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HomeMy WebLinkAboutPermit 0605-M - BANKS RESIDENCE;, sr ;, EAkW\s, io\IRA : :::::::::::::::::::::::::.:::::.ii:: , iii:.: . 1:::::::'::::::ii:::::::::::::::;;::::::1:::::ii , :::::::::::::.!:::::::::a; :i:::::: : :: :.:::::::::::;:::::::::::::.:::%:::::::;:::•:f:.:. ::: , :::::_ c opg.: B r on Banks IPHONE: UMC EDITION (YEAR: FIRE PROTECTION: Sprinklers Detectors (3)N/AH ONDITIONS (other than noted on or attached to permit/plans): 5990 South 149th Street, Tukwila, WA ZIP: 98168 APPROVED FOR . BUILDING ISSUANCE BY: Ai 7A---- OFFICIAL DATE: /6 -,2 - 823 I hereby certify that I have read and examined this permit and know the same to be true and correct. All provisions of law and ordinances governing this work will be complied with, whether' specified herein or not. The granting of this permit does not presume to give authority to violate or cancel the provisions of any other state or local laws regulating construction or the performance of work. I am authorized to sign for and obtain this mechanical permit. ;\ ,... ADDRESS: DATE: /0 . '- SIGNATURE: -----, PRINT NAME: .\ce0--I1 M. (7uz.--, COMPANY: G111/0/4' PROPERTY OWNER: B r on Banks IPHONE: 246-9107 ADDRESS: 5990 South 149th Street, Tukwila, WA ZIP: 98168 CONTRACTOR: Sunl ok Inc. IPHONE: 823 ADDRESS: 11630 Slater Avenue S . E . , Kirkland, WA ZIP: 98034 WA. ST. CONTRACTOR'S LICENSE NO. SUNLOI*107.16 EXPIRATION DATE: 4-26-92 CITY OF OF TUKWILA Department of Community Development - Building Division 6300 Southcenter Boulevard, Tukwila WA 98188 (206) 431-3670 MECHANICAL PERMIT NO. DATE ISSUED: OCIxYpnc) 10 .5 - RI SITE ADDRESS: 5990 S 149 St PROJECT NAME/TENANT: Banks, Byron TYPE OF WORK: New/Addition (x) Modifications (1 Repair DESCRIPTION OF WORK: hilECHANnAL PERMIT (POST WITH PLANS IN A CONSPICUOUS LOCATION) ... ..:',..::.::AMOUNT. 4RECEIPT:1# . 0:::::::DATE:::: , :: BaStc].Perfnit.:fe,e'7 i ....fatE tioit:Fo•: :• Ptan12bt<;:Fee:::•:L764': TO.T...AL1-:::';' Plan Check No.: 91-162 -M SUITE NO. VALUE OF WORK: () Other: . ........................................................................................ PROJECT INFORMATI Electric to gas conversion (furnace and hot water heater). 3,009.00 INSPF 0 ECOR (Cal Or ori4i1 iie: fiande DATE DATE(S) APPROVED INSPECTOR CORRECTION NOTICE ISSUED REQUIRED INSPECTIONS PHONE NO. 1 - Rough-in/Vents/Ducts 431-3670 2 - Fire Final 575-4407 3 - Planning Final 4 - 5 - Mechanical Final 431-3680 431-3670 OTHER AGENCIES: Plumbing/Gas Piping - King County Health Department (296-4732) Electrical - Washington State Department of Labor and Industries (277 This permit shall become null and void if the work is not commenced within 180 days from the date o . . issuance, or if the work is suspended or abandoned for a period of 180 days from the last inspection. . PERMIT NO. CONTACTED 0- DATE READY DATE NOTIFIED 10-Q-91 BY: ..(? PERMIT EXPIRES 2nd NOTIFICATION BY: (init.) AMOUNT OWING v . 3RD NOTIFICATION BY: (init.) PLAN CHECK NUMBER .::,.::..:..::. PAR.TMENT DA7f*:,IN BUILDING - initial review FIRE O PLANNING O OTHER g BUILDING - final rAviAw k REVIEW COMPLETED PROJECT NAME SITE ADDRESS INSTRUCTIONS TO STAFF • Contacts with applicants or requests for information should be summarized in writing by staff so that any time the status of the project may be ascertained. • Plan corrections shall be completed and approved prior to sending on to the next department. • Any conditions or requirements for the permit shall be noted on the plans or summarized concisely in the form of a formal letter or memo, which will be attached to the permit. • Please fill out your section of the tracking chart completely. Where information requested is not applicable, so note by using "N /A ". DEPARTMENTAL REVIEW "X" in box.Indicates which departments need to review the project. 1 t PP I ° I/4 O ED) INIT: INIT: INIT: MECHANICAL PERMIT APPLICATION TRACKING FIRE PROTECTION: FIRE DEPT. LETTER DATED: ZONING: REFERENCE FILE NOS.: UMC EDITION (year): UIREME SUITE NO. CONSULTANT: Date Sent - Date Approved ( Sprinklers SCREENING REQUIRED? fYes (l No FT Detectors INSPECTOR: ( ) N/A IBAR/LAND USE CONDITIONS? ( )Yes No 08/17 /90 PROPERTY OWNER 1 fon l3aan V5 AMOUNT .;': IPHONE PHONEfa Cl 1 or7 ZIPq ( 7 5 ADDRESS 5ggD � ^ I c`- CONTRACTOR . a Iv 1 in ADDRESS \ \ l.l) :20 S1 ci-wiL J . ' bfk.k.LLL11 1Z IPLt WA. ST. CONTRACTOR'S LICENSE # �N) L I i D� PLAN :CHECK FEE EXP. DATE / )26) q '::DESCRIPTION AMOUNT .;': RCPT #: . ::::::DATE:::: , ::::::' BASIC: PERMIT FEE . $ 15 . 00 UNITS) FEE PLAN :CHECK FEE . (0. OTHER >TOTAL •. . f CITY OF TUKWILA Department of Community Development - Building Division 6300 Southcenter Boulevard, Tukwila WA 98188 (206) 431 -3670 PLAN CHECK NUMBER APPLICATION MUST BE FILLED OUT COMPLETELY SITE ADDRESS 50 6 iij sr PROJE NAME/TENA TYPE OF RK: 0 New /Addition 5;0 ru t ai . t= unlace &.( Standard 1---N T • BUILDING USE (office, warehouse, etc.) NATURE OF BUSINESS: `: HEREBY: C;E :��N C O 7"RUI»,A R BUILDING OWNER OR AUTHORIZED AGENT CONTACT PERSON WILL THERE BE A CHANGE IN USE? PRINT NAME ADDRESS `1 DATE APPLICATION ACCEPTED SUITE # MECHANICAL PERMIT APPLICATION Modifications 0 Repair 0 Other: DESCRIBE WORK TO BE DONE: CC �:S C VCr No 0 Yes IF YES, EXPLAIN: LA1 . n n e) C r-o LP31) eLL)(i3O. Mechanical Fee Worksheet must also be filled out and attached to this : • •!!cation. VALUE titF CONSTRUCTION - $ 3C)C . as WILL THERE 18,kSTORAGE OR USE OF FLAMMABLE, COMBUSTIBLE OR HAZARDOUS MATERIALS IN THE BUILDING? No 0 Yes IF YES, EXPLAIN: CITY /ZI utQ uc( Q X34{ PHONEg3.4/4s l E <<READ<AND.: EXAMINED:<THIS A >PLICAT ON'sAND::KNO:W.. <THE:SAME<` :.::..: .:.:.:..:::.:..:. . AUTHORIZED<TOAPPLY :PERMIT DATE APPLICA3iON EXPIRES FEES (for staff use only) NU DATE ( q PHONE -z3 . 