Atwood Mobile Products HYDRO FLAME 2540 User's Manual
Contents
1. 28 Fil haute tension Motor Combustion Wall 32 Rupteur thermique Control Board Mounting Bracket 35 Joint d tanch it du moteur2. Ground National Electrical Code ANSI NFPA No 70 and or CSA C22 1 Park Trailers ANSI A119 5 NOTE The direct high voltage spark ignition generates a radio frequency that could cause interference with other microprocessor based equipment Locate equipment at least five feet 5 from furnace location If this distance cannot be maintained purchase KIT MPD 37773 a shielded high voltage lead A WARNING CARBON MONOXIDE POISONING Properly seal vent assembly to prevent carbon monoxide from entering coach DO NOT draw combustion air from living area DO noT vent exhaust air into the living area or an enclosed porch Return air is supplied through openings in furnace casing All return air passages must be kept clear for furnace to function properly Refer tO MINIMUM CLEARANCE TO FLOORBOARDS WALLS amp SIMILAR COMBUSTIBLE BUILDING MATERIAL The total unobstructed return air opening size s must NOT BE LESS than specified in SPECIFICATIONS MINIMUM RETURN AIR Failure to meet minimum return air requirements nullifies furnace warranty STANDARD FURNACE INSTALLATION General Installation LOCATION e Install furnace through an exterior wall e DO NOT install furnace near tilt out rooms slide outs doors or other projections that could obstruct furnace exhaust e Locate furnace near midpoint of coach for single furnace applications e DO NOT install vent in areas where projections or door openings are within 6 of vent tube o
3. 1120 North Main Street Elkhart IN 46514 PHONE 574 264 2131 FAX 574 206 9713 INTERNET http www atwoodmobile com ENGLISH FRANCAIS et Canada THIS INSTRUCTION MANUAL IS FOR USE BY AN AUTHORIZED SERVICE TECHNICIAN TO INSTALL AN ATWOOD hydro flame FURNACE INSTALLER LEAVE THIS MANUAL WITH APPLIANCE CONSUMER RETAIN THIS MANUAL FOR FURTHER REF ERENCE This furnace design has been certified for installation in recre ation vehicles as a MSP Category Ill furnace Follow this installation instruction to insure safe operation of the furnace Failure to install furnace according to this installation instruc tion nullifies the furnace warranty SAFETY ALERT SYMBOLS Safety Symbols alerting you to potential personal safety hazards Obey all safety messages following these symbols A CAUTION avoid possible injury and or property damage A WARNING avoid possible injury or death WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Evacuate all persons from vehicle e Shut off gas supply at gas container or source e Do not touch any electrical switch or use any phone or radio in vehicle e Do not start vehicle s engine or electric generator e Contact nea
4. GUN iissa ariani ingagia a a ii 3 Floor DUCtNG acnee anne a a DA dA 00 C 4 dO 0 DES 3 OPTIONAL INSTALLATION BOTTOM DISCHARGE KIT s sssssseeeeeeeeeeeeeeeeeees 3 PROPANE GAS CONNECTION 3 ELECTRICAL CONNECTIONS 3 Conductor Sizing Table 2 2 2260464 0004064026200400 004 264004 6 64 004 84 EH aiiin 3 Thermostat Installations 200520 200 00004000 iiaa 3 4 SYSTEM CHECK TESTS issue nes d 600204 8000 00 C 00 004 G0 00 RA 09 NOCA 00 RA MR 2 nos 4 DIAGNOSTIC CHART eee ee tenes 4 PROPANE GAS PRESSURE 4 STATIC PRESSURE 222322 6062406000 00520600 404 20 0005040 US d RAE LA CADES a 4 WIRING DIAGRAM orici 2604640 0253000 niina 0429 finca sanada a densos die Rebana 4 ILLUSTRATIONS ces 0640204 usant duo da dns DUE MD a a eiat 5 REPLACEMENT PARTS LIST amp DRAWING 6 SPECIFICATIONS W C Water Column MODEL 2540 HIGH BTU Input 40 000 Duct Static Pressure 4 3 12 Volt Amperage AMPS Watts Power Supply VOLT Dc Recommended Return Air MINIMUM RETURN AIR DIMENSIONS WEIGHT FURNACE 39 Ibs SHIPPING 46 Ibs ALL MODEL WIDTH HEIGHT Casing 16 1 2 9 1 8 Door 19 1 47 9 1 4 Recess Bezel 20 9 16 11 1 27 VENT 5 5 3 8
