safety hazards. Always refer to the safety warnings

provided throughout this manual concerning these

procedures. When possible, disconnect all electrical

power including remote disconnect and discharge all

energy storing devices such as capacitors before

servicing. Follow proper lockout/tagout procedures to

ensure the power can not be inadvertently energized.

When necessary to work with live electrical

components, have a qualified licensed electrician or

other individual who has been trained in handling live

electrical components perform these tasks. Failure to

follow all of the recommended safety warnings

provided, could result in death or serious injury.

Table 8. Troubleshooting guide

Symptoms Possible Cause(s) Corrective Action

A. Flame lifting from burner ports. 1. Pressure regulator set too high. 1. Reset manifold pressure. Refer to “Operation,” p. 26.

2. Defective regulator. 2. Replace regulator section of combination gas valve or

complete valve.

3. Burner orifice too large. 3. Check with local gas supplier for proper orifice size and

replace. Refer to “Operation,” p. 26.

B. Flame pops back. 1. Excessive primary air. 1. Close air shutter. Refer to “Operation,” p. 26.

2. Burner orifice too small. 2. Check with local gas supplier for proper orifice size and

replace. Refer to “Operation,” p. 26.

C. Noisy flame. 1. Too much primary air. 1. Close air shutter.

2. Noisy pilot. 2. Reduce pilot gas. Refer to “Operation,” p. 26.

3. Irregular orifice causing whistle or

resonance. 3. Replace orifice.

4. Excessive gas input. 4. Reset manifold pressure. Refer to “Operation,” p. 26;

Replace regulator section of combination gas valve or

complete valve; or check with local gas supplier for proper

orifice size and replace. Refer to “Operation,” p. 26.

D. Yellow tip flame (some yellow

tipping on propane gas is

permissible).

1. Insufficient primary air. 1. Open air shutters. Refer to “Operation,” p. 26.

2. Clogged burner ports. 2. Clean main burner ports.

3. Misaligned orifices. 3. Replace manifold assembly.

4. Clogged draft hood. 4. Clean draft hood.

5. Air shutter. 5. Check for dust or lint at air mixer opening and around the

air shutter.

6. Insufficient combustion air. 6. Check for obstruction in combustion air inlet cap and piping;

see “Installation: Piping,” p. 16.

E. Floating flame. 1. Blocked venting. 1. Clean flue. Refer to “Installation: Piping,” p. 16.

2. Insufficient combustion air. 2. Check for obstruction in combustion air inlet cap and piping;

see “Installation: Piping,” p. 16.

3. Blocked heat exchanger. 3. Clean heater.

4. Air leak into combustion chamber

or draft hood. 4. Determine cause and repair accordingly.

Diagnostics

36 GMND-SVX01B-EN

F. Gas Odor. 1. Shut off gas immediately! 1. Inspect all gas piping and repair.

2. Blocked heat exchanger/venting. 2. Clean heat exchanger/flue.

3. Drafts around heater. 3. Eliminate drafts. Refer to “Installation: Mechanical,” p. 12.

4. Negative pressure in building. 4. See “Installation: Piping,” p. 16.

5. Blocked draft hood. 5. Clean draft hood.

G. Delayed ignition. 1. Excessive primary air. 1. Close air shutter. Refer to “Operation,” p. 26.

2. Main burner ports clogged near

pilot. 2. Clean main burner ports.

3. Pressure regulator set too low. 3. Reset manifold pressure. Refer to “Operation,” p. 26.

4. Pilot decreases in size when main

burners come on. 4. Supply piping is inadequately sized. Refer to “Installation:

Piping,” p. 16.

5. Pilot flame too small. 5. Clean pilot orifice. Refer to “Operation,” p. 26.

6. Drafts around venter. 6. Eliminate drafts. Refer to “Installation: Mechanical,” p. 12.

7. Improper venting. 7. Refer to “Installation: Piping,” p. 16.

H. Failure to ignite. 1. Main gas valve off. 1. Open all manual gas valves.

2. Lack of power at unit. 2. Replace fuse or turn on power supply.

3. Thermostat not calling for heat. 3. Turn up thermostat.

4. Defective limit switch. 4. Check limit switch with continuity tester. If open, replace

high limit switch.

