79/80 SERIES OWNERS MANUAL
Contents
1. 1353 _ ONIEJA TIV INONIIHI 4 BOLOA SNOLLONYLSBO S123HM NOJHO 9 divas UNYI YO 35113 NMO19 N923H9 HOS WOIHLOTTS MOHO OOH ON lk 0 E Problem Burner Cycling On and CHECK 12 VDC SUPPLY CHECK SHORT CYCLING THERMOSTAT CHECK LIMIT SWITCH CHECK DUCT STATIC PRESSURE CHECK POWER AT THE VALVE CHECK POWER AT THE MODULE CHECK SAIL SWITCH OPERATION F Problem Ignition Pop CHECK FOR 12 VDC AT SUPPLY CHECK GAS PRESSURE PLUGGED MAIN BURNER ORIFICE CRACKED ELECTRODE INSULATORS ELECTRODE ADJUSTMENT LOW RPM MOTOR G Problem Blower or Motor Noise CHECK BLOWER WHEEL FOR BALANCE MOTOR HUMMING H Problem Erratic Fan Operation CHECK RELAY CONTACTS CHECK THERMOSTAT CONTACT ENSURE CORRECT POLARITY AT FURNACE CONNECTION REPLACE THERMOSTAT CHECK FOR CHECK WIRE PROPER LIMIT FOR CONTINUITY CHECK DUCTING CLEAN OR FOR RESTRICTIONS REPAIR CHECK WIRE REPLACE FOR CONTINUITY WIRE CHECK WIRE REPLACE FOR CONTINUITY WIRE CHECK POSITION CHECK FOR OF SAIL RESTRICTIONS REMOVE AND CLEAN REPLACE ELECTRODE ADJUSTOR REPLACE REPLACE MOTOR REPLACE MOTOR REPLACE RELAY CLEANOR REPLACE CHECK WIRING CHECK FOR REPAIR OR TOMOTOR CONTINUI2. hydro flame corporation 1874 SOUTH PIONEER ROAD SALT LAKE CITY UTAH 84104 79 80 SERIES 22 OWNERS MANUAL 2 IMPORTANT INSTRUCTIONS MUST STAY WITH UNIT OWNER READ CAREFULLY KEEP FOR FUTURE REFERENCE Discover DIRECT VENT CENTRAL AND FAN TYPE DIRECT rr VENT WALL FURNACE FOR INSTALLATION IN RECREATIONAL America VEHICLES OR MANUFACTURED MOBILE HOME TESTED TO U L 307 B APPROVED APPROVAL CERTIFIED BY C G A WARNING THIS UNIT MUST BE SERVICED ONLY BY AN AU THORIZED SERVICEMAN MODIFICATION OF THE APPLIANCE CAN BE EXTREMELY HAZARDOUS AND COULD LEAD TO SERIOUS INJURY OR DEATH FOR YOUR SAFETY if you smell gas 1 Open all windows Don t touch any electrical switches 2 FUEL BURNING APPLIANCES GENERATE TOXIC FLUE 3 Extinguish any open flame 4 5 PRODUCTS MODIFICATION OR IMPROPER MAINTE NANCE CAN CAUSE CARBON MONOXIDE IN DEADLY AMOUNTS TO PREVENT THIS MAINTAIN APPLIANCE IN SAFE OPERATING CONDITION DONOT BLOCK OR MODIFY ANY COMBUSTION AIR OR FLUE GAS PASSAGEWAYS DONOT ADD ANY DEVICES OR ACCESSORIES TO THIS APPLIANCE EXCEPT THOSE SPECIFI CALLY AUTHORIZED BY HYDRO FLAME ALWAYS CONSULT YOUR AUTHORIZED SERVICEMAN FOR ANY PROBLEMS OR QUESTIONS YOU MAY HAVE PERTAINING TO THIS APPLIANCE ALWAYS INSPECT THE APPLIANCE BEFORE START ING A NEW HEATING SEASON PAYING SPECIAL ATTENTION TO COMBUSTION AIR FLUE GAS PASSAGEWAYS AND FUEL LINES Vacate premises until ventilati
3. B and the exhaust tube extension C which will be installed from the outside of the coach sch 3 Provide 1114 high 8 wide opening in the cabinet and 2 7 16 high x 4 15 16 wide opening in the outside wall See figure 1 4 On side discharge models remove the left knockout plate See figure 3 A On front discharge type models remove the front discharge cover plate See figure 5 B On optional front side models remove or install the duct cover plate or front discharge cover plate To install duct adapters for side discharge models insert back flange over casing and insert tab into square notch then twist adapter 180 degrees 5 Install furnace into cabinet opening and secure with two screws through holes that are provided in control box flanges See figure 4 A Slide 4 ducting material over duct adapters and secure and seal for ducted models 6 To determine the vent lengths required determine the length from the back of the furnace casing to the outside of vehicle side wall this will give you A dimension See figure 2 for correct vent kit A To install combustion air box apply mastic or sealant to back of flanges on box Slide through outside wall cut out and into furnace air channel DO NOT FORCE OR BEND PARTS OUT OF SHAPE B Apply mastic or sealant to the top and sides of the outer edge of the vent cap DO NOT PLUG HOLES Slide assembly over furnace exhaust tube push into wall a
4. SCREW LIMIT SWITCH y DA j st COMBUSTION HOSE PILOT FIGURE 4 HOO QBSERVATION 2 LIGHT or MODELS ONLY FIGURE 5 PREVENTIVE MAINTENANCE 1 Clean complete furnace and air tube passageways periodically as needed to remove dust lint etc 2 Check gas system for leaks at least once a year 3 Check blower wheels annually and clean 4 Check warm air ducts and registers for dirt and lint once a year Isometric Description Part Isometric Description Part No Number Number A Door Catch 1145 AA Heating Element 1689 B Front Grill 1836 Assy Pilot Combustion Wheel 1137 BB Heating Element 1828 D Circulating Wheel 1140 Assy 051 E Sail Switch Assy 1685 F Mator 79 Only 1036 G Motor 80 Only 1035 H Electrode 1287 Electrode Gasket 2172 J Circuit Breaker 1028 K Manifold Robertshaw 2696 L Manifold W R 3180 M Burner Head Assy 2008 N Valve Bkt Robertshaw 3007 0 Valve Bkt W R 3210 Pilot Control Valve 2697 Q DSI Control Valve 2886 R 051 Board 1288 5 Duct Cover Plate 1361 T Duct Adapter 1474 U Comb Air Hose 1880 Front Discharge Cover 1348 W Thermostat 1030 Burner Plate Pilot 1452 Y Burner Plate DS 1454 2 Limit Switch 1023 5 RED ORANGE SAIL SWITCH CIRCUIT BREAKE mu WHITE BLACK 7 RED iF ANY ORIGINAL WIRE HAS TO THERMO 12VDC THERMO REPLACED 11 MUST REPLACEO o EQUIVALENT
