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York DFAH User's Manual

1. vg SUBuVdd 13 SNISN 30 39V S3OIAG ONY ONIIM AYOLOVS UYBILNVHO 20 LNSNSGHOIOVY O NOILOSNNOD MAA O g 30314 30 LVLSONYSHL NO LNSNFGYOINVY AS V 1YLSONY3HL WOCH NOILO3NNOD Atz Y Steeg CT BISILN3OI LNIW NNOILONO4 30 YNILIOYAYI e HOLIOVdVI NAY OJIHILNIOI e 3AWA_SV Ou UNANYOASNVEL 1I YINYOJSNY L LI IT 4 BI4ILN3OI LNSWSNNOILONO4 30 MOL YI YOLIOVd D MH OUI D mjd 300419373 vg 5 aas gt asn4 c mla d SNOLSI4LNSO YNSLVLNWNOD SO HOLIMS OAI S9 L os Ki ILIN 30 YNBLVLNWNOD ze HOLIMS LINI zen YOSN3S KEEN 3WdIONIYd SLINIT 30 YNSLVLNNNOD 1S7 HOLIMS LINIT AUWWIdd 1S7 canto ame aE 7 8 us S39I1d 6 Y MOTO 13 3TUNOG IHINAANOS VI 30 YNILON II IS Id HOLON Y3M079 NO L OM Nid 6 IS Id Vaug OL RE Ek TAA yay teg STOHLNOD dd TOYLNOD AYWNTHd Od TIAMA INOH Se YOLO sIviad Za Au Zy oe S Ai TETE MOT NED YNILYWYOJSNYYL LI YSNYOISNVYL NOTLINSI LI K h 27 SUIVNINd SIQHLNOD od JOYLNO9 Aen 3d zl 2 zg SE vam na YNSLON Wa HOLON yaNNa mp V Kool E S ll v m ak aay E i E dr 30N3977 NOT HOLINS WONSTYLNSO NOLL MT Heel 30 S39 3104d INOS SHNSLON S37 9 suNaqnod 20 s3003 Gi NOLIVLNANITV 7 YNOd SYNSLONOPSIG S31 ZISSINYNOA S Z3AINS S3SINV1Od 3413 LIO0 LNVYNOD Nd NOILYLNINITY T 20031 N3 SSI
2. SOLO V GMN S2ssel SUSYVdd 13 Y3ILNVHO 20 2974 Sauvdd 13 3NISN 1 20 39V14 a SAOIASEGR Mai Gap S391430 ONY ONIYIM ANOLOVS YJILNYH 20 LNSWSCHOIOVE O NOILOSNNOI Om O 20914 30 LVLSONHSHL NG LNSNFCHOIIVY AYZ Y AVLSONYSHL WOH NOLLOZNNOD AvZ J SISILN3I LN3WSNNOILINOS 30 YNILIIVAYI XOLI YdY3 NNY OJIJILNIOI MMBNUOASNVYL LI USWYOASNVYL LI GE SI4LLN3I LN3NSNNOILONOS 30 YNALIOVdVI ul YOLIOVdVO NNY OUI aqgIsns co dasni co o3 ANOTATYLN3 YNILVLNANOD SI HOLIMS WOISINLN3I SO E TL SLINIT 30 YASLVLANNOD Ce HOLIMS LINII zen BNA aa D KAND LINI 30 YNILYLNWNOD 1S7 HOLIMS LINIT AYVATYd e T 4 NS S39Id 6 Y NOHONOG 13 3TUNOG IYINAANOS VI 20 YNILON II 1S Id YOLON YIM078 NO L3x00S OC Nid 6 IS id wll 3008419773 OL re E SUIVNIdd 3TOYLNOD Od TIOHLNOD Au 3d w l OIONS10S NG Aus AS 3AWA GIONITOS AS GH 3 Tarps oe Sin 19 AVY Iu YOSNAS SEH z NOILINOLG YNILYWYOJSNYYL LI YINYO4SNY L NOILIN9SI LI oiia TP IVI BUIVNINd J7QULNOD Id 0017 And Id uana OL ve omg NO YNSLON WE YOLON HM WE TIIMANOH Bebe c IR sere 30N3937 GN393 1 ES KEE A
3. 10 Blend Air Flex Duct Blend Air Damper I 4 Floor WARMAIR DUCT _ DUCT CONNECTOR FIGURE 14 Floor Installation SECTION Ill FILTERS FILTER INSTALLATION All applications require the use of a filter A standard air filter is located in the return filter rack on the louvered door The air filter s must be replaced with air filter s that are the same size and same type Replacement filter size is shown in Table 5 Downflow Filters There are two types of downflow filter racks 1 FURNACE FILTER RACK A return filter rack is with two standard throwaway type filters are supplied on all models The return filter rack is located on the inside of the louvered door This type of filter rack is designed for two standard air filters only Pleated Media or Washable Filters cannot be used in this filter rack because they cause too much pressure drop causing a reduction in airflow 2 EXTERNAL RETURN FILTER GRILLE The second type is an external return air filter grille that can only be used in applica tions where the furnace is installed in a closet This type of fil ter grille is typically installed in a closet door or wall with the filters located within 12 30 5 cm of the return air opening of the fur nace There must be a minimum clearance of 6 15 2 cm between the front of the furnace and the closet door and or the fur nace and the filter grille to prevent the return
4. Bleed amp Gauge Port a Return Port Z3 Inlet Port Install 1 16 by Pass Pipe 1 4 NPTF Plug For Two Pipe System Only 0 64 cm Use 5 32 Allen Wrench FIGURE 36 Oil Pump SET COMBUSTION WITH INSTRUMENTS f The combustion must be adjusted using test instruments Fail ure to do so could result in burner or appliance failure caus ing potential severe personal injury death or substantial property damage Let the burner run for approximately 5 to 10 minutes 24 2 Set the over fire or stack draft to level specified by appliance man ufacturer usually 0 01 to 0 02 w c 000024 to 0 0050 kPa over fire for natural draft applications 3 Follow these four steps to properly adjust the burner a Step 1 Adjust the air until a trace of smoke level is achieved b Step 2 At the trace of smoke level measure the COs or O9 This is the vital reference point for further adjustments e Example 13 5 CO 2 6 Ov c Step 3 Increase the air to reduce CO by 1 to 2 percentage points Op will be increased by approximately 1 4 to 2 7 per centage points Example Reduce CO from 13 5 to 11 5 2 6 to 5 3 Ov d Step 4 Recheck smoke level It should be zero s This procedure provides a margin of reserve air to accom modate variable conditions s If the draft level has to be changed recheck the smoke and CO levels Adjust the burner air if necessary 4 Once
5. FIGURE 20 Line Wiring Connections LOW VOLTAGE CONTROL WIRING CONNECTIONS 1 Insert 24 volt wires through the small plastic bushing just above the control panel 2 Connect the thermostat wires to the furnace low voltage pigtails See Figure 21 heating only and Figure 22 or 23 heating and cooling 3 Connect low voltage circuit to the wall thermostat pigtails NOTE Five conductor thermostat cable is recommended for all instal lations to allow easy installation of an air conditioning system at a later time Eighteen gauge thermostat wire is highly recommended Smaller gauge thermostat wire may be used only if the guideline below is followed Thermostat Wire Length Furnace to Thermostat 0 45 feet 22 0 70 feet 18 Do not use the thermostat wire smaller than 22 gauge If thermostat wire small than 18 gauge is used pay particular attention that the con nections between the difference wire sizes are tight Operational problems may be caused by loose connections or by the use of thermostat wire that is too small to carry the required load Any such problems are the responsibility of the installer A separate 115 V A C supply circuit must be used for the furnace The circuit should be protected by a 15 amp fuse or circuit breaker Avoid locations where the thermostat could be subject to drafts from outside or exposed to direct light from lamps sun fireplaces etc or affected by air from a duct registe
6. Accepted NYC MEA 213 83E and Fuel Oil MP1192 EVC20 R00 FIGURE 1 Label Location CHECK CERTIFICATIONS APPROVALS 2 Do not allow return air temperature to be below 55 F 13 C for e Underwriters Laboratories has certified this burner to comply with extended periods To do so may cause condensation to occur in ANSI UL 296 and has listed it for use with 1 or 2 fuel oil as the main heat exchanger leading to premature heat exchanger specified in ASTM D396 Low sulfur 1 and 2 fuel oils reduce failure heat exchanger deposits with all burners compared to the stan dard fuels Reduced deposits may extend the service interval for AWARNING cleaning and improve the efficiency of the appliance over time Low sulfur fuels reduce particulate and oxides of nitrogen emis Installation in an ambient below 32 F 0 0 C could create a haz sions as well The Oil Heat Manufacturers Association recom ard resulting in damage injury or death mends these fuels as the preferred fuels for this burner e State and local approvals are shown on burner rating label See Figure 1 e All oil burners must be installed in accordance with the regula tions of the latest revision of the National Fire Protection Associa 3 If this furnace is installed in an unconditioned space and an extended power failure occurs there will be potential damage to the internal components Following a power failure sit
7. Unitary Products Group 107272 UIM B 1105 WIRING DIAGRAM OIL FIRED FURNACE SECTION IX SO020 V OMN 997Z01 S713HYddY 13 XJILNYH 30 39V NOILd3ONO9 DT Hd 30 S39 310Yd LNOS SYNILON S37 NOLIVINAWINV 1 YNOd SYNSLONOPSIG SII ZISSINYNOA 20021 N3 ISIN NIIA 3413 1100 1NIW3I0YMAN3 H 30 SLNVSOdNOD 3LNOL S39IA30 ONY NIXIM 07314 S33I430 ONY NIHIM AHOLOVS NOILDSNNOD G1314 4AVLSOWH3SHL WOON NOILOSNNOD Arz V7 YOLIDVdVD NOY OSISILNSCI e USNYOSSNVYL LI yOLIOWdVD NOY 2901 gsn4 c BGIS LH9OIY H LIMS NYJ S4 HOLIMS LIWIT Y3NuNG TIO Zen HOLIMS LINIT AMWAIYd 157 YOLON HAMO1G NO 13X00S Nd Nid 6 IS Id TOYLNOD Aen 3d JAYA GIONITOS AS YOSN3S SNV14 1739 dvd 39 USWYOISNVYL NOTLINOI LT TOYXLNOD And YSNYNE TIO 0900 BAWA GIONSIOS dd WO ASdO XOLO HSNUNG TIO Wa aN394 1 vd d uo SYAIND 20 Ws YNOd SSLLSYVW SJO LN3SW31NSS 27 D I SIS 13 SNISN 30 DEL emm Van 20 LNSNSCHOINVH O 2724 30 1LV1SONYSHL NG INANSGHOIOVY At J xoa YSNYNG TIO SISILNSGI LNSNSNNOILINOS 30 Hr e NOTLONAC YNINYOJSNYYL 1I JIJILNJOI LNSWSNNOILONOS 30 XNILIOYdYI SUI T f na IISA gt aK Lu 3109 YNALVTIL
8. 7 ad a mm mg gl L EI L sl lf mmm mmm em me LH mg mm mmm mmm eem I U HIGH EFFICIENCY SEALED COMBUSTION DRUM HEAT EXCHANGER SERIES MODEL DFAA DFAH Oil and Gas Conversion Burner Single Stage Downflow Only 66 84 MBH INPUT 19 34 24 62 KW INPUT TERTE EFFICIENCY RATING on CERTIFIED 4 e A C US ou were ISO 9001 Listed Certified Quality Management System For Installation In 1 Manufactured Mobile Homes 2 Recreational Vehicles amp Park Models 3 Modular Homes amp Buildings LIST OF SECTIONS SAFETY gebuer e E RRE dE ESER ESTIT a tare ENEE 1 SAFETY CONTROLS gt cise nie SS cia eidadincn a dree ELE cter n ritos si 22 DUCTWORK wisicciisca cee cere n nen dans ae eee sede NR an 5 START UP AND ADJUSTMENTS 0 00 c cece eee eens 23 FILTERS aen eer g eee SR STETIT EEEE EE DENDE 10 WIRING DIAGRAM OIL FIRED FURNACE 5 27 OIL ll LEE 11 GAS GUN BURN R ic cise IN UR KEEN EEN See ee ER Reg 29 ELECTRICAL POWER 13 START UP AND ADJUSTMENTS 33 VENT COMBUSTION AIR SYSTEM 000 e eee ee eens 14 WIRING DIAGRAM GAS CONVERSION BURNER 38 LIST OF FIGURES RTE Ne BEER 4 Wiring for Blend Air Accessory 14 DIMENSIONS xx rere ENEE E EE EEN av amd yn goon DIN ER la E 5 Elbow Assembly eu A NEE eatin ormetan neip SIN IEN EI EN ae 15 Air Distribution Systems 7 Combustion Air Inlet Pipe 16 Closet To Door
9. A drip leg is required by some local codes to trap moisture and contam inations Refer to Figure 39 or 40 For natural gas operation the furnace is designed for 7 W C inlet gas pressure Pressure to main burner is then reduced to 3 1 2 W C at the gas valve Refer to Figure 42 for location of Gas Valve Main Regulator Adjustment The furnace must be isolated from the gas supply piping system by closing its individual external manual shut off valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 psig 3 5 kPa Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace Refer to Figure 39 Gas Piping GAS ORIFICE CONVERSION FOR PROPANE LP This burner is constructed at the factory for natural gas fired operation but may be converted to operate on propane LP gas by using a fac tory supplied LP conversion kit Follow the instructions supplied with the LP kit Refer to Table 18 or the instructions in the propane LP con version kit for the proper gas orifice size IMPORTANT When converting gas valve from or to Propane gas it will be necessary to change main burner orifice to prevent an underfired or overfired condition Refer to furnace rating plate or to Table 18 for proper orifice size Unitary Products Group 107272 UIM B 1105 The manifold pressure does not change when converting to Natural
10. NOILAVOSYd LINN SIHL NIJIAYIS 340438 SLJJNNO9SIQ NY N3dO NOILNYO O 29NY40 K IS EES NYO c IEGEWSEH NEE EIER ENEZEI dud LL Tuan 83A N3389 NY xe NNeE NNUa o NMOYG Neg SS CONV 1a 9Nv78 iL SLIHM JHM L aNnvr NAY A EEN TBA O 3800 ono n378 naa kg ana ma st YION STON LL yv ER a s9v114 NA 5 YNSAINOD 30 3009 E A2 Y01039 SYIM bi D STON Tous wen a EU osol 990 WAIIS NVHO Wod 3381N3 f T009 1Y3H_ W39 L t aIMa1s4n0Ss v1 30 2 SSSSLIA 20 SLYVHO LYVHO 0220 43M0 1d Unitary Products Group FIGURE 37 107272 UIM B 1105 020 V OMN 1268S STIZHVddY 13 YSILNVHO 30 De S7134YddY 13 SNISN 1 30 39V SIINI Mu Dean S3OIAZG ONY NIHIM AHYOLOYV4 Y3ILNYH 30 Luuten O NOLLOBNNOD C7314 O 303Id 30 1YLSONYJHL NG IHN AS Y LVISONYSHL WOCH NOLLOSNNOD Ar Y na SI4LLNSGI LNSN3NNOILONOS 30 YNALIOVdVI HOLIQVdVI MR OJIAI
11. 31 4 1050 29 7 1000 28 3 950 26 9 Single Speed With Dry Coil 66 19 34 53 15 55 1050 29 73 1125 31 9 1070 30 3 1020 28 9 960 27 2 910 25 8 BLOWER PERFORMANCE CFM DFAA084 EXTERNAL STATIC PRESSURE INCHES WC kPa BTU H kW CFM 0 1 0 025 0 2 0 050 0 3 0 075 0 4 0 099 0 5 0 124 Blower Speed EN Input Output m min cfm cm m cfm cm m cfm cm m cfm cm m cfm cm m Single Speed No Coil 84 24 62 67 19 63 1250 35 39 1370 38 8 1305 37 0 1245 35 3 1175 33 3 1100 31 1 Single Speed With Dry Coil 84 24 62 67 19 63 1250 35 39 1195 33 8 1120 31 7 1045 29 6 1015 BLOWER PERFORMANCE CFM DFAHO66 EXTERNAL STATIC PRESSURE INCHES WC kPa BTU H kW CFM 0 1 0 025 0 2 0 050 0 3 0 075 0 4 0 099 0 5 0 124 Blower Speed p Input Output m3 min cfm cm m cfm cmm cfm cm m cfm cm m cfm cm m Single Speed No Coil 66 19 34 53 15 55 1050 29 73 1155 32 7 1111 31 5 1055 29 9 995 28 2 920 26 1 BLOWER PERFORMANCE CFM DFAH084 EXTERNAL STATIC PRESSURE INCHES WC kPa Blower Speed BTU H kW CFM 0 1 0 025 0 2 0 050 0 3 0 075 0 4 0 099 0 5 0 124 Input Output m min cfm cm m cfm cm m cfm cm m cfm cm m cfm cm m Single Speed No Coil 84 24 62 67 19 63 1250 35 39 1127 31 9 1062 30 1
12. 5 Mark cut out location on the supply duct and remove the duct con nector 6 Cut out the opening to the supply duct 7 Bend tabs down through and back up under the supply duct 8 Secure the duct connector to the floor with nails flat head screws or staples The duct connector is designed for use on ducts down to 12 in 30 5 cm width When using the connector on smaller width ducts there will not be sufficient clearance to bend the tabs on two sides of the duct connector In such cases the tabs may be attached to the sides of the duct by using sheet metal screws or other suitable fasteners Holes for sheet metal screws are provided in three 3 tabs on each side of the duct connector If more than 3 tabs need to be used to provide a more secure and air tight connection the remaining tabs can also be fas tened to the duct with screws after drilling the required screw hole TABLE 4 External Static Pressure Range Nominal Ext Static Pressure Air Flow Minimum MBH kW MBH kW CFM emm In W C kPa In W C kPa 66000 19 34 53000 15 55 1050 29 73 12 03 30 07 84000 24 62 67000 19 63 1250 35 40 12 03 30 07 1 Std Blower High Speed No Coil IMPORTANT The air temperature rise should be taken only after the furnace has been operating for at least 15 minutes Temperatures should be taken 6 15 2 cm past the first bend from the furnace in the supply duct The return air temperature m
13. Supply air ducts from warm air furnaces having a specified minimum plenum clearance shall maintain this clearance from combustible mate rial for at least the distance specified in CSA Standards CAN CSA B139 B14 0 B140 10 Unitary Products Group 107272 UIM B 1105 A Single trunk duct c Transition Duct with Branches B Transition duct Dual trunk duct with crossover connector IS D M Dual trunk duct 4 4 2 Le Branches LU LU A Crossover J v3 1 Crossover Duct must be centered directly under furnace 2 Use 12 30 5 cm Diameter Round or insulated Flex duct only 3 Terminate Flex duct opposite furnace in the center of the trunk duct 4 Flex duct material must be pulled tight No Loops or unnecessary dips Air Flow may be impeded FIGURE 3 Air Distribution Systems Furnace to Closet Door Clearance Return Air Grille Part No 5 Inches 12 7 cm or more 7900 287P A White The closet door MUST have a minimum of 250 Inches7 1613 cm of free area in the upper half of the door If opening for return air is located in the floor or sidewalls and below the top of the furnace casing 1 6 inches 15 2 cm minimum clearance must be provided on side 250 IN 161 cm where return is located and MINIMUM 2 6 inches 15 2 cm minimum clearance
14. z SS z TA Feet heel DT sre Pane ICT sre rane OE sre Pate at sze ane Sea Level 0 082 45 9951 0821 0 093 42 9951 0931 0 098 40 9951 0981 0 106 36 9951 1061 2 000 618 0 081 46 9951 0811 0 093 42 9951 0931 0 096 41 9951 0961 0 104 37 9951 1041 3 000 914 0 078 47 9951 0781 0 089 43 9951 0891 0 093 42 9951 0931 0 101 38 9951 1011 4 000 1219 0 078 47 9951 0781 0 089 43 9951 0891 0 093 42 9951 0931 0 101 38 9951 1011 5 000 1524 0 078 47 9951 0781 0 089 43 9951 0891 0 093 42 9951 0931 0 099 39 9951 0991 6 000 1829 0 076 48 9951 0761 0 086 44 9951 0861 0 089 43 9951 0891 0 098 40 9951 0981 7 000 2134 0 076 48 9951 0761 0 086 44 9951 0861 0 089 43 9951 0891 0 096 41 9951 0961 8 000 2438 0 073 49 9951 0731 0 082 45 9951 0821 0 086 44 9951 0861 0 096 41 9951 0961 9 000 2743 0 073 49 9951 0731 0 081 46 9951 0811 0 086 44 9951 0861 0 093 42 9951 0931 10 000 3048 0 070 50 9951 0731 0 078 47 9951 0781 0 082 45 9951 0821 0 089 43 9951 0891 Table shows 4 Input Reduction per 1 000 ft 304 8 m Elevation Reference Source NFPA No 54 ANSI Z 223 1 National Fuel Gas Code For Canadian high altitude 2000 4500 ft 609 6 1 371 6 reduce gas manifold pressure to 3 0 w c 0 75 kPa for Natural gas and for Propane gas SIZING FURNACE INPUT The orifice spud supplied with all burners is the size for the minimum
15. 1005 28 5 952 27 0 887 25 1 NOTES 1 Airflow expressed in standard cubic feet per minute cfm and in cubic meters per minute cm m 2 Return air is through louvered filter door only 3 Motor voltage at 115V Unitary Products Group 25 107272 UIM B 1105 26 TABLE 15 Replacement Parts Non Electrical DFAA MODEL ITEM NUMBER DESCRIPTION 1 Limit Switch Manual Upper 2 Thermostat Heat Cool 3 Exchanger Heat w Gaskets 4 Switch Rocker System 5 Transformer 115 24V 40 VA 6 Filter 16 x 20 x 1 2Required 7 Panel Door Upper 8 Panel Door Lower Tall 9 Motor 10 Plug Connector 11 Capacitor Run 12 Wheel Blower 13 Blower AC Relay 14 Switch Fan 15 Combustion Chamber Assembly 16 Oil Burner Assembly 17 Switch Limit Open 140 Close 110 18 Fastener Door Latch 2 Required 19 Diagram Wiring DFAH MODEL ITEM NUMBER DESCRIPTION 1 Limit Switch Manual Upper 2 Thermostat Heat Only 3 Exchanger Heat w Gaskets 4 Switch System 5 Transformer 115 24V 40 VA 6 Filter 16 x 20 x 1 2 Required 7 Panel Door Upper 8 Panel Door Lower Short 9 Motor 10 Plug Connector 11 Capacitor Run 12 Wheel Blower 13 Blower AC Relay 14 Switch Fan 15 Combustion Chamber Assembly 16 Oil Burner Assembly 17 Switch Limit Open 140 Close 110 18 Fastener Door Latch 2 Required 19 Diagram Wiring
16. APPLICATION TOP FRONT BACK SIDES PIPING ROOF JACK DUCT FLOOR BOTTOM In cm In cm In cm In cm In cm In cm In cm CLOSET 2 5 08 6 15 24 0 0 0 0 0 0 0 0 0 3 7 62 0 0 0 0 0 0 ALCOVE 2 5 08 24 60 96 0 0 0 0 0 0 0 0 0 3 7 62 0 0 0 0 0 0 1 Approved Duct Connector must be used Refer to Section II Ductwork 4 Unitary Products Group 107272 UIM B 1105 Cc Inches c m eg cAn E A 59 1 2 151 0 A B 76 193 0 C 24 3 4 62 9 D 23 58 4 E 19 1 2 49 5 F 9 3 4 24 8 G 12 30 5 B S e DFAH Series DFAA Series FIGURE 2 Dimensions SECTION II DUCTWORK DUCTWORK GENERAL INFORMATION The duct system s design and installation must 1 Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications 2 Be installed in accordance with standards of NFPA National Fire Protection Association as outlined in NFPA pamphlets 90A and 90B latest editions in Canada CAN CSA B1339 Installation Code for Oil Burning Equipment or applicable national provincial or state and local fire and safety codes 3 For Manufactured Mobile Home and Modular Home Return Duct System Installations A return air duct and the return air plenum cannot be installed on this furnace The return air is drawn through