5. MINIMUM CLEARANCE TO FLOORBOARDS WALLS amp SIMILAR COMBUSTIBLE BUILDING MATERIALS MUST BE PROVIDED THE FULL LENGTH AND WIDTH OF UNIT TOP 1 2 Bottom 3 16 SIDES 1 REAR 1 2 TOP 1 2 BOTTOM 0 SIDES 1 REAR 1 2 HORIZONTAL VERTICAL Spacing of 1 4 to ducting within 3 feet of furnace must be provided unless UL listed wire bound vinyl ducts are used All ducting material should be rated for continuous use at 200 F NOTE Clearances are specifically for plywood or similar building materi als surrounding the furnace i e furnace should not be located under furniture or in a closet space where clothing or other mate rial could be located NOTE Furnace efficiency rating is a thermal rating determined under continuous operating conditions independent of any installation Efficiency rate is given at 77 minimum actual efficiency rating may be higher A WARNING CARBON MONOXIDE POISONING Furnace must be installed and vented to these instructions Improper installation adjustment alteration service or mainte nance can cause injury or property damage Improper installation location may cause furnace to produce neg ative pressure affecting combustion air or venting of other appli ances A CRITICAL INSTALLATION WARNINGS DO NOT install furnace on material that restricts return air such as carpeting or any soft material i e vinyl DO NOT install furnace where clearance to combus
6. er Access Cover specify Interrupteur a abattant ON OFF Switch Circit Breaker 56 Extended Manifold El ment de chauffage Valve Coil Replacement DC 57 Vent Ring Combustion Wheel Dual Thermostat Valve Vent Assembly 58 Gas Line Gasket Joint entre le syst me d vacuation et la paroi N SUR LE SCHEMA 7 DESCRIPTION Ventilateur Arri re du bo tier du ventilateur Bo tier du ventilateur Paroi moteur ventilateur d air de combustion Electronic Ignition Board 6 Br leur Support de fixation du tableau de commande Duct Adapters Duct Cover Plate 8 Interrupteur MARCHE ARRET Coupe circuit Panneau de commande de vitesse du moteur Electrode 9 Echange du serpentin de la vanne CC Plaque adaptatrice Adapter Plate Assembly 10 Ventilateur d air de combustion Burner Access Cover sp cifier High Tension Lead 15 Double thermostat Distributeur Limit Switch 17 Soupape Anneau Motor Gasket 19 Assemblage de ventilation Joint d tanch it du tuyau gaz Motor 20 Panneau d allumage lectronique Orifice 49 22 Adaptateurs de conduit Sail Switch Element Assembly 23 Couvercle d ouverture de branchement de conduit Exhaust Wall Gasket 24 Electrode Blower Housing Back 26 Plaque adapatatrice de flexibles Blower Housing
7. ion STATIC PRESSURE TEST CASING STATIC PRESSURE TABLE If duct static pressure cannot be set casing static pressure should not exceed the values listed below when taken cold HARD 0 35 W C DUCTING SYSTEM OPERATING VOLTS DC MODELS 12 FLEXIBLE 0 25 W C Voltage greater than indicated will cause higher static readings Reducing the number of duct turns and stretching ducts will increase air flow and reduce static pressure Adding ducts or increasing dis charge system hard ducting will also reduce static pressure NOTE Special tool required to take casing static pressures Location for Static Pressure Tap for casing is on the back of casing top left corner Fig 3 ELECTRODE CHASSIS GROUND RED ELECTRONIC DIGITAL THERMOSTAT 7 1 RED E T BLACK pie YELLOW RED DUAL CONTROL uu 654321 E 000000 12 VDC TI RED E WHITE THERMO BLACK ORANGE 2 2 BLUE BLUE 313 YELLOW x 12 VDC z la YELLOW BROWN 2 THERMO z 15 GREEN SAIL 6 le SWITCH LIMIT BULK HEAD SWITCH CONNECTOR IMPORTANT If any original wire has to be replaced it must be replaced with type 105 C or it s equivalent VALVE CUSTOMER SUPPLIED WIRE 4 hydro flame 8900 III LD 2 Stage Series Furnace Model 2540 DRAWING DESCRIPTION Blower Wheel Moteur 54 p Adapter Plate Orifice 49 Burner Assembly 55 Burn