5. PN 1233 IF ANY ORIGINAL WIRE HAS TO BE REPLACED MUST BE REPLACED WITH TYPE EQUIVALENT RED ORANGE 5 SAIL SWITCH De 10 0 5 1 MODULE 4 CIRCUIT BREAKER 13 Po WHITE BLACK RED 15 AA Y 12VDC IGNITOR THERMO 12VDC THERMO W R VALVE 3276 CONTROLS COMPANY 100 W Victoria Street Long Beach CA 90805 ROOM THERMOSTAT CM60 12 24 VOLT amp CM66 MILLIVOLT HEATING THERMOSTATS DESCRIPTION The CM60 CM66 Room Thermostats control a heating system either gas oil or electric They sense the room temper ature and automatically open or close an electrical circuit to a valve or a relay in a heating appliance There are two main assemblies a cover and a base The cover has a decorative face plate and comes with or without ther mometer The temperature scales are Fahrenheit and Celsius There are three internal ribs which fit into guides in the base for centering and to provide gripping to hold the cover to the base The base mounts to the wall with two 6 screws Leveling is not required The system wiring is connected to two screw terminals on the back On the front is the bimetal coil a magnet contacts adjustable anticipator CM 60 model only a temperature setting lever and an optional OFF switch The anticipator adjusts the thermostat to the heating system and can be used to change the system cycles per hour for more even heating The lever sets the
6. board Check the high voltage wire for proper connection at both ends Clean any corrosion that may interfere with good electrical contact 4 HIGH VOLTAGE MALFUNCTION See Caution below If during the trial for ignition the spark is intermittent the valve may or may not open the following should be checked 1 Electrode spark gap should be 1 8 1 32 2 Ceramic insulators check for cracks 3 Electrode lead wires check for cracks or breaks 5 VALVE MALFUNCTION If there is power to the gas valve and a spark during the trial for ignition but the valve will not open check the valve for an open coil or other malfunction 6 ERRATIC OPERATION If the system operates properly for a period of time but randomly shuts down during the duty cycle or will not operate during cold starts check the flame proving circuit sensor wire with a D C Microamp Meter The current should be 5 15 microamps A low or marginal flame current may cause nuisance tripping If this condition is experienced the electrode location should be checked to make sure the sensor electrode is in the flame Low microamps can also be caused by too much combustion air The solid state control module is not field repairable Any modifications or repairs could alter the function of sensitive electronic circuits and cause unsafe operation CAUTION SERVICING THIS DEVICE SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE MAN WITH DUE REGARD FOR SAFETY AS IMPROP
7. in this bulletin are approved by the Manufacturer Replace thermostat if other service is required 1 Disconnect electricity to the appliance before in stallation or service Reconnect when through 2 DO NOT short control terminals at appliance to test system Room thermostat will be damaged 3 DO NOT locate thermostat in a humid area The life expectancy will be reduced 4 Wiring must conform to local codes and ordi nances 5 When appliances have time delay control the system operation will lag behind thermostat a 2 1 4 57 15 MM CONTACTS TEMPERATURE SETTING LEVER MOUNTING HOLE COVER GUIDE 3 INDICATOR MAGNET 41 275 MM MOUNTING HOLE OPTIONAL ADJUSTABLE HEAT ANTICIPATOR CALIBRATION SHAFT SLOTTED MODEL 80 ONLY CM60 Shown Above THERMOSTAT BASE FIGURE 2 INSTALLATION 1 Disconnect electricity warning note 1 2 Grip cover at top and bottom and pull off 3 Drill mounting holes in wall fig 2 4 Pull about 3 inches of wire through wall opening and strip the ends 3 8 inch Connect wires to screw terminals fig 3 and tighten securely Bend wires to prevent in terference with the temperature setting lever 5 Push wires back through wall opening leaving some slack Close opening with insulating material 6 Mount base to wall with the furnished screws ADJUSTMENTS ANTICIPATOR CM60 Model Only The anticipator must be set by the installer Set