17. CONNECT FUEL LINES Carefully follow the fuel unit manufacturer s literature and the latest edi tion of NFPA 31 for oil supply system specifications If this information is unavailable use the following basic guidelines ANOTICE Fuel units with automatic bypass do not require a bypass plug ANOTICE Burners equipped with a Beckett CleanCut pump must have a con trol system that provides a valve on delay prepurge Unitary Products Group 107272 UIM B 1105 TABLE 6 Burner Specifications Furnace Model Burner Spec ATG Head DFAAO84BBTA EVC 201 AF36YHHS F3 DFAH084BBSA DFAAO66BBTA EVC 202 AF36YHHS F3 DFAHO66BBSA Static Plate Nozzle Pump Pressure Air Boot Setting 3 3 8 U 0 65 x 70 A 100 psi 4 0 Delavan 689 5 kPa 3 3 8 U 0 50 x 70 A 100 psi 3 0 Delavan 689 5 kPa AWARNING The burner fuel unit is shipped without the bypass plug installed You must install this plug on two pipe oil systems DO NOT install the plug in the fuel unit if connected to a one pipe oil system Fail ure to comply could cause fuel unit seal failure oil leakage and potential fire and injury hazard Fuel Supply Level With or Above Burner The burner may be equipped with a single stage fuel unit for these installations Connect the fuel supply to the burner with a single supply line if you want a one pipe system making sure the bypass plug is NOT inst
18. ES t L Di ISL d WR El z le E Si GE EE we DG NOILdSONOD HI Yd 30 SET AL LNOS SUNZLON S31 9 ax 1e aa Eg y NOLIVINANITV 1 MO SHNIL NOFSIO S31 ZISSINYNOJ S me E SUUBL N3 ASIN N3IG 3413 LIOO LNSW3OVTGNSY 30 SLNVSOdNOD SLNOL BUAIND 30 T4 HDD SILLIYYN S30 INIWITNIS S 9 501 40122 SON N C S3YNLVYSGNAL S30 Y X3LSIS3H LNVANOd XAVINSLYN Mi JJAY 34437 1100 TI INOL N3 NO STWLWd N3 FOWIdWaY 3413 1100 39V F1 1S Z xMVdIIINNN LA RO S3003 9 SaNa IN0I 20 S3009 53 N0 13 939 NaIQYNY9 9373 3009 8 ZAAINS SSSINV10d AYIA LIOQ LNVENOD NQ NOILVINSWT1V 1 N0 13 N30 7YNOILYN 9373 3009 Y MOIS Y3ILNVHD N3 JOVI NOL I ONIGOD X07709 3AY3S8g0 CSZIYV 10d e LSNW YSMOd SONIWOONI Ca 0510a ATUNSHSENT HV SHOLON g SALON HOLIMS ENGER HASS OL SBITddNS Y3MOd TV Y04 SLOSNNOISIO 3OIAOUd S WALSAS AE ONNOYS IW OJANNOY9 ATHadOUd 3G 1SNW SINSNOdNOD IN2N2W 30 TV wa 7 ATINO SHYOLONGNOD H3ddO X04 STGYLINS SYOLOSNNOD S j OVA SII 9 501 4122 1SV37 IN 40 ONILVY JYNLYYIJNIL HOYH 3l Yd 33 ILNJA od dud n a Y ONIAVH Jeu Lem OT HLIM GS0V1d3Y 38 LSAW LI 039Y7d3Y 7 08 SSIVNYNO 4 we THK NaN 38 LSNA Za 201 HLIM GaITddNS SV SHIM WNISIHO JHL JO ANY AS 3009 ALI YO 1907 9 JOHR 7SO ONV 949 3009 0373 NVIGWNVO 9 SOVNYNA MOTANMOG 08 TIVA 7dO 0NV 93N 3009 9373 TYNOILYN Y ed ONIYIM O73143 TV Y M iSJION 39IA43S 31 OBAV 43039044 30 F ANVAY SUNSLONOPSIG SII Z3YANO D 4NVHO VWIND LV LSONYSHL AT ELE LE E G
19. boxes and other objects is minimized 5 Materials located in the return duct system have a flame spread classification of 200 or less 6 Non combustible pans having 1 2 5 cm upturned flanges are located beneath openings in the floor return duct system 7 Wiring materials located in the return duct system conform to Arti cle 300 22 B amp C of the National Electrical Code NFPA 70 8 Fuel piping is not run in or through the return duct system 9 The negative pressure in the closet as determined by test with the air circulating fan operating at high heating speed and the closet door closed is to be not more negative than minus 0 05 inches 1 2 kPa water column 10 For floor return systems the manufactured home manufacturer or installer shall affix a prominent marking on or near the appliance where it is easily read when the closet door is open The marking AWARNING HAZARD OF ASPHYXIATION DO NOT COVER OR RESTRICT FLOOR OPENING BLEND AIR INSTALLATIONS If a blend air ventilation system is installed the 5 12 7 cm diameter knockout in the top cover must be removed The blend air damper is to be placed on the top cover and secured with screws as shown in Figure 14 The power wires for the Blend Air Damper are inserted through the 7 8 2 22 cm hole in the top cover The wires to the Blend Air Damper will be connected as shown in Figure 24 Refer to the Blend Air Installa tion Manual to complete the installation
20. or Propane Gas The manifold pressure is 3 5 in w c 0 87 kPa on both Natural and Propane Gas Change only the gas orifice when converting this burner to Natural or Propane Gas Manifold pres sure in excess of 4 0 in w c 0 99 kPa can cause premature heat exchanger failure High levels of carbon monoxide excessive soot ing a fire hazard personal injury property damage and or death HIGH ALTITUDE GAS ORIFICE CONVERSION This furnace is constructed at the factory for natural gas fired operation at 0 2 000 ft 0 m 610 m above sea level The gas orifices on this furnace must be changed in order to maintain proper and safe operation when the furnace is installed in a location where the altitude is greater than 2 000 ft 610 m above sea level on natural gas or the altitude is greater than 4 000 ft 1219 m above sea level on propane LP gas Refer to Table 18 or the instructions in the high altitude conversion kit for the proper gas orifice size For Propane gas operation the furnace is designed for 11 w c 2 74 kPa inlet gas pressure Pressure to main burner is then reduced to 3 5 w c 0 87 kPa The unit may also be converted for altitudes up to 10 000 ft 3048 m on natural and propane LP gas with additional derate as shown in Table 18 or refer to ANSI Z223 1 NFPA 54 National Fuel Gas Code or in Canada CAN CGA B149 1 00 Natural Gas and Propane Installation Code PROPANE AND HIGH ALTITUDE CONVERSION KITS It
21. then use the following calculation 3 8 0 95 cm line L 6 0 75 x H 0 0086 x Q 1 2 1 27 cm line L 6 0 75 x H 0 00218 x Q IMPORTANT The recommended piping configuration is a single or two pipe system that is inserted into the top of the tank as shown in Figure 17 or 18 The two pipe system should be used in applications where the oil tank is considerably lower than the burner and the oil pump keeps losing its prime The oil line should never be connected to the bottom of the oil tank if the oil tank is outdoors Water in the bottom of the oil will freeze in the winter causing the oil line to freeze ONE PIPE SYSTEM DO NOT INSTALL BY PASS PLUG Connect inlet line to pump inlet Start burner Arrange primary burner control for continuous operation during the purging Place a clear plastic tube on bleed valve Open bleed valve 1 turn counterclock wise Bleed until all air bubbles disap pear Tighten bleed valve securely Hurried bleeding will impair efficient operation of unit Refer to Figures 16 and 17 C Air L H R Vent o Fuel Unit Fill Pipe Shut Off Valve Maximum One Pipe H Lift 8 Ft Primary Fy Filter FIGURE 17 One Pipe System TWO PIPE SYSTEM Remove 1 16 0 16 cm pipe by pass plug from plastic bag attached to the unit Remove 1 4 0 635 cm plug from return port Insert by pass plug into the return port of the oil pump The oil pump return port loca tion is shown i
22. 4 This plate must be sealed to prevent leaks Table 2 is a guide for determining whether the rectangular duct system that the furnace is being connected to is of sufficient size for proper fur nace operation 107272 UIM B 1105 Use the example below to help you in calculating the duct area to deter mine whether the ducts have sufficient area so that the furnace oper ates at the specified external static pressure and within the air temperature rise specified on the nameplate Example The furnace input is 80 000 BTUH 23 4 kW 1 200 CFM 34 0 m3 The recommended duct area is 280 inch 1 there are two 8 in x 14 in 20 3 cm x 35 6 cm rectangular ducts attached to the plenum and there are two 7 inch 722 cm round ducts attached to the furnace 1 Take 8 in x 14 in 20 3 cm x 35 6 cm which equals 112 inch X 2 35 6 cm x 2 which equals 224 inch 1445 cm then go to round duct size located in Table 3 TABLE 2 Minimum Duct Sizing For Proper Airflow 2 The square inch area for 7 inch 17 8 cm round pipe is 38 4 mul tiply by 2 for two round ducts which equals 76 8 inch 495 cm 3 Then take the 224 inch 1445 cm from the rectangular duct and add it to the 76 8 inch 495 cm of round duct The total square inch of duct attached to the furnace plenum is 300 8 inch 1 940 cm This exceeds the recommended 280 inch 1 806 cm of duct In this example the duct system attached to the plenum has a sufficient area so
23. 56 2 12 Note All examples are for 7000 ft elevation 1 84 x 7 for 7000 ft 12 9 100 12 9 87 1 ft feet m meters gph gallons per hour I h liters per hour EXAMPLE 1 Re Rating of the Maximum Firing Rate for Burners 7000 ft Burner Maximum Firing Elevation Adjusted Model Rate of Burner X Re rate Factor Maximum Sea Level 7000 ft Firing Rate AFG 3 00 gph 11 4 L h X 87 1 2 61 gph 9 83 Lh AF 3 00 gph 11 4 L h X 87 1 2 61 gph 9 83 Lh Nozzle Port By Pass 3 16 Flare Solenoid Inlet Port Fittting e d Wie Cordset 1 4 NPTF Pressure ee Adjustment Screw Bleed amp A Gauge Port DGed Return Port EE Install 1 16 by Pass Pipe 0 64 cm Plug For Two Pipe System Only Use 5 32 Allen Wrench FIGURE 16 Oil Pump INSTALLATION AND CHECKING OF OIL PIPING Location and installation of oil tanks and oil piping must comply with local codes and regulations In absence of such codes follow NFPA 31 Standard Floor Installation of Oil Burner Equipment Unitary Products Group Follow information provided with the burner the fuel pump or the calcu lation below to determine pipe size and length L Line Length in feet H Head in feet Q Firing rate in GPH 3 8 0 95 cm line L 6 0 75 x H 0 0086 x Q 1 2 1 27 cm line L 6 0 75 x H 0 00218 x Q If tank is above the oil pump
24. AWARNING The manifold pressure must be checked with the screw off cap for the gas valve pressure regulator in place If not the manifold pres sure setting could result in an over fire condition A high manifold pressure will cause an over fire condition which could cause pre mature heat exchanger failure If the manifold pressure is too low sooting and eventual clogging of the heat exchanger could occur Be sure that gas valve regulator cap is in place 35 107272 UIM B 1105 MAINFOLD PRESSURE U TUBE CONNECTION Outlet Pressure Tap Tubing Gas Valve 4 3 5 IN 0 87 kPa Water Column Gas Pressure Shown FIGURE 43 Reading Gas Pressure Observing Burner Operation 1 Observe burner to make sure it ignites Observe color of flame On natural gas the flame will burn blue with appreciably yellow tips On Propane gas a yellow flame may be expected If flame is not the proper color call a qualified service technician for service Let furnace heat until blower cycles on Turn thermostat down Observe burner to make sure it shuts off Let the furnace cool and blower cycle off gii e ob Should overheating occur or the gas supply fail to shut off shut off the manual gas valve to the furnace and allow burner to run until furnace cools down and blower shuts off before shutting off the electrical supply If any abnormalities are observed when chec
25. After unpacking the roof jack check the rain caps Insure they are not damaged tilted or crooked Do not twist crush or sit on the roof caps during installation Damaged roof caps will cause improper furnace operation The furnace will not heat properly and could result in explosion Before inserting the roof jack into the furnace top inspect the fur nace flue and combustion air opening for debris or insulation which might have fallen in during pre installation steps Do not pro ceed unless all debris has been cleaned out or removed After installing roof jack on furnace top collar check to make sure there is no gap in back or side between the pipe collar and the fur nace casing top Use only the pipes provided with the roof jack assembly Do not add to or adapt other sheet metal pipes Do not cut insert or add other pipes to this assembly In no case should there be a gap between sections of the flue pipe or the combustion air pipe If necessary to prevent excessive air leakage the installer should seal joints in the combustion air tube with Chemcaulk 900 sealant or other suitable sealant NEW HOME INSTALLATION If this furnace is installed in a new home do the following 1 Inspect the furnace top collars for signs of insulation or ceiling debris which might have fallen in during cutting of the ceiling and roof holes Remove all debris before continuing The vent and combustion air openings in the top of the fur
26. BTU input of the burner for the type gas shown on the rating plate Table 18 shows the correct drill size for various inputs The correct manifold pressure for natural and LP gas is 3 5 w c 0 87 kPa Only minor adjustments in the input rate should be made by adjusting the pressure regulator The minimum manifold pressure should be 3 0 w c 0 75 kPa and the maximum pressure should be 3 5 w c 0 87 kPa the next size larger or smaller orifice size should be used if the desired input rating cannot be obtained within the above manifold pressure adjustment range 32 TABLE 19 Gas Burner Settings Gas Firing Rate Orifice Air Shutter 3 5 W C BTU Hr kw Size Setting Natural 66 000 19 3 0 142 3 61mm 1 0 Natural 84 000 24 6 0 166 4 22 mm 3 5 LP 66 000 19 3 0 116 2 95 mm 2 0 LP 84 000 24 6 0 100 2 54 mm 3 5 NOTE The BTU input valves in the above table show the approximate hourly input of the burner for the various drill sizes shown To determine the actual input of the burner turn off all other gas appliances Unitary Products Group 2 3 8 107272 UIM B 1105 CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the vent
27. FIGURE 35 Electrode Settings Unitary Products Group SPECIFICATIONS Models Table 11 lists the major features and the applicable wiring diagram num bers for the R7184 Timing 1 Safe Start Check 5 seconds approximately 2 Valve on Delay 15 seconds 3 Burner motor off Delay 0 2 4 or 6 minutes Field selectable using dual in line programmable DIP switch positions 1 and 2 Select models have 0 5 2 4 or 8 minute delays NOTE Valve on delay and burner motor off delay timings can be enabled values as listed or disabled values are zero in the field using DIP switch position 3 4 Lockout 15 30 or 45 seconds factory programmed 5 Recycle 60 seconds fixed 6 Ignition Carryover 10 seconds fixed Electrical Ratings Inputs a Voltage 102 to 132 VAC 120 VAC nominal b Current 100 mA plus burner motor valve and igniter loads c Frequency 60 Hz Outputs a Burner 120 VAC 10 full load amperes FLA 60 locked rotor amperes LRA Valve 120 VAC 1A Igniter 120 VAC 360 VA Alarm 30 VAC 2A Thermostat Current Available 100mA EnviraCOM Current Available 150mA moans TABLE 12 Burner Specifications 107272 UIM B 1105 NOTE Reduce burner FLA rating by igniter load For example if the igniter draws 3A 120 VAC 360 VA reduce the burner motor FLA to 7A SECTION VIII START UP AND ADJ USTMENTS The initial start up of the furnace requires the following additional procedur
28. HION osor oe wu l an p oi ES YOLIOVdVD LNOHLIM SHOLOW NO MO SION 33S O9 I SI ATddNS HaMOd WAT19 N HO WOd 3381N3 6 HOLIMS WLSAS 1009 1Y3H N49 Let YOLIOVavo SI 3144N0S YI 20 LNSIVAINOS SLI YO DILSVIdONYSHL 3 SO0I SdAL HLIM GS9V1dSH 3g LSNW LI QS9V1d5Y 3g Lem LINN SIHL HLIM O3NMddNS SAYIM TWNISIYO JHL 20 ANY HI SYIVLNAWA14 SANNVHOVIG WvOCOVIO HO SSSSLIA 30 SLYVHO LYVHO GssadS YsMO 1d for DFAH Oil Furnace iagram D iring Wi FIGURE 38 Unitary Products Group 28 SECTION X GAS GUN BURNER These instructions were prepared for the guidance of those installing this particular gas conversion burner While they apply in principle to all installations they should not be interpreted as meaning the only safe and economical way to install a conversion burner It may be necessary to deviate from these instructions in some instances in order to comply with local gas company rules or codes in effect in the area in which the installation is made It is recommended that the installer confer with the local gas company and with the proper municipal officials regarding any specific code or regulation governing the installation of gas conversion burners the installation must conform with local codes or in the absence of local codes with the American National Standard Installa tion of Domestic Gas Conversion Burners Z21 8 latest edition and the National Fuel Gas Code ANSI Z223 1
29. Jack flashing Seal Roof Jack swivel joint Chemcaulk 900 sealant Not required for Roof Jacks with fixed slant flashing apron Complete Installation as required 1 Install Exterior Roof Jack Extension if applicable Refer to installa tion instructions provided with Exterior Roof Jack Extension Refer to Figure 32 2 Install Crown Assembly if applicable Refer to installation instruc tions provided with Crown Assembly If Crown Assembly is not installed attach warning tags provided with Roof Jack to Refer to Figure 32 17 107272 UIM B 1105 DFAH FURNACES DFAA FURNACES SWIVEL FLASHING SLANT ADJUSTS FROM FLASHING INSTALLATION DIMENSIONS INSTALLATION DIMENSIONS 0 12 TO 5 12 PITCH 3 12 PITCH A B ADJUSTABLE HEIGHT ADJUSTABLE HEIGHT 4000 7101 C 4000 6101 A 70 to 79 86 to 95 4000 7121 C 4000 6121 A 75 to 86 91 to 102 4000 7141 C 4000 6141 A 83 to 104 99 to 120 4000 7151 C 4000 6151 A 90 to 116 106 to 132 4000 7171 C 4000 6171 A 127 to 157 143 to 173 The 4084 7141 is dimensionally the same as 4000 7141 C and is available only in Canada The 4084 7151 is dimensionally the same as 4000 7151 C and is available only in Canada A A Fide Z N Carefully Caulk All Around Swiv
30. SAFETY This is a safety alert symbol When you see this symbol on A labels or in manuals be alert to the potential for personal injury Understand and pay particular attention to the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It is also used to alert against unsafe practices and hazards involving only property dam age AWARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or mainte nance can cause injury or property damage Refer to this manual for assistance or for additional information consult a qualified con tractor installer or service agency A CAUTION This product must be installed in strict compliance with the installa tion instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes 107272 UIM B 1105 107272 UIM B 1105 SPECIFIC SAFETY RULES AND PRECAUTIONS i U S No 1 or No 2 heating oil only A
31. SCF 38 4 Mu m times 2 cubic ft 0 056 m of gas measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time In seconds it took to measure 2 cubic ft 0 056 m of gas from the gas meter For propane LP gas multiply the heat content of the gas BTU SCF or Default 2500 BTU SCF 93 15 Mim times 1 cubic ft 0 028 m of gas mea sured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time In seconds it took to measure 1 cubic ft 0 028 m of gas from the gas meter The formula for US input calculation using a cubic foot gas meter BTU tt x 2 cu ft x 0 960 x 3600 BTU H BTUm x 1 cu ft x 0 960 x 3600 z BTU H Seconds it took to measure the 2 cu ft of gas Seconds it took to measure the 1 cu ft of gas NATURAL GAS INPUT CALCULATION PROPANE LP GAS INPUT CALCULATION EXAMPLE EXAMPLE 1030 x 2 x 0 960 x 3600 78 666 90 2500 x 1 x 0 960 x 3600 e 80 000 00 90 5 108 Natural Gas Propane Gas 1030 BTU SCF 2500 BTU SCF In Canada you will use the following formula to calculate the furnace input if you are using a cubic foot gas meter For Natural Gas multiply the Heat content of the gas MJ m or Default 38 4 times 2 cubic ft of gas x 0 028 to convert from cubic feet to cubic meters measured at the gas meter times a barometric pressure and temperature correction fac
