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Thomas & Betts RGM 405 User's Manual

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1. Pipe_ Natural 2 Bl WwW SISS ron 52 os 285 m so 300 890 sa 1650 1007 w 1 46 885 2 4 270 775 350 604 mo o 160 _ 130 _79_ s 8 ao 250 1 780 _476_ 120 73 _ 100 125 150 175 200 i 0 Tae We sizing 2 lines possibilities of future expansion and increased requirements Refer to National Fuel Gas Code for additional information on line sizing Q Em 70 64 59 48 BEJE 34 Mfg No 164771 Page 13 9 Gas Piping and Pressures cont d Manifold Pressure Settings cont d supply pressure must be within the specified range for the gas being used both when the heater is in operation and on standby Incorrect inlet pressure could cause excessive mani fold gas pressure immediately or at some future time Instructions to Check Manifold Pressure when unit is operating 1 With the manual valve positioned to prevent flow to the main burners connect a manometer to the 1 8 pipe outlet pressure tap in the valve NOTE A manometer fluid filled gauge is recommended rather than a spring type gauge due to the difficulty of maintaining calibration of a spring type gauge 2 Open the valve and operate the heater Measure the gas pre
2. Model CAUA Gas Fired Indoor Vertical Upflow Power Vented Heater INSTALLATION FORM RZ 405 Version Obsoletes Form RGM 405 Version A APPLIES TO Installation Table of Contents Installation and Operation Optional Accessories Check Installation and Start Up Index Index Belt Drive Blower Motor and Drive Check Test Start Up Clearances Combustion Air Combustion Air Proving Switch Concentric Adapter Condensate Drain Confined Space Installation Cased Cooling Coil Model ACU Control Location Illustration Dimensions By Page No Duct Connections Gas Valve General Ignition System Installation Codes Discharge Plenum Optional Electrical Supply and Connections Filter Cabinet Optional Gas Piping and Pressures Hazard Intensity Levels Paragraphs 1 18 Pages 1 18 Paragraphs 19 21 Pages 19 21 Paragraph 22 Pages 22 23 Index Motor Amps Mounting the Heater Start Up Thermostat Uncrating and Preparation Vent and Combustion Air Determine Type of Vent Power Vent Only Installation Separated Combustion Installation 5 9 By Page No By Page No Inlet Base Optional Wiring Diagrams Mixing Cabinet Optional REFERENCES Operation Maintenance Service Manual Form RZ 405 OMS Installation Manual for Model ACU Cooling Coil RZ 405 CC Gas Conversion Instructions for Model CAUA RZ 405 GC FOR YOUR SAFETY What to do if you smell gas
3. 3 3 4 12 1 2 24 33 31 19 34 4 5 8 200 38 34 3 4 36 21 7 1 4 3 3 4 12 1 2 24 33 31 19 34 4 5 8 250 50 34 3 4 48 21 7 1 4 4 3 8 12 3 4 27 1 4 45 31 16 46 4 3 4 300 50 34 3 4 48 21 7 1 4 4 3 8 12 3 4 27 1 4 45 31 16 46 4 3 4 350 50 49 3 4 48 34 7 4 3 8 14 1 8 26 3 4 45 44 32 46 4 7 8 400 50 49 3 4 48 34 7 4 3 8 14 1 8 26 3 4 45 44 32 46 4 7 8 Dimensions mm or 3 Sie A B C D E F H J K M N P 150 965 883 914 533 184 95 318 610 838 787 483 864 117 200 965 883 914 533 184 95 318 610 838 787 483 864 117 250 1270 883 1219 533 184 111 324 692 1143 787 406 1168 121 300 11270 883 1219 533 184 111 324 692 1143 787 406 1168 121 350 1270 1238 1219 864 178 111 359 679 1143 1118 813 1168 124 400 1270 1238 1219 864 178 111 359 679 1143 1118 813 1168 124 Side 13 114 View 337mm Alternate Gas Connection Corner indicators for cutting inlet air opening 2 1 8 54mm 1 1 2 38mm o Corner indicators for cutting inlet air opening 2 1 8 54mm T 2 1 2 64mm Control Side of Hater Corner indicators for cutting inlet air opening BOTTOM VIEW Air Opening Dimensions Supply Air Discharge with duct fl
4. correct tension is achieved re tighten the locknut on the adjustment screw Be sure that the belt is aligned in the pulleys Figure 16 Check Belt Tension 3 4 19mm Most blower motors are equipped with thermal overload protection of the automatic reset type If the motor is not equipped with thermal overload protection the unit will be equipped with a starter The adjustable setting on the starter will be factory set to match the amp draw of the motor and sealed No change should be made to the starter setting unless the original motor is replaced Starters are equipped with a manual reset If an overload condition is experienced the condition must be corrected and the starter must be manually reset After the installation is complete including all ductwork the amp draw of the motor should be checked with an amp meter to verify that the motor amp rating on the motor nameplate is not being exceeded Amps may be adjusted downward by reducing the blower speed or by increasing the duct system static pressure The temperature rise must be within the range specified on the unit rating plate Mfg No 164771 Page 15 14 Blower Motor and Drive cont d Adjusting Blower Speed The blower speed may be adjusted to achieve the desired outlet tem perature as long as the adjustment is within the temperature rise and the static pressure limits shown on the heater rating plate Direct drive motors are factory set at medium speed for hea
5. to 5 reducer is required on Sizes 300 400 Figure 4 When joining different pipe diameters use taper type pipe connectors Taper type Connector Reducer z Airflow 6 Support Support horizontal runs every six feet 1829mm do not rely on the heater or concentric adapter for support of either horizontal or vertical pipes 7 Clearance Clearance from the vent pipe to combustibles is 6 152mm Do not enclose the vent pipe Either collar or smaller diameter pipe Secure joints with sheetmetal screws and seal Instructions and Requirements for Installing Horizontal Vent Terminal Combustion Air Inlet Option CC6 Option CC6 Package includes 150 250 300 200 350 400 157158 82131 155392 68404 155096 53316 151755 124940 37661 37661 164492 164493 53335 53335 Field supplied installation requirements Thimble a thimble is not required if wall is of non combus tible construction Flashing Vent pipes see requirements on pages 4 and 6 e Combustion air pipes see requirements on pages 4 and 6 Form 405 Page 6 Complete Horizontal Vent Kit Same as Option CC6 Concentric Box Assembly See Figures 3A and 3B Screened Exhaust Assy 10 16x1 2 1g Screws to attach the inlet guard Rubber seal for vent pipe opening in concentric adapter Tube of high temperature 450 F silicone sealant e Mounting brackets for conc
6. 2 7 8 Suction Lines or the one on the 120 2 3 8 Liquid Lines opposite side see Paragraph 10 page 150 180 2 1 2 Liquid Lines 14 Drain line connection is 3 4 for all sizes Suction Line Connection s Burner Condensate Drain When a system includes a cooling coil a burner condensate drain must be installed The parts required for the drain are shipped with the heater Instructions for installing the drain are in Paragraph 10 page 14 Electrical Connections Figure 20 Typical Heater Terminal Strip Low Voltage Wiring 24V Supply Condensing Unit field supplied onnections to Connections Read thermostat Read manufacturer s c manufacturer s installation common installation instructions instructions befi iting Si efore wiring Ist Stage Cooling before wiring st stage cooling 2nd Stage Cooling 24V control relay 2nd stage cooling 1st Stage Heating 24y control relay or Sizes 090 120 150 and 180 Optional 2 Stage Heating Fan A separate 24V control transformer may be required for the condensing equipment controls Install a jumper wire between RH and RC terminals on the thermostat for single transformer operation Consult the thermostat manufacturer s instructions Legend field supplied 24V wiring Thermostat wiring 24V Field control wiring 24V Mfg No 164771 Page 19 OPTIONAL ACCESSORIES con
7. AT HEAT POSITION FAN SWITCH AT AUTO POSITION THERMOSTAT CALLS FOR HEAT ENERGIZING THE VENTER MOTOR VENTER PRESSURE SWITCH CLOSES FIRING UNIT BURNER FLAME IS SENSED AND IN 30 SECONDS THE BLOWER MOTOR IS ENERGIZED IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT SEE LIGHTING INSTRUCTIONS 9 SET THERMOSTAT SYSTEM SWITCH AT COOL POSITION FAN SWITCH AT AUTO POSITION A ON ACALL FOR COOLING BLOWER MOTOR IS ENERGIZED AT HIGH SPEED AND COOLING CIRCUIT IS ENERGIZED 10 WHEN BLOWER DOOR IS OPENED THE UNIT IS SHUTDOWN 11 SET THERMOSTAT SYSTEM SWITCH OFF POSITION FAN SWITCH AT AUTO POSITION FOR SHUTDOWN NOTES 1 THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS THERMOSTAT 2 DOTTED WIRING AND COOL RELAY COIL INSTALLED BY OTHERS 3 CAUTION IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 C EXCEPT FOR SENSOR LEAD WIRE WHICH MUST BE 150 C 4 USE 18 GA WIRE FOR CONTROL WIRING ON THE UNIT 5 USE 14 GA WIRE FOR LINE AND MOTOR WIRING ON UNIT 6 LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5 OF SUPPLY LINE VOLTAGE 7 SECOND BLOWER MOTOR ON 250 400 UNITS ONLY 8 VENTER MOTOR ON 350 400 UNITS HAS BROWN AN
8. Donot try to light any appliance Donot touch any electrical switch do not use any phone in your building e Immediately call your gas supplier froma neighbor s phone Follow the gas supplier s instructions Ifyou cannot reach your gas supplier call your fire department WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier WARNING Gas fired appliances are not designed for use in hazardous atmospheres containing flammable vapors or combustible dust See Hazard Levels page 2 Installation Manual for Optional Filter Cabinet RZ 405 FC Installation Manual for Optional Mixing Box RZ 405 MB Installation Instructions for Optional Inlet Base RZ 405 IB Installation Instructions for Optional Discharge Plenum RZ 405 DP FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance GENERAL Installation should be done by a qualified agency in accordance with the instructions in this manual and in compliance with all codes and re quirements of authorities having jurisdiction The instructions in this manual apply to the heater model shown below Description Gas Fired Power Vented Vertical Upflow Heater Model CAUA heaters a
9. Filter Cabinet 32 813mm 250 300 Side Filter Cabinet 32 313mm 250 300 Rear Filter Cabinet 45 1 8 1146mm 350 400 Rear or Side Filter Cabinet 45 1 8 1146mm 16 406mm Inlet Opening Requirements and Suggestions for Connecting and Installing Ducts Type of Ductwork The type of duct installation to be used de pends in part on the type of construction of the building Ductwork Material Rectangular duct should be constructed of not lighter than No 26 U S gauge galvanized iron No 24 B amp S gauge aluminum Ductwork Structure All duct sections 24 inches or wider and over 48 inches in length should be cross broken on top and bottom and should have standing seams or angle iron braces Joints should be S and drive strip or locked Through Masonry Walls No warm air duct should come in con tact with masonry walls Insulate around all air duct through ma sonry walls with not less than 1 2 1 is recommended of insula tion Through Unheated Space Insulate all exposed warm air ducts passing through an unheated space with at least 1 2 1 is recom mended of insulation Duct Supports Suspend all ducts securely from buildings mem bers Do not support ducts from unit duct connections Duct Sizing Proper sizing of the supply air ductwork is neces sary to ensure a satisfactory heating installation The recognized authority for such information is the Air Condition