5. Improper thermostat or

transformer wiring. 5. Check wiring per diagrams.

6. Defective gas valve. 6. Replace gas valve.

7. Defective thermostat. 7. Check thermostat and replace if defective.

8. Defective transformer. 8. Be sure 115 volts is supplied to the transformer primary,

then check for 24 volts at secondary terminal before

replacing.

9. Loose wiring. 9. Check and tighten all wiring connections per diagrams.

10. Defective ignition control. 10. Replace, if necessary. Also see U, V, and W symptoms.

I. Condensation of water vapor. 1. Condensation of water vapor. 1. Refer to “Installation: Venting,” p. 18.

J. Burner won't turn off. 1. Poor thermostat location. 1. Relocate thermostat away from drafts.

2. Defective thermostat. 2. Replace thermostat.

3. Improper thermostat or

transformer wiring at gas valve. 3. Check wiring per diagrams.

4. Short circuit. 4. Check operation at valve. Check for short (such as staples

piercing thermostat wiring), and correct.

5. Defective or sticking gas valve. 5. Replace gas valve.

6. Excessive gas supply pressure. 6. Refer to “Installation: Piping,” p. 16.

K. Rapid burner cycling. 1. Loose wiring connections at gas

valve or thermostat. 1. Tighten all connections.

2. Excessive thermostat heat

anticipator. 2. Adjust thermostat for longer cycles. Refer to “Installation:

Electrical,” p. 24.

3. Unit cycling on high limit. 3. Check for proper air supply across heat exchanger.

4. Poor thermostat location. 4. Relocate thermostat. (Do not mount thermostat on unit).

5. Draft on pilot. 5. Eliminate drafts. Refer to “Installation: Mechanical,” p. 12.

6. Defective ignitor control. 6. Replace ignitor.

7. Defective high limit. 7. Jumper limit switch terminals 1 and 2. If burner operates

normally, replace switch.

L. Noisy power venter. 1. Power venter wheel loose. 1. Replace or tighten.

2. Power venter wheel dirty. 2. Clean power venter wheel.

3. Power venter wheel rubbing

housing. 3. Realign power venter wheel.

4. Bearings are dry. 4. Oil bearings on power venter motor. (Refer to label on

motor.)

M. Pilot will not light or will not stay

lit. 1. Main gas valve off. 1. Open all manual gas valves.

Table 8. Troubleshooting guide (continued)

Symptoms Possible Cause(s) Corrective Action

Diagnostics

GMND-SVX01B-EN 37

2. Pilot adjustment screw turned too

low on combination main gas

valve.

2. Increase size of pilot flame. Refer to “Operation,” p. 26.

3. Air in gas line. 3. Purge air from line.

4. Incorrect lighting procedure. 4. Follow lighting instruction label adjacent to gas valve.

5. Dirt in pilot orifice. 5. Remove pilot orifice. Clean with compressed air or solvent.

(Do not ream.)

6. Extremely high or low gas

pressure. 6. Refer to “Operation,” p. 26.

7. Drafts around unit. 7. Eliminate drafts. Refer to “Installation: Mechanical,” p. 12.

8. Pilot valve not opening (faulty

wiring). 8. Inspect and correct all wiring.

9. No spark (faulty wiring). 9. Inspect and correct ignition system wiring. See symptoms

U, V, and W.

10. Defective gas valve. 10. Replace gas valve.

N. Power venter will not run. 1. Loose wiring. 1. Check and tighten all wiring connections per diagrams.

Thermostat wires tagged “W” and “G” must be connected

together (unless special thermostats are used; if so, see

thermostat wiring diagram, “Electrical Connections,” p. 24).

2. Defective motor overload

protector or defective motor. 2. Replace motor.

3. Defective power venter relay. 3. Check for 24V across terminals on fan relay. If 24V is

present, jumper terminals numbered 2 and 4. If motor runs,

the fan relay is defective and must be replaced. If 24V is not

present, check wiring per diagrams.

O. Power venter motor turns on and

off while burners are operating. 1. Fan relay heater element

improperly wired. 1. Be sure venter relay heater terminals are connected per

diagrams.

2. Defective venter relay switch. 2. Replace venter relay.

3. Motor protector cycling on and off. 3. Check motor amps against motor name plate rating, check

voltage, replace venter relay motor if defective.