32. Teos ECH Le 1D Lv3H Ak am 440 ma g 1H EWEN z RW 003 EES TA 3NIT z EU ITNO PO S RABS e AE ona Nozi IN a iy Oe at W I Ou woo ASII REG Luew _ dis A INVIA S4 33S Atz e r e J L Gef weii Eeer oer IEN 03ddINO3 41 a 200 aoe 34931 N3 IT pd L Biv DD ana og 3d eG Ble Oa ch g 93S AvZ LHM Lolo ml S 1 oe zm 4 p 3 2 o 21 woo I 8d agi 17 So o fo 199 La E Z i it TE SA ojo S dud g zl 34831 aa be ou aam fo 4 elle Zo o Toon He 5 A8 lol o YMO Oe O4 fo ON f 3 Sun Zid uciion 31u3744N0S QW O A734 20 HAL Aug me ee Dk el avy Nuys Ing 1 210u HIOA O9 I SII NOILVLNANITY po e 980 GE 1 BION 33S O9 I SIl ATddNS HIMOd YOLIOVdVD LNOHLIM SHOLON NO MO YOLIovava HOLINS WSUSAS LNSN3S04099VY 20 SNWVHOVIG WVYOVId NOILISNNOS 9 G01 4 122 SNIOW NV SSYUNIVHSdNAL S30 Y YSLSISSY INVANOd XNYIHJLYN NN JAY 3443 7 1100 7I LNOL N3 NO 21014 N3 30VIdWIY 3413 1100 39V 37 IS e N0 13 N39 WWNOILYN 93713 3009 Y we Y3ILNVHO N3 290 LNOL I 3XIVLN3NM373 SNNVYSVIC WvOCvIO OO SALON LAV 31 8d 45 WLNSA 200 ASIVNYNO 4 SOVNEN4 MOTSANMOCG 08 SOIAYAS 37 SAV 43039044 30 ANVAY SYNSLONOPSIG S37 ZSYANO
33. area where there will be no exposure to the substances listed above The furnace area must not be used as a broom closet or for any other storage purposes as a fire hazard may be created Never store items such as the following on near or in contact with the furnace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning com pounds plastic items or 3 Containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluid 4 Paint thinners and other painting compounds 5 Paper bags boxes or other paper products Never operate the furnace with the blower door removed To do so could result in serious personal injury and or equipment damage INSPECTION As soon as the furnace and or accessories are received it should be inspected for damage during transit If damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing Also before installation the furnace and or accessories should be checked for screws or bolts which have loosened in transit or shipping and spacer brackets that need to be removed ANOTICE CONCEALED DAMAGE If you discover damage to the burner or controls during unpacking notify carrier at once and file the appro ANOTICE WHEN CONTACTING B
34. as the furnace flue collar See Figures 30 and 31 Mark this location on ceiling and scribe a circle with a 5 1 5 m radius 10 25 4 cm diameter around this mark Cut opening for roof jack through ceiling and roof If furnace was installed during construction cover furnace and flue opening to prevent debris from entering flue when hole is cut for roof jack INSTALLING ROOF J ACK IN ROOF 1 Provide protection for Vent Connector and Air Intake Connector from damage and debris 2 Mark Roof Jack center line on ceiling Cut a 5 1 5 m radius 10 25 4 cm diameter hole through ceiling 3 Mark Roof Jack center line on roof Cut oblong hole through roof 4 Insert Roof Jack through roof opening Do not secure Roof Jack to roof 16 Connect Roof Jack to Furnace 1 Install Flue Shield inside Vent Connector Push Flue Shield down until in contact with the built in stop inside the Vent Connector See Figures 28 and 29 AWARNING Failure to install the Flue Shield may cause premature flue pipe deterioration Damaged flue pipe can result in asphyxiation fire or equipment malfunction Flue Shield Furnace Vent Connector FIGURE 28 Flue Shield Installation 2 Verify gasket is around outside of Air Intake Connector Install new gasket if missing or damaged 3 Pull the Roof Jack s telescoping section down onto furnace Fully engage Roof Jack onto Vent Connector and Air Intake Connector and compress ga
35. coil a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indi cate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks RETURN AIR REQUIREMENTS Closet Installations Additional Requirements Additional requirements for floor and ceiling return system for closet installed sealed combustion heating appliances are given in the next paragraph Floor or Ceiling Return Air System Listed in the next paragraph are the conditions to be met by Manufac tured Home Manufacturers to have U L acceptance of in floor or ceiling return air systems of closet installed direct vent forced air heating appli ances for Manufactured Homes to be sold in the United States 1 The return air opening into the closet regardless of location is to be sized not less than 16 X 24 40 6 cm x 101 6 cm 2 Ifthe return air opening is located on the floor of the closet versus the vertical front or side wall the opening is to be provided with means to prevent its inadvertent closure by a flat object placed over the opening 3 The cross sectional area of the return duct system when located in the floor or ceiling of the manufactured home leading into the closet is to be not less than 16 X 24 40 6 cm x 101 6 cm 4 At least one register is to be located where likelihood of its being covered by carpeting
36. excessive gas pressure wrong size orifice high altitude etc the burner flame will be sooty and may produce carbon monoxide which could result in unsafe operation explosion and or fire or asphyxiation Unitary Products Group A CAUTION To install gas line and to connect it to the gas valve care must be taken to hold gas valve firmly to prevent misalignment of the burner orifice or to damage gas valve which could result in improper heating explosion fire or asphyxiation DO NOT USE EXCESSIVE PIPE SEALANT ON PIPE JOINTS Pipe sealant metal chips or other foreign material that could be deposited in the inlet of the gas valve when gas pipe is installed or carried through the gas piping into the gas valve inlet after installation may cause the gas valve to malfunction and could result in possible improper heating explosion fire or asphyxia tion Also pipe sealant must be resistant to Propane gas A main shut off valve shall be installed externally of furnace cas ing After piping has been installed turn gas on and check all connections with a leak detector or soap solution Never use open flame to test for gas leaks as fire or explosion could occur Do not test the fuel system at more than 14 W C after furnace has been connected to fuel line Such testing could void the warranty Any test run above 14 W C may damage furnace control valve which could cause an explosion fire or asphyxia tion
37. for Manufactured Mobile Home and Modular Homes This appliance must be vented with an approved manufacturer supplied roof jack May not be common vented with another gas fired or oil fired appliance Unitary Products Group EXTERIOR ROOF J ACK EXTENSION Application Available to comply with instances in which the roof jack crown needs to be raised to meet a roof clearance requirement One extension will raise the roof jack crown by 18 45 7 cm ROOF J ACK Failure to follow all venting instructions can result in fire asphyxiation or explosion A CAUTION Only use the appropriate roof jack See Figures 26 27 30 and 31 for correct application Do not exceed the maximum height as determined from Table 9 Installer should allow an additional 1 1 2 3 8 cm travel before the flue pipe assembly is fully extended against the built in stop This provides an additional safe guard against the flue assembly being pulled from the roof jack during transportation or other stress conditions EXISTING FURNACE REPLACEMENT If this furnace replaces an existing furnace do the following 1 If a 2nd roof roof cap or addition has been made to the existing roof of the home remove the old roof jack completely To avoid the possibility of an improperly installed pipe or gaps in the old roof jack INSTALL A NEW ROOF JACK Your ceiling and roof height will determine the correct roof jack to use
38. have a lower operating current The actual load should be determined by a cur rent meter NOTE See appliance manufacturer s burner specifications for required outlet pressure Pressure is 100 psig 689 kPa unless otherwise noted SUPPLY VOLTAGE CONNECTIONS 1 Provide a power supply separate from all other circuits Install overcurrent protection and disconnect switch per local national electrical codes With the control box switch in the OFF position check all wiring against the unit wiring label Refer to the wiring diagram in this instruction 2 Remove the screws retaining the wiring box cover Route the power wiring through the opening in the unit into the junction box with a conduit connector or other proper connection In the junction box there will be two wires a Black Wire a White Wire and a Green Screw Connect the power supply as shown on the unit wir ing label on the coil compartment panel on the DFAA or the onside of the burner door on the DFAH or the wiring schematic in this sec tion The black furnace lead must be connected to the L1 hot wire from the power supply The white furnace lead must be connected to neutral Connect the green furnace lead equipment ground to the power supply ground screw 3 The furnace s control system requires correct polarity of the power supply and a proper ground connection Refer to Figure 20 BLK A BLK Hot 3 Nominal WHT A WHT Neutral 120 Volt GRN CRN
39. ing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those who have not kept up with changing Modular Home and Manu factured Mobile Home construction practices These instructions are required as a minimum for a safe installation COMBUSTION AIR QUALITY LIST OF CONTAMINANTS The furnace will require OUTDOOR AIR for combustion when the fur nace is located in any of the following environments e Restricted Environments e Commercial buildings e Buildings with indoor pools e Laundry rooms e Hobby or craft rooms e Near chemical storage areas e Chemical exposure The furnace will require OUTDOOR AIR for combustion when the fur nace is located in an area where the furnace is being exposed to the fol lowing substances and or chemicals Unitary Products Group 107272 UIM B 1105 e Permanent wave solutions e Chlorinated waxes and cleaners e Chlorine based swimming pool chemicals e Water softening chemicals De icing salts or chemicals e Carbon tetrachloride e Halogen type refrigerants e Cleaning solvents such as perchloroethylene e Printing inks paint removers varnishes etc e Hydrochloric acid Cements and glues e Antistatic fabric softeners for clothes dryers e Masonry acid washing materials When outdoor air is used for combustion the combustion air intake duct system termination must be located external to the building and in an
40. is very important to choose the correct kit and or gas orifices for the altitude and the type of gas for which the furnace is being installed Only use natural gas in furnaces designed for natural gas Only use propane LP gas for furnaces that have been properly converted to use propane LP gas Do not use this furnace with butane gas Incorrect gas orifices or a furnace that has been improperly con verted will create an extremely dangerous condition resulting in pre mature heat exchanger failure excessive sooting high levels of carbon monoxide personal injury property damage a fire hazard and or death High altitude and propane LP conversions are required in order for the appliance to satisfactory meet the application An authorized distributor or dealer must make all gas conversions In Canada a certified conversion station or other qualified agency using factory specified and or approved parts must perform the conversion The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed Do not attempt to drill out any orifices to obtain the proper orifice size Drilling out a gas orifice will cause misalignment of the burner flames causing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury property damage and or death 31 107272 UIM B
41. loos 003 Zemmer P i E IA b I SNZ o 19 SNVHO v80 N vgl THM E 3 z DIS A Yo BONVYO NYO WE Idd AOZI ony Suaunod 3udundd YOSNIS woo IHd ASi Ky No aes dud DEE OSS Are mu DEEL 183A NY4 Neo 2 01000000 0 r L I I q FN word ees Se e sal N3349 NYO avoa 34 IS Gaddinoa 41 e A Noe unge z XO TOY LNOO Nor ER a EH ait E aIv ONa78 34431 N3 i z Bs S el B N9 ILIHM LHM ie E mot e NAYA NAYTI 8 Ae AN l Si MOTZA REI B IHM A GI 93S AvZ a9nou noe o o 0 004 a34 RER g 9 i ree oie 4 nate nate 2 SS 217 woo THs agi 17 ane mg Si AF YION HION US 5 yowie ER p S i TE ss JA sl S9v114 NG ol dud ot S 34831 N3 oul T aa fo TZ r Zolo K Ey Gesi Hr OO 20 3009 6 HO LOW 548 lolo ut Ady 40709 SYIM ON EG 3143744N0S YOLON AW HION er LUO e t D cna 30 YN3LON aro Grci 80 980 oy Nes 1 3LON HIOA O9 I SI NOILVLNAWINV TATON osol 990 SS Setz i e 9 VE WAT 19 NVHO WOd 3381N3 YOLIOWdVD LNOHLIM SHOLOW NO MO Ak Defter EC HOLIMS WALSAS 710037 1V3H IW LAGNT a1437044N0S YI 30 LNSTVAINOS SLI YO SILSVIdOWYSHL 3 SOI JdAL HLIM 039Yd3Y 3G LSNW LI q39ya3 Y 38 LSNW LINN SIHL HLIM O3lNMddNS AXIM TYNI IHO JHL 40 ANV AI SIV LNAN3 14 SNWVHOVIG WvOCVIO Ysqqv SSSSLIA 20 3LYYH93 LYVHD GaSdS 02009 FIGURE 45 Wiring Diagram for DFAA Gas Conversion Burner Unitary Products Group 38 107272 UIM B 1105
42. manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following TABLE 21 Nominal Manifold Pressure NOMINAL MANIFOLD PRESSURE 3 5 w c 0 87 kPa 3 5 w c 0 87 kPa Natural Gas Propane LP Gas Outlet Pressure Port Vent Port Inlet gt Wrench je Boss Inlet Pressure Port 1 4 Quick Connect Electrical Terminals Main Regulator On Off Switch Adjustment Shown in ON position FIGURE 42 Gas Valve IMPORTANT If gas valve regulator is turned in clockwise manifold pressure is increased If screw is turned out counter clockwise mani fold pressure will decrease 3 After the manifold pressure has been adjusted re calculate the furnace input to make sure you have not exceeded the specified input on the rating plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 4 Once the correct BTU kW input has been established turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexible tubing and fittings from the gas valve pressure tap and tighten the pressure tap plug using the 3 32 Allen wrench 5 Turn the electrical and gas supplies back on and with the burners in operation check for gas leakage around the gas valve pressure port for leakage using an approved gas detector a non corrosive leak detection fluid or other leak detection methods
43. natu ral gas 12 1 for propane gas b CARBON MONOXIDE Should be checked for its presence in the flue gas This percentage should not exceed 04 or 400 PPM NOTE Check overfire draft and adjust to NEGATIVE 01 0 0025 kPa to 02 4 982 pa inches w c during burner operation OPERATION AND TROUBLESHOOTING SEQUENCE OF OPERATION SC80 C GAS BURNER UTI LIZING HONEYWELL S87K GAS PRIMARY WITH BUILT IN 30 SECOND PREPURGE 107272 UIM B 1105 On a call for heat voltage 24V is applied to motor start relay and air switch Once the fan motor reaches operating rpm combustion air pres sure is sensed by the air proving switch and closes the switch contacts energizing the S89F gas primary control The S87K gas primary control has an internal 30 second prepurge timer After the initial 30 second prepurge an internal 8 second safe start check of the S89F will commence Once this is successfully com pleted the S87K simultaneously energizes the gas valve and ignition transformer Gas flows and the transformer produces an approximate 7300 volt spark end point grounded at the burner head establishing main burner flame At the start of each heat cycle there is a trial for an ignition period of a four 4 second duration Normally burner flame will be established before the end of this period Once the flame is established sparking will cease and the flame rod will provide flame monitoring to the S87K gas control primary for the rem
44. rating plate Three typical distribution systems are illustrated in Figure 3 Location size and number of registers should be selected on the basis of best air distribution and floor plan of the home The Air Temperature Rise is to be adjusted to obtain a temperature rise within the range s specified on the furnace rating plate DUCT DESIGN CANADA Supply duct design shall be in accordance with the latest HRA Digest the ASHRAE Handbook Fundamentals or other good engineering prin ciples NOTE Refer to HRA Digest Residential Air System Design Manual Sections 5 and 6 the requirements of which are summarized as fol lows 1 The kilowatt output of each duct register shall not exceed 2 35 kW 2 The furnace output should not be more than 20 greater than the calculated heat loss of the home If a larger furnace is used the duct system shall be capable of the increased air volumes neces sary to maintain a maximum air temperature rise of 50 C as the air passes over the furnace heat exchanger 3 Atleast one warm air supply outlet shall be provided in each room 4 When rooms are located adjacent to the exterior walls warm air outlets shall be located so as to bathe at least one exterior wall and where practical a window area with warm air except for bath rooms or kitchens where this might not be practical 5 Where practical outlets shall be provided near the exterior doors of the home CLEARANCE REQUIREMENTS CANADA
45. seconds c The solenoid valve on the oil pump will open providing oil flow to the nozzle d The oil vapor will ignite The cad cell flame detector will detect the flame The resistance will drop below 1600 ohms e After flame is established the supply air blower will start when the fan switch reaches approximately 110 F 43 3 C f After flame is extinguished the supply air blower will continue to operate until the air temperature at the fan switch is below 90 F 32 2 C AWARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Pressing the reset button repeatedly could cause a pool of oil to form in the bottom of the chamber If ignited could result in a very dangerous situation which could result in personal injury property damage and or death IMPORTANT Burner ignition may not be satisfactory on first start up due to residual air in the oil line or until pump pressure is adjusted The ignition control will make 3 attempts to light before locking out The furnace should have a safety or fire shut off valve connected to the inlet part of the oil pump to shut off the flow of oil in an emergency Refer to Figure 36 for inlet port location ADJ USTMENT OF OIL PUMP PRESSURE Nozzle Port heed 3 16 Flare ce Inlet Port Fitting Cordset 1 4 NPTF Pressure cn Adjustment Screw S
46. sequence of gas control operation in the Operation and Troubleshooting section before proceeding 2 Move the gas valve control switch to the OFF position Adjust the primary air Set the damper to the start up settings 4 On new gas line installations air may be trapped in the line the burner may experience several lockouts until all the air is purged from the lines 5 Turn on the main electrical power and set the thermostat to call for heat Allow the burner to run a MINIMUM of 5 minutes to purge combustion chamber and appliance heat exchanger 6 Set the thermostat below room temperature shutting the burner OFF 7 Move the gas valve control switch to the ON position 8 Set the thermostat or operating control to call for heat The burner will start and go through the applicable sequence of burner pri mary gas control operation refer to step 1 9 Once burner is running adjust the orifice manifold pressure regu lator as described in Pressure Regulator Adjustment Gei A CAUTION Be sure to relight any gas appliances that were turned off at the start of this input check CHECKING THE GAS PRESSURES 1 The pressure ports on the gas valve are marked OUT and INLET 2 The manifold pressure must be taken at the port marked OUT 3 The inlet gas supply pressure must be taken at the port marked IN LET 4 Using a 3 32 0 2 cm Allen wrench loosen the set screw by turn ing it 1 turn c