8. most of the remaining gases and heat from the heat exchanger OPERATING INSTRUCTIONS PILOT IGNITION MODELS Important Failure to follow these lighting instructions exactly may result in damage to the furnace To place furnace into operation 1 2 Press gas valve knob and turn to off Set thermostat to highest setting if thermostat has an on off switch turn to on and wait 5 minutes Turn gas valve knob to pilot position NOTE Fan should be running Press gas valve knob in and light pilot by pushing in on ignitor repeatedly until pilot lights Hold gas vaive knob in for one minute or until pilot remains lit Set thermostat to desired setting FAN SHOULD BE RUNNING then turn gas valve knob to on position For complete shut down Turn gas valve knob to off position and thermostat to lowest setting or switch to off position SEQUENCE OF NORMAL OPERATION 1 2 3 When the wall thermostat contacts close a time delay fan relay is energized After a 15 second delay the motor starts turning the circulating and combustion air wheels When the blower reaches the R P M s necessary to close the air operated sail switch power is supplied through a temperature limit switch to open the main gas valve The burner is then ignited by the pilot flame When the wall thermostat contacts open the fan relay is de energized the gas valve closes and the blowe
9. of 15 to 30 seconds will elapse before the time delay relay energizes the fan motor 2 As the fan motor reaches approximately 75 of the normal R P M within 1 to 2 seconds the sail switch in response to the air flow will close allowing current flow to the direct spark ignition board 3 The direct spark ignition board will send current to the gas valve and allow gas to flow to the main burner where it is ignited by a direct spark igniter 4 f the thermostat is satisfied or turned down the gas valve will close and the flame on the main burner will go out The blower will continue to run for a short period of time and then shut off The purpose of this is to remove most of the remaining gases and heat from the exchanger OPERATIONAL CHECKOUT IMPORTANT Failure to follow these lighting instructions exactly may result in damage to the furnace 1 Set thermostat to off position 2 Turn gas valve to off position if is so equipped Wait 5 minutes Gas valve 5 located behind front door panel To remove pull forward at the bottom of door and lift off 3 Turn gas valve to full on position Correct operation of the furnace depends on this valve being in the full on position Never attempt to operate the furnace with valve partially closed furnace is equipped with a shut off 4 Set thermostat to the desired temperature Furnace will now operate automatically When the thermostat calls for h
10. running 4 Press gas valve knob in and light pilot by pushing in on ignitor repeatedly until pilot lights Hold gas valve knob for one minute or until pilot remains lit 5 Set thermostat to desired setting fan should be running then turn gas valve knob to on position For complete shut down Turn gas valve knob to pilot position depress and turn to off position and thermostat to lowest setting or switch to off position SHORT CIRCUIT CHECKOUT If a fuse is blown or circuit breaker is tripped a short is indicated and should be checked 1 Turn off all appliances including the furnace 2 Install an ammeter on the positive lead of the battery The meter reading should be 0 If an amperage reading ceases the furnace electrical system is shorted or mis wired amp should be checked See wiring diagram 3 Refer to the operation and service instructions tor a complete checkout FIGURE Ya 4 FIGURE FRONT VIEW 79 80 VENT KIT CABINET VENTIEXTENSIONS DIM DEPTH KIT EXH AIR MODELS MIN T MAC MAX NO 75 1 97182 720 585 5412150 168016277 HF 80 E 3 1 2 7 1 2123 3 4128 8 8 2151 1679 1676 7 1 2 1 1 2 20 98 32 2145 1678 1675 FIGURE 2 EXTENSION 8 DUCT ADAPTEA SIDE DUCTING FIGURE 3 GAS CONNECTION BURNER PLATE MOUNTNG HOLES FRONT DISCHAR COVER PLATE oe CIRCUIT BREAKER JUNCTION BOX COVER
11. 41434 MOHO ATNO Ni SONJ S WAWININ 39V 1438 300419313 ONNOYD 93 9 HOZHO SNOLLOINNOO NadO LYOHS auvod 803 LINDUID NOSHO HOSNSS A93HO 05 36 NOSHO SONOD3S LNI SINDOO IND APOT sawung wsjqoid JGOLULIJTI YOIH SNOLL IYLSJY HOS 3013180 YANHNE NOSHO 30V1d3y 9 OL LSnray dY9 373 NOJHO NYIT SAOWSH OM TL ONY 9 01 8 135 34NSS3YUd SVD ADIHO ONINSdO TOULNOO IOULNOD SVD 3041434 S 9 NOSHO YOHLNOOD SYD OL3Y M 40 ALINNILNOD HOSHO JUM 391438 330 10 5 SYD MOSHI NadO TINS OLNYNL 4 ON suny J98MOjg 0 O 50 09435 4 5531 SI ONIMYVdS dl ONTAJ 1VISONY3HL NIIMLIO SONOI3S 09 LIVM YOLOANNOOD NO NOISOYHO9 A93H9 INIALSNFOV 3004819313 93 9 JINON 39V1434 Ind LNO AUYAS INGON NIH SINGOW OL X93H9 HOLIMS TIVS OL ALINNLLNOO 321939 JIM ADTHO JAM ONY OL reds 9 014 8 Nvo SAOWSH SLOVLNOO SSOYIV ON dl
12. ER ACTIONS COULD RESULT IN A HAZARDOUS CONDITION RESULTING IN SERIOUS INJURY OR DEATH WARNING DO NOT APPLY POWER TO CONTROL MODULE UNLESS WIRING CONNECTIONS ARE COMPLETE AND ELECTRODE 15 PROPERLY GROUNDED USE EXTRA CAUTION IN AREAS WHERE HIGH VOLTAGE IS PRESENT IF ANY ORIGINAL WIRE HAS 27 REPLACED MUST BE REPLACED WITH 106 C WIRE OR ITS EQUIVALENT CIRCUIT 5 RED ORANGE SAIL SWITCH A 0 5 1 MODULE BREAKER 0 WHITE BLACK RED 1 2 3 12VDC THERMO 12VDC THERMO RELAY L CIRCUIT REAKER WHITE BLACK THERMO 12VDC THERMO 12 VDC SS 16 SENSOR DG IGNITOR W R VALVE 5 RED ORANGE F SAIL SWITCH up IF ANY ORIGINAL WIRE HAS TO BE REPLACED 11 MUST REPLACED WITH TYPE 105 C WIRE OR ITS EQUIVALENT PN 1233 1874 SOUTH PIONEER ROAD SALT LAKE CITY UTAH 84104 601 972 4621 FAX 801 973 9838 hydro flame corporation 4 E merica DIRECT SPARK IGNITION TROUBLE SHOOTING GUIDE CAUTION SERVICING THIS FURNACE SHOULD ONLY BE PERFORMED BY A QUALIFIED SER VICEMAN WITH DUE REGARD FOR SAFETY AS IMPROPER ACTIONS COULD RESULT IN A HAZARDOUS CONDITION RESULTING IN SERIOUS INJURY OR DEATH OPERATING SEQUENCE A When the thermostat contacts close a circuit is completed to the blower time delay relay coil ground to the gas valve and to terminal ground of the control module see wiring sche