44 4 /S 4 1 APPLICATION SUBMITTAL In order to ensure that your application is accepted for plan review, please make sure to fill out the application completely and follow the plan submittal checklist on the reverse side of this form. A completed "Mechanical Permit Fee Worksheet" must accompany this permit application. Handouts are available at the Building counter which provide more detailed information on application and plan submittal requirements. Application and plans must be complete in order to be accepted for plan review. BUILDING OWNER / AUTHORIZED AGENT If the applicant is other than the owner, registered architect/engineer, or contractor licensed by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the permit will be required as part of this submittal. VALUATION OF CONSTRUCTION The valuation is for the work covered by this permit and must be filled in by the applicant. This figure is used for budget reporting purposes only and not to calculate your fees. EXPIRATION OF PLAN REVIEW Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The Building Official may extend the time for action by the applicant for a period not exceeding 180 days upon written request by the applicant as defined in Section 304(d) of the Uniform Mechanical Code (current edition). No application shall be extended more than once. If you have any questions about our process or plan submittal requirements, please contact the Department of Community Development at 431 -3670. 06/18/00 DESCRIPTION UNIT COST NO OF UNITS X TOTAL COST BASIC FEE $15.00 $4.50 SUPPLEMENT PERMIT FEE 1 Installation or relocation of each forced -air gravity -type furnace or burner, including ducts and vents attached to such appliance, up to and including 100,000 Btu /h. $9.00 i 1 x c I , ti_i _,0 2 Installation or relocation of each forced -air or gravity -type furnace or burner, including ducts and vents attached to such appliance over 100,000 Btu /h. $11.00 X 3 Installation or relocation of each floor furnace, including vent. $9.00 x 4 Installation or relocation of each suspended heater, recessed wall heater or floor- mounted unit heater. $9.00 X 5 Installation, relocation or replacement of each appliance vent installed and not included in an appliance permit. $4.50 x 6 Repair of, alteration of, or addition to each heating appliance, refrigeration unit, cooling unit, absorption unit, or each heating, cooling, absorption, or evaporative cooling system, including installation of controls regulated by this code. $9.00 X 7 Installation or relocation of each boiler or compressor to and including three horsepower, or each absorption system to and including 100,000 Btu /h. $9 X 8 Installation or relocation of each boiler or compressor over three horsepower to and including 15 horsepower, or each absorption system over 100,000 Btu /h and including 500,000 Btu /h. $16.50 X 9 Installation or relocation of each boiler or compressor over 15 horsepower to and including 30 horsepower, or each absorption system over 500,000 Btu /h to and including 1,750,000 Btu /h. $22.50 X 10 Installation or relocation of each boiler or. compressor over 30 horsepower to and including 50 horsepower, or for each absorption system over 1,000,000 Btu /h to and including 1,750,000 Btu /h. $33.50 x 11 Installation or relocation of each boiler or refrigeration compressor over 50 horsepower, or each absorption system over 1,750,000 Btu /h. $56.00 X 12 Each air - handling unit to and including 10,000 cubic feet per minute, including ducts attached thereto. (NOTE: This fee shall not apply to an air - handling unit which is a portion of a factory - assembled appliance, cooling unit, evaporative cooler or absorption unit for which a permit is required elsewhere in this code.) $6.50 X 13 Each air - handling unit over 10,000 cfm. $11.00 X 14 Each evaporative cooler other than a portable type. $6.50 X 15 Each ventilation fan connected to a single duct. $4.50 X 16 Each ventilation system which is not a portion of any heating or air- conditioning system authorized by a permit. $6.50 X 17 Installation of each hood which is served by mechanical exhaust, Including the ducts for such hood. $6.50 X 18 Installation or relocation of each commercial or industrial -type incinerator. $11,00 X 19 Installation or relocation of each commercial or industrial -type incinerator. $45.00 x 20 I Each appliance or piece of equipment regulated by the code but not classed in other appliance categories, or for which no other fee is listed in this code. $6.50 I X I 08/19!00 SUBTOTAL 30 • 53 PLAN CHECK FEE (25% of subtotal) "] . ( GRAND TOTAL $ �3% I CITY OF TUKWILA Department of Community Development - Building Division 6300 Southcenter Boulevard, Tukwila WA 98188 (206) 431 -3670 THIS WORKSHEET MUST ACCOMPANY YOUR MECHANICAL PERMIT APPLICATION. MECHANIC:.._ PERMIT FEE WORKSHEET INSTRUCTIONS - Complete the worksheet, indicatin the number of units being installed iR each category, At time of ubmittal, 'staff will calculate the fees, CITY OF TUKWILA 6200 SOUTHCENTER BOULEVARD, TUKWILA, WASHINGTON 98188 PHONE # (206) 433.1800 Gary I,. VanDuscu, Mayor Plan Check #91- 162 -Me Banks, Byron 5990 S 149 St THE FOLLOWING COMMENTS APPLY TO AND BECOME PAR OF THE APPROVED PLANS UNDER TUKWILA MECHANICAL PERMIT NUMBER 1. No changes will be made to the plans unless approved by the Architect and the Tukwila Building Division. 2. Plumbing permit shall be obtained through the King County Health Department and plumbing will be inspected by that agency, including all gas piping (296 - 4732). 3. Electrical permit shall be obtained through the Washington State Division of Labor and Industries and all electrical work will be inspected by that agency (872- 6363). 4. All permits, inspection records, and approved plans shall be posted at the job site prior to the start of any construction. 5. Any exposed insulations backing material to have Flame Spread Rating of 25 or less, and material shall bear identification showing the fire performance rating thereof. 6. All construction to be done in conformance with approved plans and requirements of the Uniform Building Code (1988 Edition), Uniform Mechanical Code (1988 Edition), Washington State Energy Code (1991 Edition), and Washington State Regulations for Barrier Free Facility (1989 Edition). 