47. straight through the roof or it can be offset by using up to 4 90 elbows Horizontal PVC pipe can be up to 10 ft 3 1 m long in any direction from the furnace vent connection Ver tical PVC pipe can be up to 10 ft 3 1 m in length 90 Elbow 90 Street Elbow Screen to Furnace FIGURE 25 Elbow Assembly 9 Attach elbow assembly to combustion air inlet piping See Figure 26 or 27 Inlet must be minimum 6 15 2 cm above highest antic ipated snow level but no more than 24 61 0 cm above roof 15 107272 UIM B 1105 J a 12 Min 9 Min Ma 6 Min or 6 Above the Snow Line D 2 Pipe Rubber Coupling with Hose Clamp Re 6 Min PN a FIGURE 26 Combustion Air Inlet Pipe LL Min T 9 Min JL 6 Min or 6 Above the Snow Line 2 Pipe ee Rubber Coupling with Hose Clamp Ai V FIGURE 27 Combustion Air Inlet Pipe Alternate NOTE Roof flashing PVC pipe PVC 90 elbows and fire stop are not supplied with the furnace LOCATING AND CUTTING ROOF J ACK OPENING To facilitate the proper installation of the roof jack it is very important that the roof jack opening in the ceiling and roof be on the same vertical center line
48. the louvers on the blower door The vent system is a Sealed Combustion Direct Roof Jack Vent System This is the ONLY vent system approved for use on this furnace 4 Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and from the conditioned space 5 Consideration should be given to the heating capacity required and also to the air quantity CFM required These factors can be determined by calculating the heat loss and heat gain of the home or structure If these calculations are not performed and the fur nace is over sized the following may result a Short cycling of the furnace b Wide temperature fluctuations from the thermostat setting c Reduced overall operating efficiency of the furnace A CAUTION On DFAA furnaces the cooling coil must be installed in the bottom of the casing DFAH furnaces must have the cooling coil installed downstream of the furnace Cooled air may not be passed over the heat exchanger Unitary Products Group When the furnace is used in conjunction with a cooling coil the coil must be installed parallel with or in the supply air side of the furnace to avoid condensation in the primary heat exchanger When a parallel flow arrangement is used dampers or other means used to control airflow must be adequate to prevent chilled air from entering the furnace If manually operated the damper must be equipped with means to pre vent th
49. to Fig ures 39 40 and 41 It is recommended that the pipe diameter in Table 16 be used to deter mine the size pipe to use from the meter to the burner 29 107272 UIM B 1105 TABLE 16 Gas Line Piping Size and Length i Rote Nominal Diameter of Pipe in Inches mm th of Pipe in Zoe Meter 3 4 19 05 1 25 4 1 1 4 81 75 1 1 2 38 1 2 50 8 Capacity Cu Ft m Per Hr with a 0 6 Sp Gr Gas and Pressure Drop of 0 3 in 74 72 Pa Water Col 15 4 572 172 4 87 345 9 77 750 21 24 Z 30 9 144 120 3 4 241 6 82 535 15 15 850 24 07 45 13 72 99 2 8 199 5 64 435 12 32 700 19 82 60 18 29 86 2 44 173 4 90 380 10 76 610 17 27 75 22 86 77 2 18 155 4 34 345 9 77 545 15 43 105 32 65 1 84 131 3 71 285 8 07 450 12 74 920 26 05 120 36 58 120 3 4 270 7 65 420 11 89 860 24 35 180 54 86 100 2 83 225 6 37 350 10 76 720 20 39 The building structure should not be weak end by installation for the gas piping The piping should not be supported by the other piping but should be firmly supported with pipe hooks straps bands or hanger Butt or lap welded pipe should not be bent The gas piping should be so installed so as to prevent an accumulation of condensation and it must be protected against freezing A horizontal pipe should be pitched so that it grades toward the meter and is fre
50. 1105 TABLE 18 High Altitude Duration Chart NATURAL GAS 56 000 Input 70 000 Input 77 000 Input 90 000 Input Elevation T 7 T T SS S Feet Meters Tin size Fa Dia sie fang Sia sue Pat Dia Sze Fa Sea Level 0 136 29 9951 1361 0 154 23 9951 1541 0 161 20 9951 1611 0 180 15 9951 1801 2 000 618 0 136 29 9951 1361 0 149 25 9951 1491 0 157 22 9951 1571 0 177 16 9951 1771 3 000 914 0 128 30 9951 1281 0 149 25 9951 1491 0 157 22 9951 1571 0 173 17 9951 1731 4 000 1219 0 128 30 9951 1281 0 147 26 9951 1471 0 154 23 9951 1541 0 173 17 9951 1731 5 000 1524 0 128 30 9951 1281 0 144 27 9951 1441 0 152 24 9951 1521 0 169 18 9951 1691 6 000 1829 0 128 30 9951 1281 0 144 27 9951 1441 0 149 25 9951 1491 0 166 19 9951 1661 7 000 2134 0 120 31 9951 1201 0 140 28 9951 1401 0 147 26 9951 1471 0 161 20 9951 1611 8 000 2438 0 120 31 9951 1201 0 136 29 9951 1361 0 144 27 9951 1441 0 161 20 9951 1611 9 000 2743 0 120 31 9951 1201 0 136 29 9951 1361 0 140 28 9951 1401 0 157 22 9951 1571 10 000 3048 0 116 32 9951 1161 0 128 30 9951 1281 0 136 29 9951 1361 0 152 24 9951 1521 PROPANE GAS 56 000 Input 70 000 Input 77 000 Input 90 000 Input Elevation
51. 4 26 0 cm 7990 6321 12 1 4 21 1 cm FIGURE 7 Duct Connector Dimensions Rear Wall Ceiling Cut Out of Enclosure f For Roof Jack 2 3 4 7 0 cm Min Floor Cut Out For Duct Connector S 5 Furnace E e Outline Yo ag x S Optional Gas y or Electric Entrance 2 1 8 5 4 cm Front Panel of Furnace 4 l 1 3 8 It 6 3 8 gt 1 1 8 H 16 2 cm r 3 1 4 2 9 cm 8 3 cm Future Refrigerant EE 20 gt Foor Line Entrance 50 8 cm FIGURE 8 Recommended Floor Cut out Ea Floor i 5 Floor Duct Connector Joist Depth Supply Duct FIGURE 9 Duct Connector Depth Locator Bracket Nails Flat Head Screws or Staples Screws Supply Duct FIGURE 10 Duct Connector Screw Attachment INSTALLATION OF SCREW ATTACHMENT DUCT CONNECTOR 1 Make floor cut out as shown in Figure 8 2 Determine the depth of the floor cavity from the surface of the floor to the top of the supply air duct and select the appropriate duct connector from the chart 3 Place locating bracket supplied with the duct connector to the back edge of the floor opening See Figure 10 4 Apply a water based duct sealant to the 1 2 in 1 3 cm supply duct attachment flange of the duct connector 5 Determine which of the four positions the duct connec
52. 61 om free area of the lower grille MUST be a minimum of 50 Inches 322 cm MINIMUM The grilles MUST BE ALIGNED directly opposite the return air grille of FREE AREA the furnace door 50 IN 322 cm MINIMUM FREE AREA FIGURE 6 Furnace To Closet Door Clearance Less Than 1 Unitary Products Group 7 107272 UIM B 1105 DUCT CONNECTORS bc 18 3 4 47 6 cm _ gt _ 2 3 8 6 0 cm SEE 2 3 8 14 35 6 cm CHARTZ 6 0 cm e d A z r 12 30 5 cm 18 3 4 47 6 cm D S a S y 4 3 8 DUCT CONNECTOR DIMENSIONS 11 1 em DUCT CONNECTOR DUCT CONNECTOR PART NUMBER DEPTH 7990 6011 1 2 5 cm 7990 6021 2 5 7 cm 7990 6041 4 1 2 11 4 cm 7990 6061 6 1 2 16 5 cm 7990 6071 7 1 2 19 0 cm 7990 6081 8 1 2 21 6 cm 7990 6101 10 1 4 26 0 cm 7990 6121 12 1 4 21 1 cm jt 18 3 4 47 6 cm 2 3 8 6 0 cm SEE 2 3 8 14 35 6 cm gt CHARTE 6 0 cm A A bach 12 e 30 5 cm 18 3 4 47 6 cm S Yy D D i 4 3 8 11 1 cm DUCT CONNECTOR DIMENSIONS DUCT CONNECTOR DUCT CONNECTOR PART NUMBER DEPTH 7990 6211 1 2 5 cm 7990 6221 2 5 7 cm 7990 6241 4 1 2 11 4 cm 7990 6261 6 1 2 16 5 cm 7990 6271 7 1 2 19 0 cm 7990 6281 8 1 2 21 6 cm 7990 6301 10 1
53. Clearance 5 or Greater 7 Combustion Air Inlet Pipe Alternate 16 Furnace To Closet Door Clearance 1 To 5 1 0 2 2 eee eee 7 Flue Shield Installation 16 Furnace To Closet Door Clearance Less Than 7 Roof Jack Attachment to Furnace 0 0 00000000002 16 Duct Connector Dimensions 8 Standard Roof Jack wie ax ag cities hd ERR Aa wean AEN NN ENNEN SE 18 Recommended Floor Cut out 0 0 0 20 e eee eee eee 8 Roof Jack With Removable Crowns 19 Duct Connector Depth virsi caus REENEN ae 8 Installing Roof Jack Extension 20 Duct Connector Screw Attachment 8 Ceiling RUNG sci isc Stes incase as E aa Rena ce adda RE Ei das a Eug 20 Duct Connector Tab Attachment 9 Home Layout sss vce ana na ace ate EE ALE EE EA ope ache 21 Anti Backflow Damper 9 Electrode SOMOS deene Sen aha thawte detonate ited Eech 22 Installation of Furnace 9 OIP UMP eu e a Sea OE Na cence ce EE 24 Floor Installation az e dE NEEN SN wld ee dg IT 10 Wiring Diagram for DFAA Oil Fired Furnace 27 Furnace Air Filters 4 vce ie ger ert de dE Bes Ve e Denali EN 11 Wiring Diagram for DFAH Oil Furnace 28 OIL PUTA oe sed aera tin ede ta ea ie a e gl 12 Gas Piping ug de ace a ack Sak eke e eS ch elastase hie Ar ds Resa eat 29 One Pipa Systemi oero dueraren ttita aod ace alle EE dye E E Ee Ee e 13 Manual Shut off Valve Gas Piping 30 TWO PIPS SYSTEM usta calc Eh ya a ete dg et aah bb 13 Proper Pi
54. E COMBUSTION TEST INSTRU MENTS BEING PROFICIENT IN THE USE OF THESE INSTRU MENTS AND INTERPRETING THE DATA IS NECESSARY FOR SAFE RELIABLE AND EFFICIENT BURNER OPERATION IT IS ESSENTIAL TO MAKE CERTAIN THAT THE PRODUCTS OF COMBUSTION DO NOT CONTAIN CARBON MONOXIDE CO The most common causes of CO are flame impingement on cool sur face and insufficient primary air both of which could be caused by over firing The only answer is to reduce the firing rate or increase the pri mary air Unitary Products Group Combustion efficiency is determined by the percent CO and the tem perature of the flue gases These two measurements are taken on the vent Combustion efficiency and stack loss calculators are available from several manufacturers of combustion test equipment IMPORTANT DRAFT When installing Wayne power conversion gas burners in oil fired furnaces a minimum negative draft of 01 w c 0 0025 kPa over fire must be maintained Refer to your local gas company and codes for assistance 3 Perform the following combustion analysis All adjustments below must be made with the following instruments draft gauge Oo or CO analyzer and CO tester a Adjust the primary air damper to provide about 25 excess combustion air Confirm this by checking the flue gas for its FREE OXYGEN Qs or CARBON DIOXIDE COs PER CENTAGES with a test instrument Free oxygen should be about 4 5 or carbon dioxide should be about 9 5 for
55. ECKETT FOR SERVICE INFORMATION Please record the burner serial number and have available when calling or writing You will find the serial number on the Underwrit ers Laboratories label located on the left rear of the burner or cover mounting plate See Figure 1 107272 UIM B 1105 General Model et AFEVC MFR S SETTINGS Information Modely S Series Oil Burner eege o FIRING RNG 0 5 1 10 GPH R W Beckett o o ES al Serial Number SE zen rom Manufacturer s Settings Si D d 020923 49038 NOZZLE 0 65 X 70A DIN HW Including Date Code nem mm Ge O O J I AGO ina a R W Beckett Specification ab Rating Information Fling Rng 0 50 0 75 GPA 020923 49038 Number and Revision g H 120V 60Hz 5 8A T ebe Approval Agency e d USTED e L Symbols aeeai osansa ee RWBackatt Corp Individual Specification Eio ono Foruse wih Group or2 Eat SE Pamay sale cerno LZ Je e State and Local Approvals P Primary Group t nee een 1 1988
56. EFFECT OF ELEVATION ON OIL BURNER FIRING The elevation of the installation of a modern high speed flame retention oil burner affects the performance of the burner Allowance for elevation must be taken into consideration when choosing an oil burner and oper ating it above 2000 ft 610m It is especially important in high elevation installations to adjust air set tings to match the burner nozzle firing rate As elevation increases above sea level the ambient air contains less oxygen Because there is less available oxygen per cubic foot of air the burner must deliver a greater volume flow cfm of air to provide the proper amount of oxygen for the amount of oil being burned This is the reason that an increase in the burner air setting may be required It is also important in high elevation installations to consider the maxi mum firing rate of the burner so that the heat input as required by the application is maintained Regardless of elevation the oil burner has a maximum volume flow of air that it can deliver As a result the maxi mum firing rate of the oil burner decreases as the elevation increases because the combustion air contains less oxygen An increase in the size of a fixed type retention head or even the use of an oil burner with a higher maximum firing rate may be necessary The effect of elevation up to 2000 ft 610 m is minimal so no re rate is necessary up to 2000 ft 610 m elevat
57. LNIOI e HO AEN LI USNUOASNVHL LI D ich SI4LLN3GI LNSWANNOILONOS 30 YNSLIOVdVa WI HOLIOVdVI MR 20 Nyang 1 awasna co asn4 en xog Haane MO ANOLSIYLN39 YNBLVINWNDD SO HOLIMS WOLJINLN39 S3 NOTLINAP JLINIT 30 YNSLVLNWNOD zen HOLIMS LINIT 257 J WdIONIdd JLINIT 30 HNILYLNNWOD 1S7 HOLIMS LINIT AMWWIYd 1S7 Elte d de XNS S3 Id 6 Y NOHONO 13 200 3w3T44NOS VI 30 ANILON II IS id X0LON H3MO7G NO 1300S Or Nid 6 1S ld 139 avoy BUIVNIYd STONLNOD Od TOYLNOD And 3d aACKAG SGIONS10S Nd MS AS AAA GIONIIOS AS dud dud Urs Siem 14 Aerm H 21 Tar 3 NOILINSI G YNILYWYOJSNYYL LI YIWY04SNYY1 NOILIN9SI LI Ia ED SG TAK BUIVNTYd 3QHLNOD dd ONE ANN 3d war e ASO anana na Wan mg HOON yanana mg BR oxo i HOLINOL J30N3941 aN3931 gages LNIO fme me f e ol U THM En NOILd3ONOD YN Y d 30 S39 3L0Yd LNOS SUNSLON S37 9 RES NOLIVINANIT 1 YNOd SHNALONOPSIG SIT Z3SSINYNOS S Aono d SUUSL N3 ISIN Mag 3413 LIOG LNAWSOV1TdW3Y 30 SLNVSOdNOD SLNOL BYAIND 30 4 YNOd SILLIYYN SIA LNINITNIS we 9 501 4 122 SNIOW Den lI SBUNLVYSINSL S30 V Y3LSISJH LNVANOd XNYIHJLVN NN JJAY 38437 THK 1100 I 1001 N3 NO SIN N3 Z0VIdNSY 2013 1100 294 IIe e xMVdIOINNN 13 XNY207 2000 9 e G UO 20 S3009 S31 N0 13 939 NaIGYNV9 9373 3009 8 ZAAINS 33SI Y 104 2012 L100 LNVYNOD NG NOILVLINANT 1 1 700 13 N39 TWNOLLWN 0373 3009 Y NOTSS Y3ILNVHO N3 ZEIL LOL ONIGOD YO1O9 3A834390 CSZIYV 10d 2 LSNW YSAMOd SNINOONI GSLOSLO d ATLNJYJHNI JYV SHOLON a SILON HOLIMS gauas A 009 H
58. LVISONYSHL 1009 1V3H NOILAVS4SYd Q d poe re i 4 so Es 157 4NVHO LINN SIHL ONISIAYSS aay iH 340439 SLOSNNOOSIO 1Y NadO A 430 AYO 9 ra NOILNVO HOLIMS d 5 1009 LIATI a D va e D envio eo Ep CIS onv suaunod 38a8N0a Ou dud c ja gt be 3 1duNd dd S Lesa 1834 Oo 50 Wis se Ve e sl V NYa HOLIMS 34831 N3 wnua Tv o HOLIAS LIMIT Ee NMONG Nee Sa Wi 13534 SENZRRESCAEN 5 Tenuen 3LIHM 198 Sale Nei annvr Nave I LHM Eo T o Ao MOTISA THA I fe Toon N08 aay ES Lon pooo THM Lo 0 nate n310 LL 9 EDICI ne CO o o XION HION G Slo yovig we Ss ly D 540 vg LGL Naj S9V1I4 NG E Fo o No el SR HOT IO 20 3009 cas T Cou S4 D __ umoa e AT A2 OO 201 lo o SS amp Ze Ee THTONT Q 30 NILON Y01OW Ei ER Srel w D bai EE 3L0N YIOA O9 I SII NOILYLN WITY ION osol 990 Ko vwgl kr i Sr oer a HOLIDVdVI LNOHLIM SHOLOW NO MO 1 3L0N 33S 09 I SIl ATddNS HOM IRAK EREUREEGCOSEH CHES HOLIMS WALSAS 0010 W39 1NdNI Y01LI9Ydy3 D SINS144N0S YI 20 INSTVAINOZ SLI YO SILSVIGONYSHL 201 3dAL HLIM G3OVIdSY 3a Lem LI SYIVLINSWS145 SWAVYSVIG SSSSLIA 30 SLYVHO Qa9vV1dSY 3g LSAW LINN SIHL HLIM G3IdddAS AYIM TWNISIYO JHL A0 ANY JI tS WT 4300Y LOVE Oo 020 jg FIGURE 46 39 Unitary Products Group NOTES Subject to change without notice Printed in U S A 107272 UIM B 1105 Copyright by York International Corp 2005 All righ
59. N NII 3413 1100 INN 30 SLNVSOdNOD SLNOL ONIGOD Y07109 SAYSSEO OSZIYV1Od 3d LSNW Y3MOd NIWOONI SHAING 30 TL ges Gu 20 SaN INANA NAS 2 S01 4 122 SNIOW Dei HOLIMS 009 Hlava OH i SJYNLYYJJM3L SJO _V_YSLSISSY LNVANOd XNVINSLWN NN JAY 3443 7 WALSAS EE 1100 WI 001 N3 NO 2014 N3 SOVIdNSY 3413 U00 JOvU4 31 IS Z aNnow9 a LV LSOWHSHL R Cen XNVAISINNW 13 M20 53009 9 wie 3 N0 L3 939 N3IQYNY3 9373 3009 a oO e ova sil JA 8 9M 70 13 N39 qYNOILYN 9373 3009 Y NOTSS YSILNVHD N3 294 1NOL I a O 4a THM NIN ry Ze CLD ATLNSYSHNI SHV SYOLOW 9 SILON ios le S3INddNS HIMOd TV X04 SLOSNNOISIG 30IAOYd S c a mar O3ONNOYD Add 38 LSM SLNSNOdNOD LINKEN TW G3ddINO3 At ATNO SHOLINGNOD H 404 STGVLINS SHOLISNNOD e OLOVLNOD 9 G01 ASS 1SY37 LY 40 ONILVY JYNLYYIJNIL LAVA dl dvd dd ITINAA LINN Y ONIAVH tu len NIT HLIM 039V d3 20 SMW lI 0972 08 SSIVNYNO J NISNIONOD 38 SMW 3OVNYNS 201 HUN G3ITddNS SV SHIM TWNISINO IHL 20 ANY AS Lowy i WE AU O_W907 D MI MO MET 08 70 ONY 939 3009 9373 NYIQYNYO 8 780 0NY 33N 3003 0373 TWNOILYN Y H ONIMIM 07314 TV 1 D S3J 10N BOIAYSS 37 J3AV 43039044 30 R ISNA dg e 41a INVAY SYNSLONOPSIG S37 ZIYANO 3NYH ZYWIT LV LSONYSHL SDE Pes a 2 agg eA dau d D LVISONYSHL 7009 1V3H NOILAVSSYd Eee Fo 72 i Vue oo L Y ame IS 4NYHI AINA SIHL SNIOTAYSS aed ne EN 340439 SLOSNNOISIO Tv N3dO ze z 2009 Sa uanuos gt 3 T O based NOILNVS aud HUTT au o
60. NSA NG YNALVLNWNOD S4 1139 Oort YNILYLNWAOD STINT y YNSINYa Nd ALIN 30 ei ANAC Sug aud SvdIONIdd SLINIT 30 YNSLVLNWNOD 1S7 zi u NS S39Id 6 Y NOHONOG 13 3TUNOG SINA VI 20 YNILON II IS Id ad LAK L E GE BYIVWIYd JTOY1NO9 dd noa E SQIONST0S NO IdNOS AS Ee DCH 30 uNALdvd Oe INNA V7 30 Sue 39 HMD 980 NOTLINSI G YNSLVWHOISNVHL LT oap STINH T Y HIR NO SMIVWIHd 3IQHLNOD 3980 mg be ma MG 3dYdN0S MINH Y 3dNOd YI 30 3OIONIT0S ASdO aom 4M YNBLOW INHI Y snaa NO na x fo i d JUNAJ QAAN O S wie it THK suN3a1NOD 30 S3003 S37 ZAAINS SSSINV10d 2017 L100 LNY XNO NG NOTLVINAWT 1 7 ONIGOD Y40709 3484390 GSZIYV10d 3G LSNN YSMOd SNINOONI HOLIMS ONNOYS HWS OLH W3LSAS MAYS ey Se Tf reg Eeer D 1YLSOWY3HL XMWAIDINAW 13 XNY307_53009 3 2 wa E TIVA Z00713 939 N3IGWNVO 9373 3009 8 Vo E H Iva SII JA H 9M ye I AEN oF Pe CBLOSLO d ATLNSNSHNI Su SHOLON 9 S3ITddNS YAMOd TV X04 SLOSNNOOSIC 3GIAOUd S EWEN O3ONNOY9 Add 38 LSNW SINSNOdNOD LNSWIIVIdSY NY TE Oo vr R d Troaadtnga art ATNO SHOLONGNOD H lt YO4 STAVLINS SHYOLOSNNOD YOLOVINOD 2 601 4elZ2 1SV37 LV A0 ONILVY HUH LINN V ONIAVH Ir elt ONIYIM HUN OU 38 LSNW LT ON M30 er n 38 Lann Zar 201 HLIM OU SY SIM TWNISIHO SHL 40 ANY dI Z EC 3009 AU YO W907 3 L o 40 0NY 939 2000 0373 NVIGYNV 8 740 ONV JAN 3009 3373 Tuten Y 43d ONIMIM 07314 TIY I ISNA MY SS G o 4NVHO WNIID LV LSONY3HL E 0 SSO D AWLSONYSHL 1009 1V3H 3 Se RES ase p
61. STM D396 CANADA No 1 stove oil or No 2 furnace oil only are approved for use and can be burned in this furnace Refer to the furnace rat ing plate or SECTION IV of these instructions Install this furnace only in a location and position as specified in SECTION of these instructions An oil fired furnace for installation in a residential garage must be installed as specified in SECTION of these instructions Combustion products must be discharged outdoors The Roof Jack vent system is the only approved vent system that can be installed on this furnace Install as specified in SECTION VI of these instructions FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Read all instructions before proceeding Follow all instructions com pletely Failure to follow these instructions could result in equipment malfunction causing severe personal injury death or substantial property damage Test for leaks in the oil line as specified in SECTION VIII of these instructions Always install the furnace to operate within the furnace s intended temperature rise range Only connect the furnace to a duct system which has an external static pressure within the allowable range as specified on the furnace rating plate The return air duct system is not required by the furnace manufac turer This furnace utilizes a sealed combustion a