13. NACE IS NOT DESIGNED FOR USE WITH AIR FILTERS NOR ARE THEY TO BE USED IN CONJUNCTION WITH COOLING UNITS READ ALL INSTRUCTIONS BEFORE STARTING These furnaces are design certified for propane gas only DO NOT CONVERT TO NATURAL GAS at the following gas inlet pressure 11 0 W C maximum W C Water Column WARNING THESE FURNACES MUST BE INSTALLED AND VENTED SO THAT THE NEGATIVE PRESSURE CREATED BY THE CIRCULATING AIR BLOWER CANNOT EFFECT THE COMBUSTION AIR INTAKE OR VENTING OF ANY OTHER APPLIANCE 100 0106 P N 3227B Input Output Type Electrical Model No BTU HR BTU HR Gas Rating Amps Watts FA 7920 D or P 19 500 15 700 Propane 12 VDC 2 9 34 8 FA 7916 D or P 16 000 12 900 Propane 12 VDC 2 9 34 8 FA 7912 Dor P 12 000 10 000 Propane 12 VDC 2 9 34 8 HF 8012 D or P 12 000 10 000 Propane 12 VDC 1 6 19 2 LETTERS AFTER THE MODEL NUMBER STAND FOR D Direct Spark Ignition P Piezo Spark Ignition FURNACE DIMENSIONS Casing Door Vent Cap Width 8 97 57 Height 11 1112 3 Length 20 5 16 Depth 114 Y Due to High Temperatures the appliance should be located out of traffic and away from furniture and draperies Adults and Children should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room as the appliance Clothing or other flammable materials should not be placed o
14. TY REPLACE REPLACE WIRE hydro flame corporation 1874 SOUTH PIONEER ROAD SALT LAKE CITY UTAH 84104 801 972 4621 FAX 801 973 9836 gt Installation Instructions For Models FA 7920 FA 7916 FA 7912 and HF 8012 Direct Vent Central and Fan Type Direct Vent Wall Furnaces for Installation in Recreational Vehicle or Manufactured Mobile Home Disen APPROVED O CERTIFIED BY C G A TESTED TO U L 307 b These furnaces are for use with propane gas only and must be installed only by QUALIFIED personnel in accordance with these instructions The installation must also with the following codes where they apply ALL LOCAL CODES National Fuel Gas Code ANSI Z 223 1 1984 American National Standard for Recreational Vehicles ANSI A 119 2 1982 and A 119 5 CSA Z 240 4 1 and 2 and 2 240 6 2 Can 1 B 149 Installation Code The Manufactured Home Construction and Safety Standard Title 24 CFR part 3280 This furnace conforms to Part 280 707 a 2 of Hud Mobile Home Construction and Safety Standard THIS FURNACE WAS TESTED AND INSPECTED BEFORE IT LEFT THE FACTORY IF ANY PARTS ARE FOUND TO BE DAMAGED DO NOT INSTALL THE FURNACE IMMEDIATELY CONTACT THE TRANSPORTATION COMPANY AND FILE A CLAIM WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJURY PROPERTY DAMAGE OR DEATH THIS FUR
15. e of the battery Amperage reading should be 0 If the amperage reading ceases the furnace electrical system is shorted or miswired should be checked AMPERAGE DRAW THROUGH FURNACE WITH THERMOSTAT OFF 1 Incorrect wiring If the 12 volt and thermostat wires are not connected properly at the furnace a continuous circuit can be created through the heater of the fan relay If this condition exists the blower will start as soon as the thermostat closes and will shut off when the thermostat opens instead of having a delayed action In some cases this will also burn out the thermostat Refer to the wiring diagram for correct connections 2 Internal short to ground in gas control or motor Disconnect all wiring to contro or motor and use an ohmeter to check for shorts to ground At no point should there be a reading between the electrical circuit of the motor control and ground GAS SUPPLY Be sure manual gas valve is in the full open position NEVER operate furnace with valve partially open THERMOSTAT Check to be sure thermostat is properly wired and is calling for heat MALFUNCTION CIRCULATING AIR SWITCH Be sure the circulation air switch is moving enough to close its contacts If the switch is not closing clean any dust or dirt from the actuator pin Other reasons for the switch not operating are 1 Insufficient fan speed slow motor due to low charged battery faulty motor or line and dust accumulation restricting r