10. Follow the installation instructions included with the cabinet e Cased Cooling Coil Model ACU cooling coils are designed for the Model heaters The coil cabinet is shipped separately for installation over the discharge opening of the heater e Mixing Cabinet If outside air is desirable a mixing cabinet with dampers is available The mixing cabinet is field attached to the rear of the unit Check to be sure that the mixing box is the configuration ordered Follow the installation instructions included with the shipped separate package Inlet Base If an optional inlet base is included follow the instruc tions included with the inlet base to select the location The heater mounts on the inlet base heater has a bottom inlet air opening Discharge Plenum The discharge plenum is shipped separately for installation over the discharge opening of the heater If the dis charge plenum and a cased cooling coil are part of the installation the discharge plenum is factory attached to the cooling coil casing Also shipped with the heater are the parts needed to install a conden sate drain needed if installing a cooling coil Other shipped separate options could include a gas shutoff valve a thermostat a thermostat guard and or a vent cap Make sure all parts are at the site before beginning installation 4 Clearances Unit must be installed so that the clearances in the table are provided for service and in spection
11. Manual Gas Valve Ground Joint Union Connections shown are by the installer 6 Drip Le Figure 13 Supply Piping Connection WARNING components of a gas supply system must be leak tested prior to placing equipment in service NEVER TEST FOR LEAKS WITH AN OPEN FLAME Failure to comply could result in personal injury property damage or death Manifold or Orifice Pressure Settings Measuring manifold gas pressure cannot be done until the heater is in operation It is included in the steps of the Check Test Start proce dure in Paragraph 22 The following warnings and instructions apply WARNING Manifold gas pressure must never exceed 3 5 w c for natural gas or 10 w c for propane gas For Natural Gas Manifold gas pressure is regulated by the combina tion valve to 3 5 w c Inlet pressure to the valve must be a minimum of 5 w c or as noted on the rating plate and a maximum of 14 w c For Propane Gas Manifold gas pressure is regulated by the combina tion valve to 10 w c Inlet pressure to the valve must be a minimum of 11 w c and a maximum of 14 w c Before attempting to measure or adjust manifold gas pressure the inlet Capacity of Piping Cubic Feet per Hour based on 0 3 w c Pressure Drop Specific Gravity for Natural Gas 0 6 Natural Gas 1000 BTU Cubic Ft Specific Gravity for Propane Gas 1 6 Propane Gas 2550 BTU Cubic Ft Length Diameter of Pipe of
12. Operating Instructions and Operating Sequence 1 Set thermostat at lowest setting 2 Turn off all electric power to the appliance 3 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Open the access door and locate the gas valve 4 Models CAUA 150 and 200 Locate the gas control ON OFF knob on the gas valve Turn the gas control knob clockwise to OFF Models CAUA 250 300 350 and 400 Locate the gas con trol ON OFF knob on the gas valve Turn knob clockwise to align the line on the knob with the position indicator Depress knob and continue rotation to the OFF position Top View of Gas Valve used on Control Knob on Top of CAUA 150 and 200 Gas Valve used on CAUA 250 400 Gas Flow Position Gas Control Indicator Knob 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP and follow the steps in the WARNINGS printed in the right column or on the Operating Label on the heater If you do not smell gas proceed to the next step 6 Models 150 and 200 Turn the gas control knob coun terclockwise to ON Models CAUA 250 300 350 and 400 Turn knob counter clockwise to align the line on the knob with the position indi cator Allow knob to pop up and continue rotation to the ON position 7 Close the access door 8 Turn on the electric power to
13. SWITCH e z 40 VA CONTROL TRANSFORMER LINE VOLT OPERATING SEQUENCE SET THERMOSTAT SYSTEM SWITCH AT OFF POSITION FAN SWITCH AT AUTO POSITION TURN ON MANUAL GAS VALVE TURN ON POWER TO UNIT SET THERMOSTAT SYSTEM SWITCH AT HEAT POSITION FAN SWITCH AT AUTO POSITION THERMOSTAT CALLS FOR HEAT ENERGIZING THE VENTER MOTOR VENTER PRESSURE SWITCH CLOSES FIRING UNIT BURNER FLAME IS SENSED AND IN 30 SECONDS THE BLOWER MOTOR IS ENERGIZED IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND 9 MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT SEE LIGHTING INSTRUCTIONS SET THERMOSTAT SYSTEM SWITCH AT COOL POSITION FAN SWITCH AT AUTO POSITION A CALL FOR COOLING BLOWER MOTOR IS ENERGIZED AND COOLING CIRCUIT IS ENERGIZED 10 WHEN BLOWER DOOR IS OPENED THE UNIT IS SHUTDOWN 11 SET THERMOSTAT SYSTEM SWITCH AT OFF POSITION FAN SWITCH AT AUTO POSITION FOR SHUTDOWN NOTES THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS THERMOSTAT 2 DOTTED WIRING AND COOL RELAY COIL INSTALLED BY OTHERS 3 CAUTION IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE Oar APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 C EXCEPT FOR SENSOR LEAD WIRE WHICH MUST BE 150 C USE 18 GA WIRE FOR CONTROL WIRING ON THE UNIT USE 14 GA WIR
14. Termination Location all directions unless specified Forced air inlet within 10 ft 3 ft 0 9m above ee Combustion air inlet of 6 ft 1 8m a Door window or gravity air 4 ft 1 2m horizontally inlet any building opening 4 ft 1 2m below 1 ft 30cm above Electric meter gas meter 4ft 1 2m Do not terminate and relief equipment horizontally the vent directly above a gas meter Gas regulator 3 ft 0 9m lor service regulator Adjoining building or parapet 6 ft 1 8m Adjacent public walkways 7 ft 2 1m above Grade ground level 2 Prepare clearance hole through the outside wall for a 6 diameter pipe Size 150 or 200 or an 8 diameter pipe Size 250 300 350 or 400 Outside wall construction thickness should be between 1 25mm minimum and 30 762mm maximum The larger diameter combustion air pipe serves as clearance for the exhaust pipe on non com bustible construction A thimble may or may not be re quired depending on wall construction and or local codes 3 Prepare the concentric adapter box 3a Determine whether field supplied brackets are required The box must be positioned so that the distance from the outside of the wall to the box is a minimum of 12 305mm Maximum distance is 60 1524mm If brackets are used box should be angled slightly to allow for downward pitch of pipes If used attach brackets securely do not leave any unsealed holes in the adapter box If brackets a
15. and for proper spac ing from combustible con struction Required Clearances All Sizes Right Side 0 0mm Left Side 0 36 914mm 0 0mm Bottom 0 0mm Flue Connector 6 152mm 1 25mm 5 Mounting the Heater Check the supporting structure to be used to verify that it has suffi cient load carrying capacity to support the weight of the unit The heater must be level Approximate Net Weight lbs s owa 460 WARNING Unit must be level for proper operation Do not place or add additional weight to the heater See Hazard Levels page 2 Determine the position of the heater with regard to venting combus tion air gas supply connection electrical supply connection and inlet air opening Either cut out the inlet air opening requires tin snips or aviation shears now or when attaching ductwork or filter cabinet Use caution when cutting the opening as the cut edges of the metal will be sharp NOTE If ordered with an optional inlet base the heater is shipped with a bottom inlet air opening 6 Dimensions Figure 1 Dimensions of Model CAUA Top View A C Plenum Opening Js D Plenum Opening Electrical supply voltage 2 3 8 60mm Control Door co Blower Door 1 2 Front View NOTE Composite drawings are not proportional for all sizes Dimensions inches or 1 8 Size A B G H 150 38 34 3 4 36 21 7 1 4
16. inlet air pipe on the outside wall Flashing is field supplied 5 Slide the inlet guard over the end of the vent pipe and position it on the end of the combustion air pipe See Figure 5B Attach the guard to the inlet air pipe with the four 1 2 lg screws provided 6 Position the vent cap on the end of the vent pipe Align the cap so that its baffle strips are positioned on the horizontal and vertical centerlines See Figure 5 Attach the exhaust cap to the vent pipe with sheetmetal screws Flash or caulk First attach the inlet air guard 5C Second attach the exhaust cap Inlet Air Guard IMPORTANT Install exhaust cap with baffles positioned on horizontal and vertical centerlines as illustrated 7 Horizontal vent terminal combustion air inlet Option CC6 is installed and ready for connection to the heater 8 Connect the Concentric Adapter Box to the Heater Use the pipe specified and joints required for type of pipe If collar or opening at the heater or adapter are different diameters from the pipe use only diameters allowed on page 6 make joint connection with field supplied taper type reducer or enlarger A minimum of 12 305 mm of straight pipe is required at the venter outlet Due to the high temperature do not enclose the exhaust pipe or place pipe closer than 6 152 mm to combustible material Installation of the horizontal vent and combustion air system on your separated combustion unit is c
17. roof 6 2M minimum Roof pitched from 0 to 45 gt Parapet or Adjoining Building Approved clearance thimble for single wall vent pipe is required when flue pipe extends through combustible materials Follow the requirements of the double wall pipe manufacturer Follow instructions on page 10 to join single and double wall pipe and to seal the connection Mfg No 164771 Page 11 8 Duct Connections and Ductwork Both inlet air ductwork and supply air discharge ductwork are required unless the heater is equipped with an optional inlet base and or an optional discharge plenum IMPORTANT NOTE If a Model ACU cased cooling coil is part of the installation it must be installed before attaching discharge ductwork Installation of a filter cabinet is rec ommended when a cooling coil is installed Discharge Duct Connection The discharge duct connects to the top of the heater or to the outlet of the optional cooling coil cabinet See Figures 10 and 11 Connect the ductwork plenum to the duct flange as illustrated in Figure 11 1 The duct connection on the top of the heater has a 90 flange 2 The duct may either have no flange or a 90 flange 3 Position ductwork around the outside of the heater flange 4 If the ductwork has a flange drill holes vertically through duct flange into the top of the heater and secure with sheetmetal screws If the ductwork does not have a flange drill holes hori zontally throug
18. should be used Verify that fusing or circuit breakers are adequate for the load use Start Up WARNINGS For your safety read before operating If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot It is equipped with an ignition device which auto matically lights the burner Do not try to light the burner by hand Before operating smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call your fire department e Use only your hand to turn the gas control ON OFF knob on the gas valve Never use tools If the valve ON OFF knob will not turn by hand do not try to repair it Call a qualified service technician Force or attempted repair may re sult in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified ser vice technician to inspect the appliance and to Form 405 Page 22 replace any part of the control system and any gas control which has been under water