62. ainder of the heat cycle If the flame should be extinguished during the heat cycle the S87K gas control pri mary will go into the 30 second prepurge and 8 second safe start check then re energize the gas valve and ignition transformer in an attempt to establish the main burner flame If this does not occur within the 4 sec ond trial for ignition period the S87K gas primary control will go into lockout de energizing the gas valve and ignition transformer To restart the system the main power or thermostat must be de ener gized momentarily then re energized If at any time during the heat cycle there is an insufficient supply of combustion air to the burner the air switch will open putting the system into lockout closing the gas valve FIGURE 44 Electrode Orientation and Gap Unitary Products Group le 13 Igniter Gap Le 13 Flame Sense Rod Gap 37 107272 UIM B 1105 WIRING DIAGRAM GAS CONVERSION BURNER SECTION XII Eech STIBYVdd 13 YSILNVHO 30 2074 ene S39IAZ0 ONY NIXIM OTALA
63. air flow from being obstructed Refer to Table 1 Unit Clearances to Combustibles a If the standard throwaway filter are used the external filter grille must have a minimum area of 540 in 3483 cm which would equal a 15 X 36 38 1 cm x 91 4 cm filter grille b If the Pleated Media or Washable Filters are used the exter nal filter grille must have a minimum area of 684 in 4413 cm which would equal a 18 X 38 38 1 cm x 91 4 cm filter grille The increased area is to reduce the pressure drop across the air filter c Consideration should be given when locating the return filter grille for maintenance d Any filter that has a large pressure drop should be checked to be sure the pressure drop caused by the air filter will not pre vent the furnace from operating within the rise range speci fied on the rating plate and in Table 8 If the furnace does not operate within the specified rise range then a larger air filter or an air filter that has a lower pressure drop must be installed TABLE 5 Filter Sizes Input Output CFM BTU H kW m mm 66 53 19 34 15 53 1050 29 73 84 67 24 62 19 64 1250 35 40 Top Return Filter In cm 2 14 x 20 35 56 x 50 8 2 14 x 20 35 56 x 50 8 Unitary Products Group IMPORTANT Air velocity through throwaway type filters must not exceed 300 feet per minute 1 52 m m A CAUTION All installations must have a filter installed Air Filters C
64. alled in the fuel unit Manual venting of the fuel unit is required on initial start up If connecting a two pipe fuel supply install the fuel unit bypass plug AWARNING The oil supply inlet pressure to the fuel unit cannot exceed 3 psi 20 7 kPa Install a pressure limiting device in accordance with NFPA 31 Fuel Supply Below the Level of the Burner When the fuel supply is below the level of the burner a two pipe fuel supply system is required Depending on the fuel line diameter and hor izontal and vertical length the installation may also require a two stage pump Consult the fuel unit manufacturer s literature for lift and vacuum capability Fuel Line Installation e Continuous lengths of heavy wall copper tubing are recom mended Always use flare fittings Never use compression fit tings e Always install fittings in accessible locations Fuel lines should not run against the appliance or the ceiling joists to avoid vibra tion noise AWARNING Never use Teflon tape on any fuel fitting Tape fragments can lodge in fuel line components and the fuel unit damaging the equipment and preventing proper operation Fuel Line Valve and Filter Install two high quality shut off valves in accessible locations on the oil supply line Locate one close to the tank and the other close to the burner upstream of the filter ANOTICE Some states require these valves to be fusible hand
65. an Be lt S gt a Zt Found On The Inside az Of This Access Panel FIGURE 15 Furnace Air Filters SECTION IV OIL PIPING OIL SAFETY IMPORTANT INFORMATION Long or oversized inlet lines may require the pump to operate dry during initial bleeding period In such cases the priming may be assisted by injecting fuel oil in the pump gearset Under lift conditions lines and fittings must be air tight To assure this Pipe Dope may be applied to both the used and unused inlet and both return fittings DO NOT USE TEFLON TAPE DO NOT USE COM PRESSION FITTINGS VACUUM CHECK A vacuum gauge may be installed in either of the 1 4 NPT inlet ports The Beckett CleanCut pump should be used where the vacuum does not exceed 6 hg 20 3 kPa single pipe and 12 hg 40 6 kPa two pipe Remember running vacuum is the total of all pres sure drops AP in the system from tank to inlet of pump PRESSURE CHECK When a pressure check is made use either the BLEED PORT OR NOZZLE PORT CUTOFF CHECK To check cut off pressure dead head a pressure gauge in nozzle port Run burner for short period of time Shut burner off The pressure will drop and hold above zero A CAUTION Pressurized or gravity feed installations must not exceed 3 P S I 20 7 kPa on inlet line or return line at the pump per NFPA 31 A pressure greater than 10 P S I 69 0 kPa may cause damage to the shaft seal
66. ature Read ing 2 The External Static Pressure is determined by the Supply Duct Static Pressure reading TABLES 2 and 3 are to be used as a guide only to help the installer determine if the duct sizes are large enough to obtain the proper air flow CFM through the furnace TABLES 2 and 3 ARE NOT to be used to design ductwork for the building where the furnace is being installed There are several variables associated with proper duct sizing that are not included in the tables To properly design the ductwork for the build ing Refer to the ASHRAE Fundamentals Handbook Chapter on DUCT DESIGN or a company that specializes in Residential and Mod ular Home duct designs The supply air temperature MUST NEVER exceed the Maximum Supply Air Temperature specified on the nameplate Operating the furnace above the maximum supply air temperature will cause the heat exchanger to overheat causing premature heat exchanger failure Improper duct sizing dirty air filters incorrect oil pump pressure incorrect oil orifice and or a faulty limit switch can cause the furnace to operate above the maximum supply air tem perature Refer to SECTIONS II III and VIII for additional informa tion on correcting the problem DUCKWORK INSTALLATION Air Distribution Systems For proper air distribution the supply duct system shall be designed so that the static pressure does not exceed the listed static pressure rating on the furnace
67. combustion is set tighten all fasteners on the air adjustment and escutcheon plate 5 Start and stop the burner several times to ensure satisfactory operation Test the primary control and all other appliance safety controls to verify that they function according to the manufacturer s specifications ADJ USTMENT OF TEMPERATURE RISE The temperature rise or temperature difference between the return air and the supply heated air from the furnace must be within the range shown on the furnace rating plate and within the application limitations shown in Table 8 ELECTRICAL AND PERFORMANCE DATA The supply air temperature cannot exceed the Maximum Supply Air Temperature specified in these instructions and on the fur nace rating plate Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature Operating the furnace above the Maximum Supply Air Temperature will cause premature heat exchanger failure high levels of Carbon Monoxide a fire hazard personal injury property damage and or death After about 20 minutes of operation determine the furnace temperature rise Take readings of both the return air and the heated air in the ducts about six feet 1 83 m from the furnace where they will not be affected by radiant heat FILTER PERFORMANCE The airflow capacity data published in Table 14 represents blower per formance WITH CLEAN filters The filter press
68. contained in Manufactured Homes A119 1 Recreational Vehicles A119 2 and H U D Title 24 Section 3280 705 and any local or state codes NOTE The gas line inlet on the gas valve is 1 2 14 N P T The gas line may be installed through the furnace floor or either side of the furnace to the gas valve MANUAL SHUT OFF VALVE MANUAL SHUT OFF gt VALVE BRP ge LEG BURNER Wee ee NI FIGURE 39 Gas Piping A CAUTION The gas valve body is a very thin casting that cannot take any external pressure Never apply a pipe wrench to the body of the gas valve when installing piping A wrench must be placed on the octa gon hub located on the gas inlet side of the valve Placing a wrench to the body of the gas valve will damage the valve causing improper operation and or the valve to leak Refer to Figure 42 The gas line should be a separate supply direct from the meter to the gas valve It is recommended that new pipe be used and located so that a minimum amount of work will be required in future servicing The pip ing should be so installed as to be durable substantial and gas tight It should be clear and free from cutting burrs and defects in structure or threading Cast iron fittings or aluminum tubing should not be used for the main gas circuit Joint compounds pipe dope should be used spar ingly on male threads only and be approved for all gases Refer
69. d Roof This is the Installer s Responsibility A B 76 59 1 2 DFAA MODELS DFAH MODELS Floor D P be S SZ Kees D KE X Z Z Za Leg es zZ z Warm Air Duct Duct Connector Duct Connector Warm Air Duc X X XX X X X X X X XX XXXXXX xX X XO EO K EEEE EEE X X X X X XX XXX xXx xX FIGURE 31 Roof Jack With Removable Crowns Unitary Products Group 107272 UIM B 1105 STEP 1 Remove upper and lower cap Remove the two 2 screws that secure the upper cap to the crown assembly base and remove the upper cap Next remove the three 3 screws that secure the lower cap to the crown assembly base Set bothcaps aside for later use Crown Assembly Base STEP 2 Place the roof jack extension on top of the crown assembly base pushing down firmly to assure a snug fit IMPORTANT Make sure that the pipes are connected Using the four 4 holes at the base of the extension as a guide drill four 4 holes 1 8 diameter into the crown assembly base Secure the extension to the crown assembly base with the four 4 screws provided Install the lower cap on top of the extension so that the center pipe sticks through the hole in the lower cap STEP 3 Reinstall upper and lower cap to extension Using the three 3 screws removed in Step 1 attach the lower cap to the extension bracket Install the upper cap over the center pipe of the extension Using the two 2 holes loca
70. depleted combustion air supply Therefore if the furnace will be located in regions where snow accumu lation on the roof exceeds 4 or in H U D Snow Load Zones a roof jack extension and PVC combustion air inlet extension is recommended Refer to Figure 26 or 27 COMBUSTION AIR INLET All combustion air pipe and fittings must conform to American National Standards Institute ANSI standards and American Society for Testing and Materials ASTM standards D1785 Schedule 40 PVC D2665 PVC DWV F891 PVC DWV cellular core D2241 SDR 21 and SDR 26 PVC D2261 ABS DWV or F628 Schedule 40 ABS Pipe cement and primer must conform to ASTM Standards D2564 PVC or D2235 ABS 1 Mark vertical combustion air inlet centerline on ceiling Cut hole for combustion air inlet piping Clearance to combustible materials is not required Cut hole in roof Provide minimum 12 30 5 cm vertical separa tion between combustion air inlet pipe and roof jack vent cap Clearance to combustible materials is not required Route piping through ceiling and holes Provide firestop as required Insert combustion air inlet coupling into casing See Figure 26 or 27 Slide PVC pipe into coupling Use a hose clamp to secure the PVC pipe to the coupling Complete piping through roof Provide flashing at roof penetration Prepare elbow assembly See Figure 25 Insert screen into elbow socket Secure in place with street elbow or nipple PVC pipe can be
71. e from sags The pipe can not be run through or in an air duct or clothes chute The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressure in excess of 1 2 3447 PaG psig The appliance must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 3447 PaG psig Refer to Figure 40 Gas Piping Manual From Meter Shutoff Valve Close this valve during pressure testing of the gas line Gas Line j ea L 1 8 NPT Plugged 4 Tapping Pressure ae H Gauge Port Direction of Flow Union Black To Gas Iron Pipe Valve Si 3 00 Min T Control 72 6 Se Manifold Drip Leg Sa Kee Pipe Can S Floor Level LOCATION OF UNION AND DRIP LEG FOR CONNECTING BURNER TO HOUSING PIPING FIGURE 40 Manual Shut off Valve Gas Piping GAS PIPING INSTALLATION Properly sized wrought iron approved flexible or steel pipe must be used when making gas connections to the unit If local codes allow the use of a flexible gas appliance connection always use a new listed con nector Do not use a connector that has previously serviced another gas appliance 30 Some utility companies or local codes requ
72. e furnace or the air conditioner from operating unless the damper is in full heat or cool position AWARNING The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed Refer to Table 8 and the furnace rating plate for the correct rise range and Table 4 for static pressures If the ducts are undersized the result will be high duct static pres sures and or high temperature rises which can result in a heat exchanger OVERHEATING CONDITION This condition can result in premature heat exchanger failure which can result in personal injury property damage or death HAZARD OF ASPHYXIATION DO NOT COVER OR RESTRICT FLOOR OPENING The duct system is a very important part of the installation If the duct system is improperly sized the furnace will not operate properly The ducts attached to the furnace duct connector should be of sufficient size so that the furnace operates at the specified external static pres sure and within the air temperature rise specified on the nameplate IMPORTANT Fabricate and install an inspection door in the plenum base below the unit to allow an annual inspection of the heat exchang ers The inspection door can be fabricated by following method 1 Cut a rectangular opening in the plenum base 2 A Sheet metal plate can be made that completely covers the open ing in the base 3 The plate must be secured with screws
73. e safety switch open the vent plug when the motor starts rotation and complete the venting procedure NOTE Electronic safety switches can be reset immediately others may require a 3 to 5 minute wait e Ifthe burner stops after flame is established additional venting is probably required Repeat the venting procedure until the pump is primed and a flame is established when the vent plug is closed e For R7184 primary controls see Technician s Quick Reference Guide Beckett part number 61351 for special pump priming sequence e Prepare for combustion tests by taking a sample in the flue pipe A combustion sample should be taken with a 1 4 0 4 km tube placed in the center of the vent pipe outside beneath the crown assembly 6 Initial air adjustment Using a smoke tester adjust the air to obtain a clean flame Now the additional combustion tests with instru ments can be made Never drill a hole in the roof jack to take com bustion sample or smoke tests 23 107272 UIM B 1105 IGNITION SYSTEM SEQUENCE ils 2 3 Turn the oil supply ON at external valve on the oil pump and or at the oil tank Set the thermostat above room temperature to call for heat System start up will occur as follows a The burner motor will start and come up to speed b Shortly after the burner motor starts up the ignition trans former will provide 10 000 volts through the electrods causing a spark that will last approximately 15
74. eet 91 cm 3 feet 91 cm 12 inches 30 cm for models lt 100 000 BTUH J Clearance to nonmechanical air supply inlet to building 30 kW 35 inches 91 cm for models gt 100 000 4 Feet or the combustion air inlet to any other appliance BTUH 30 kW i 3 feet 91 cm above if within 10 feet 3 cm K Clearance to a mechanical supply inlet 6 feet 1 83 m horizontally L Clearance above paved sidewalk or paved driveway located on public property 7 feet 2 13 m t 7 feet 2 13 m M Clearance under veranda porch deck or balcony 12 inches 30 4 cm 12 inches 30 4 cm Vent Termination from any Building Surface 12 30 4 cm 12 30 4 cm Above anticipated snow depth 12 30 4 cm 12 30 4 cm 1 In accordance with the current CSA B149 1 00 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI 2223 1 NFPA 54 National Gas Code In accordance with the current UL 311 Standard for Safety for Roof Jacks for Manufac tured Homes and Recreational Vehicles t A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor For clearance not specified in UL 311 Standard for Safety for Roof Jacks for Manufactured Homes and Recreational Vehicles Clearance in accordance with local installation code
75. el Burner Spec ATC Head Static Plate Nozzle Pump Pressure Air Boot Setting DFAAO84BBTA 0 65 x 70 A DEAHO84BBSA EVC 201 AF36YHHS F3 3 3 8 U D lavan 100 psi 689 kPa 4 0 DFAAO66BBTA 0 50 x 70 A e DFAHO66BBSA EVC 202 AF36YHHS F3 3 3 8 U Delavan 100 psi 689 kPa 3 0 START UP AND ADJ UST BURNER Start up Burner Set Combustion AWARNING Do not attempt to start the burner when excess fuel or vapor has accumulated in the appliance Starting the burner under these con ditions could result in a puff back of hot combustion gases high smoke levels or otherwise hazardous operation 1 Open the shut off valves in the oil supply line to the burner 2 Set the air boot adjustment to the setting stated in Table 12 This is an initial air setting Additional adjustments must be made with instruments 3 Set the thermostat substantially above room temperature 4 Close the line voltage switch to start the burner If the burner does not start you may have to reset the safety switch of the burner pri mary control 5 Vent air from fuel pump as soon as burner motor starts rotating To vent the fuel pump attach a clear plastic hose over the vent plug Loosen the plug and catch the oil in an empty container Unitary Products Group Tighten the plug when all air has been purged from the oil supply system e If the burner locks out on safety during venting quickly close the vent plug reset th
76. el Joint with PAA Gases e Sealant Supplied by Furnace Manufacturer 19 1 2 19 1 2 Combustion Air Combustion JA wy Air y y A Caulk Caulk A Under Under Flashing Flashing The End of Upper Portion of Roof Jack need bom Not extend below the ceiling IMPORTANT Seal Roof Jack Flashing to the Roof Jack and Roof This is the Installer s Responsibility _ A IT A B El 76 59 1 2 DFAA MODELS DFAH MODELS e A 7 Floor e T y y jes e e es a is S z Z Cas C O er Warm Air Duct Duct Connector Duct Re Warm Air Duct XO EX XX xX xX X EEEE e xX Xx ee es em es e e e Ss x x EEEE e e FIGURE 30 Standard Roof Jack 3s Unitary Products Group 107272 UIM B 1105 DFAH FURNACES DFAA FURNACES SWIVEL FLASHING SLANT ADJUSTS ERONI FLASHING INSTALLATION DIMENSIONS INSTALLATION DIMENSIONS 0 12 TO 5 12 PITCH 3 12 PITCH A B ADJUSTABLE HEIGHT ADJUSTABLE HEIGHT 4000 8161 C 4000 9161 A 85 to 101 101 to 117 4000 9181 A 99 to 129 115 to 145 4000 8181 C Carefully Caulk All Around Swivel Joint with Sealant Supplied by Furnace Manufacturer ee SSS A Caulk 5 Caulk A Under Under Flashing Flashing The End of Upper Portion of Roof Jack need e Not extend below the ceiling IMPORTANT Seal Roof Jack Flashing to the Roof Jack an