7. Validity of Permit. The issuance of a permit or approval of plans, specifications and computations shall not be construed to be a permit for, or an approval of, any violation of any of the provisions of this code or of any other ordinance of the jurisdiction. No permit presuming to give authority or violate or cancel the provisions of this code shall be valid. r e : ll r '" � "i Type or Inspedio ! ( ! R e l- ,...,..24-.. Address: '0( Ca - /Y r3- Date Called: Special In lone: Date Wanted: ..." am. Requester: Phone No.: CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd., #100, Tukwila, WA 98188 ,pproved per applicable codes. ( Inspector INSPECTION RECORD 1 Retain a copy with permit 61,<4 4q,1z -, (206) 431 -3670 ❑ Corrections required prior to approval. COMMENTS( Date: ❑ $30.00 REINSPECTION FEE REQUIRED. Prior to reinspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. • COMMENTS: 0 ,L , 1 ?0 J7. i s Z i - 549/ r I n o Address: 5990 3 t y-(� 1 �I Date Called: i - ao - ga C *hi O %' 1 /— /41W-,✓ as L.: _.•,-1.,ei 7s „ "0 /h. /e 4 S . - .. 5 4. ) ,1 4,-, r G, h. 4 i.4 19 ) h / -- /4 / S .�.. , 4( ,e, . W L /1 ��e L� ' roe C Ja1 1_ J ' U, �� \ ype o nspedwn: r I n o Address: 5990 3 t y-(� 1 �I Date Called: i - ao - ga Special Instructions: M .• -t-,.e r 3 ; oo Date Wanted; n ._a I lam. .6 Requester: Q fon Phone No.. a r "1 (0 _ Recept No.: •• \ INSPECTION RECORD - -- ;Retain a copy with permit S. o. CITY or TUKWILA BUILDING DIVISION 6300 Southcenter Blvd., #100, Tukwila, WA 98188 Date: PERMIT N0. (206) 431 -3670 ❑ Approved per applicable codes. g Corrections required prior to approval. ❑ $30.00 REINSPECTION FEE REQUIRED. Prior to reinspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. ro ect: 0, I; ype o nspection: ' e •ress: gate a e : Special Instructions: Date Wanted: Requester: Phone No.: • INSPECTION RECORD Retain a copy with permit CITY OF TUKWILA BUILDING DIVISION 6300'Southcenter Blvd., #100, Tukwila, WA 98188 ❑ Approved per applicable codes. Corrections required prior to approval. COMMENTS; ' r..re, ss u teri /.� e/ (- ,z 40.4- a ❑ $30.00 REINSPECTION FEE REQUIRED. Prior to reinspection, fee must be paid at 6300 Southcenter Blvd., Suite 100. Call to schedule reinspection. Date; Building Component Description including U -value or F -value in e U =1. + Heat Loss Factor (HLF = U x 46° at . / ' - Component Square Ft(SF) Linear Ft(LF) Cubic Ft (CF ) « ■ SF Component Heat Loss (HLF x SF, LF or CF) G . Window, Skylight, Sliding Double U= .90 41.4/SF \ 5F 5 o92BTUN U= .75 34.5/SF SF BTUH Glass Door I_ ..0 ] .. /5F --- BTUH BTUH - Dther _ It er U= /S 21.6 /SF 1•. S SF 7 SF SF B UH 1598BTUH BIUH B .Opaque Door • Wood U .47 W /storm door r= . Insul. metal (U .20 9.2/SF SF UH Other (U done ( .40 /SF 18.4 /SF SF SF BTUH BTUH 777707 Ceiling Insulation R -19 (U= .055 2.6/SF SF STUN STUN R -30 (U= .035 1.6 /SF sr R -38 (U= .026 1.2/SF SF BTUH - U .021 .'/ S UH 5 21687UH ' 67 o °o 4 /SF 1242_ SF S. a Insulation (above and below grade) one U= . UH R -11 (U= .08 ) 16 9 a. SF : • - • U= .6 Sr ' UH 9T UH R -27 (U= .037 1.7/SF R- (U= /SF I1*` BTUH F loor Over Unheated Space Insulation None U= .25 (U= 11.5 /SF R -11 .08 3.7 /SF 2.6/SF 5767 SF SF 2 O98BTUH BTUH "T (U= .055 R -30 (U= .035 1.6 /SF SF STUN R- (U= - hone (F= .032 /SF 1.5 /SF /S F SF 67-5- SF STUN (2_BTUH r BTUH `F. asement Floor - It- _ G. Slab On Grade Floor Perimeter Insulation None F= .81 37.3/LF 28.17LF 1F Lr STUN UH `B•3 F= .61 '_=B (F= .56 25.8/LF L UH - K =TD (F= .5• 1 24.8 /LF °L� UH • - _ I /L L • H '. n i tra- ti on 're :1 t(�1t�131lf'�iLlR] •ost • : s , 0 :x6.. • .0/ 33- 36 : UH / �i f -){ � �{l4:l 1t A P R 0 V E D 19� : UH +27 3 STUN I Total Heating Load (THL) in Btuh F> P if electric divide by 3.413 for THL in watts isc. WATTS r�6 ENERGY CODE v � •,, TV , J K5 Seattle Department of Constr v and Land Use HEATING LOAD CALCULATION FORM February 1986 Project Address: 5 0 •� 11 St, Date of this application w Project Number: Instructions: See reverse. PART I: BUILDING ENVELOPE HEAT LOSS Permit Number: FILE COPY PART II: SPACE HEATING EQUIPMENT SIZING LIMITS Minimum Allowed Equipment Size (THL x .9) Maximum Allowed Equipment Size (THL x 1.5) . Proposed Equipment Size (Output) Heated Floor Area Proposed Equipment Size /Heated Floor Area = t907 tl /hlc.1 -2 i3U►L ;; ' ' ' 6 : tu or watts hi-, I n0 Btuh or watts 6 q , DOD Btuh or watts 19 (7 Square feet 3 E l or watts/ square feet CD CD CC so o. cr D _ . o 9. co M 0 0 Residential Gas AUTOMATIC STORAGE WATER HEATER FOR DIRECT VENT INSTALLATION USE & CARE MANUAL WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR FOR YOUR SAFETY 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 sup- plier from a neighbor's phone. Follow the gas supplier's instruc- tions. • If you cannot reach your gas sup- plier, call the fire department. ALF COPY The purpose of this manual,is,twofotd;- foYfn4 installing contractor, to provide requirements and recommendations for the proper installation and adjustment of the water heater, and for the owner= operator to explain the features, operation, safety precautions, maintenance and trouble shooting of the water heater. The manual also includes athermo- stat and burner parts list. It is imperative that all persons who are expected to install, operate or adjust this water heater read the instructions carefully so that they may understand how to do so. Any questions regarding the operation, mainte- nance, service orwarranty of this water heater should be directed to the entity from whom it was purchased. If additional information is required, refer to the section on How to Obtain Service Assistance. FOR YOUR SAFETY Do not store or use gasoline or.other flammable vapors and liquids in the vicinity of this or any other appliance. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Referto this man- ual. For assistance or additional information consult a qualified in- staller, service agency or the gas supplier. COMPONENTS OF YOUR WATER HEATER — So that you may better understand the operation of your new water heater, the follow- ing section illustrates the basic components of a typical water heater. 1. Thermostatic Gas Valve . 