19. supply voltage and current require ments A separate line voltage supply with fused disconnect switch should be run directly from the main electrical panel to the heater All external wiring must be within approved conduit and have a minimum temperature rise rating of 60 C Conduit from the disconnect switch must be run so as not to interfere with the service panels of the heater The electrical supply and control wiring enter at the top of the heater See Figure 1 page 3 and connect to the terminal strip behind the gas valve See Figure 15 Consult the wiring diagram supplied with your heater Typical wiring diagrams are on pages 17 and 18 CAUTION If any of the original wire as supplied with the appliance must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C except for sensor lead wires which must be 150 C See Hazard Levels page 2 12 Thermostat and Connections A thermostat is not standard equipment but is an installation requirement Use either an optional thermostat available with the heater or a field supplied 24 volt thermostat Install according to the thermostat manufacturer s instructions Con trol wiring enters on the right side of the heater and connects to the terminal strip in the control compartment see Figure 15 Make sure that the heat anticipator setting on the thermostat is in accordance with the amperage value noted on the wiring diagram of your heater WA
20. 8 6 16x 16 5000 521 6 16 16 5000 521 6 16x 16 6000 625 6 16 16 6000 625 6 16 x 16 4300 448 6 16 16 NOTES 4300 448 6 16x 16 5000 521 6 16 16 5000 521 6 16x 16 6000 625 6 16x 16 6000 625 6 16 x 16 Requires 2 permanent filters Tf using side inlets two cabinets must be installed one on each side 19 Mixing Cabinet Outside and Return Air The optional mixing box for the Reznor Model CAUA heater is designed instructions for routing the damper motor wires and connect the to provide the system with a supply air mixture of return air and outside wires according to the wiring diagram If there are both return air and air Any percentage of outside air can be supplied to the unit as long as the outside air dampers follow the directions to adjust the damper air temperature entering the blower is 35 F or above The mixing box is linkage available in an assortment of configurations with a selection of actuators All mixing box inlet air openings have duct flanges for attachment of and controls All mixing boxes are completely assembled at the factory for ductwork Ductwork must be attached to the outside air opening field attachment to the rear of a Model CAUA heater Removable door panels provide for filter access from either end of Follow the instructions packed with the mixing box to cut out the opening the cabinet If the box was ord
21. D BLUE WIRES 9 ON 208 230V UNITS THE CONTROL TRANSFORMER HAS A DUAL VOLTAGE PRIMARY FOR 230V UNITS USE BLACK AND YELLOW LEADS CAP RED FOR 208V UNITS USE BLACK AND RED LEADS CAP YELLOW 10 WHEN PROVIDING OR REPLACING FUSES IN THE FUSIBLE DISCONNECT SWITCH USE DUAL ELEMENTS TIME DELAY FUSES AND SIZE ACCORDING TO TIMES THE MAXIMUM TOTAL INPUT AMPS CONTACTOR COIL CONTACTOR COIL MOTOR WIRE COLORS WHITE NEUTRAL BLACK HIGH SPEED BLUE MEDIUM SPEED RED LOW SPEED DO NOT USE WITH 208V VENTER MOTOR SEE NOTE 8 WIRING CODE BLACK BK BROWN BR RED R ORANGE O YELLOW Y GREEN G BLUE BL PURPLE PR WHITE W COOL SPEED BR BL ain OMBO BK BY PASS GAS VALVE PLUG PILOT OUTLET ALTERNATE W R OR ROBERTSHAW FACTORY WIRING EN a T e FIELD WIRING HONEYWELL BY PASS GAS VALVE OPTIONAL FACTORY WIRING PLUG PILOT OUTLET MAIN TERMINAL BLOCK 0 UNIT TERMINAL STRIP THERMOSTAT TERMINAL STRIP LED CODES SLOW FLASH NORMAL OPERATION NO CALL FOR HEAT FAST FLASH NORMAL OPERATION CALL FOR HEAT 2 FLASHES SYSTEM LOCKOUT FAILED TO DETECT OR SUSTAIN FLAME 3 FLASHES PRESSURE SWITCH OPEN OR CLOSED 4 FLASHES HIGH LIMIT OPEN 5 FLASHES FLAME SENSED AND GAS VALVE NOT ENERGIZED STEADY ON INTERNAL FAILURE MICRO CONTROLLER FAILURE SELF CHECK FIELD CONTROL WIRING TOTAL WIRE DISTANCE FROM MIN RECOMMENDED LE
22. E FOR LINE AND MOTOR WIRING ON UNIT LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5 OF SUPPLY LINE VOLTAGE 7 ON 208 230V UNITS THE CONTROL TRANSFORMER HAS A DUAL VOLTAGE PRIMARY Form 405 FOR 230V UNITS USE BLACK AND YELLOW LEADS CAP RED FOR 208V UNITS USE BLACK AND RED LEADS CAP YELLOW VENTER MOTOR ON 350 400 UNITS HAS BROWN AND BLUE WIRES WHEN PROVIDING OR REPLACING FUSES IN THE FUSIBLE DISCONNECT SWITCH USE DUAL ELEMENTS TIME DELAY FUSES AND SIZE ACCORDING TO 1 25 TIMES THE MAXIMUM TOTAL INPUT AMPS age 18 LED CODES SLOW FLASH NORMAL OPERATION NO CALL FOR HEAT FAST FLASH NORMAL OPERATION CALL FOR HEAT 2 FLASHES SYSTEM LOCKOUT FAILED TO DETECT OR SUSTAIN FLAME 3 FLASHES PRESSURE SWITCH OPEN OR CLOSED 4 FLASHES HIGH LIMIT OPEN 5 FLASHES FLAME SENSED AND GAS VALVE NOT ENERGIZED STEADY ON INTERNAL FAILURE MICRO CONTROLLER FAILURE SELF CHECK FIELD CONTROL WIRING TOTAL WIRE DISTANCE FROM MIN RECOMMENDED LENGTH UNIT TO CONTROL WIRE GUAGE 7 150 75 18 GA WIRE 250 125 16 GA WIRE 350 175 14 WIRE OPTIONAL ACCESSORIES 17 Optional Cased Cooling Coil Model ACUA ACUB or ACUC This cased cooling coil is designed for use with the Model CAUA upflow heater It is shipped separately for field installation over the discharge opening of the heater Before installing verify that the coil cabinet is the same size as the heater cabine
23. NGTH UNIT TO CONTROL WIRE GUAGE 0 75 18 GA WIRE 250 125 16 GA WIRE 350 175 14 GA WIRE CAUA SERIES 150 400 DWG B 164607 REV 1 1 AK2 OR AK3 CL10 DIRECT DRIVE BABS Mfg No 164771 Page 17 TYPIC AL WIRING DIAGRAMS cont d Figure 18 Typical Wiring Diagram for Models CAUA with Belt Drive Blower Motor 208 OR 230 1 60 NOON OPTIONAL DISCONNECT SWITCH SEE NOTE 4 GRD MOTOR CONTACTOR DSI CONTROL INHERENTLY PROTECTED BLOWER BK MOTOR O MAIN TERMINAL BLOCK UNIT TERMINAL STRIP O THERMOSTAT TERMINAL STRIP VENTER MOTOR SEE NOTE oS LINE CMB BK OR BR BKORBL WIRING CODE VAC HOT BLWR AUX BLACK BK 7 BROWN BR 24VAC HEAT w ORANGE O FLAME YELLOW Y ROLLOUT SWITCH GREEN G EL ROLLOUT AeB COOL BLUE BL L CUSTOMER S IN PURPLE PR COOL RELAY COIL WHITE W GROUND BR IGNITOR THERMOSTAT TERMINAL STRIP BURNER GROUND FLAME SENSE CcC FLAME SENSING FACTORY WIRING a a a FIELD WIRING ri OPTIONAL FACTORY WIRING D x R i CR D Psw as lt 2 HI LIMIT sel CO 1 IN Be Og EO HI LIMIT amp 1 OUT 95 LED BL 2 BR lt 5 si VALVE z 25 20 BL aan CHASSIS go PII 2s 3 i Baz rn Oga 655 lt o zz 238 oo we g bya saa DOOR
24. RNING If you turn off the power supply turn off the gas See Hazard Levels page 2 Pressure Switc Transformer Terminal Strip Ignition Control Module 13 Combustion Air Proving Switch The combustion air proving switch is a pressure sensitive switch that monitors air pressure to ensure that proper combustion air is available The switch is single pole double throw with the normally open contacts closing when the proper airflow is sensed in the system On start up when the heater is cold the sensing pressure is at the most negative level and as the heater and flue system warm up the sensing pressure becomes less negative After the system has reached equilibrium about 20 minutes the sensing pressure levels off If a restriction or excessive flue length or turns cause the sensing pressure to be outside the switch setpoint the pressure switch will function to shut off the main burners The main burners will remain off until the system has cooled and or the flue system resistance is reduced The table below lists the approximate water column nega tive pressure readings and switch setpoints for sea level operating conditions Model Start Up Equilibrium SetPoint Set Point Size Cold OFF ON 150 1 45 1 05 75 90 5 200 1 50 1 05 250 1 55 1 10 75 1 60 1 15 75 350 1 30 1 05 75 400 1 20 1 00 DANGER Safe operation of this unit requires proper venting flow NEVER bypass the com bustion air
25. See Figure 2 Insert the pipe through the hole and hole for attach it to the collar inside the heater Seal the joint Larger size combustion heaters have oval collars If the collar is oval form the pipe to fit air pipe the collar 2 Venter Outlet The venter outlet size is 5 for Sizes 150 200 and 250 and 6 for Collar for Sizes 300 350 and 400 A minimum length of 12 of straight connecting pipe is required at the venter outlet combustion air pipe 3 Concentric Adapter If installed as a separated combustion unit a concentric adapter is required Option 2 and CC6 The concentric adapter is a metal box that attaches to the inside of the building See 2 Cut the hole the illustrations and dimenstions in Figures 3A and 3B 3 Slide pipe down through hole Option CC6 is horizontal Option CC2 is vertical Op 4 If collar is oval form pipe to fit Attach pipe to collar with tion kits also include a vent terminal and combustion air sheetmetal screws and seal the connection inlet or guard 1 Remove door panel Figure 3A Concentric Adapter Assembly in Options CC2 and CC6 View of Heater Connection Side View of Vent Terminal Connection Side Collar for connecting i indoor portion Collar for outside portion of the of the 4 combustion air pipe vent pipe combustion J 24 extends through the box air pipe internally concentric to the Install r bber seal outside portion of the combustion for v
26. always be vented to the outdoors Installation should be done by a qualified agency in accordance with these instructions The qualified service agency installing the vent or vent combustion air system is responsible for the installation The venting or venting combustion air systems illustrated in this manual are the only ones approved for a Model CAUA heater However since more than one system is approved and requirements vary depending on the type of installation the first step must be deciding which vent or vent combustion air system is going to be installed Review the follow ing matrix of vent types and installation requirements If there is any doubt as to what type of vent is required contact the equipment dis tributor before beginning installation Hazards of Chlorines The presence of chlorine vapors in the com bustion air of gas fired heating equipment presents a potential corro sion hazard Chlorine will when exposed to flame precipitate from the compound usually freon or degreaser vapors and go into solution with any condensation that is present in the heat exchanger or associated parts The result is hydrochloric acid which readily attacks all metals including 300 grade stainless steel Care should be taken to separate these vapors from the combustion process This may be done by installing a separated combustion sys tem and or wise location of the furnace with regard to exhausters or prevailing wind direction Chlorine
27. ange C xD Inlet Air Opening location selected by installer Right Side of Heater K x 16 406mm Left Side of Heater K x 16 406mm Rear of Heater J x 16 406mm Bottom of Heater MxN Right side is illustrated corner indicators for open ing are the same on the left side Mfg No 164771 Page 3 7 Venting and Combustion Air WARNING The vent must be installed in accordance with national and local regulations Failure to provide proper venting could result in death serious injury and or property damage This unit must be installed with a vent to the outside of the building Safe operation of any power vented gas fired equipment requires a properly operating vent system correct provision for combustion air and regular maintenance and inspection WARNING Units installed in multiples require individual vent pipe runs and vent caps Manifolding of vent runs is not permitted due to possible recirculation of combustion products into the building and back pressure effects on the combustion air proving switch Venting must be in accordance with the National Fuel Gas Code Z223 1 or CAN CGA B149 1 and B149 2 Installation Code for Gas Burning Appliances and Equipment and all local codes Local requirements supersede national requirements Combustion air for this heater may be either taken from the space or may be ducted from the outside using the concentric adapter combustion air vent system Flue products must