77. er must be installed in the furnace as specified in the installation instructions and must be replaced or thoroughly cleaned prior to occupancy of the home Again drywall dust is the key issue as that dust can be pulled into the circulating blower motor plugging the motor vents coating the rotors and stators etc which can lead to a potential fire hazard 14 c The temperature of the return air to the furnace must not be less than 55 F 13 C with no evening setback or furnace shutdown to prevent condensation in the primary heat exchangers d The air temperature rise must be within the stated rise range as indicated on the furnace rating plate and the firing input rate must be set to the unit nameplate value e The external static pressure of the air distribution system ductwork must be set for heating operation to be at least 0 12 03 kPA to 0 30 0 7 kPA inches water column based on the input rate of the furnace with the lower value for input rates at 66 000 btu hr and the upper value for units with input rates at 84 000 btu hr f The furnace and ductwork should be thoroughly and com pletely cleaned prior to occupancy of the dwelling to insure the proper operation of the furnace and to avoid potential health concerns In Canada refer to the Oil fired Central Furnace Installation code CANCSA B139 When installed in a Manufactured Mobile Home combustion air shall not be supplied from occupied spaces The size of
78. es IMPORTANT All electrical connections made in the field and in the fac tory should be checked for proper tightness When the oil line is initially connected to the furnace the tubing may be full of air In order to purge this air it is recommended that the bleed valve be loosened until no air bubbles are detected in the plastic tubing If burner does not light press the reset button on the primary control once only and bleed oil pump again If burner still does not light turn off the power to the furnace and call a qualified service technician DO NOT CONTINUE TO PRESS THE RESET BUTTON ON THE PRI MARY CONTROL TOOLS AND INFORMATION THAT WILL BE REQUIRED IN ORDER TO PROPERLY PERFORM THE FURNACE STARTUP PROCEDURE 1 You will need a thermometer or portable digital thermometer to read the supply and return air temperatures 2 You will need a pressure gauge that has the ability to read pres sures between 0 100 PSIG 0 689 kPa in order to measure the oil pump pressures You will need a 3 32 Allen wrench for the pressure port adjust ment screw in the oil pump 4 You will need 1 piece of 1 4 0 63 cm ID flexible tubing that is 12 30 cm in length 5 You will need a clear plastic jug 6 You will need a 7 16 open end or box wrench 7 You will need a 1 4 brass NPT x flare fitting These items are required in order to properly perform the required start up procedure Furnace Mod
79. es Check the oil pump pressure Check the piping to the oil tank _ Check the oil nozzle oil supply and oil filter Check Oil Primary Control NO oP ON gt If the trouble is not in the burner or ignition hardware check the oil pri mary control by using the following equipment 1 Screwdriver 2 Voltmeter 0 to 150 VAC range 3 Insulated jumper wire with both ends stripped 4 Refer to the trouble shooting guide located after the wiring dia grams to determine failure AWARNING Electrical Shock Hazard Can cause severe injury death or property damage Be careful to observe all precautions to prevent electrical shock or equipment damage Delay Timings DIP Switch Settings Burner Motor Off Dela Valve On Delay minutes X e 5 S 3 Enable Disable seconds R7184U R7184P R7184U R7184P 0 0 X xX Off 0 0 5 Off Off 2 2 Off On b 4 4 On Off SR 5 8 On On X No Difference or Impact a Specific models may have different timings Be sure to check device label b S 3 not provided on R7184P models Check Adjust Electrodes inven SE Check the electrode tip settings Adjust if necessary to comply with the dimensions shown in Figure 35 To adjust loosen the electrode clamp screw and slide rotate the electrodes as necessary Securely tighten the clamp screw when finished 22 Nozzle to tip Spacing ela 5 16 Above Nozzle Center
80. ing system being placed into operation while all other appliances connected to the venting system are not in operation 1 Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition Close all building doors and windows and all doors Turn on clothes dryers and TURN ON any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Open the fireplace dampers Do not operate a summer exhaust fan Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so the appliance shall operate contin uously Test each appliance such as a water heater equipped with a draft hood for spillage down draft or no draft at the draft hood relief opening after 5 minutes of main burner operation Appliances that do not have draft hoods need to be checked at the vent pipe as close to the appliance as possible Use a combustion analyzer to check the CO2 and CO levels of each appliance Use a draft gauge to check for a downdraft or inadequate draft condition After it has been determined that each appliance properly vents when tested as outlined above return doors windows exhaust fans fire place dampers and any other gas burning appliance to their normal condition If improper venting is observed during any of the above tests a proble
81. ing will fit between the warm air plenum and roof jack FIGURE 33 Ceiling Ring VENT CLEARANCES IMPORTANT The vent must be installed with the minimum clearances as shown in Figure 34 and must comply with local state regional codes and requirements Unitary Products Group 107272 UIM B 1105 Inside Corner Detail Vent Terminal Air Supply N Area Where Terminal is Not Permitted Operable FIGURE 34 Home Layout Canadian Installations US Installation A Clearance above grade veranda porch deck or balcony 12 inches 30 cm 12 inches 30 cm 12 inches 30 cm for models lt 100 000 BTUH B Clearance to window or door that may be opened 30 kW 36 inches 91 cm for models gt 100 000 4 Feet BTUH 30 kW C Clearance to permanently closed window 4 Feet 4 Feet D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 4 Feet 4 Feet of 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit 12 Inches 12 Inches F Clearance to outside corner 12 Inches 12 Inches G Clearance to inside corner 6 Feet 6 Feet 3 feet 91 cm within a height 15 feet 4 5 m H Clearance to each side of center line extended above meter regulator assembly 3 feet 91 cm within a height 15 feet 4 5 m EE above the meter regulator assembly meter regulator assembly Clearance to service regulator vent outlet 3 f
82. ion Above 2000 ft 610 m for every 1000 ft 305 m above sea level including the first 2000 ft 610 m there is a 1 84 rate reduction of the burner To assist you we have included the following chart and some examples Refer to Table 7 The pressure regulator on the fuel pump must not be adjusted in excess of 100 PSIG 689 kPa Pressures exceeding 100 PSIG 689 kPa may cause an overheat ing condition which can lead to premature heat exchanger failure resulting in a fire or explosion or cause damage to the furnace of some of its components that will result in property damage and loss of life Refer to Figure 16 for Pressure Regulator Location 12 TABLE 7 Burner Rating at Elevation Above Sea Level gph l m Elevation Nozzle Size Above Sea Level 0 50 1 892706 0 65 2 460518 ft m gph Uh gph Uh 500 152 0 50 1 89 0 65 2 46 1 000 305 0 50 1 89 0 65 2 46 1 500 457 0 50 1 89 0 65 2 46 2 000 610 0 50 1 89 0 65 2 46 2 500 762 0 49 1 86 0 65 2 46 3 000 914 0 48 1 82 0 64 2 42 3 500 1 067 0 48 1 82 0 64 2 42 4 000 1 219 0 47 1 79 0 63 2 37 4 500 1 372 0 47 1 79 0 63 2 37 5 000 1 527 0 46 1 76 0 61 2 33 5 500 1 676 0 46 1 76 0 61 2 33 6 000 1 829 0 46 1 72 0 60 2 28 6 500 1 981 0 46 1 72 0 60 2 28 7 000 2 134 0 45 1 69 0 59 2 24 7 500 2 286 0 45 1 69 0 59 2 24 8 000 2 438 0 44 1 66 0 58 2 20 9 000 2 743 0 43 1 63 0 57 2 16 10 000 3 048 0 42 1 60 0
83. ir and vent sys tem referred to as a roof jack The Roof Jack must be installed as specified in these instructions and must conform with state local or regional codes It is permitted to use the furnace for heating of buildings or struc tures under construction Installation must comply with all manu facturer s installation instructions including e Proper vent installation Furnace operating under thermostatic control e Return air filter door must be sealed to the furnace e Air filters in place e Set furnace input rate and temperature rise per rating plate marking e Means for providing outdoor air required for combustion Return air temperature maintained between 55 F 13 C and 80 F 27 C s The air filter must be replaced or thoroughly cleaned upon sub stantial completion of the construction process e Clean furnace duct work and components upon substantial completion of the construction process and verify furnace operating conditions including ignition input rate temperature rise and venting according to the manufacturer s instructions The following requirements to be met a Clean outside combustion air is provided to the furnace to minimize the impact of corrosive adhesives sealants and other construction materials Drywall dust is a major concern during construction which can be pulled into the combustion air path leading to plugged heat exchangers burners and inducer assemblies b Filt
84. ire pipe sizes larger than the minimum sizes listed in these instructions and in the codes The furnace rating plate and the instructions in this section specify the type of gas approved for this furnace only use those approved gases IMPORTANT An accessible manual shut off valve must be installed upstream of the furnace gas valve and within 6 feet 1 8 m of the fur nace TESTING PIPING FOR LEAKS Before turning on gas under pressure into piping all openings from which gas can escape should be closed Immediately after turning on gas the system should be checked for leaks This can be done by watching the 1 2 cubic feet 0 14 m3 test dial and allowing 5 minutes to show any movement or by soaping each pipe connection and watching for bubbles If a leak is found make the necessary repairs and repeat the above test DEFFECTIVE PIPES OR FITTINGS SHOULD BE REPLACED AND NOT REPAIRED NEVER USE A FLAME OR FIRE IN ANY FORM TO LOCATE GAS LEAKS USE A SOAP SOLUTION TABLE 17 Length of Standard Pipe Threads in Inches mm Threads EFFECTIVE LENGTH OVERALL LENGTH PIRE SIZE OF THREAD OF THREAD 3 8 9 53 3 8 9 53 9 16 14 29 1 2 12 7 1 2 12 7 3 4 19 05 3 4 19 05 1 2 9 16 14 29 13 16 20 64 1 25 4 9 16 14 29 1 25 4 2 Imprerfect Leave 2 End T Threads Bare FIGURE 41 Proper Piping Practice A CAUTION If the gas input to the furnace is too great because of
85. king for correct operation such as burner failing to ignite or to turn off sooty flame etc call your nearest authorized service technician as shown in the Service Center List included in the home owner envelope with the furnace If Furnace Fails to Operate Properly 1 Check setting of thermostat and position of HEAT COOL switch if air conditioning is installed If a set back type thermostat is employed be sure that the thermostat is in the correct operating mode 2 Check to see that electrical power is ON 3 Check to see that the switch on the gas control valve is in the full ON position 4 Make sure filters are clean return grilles are not obstructed and supply registers are open 5 Be sure that furnace flue piping is open and unobstructed If the cause for the failure to operate is not obvious do not attempt to service the furnace yourself Call a qualified service agency or your gas supplier 36 ADJ USTMENT OF TEMPERATURE RISE The temperature rise or temperature difference between the return air and the supply heated air from the furnace must be within the range shown on the furnace rating plate and within the application limitations shown in Table 8 ELECTRICAL AND PERFORMANCE DATA The supply air temperature cannot exceed the Maximum Supply Air Temperature specified in these instructions and on the fur nace rating plate Under NO circumstances can the furnace be allowed to operate above the Maxim
86. latest edition Safe and economical operation of the burner throughout its service life is dependent to a large extent upon its proper installation in the heating appliance Therefore we may impress upon the installer that good clean workmanlike installations mean satisfied customers PREPARATION OF COMBUSTION CHAMBER The power gas burner is designed for inshot firing into a refactory lined combustion chamber constructed in the furnace originally designed for oil firing When converting oil designed furnaces it is recommended that the same combustion chamber be used with the oil burner If the blast tube opening into the combustion chamber is larger than the 4 101 6 mm diameter high temperature cement should be used to reduce the open ing to 4 101 6 mm diameter IN NO CASE SHOULD THE TUBE BE ALLOWED TO EXTEND INTO THE CHAMBER IT MUST BE AT LEAST 1 8 3 175mm SHORT OF THE INSIDE SURFACE OF THE COMBUSTION CHAMBER COMBUSTION CHAMBER The chamber is very fragile DO NOT come in contact with the chamber with the vacuum cleaner hose The suction from the hose will create a hole in the chamber Hold hose at an angle when vacuuming chamber INSTALLATION OF BURNER AND CONTROLS The inshot power gas burner was designed especially for converting gun fired oil designed furnaces Due consideration was given to making it as simple and easy to install and service as possible without weaken ing its durability or efficiency The bur
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88. le design for protection in the event of fire We recommend this as good industry practice for all installations Install a generous capacity filter inside the building between the fuel tank shut off valve and the burner locating both the filter and the valve close to the burner for ease of servicing The filter should be rated for 50 microns 50 micrometers or less 11 107272 UIM B 1105 NOTICE SPECIAL REQUIREMENTS A CAUTION This equipment must be installed adjusted and started only by a qualified service technician an individual or agency licensed and experienced with all codes and ordinances who is responsible for the installation and adjustment of the equipment The installation must comply with all local codes and ordinances and with the National Fire Protection Standard for Liquid Fuel Equipment NFPA 31 or in Canada the installation must comply with CSA B139 A CAUTION This pump must be used with a control system that provides a valve on delay pre purge This furnace is designed to operate on 1 FUEL OIL or 2 FUEL OIL ONLY Do Not burn any other fuel in this furnace Burning any fuel except 1 FUEL OIL or 2 FUEL OIL in this furnace can cause premature heat exchanger burnout high levels of carbon monox ide excessive sooting a fire hazard personal injury property dam age and or death In Canada the furnace is designed to operate on 1 STOVE OIL or 2 FURNACE OIL ONLY THE
89. m exists with either the venting system or the appliance does not have enough combustion air Supply Air from outside to complete combustion This condition must be corrected before the appliance can function safely NOTE An unsafe condition exists when the CO reading at the furnace vent exceeds 40 ppm and the draft reading is not in excess of 0 1 in W C 0 025 kPa with all of the appliance s operating at the same time Any corrections to the venting system and or to the supply outside air system must be in accordance with the National Fuel Gas Code Z223 1 or CAN CGA B149 1 00 Natural Gas and Propane Installation Code latest editions If the vent system must be resized follow the appropriate tables in Appendix G of the above codes or for this appliance SECTION XI START UP AND ADJ USTMENTS The initial start up of the furnace requires the following additional procedures IMPORTANT All electrical connections made in the field and in the fac tory should be checked for proper tightness When the gas supply is initially connected to the furnace the gas piping may be full of air In order to purge this air it is recommended that the ground union be loosened until the odor of gas is detected When gas is detected immediately retighten the union and check for leaks Allow five minutes for any gas to dissipate before continuing with the start up procedure Be sure proper ventilation is available to dilute and carry awa
90. must be maintained from FREE AREA the front of furnace 250 IN 2 161 cm 50 IN 322 cm REE APEN MINIMUM FURNACE FREE AREA O i pHa 5 in 12 7 cm or greater Closet upPer to Door Clearance ta b Return Air Closet Door Part No DOOR 7900 7771 C White FIGURE 4 Closet To Door Clearance 5 or Greater Furnace to Closet Door Clearance Greater than 1 Inch 2 54 cm and Up to 5 12 7 cm Inches 1 The closet door MUST have a minimum of 250 Inches 1613 cm of free area in the upper half of the door and a minimum of 50 Inches 322 cm of free area in the lower area of the door The lower closet door grille may be omitted if an undercut of 2 1 2 inches 16 1 cm is provided in the door 2 A fully louvered closet door MUST have a minimum of SE 161 cm 250 Inches 1613 cm of free area in the upper half of the door FREE AREA 250 IN 164cm MINIMUM 50 IN 322 cm FREE AREA MINIMUM FREE AREA LI pref le As an option to the lower grill Y an undercut of 2 1 2 will provide 50 inches 322 cm of free area FIGURE 5 Furnace To Closet Door Clearance 1 To 5 Se as e Furnace to Closet Door Clearance Less than 1 Inch 2 54 cm The closet door MUST have three return air grilles The total free area of the J two upper grilles must be minimum of 250 Inches 1613 cm The total 250 IN2 1
91. n Figure 16 Insert a 1 4 MPT x flare adaptor into the by pass port and the inlet port Attach the return and inlet copper lines that go to the oil tank Start the burner DO NOT open the bleed valve The air in the oil lines will bleed automatically TABLE 8 Ratings amp Physical Electrical Data 107272 UIM B 1105 The return line must terminate 3 to 4 above supply line in the oil tank Failure to do this may introduce air into the system and could result in the loss of the prime Refer to Figure 18 Outside Tank Fuel Unit Above Bottom of Tank CARER wel Primary a Air Filter Fill Vent Fuel Inlet XZ V KX Use Protective Plastic Tubing in Concrete or as Local Codes Require FIGURE 18 Two Pipe System SOLENOID WIRING DISCONNECT THE POWER SUPPLY BEFORE WIRING TO PRE VENT ELECTRICAL SHOCK OR EQUIPMENT DAMAGE Lead wires on these devices are long enough to reach the junction box on most burner installations Refer to Figure 19 NOTE Check the burner manufacturer s installation sheets for the cor rect solenoid wiring All electrical wiring must be done in accordance with the local codes NOTE Solenoid power requirements 115 VAC 0 1 Amp 60 Hz Bypass Solenoid Valve Violet To Power Control White FIGURE 19 Solenoid Wiring SECTION V ELECTRICAL POWER Electrical Power Connections Field wiring to the unit mus