8. ntake tube Secure to wall with four 4 screws 7 Vent assembly must have a minimum of 1 1 4 overlap on exhaust and 1 2 minimum on combustion air 8 Horizontal units secure to floor with two 2 screws through legs on back of casing Vertical units use vertical mounting brackets and self tapping screws to hold furnace to floor tabs on control box can be used also to secure furnace q DUCTING Horizontal amp VERTICAL FIG 2 3A HORIZONTAL PROPER DUCT INSTALLATION IS CRITICAL TO THE OPERATION OF THIS FURNACE CONTINUOUS USE MATERIALS RATING DUCTS 9 IN LENGTH OR MORE 200 F 4 DUCTS LESS THAN 9 IN LENGTH 250 F METAL BOOTS LESS THAN 9 IN LENGTH 250 F Ducting systems can include any combination of discharge openings as long as static pressure and minimum discharge area requirements are met ALL MODELS also see STATIC PRESSURE TEST REQUIRED MINIMUM DISCHARGE 48 in REQUIRED MINIMUM RETURN AIR 80 in e See MINIMUM CLEARANCE TO FLOORBOARDS WALLS amp SIMILAR COMBUSTIBLE BUILDING MATERIALS e Each 4 inch duct opening provides 12 in of discharge area Provide an extra 12 in of non closeable duct discharge area for each closeable register used e Use of 2 ducts does not count toward achieving minimum discharge requirements Ducting in dead air space with no return air such as holding tank areas does not count toward achieving minimum dis charge requirements e Adjust ducting installation t
9. o obtain air rise of 100 F 130 F Flexible Ducting Systems When designing Flexible Duct Systems avoid sharp bends or crushed ducts stretch all ducts and run them directly to outlets keeping quanti ty and angles of bends to a minimum 1 Remove knockout plates from desired outlets 2 Attach a duct adapter to each opening by inserting flange over cas ing locking the tab into casing slot and turning adapter 90 3 Attach and secure FOUR INCH flexible ducts to adapters 4 Run ducts to desired location within RV secure to registers 5 Additional ducting may be needed to maintain correct static pressure Floor Hard Ducting Systems When designing Hard Ducting Systems undersize ducting will cause high temperature limiting oversize ducting will cause inadequate air flow from registers when hard ducting is 1 1 2 in depth an additional flex duct may be needed to maintain installation static requirements DO NOT install floor registers within 2 feet of return air openings OPTIONAL INSTALLATION BOTTOM DISCHARGE FIG 4 1 Remove bottom discharge cover plate This ducting option must be connected to a ducting system ria 3 parts breakdown 40 GASKET AND PLENUM PLATE KIT is available when attaching furnace 2 If cutout is required FLOOR CUTOUT BOTTOM DISCHARGE A B C D HORIZONTAL WITHOUT DOOR ric 4 18 20 1 2 5 1 2 10 1 2 3 47 3 Fasten plenum plate 3 E over floor cutout If a gasket and plenum
10. ole in base plate Attach thermostat sub base to the wall at the desired mounting location Mount the sub base to the wall before connecting the wires See instruction provided with thermostat SYSTEM CHECKS FIRE OR EXPLOSION Never check for leaks with an open flame DIAGNOSTIC CHART A diagnostic LED is located inside the exterior access cover on the out side edge of the horizontal 2 stage control board The following graph defines the codes Low Input voltage Ignition Failure Open High Limit Stuck Sail Switch Module Fault 2 STAGE MODEL 2540 NOTE A sort lockout is a condition that is timed and will make addition al attempts to correct the problem A HARD lockout requires reset of the thermostat or turning the power switch off then back on PROPANE GAS PRESSURE TEST The furnace and any individual shut off valve must be disconnected from gas supply piping system during any pressure testing of system at test pressures of more than 1 2 PSI Before furnace is connected piping systems must be tested to be leak free The test must maintain air pressure of at least 6 of mercury or 3 PSI for at least 10 minutes The entire piping system must be maintained within a range of 10 14 W C when all appliances are in operation Test gas connections for leakage with a leak test solut