16. e thermostat to stabilize for 10 minutes 2 Set the lever to the reading of a thermometer that is accurate and is close to the thermostat or to the ther mostat thermometer if so equipped Remove cover Do not let heat from hands breath etc affect calibration Work quickly 3 Hold the lever stationary and with a blade screwdriver turn the calibration shaft fig 2 counter clockwise until the contacts are apart and slowly turn the shaft clock wise until the contacts just snap closed 4 Replace cover and set temperature setting lever to the desired setting THERMOMETER CALIBRATION 1 Place an accurate thermometer close to the thermostat 2 Remove cover and with a blade screwdriver turn push the small slotted shaft on the inside of the cover until the pointer has correct reading on the scale Breath and body heat will affect the sensitive bimetal make adjustment quickly SERVICE CONTACT CLEANING 1 Grip cover at top and bottom and pull off carefully 2 Move temperature lever to open contacts Place a piece of unprinted unglazed paper between the contacts and move the lever to close them Press lightly on the moveable contact and polish by moving the paper back and forth Removes tarnish 3 Replace cover and test system operation by setting lever 28 050 0430E 87520 8 88
17. eat a delay of 15 to 30 seconds will occur before the fan motor is energized 5 Allow 15 seconds for burner to ignite 6 If burner does not ignite set thermostat to the off position Wait 60 seconds and reset to on position 7 Mignition is not obtained after three tries go to complete shut down and determine cause FOR COMPLETE SHUT DOWN TURN GAS VALVE KNOB TO OFF IF FURNACE IS SO EQUIPPED SET THERMOSTAT TO OFF SETTING SEQUENCE OF PILOT OPERATION When the wall thermostat contacts close a time delayed relay is energized After a 15 second delay the motor starts turning the circulating and combustion wheels When the blower reaches the 5 necessary to close the air operated sail switch power is supplied through a temperature limit switch to open the main gas valve The burner is then ignited by the pilot flame When the wall thermostat contact opens the fan relay is de energized the gas valve closes and the blower motor stops running after 45 seconds to 2 minutes This is a cool down period and is normal OPERATIONAL CHECKOUT IMPORTANT Failure to follow these lighting instructions exactly may result in damage to the furnace To place furnace into operation 1 Press gas valve knob in and turn to off 2 Set thermostat to highest setting if thermostat has an on off switch turn to and wait 5 minutes 3 Tum gas valve knob to pilot position NOTE Blower should be
18. eturn air to furnace Check wiring in accordance with units wiring diagram to ensure that proper polarity of the 12 volt D C power supply is observed This polarity must be observed so the motor will run in the proper direction of rotation to insure correct air delivery 2 Faulty circulating air switch if there is no continuity through the contacts when the sail is closed Switch should also be replaced if battery is fully charged and with fan motor running at normal speed the switch fails to close within 3 to 4 seconds GAS CONTROL VALVE Check valve terminals If voltage is present but valve does not open when circulating air switch is closed replace control valve FAN NOT OPERATING Check for burned out motor loose wiring terminals blown fuse tripped circuit breaker or no power to the furnace DEFECTIVE FAN RELAY Relay may be at fault if motor fails to start within 60 seconds after thermostat calls for heat EXCESSIVE BLOWER NOISE 1 Motor or blower wheel out of balance Replace motor or blower wheel Also blower wheel may need to be repositioned on the motor shaft if blower wheel is rubbing housing 2 Motor hum Replace motor FAN OPERATION A loose terminal defective relay or reversed wiring polarity may cause the motor to cycle off while the thermostat is calling for heat Repair terminal or replace relay DIRECT SPARK IGNITION SYSTEM DESCRIPTION The direct spark ignition system consists of a so
19. lid state printed circuit control module an electrode assembly a 12 volt gas control and connecting high and low voltage wires To ignite the burner it is necessary only to set the thermostat The thermostat in series with the air prover switch powers the ignitor to simultaneously open the main burner valve and provide the ignition spark Should the flame not be established within a period of 7 seconds the system provides safety shut down Electronic flame sensing circuitry in the ignitor detects the presence or absence of the main burner flame If the flame is not established during the flame establishing period the system closes the gas valve and locks out If the flame is extinguished during the ignition cycle the ignitor will provide one retry for ignition before going into lock out To reactivate or retry for ignition if lock out has occurred set the thermostat to the off position for 60 seconds then reset to the on position 1 INPUT POLARITY If a spark is present and the gas valve opens but the system shuts down after the trial period check input voltage for proper polarity 2 GROUNDING It is essential to proper operation that the system be properly grounded If a spark is present and the gas valve opens but the system shuts down after the trial for ignition period check for proper ground 3 WIRING Check all wiring for proper and secure connections Be sure the connector is fully engaged on the control