92. nace must be free of construction debris before the Roof Jack is installed Failure to ensure that these openings are free will result in excessive amounts of CARBON MONOXIDE and elevated heat exchanger temperatures which can lead to premature heat exchanger failure resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life Unitary Products Group 107272 UIM B 1105 After unpacking the roof jack check the rain caps Insure they are not damaged tilted or crooked Do not twist crush or sit on the roof caps during installation Damaged roof caps will cause improper furnace operation The furnace will not heat properly and could result in explosion Before inserting the vent pipe into the furnace top inspect the fur nace flue and combustion air opening for debris or insulation which have fallen in during pre installation steps Do not proceed unless all debris have been cleaned out or removed After installing roof jack on furnace top collar check to make sure there is no gap in back or side between the pipe collar and the fur nace casing top If necessary to prevent excessive air leakage the installer should seal joints in the combustion air tube with Chem caulk 900 sealant or other suitable sealant INSTALLATION IN SNOW REGIONS When the combustion air pipe inlet is covered or blocked with snow the furnace will not operate properly due to the
93. nd from any direction will not create a positive pressure in the vicinity of the vent Also in accordance with the current UL 727 Standard for safety for oil fired central furnaces Unitary Products Group 21 107272 UIM B 1105 FAN ASSISTED COMBUSTION SYSTEM An appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and or heat exchanger SECTION VII SAFETY CONTROLS CONTROL CIRCUIT FUSE A 3 amp fuse is provided to protect the 24 volt transformer from over load caused by control circuit wiring errors This is an ATO 3 automo tive type fuse and is located in the control box Flashes Cad Cell Resistance in Ohms 1 Less than 400 A CAUTION 2 More than 400 and less than 800 Main power to the unit must still be interrupted at the main power 3 EE disconnect switch before any service or repair work is to be done to 4 More than 1600 and less than 5000 the unit Blower and burner must never be operated without the blower panel in place LIMIT CONTROLS There is a high temperature limit control located on the furnace vesti bule panel near the control box This is an automatic reset control that provides over temperature protection due to reduced airflow that may be caused by a dirty filter or if the indoor fan motor should fail INDOOR FAN SWITCH The indoor fan motor is an operation controlled by normally open tem perature actuated switch loca
94. ner is supplied as a completely assembled package unit NOTE The burner must be installed in such a manner that the unit and all controls will be readily accessible for inspection cleaning adjust ment and repairs This conversion burner is designed to operate on NATURAL GAS or PROPANE GAS ONLY Do Not Burn any other Fuel in this fur nace Burning any fuel except NATURAL GAS or PROPANE GAS can cause premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury prop erty damage and or death Unitary Products Group 107272 UIM B 1105 An overpressure protection device such as a pressure regulator must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0 5 PSI 14 w c 3 48 kPa Pressures exceeding 0 5 PSI 14 w c 3 48 kPa at the gas valve will cause damage to the gas valve resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life GAS PIPING Installation and Checking of Gas Line Gas Supply piping must be sized in accordance with the recommenda tions contained in National Fuel Gas Code ANSI Z223 1 NFPA 54 unless local codes or regulations state otherwise Materials used and pipe sizing for U S manufactured mobile homes must comply with requirements
95. ng shall not be installed directly on carpeting tile or other combustible material other than wood flooring Check the rating plate and power supply to be sure that the elec trical characteristics match All models use nominal 115 VAC 1 Phase 60 Hertz power supply DO NOT CONNECT THIS APPLI ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE 130 VOLTS Furnace shall be installed so the electrical components are pro tected from water e Installing and servicing heating equipment can be hazardous due to the electrical components and the oil fired components Only trained and qualified personnel should install repair or service oil heating equipment Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters When working on heating equipment observe precau tions in the manuals and on the labels attached to the unit and other safety precautions that may apply NOTICE SPECIAL REQIREMENTS This equipment must be installed adjusted and started only by a qualified service agency an individual or agency licensed and experienced with all codes and ordinances who is responsible for the installation and adjustment of the equipment The installation must comply with all local codes and ordinances and with the latest revision of the National Fire Protection Association Standard NFPA31 or CSA B139 These instructions cover minimum requirements and conform to exist
96. nufactured mobile home installation must conform with the Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 Federal Manufactured Home Construction amp Safety Standard H U D Title 24 Part 3280 or when such stan dard is not applicable the standard for Manufactured Home Installations Manufactured Home Sites Communities and Set ups NFPA 31 Installation of Oil Burning Equipment CAN CSA B139 Installation Codes This furnace has been certified to the latest edition of standard UL 727 Standard for Safety for Oil Burn ing Equipment and for Oil Fired Central Furnaces Latest Edi tion CSA B140 10 Latest Edition and all local codes and ordinances Refer to the unit rating plate for the furnace model number and then see the dimensions page of these instructions for return air door dimensions in Figure 2 The filter s must be installed according to the instructions Unitary Products Group e Provide clearances from combustible materials as listed under Furnace Locations and Clearances e Provide clearances for servicing ensuring that service access is allowed for both the burners and blower These models are ETL listed and approved for installation into a Modular Home or a Manufactured Mobile Home e Failure to carefully read and follow all instructions in this manual can result in furnace malfunction death personal injury and or property damage e Furnaces for installation on combustible floori
97. o provide 24 Volt power for an air condi tioning unit contactor DFAA has a separate 24 Volt transformer that maybe used to provide 24 volt power for air conditioning contactor SECTION VI VENT COMBUSTION AIR SYSTEM VENT AND COMBUSTION AIR SAFETY This furnace is designed for Manufactured Mobile Home and Modular Home application It may be installed without modification in an equip ment room alcove or any other indoor location where all required clearance to combustibles and other restrictions are met The venting system must be installed in accordance with UL311 Stan dard For Safety for Roof Jacks for Manufactured Mobile Homes and Recreational Vehicles NFAA 501C and in the Federal Manufactured Home Construction and Safety Standings or CAN CSA B139 00 Installation Code for Oil Burning Equipment latest edition or applicable provisions of the local building code and these instructions The furnace shall not be connected to any chimney a flue serving a separate appli ance or any appliance designed to burn solid fuel It is recommended that the appliance is installed in a location where the space temperature is 32 F 0 C or higher If the appliance is installed in a location where the ambient temperature is below 32 F 0 C the combustion by products could condense causing damage to the appli ance heat exchanger and or the Roof Jack IMPORTANT The VENT SYSTEM must be installed as specified in these instructions
98. onal safeguard against the flue assem bly being pulled from the roof jack if upward movement should occur when the home is being transported or subjected to other stress conditions Failure to follow these instructions may result in fire explosion or asphyxiation TABLE 9 Roof Jack Options Adjustable Height with no Interior Extension Adjustable Height with a 17 Interior Extension IN CM IN CM Roof Jack Part Number 4000B7141 14 to 78 35 6 to 198 1 64 to 95 162 6 to 241 3 4000B7151 66 to 90 165 1 to 228 6 83 to 107 210 8 to 271 8 4000B8161 59 to 79 149 9 to 200 7 76 to 96 193 0 to 243 8 4000B8181 73 to 103 185 4 to 261 6 90 to 110 228 6 to 279 4 Models 4000B8161 and 4000B8181 have removable crowns A CAUTION Use 1 2 1 27 cm blunt or sharp end sheet metal screws to fasten roof jack combustion air pipe to furnace combustion air collar Screw holes are provided in pipe and collar Excessively long screws may extend to flue pipe and puncture it If substitute screws are used they must not exceed 1 1 2 3 81 cm in length It is man datory that the combustion air and flue tube assembly be properly engaged and the combustion air pipe fastened to the furnace with sheet metal screws in the holes provided Unitary Products Group 107272 UIM B 1105 If using an optional interior extension
99. ounter clockwise DO NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT 5 Use the 4 10 2 cm piece of 3 8 0 9 cm tubing to connect the positive side of the manometer to the gas valve pressure refer ence port Refer to Figure 43 for connection details TABLE 20 Inlet Gas Pressure Range INLET GAS PRESSURE RANGE Natural Gas 4 5 W C 1 12 kPa 10 5 W C 2 61 kPa Propane LP 8 0 W C 1 99 kPa 13 0 3 24 kPa W C Minimum Maximum IMPORTANT The inlet gas pressure operating range table specifies the minimum and maximum gas line pressures required for safe fur nace operation The minimum inlet gas pressure required to obtain the BTU input speci fied on the rating plate and in these instructions is shown below e 7 0 w c 1 74 kPa for Natural Gas e 11 0 w c 2 74 kPa for Propane LP Gas Unitary Products Group 107272 UIM B 1105 ADJ USTMENT OF MANIFOLD GAS PRESSURE Manifold gas pressure may be measured at the gas valve Turn gas off at the ball valve or gas cock on gas supply line before the gas valve Find the pressure ports on the gas valve marked OUT and INLET IMPORTANT The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw Loosening or tightening the cap does not adjust the flow of gas 1 Refer to Figure 42 for location of pressure regulator adjustment cap and adjustment screw on main gas valve 2 Adjust
100. ping Practice cs ed Se Seege e Se dE SE Dee 30 Solenoid WIRING siete Sasi tunes Gn Shae anand aie tice ia EEN 13 Gas EE cnt Eka el ah Ee 35 Line Wiring Connections 00 00 e cee eee 14 Reading Gas Pressure 36 Wiring for Heat Only Thermostat 14 Electrode Orientation and Gap 37 Wiring for Electronic Heat Cool Thermostat 0 0 14 Wiring Diagram for DFAA Gas Conversion Burner 38 Wiring for Standard Heat Cool Thermostat 14 Wiring Diagram for DFAH Gas Gun 39 LIST OF TABLES Unit Clearances to Combustibles 0 0 0 0 cee eee eee 4 Timings and Settings 22 Minimum Duct Sizing For Proper Airflow 6 Burner Specifications 23 Round Duct SiZe egene Ee 6 Filter Performance Pressure Drop Inches W C and kPa 24 External Static Pressure Range 9 Blower Performance CFM 25 Filter SIZES ax sanoko t Gen iaeo ee kaa eee ay ee deck Eed 10 Replacement Parts Non Electrical 26 Burner Specifications 11 Gas Line Piping Size and Length 30 Burner Rating at Elevation Above Sea Level gph I m 12 Length of Standard Pipe Threads in Inches mm 30 Ratings amp Physical Electrical Data 13 High Altitude Duration Chart 32 Roof Jack Options oni aces dex anda aia eena nants Dae dee 17 Gas Burner Settings 32 Cad Cell Resistance When Sensing Flame 22 Inlet Gas Pressure Range 35 Nominal Manifold Pressure 35 SECTION I
101. place extension down on furnace top and mate with furnace flue and combustion air collar until it lines up with screw holes in combustion air collar Secure the extension to the furnace using the pre punched holes Use 1 2 1 27 cm blunt or sharp end sheet metal screws to fasten roof jack combustion air pipe to fur nace combustion air collar Screw holes are provided in pipe and collar Excessively long screws may extend to flue pipe and puncture it If substitute screws are used they must not exceed 1 1 2 3 8a cm in length Pull the roof jack flue and combustion air pipe assembly down and mate with extension flue and combustion air pipes until the screw holes line up See Figure 29 Fasten interior extension to combustion air pipe assembly with sheet metal screws not exceeding 1 1 2 3 8 cm in length IMPORTANT Under no circumstances shall the connection between the flue and combustion air pipe assembly of the roof jack and the inte rior extension be above the ceiling line Secure the roof jack to the roof with screws Non hardening mastic sealer or caulking compound must be used to seal the roof flange to prevent water leakage The roof jack swivel joint must also be sealed to prevent water leakage Secure Roof Jack to Roof 1 Apply caulk or other sealant to underside of Roof Jack flashing Locate Roof Jack such that pipes are plumb Secure Roof Jack flashing with nails screws or staples Install roofing material over Roof
102. r blowing directly on the thermostat The wall thermostat should be located 52 to 66 inches above the floor The preferred location is on an inside wall situated in an area with good air circulation and where the temperature will be reasonably represen tative of other living areas the thermostat is controlling Thermostat Wire Gauge 14 Room Furnace Thermostat Control RR W Ww FIGURE 21 Wiring for Heat Only Thermostat Room Furnace Condensing Thermostat Control Unit R R To Air Conditioner G e Controls Y Y Common T stat Connection FIGURE 22 Wiring for Electronic Heat Cool Thermostat Room Furnace Condensing Thermostat Pigtails Unit R R To Air Conditioner W G G Controls xi Le cA FIGURE 23 Wiring for Standard Heat Cool Thermostat Room Furnace Condensing Thermostat Pigtails Unit To Air Conditioner Controls Blend Air Control Box FIGURE 24 Wiring for Blend Air Accessory IMPORTANT Some electronic thermostats do not have adjustable heat anticipators They may have other type cycle rate adjustments Follow the thermostat manufacturer s instructions The 24 volt transformer is part of the Electronic Oil Primary Control The transformer may not be used t
103. s and the Manufacturer s Installation Manual Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet Avoid areas where condensate drippage may cause problems such as above planters patios or adjacent to windows where steam may cause fogging A terminus of a vent shall be either Fitted with a cap in accordance with the vent manufacturer s installation instructions or In accordance with the installation instructions for a special venting system Does not apply to multiple installations of this furnace model Refer to VENTING MULTIPLE UNITS in this section of these instructions IMPORTANT Consideration must be given for degradation of building materials by flue gases Sidewall termination may require sealing or shielding of building surfaces with a corrosion resistant material to protect against combustion product corrosion Consideration must be given to wind direction in order to prevent flue products and or condensate from being blown against the building surfaces If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 50 8 cm It is recommended that a retaining type collar be used that is attached to the building surface to prevent movement of the vent pipe Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer Vent shall extend high enough above building or a neighboring obstruction so that wi
104. sion and lighting instructions Obtain a temperature rise within the ranges specified on the name plate A CAUTION All installations must have a filter installed Automatic Damper Supply Duct Opening Furnace Base Duct Connector NOTE FOR BEST AIR DELIVERY INSTALL DAMPER WITH BLADES PARALLEL TO SUPPLY DUCT FIGURE 12 Anti Backflow Damper INSTALLATION OF THE FURNACE 1 Remove the front panels and set the furnace onto the duct con nector Slide it back until the rear of the unit engages the locator bracket 2 Secure the front of the furnace with two screws at the mounting holes provided See Figure 13 ho nae Furnace Seated 7 s Against the Locator Bracket e Secure Furnace to Floor with Two Nails or Screws el D nf fi H H FIGURE 13 Installation of Furnace 3 Secure the top of the furnace to a structural member using screw through the strap at the back of the furnace Strap may be moved to any of the holes located along the top back of the furnace Installer may provide an equivalent method such as screws through the casing side 107272 UIM B 1105 DFAH Furnaces If a matching cooling coil is used it may be placed directly on the fur nace outlet and sealed to prevent leakage Follow the coil instructions for installing the supply plenum On all installations without a
105. sket See Figure 29 Refer to Interior Roof Jack Extension installation instructions if applicable 4 Align holes in Roof Jack and Air Intake Connector Secure Roof Jack to furnace using 10 x 1 2 1 1 2 10 x 1 3 3 8 cm Type AB or Type B sheet metal screw Bottom of Roof Jack Roof Jack Air Intake Connector Opening for Combustion Air Inlet Grommet Front of Furnace FIGURE 29 Roof Jack Attachment to Furnace INTERIOR EXTENSIONS There is an optional 11 43 2 cm long interior extension that can be used to provide added interior roof jack length if needed To choose the proper length roof jack with or with out the optional extension see Fig ures 30 and 31 and Table 9 More than one interior extension may be used to accommodate A dimensions up to 110 284 5 cm AWARNING The joint where the optional interior extension connects to the roof jack must be below the ceiling Failure to observe this requirement may result in asphyxiation fire or explosion NOTE Use of an interior extension will increase the roof jack adjust able heights by the amount of the interior extension height Unitary Products Group A CAUTION Do not exceed the maximum adjustable height as listed in Table 9 These maximum heights allow an additional 1 1 2 3 81 cm travel before the flue pipe assembly is fully extended against the built in stop This provides an additi
106. t be grounded Electric wires that are field installed shall conform to the temperature limitation for 63 F 35 C rise wire when installed in accordance with instructions Refer to Table 8 in these instructions for specific furnace electrical data A CAUTION Use copper conductors only Input Output Nominal Burner Air Temp Rise AFUE Input Rate MBH kW MBH kW CFM cm Amps HP RPM Rotation F C GPH Liter H 66 19 3 53 15 5 1050 29 7 2 1 1 7 3450 CCW 45 75 28 47 80 0 50 1 9 84 24 6 67 19 6 1250 35 4 2 1 1 7 3450 CCW 45 75 28 47 80 0 65 2 5 d Total S DEAA DFAH Input L ale Blower eae de eg Min Wire Blower Size Operation Wgt Operation Wgt MBH kW F C Hp Amps 75ft protect Amps Qne Way In cm LBS Kg LBS Kg 66 19 3 165 74 1 6 8 0 15 8 3 14 10 x 8 25 4 x 20 3 175 79 4 158 71 7 84 24 6 165 74 1 4 5 9 15 7 8 14 10 x 8 25 4 x 20 3 175 79 4 158 71 7 Annual Fuel Utilization Efficiency AFUE numbers are determined in accordance with DOE Test procedures Wire size and over current protection must comply with the National Electrical Code NFPA 70 latest edition and all local codes The furnace shall be installed so that the electrical components are protected from water Rotation when facing shaft end Unitary Products Group 13 107272 UIM B 1105 NOTE A burner with an electronic igniter or a PSC motor will