28. ater while providing an inlet for return air The mounting base is designed to be used with an optional discharge plenum Paragraph 20 creating a packaged stand alone heating or heating cooling upflow system which can be used in an air turnover application However if the installation requires it the mounting base may also be used with discharge ductwork The mounting base has guarded openings on all four sides and is avail able with optional 1 flat disposable 1 permanent aluminum or 1 pleated disposable filters The base is designed for a fairly open area and must have at least three of the four sides open The base adds 36 1 2 927mm to the overall height Mfg No 164771 Page 21 Check Test Start Up 22 Check Installation amp Start Up Check the installation prior to start up L Check clearances from combustibles Requirements are shown in Paragraph 4 If installed as a separated combustion unit check vent combustion air system to be sure that it is installed according to the instructions in Paragraph 7A Check piping for leaks and proper gas line pressure Bleed gas lines of trapped air See Paragraph 9 Check the blower compartment to be sure that all shipping sup ports have been removed Close the blower compartment door se curely Heater will not operate if the blower compartment door is not closed Check electrical wiring Be sure all wire gauges are as recommended A service disconnect switch
29. bustible materials 3 Uncrating and Preparation This unit was test operated and inspected at the factory prior to crating and was in operating condition If the heater has incurred any damage in shipment file a claim with the transporting agency Check the rating plate for the gas specifications and electrical character istics of the heater to be sure that they are compatible with the gas and electric supplies at the installation site Read this booklet and become familiar with the installation require ments of your particular heater If you do not have knowledge of local Form 405 Page 2 requirements check with the local gas company or any other local agencies who might have requirements concerning this installation Before beginning make preparations for necessary supplies tools and manpower Shipped Separate Accessories e Concentric Adapter and Vent Terminal If the heater is installed as a separated combustion system a concentric adapter assembly is required The concentric adapter and parts are shipped in a sepa rate carton Be sure that the shipped separate carton is at the instal lation site See Paragraph 7A Filter Cabinet The return air filter cabinet is shipped separately for field installation over the inlet air opening of the heater The inlet air opening location is determined by the application The filter cabinet can attach at the opening on either the rear the left side or right side of the unit
30. c tion leakage corrosion and other deficiencies which could cause an unsafe condition 99 In so far as practical close all building doors and win dows and all doors between the space where the heater is and other spaces of the building Turn on clothes dryers and exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Light the heater following the lighting instructions Ad just the thermostat for continued operation Verify that combustion products are venting properly After deter mining that the heater vents properly return doors win dows exhaust fans and fireplace dampers to their previ ous conditions If improper venting is observed the vent ing system must be corrected With the unit in operation measure manifold gas pressure Manifold pressure for natural gas should be 3 5 w c and 10 w c for propane gas See Paragraph 9 C Turn the unit off and on pausing two minutes between each cycle Observe for smooth ignition Place the Owner s Envelope containing the Limited War ranty this booklet the operation maintenance service manual and any control or optional information in an accessible loca tion near the heater Follow the instructions on the envelope DANGER The gas burner in this gas fired equipment is designed and equipped to provide safe and economically controlled complete combu
31. d in Items 1 2 and 3 below Figure 7 Confined Space A space whose volume is less than Confined 50 cubic feet per Space 1000 BTUH ofthe E installed appliance i input rating Add total BTUH of all appliances in the confined space and divide by figures below for square inch free area size of each top and bottom opening 1 Air from inside the building openings 1 square inch free area per 1000 BTUH Never less than 100 square inches free area for each opening See 1 in Figure 7 2 Air from outside through duct openings 1 square inch free area per 2000 BTUH See 2 in Figure 7 3 Air direct from outside openings 1 square inch free area per 4000 BTUH See 3 in Figure 7 NOTE For further details on supplying combustion air to a confined space see the National Fuel Gas Code ANSI Z223 1a latest edition Specific Venting Requirements read all before installing 1 Venter Flue Outlet Venter Outlet Model Size 150 200 250 300 350 400 Size Venter Outlet Attachment Requirements A minimum of 12 of straight pipe is required at the venter outlet before installing an elbow in the vent system An elbow should never be attached directly to the venter An elbow attached to the straight pipe can be in any position at or above horizontal See Figure 8 Form 405 Page 10 Figure 8 Alternate Vent Directions Ventinany Zz position above horizontal 42 A minimum
32. e listed above for a horizontal power Vent Length is Vertical Option vented system may be used OR vent pipe Vent Cap or field sup plied equivalent see page 11 approved for a Category I heater may be used Single wall pipe or double wall Type B vent pipe are suitable for use with a Category I heater If local code requires the terminal section may be double wall pipe with a single wall vent run STEP 2 Follow the instructions that apply to the type of vent being installed Separated Combustion requires air inlet pipe exhaust vent pipe and concentric adapter kit Option CC2 or CC6 Using required pipe See Table above FOLLOW INSTRUCTIONS IN SECTION 7A Power Vent requires vent pipe and vent cap Option or field supplied L Breidert Air x hauster or equivalent vent cap Using required pipe See Table above FOLLOW INSTRUCTIONS IN SECTION 7B Form 405 Page 4 7A Venting and Combustion Air Requirements for Separated Combustion Installation must use either Option CC2 or CC6 Specific Requirements read all before installing Comply with the specific requirements and instructions in the following paragraphs and illustrations 1 Combustion Air Inlet Diameter is 5 for Sizes 150 and 200 and 6 for Sizes 250 300 Figure 2 Attach Combustion Air Pipe 350 and 400 Use tin snips Use tin snips or aviation shears to cut out the hole in the top of to cut out the heater
33. e of the pipe 2c Attach the outside portion of the com bustion air pipe to the box Determine the length of the combustion air pipe so that dimension X Figure 6A is equal to the roof thickness plus snow depth 559mm and ridge or parapet clearance but does Minimum not exceed 60 1524 mm Attach the combustion air pipe to collar with sheetmetal screws being careful not to penetrate the vent pipe 3 Attach the concentric adapter Insert the vent pipe and combustion air pipe up through the roof and secure the adapter box Flash the combustion air pipe to the outside of the roof as required 4 Slide the combustion air inlet over the vent pipe and fasten the collar to the end of the combustion air pipe with sheet metal screws See Figure 6C Seal joint at top between vent pipe and combus tion air inlet with silicone seal Qa ant to prevent water leakage 3 Seal the OD jomt 5 Attach the exhaust termi with silicone nal with sheet metal screws See Figure 6D 6 Vertical vent terminal combus tion air inlet is installed and ready for connection to the heater 7 Connect Concentric Adapter Box to the Heater Use the pipe speci fied and joints required for type of pipe If collars at the heater or adapter are dif 12 305mm ferent diameters from the pipe use only diameters allowed on page 6 make con nection with field supplied taper type re ducer or enlarger i A minimum of 12 305 mm of Combustion straig
34. eater side NOTE Be sure flow direction is correct Combustion air pipe Field supplied mounting brackets Combustion Air Flow Concentric Adapter Box Collar for combustion air pipe Vent Pipe when a taper type reducer is required in the vent pipe it must be no more than 6 152mm from the box Install seal in vent pipe opening cause the pipe diameter does not change plus bracket length plus the width of the roof plus the length of the outer inlet air pipe plus a minimum of 22 559mm Lubricate the seal and pipe with liquid soap or a rubber lubri cant Installation Tip Spray cooking oil works well as a lubri cant for this task Being sure the pipe is in the proper flow direction slide the end through the box and push it out through the rubber seal Push evenly using caution not to displace the seal from its position on the edge of the hole If the rubber seal moves slide the pipe back slightly re position the seal and slide the pipe through again Position the vent pipe so that it will extend a minimum of 22 559mm past the end of the combustion air pipe See Figure 6B A maximum of 6 152mm of vent pipe should extend out the heater side Any time the pipe is re positioned re check the seal to be sure that it has not rolled Adjust the pipe and seal until the pipe is the correct length on each side of the box and the seal is over the edge of the hole and tight to the entire circumferenc
35. ee trial system The unit will lockout for one hour before initiating another trial for ignition If the unit fails after one recycle interval the unit will go into hard lockout and must be reset by interrupting power or resetting the thermostat To initiate another trial for ignition before the one hour interval either reset the thermostat or interrupt power to the unit for 30 seconds TYPICAL WIRING DIAGRAMS Figure 17 Typical Wiring Diagram for Model with Direct Drive Blower Motor s 208 OR 230 1 60 OPTIONAL DISCONNECT SWITCH G GRD SEE NOTE 24 i ot BL_ INHERENTLY HEAT SPEED PROTECTED CONTACTS INHERENTLY BLOWER PROTECTED BLOWER N MOTOR MOTOR SEE NOTE 7 N D 7 7 meee wa BIOL 7 BK OR BR VAC HOT HEAT SPEED BLWR AUX 24VAC HOT ACB HEAT BL BL a 1 ad ROLLOUT SWITCH BL BL A BL CUSTOMER S COOL RELAY COIL ROLLOUT ACB COOL IN GROUND IGNITOR HV LEAD l THERMOSTAT 1 TERMINAL STRIP w FLAME SENSE HI LIMIT IN HI LIMIT OUT 87 THERMOSTAT Q539A SUBBASE SET ANTICIPATOR AT 0 6 AMPS 000000 CHASSIS GRND DOOR SWITCH BL BL BL BR OO 40 VA CONTROL TRANSFORMER LINE VOLT OPERATING SEQUENCE SET THERMOSTAT SYSTEM SWITCH AT OFF POSITION FAN SWITCH AT AUTO POSITION TURN ON MANUAL GAS VALVE TURN ON POWER TO UNIT SET THERMOSTAT SYSTEM SWITCH
36. ent pipe air pipe Figure 3B Concentric Adapter Box Dimensions inches mm Top View of the Concentric Adapter CAUA 150 200 250 300 350 400 Box Showing Air Flow 5 127 6 152 Combustion Air Flow 4 102 5 127 Exhaust Vent Gas Flow 4 102 4 102 Field supplied vent 7 1 2 191 7 1 2 roug e 5 127 5 127 rubber seal the 4 102 5 127 concentric adapter box extending out 16 1 2 419 16 1 2 419 both sides of the 8 203 10 254 box 6 152 8 203 ale gt A Diameter of the Collar for attaching D t f th A m for ihe the inside Side View Side of the Outside Portion of the Combustion Air Pipe Adapter Box that Connects Combustion Air Pipe from the Heater to the Heater Mfg No 164771 Page 5 7 Venting and Combustion Air cont d 7A Venting and Combustion Air Requirements for Separated Combustion Installation must use either Option CC2 or CC6 cont d 4 Pipe Diameter and Length minimum length is five feet 1524mm CAUA Vent Inlet Air Length Equals Equals 40 ft 12 2 M 50 ft 152 2 Reduce maximum length by this amount for each elbow Concentric Pipes the vent pipe runs concentric through the out door portion of the combustion air pipe Sizes 150 and 200 require 6 diameter combustion air pipe for outdoor portion and a 4 diam eter vent pipe through the concentric adapter to the terminal Sizes 250 400