11. pening e DO NOT install furnace in an area where wires pipes or other objects will interfere with installation or operation of furnace e It is not recommended to install furnace on material that restricts return air such as carpeting or soft material such as vinyl e DO NOT directly install furnace on carpeting or soft material install furnace on cleats or on a wood or metal panel extending the full width and depth of furnace plus minimum clearances to combustibles DO NOT use petroleum or citrus type cleaners on plastic parts as damage may occur e The furnace must always be installed level front to back side to side to prevent water intrusion into the interior WALL CUTOUT OPTIONS orizontar amp VERTICAL RECOMMENDED WALL THICKNESS 0 to 2 1 2 DO NOT OVERSIZE HOLE OVERSIZING CAN RESULT IN WATER LEAKAGE EXTERIOR WALL CUTOUT FIG 1 1A A B C HORIZONTAL amp VERTICAL 3 1 8 2 3 8 3 1 2 dia hole VENT INSTALLATION Horizontal amp VERTICAL INSTALLATION FIG 1 1A 1 Locate vent hole cutout as called out in FIG 1 1A 2 Drill 3 1 2 diameter hole through side wall of coach 3 Remove vent and vent ring from furnace 4 Insert furnace from backside of wall Line up hole in wall with hole for vent to furnace Apply sealant to back of vent ring and vent cap base 6 Install vent assembly with HOT at top for horizontal and on right side for vertical installation Fig 1 1A Slip into combustion air i
12. plate are not used seal furnace to hard duct system mak ing sure seal is air tight and continue with STEP 5 4 Position gasket 3 F on plenum plate 5 Set furnace on gasket make sure gasket remains in position 6 Additional ducting can be used to maintain correct static pressure VERTICAL There is only one ducting option when using vertical installation Option 1 has already been illustrated the other configuration is using top two ducts and two ducts off the back of the casing This is the only configuration allowed with vertical installation Fic 3A PROPANE GAS CONNECTION ric 2 1 Connect gas line to fitting on top rear of furnace Be sure all male pipe threads other than flare fittings are treated with a sealing com pound resistant to the action of propane LP gas DO NoT put sealing compound on flare fittings 2 A 3 8 flared fitting connection is provided at gas control valve inlet for gas supply connection to furnace The gas supply line of the fur nace must be of adequate size to provide 11 W C gas pressure This pressure must be maintained under maximum flow conditions with all gas appliances in operation 3 Use two wrenches to hold fitting and flare nut when tightening gas line to fitting DO NOT twist fittings FIG 2 ELECTRICAL CONNECTION A WARNING INJURY OR PROPERTY DAMAGE Label all wires before disconnecting for servicing Wiring errors can cause improper and dangerous operation Verify p
13. rest gas supplier or qualified Service Technician for repairs e If you cannot reach a gas supplier or qualified Service Technician contact the nearest fire department e Do not turn on gas supply until gas leak s has been repaired Installation and service must be performed by a qualified Service Technician Service Center or gas supplier LITERATURE NUMBER MPD 31230 hydro flame 8900 III LD 2 Stage Series Furnace MODEL 2540 Technical Installation Manual Patent No US 6 464 000 6 719 207 Other Patents Pending installation Effective 1 08 INDEX FURNACE SPECIFICATIONS 1 DIMENSIONS 2322222200002430 40 64 0 505 24 00600 460 ASSO AGA M0 A0 4 8 1 WEIGHT 2220223660332340 04000 202063202 welch sins dasean vob vests ATOA YED RR A8 0 G 1 MINIMUM CLEARANCE TO FLOORBOARDS WALLS amp SIMILAR COMBUSTIBLE BUILDING MATERIALS 1 2 SAFETY INFORMATION rem 1 2 FURNACE INSTALLATION cccsceccecsceccseacecescasaseneeseneneaseneneeseens 2 WALL CUTOUT OPTIONS HORIZONTAL amp VERTICAL ccccccccceescseseeeesseeeeseeeeees 2 VENT INSTALLATION MODELS WITHOUT DOOR HORIZONTAL amp VERTICAL 2 DUCTING HORIZONTAL amp VERTICAL 2222466246264644 60 6060 600004004 600 06 04 0 0 60 C C iia 2 3 Required Minimum Discharge Chart sceceeeeeeeaeeeeeeeaeeaeees 3 Flexible DU