20. match your level setting If it doesn t remove cover and turn the small inside slotted shaft on the inside of the cover until thermometer reading and thermostat lever setting match ATTENTION When first fired the furnace may circulate fumes caused by the burning of material used in the manufacturing process These fumes may cause physical irritation in some per sons We therefore recommend that you open all windows and doors on initial firing until the fumes have fully dissi pated to the outside 2 When snapping the cover onto thermostat base make sure that on off switch on the front cover is in the on switch position This will allow the switch to function properly Turn the switch to off when the furnace is not in use Failure to do so may cause battery drain SERVICE HINTS DIAGNOSIS AND CORRECTIVE MEASURES INSTALLATION AND SERVICE SHOULD BE DONE ONLY BY A QUALIFIED SERVICE PERSON THE APPLIANCE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A PROFESSIONAL SERVICE PERSON MORE FREQUENT CLEANING MAY BE REQUIRED DUE TO EXCESSIVE LINT FROM CARPETING BEDDING MATER IAL ETC IT IS IMPERATIVE THAT CONTROL COMPARTMENTS BURNERS AND CIRCULATING AIR PASSAGEWAYS OF THE APPLIANCE BE KEPT CLEAN SHORT CIRCUIT CHECKOUT if fuses are blown or circuit breaker is tripped short is indicated and should be checked 1 Turn off all appliances including furnace 2 Install an ammeter on the positive sid
21. matic The module does not operate at this time the sail switch is open no power to L1 B After a 15 30 second delay the blower relay contacts close completing the circuit to the blower motor C When the blower motor reaches approximately 75 of its rated speed the sail switch closes completing the power circuit through the limit switch to terminal L1 of the control module When the control module receives power it simultaneously energizes three separate circuits 1 12 vdc is supplied to the gas control allowing gas to flow to the main burner 2 Intermittent high voltage is applied to the ignition electrode causing a spark to ground igniting the gas from the burner 3 An AC voltage is applied to the flame sensor If a proper flame is present small rectified DC current signals the control module that flame is present and the heater will remain on until the end of the heating cycle when the thermostat opens The blower will continue to run for approximately 45 seconds to 2 minutes DIRECT SPARK IGNITION SCHEMATIC T STAT CIRCUIT BREACKER j SENSOR GROUND la L gt alk HIGH VOLTAGE IGAS IGNITOR VALVE 71 100 0105 3222 6300319319 YO SUSOd30 NOSyVO MOSH 8OLVINDIY AlddNS SVD ONIGYIY SCNOO3S HOAHD 293137 TINGON ONIOVIY dV ATIVNOISY990 39
22. n or near the appliance Any safety screen or guard removed for servicing an appliance must be replaced prior to operating the appliance Installation and repair should be done by a qualified service person The appliance should be inspected before each use and at least annually by a professional service person Note frequent cleaning may be required due to excessive lint from carpeting bedding material It is imperative that control compartments burners and circulating air passageways of the appliance be kept clean MINIMUM CLEARANCE TO COMBUSTIBLES TOP AND SIDES 1 4 0 TO SPACERS AIR TUBE 0 REAR 0 FRONT AS REQUIRED FOR SERVICE DUCTS WITHIN 3 0 OF FURNACE 1 4 EXCEPT THAT ULL LISTED WIRE BOUND VINYL AIR DUCTS MAY HAVE 0 CLEARANCE BOTTOM EQUALS 1 0 TO SPACERS DO NOT INSTALL ON CARPETING RETURN AIR 1 Return air is supplied through front grill panel All that is needed is to maintain the required clearances as called for 2 Route wiring to right side of furnace using a minimum of 22 to 18 guage wire to thermostat INSTALLATION This furnace must be installed in accordance with these instructions and all National or Local Codes and C S A Standards 1 Select a location for installing the furnace through an outside wall It is recommended that it be located as far as possible from any outside projection such as a tilt out room 2 Remove from furnace the combustion air box extension
23. nd secure with two screws Note bottom flange is not sealed to allow water drainage 7 Install self trim door by sliding door flange over control box top flange and pushing in on bottom of door NOTE To assure sufficient return air to the circulating blower maintain specified clearances ELECTRICAL 1 Remove junction box cover from furnace by removing screw located on the right side See figure 5 2 Route wiring to right side of furnace using a minimum of 18 GA wire except for thermostat wires 3 Connect furnace wiring to field wiring as shown FIELD LEADS FURNACE LEADS 12 VDC and thermostat to Red 12 VDC and thermostat 12 VDC to Black 12 VDC Thermostat to White thermostat 4 Replace junction box cover NOTE 1 OBSERVE POLARITY OF LEADS WHEN CONNECTING 2 Ground the furnace in accordance with national electrical ANSI NPFA No 70 1984 and all local codes Canadian Electrical Code C 22 1 GAS PIPING For gas piping and pipe sizing refer to the Federal Mobile Home Construction and Safety Standard part 280 N F P A 54 or ANS N F P A NO 501C 1977 and all state and local codes Gas Line hook up is made through the left side of the furnace casing Actual hook up is accomplished inside the furnace casing immediately ahead of the Gas Control Valve A 3 8 flared fitting connection is provided at the control valve inlet for gas supply connection to the furnace The gas supply line of the furnace mus