37. entric adapter box or box may be mounted flush depending on building construction Taper type reducers as required see requirements above Installation Instructions for Option CC6 1 Determine the location on the outside wall for the vent terminal Applies to all horizontal vent kits In most applications the terminal would be on a level with the heater mounting height Allow 1 4 per foot downward pitch toward the terminal for draining of condensation The distance of the termination of the horizontal vent from adjacent public walkways adjacent buildings openable windows and building openings must be in accordance with local codes or in the absence of local codes must conform with National Fuel Gas Code Local codes supersede all provisions in these instructions and in the National Fuel Gas Code Mini mum clearances for the horizontal vent terminal are as shown in the table on page 7 Products of combustion can cause discoloration of some building finishes and deterioration of masonry materials Applying a clear silicone sealant that is normally used to protect concrete driveways can protect masonry materials If discoloration is an esthetic problem relocate the vent or install a vertical vent WARNING vent terminals must be positioned or located away from fresh air intakes doors and windows to preclude combustion products from entering occupied space See Hazard Levels page 2 Minimum Clearances for Vent Structure
38. ered with optional filters it is shipped and attach the mixing box If the mixing box has dampers follow the with the filters installed Form 405 Page 20 Figure 22 Optional Outside Air and Return Air Mixing Box Configurations Accessories Before installing check to be sure that the configuration of the mixing box matches the order and that any accessories ordered are part of the cabinet Factory installed optional accessories could include a damper motor potentiometer return air controller mixed air controller and or filters NOTE If the potentiometer is to be field installed it is shipped in a separate carton Top View Inlet Opening with Duct Flange If bottom inlet opening is symmetrical with top view 19 1 2 495 Rear View Inlet Opening with Duct Flange a 19 1 2 495 2 20 Discharge Plenum Sizes 350 and 400 only The optional discharge plenum is designed to be used with a screened mounting base Paragraph 21 to create a packaged stand alone upflow system that circulates building air However the discharge plenum may also be used in place of ductwork in applications that do not have an optional mounting base The discharge plenum is available in three types Option CD60 and CD61 are for a heater without a cooling coil Option CD60 is designed for an open area and Option CD61 includes field installed blockoff plates to block off one or two sides Option CD62 can only be ordered
39. et Determine Length of the roof Vent Pipe through the Box Field supplied installation requirements e Thimble a thimble is not required if wall is of non 2b Install the rubber seal and the een Side nian G 152 combustible construction vent pipe Locate the vent pipe open Flashing ing and place the rubber seal around diameter changes Vent pipes see requirements on pages 4 and 6 and ONER the edge of the metal oe ee gt 6 l Combustion air pipes see requirements pages 4 and 6 Determine the length of the Section of ere i f a t e Mounting brackets for concentric adapter box or box vent pipe by adding the requirements 1 h may be mounted flush depending on building construc On the heater side of all Sizes except let Pipe Height __ __ tion CAUA 250 the vent pipe must ex Terminal Side min 22 559 e Taper type reducers as required see requirements on tend no more than 6 152mm length Length of Pipe page 6 limit does not apply to Size 250 be Form 405 Page 8 X is the length of combustion air pipe required through and above the roof X must equal roof thickness plus clearance required for anticipated snow plus ridge and or parapet clearance X must not exceed 60 1524mm Seal the seam in the vent pipe Install the vent pipe by inserting it into the terminal side of the box and pushing it out through the seal on the h
40. h the ductwork and the heater flange secure with sheetmetal screws Figure 10 Top View showing Discharge Duct Connection Dimensions inches Tm Combustion Air Knockout Venter Outlet Electrical Removable Access Panel in the Ductwork ae 6 x 10 152mm x 254mm Attach to Duct Flange Heater Inlet Air Ductwork The location of the inlet air duct connection depends on the installation Corner indicators for the opening are pro vided on the right side the left side and the rear of the heater See Dimensions in Figure 1 page 3 Determine where the inlet air opening s should be and cut out using tin snips or aviation shears CAUTION Form 405 Page 12 The cut edges of the metal will be sharp If installing an optional filter or filter mixing cabinet shipped with the heater attach the cabinet at the cutout opening See Optional Acces sories Paragraph 18 or 19 Depending on the cabinet and how it is installed the inlet opening may be horizontal or vertical Attach the ductwork to the heater or to the inlet cabinet Figure 12 Duct Opening for Connecting the Inlet Air Duct to the field installed Filter or Mixing Cabinet Depending on the heater size and whether the cabinet is on the side or the rear the inlet opening may be either vertical on the top of the filter cabinet or horizontal on the side of the filter cabinet Filter Cabinet Inlet Opening 150 200 Rear or Side
41. hes on Either Side of the Heater Attaches on the Rear of the Heater Option CW10 for Field Supplied e Vertical Top or Horizontal Inlet Opening Vertical Top or Horizontal Inlet Filters e V Filter Rack Arrangement Opening Attaches on either Side or the Rear V Filter Rack Arrangement of a Size 150 or 200 Heater Horizontal Inlet Opening V Filter Rack Arrangement i 5 Figure 21B T with Assembled Figure 21C with Small Filter Horizontal Cabinet for Sizes Air Inlet 150 and 200 only Opening Horizontal Air Vertical Air Inlet Opening Sizes of Permanent or Pleated 2 Sizes of Permanent or Pleated 2 Filters for Options CW4 CW5 or CW6 Filters for Options CW7 CW12 or Size CFM FPM Filters Filters for Options CW8 CW9 CW10 150 1800 281 4 16x 16 Size CFM FPM Filters SizeCFM FPM 2 Filters 2400 375 4 16 x 16 150 1800 281 4 16x 16 Pleated Permanent 3000 469 4 16x 16 2400 375 4 16x 16 150 1800 375 2 12 32 4 12 16 2400 375 4 16x 16 3000 469 4 16x16 2400 500 2 12x32 4 12x 16 3000 469 4 16 x 16 2400 375 4 16 16 3000 625 4 12x 16 3000 469 4 16x 16 3000 469 4 16 16 200 2400 500 2 12 32 4 12 16 4000 625 4 16 16 3000 313 6 16 16 3000 625 E 4 12x 16 5000 781 4 16x 16 4000 417 6 16x 16 4 16x 16 5000 521 6 16 16 3000 469 4 16 16 3000 313 6 16 16 4000 625 4 16 x 16 4000 417 6 16x 16 5000 781 4 16 x 16 5000 521 6 16 16 4 16x 16 4300 448 6 16x 16 4300 44
42. ht pipe is required at the venter Air Inlet outlet Due to the high temperature do not enclose the vent pipe or place pipe 6D closer than 6 152 mm to combustible material Installation of the vertical vent and combustion air system on your sepa rated combustion unit is complete Refer to Figure 6E and verify that all installation requirements are met 6B 22 Snow Clearance 6C 1 Slide combustion air inlet over the vent pipe 2 Fasten to the end of the combus tion air pipe Install field supplied flashing at roof opening flashing not illustrated Exhaust Terminal minimum Figure 6E Installation of Separated Combustion Unit with Vertical Vent and Combustion Air Pipes Option CC2 Vent Terminal Seal with high temperature silicone rubber sealant supplied with the kit Combustion Air Inlet field supplied Roof Combustion Air Pipe Concentric Adapter Side View 238mm 6 ft 1829mm minimum 5 ft 1524mm maximum Size Flashing according to il i snepi field supplied snow depth Roof 18 457mm minimum Adapter he Roof View of a typical installation of a vertical vent inlet air terminal and concentric adapter Option CC2 Mfg No 164771 Page 9 7 Venting and Combustion Air cont d 7B Venting and Combustion Air Requirements for Power Vent Drawing Combustion Air from THE INSIDE SPACE and Venting Flue Products to the Outdoors vent cap is
43. ing Contractors Association 1228 17th Street N W Washington D C 20036 A manual covering duct sizing in detail may be purchased directly from them CAUTION An external duct system static pressure not within the limits shown on the rating plate or improper motor pulley or belt adjustment may overload the motor See Hazard Levels page 2 Removable Panels The ducts should have removable access pan els on both upstream and downstream sides of the furnace These openings must be accessible when the furnace is in service and should be a minimum of 6 x 10 in size so smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger The covers for the openings must be attached in such a manner as to prevent leakage See Figure 11 9 Gas Piping and Pressures WARNING This appliance is equipped for a maximum gas supply pressure of 1 2 pound 8 ounces or 14 inches water column Supply pressure higher than 1 2 pound requires installation of an additional lockup type service regulator external to the unit PRESSURE TESTING SUPPLY PIPING Test Pressures Above 1 2 PSI Disconnect the heater and manual valve from the gas supply line which is to be tested Cap or plug the supply line Test Pressures Below 1 2 PSI Before testing close the manual valve on the heater All piping must be in accordance with requirements outlined in the National Fuel Gas Code ANSI Z223 1a latest ed
44. ir Inlet Requires Concentric Adapter Kit Option CC2 Vertical Vent Terminal Combustion Air Package Installation Instructions for Option CC2 Option CC2 includes 1 Determine the location for the vent terminal on the roof allowing room for the Qty Description 150 250 300 concentric adapter box inside A thimble may or may not be required depending 200 350 400 a f on building construction and or local codes Prepare a hole through the roof for Complete Vertical ba Kit 157156 54444 the combustion air pipe Sizes 150 and 200 pipe is 6 Sizes 250 400 pipe is 8 Same as Option CC2 The air inlet pipe must be flashed or sealed to the roof Flashing is to be supplied Concentric Box Assembly 155392 68404 by the installer as required by roof construction and or codes Terminal 3 WARNING All vent terminals must be positioned or located away from fresh air intakes doors and windows to 1 Combustion i 155635 53330 preclude combustion products from entering occupied Air Inlet space See Hazard Levels Page 2 i 2 Prepare the concentric adapter box 1 Rubber seal for vent pipe 164492 164493 2a Determine whether field supplied brackets are required If used attach opening in concentric adapter brackets securely do not leave any unsealed holes in the adapter box 1 Tube of High Temperature 53335 53335 If brackets not used when in 450 F Silicone Sealant stalled the box should be tight against Workshe