2. Gas Cock Knob 3. Red Button 4. Thermostat Temperature Dial 5. Steel Burner • 6, Pilot Burner 7. Thermocouple 8. .Air Supply Box, Upper 9. Glasslined Tank • • 10. Insulation 11. Jacket 12. Flue Baffle 13. Jacket•Door 14. Inner Door 15. Floor Shield 16. Drain Valve 17. Internal Fluev9ay 18. Dip Tube (Cold Water Inlet) 19. Mode 20. Relief Valve Opening 21. Water Connections (on top) 22. Air Tube 23. Vent Terminal Cap 24. Vent Tube (Inner - not shown) FIB. 2 — Thermostat and Burner 14 Basle Gas Water Heater Oat. Me Side Outlet Bottom Outlet Dle. "A" 30 AS- 21990A -D AS- 2199A4 -D 22 -5/8 40 AS- 21990A -E AS- 21994A -E 24 -5/8 ' 50 AS- 21990A -F AS- 21994A -F 27 -1/8 1 • The location chosen for the water heater must take into considera- tion the following: LOCAL INSTALLATION REGULATIONS This water heater must be installed In accordance with these instructions, local codes, utility company requirements, and /or in the absence of local codes, the latest edition of the American National Standard, National Fuel Gas Code, a copy of which can be purchased from either American Gas Association, 1515 Wilson Blvd., Arlington, VA 22209 as booklet Z223.1 -1984 or National Fire Prevention Associ- ation, Batterymarch Park, Quincy, MA 02269 as booklet NFPA No. 54 -1984. LOCATION • This water heater is of the direct vent design. All air for combustion and all products of combustion are routed through the ducting provided, directly from and to the outside of the building. It there- fore must be located next to the outside wall, within the range of the telescopic adjustments illustrated In Fig. 4. DO NOT attempt to extend the air supply tube or inner flue vent tube beyond the dimensions shown. • Choose a tentative location where the vent terminal, when Installed outside on the exterior wall, will not be less than 9 inches from any opening through which flue gases could enter a building and 18 inches from building corner or other irregularity. The bottom of the vent terminal cap should be at least 12 inches above grade (higher in areas of heavy snowfall). • Water heater may be installed on combustible floors, but not directly on carpeting. If the water heater must be installed on carpeting, place a metal or wood panel beneath water heater, extending beyond Its full width and depth at least 3 Inches in•all directions. If the water heater is installed in an alcove or closet, the entire floor must be covered by the panel. • A gas fired water heater should not be installed in a space where liquids which give off flammable vapors are to be used or stored. Such liquids include gasoline, LP gas (butane and propane), paint or adhesives and their thinners, solvents or removers. Because of natural air movement in a room or other enclosed space, flam- mable vapors can be carried some distance from where their liquids are being used or stored. The open flame of the water heater's pilot light or main burner can ignite these vapors causing an explosion or fire which may result in severe burns or death to those in range, as well as property damage. For these reasons installation of a gas fired water heater in a garage is not desirable. If a location in a garage is the only alternative, the gas water heater should be installed so that the open flame of the pilot and main burner are no less than 18 inches above the garage floor, unless specifically exempted from this by local code. The water heater must be located or protected so it is not subject to physical damage by moving vehicles or area flooding. Raising the gas fired water heater will reduce but not eliminate the possibility of lighting the vapor of any flammable liquids which may be improperly stored or accidentally spilled. Introduction tfr • CAUTION!! The water heater should not be located in an area where leakage of the tank or connections will result in damage to the area adjacent to it or to lower floors of the structure. When such areas cannot be avoided, it is recommended that a suit- able catch pan, adequately drained be installed under the water heater. • Minimum clearance from combustible materials are: 0 Inch rear and top tubes; 1 inch sides; 3 inches front. If the water heater is installed in a closet, allow at least 3 inches clearance from the closet door to the front of the water heater. A minimum of 24 inches clearance from the front and top should be available for adequate inspection and servicing. • Select the final location for the water heater after locating the wall studs, electrical conduit or any obstruction that would interfere with cutting the required 5 -1/2 or 6 inch diameter hole for vent penetration. Recommended Factory Designed Catch Pan Other catch pans must conform to the limitations of tho Illustration below. B — Maximum 1 -1/2" To open drain, pipe should be at least 1 3/4" I.D. and pitched for proper drainage. Fig. 3 — Auxiliary Catch Pan CORROSIVE ATMOSPHERES — The water heater should not be installed near an air supply containing halogenated hydrocarbons. For example, the air in beauty shops, dry cleaning establishments, photo processing labs, and storage areas for liquid and powdered bleaches or swirnpool chemicals often contain such hydrocarbons. The air there may be safe to breathe, but when it passes through a gas flame, corrosive elements are released that will shorten the life of any gas burning appliance. Propellants from common spray cans or gas leaks from refrigeration equipment are highly corrosive after passing through a flame. The limited warranty is voided when failure of water heater is due to a corrosive atmosphere. (Reference is made to the limited warranty for complete terms and conditions.) y ` Installation 1. INSPECT SHIPMENT — There maybe hidden damage caused by transit. Check to be certain all parts of the venting system, as shown in Fig. 4, are present. Inspect the upper and lower air inlet boxes, rear air tube and all parts of the venting system. CAUTION!! 11 there are any damaged pads, DO NOT Install this water heater. Report any shortage to your distributor or damage to your carrier. Note: The four fasteners that are required to secure the vent cap to the external wall are not provided. These should be screw type (not nails) chosen for the type of construction and obtained locally. 2. VENT CONNECTIONS — After the location for the vent terminal has been selected as previously described: A. Cut a clearance hole, approximately 6 inches in diameter, through the exterior wall for the 5 inch diameter air tube. B. Move the water heater to its final installed location. Make certain'clearances from combustible material are observed. C. Place the 3 inch steel elbow on the water heater flue pipe and press it firmly downward until seated and pointed in the desired direction. Apply silicone sealant as shown in Fig. 4. Vent Terminal Cap 61.1/8' flue —0.