24. on is complete and gas source is found and corrected Immediately call your supplier FOR YOUR SAFETY Clothing or other flammable material should not be placed on or near the appliance Do not store or use gasoline or other flammable vapors liquids in the vicinity of this or any other appliance Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room as the appliance WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE REFER TO THIS MANUAL FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER 100 0107 P N 3220C THE AREA IN WHICH THIS FURNACE IS INSTALLED MUST BE KEPT CLEAN DO NOT STORE ANYTHING AROUND THE FURNACE THAT WILL RESTRICT THE AIR FLOW TO THE FURNACE NEVER PLACE HAZARDOUS MATERIALS SUCH AS AEROSOL CANS PLASTIC CONTAINERS GASOLINE OR ANY OTHER FLAMMABLE MATERIALS NEAR THE FURNACE Before proceeding check all gas connections with a soap solution to detect any leaks NEVER check for leaks with a lighted match OPERATING INSTRUCTIONS AUTOMATIC DIRECT SPARK IGNITION MODELS Important Failure to follow these lighting instructions exactly may result in damage to the furnace 1 2 Set thermostat on off po
25. r motor stops after a 45 to 120 seconds for a cool down period TIME DELAY FAN RELAY This relay controls the sequence of the blower operation When the bimetal disc of the relay is heated internally to its operating temperature the switch closes This completes the circuit to the motor The blower will continue to run as long as the relay is hot even though the thermostat is satisfied and the main bumer is off When the relay sensor cools after the thermostat is satisfied the switch opens and the blower shuts off LIMIT SWITCH The purpose of the limit control is to open the circuit to the main burner if for any reason the furnace becomes abnormally hot If the circulating air system is blocked even partially the limit contro will function and cause the main burner to cycle if cycling of the limit control occurs the circulating air passage should be thoroughly cleaned the ducts and register checked for restriction check for 12 volts to the furnace If the limit control is damaged it cannot be repaired lt must be replaced with a new one CAUTION NEVER SHORT ACROSS OR BYPASS THE LIMIT CONTROL EVEN FOR ONLY TEMPORARY OPERATION AIR SWITCH The circulating air switch has two purposes 1 It is an air prover It operates in response to the flow of air generated by the blower wheel Hence if for any reason the air from the blower wheel is not sufficient the switch will not operate One cause of insufficient air is a slow motor cau
26. sed by low voltage 2 The switch allows time for the blower to pull in a sufficient amount of air for combustion before it engages it closes power is supplied to the direct spark ignition module and the ignition cycles starts BLOWER ASSEMBLY BURNER One motor is used to drive both the combustion air and the circulating air blower wheels Although one motor drives both wheels the blowers are separate The combustion air blower is sealed so as to allow no passage of air between it and the circulating room air blower The combustion air blower draws air from the outside atmosphere and into the burner box then the gas controls allow gas to flow into the burner where it is mixed then expelled through the burner screen where it is ignited in the combustion chamber MAINTENANCE AND CLEANING NOTE For continued satisfactory performance of this unit it is necessary that the control compartment be kept clean It is also important that the appliance area be clean and free of combustible materials vapors and liquids Routine inspections maintenance and cleaning of venting system and gas connections is recommended at least on a yearly basis or as required The motor is permanently lubricated and sealed and requires no oiling THERMOSTAT 1 Thermometer adjustment for correct temperature setting Move control lever so that your heater comes on about 3 degrees below room temperature When the heater shuts off your thermometer should