45. is heavier than air This fact should be kept in mind when determining installation locations of heating equip ment and building exhaust systems STEP 1 Decide which Venting System to Install Type of Type of Vent System Vent Configuration Options ne 2 Separated Combustion INDUS TRIAL Harmonized ANSI Z83 8 1996 and exhaust flue products to and Canadian the outdoors follow Standard Instructions in Section 7A CAN CGA 2 6 inlet uses a power venter to duct M96 Power Vented uses apower Horizontal Vent Option CC1 venter to draw combustion air Vent Cap or field supplied from the indoor space and exhaust flue products to the outdoors follow Instructions in Section 7B At least 1 2 of the Equivalent Horizontal Vent Option CC6 includes concentric adapter box equivalent see page 11 Use either vent pipe approved for a Category III appliance OR single wall 26 gauge or heavier combustion air from outdoors exhaust terminal and inlet air guard galvanized or a material of equivalent durability Vertical Vent Option CC2 includes concentric adapter box and corrosion resistance vent pipe exhaust terminal and combustion air Use either vent pipe approved for a Category III appliance OR appropriately sealed 26 gauge galvanized steel or equivalent single wall pipe If local code requires the terminal section may be double wall pipe with a single wall vent run Vent pip
46. ition or CAN CGA B149 1 and B149 2 See Paragraph 1 Gas supply piping installation should conform with good practice and with local codes Unit heaters are orificed for operation with natural gas having a heating value of 1000 50 BTUH per cubic ft or propane gas with a heating value of 2550 BTUH per cubic ft If the gas at the installation site does not meet these specifications consult the factory for proper orificing Pipe joint compounds pipe dope shall be resistant to the action of liquefied petroleum gas or any other chemical constituents of the gas being supplied Install a ground joint union and manual shutoff valve upstream of the unit control system as shown in Figure 13 The 1 8 plugged tapping in the shutoff valve provides connection for a supply line pressure test gauge The National Fuel Gas Code requires the installation of a trap with a minimum 3 drip leg Local codes may require a minimum drip leg longer than 3 typically 6 Bleed gas lines of trapped air Gas connection is either 1 2 or 3 4 depending on size and type of gas Size Gas Gas Connection 150 200 Natural 1 2 250 400 Natural 3 4 150 400 Propane 1 2 Leak test all connections by brushing on a leak detecting solution Sizing a Gas Supply Line Immediately upstream of the gas From Gas Supply supply connection install a manual shutoff valve with a 1 8 NPT plugged tap accessible for test gauge connection t i
47. nel Turn on the gas and electric Check for proper operation Belt drives have an adjustable pulley which permits adjustment of the blower speed Follow these instructions to adjust blower speed 1 Turn off the gas and the electric power 2 Loosen belt tension and remove the belt 3 Loosen the set screw on the side of the pulley away from the motor 4 To increase the blower speed turn the adjustable half of the pul ley inward To decrease the blower speed turn the adjustable half of the pulley outward One turn of the pulley will change the speed 8 10 5 Tighten the set screw on the flat portion of the pulley shaft 6 Replace the belt and adjust the belt tension Adjust tension by turning the adjusting screw on the motor base until the belt can be depressed 3 4 See Figure 16 Re tighten the lock nut on the adjusting screw Be sure that the belts are aligned in the pulley grooves properly and are not angled from pulley to pulley 7 Turn on the gas and electric Light the heater following the instruc tions on the lighting instruction plate 8 Check the motor amps with an amp meter The maximum motor amp rating on the motor nameplate must not be exceeded When service is complete check for proper operation Motor Amps Use an amp meter to check motor amps The chart lists full load amps for various HP s and voltages Amps may be adjusted downward by reducing blower RPM or increasing duct system static pressure The char
48. of 12 of straight pipe is required before an elbow Do not install dampers or any other type of flue restrictor device 2 Vent Pipe Diameter and Length Maximum Vent Length minimum length is 5 ft 1 5M CAUA Pipe Maximum 90 Elbow 45 Elbow Diameter Length Equals Equals 150 250 50 ft 15 2M 5 ft 1 5M 2 5 ft 8M 300 400 6 50 ft 15 2M 5 ft 1 5M 2 5 ft 8M Reduce by this amount for each elbow Note If the system contains all vertical pipe or a combination of horizontal and vertical vent pipe the Maximum Permissible Vent Length may be in creased one foot 305mm for each foot 305mm of vertical rise up to a maximum increase of ten feet 3M 3 Vent Pipe and Joints Provide field supplied vent pipe as specified in the Table on page 4 e If using single wall 26 gauge or heavier galvanized pipe secure slip fit connections using sheet metal screws or rivets Seal pipe joints either with tape suitable for 550 F such as Option FA1 P N 98266 or high tem perature silicone sealant If using Category vent pipe follow pipe manufacturer s instructions for joining pipe sections When attaching Category III pipe to the venter outlet or the vent cap make secure sealed joints following a procedure that best suits the style of Category III pipe being used e Ifusing double wall Type B vent pipe at least 1 2 of the equivalent vent length must be vertical follow pipe manufacturer s instructions for j
49. oin ing pipe sections For joining double wall pipe to the venter outlet collar single wall pipe and or the vent cap follow the instructions below Instructions for attaching double wall Type B vent pipe to the ven ter outlet a single wall pipe run or to the vent cap use these in structions for either full length double wall or terminal only Hardware and Sealant Required 3 4 long sheetmetal screws and a tube of high temperature silicone sealant 1 Look for the flow arrow on the vent pipe attach according to the arrow Slide the pipe so that the venter outlet the single wall pipe or the vent cap is inside the double wall pipe 2 Drill a hole through the pipe into the outlet collar the single wall pipe or the vent cap Hole should be slightly smaller than the sheet metal screw being used Using a 3 4 long sheet metal screw attach the pipe Do not overtighten Repeat drilling and inserting two additional screws evenly spaced 120 apart around the pipe 3 Use silicone sealant to seal any gaps If there is an annular opening run a large bead of sealant in the opening The bead of sealant must be large enough to seal the opening but it is not necessary to fill the full volume of the annular area 4 Vent System Support Lateral runs should be supported every six feet 1 8M using a non combus tible material such as strap steel or chain Do not rely on the heater for support of either horizontal or vertical vent
50. omplete Refer to Figure 5D and verify that all installation requirements are met Continue to Paragraph 8 Mfg No 164771 Page 7 7 Venting and Combustion Air cont d 7A Venting and Combustion Air Requirements for Separated Combustion Installation must use either Option CC2 or CC6 cont d Figure 5D Installation of a Typical Separated 60 1524mm maximum Top Combustion Unit with Horizontal Vent and Combustion 12 305mm minimum View Air Pipes Option CC6 Concentric Adapter Seal Joints gt gt gt Inlet Air Combustion Air Pipe Seal joints see Require Vent Flue Exhaust Pipe Maximum Length See Requirement No 4 on page 6 Minimum length is 5 ft 1 5M ic 2 ge Exhaust Cap Side View Vent Pipe PITCH TO E Concentric Adapter Box A s 6 15 16 176mm 6ft 1829mm minimum 24 610mm minimum Adjoining Thimble Building Combustion Air Pipe PITCH TO DRAIN IMPORTANT NOTE Exhaust cap must be installed so the baffles are positioned on horizontal and vertical centerlines Through the Wall View of a typical installation of a horizontal vent inlet air terminal and concentric adapter Option CC6 3 ft 914mm lt minimum Building Projection we dd gt Instructions and Requirements for Installing a Vertical Vent Terminal Combustion A
51. osure See Hazard Levels page 2 16 Ignition System This heater is equipped with a direct spark integrated control system The system monitors the safety devices and controls the operation of the blower and venter motors and the gas valve Ignition System Operating Sequence On a call for heat from the thermostat the system energizes the venter motor and goes through a 10 second prepurge The system verifies that the pressure switch has changed states closing the normally open con tactor and that the high limit is in the closed state The gas valve is then energized and the ignition system provides the high voltage spark to the electrode to ignite the main burner gas Burner flame is electronically sensed by the control minimum 1 0 microamps upon carryover of all burners A separate solid metal probe is used as the flame sensing function A low voltage electrical signal is imposed on the metal probe which is electrically isolated from ground When the flame impinges on the flame sensing probe the flame acts as a conduc tion path to ground The flame rectifies and completes the DC circuit and the ignition system acknowledges the flame The blower motor is energized by the system after 30 seconds of flame sensing After the thermostat has been satisfied the system de energizes the gas valve the venter motor goes through a 45 second post purge and the blower motor remains energized for an additional 135 seconds NOTE This is a thr
52. pipe 5 Condensation Any length of single wall vent pipe exposed to cold air or run through an unheated area or an area with an ambient temperature of 45 F or less must be insulated along its entire length with a minimum of 1 2 foil faced fiberglass 1 1 2 density insulation Where extreme conditions are anticipated install a means of con densate disposal 6 Vent Terminal Pipe and Vent Ca The vent system must be terminated with the type of vent cap approved for use with this heater The vent cap must be the same size as the vent pipe Use either a vent cap available from the Figure 8 Horizontal Vent Terminals Single Wall Vent Run and Single Wall Terminal Roof or Building Overhang 3 IM 12 305mm y minimum minimum 6 2M minimum Parapet or J Adjoining Building Note position of vent Approved clearance cap openings thimble for single wall vent pipe is required when flue pipe extends through combustible materials Pitch flue pipe down toward outlet 1 4 per foot for condensate drainage NOTE Applies to entire horizontal vent run Horizontal Vent Terminal Clearances A vent cap is required Maintain a clearance Structure of 12 from the wall to the vent terminal cap for stability under wind conditions Products of combustion can cause discolora tion of some building finishes and deteriora tion of masonry materials Applying a clear silicone sealant tha
53. plug Follow the instructions in Figure 14 to install the drain Complete all steps as listed in the illustration When installation of the burner condensate drain is com plete re assemble the heater Form 405 Page 14 Figure 14 Burner Condensate Drain Connection ot IP Oe Hex Locknut silver Burner Bottom Pan Sealing Washer Brass Nut 90 Nylon Fitting 1 Assemble the brass nut the sealing washer and the 90 fitting 2 Position the threaded fitting up through the hole so that the hose barb is toward the bushing in the side of the cabinet Attach using the silver colored locknut 3 Under the burner push the tubing onto the hose barb being sure that it is secure Maintaining a downward slope extend the hose out through the cabinet side 4 Just after exiting the cabinet create a trap in the line by making a loop in the hose Secure the loop with the wire ties 5 Continue downward with the tubing connecting it into the coil drain pipe 11 Electrical Supply and Connections All electrical wiring and connections including electrical grounding MUST be made in accordance with the National Electric Code ANSI NFPA No 70 latest edition or in Canada the Canadian Electrical Code Part I C S A Standard C22 1 In addition the installer should be aware of and comply with any local ordinances or gas company requirements Check the rating plate on the heater for the