- Oss Vent Cep Bass Outside Air Screw Wieners t. Warier . --Wall Thickness Main Bas Vent Tube Interior Clearance 30 8e1. - 161 /I 40 Bel. — 17.3/4' 60 Gal. - 19'3/4' B angs of Adjustments Main Air Tube it aide wall Is of combustible mate Ial, deduct 1" from adlustment range. Sliding Air Tube Fig. 4 4 D. Install the 5 inch aluminum elbow over the 3 inch steel elbow Be certain both are pointed in the desired direction with the; inch centered inside the 5 inch elbow. As an aid to leveling thi 5 inch elbow, temporarily place the 5 inch sliding tube onto th elbow. When leveled, drill two 1/8 inch diameter holes througi the elbow into the collar at the front and back. Secure with tN two M8 sheet metal screws provided. E. Place the finishing collar on the 5 inch elbow, as it will b' positioned later. F. Extend the 3 Inch tube assembly to its maximum installe length, 20-3/4 inches. Place the larger main section through th' hole in the external wall to the outside. Place the inner slidih section fully onto the 3 inch elbow. Apply silicone sealant i shown in Fig. 4. G. Attach the 5 Inch main tube to the vent cap base, Drill a 1/8 inc hole through the tube into the collar of the base. Secure with, #8 sheet metal screw, furnished. Repeat with a second hole al` screw approximately 180° from the first. Reinstall the 5 int inner sliding section at its maximum extended length, 19 -3 Inches. * Seal with Slllcons Sealant Sheet Metal Screw Bas Venl Tube Elbow Air Tube Elbow l4.3/4' 61.1/8' Rear Venting tilde" Venting Gal. Mln. Max. Min. Max. 30 4 -3/4" 14-3/4" 9 - 3/4" 19.3/4" 40 4 -1/8" 14 - 11W' 9-1/8" 19-1/8" 60 3 -1/8" 13 -1/8" 8 -1/8" 18.1/8" y ` Installation 1. INSPECT SHIPMENT — There maybe hidden damage caused by transit. Check to be certain all parts of the venting system, as shown in Fig. 4, are present. Inspect the upper and lower air inlet boxes, rear air tube and all parts of the venting system. CAUTION!! 11 there are any damaged pads, DO NOT Install this water heater. Report any shortage to your distributor or damage to your carrier. Note: The four fasteners that are required to secure the vent cap to the external wall are not provided. These should be screw type (not nails) chosen for the type of construction and obtained locally. 2. VENT CONNECTIONS — After the location for the vent terminal has been selected as previously described: A. Cut a clearance hole, approximately 6 inches in diameter, through the exterior wall for the 5 inch diameter air tube. B. Move the water heater to its final installed location. Make certain'clearances from combustible material are observed. C. Place the 3 inch steel elbow on the water heater flue pipe and press it firmly downward until seated and pointed in the desired direction. Apply silicone sealant as shown in Fig. 4. Vent Terminal Cap 61.1/8' flue —0.- Oss Vent Cep Bass Outside Air Screw Wieners t. Warier . --Wall Thickness Main Bas Vent Tube Interior Clearance 30 8e1. - 161 /I 40 Bel. — 17.3/4' 60 Gal. - 19'3/4' B angs of Adjustments Main Air Tube it aide wall Is of combustible mate Ial, deduct 1" from adlustment range. Sliding Air Tube Fig. 4 4 D. Install the 5 inch aluminum elbow over the 3 inch steel elbow Be certain both are pointed in the desired direction with the; inch centered inside the 5 inch elbow. As an aid to leveling thi 5 inch elbow, temporarily place the 5 inch sliding tube onto th elbow. When leveled, drill two 1/8 inch diameter holes througi the elbow into the collar at the front and back. Secure with tN two M8 sheet metal screws provided. E. Place the finishing collar on the 5 inch elbow, as it will b' positioned later. F. Extend the 3 Inch tube assembly to its maximum installe length, 20-3/4 inches. Place the larger main section through th' hole in the external wall to the outside. Place the inner slidih section fully onto the 3 inch elbow. Apply silicone sealant i shown in Fig. 4. G. Attach the 5 Inch main tube to the vent cap base, Drill a 1/8 inc hole through the tube into the collar of the base. Secure with, #8 sheet metal screw, furnished. Repeat with a second hole al` screw approximately 180° from the first. Reinstall the 5 int inner sliding section at its maximum extended length, 19 -3 Inches. * Seal with Slllcons Sealant Sheet Metal Screw Bas Venl Tube Elbow Air Tube Elbow l4.3/4' 61.1/8' Installation H. From the outside of the building, insert the 5 inch tube /base assembly through the hole in the exterior wall and onto the 5 inch elbow. Then seat the base onto the wall. I. Next place the 3 Inch main tube fully onto the collar of the vent cap. Then seat the cap against the base. J. Secure the vent cap /base assembly to the exterior wall with four screw anchors appropriate for the type of wall construction. The 5 inch tube should be essentially level. However, a small amount of upward or downward pitch will not affect operation. K. Apply caulking compound around the junction of the vent terminal base and the exterior wall. L. Position and fasten the finishing collar, previously Installed on the 5 inch elbow, against the wall to close the opening around the tube. M. Make certain the 5 inch tube sliding section has been fully engaged onto the 5 inch elbow. Drill two each 1/8 inch holes (180° apart) in the junction of the two joints in the five inch tube. Fasten with four #8 sheet metal screws, furnished. N. Seal all the 5 inch tube joints with silicone sealant including the elbow joint to the collar on the heater's air supply box. 3. WATER SUPPLY CONNECTIONS — Refer to Fig. 5 for suggested typical Installation. The installation of unions or flexible copper connectors is recommended on the HOT and COLD water lines, so that the water heater may be easily disconnected for servicing if necessary. The HOT and COLD water connections are clearly marked. Install a shut -off valve in the cold water line near water heater. A check valve located in the cold water Inlet line can cause a "Closed" water system. Contact the water supplier or local plumb- ing inspector on how to control this. IMPORTANT!! Do not apply heat to the cold water supply fitting. II sweat connections are used, sweat tubing to adapter before fitting adapter to cold water Inlet of heater. Any heat applied to the cold water inlet will permanently damage the dip tube. 4. RELIEF VALVE — A marked opening on the water heater is pro- vided for the field installation of a relief valve. Refer to Fig. 5. An ANSI design certified "Temperature and Pressure" relief valve must be installed In this opening at the time of installation of this water heater. Local codes shall govern the installation of relief valves. 