27. sition Turn thermostat on off position If furnace is so equipped Wait 5 minutes See figure 1 Gas valve is located behind louver panel door To remove pull forward and lift off Set thermostat to on position and adjust to desired setting Allow 15 to 30 seconds for burner to ignite If burner does not light set thermostat on off position wait 60 seconds then re set thermostat to on position If ignition is not obtained after 3 tries go to complete shut down and determine cause Turn gas valve knob to off position if furnace is so equipped See figure 1 Set thermostat to off position FIGURE 1 KNOB POSITIONS a SEQUENCE OF NORMAL OPERATION 1 When the thermostat calls for heat a delay of 15 to 30 seconds will elapse before the time delay relay energizes the fan motor When the fan motor reaches approximately 75 of the normal R P M within 1 to 2 seconds the sail switch in response to the air flow will engage allowing current flow to the gas valve through the direct spark ignition module The gas valve will open and allow gas to flow to the main burner where it is ignited by the direct spark ignition system If the thermostat is satisfied or turned down the gas valve will close and the flame on the main burner will go out The blower will continue to run for a short period of time and will then shut off The purpose of this is to remove
28. t be of adequate size to provide 11 water column gas pressure This pressure must be maintained under maximum flow conditions with all gas appliances in operation Tubing may be type K for propane gas Bottled Gas however be sure to check with ANS CGA and CSA Standards for any other requirements concerning gas piping This furnace and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressure in excess of 1 2 psig 3 45 KPA This furnace must be isolated from the gas supply piping system by closing the manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 45 KPA A 1 8 N P T plugged tapping accessible for test gage connection is recommended installed immediately up stream of the gas supply connection to the furnace IMPORTANT All pipe joints must be sealed with a sealing compound resistant to the effects of LP or Natural Gas These joints must then be leak checked NEVER USE A FLAME TO CHECK FOR LEAKS CAUTION DO NOT TWIST VALVE DURING PIPING NOTE Standards may require installation of an external manual shut off valve if required the manual valve must be located outside the confines of the furnace casing except if shut off is supplied as part of the furnace SEQUENCE OF DIRECT SPARK IGNITION OPERATION 1 When the thermostat calls for heat a delay
29. temperature at which the thermostat turns the system ON SPECIFICATIONS ELECTRICAL RATING CM60 24 volt nominal 30 VAC 1 0 amperes 12 volt D C nominal CM66 Millivoit 250 to 750 millivolt APPLICATION Two wire heating ANTICIPATOR 18 1 0 amperes adjustable CM60 only TEMPERATURE RANGE 50 F to 90 F 10 C to 30 C TEMPERATURE DIFFERENTIAL 2 F 1 SIZE 3 1 4 x 1 1 2 inches OPTIONAL FEATURES OFF switch thermometer custom zed cover face plate HI LO temperature setting stops TRANSFORMEA GAS VALVE A suitable timit control is required in either the 24 volt 12 volt DC or 120 volt side of the transformer iSsLimit Switch PILOT GAS VALVE ROOM GENERATOR THERMOSTAT LOCATION e Locate an inside wall about five feet off the floor access ible to wiring service and adjustment in a frequently used room such as a living room etc e Do not locate in unusual heating conditions such as in sunlight close to lamps TV sets radiators registers or other heat producing appliances e Do not locate in unusual cooling conditions such as on an outside wall or one separating an unheated room or in drafts from stairwells doors windows e Do not locate where air circulation is poor such as in a corner alcove over furniture or behind an open door WARNING READ CAREFULLY BEFORE PROCEEDING This is a precision instrument handle carefully Only the procedures outlined
30. to one of the following conditions 1 The same reading as the replaced thermostat 2 current draw amperage of the valve or relay see label on the control 3 The circuit amperage determined as follows A Set the temperature setting lever to the lowest position LH side so that contacts are open B Use an AC ammeter for 24 volt applications or DC ammeter for 12 VDC applications 0 1 ampere range and place probes on point A and point B fig 2 Heating control or relay must then turn ON and a reading appear on the meter Do not use a voltmeter NOTE If equipped with an OFF switch put it in an ON position point B C Set anticipator slider to meter reading This is the nominal setting 4 After system has operated for several hours heating cycles should be from 4 6 per hour typical For more even heating cycles can be increased or decreased by adjusting anticipator Set to higher number for fewer cycles Make adjustments in smal increments POINT TEMPERATURE SETTING LEVE TERMINAL W Le OFF SWITCH OPTIONAL TERMINAL R COMMON THERMOSTAT BASE REAR VIEW FIGURE 3 CALIBRATION A thermostat responds to the temperature in its immediate area It is factory calibrated to turn ON when the room tem perature is at or below the selected temperature If re cali bration becomes necessary proceed as follows 1 Set temperature setting lever to the lowest position and allow th
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