54. proving switch or attempt to operate the unit without the venter running and the proper flow in the vent system Hazardous conditions could result See Hazard Levels page 2 Contactors Figure 15 Control Locations Limit Control Supply Wiring Terminal Block behind the gas valve Line voltage enters the control compartment through a hole in the top of the heater cabinet Thermostat Terminal Strip Thermostat wires enter the control compartment through a hole in the right side of the heater cabinet 14 Blower Motor and Drive Model units are equipped with either direct drive motor s and blower s or adjustable belt drive blower s and motor Direct Drive All direct drive blower motors are 1 horsepower Sizes 150 200 have a single motor Size 150 has a 12 9 blower Size 200 has a 12 12 blower Sizes 250 400 have dual motors with dual 12 9 blowers Belt Drive The motor horsepower on a belt drive unit is whatever was specified on the order ranging in size from 1 4 HP to 5 HP Check the heater rating plate and the motor rating plate As part of the start up procedure check belt tension Proper belt tension is important to the long life of the belt and motor A loose belt will cause wear and slippage Too much tension will cause excessive motor and blower bearing wear Adjust the belt tension by turning the adjusting screw on the motor base until the belt can be depressed 3 4 See Figure 16 After
55. r water Immediately call a qualified service technician to inspect the appliance and replace any gas control which has been under water CAUTION Do not locate the heater where it may be exposed to water spray rain or dripping water HAZARD INTENSITY LEVELS 1 DANGER Failure to comply will result in severe personal injury or death and or property damage 2 WARNING Failure to comply could result in severe personal injury or death and or property damage 3 CAUTION Failure to comply could result in minor personal injury and or property damage 1 Installation Codes These units must be installed in accordance with local building codes In the absence of local codes in the United States the unit must be in stalled in accordance with the National Fuel Gas Code ANSI Z223 1a latest edition A Canadian installation must be in accordance with the CAN CGA B149 1 and B149 2 Installation Code for Gas Burning Ap pliances and Equipment These codes are available from CSA Informa tion Services 1 800 463 6727 Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements 2 Warranty Refer to the limited warranty information on the Warranty Card in the Owner s Envelope Warranty is void if a Wiring is not in accordance with the diagram furnished with the heater b The unit is installed without proper clearance to com
56. re design certified by the Canadian Standards Association CSA to ANSI Z83 6 and CGA 2 6 M96 for industrial commercial installations in the United States and Canada Heaters are available for use with either natural or propane gas The type of gas the firing rate and the electrical characteristics are on the unit rating plate A Model CAUA heater requires installation of an inlet air duct or an optional inlet air base and a supply duct or an optional discharge ple num This heater may be installed as a separated combustion system taking combustion air from outside or as a power vented system taking combustion air from the space where the heater is installed Mfg No 164771 Page 1 GENERAL Cont d Separated combustion units are designed to separate the air for com bustion and the flue products from the environment of the building in which the unit is installed Separated combustion appliances are rec ommended for use in dust laden and some corrosive fume environments or in buildings with negative pressure up to 15 w c If installed as a separated combustion system the heater must be equipped with both combustion air and exhaust piping to the outdoors All Model CAUA heaters must be vented to the outdoors WARNING Should overheating occur or the gas supply fail to shut off shut off the manual gas valve to the appliance before shutting off the electrical supply WARNING Do not use this appliance if any part has been unde
57. re not used when the box is installed position it tight against the wall 3b Install the rubber seal and the vent pipe Locate the vent pipe opening no collar and place the rubber seal around and over the edge of the metal Determine the length of the section of vent pipe by adding the requirements On the heater side of all Sizes except CAUA 250 the vent pipe must extend no more than 6 152mm length limit does not apply to Size 250 because the pipe diameter does not change plus 6 152mm through the box plus bracket length plus the width of the wall plus a minimum of 18 457mm on the outside if the inlet air pipe extends recom Worksheet Determine Length of Vent Pipe through the Box inches mm 7 mended 2 Heater Side maxif 6 152 51mm beyond cee TS OOS E Lubricate the seal Bracket Length o o arrest and pipe with liq Width of Wall id soap or atub Terminal Side min 18 457 ber lubricant In stallation Tip Spray cooking oil works well as a lubricant for this task Being sure the pipe is in the proper flow direction slide the end through the box and push it out through the rubber seal Push evenly using caution not to dis place the seal from its position on the edge of the hole If the rubber seal moves slide the pipe back slightly re position the seal and slide the pipe through again Position the vent pipe so that it will extend a minimum of 16 past the end of the combus
58. require an 8 diameter combustion air pipe for the outdoor portion and a 5 diameter vent pipe through the concentric adapter to the terminal Length depends on building construction specific requirements are included with the concentric adapter kit instructions 250 5 5 Determined by type of pipe Provide field supplied vent pipe as specified in the Table on page 4 e If using single wall 26 gauge or heavier galvanized pipe secure slip fit connections using sheet metal screws or rivets Seal all joints Seal combustion air pipe with pressure sensitive tape ordi narily used for warm air ductwork Seal flue exhaust pipe with either tape suitable for 550 F such as Option FA1 P N 98266 or high temperature 450 F silicone sealant If using Category III vent pipe follow the pipe manufacturer s in structions for joining pipe sections In Concentric Pipes outdoor portion from Concentric Adapter Box to Air Inlet and Vent Terminal Follow the installation instruc tions for the specific option CC6 for horizontal vent CC2 for vertical vent Joints Requiring Taper type Connections See Figure 4 When the diameter of the pipe in the vent pipe run is different from the vent pipe in the terminal section the joint must be made with a taper type pipe connector Install the connector no more than 6 152mm from the concentric adapter box A 5 to 4 reducer is required in the vent pipe on Sizes 150 200 a 6
59. required If the environment has a positive pressure and is such that it is not detrimental to combustion air this system may be installed To provide combustion air to the heater sufficient air must enter the equipment location to replace that exhausted through the heater vent system In the past the infiltration of outside air assumed in heat loss calculations one air change per hour was assumed to be sufficient However current construction methods using more insulation vapor barriers tighter fitting and gasketed doors and windows weather stripping and or mechanical ex haust fans may now require the introduction of outside air through wall openings or ductwork to the equipment room The requirements for combustion and ventilation air depend upon whether the unit is located in a confined or unconfined space An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1000 BTUH of the installed appliance Under all conditions enough air must be provided to ensure there will not be a negative pressure condition within the equip ment room or space Follow the specific requirements below for a confined space installation Confined Space Installation Do not install a unit in a con fined space without providing wall openings leading to and from the space Provide openings near the floor and ceiling for ventila tion and air for combustion as shown in Figure 7 depending on the combustion air source as note
60. ssure to the manifold Normally adjustments should not be necessary to the factory preset regulator If adjustment is necessary set pressure to correct settings by turning the regulator screw IN clockwise to increase pressure Turn regulator screw OUT counterclockwise to decrease pressure 10 Burner Condensate Drain If an optional cooling coil is installed on a Model CAUA heater either now or at a later time a burner condensate drain line must be installed The following parts to install the drain line are packaged and shipped with all Model heaters 1 165955 6 ft length of 3 8 LD Tubing 1 165952 90 Nylon Fitting 1 4 NPT x 3 8 tubing 1 110628 1 4 NPT Brass Nut 1 171527 1 4 Locknut Hex T amp B 139 165953 Sealing Washer 1 2 20913 Nylon Wire Ties T amp B TY 24M 1 87556 Snap Bushing Heyco SB 625 8 Instructions for Installing the Burner Condensate Drain Figure 14 1 Remove the burner compartment door 2 The burner box cover is in two sections On the left side of the burner box cover disconnect the flame sensor wire and the flame rollout switch wires Disconnect the sili cone tubing from the static tap Remove the left section of the burner box cover 3 Determine which side of the cabinet will be most conve nient for the drain line Remove the hole plug on that side and insert the snap bushing from the package 4 Locate the hole in the bottom center of the burner pan and remove the
61. stion However if the installation does not permit the burner to receive the proper supply of combustion air complete combustion may not occur The result is incomplete combustion which produces carbon monoxide a poisonous gas that can cause death Safe operation of indirect fired gas burning equipment requires a properly operating vent system which vents all flue products to the outside atmosphere FAILURE TO PROVIDE PROPER VENTING WILL RESULT IN A HEALTH HAZARD WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH If installed as a separated combustion unit install either the horizontal or vertical combustion air vent system illustrated in Paragraph 7A using the concentric adapter supplied Always comply with the combustion air requirements in the installation codes and instructions Combustion air at the burner should be regulated only by manufacturer provided equipment NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER CHECK THE VENT SYSTEM FOR SOUNDNESS AND FUNCTION MAINTAIN IT IN PROPER OPERATING CONDITION Mfg No 164771 Page 23 Thomas Betts Form 405 Page 24 2001 Thomas amp Betts Corporation All rights reserved Printed in the U S A MANUFACTURER OF HEATING COOLING AND VENTILATING SYSTEMS Trademark Note Reznor is registered in the United States and other countries 800 695 1901 www ReznorOnLine com 2 01 YL Form RZ 405 Version B