5 Heat Trap 6" Min. Hot Water Outlet to Fixtures Temperature and Pressure Relief Valve Manual Gas Shut-Off To Gas Supply Ground Joint Union Sediment Trap /Drip Leg Cap Thermostat Vent Terminal Cap (Outside) Union ; f Tube i t I vim, • ��Alr i 1 I/1 i i Union { I ■ 1 Heal Trap 6" Min. Shut•I Valve Jacket Door Drain Valve AuxIlla Catch Pan Relief Valve Discharge Line to Suitable Open Drain Alr Gap o Cold Water Supply Fig. 5 — Typical Installation The pressure rating of the relief valve must not exceed 150 psi, the maximum working pressure of the water heater as marked on Its rating plate. The BTUH rating of the relief valve must equal or exceed the BTUH input of the water heater as marked on its rating plate. Connect the outlet of the relief valve to a suitable open drain. The discharge line must pitch downward from the valve to allow complete drainage (by gravity) of the relief valve and discharge line and must be no smaller than outlet of the valve. The end of the discharge Tine should not be threaded or concealed and should be protected from freezing. No valve, restriction or reducer coupling of any type should be installed between the relief valve and the tank or in the discharge Tine. WARNING!! Tank MUST be full of water before water heater Is turned on. 5. TO FILL WATER HEATER — Make certain drain valve is closed. Open shut -off valve in cold water supply line. Open each hot water faucet slowly to allow air to vent from the water heater and piping. A steady flow of water from the hot water faucet(s) indicates a full water heater, Installation 6. GAS SUPPLY — The inlet gas pressure to the water heater must not exceed 1/2 psig (14" W.C.). The minimum inlet gas pressure and manifold pressure are shown on the water heater rating plate. if high or low gas pressures are present, consult the gas supplier for correction. CAUTION!! Do not attempt to convert this water heater for use with a different type of gas other than the type shown on the rating plate. Such conversion could result in hazardous operating conditions. The branch gas supply line to the water heater should be clean 1/2 inch black steel pipe or other approved gas piping material, and should be pitched toward water heater. A ground union or ANSI design certified semi -rigid or flexible gas appliance connector should be installed in gas line close to the water heater, and a manual gas shut -off valve should be installed in the gas line prior to the union. The manual gas shut -off valve should be at least 5 feet above the floor and readily accessible for turning on or off. A sediment trap /drip leg should be installed at bottom of the gas line. Refer to Fig. 5. Compound used on threaded joints of the gas piping shall be of the type resistant to the action of liquefied petroleum gas. Use com- pound sparingly on male threads only. Do not use excessive force (over 31.5 Ft.Lbs.) in tightening the pipe joint at the thermostat inlet, particularly if teflon pipe compound is used, as the valve body may be damaged. 7. LEAK TESTING — The water heater and its gas connections must be leak tested at normal operating pressures before it is placed in operation. Turn on the manual gas shut -off valve near the water heater (Refer to Fig. 5). Use a soapy water solution to test for leaks at all connections and fittings. Bubbles indicate a gas leak that must be corrected. The water heater factory connections to the thermostat should also be leak tested after the water heater is placed in operation. WARNING!! Do not use open flame to test for leak. PRESSURE TESTING THE GAS SUPPLY SYSTEM -- The water heater and its manual gas shut -off valve must be disconnected from the gas supply piping system during any high pressure testing of that system at pressures in excess of 1/2 psig (14" W.C.). The water heater must be isolated from the gas piping system by closing the manual gas shut -off valve (Refer to Fig. 5), during any pressure testing of the gas supply piping at pressures equal to or less than 1/2 psig (14" W.C.). WARNING!! The manufacturer's warranty does not cover any damage or defect caused by installation, attachment or use of any type of energy saving devices (other than those authorized by the manufacturer) into, onto or In conjunction with the water heater. The use of unauthorized energy saving devices may shorten the B. C. D. E. life of the water heater and may endanger life and property. The manufacturer disclaims any responsibility for such loss or injury resulting from the use of such unauthorized devices. If local codes require external application of insulation blanket kits, the manufacturer's instructions included with the kit must be carefully followed. CAUTION!! Application of any external Insulation to this water heater will require careful attention to the following: • Do not cover burner access panel, thermostat /gas valve or pressure and temperature relief valve. • Do nof cover operating instructions or warning labels attached to the water heater nor attempt to,relocate them on exterior of the insulation blanket. INSTALLATION CHECK LIST A. Water Heater Location ❑ Close to outside wall. O Indoors and protected from freezing temperatures. ❑ Proper clearance from combustible surfaces observed and water heater not Installed on carpeted floor. ❑ Sufficient fresh air supply for proper operation of water heater. ❑ Air supply free of corrosive elements and flammable vapors. ❑ Provisions made to protect area from water damage. ❑ Sufficient room to service heater. Water Supply ❑ Water heater completely filled with water. ❑ Water heater and piping air vented. ❑ Water connections tight and free of leaks. Relief Valve ❑ Temperature and Pressure Relief Valve properly installed and discharge line run to open drain. ❑ Discharge line protected from freezing. Gas Supply ❑ Gas line equipped with shut -off valve, union and drip leg. ❑ Approved pipe joint compound used. ❑ Soap and water solution used to check all connections and fittings for possible gas leak. ❑ Gas Company inspected installation (if required). Venting ❑ Flue baffle hung in top of heater's flueway. ❑ Air tube and vent tube properly installed. ❑ Vent terminal, air tube sealed with caulk. Q Air tube securely fastened with screws. 