4. Motor not properly oiled. 4. Refer to label on motor.

P. Power venter motor will not stop. 1. Improperly wired venter relay. 1. Check all wiring.

2. Main burners not lighting while

thermostat calls for heat. 2. Refer to H and N symptoms.

3. Defective venter relay. 3. Replace venter relay.

Q. Not enough heat. 1. Incorrect gas input. 1. Refer to “Operation,” p. 26.

2. Heater undersized. 2. This is especially true when the heated space is enlarged.

Have the heat loss calculated and compare to the heater

output (80 percent of input). Your gas supplier or installer

can furnish this information. If heater is undersized, add

additional heaters.

3. Thermostat malfunction. 3. Replace thermostat.

4. Heater cycling on high limit. 4. Check air movement through heat exchanger. Check

voltage to fan motor. Clean power venter motor.

5. Check outside dampers if used. 5. Adjust dampers accordingly.

R. Too much heat. 1. Thermostat malfunction. 1. Replace thermostat.

2. Heater runs continuously. 2. Check wiring per diagrams; check operation at valve. Look

for short (such as staples piercing thermostat wiring), and

correct; replace gas valve. Refer to “Operation,” p. 26.

S. Cold air is delivered on start up. 1. Fan relay heater element

improperly wired. 1. Be sure fan relay heater terminals are connected per

diagrams.

T. Cold air is delivered during heater

operation. 1. Incorrect manifold pressure or

input. 1. Refer to “Operation,” p. 26.

2. Voltage to unit too high. 2. Check motor voltage with fan running. Should be 115 volts

AC.

3. Air throughput too high. 3. Refer to “Operation,” p. 26.

Table 8. Troubleshooting guide (continued)

Symptoms Possible Cause(s) Corrective Action

Diagnostics

38 GMND-SVX01B-EN

U. No Spark. 1. Thermostat not calling for heat. 1. Close thermostat contacts.

2. No low voltage. 2. Check for 24V across 24V terminals of S8600.

3. Spark gap closed or too wide. 3. Set gap to 0.1.

4. Broken or cracked ceramic on

spark electrode. 4. Replace pilot assembly.

V. Spark present but pilot does not

light. 1. Loose S8600 connections. 1. Check all connections, term. PV feeds 24V to pilot valve.

2. Improper gas pressure. 2. Check pressure—pressure that is either too high or too low

may cause a problem.

3. Is spark in pilot gas stream? 3. Spark should arc from electrode.

4. No pilot gas — do not use match to

test - presence of gas is easily

detected by the odor.

4. Check pilot line for kinks. Ensure there are no drafts.

W. Pilot lights — Main valve does not

energize. 1. Loose S8600 connections. 1. Check connections-term. MV feeds main valve.

2. Cracked or broken sensor

ceramic. 2. Replace pilot assembly.

3. Check sensor/spark lead for

continuity. 3. Replace if needed.

4. Measure 24 volts from term. MV to

term. MV/PV. 4. If present, replace main valve; if not, replace S8600 Igniter.

X. Hi-Limit switch tripping. 1. Unit is overfiring. 1. Manifold pressure too high; adjust. Burner orifices may be

too large: verify/replace if required.

2. Air flow too low. 2. Increase air flow; check fan size. Check for proper voltage.

3. Defective switch. 3. Replace.

Table 8. Troubleshooting guide (continued)

Symptoms Possible Cause(s) Corrective Action

GMND-SVX01B-EN 39

Wiring Diagrams

Figure 22. Standard wiring diagram for unit with S8600 ignition system

Wiring Diagrams

40 GMND-SVX01B-EN

Figure 23. Standard wiring diagram for unit with G770 ignition system

Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the

leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad

portfolio of advanced controls and HVAC systems, comprehensive building services, and parts.

For more information, visit www.Trane.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.

We are committed to using environmentally

conscious print practices that reduce waste.

GMND-SVX01B-EN 16 Mar 2012

Supersedes GMND-SVX01A-EN (01 Mar 2010)

Trane Gas Unit Heaters Installation And Maintenance Manual GMND SVX01B EN 03/16/2012 Installation, Operation, Heater Separated Combustion Indoor Fired Duc

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