62. t Follow the installation instructions shipped with the cooling coil Installation Form RZ 405 CC the wiring diagram and the instructions provided by the compressor manufacturer a T E Heater Coil Cross Reference 1ze Nominal Cooling Capacity MBH 90 90 120 150 120 150 180 Table by Cabinet Size Refrigerant Type R22 Heater Model CAUA Thermal Expansion Valves 1 150 200 250 300 350 400 Approximate Weight 165 86 105 110 122 140 176 180 188 No of Intertwining Circuits 12 12 18 12 16 18 Face Area sq ft 17 13 15 38 17 13 Rows Fins Inch 2 12 3 10 3 12 2 12 3 10 3 10 Airflow cfm Low 1800 3000 4000 Nominal 2400 4000 5000 High 3000 5000 6000 are factory supplied Models with two TXV s have intertwined circuiting _ Airflow in excess of maximum values shown may result in blow off of condensation Figure 19 A Model ACU cooling coil installed on a Model heater and the line connection sizes Model Size Connections ACUA 060 072 1 7 8 Suction Line aan Model ACU 060 1 3 8 Liquid Line iquid Line Cased ans Connection s Cooling Coil 072 1 12 Liquid Line 090 2 7 8 Suction Lines 3 4 Drain Line Connection 090 2 3 8 Liquid Lines ACUB 090 120 150 2 7 8 Suction Lines Hole for Burner 090 120 2 3 8 Liquid Lines Model CAUA Condensate Drain 150 2 1 2 Liquid Lines Heater _ Tube use this hole ACUC 120 150 180
63. t below can be used for sizing line wiring but should not be interpreted as the exact motor amps See the motor rating plate for exact Form 405 Page 16 motor specifications At final adjustment amperes should not ex ceed motor nameplate amp rating The installation must be ad justed to obtain a temperature rise within the range specified on the heater rating plate gt epa 2 5 57 ES Optional Belt Drive Motors 208V 1 PH 2 1 3 2 5 1 63 7 5 83 10 0 230V IPH 2 3 28 4 4 5 5 65 75 102 208v 3 PH 11 1 4 3 0 2 9 3 7 5 6 7 0 9 0 13 4 230V 3PH 14 16 2 5 26 3 2 5 0 66 8 6 13 2 460V 0 75 0 8 1 0 1 3 16 27 35 43 6 6 575v 3PH J it 16 21 3 6 5 4 CAUTION An external duct system static pressure not within the limits shown on the rating plate or improper motor pulley or belt adjustment may overload the motor or cause the limit control to activate See Hazard Levels page 2 15 Gas Valve The main operating gas valve is powered by the 24 volt control circuit through the thermostat and safety controls The main control valve is of the diaphragm type providing regulated gas flow preset at the fac tory WARNING The operating valve is the prime safety shutoff All gas supply lines must be free of dirt or scale before connecting the unit to ensure positive cl
64. t d 18 Optional Filter Cabinet return air only A filter cabinet designed for 2 pleated disposable or permanent metal filters is shipped separately for field assembly and installation Depending on the option selected filters are either shipped with the cabinet or are field supplied To adapt to a variety of applications the heater cabinet is designed so that the filter cabinet can attach on either the right side the left side or the rear of the heater The larger filter cabinets left two tables below are uniquely designed so that the same cabinet can be field assembled and installed with either a horizontal or vertical air inlet The smaller filter cabinet in the table on the right is limited to Sizes 150 and 200 and is available with a horizontal inlet only All cabinets have door panels for easy filter removal for changing or cleaning All of the filter cabinets have a duct flange for attaching the inlet air duct For inlet duct dimensions see Paragraph 8 Follow the step by step instructions included with the filter cabinet package to assemble and attach it to the heater Figure 21 Filter Cabinets with Filter Arrangements and Filter Sizes Option CW4 with 2 Pleated Filters Option CW7 with 2 Pleated Filters Option CW8 with 2 Pleated Filters Option CWS with 2 Permanent Filters Option CW12 with 2 Permanent Filters Option CW9 with 2 Permanent Option CW6 for Field Supplied Filters Option CW11 for Field Supplied Filters Filters e Attac
65. t is normally used to pro tect concrete driveways can protect masonry materials If discoloration is an esthetic prob lem relocate the vent or install a vertical vent any building openin equipment Gas regulator Grade ground level Figure 9 Vertical Vent Terminals Single Wall Vent Run and Single Wall Terminal Vertical flue extension to be 6 152mm higher than anticipated snow depth but no less than 2 feet 610mm above the roof Vertical pipe extension Nut be insulated G 6 2M minimum Roof pitched from 0 to 45 Parapet or Adjoining Building Approved clearance thimble for single wall vent pipe is required when flue pipe extends through combustible materials Forced air inlet within 10 ft 3 1m Combustion air inlet of another applian Door window or gravity air inlet Electric meter gas meter and relief Adjoining building or parapet Adjacent public walkways heater manufacturer Option CC1 or a field supplied cap If the vent cap is field supplied use a Type L Breidert Air x hauster or equivalent vent cap Type L Air x hauster is a trademark of The G C Breidert Company Use of a vent cap supplied by the pipe manufacturer is not permitted the vent cap must be the type approved for use with this heater A different style vent cap could cause nuisance problems or unsafe conditions See the illustrations in Figures 9A and 9B for requirements of vertical and horizontal vent
66. termination The vent terminal pipe may be either single wall or double wall Type B If double wall pipe is used in the vent termi nal with a single wall vent run follow the instructions on page 10 to attach the vent cap and to connect the double wall pipe to the single wall vent pipe run Single Wall Vent Run and Double Wall Terminal Roof or Building Overhang minimum 127 305mm minimum 6 152mm minimum le 3 1M 272220272 6 2 minimum Parapet or Adjoining Building Note position of vent cap openings Approved clearance thimble for single wall vent pipe is required when flue pipe extends through combustible materials Follow the requirements of the double wall pipe manufacturer Pitch flue pipe down toward outlet 1 4 per foot for con densate drainage NOTE Applies to entire horizontal vent run Follow instructions on page 10 to join single and double wall pipe and to seal the connection Minimum Clearances for Vent Termination 3 ft 0 9m above 6 ft 1 8m 4 ft 1 2m horizontally 4 ft 1 2m below 1 ft 30cm above 4 ft 1 2m Do not terminate the vent horizontally directly above a gas meter or service regulator 6 ft 1 8m 7 ft 2 1m above 7 ft 2 1m above g Single Wall Vent Run and Double Wall Terminal Vertical flue extension to be 6 152mm higher than anticipated snow depth but no less than 2 feet 610mm above the
67. the heater 9 Set the thermostat to the desired setting NOTE If the appliance does not operate follow the instructions To Turn Off Gas to the Appliance printed below and on the Operating Label on the heater Call your service technician 10 Thermostat calls for heat energizing the venter motor 11 Venter pressure switch closes allowing the unit to fire 12 Burner flame is sensed and in 30 seconds the blower motor is energized 13 If the flame is extinguished during the main burner operation the integrated control system closes the main valve and must be reset by interrupting power to the control circuit See lighting instructions on the heater TO TURN OFF GAS TO THE APPLIANCE 1 Set thermostat to lowest setting 2 Ifservice is to be performed turn off all electric power to the appliance 3 Open the access door 4 Turn the gas control knob to OFF follow instruc tions in No 4 above Do not force control knob 5 Close the access door Check installation after start up 0 Vent System Testing Procedure Power Vent Units does not apply to separated combustion installation Seal any unused openings in the venting system NS Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI 2223 1 or CAN CGA B149 1 and B 149 2 Installation Code for Gas Burning Appliances and Equipment and this manual Determine that there is no blockage or restri
68. ting and high speed for cooling if ordered Belt drive motors are factory set between maxi mum and minimum blower speeds If the duct resistance is low the blower may deliver too high an air volume If the resistance is very low the blower may deliver excess air to overload the motor causing the overload protector to activate Re ducing the blower speed will correct these conditions If ductwork is added to an installation it may be necessary to increase the blower speed Direct drive motors have multi speed taps for speed adjustment If your installation requires an adjustment of the blower speed the motor may be re wired to an alternate tap by following these instructions 1 Turn off the gas and electric power 2 Remove the blower door panel 3 Consult the wiring diagram on the heater and follow the chart below to choose the wiring for the desired adjustment Units are wired at high speed for cooling if ordered and medium speed for heating Model Sizes 150 200 250 350 Speed Use these two motor wires High White and Black Medium White and Blue Low White and Red 300 and 400 High White and Black foe Medium White and Blue 4 Cut the crimped cap for the end of the wire that you intend to use and strip the insulation 5 Disconnect the factory wired connection and re wire using the newly stripped wire 6 Put a wire nut on the end of the blower motor wire that was discon nected 7 Replace the heater door pa
69. tion air pipe See Length of Pipe Collar for combustion air pipe Concentric Adapter Box Field supplied mounting brackets 24 inimum a 406mm m 2 51mm approx plus wall thickenss Vent Pipe when a taper type reducer is required in the vent pipe the connection must be no more than 6 152mm from the box Install rubber seal in vent pipe opening Figure 5A On all Sizes except 250 no more than 6 152mm of vent pipe should extend out the heater side Any time the pipe is re positioned re check the seal to be sure that it has not rolled Adjust the pipe and seal until the pipe is the correct length on each side of the box and the seal is over the edge of the hole and tight to the entire circumference of the pipe 3c Attach the outside portion of the combustion air pipe to the box Determine the length by measuring the bracket length if brackets are used plus the wall thickness plus 2 51 mm The inlet pipe should extend beyond the outside wall approximately 2 51mm Attach the inlet air pipe to the collar of the concentric adapter with sheetmetal screws being careful not to penetrate the vent pipe 4 Attach the concentric adapter box to the wall Insert the vent pipe and combustion air pipe through the wall the inlet air pipe Push the concentric adapter box flush against the inside on the outside wall or attach to the wall with the field supplied brackets wall Caulk or flash
70. with a cooling coil and includes blockoff plates to provide higher veloc ity required for cooling A discharge plenum adds 49 15 16 1268mm to the height of the heater If installing Option CD62 this height includes the cooling coil Option Configuration GA1 Top Outside Air Opening with Dampers Rear or Bottom Return Air Opening without Dampers GA2 Rear Outside Air Opening with Dampers Top or Bottom Return Air Opening without Dampers GA3 Bottom Outside Air Opening with Dampers Top or Rear Return Air Opening without Dampers GA4 Bottom Outside Air Opening with Dampers Rear Return Air Opening with Dampers GAS Bottom Outside Air Opening with Dampers Top Return Air Opening with Dampers GA6 Rear Outside Air Opening with Dampers Top Return Air Opening with Dampers 7 Rear Outside Air Opening with Dampers Bottom Return Air Opening with Dampers GA8 Top Outside Air Opening with Dampers Rear Return Air Opening with Dampers GA9 Top Outside Air Opening with Dampers Bottom Return Air Opening with Dampers Figure 23 Dimensions of Optional Mixing Box inches mm 150 200 250 400 38 965 50 1270 22 3 4 578 36 1 2 927 7 5 8 194 6 3 4 171 Note Damper frame fits in the inlet opening Side View Removable filter access door 1 8 664 24 26 4 Airflow 30 1 8 765 21 Inlet Base Sizes 350 and 400 only The optional mounting base is designed to support a Model CAUA 350 or 400 he

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