14. roper oper ation after servicing Disconnect electrical power before servicing Conductor Sizing Table max 10 VOLTAGE DROP 12 VDC CURRENT DRAW AMPS 3 4 5 6 7 8 9 10 15 16 GAGE MAX LENGTH OF SAE CONDUCTOR IN FEET FROM SOURCE TO DEVICE 18 57 43 34 29 25 21 19 17 11 16 87 6 52 43 37 33 29 26 17 14 52 46 41 28 21 A CAUTION PROPERTY DAMAGE This connection is for low voltage battery or direct current only Do not connect to 120 or 240 volts AC This furnace is designed for negative ground 12 volts DC only DO not attempt to alter furnace for a positive ground system or connect the furnace directly to 120 volts AC Damage to furnace components will occur and warranty will be voided Use a minimum of 14 GA wire to minimize voltage drop Furnace must be installed so electrical components are protected from water To make electrical connections see wiring diagram FIG 4 1 Route wiring to left side of furnace 2 Connect red wire to positive side of power supply 3 Connect yellow wire to grounded side of power supply 4 Connect blue wire to thermostat using 22 18 GA stranded wire 5 Connect the green wire to the green thermostat lead using mini mum 22 18 GA stranded wire See instruction with thermostat for complete wiring directions For best furnace performance when power supply is from a converter equipped with a charging port wire converter to furnace parallel with battery This provides consistent
15. tibles cannot be maintained DO NOT modify furnace in any way Installation must provide accessibility if any repairs are necessary to the furnace Failure to meet this requirement will create additional labor costs that will be the responsibility of the installer DO NOT alter furnace for a positive grounding system DO NOT HI POT furnace unless electronic ignition system circuit board has been disconnected DO NOT use battery charger to supply power to DC model furnace hen testing r use 120 volt AC current with DC models T use furnace cabinet area as a storage compartment T vent furnace with venting system serving another appliance T vent furnace to an outside enclosed porch area T use for temporary heating of buildings or structures under construction Protect building materials from degrading from flue gas exhaust Protect furnace electrical components from water USA AND CANADA FOLLOW ALL APPLICABLE STATE AND LOCAL CODES IN THE ABSENCE OF LOCAL CODES OR REGULATIONS REFER TO CURRENT STANDARDS OF Recreation Vehicles ANSI A119 2 NFPA 501C National Fuel Gas Code ANSI 2223 1 and or CAN CGA B149 Installation Codes Federal Mobile Home Construction amp Safety Standard Title 24 CFR part 3280 or when this Standard is not applicable the Standard for Manufactured Home Installations Manufactured Home Sites Communities and Set Ups ANSI A255 1 and or CAN CSA Z240 MH Series Mobile Homes
16. voltage to furnace increasing compo nent life filtering power surges and AC spikes Each unit ships with a standard field harness connection with 12 wire leads NOTE All units are supplied with a power switch which when turned off for servicing will remove power through furnace wiring Switch must be in ON position for furnace to operate FIG 2 G POWER SUPPLY Atwood Mobile Products highly recommends the use of an electronic solid state converter with clean clear power output This will assure the life of the electronic controls and motor life could be extended as much as 500 beyond typical linear converter applications THERMOSTAT INSTALLATION MODEL 2H2C FURNACE MODEL 2540 MUST USE THIS THERMOSTAT The thermostat is very sensitive HANDLE WITH CARE AT ALL TIMES Locate thermostat 48 to 54 above floor on an INTERIOR wall Pick a dry area where air circulation is good EXTERIOR wall location must have a 3 4 spacer between thermostat and exterior wall 1 Be sure all electrical power has been disconnected from the air con ditioner furnace and the power supply 2 Do not install the thermostat where there are unusual heating condi tions such as direct sunlight heat producing appliances television radio wall lamp etc or a furnace or air conditioner supply register 3 ATTACHING THE WALL THERMOSTAT Separate the thermostat body from the sub base by gently squeezing the top and bottom Pull wires through access h
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