1 SAFETY PRECAUTIONS 1. Do not store or use gasoline or other flammable vapors and liquids, such as adhesives or paint thinners, in vicinity of this or any other appliance. If such flammables must be used, open doors and windows for ventilation, and all gas burning appliances in vicinity should be shut off, including their pilot lights, to avoid vapors igniting. NOTE: Flammable vapors may be drawn by air currents from surrounding areas to the water heater. 2. Do not allow combustible materials such as newspaper, rags or mops to accumulate near water heater. FOR YOUR SAFETY READ WARNING!! If you do not follow these instructions exactly, a fire or explosion A. This water heater has a pilot which must be lighted by hand. When lighting the pilot, follow these Instructions exactly. B. BEFORE LIGHTING smell all around the water heater 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 electric switch; do not use any telephone in your building. • Immediately call your gas supplier from a neighbor's phone. . LIGHTING PROCEDURE (Make certain gas supply line manual shut -off valve is In the "ON" position. Fig. 5) STOP!! READ THE SAFETY INFORMATION ABOVE. c) Turn gas cock knob c clockwise to "off" position. O Turn temperature dial counter clockwise to lowest setting. Turn gas cock knob 13 counterclockwise to "on" position. Ono pilot llama is eslab- 1 llshal, replace end tighten the two screws In the right side of hinged door. Replace access door. O 7 Oe rus red button and I gn pilot. Operation © Alter lighting pilot burner with match then close Inner door Immsdlately. 7 3. CAUTION!! Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time (generally two weeks for more). HYDROGEN GAS IS EXTREMELY FLAMMABLE. To dis- sipate such gas and to reduce risk of Injury, it is recom- mended that the hot water faucet can be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow. Do not smoke or use an open flame near the faucet at the time it is open. C. D. BEFORE LIGHTING may result causing property damage, personal Injury or loss of life. Follow the gas supplier's instructions. • If you cannot reach your supplier, call the fire department. Use only your hand to turn the gas control knob. Never use tools. If the knob will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repairmay result In a lire or explosion. Do not use this water heater if any part has been under water. Immediately call a qualified service technician to Inspect the water heater and replace any part of the control system and gas control which has been under water. O With a Phillips screwdriver, remove two screws from right side ot hinged Inner door, then open. Wall al least 5 minutes. Sniff near floor 10 make sure no gas is In area. Be especially careful with propane gas. II you smell gas STOPA See "B" In solely Information above. CON Screws View Pun Door Duksl O With Inner door closed, allow pilot to burn pprosl- metely BO seconds before Releasing red button. See note NI. TO SHUT OFF WATER HEATER Turn temperature dial c counter clockwise to lowest setting. Turn gas cock knob c7 clockwise to "OFF." Turn gas cock knob c counter clockwise to "pilot" Ilion. — mean Note 1: If red button does not pop up when released, STOP and Immediately call your service technician or gas supplier. Note 2: If pilot will not stay lit after several tries, turn gas cock knob C- clockwise to "OFF" and call your service techni- cian or gas supplier. 11 II pilot goes out turn gas cock knob clockwise to "AA." Walt 5 minutes and repeal operation allowing longer period before releasing red button. See note N2 v Components 1 -- 3" 90° steel elbow 1 — 5" 90° aluminum elbow 1 — 3" tube assembly (2 -pcs. meshed) 1 -- 5" tube assembly (2 -pcs. meshed) 1 -- Finishing collar (inside) 1. Make certain to observe vent location limitation. See Fig. 1 2. INSPECT SHIPMENT — There may be hidden damage caused in transit. Check to be certain ail parts of the venting system, as listed above, are present. Inspect the upper and lower air inlet boxes, rear air tube and all parts of the venting system. CAUTION!! If there are any damaged parts, DO NOT Install this water heater. Report any shortage to your distributor or damage to your carrier. NOTE: The four fasteners that aro required to secure the vent cap to the external wall are not provided. These should be screw type (not nails) chosen for the type of construction and obtained locally. 3. VENT CONNECTIONS — Atter the location for the vent terminal has been selected as previously described: Use the following illustrations for simple installation. • F. Place the 3 inch steel elbow on the water heater flue pipe and press it firmly downward until seated and pointed in the desired direction. Apply silicone sealant around to seal. SUPPLEMENT SHEET FOR USE WITH DIRECT VENT MANUAL AP -10189 -- Installation A. Cut a clearance hole, approximately t3 inches in diameter, through the exterior wall for the 5 inch diameter air tube. 1 — Vent terminal base (outside) 1 - Vent terminal cap (outside) 1— Tube silicone sealant 8 — Sheet metal screws Fig.1 3' 91r Elbow (Steel) S Aluminum w D. Install the 5 inch aluminum elbow over the 3 inch steel elbow, Be certain both are pointed in the desired direction with the 3 inch centered inside the 5 Inch elbow. 