107. ted above the limit control which is set to close at 110 F 43 3 C and open at 90 F 32 2 C OIL BURNER PRIMARY CONTROL The R7184A B P U Interrupted Electronic Oil Primary is a line voltage safety rated interrupted ignition oil primary control for residential oil fired burners used in forced air furnaces The R7184A B P U used with a cad cell flame sensor operates an oil burner and optional oil valve The primary controls fuel oil senses flame controls ignition spark and notifies a remote alarm circuit when in lockout The indicator light on the oil primary control provides lockout recycle and cad cell indications as follows 1 Flashing at 1 2 second on 1 2 second off system is locked out or in restricted mode 2 Flashing at 2 seconds on 2 seconds off control is in recycle mode TABLE 11 Timings and Settings 3 On cad cell is sensing flame 4 Off cad cell is not sensing flame Cad Cell Resistance Check For proper operation it is important that the cad cell resistance is below 1600 ohms During a normal call for heat once the control has entered the Run mode press and release the reset button See Table 10 for equivalent cad cell resistance TABLE 10 Cad Cell Resistance When Sensing Flame Preliminary Steps Check wiring connections and power supply Make sure power is on to controls Make sure limit control is closed Check contacts between ignitor and the electrod
108. ted at the base of the upper cap as guides drill two 2 1 8 diameter holes into the center pipe Finally attach the upper cap to the center pipe using the two 2 screws removed in Step 1 to the center pipe STEP 4 Complete assembly Place these instructions in the customer packet provided with the furnace Le EXTENSION i CROWN ASSEMBLY BASE EXTENSION BRACKET EXTENSION CROWN ASSEMBLY BASE FIGURE 32 Installing Roof Jack Extension 20 VENT SYSTEM This furnace is a sealed combustion direct vent unit and is design cer tified to use only a 4000 Series roof jack These roof jacks are designed to exhaust flue products to the outside INSTALLING CEILING RING The ceiling ring is to meet fire stop requirements Accessory Ceiling Ring may be installed in Manufactured mobile Homes or Modular Homes Refer to the UL 311 Standard for Safety for Roof Jacks for Manufac tured Homes and Recreational Vehicles or in Canada use CAN CSA Z240 MH Series latest edition or applicable provisions of the state regional or local building codes and these instructions The installer must follow approved methods in the above standards and or codes for a fire stop If required the installer may use up to three sections of the Accessory Ring Refer to Figure 33 NOTE A portion of the outer edge of the ceiling ring may be trimmed so the r
109. that the furnace operates at the specified external static pres sure and within the air temperature rise specified on the nameplate Input Airflow Return Rectangular Round Supply Rectangular Round BTU H kW CFM m In cm in x in cm x cm in cm dia In cm in x in cm x cm in cm dia 66000 19 34 1 050 29 73 280 711 14 x 20 35 6 x 50 8 18 45 7 216 549 12 x 18 30 5 x 45 7 16 40 6 84000 24 62 1 250 35 40 360 914 18 x 20 45 7 x 50 8 22 55 8 280 711 14 x 20 35 6 x 50 8 18 45 7 NOTE This chart does not replace proper duct sizing calculations or take into account static pressure drop for run length and fittings Watch out for the temperature rise and static pressures 1 Maximum return air velocity in rigid duct 700 feet per minute 19 82 m minute 2 Example return main trunk duct minimum dimensions 3 Maximum supply air velocity in rigid duct 900 feet per minute 25 49 m minute TABLE 3 Round Duct Size Round Duct Size _ Calculated Area For Each Round Duct Size Inches cm Sq Inch cm 5 13 19 8 126 6 15 28 2 182 7 18 38 4 248 8 20 50 2 324 9 23 63 6 410 10 25 78 5 506 11 28 95 0 613 12 30 113 1 730 13 33 132 7 856 14 36 153 9 993 1 The Air Temperature Rise is determined by subtracting the Return Air Temperature Reading from the Supply Air Temper
110. the unit should be based on an acceptable heat loss calculation for the structure ACCA Manual J or other approved methods may be used Manufactured Mobile Home and Modular Home Installation This appliance must be installed in a sealed combustion configu ration using a roof jack vent system A roof jack is the only approved vent system that can be used to vent this appliance Modular Home Definition Factory built home constructed to the state local or regional code where the house will be located The home is transported in one or more modules and joined at the home site Manufactured Mobile Home Definition Factory built home constructed transported and installed under the federal building code administered by the U S Department of Housing and Urban Development HUD Code rather than to building codes at their destination The house is built transported and installed on a non removable chassis This furnace is approved for installation in trailers or recreational vehicles SAFETY REQUIREMENTS e e A CAUTION Never attempt to alter or modify this furnace or any of its com ponents Never attempt to repair damaged or inoperable components Such action could cause unsafe operation explosion fire and or asphyxiation If a malfunction has occurred or if you feel that the furnace is not operating as it should contact a qualified service agency or oil supplier for assistance A ma
111. this difference by the difference in ESP values in the table 0 20 w c 150 Pa 0 10 w c 125 Pa to obtain a percentage 0 30 0 10 0 20 0 10 0 5 TABLE 14 Blower Performance CFM 107272 UIM B 1105 Multiply percentage by airflow difference to obtain airflow reduction 0 5 X 65 32 5 Subtract airflow reduction value to airflow 0 10 w c 125 Pa to obtain actual airflow 0 30 wc 144 Pa ESP 1050 32 5 1017 5 FINAL PROCEDURE Install Furnace Doors Install the lower door first by sliding the bottom of the door down until the tabs on the casing base engage the slots in the bottom door end cap Then push the top of the lower door in until the door clips snap into place Install the upper door in a similar manner first engaging the slots in the top of the upper door on the tabs on the casing top Then snap the bottom of the upper door into place against the casing Finish and Trim Alcove and Closet Installations may now be finished and trimmed as necessary BLOWER PERFORMANCE CFM DEAAOGG FACTORY EQUIPPED WITH STANDARD BLOWERS AND FILTERS EXTERNAL STATIC PRESSURE INCHES WC kPa BTU H kW CFM 0 1 0 025 0 2 0 050 0 3 0 075 0 4 0 099 0 5 0 124 Blower Speed Bi jo Input Output Im mini cfm cm m cfm cm m cfm cm m cfm cm m cfm cm m Single Speed No Coil 66 19 34 53 15 55 1050 29 73 1175 33 3 1110
112. tor best cen ters over the supply duct and insert it through the floor cut out 6 When properly aligned with the supply duct secure the duct con nector to the floor with nails flat head screws or staples 7 Use screws as required to secure the duct connector to the supply duct 8 Cut out the opening to the supply duct If sealant was not used the installer should tape the mating flanges to provide a good air seal NOTE Duct sealant and tape must be classified as meeting HUD Stan dard 3280 715 U L Standard 181A If tape is used to provide a better air seal it should be a type approved by the applicable national or local codes Unitary Products Group Locator Bracket Nails Flat Head Screws or Staples Bend Tabs Under Duct Opening to Secure to the i Supply Duct x a Floor e Supply Duct FIGURE 11 Duct Connector Tab Attachment INSTALLATION OF TAB ATTACHMENT DUCT CONNECTORS 1 Make floor cut out as shown in Figure 8 2 Determine the depth of the floor cavity from the surface of the floor to the top of the supply air duct and select the appropriate duct connector from the chart 3 Place locating bracket supplied with the duct connector to the rear of the floor area for the furnace See Figure 11 4 Determine which of the four positions the duct connector best cen ters over the supply duct and insert it through the floor cut out
113. tor of 0 960 times 3600 then divided by the time it took to measure 2 cubic ft 0 056 m of gas from the gas meter For Propane LP Gas multiply the Heat content of the gas MJ m or Default 93 15 times 1 cu ft of gas x 0 028 to convert from cubic feet to cubic meters measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 1 cubic ft 0 028 m of gas from the gas meter The formula for metric input calculation using a cubic foot gas meter MJ m x 2 cu ft x 0 028 x 0 960 x 3600 MJ H x 0 2777 Seconds it took to measure the 2 cu ft of gas NATURAL GAS INPUT CALCULATION EXAMPLE 38 4 x 2 x 0 028 x 0 960 x 3600 90 5 kW D 3412 14 BTU H 82 12 x 0 2777 22 80 D 3412 14 77 796 80 Natural Gas 1030 BTU SCF 38 4 MJ m PROPANE LP GAS INPUT CALCULATION EXAMPLE 93 15 x 1 x 0 028 x 0 960 x 3600 83 46 x 0 2777 23 18 D 3412 14 79 093 4 Propane Gas 2500 BTU SCF 93 15 MJ m In Canada use the following formula to calculate the furnace input if you are using a gas meter that measures cubic meters For Natural Gas multiply the Heat content of the gas MJ m or Default 38 4 times 0 10 mi of gas measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 0 10 m of gas from the gas meter For Propane LP Gas multipl
114. ts reserved Supersedes 107272 UIM A 0905 Unitary 5005 Norman Product York OK Group Drive 73069
115. uation do not operate the unit until inspection and repairs are performed tion Standard NFPA 31 and in complete accordance with all local Clearances for access codes and authorities having jurisdiction Regulation of these Ample clearances should be provided to permit easy access to the unit authorities take precedence over the general instructions pro The following minimum clearances are recommended viggd Innis Intel HOM manua 1 Twenty four 24 inches 61 cm between the front of the furnace FURNACE LOCATION AND CLEARANCES and an adjacent wall or another appliance when access is The furnace shall be located using the following guidelines required for servicing and cleaning 2 Twenty four 24 inches 61 cm at the side where access is We The tumace shouid b located Where the root jack can be installed required for passage to the front when servicing or for inspection without major modifications to the roof of the structure or replacement of flue vent connections 2 A ntralized with the air distribution as possible E E EE EEN P In all cases accessibility clearances shall take precedence over clear 3 Wiere there is access to fresh air particularly when the blend air ances for combustible materials where accessibility clearances are accessory will be installed greater 4 Where it will not interfere with proper air circulation in the confined sa SE AWARNING 5 Where the outdoor section of the roof jack
116. um Supply Air Temperature Operating the furnace above the Maximum Supply Air Temperature will cause premature heat exchanger failure high levels of Carbon Monoxide a fire hazard personal injury property damage and or death The temperature rise or temperature difference between the return air and the heated supply air from the furnace must be within the range shown on the furnace rating plate and within the application limitations as shown in Table 8 After about 20 minutes of operation determine the furnace temperature rise Take readings of both the filter door and the heated air in the ducts Increase the blower speed to decrease the temperature rise decrease the blower speed to increase the rise A CAUTION Do not energize more than one motor speed at a time or damage to the motor will result PERFORMANCE CHECK 1 After the desired input has been obtained re adjust the primary air damper open or closed to visually obtain a blue flame with well defined orange or yellow tips for natural gas or well defined yellow tips for propane gas 2 After the burner has been in operation for at least 20 minutes assuring combustion chamber and heat exchanger are fully warmed take combustion analysis flue gas samples in the flue pipe All adjustments below must be made with the following instructions a Draft Gauge b Op or CO Analyzer c CO Tester d Water Column Gauge NOTE ALWAYS USE RELIABL
117. ure drop values in Table 13 are typical values for the type of filter listed and should only be used as a guideline Actual pres sure drop ratings for each filter type vary between filter manufacturers DO NOT USE Pleated Media or Hogs Hair filters on this furnace Be sure to check for leaks in the oil line and fittings A leak will cause oil pump to loose its prime Repair leaks before continuing with the final adjustments to the oil burner TABLE 13 Filter Performance Pressure Drop Inches W C and kPa Minimum Filter Type Airflow Range Opening Size Disposable 1 Opening 1 Opening CFM Cm m In2 m2 inwc kPa 1001 1250 28 35 35 40 488 45 34 0 1 0 0249 1251 1500 35 42 42 47 488 45 34 0 1 0 0249 Unitary Products Group APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW Example For a 84 000 BTUH 38 06 kW furnace with 1 return open ings and operating on high speed blower it is found that total system static is 0 30 w c 0 075 kPa To determine the system airflow com plete the following steps Obtain the airflow values at 0 10 w c 125 Pa amp 0 20 w c 150 Pa ESP Airflow 0 10 1175 CFM 60 17 m min Airflow 0 20 1110 CFM 57 62 m min Subtract the airflow 0 10 w c 125 Pa from the airflow 0 20 w c 150 Pa to obtain airflow difference 1175 1110 65 CFM 2 55 m min Subtract the total system static from 0 10 w c 125 Pa and divide
118. ust be taken at the return air louvered door Return static pressures can be taken by pushing probe through the air filter on the louvered door Furnace and Air Conditioner Installations If an air conditioner is installed which does not use the blower for air dis tribution and operates completely independent of the furnace the ther mostat system must have an interlock to prevent the furnace and air conditioner from operating at the same time This interlock system usu ally contains a heat cool switch which must be turned to either HEAT or COOL to activate either heating or cooling operation or a positive OFF switch on the cooling thermostat When used in connection with a cooling unit the furnace shall be installed parallel with or on the upstream side of the cooling unit to avoid condensation in the heat exchanger Input Output Maximum Unitary Products Group 107272 UIM B 1105 For installations with a parallel flow arrangement the furnace must be equipped with a damper to prevent cold air from being discharged up around the heat exchanger Cold air causes condensation inside the exchanger and can cause it to rust out which can allow products of combustion to be circulated into the living area by the furnace blower resulting in possible asphyxiation An air flow activated automatic damper is available from furnace manufacturer See Figure 12 NOTE See label on coil panel for conver
119. will not be blocked or restricted Refer to VENT CLEARANCES located in SECTION VI Check the rating plate and power supply to be sure that the electri of these instructions These minimum clearances must be main cal characteristics match All models use nominal 115 VAC 1 tained throughout the installation Phase 60Hz power supply Furnace shall be installed so the electrical components are pro tected from water 6 Where the unit will be installed in a level position with no more than 1 4 0 64 cm slope side to side and front to back to provide a proper roof jack connection and seal Installation in a residential garage Installation in freezing temperatures 1 An oil fired furnace for installation in a residential garage must be 1 Furnace shall be installed in an area where ventilation facilities installed so the burner s and the ignition source are located not less than 18 inches 46 cm above the floor and the furnace must provide for safe limits of ambient temperature under normal oper be located or protected to avoid physical damage by vehicles ating conditions Ambient temperatures below 32 F 0 C may result in the vent temperature falling below 260 F 127 C at any point in the vent pipe Vent temperatures below 260 F 127 C will cause the flue products in the vent pipe to condense causing the vent pipe to deteriorate rapidly TABLE 1 Unit Clearances to Combustibles AIR INLET
120. y any vented gas PURGING After the piping has been checked all piping and appliances receiving gas through the meter shall be fully purged A suggested method for purging the gas line to the burner is to allow the burner to cycle until burner ignites Do not purge by loosening gas lines Under no circum stances shall the line be purged into the combustion chamber Unitary Products Group After the gas line to the conversion burner has been fully purged the gas supply at other pilot burners located on other gas appliances which were extinguished as the result of interrupted service will need to be reignited Check all appliances to make sure the pilots are ignited CALCULATING THE FURNACE INPUT NATURAL GAS NOTE Front door of burner box must be secured when checking gas input NOTE Burner orifices are sized to provide proper input rate using natu ral gas with a heating value of 1030 BTU Ft 3 6 m m If the heating value of your gas is significantly different it may be necessary to replace the orifices 1 Turn off all other gas appliances connected to the gas meter 2 At the gas meter measure the time with a stop watch it takes to use 2 cubic ft 0 0566 m of gas 3 Calculate the furnace input by using one of the following equa tions 33 107272 UIM B 1105 In the USA use the following formula to calculate the furnace input For natural gas multiply the heat content of the gas BTU SCF or Default 1030 BTU
121. y the Heat content of the gas MJ m or Default 93 15 times 0 10 m of gas measured at the gas meter times a baro metric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 0 10 m of gas from the gas meter The formula for metric input calculation using a cubic meter gas meter MJ m x m x 0 960 x 3600 Seconds it took to measure the 0 10 m of gas NATURAL GAS INPUT CALCULATION EXAMPLE 38 4 x 0 1 x 0 960 x 3600 160 MJ H x 0 2777 kW D 3412 14 BTU H 82 94 x 0 2777 23 03 D 3412 14 78 581 60 Natural Gas 1030 BTU SCF 38 4 MJ m PROPANE LP GAS INPUT CALCULATION EXAMPLE eee 8319 x 02777 2310 x 341214 78 8263 Propane Gas 2500 BTU SCF 93 15 Mim DO NOT ADJUST the manifold pressure regulator if the actual input is equal to or within 8 less than the furnace input specified on the rating plate or if the furnace rise is above the specified rise range on the rating plate If the actual input is significantly higher than the furnace input specified on the rating plate then replace the gas orifices with the gas orifices of the proper size for the type of gas you are using For altitudes above 2 000 ft 610 m the furnace input MUST BE DERATED Refer to the GAS CONVERSION FOR PROPANE LP AND HIGH ALTITUDES IN SECTION IV for information on high altitude conversions 34 Unitary Products Group INITIAL START UP 1 Read the applicable

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