18' Min. To Overhang Appliance Vent Terminal I8' Min. Building Corner Or Other Irregularity )cell 12 Mln Window. Door. Or Any Other Opening Above Or Appliance Vent Terminal _L. • Appliance Water Heater °Vent Vent Terminal Terminal 48' Min. )Below Or Horizontal) 12' Min. iHigher in Areas Ill Meavy Snowfall) B. Move the water heater to its final installed location. ♦ Sheet Metal Screws diL OA E. As an aid to leveling the 5 inch elbow, temporarily place the 5 inch sliding tube onto the elbow. When leveled, drill a 1/8 inch diameter hole through the elbow into the collar at the front and back. Secure with the two 08 sheet metal screws provided. w F. (1) Extend the 3 Inch tube assembly to its maximum installed length, 20 -3/4 Inches. (2) Place the main vent tube through the hole in the external wall to the outside. (3) Place the inner sliding tube fully onto the 3 inch elbow. (4) Apply silicone sealant as shown. H. (1) From the outside of the building, insert the 5 inch tube /base assembly through the hole in the exterior wall and onto the 5 inch elbow. (2) Then seat the base onto the wall. J. Position and fasten the finishing collar, previously installed on the 5 inch elbow, against the wall to close the opening around the tube. K. (1) Make certain the 5 Inch Inner sliding air tube has been fully engaged onto the 5 Inch elbow. (2) Drill two each 1/8 inch holes (180° te apart) inch in ube. (3) Fasten with four jointti #8 sheet metal screws, furnished. L. Seal all the 5 inch tube oints with silicone sealant including the elbow joint to the collar on the heater's air supply box. Outside will 5' Tube 3' Tubs Screw Anchors * Seal with Sillcene Sealer Wall G. (1) Attach the 5 inch main tube to the vent cap base. (2) Drill a 1/8 inch hole through the tube into the collar of the base. (3) Secure with a $18 sheet metal screw, furnished. Repeat with a second hole and screw approximately 180° from the first. (4) Reinstall the 5 Inch inner sliding section at its maximum extended length, 19-3/4 inches. Vent Terminal Base . (1) Next place the 3 inch main tube fully onto the collar of the vent cap. Then seat the cap against the base. (2) Secure the vent cap /base assembly to the exterior wall with four screw anchors appropriate for the type of wall construction. The 5 inch tube should be essentially level. However, a small amount of Upward or downward pitch will not affect operation. (3) Caulk the junctions of the vent terminal base and the exterior wall with the . silicone sealant. FORCED DRAFT UPFLOW GAS FIRED FURNACE REVISED: NOVEMBER, 1986 SUPERSEDES: JANUARY, 1986 HEATING CAPACITIES INPUT (BTUH) t 40,000 60,000 80,000 80,000 100,000 100,000 120,000 120,000 OUTPUT (BTUH) tt 32,000 48,000 64,000 64,000 80,000 80,000 96,000 96,000 ELECTRICAL SPECIFICATIONS UNIT VOLTAGE 120V 60 HZ 120V 60 HZ MIN. /MAX. VOLTAGE RANGE 115/120 115/120 DIRECT DRIVE BLOWER DRIVE (CFM) 1000 1200 1200 1600 1600 2000 1600 2000 R.L.C.© 5.4 5.8 6.5 9.4 8.2 11.7 8.2 11.7 AMPACITY 7.1 7.6 8.5 12.1 10.6 15.0 10.6 15.0 MAX. OVERCURRENT PROTECTION 10 15 15 20 15 20 15 20 AIR DELIVERIES® MAX. CFM Q 0,5 ESP DIRECT DRIVE 1100 1195 1325 1660 1590 2025 1520 2180 STANDARD CONTROLS AND PIPING INFORMATION ADJ. FAN & FIXED LIMIT CONTROL STANDARD TRANSFORMER (120V/24V) STANDARD COOLING BLOWER RELAY STANDARD GAS VALVE STANDARD Y" INLET MANIFOLD SIZE (INLET) STANDARD 1/2" N.P.T. GENERAL INFORMATION AIR FILTER FILTER TYPE WASHABLE FILTER SIZE (QTY) 16 x 24 x 1 (1) UNIT VENT SIZE (INCHES) 3 3 3 3 4 4 4 4 UNIT SHIPPING WEIGHT LBS. 176 191 191 191 220 220 225 225 UPFLOW GAS FIRED FURNACE SERIES: • SPECi FICATIONS AND INFOR ' ATION THESE SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE ® REFER TO PAGE 9 FOR COMPLETE BLOWER CHARTS. 0 NOMINAL AMP. LOAD DEPENDING ON INSTALLATION CONDITIONS AND HEATING OR COOLING OPERATIONS, t RATINGS SHOWN ARE FOR ELEVATIONS UP TO 2000 FT. RATINGS SHOULD BE REDUCED 4% PER 1000 FT. FOR EACH 1000 FT. ABOVE SEA LEVEL. tt RATED IN ACCORDANCE WITH D.O.E. TEST PROCEDURES. CODE: GUA NOTICE TO INSTALLER — Instruct the owner or operator of the furnace in the proper procedure to follow for shutting off the furnace in case of an emergency. Explain how to change, service or clean filters and setting of controls for best comfort conditions. Show the owner where the lighting instruction label is located and explain lighting procedures. CONTINUING ENGINEERING RESEARCH RESULTS IN STEADY IMPROVEMENTS, THEREFORE, THESE SPECIFICATIONS ARE SUB- JECT TO CHANGE WITHOUT NOTICE, ALWAYS CONSULT EQUIPMENT NAMEPLATE FOR EXACT ELECTRICAL REQUIREMENTS, ,. INPUT BTU /HR. FRONT REAR SIDES TOP VENT CONNECTION' FURNACE FLUE PIPE SIZE COMBUSTIBLE FLOOR" 40,000 6 1 1 1 6 3 Dia. 0 60,000 6 1 1 1 6 3 Dia. 0 80,000 6 1 1 1 6 3 Dia. 0 100,000 6 1 1 1 6 4 Dia. 0 120,000 6 1 1 1 6 4 Dia. 0 GAS FIRED — FORCED IcHAFT FURNACE-- PREWiRE i & PREASSEMBLED UPFLOW SERIES INFORMATION CONTAINED IN THIS MANUAL IS DESIGNED TO ACQUAINT YOU WITH THE MECHANICAL FEATURES, AND TO SERVE AS AN EMERGENCY REPAIR GUIDE iN CASE OF HEAT FAILURE. PROPER CARE OF YOUR GAS FURNACE WILL ASSURE YOU OF MANY YEARS OF ECONOMICAL COMFORT AND SERVICE. LIKE EVERY PIECE OF FINE MECHANICAL EQUIPMENT, YOUR FURNACE SHOULD BE SERVICED PERIODICALLY BY AN EXPERT. WE RECOMMEND A COMPLETE INSPECTION BY AN AUTHORIZED SERVICEMAN AT LEAST ONCE EACH YEAR — USUALLY AT THE BEGINNING OF THE HEATING SEASON. Section I— GENERAL INSTALLATION REQUIREMENTS UNCRATING AND INSPECTING After uncrating the unit, inspect thoroughly for concealed damage, if found, notify transportation company im- mediately and file concealed damage claim. GENERAL REQUIREMENTS Ail installations should be made as outlined in the latest edition of National Fuel Gas Code ANSI- Z223.1 -1984, and other applicable National and Local codes, including requirements of Local Utilities. In addition, the unit must be electrically grounded in accordance with the latest edition of National Electric Code ANSI - NFPA - #70 -1984. Current Code Edition(s) are available for a fee from the American Gas Association, 1515 Wilson Blvd. Arlington, Virginia 22209. Select a level spot for the installation of the unit. Install as near to the flue or chimney as possible and install the vent pipe with a minimum number of elbows. It Is also recommended that if possible, the unit be centralized with relation to the distribution system. LOCATION OF THERMOSTAT Thermostat should be mounted 4 to 5 feet above the floor, on an Inside wall of the living room, dining room, or a hallway that has good air circulation from the other rooms being controlled by the thermostat. It is essential that there be free circulation of air at this location, of the same average temperature as other rooms being con- trolled. Movement of air should not be obstructed by furniture, doors, draperies, etc: The thermostat should not be mounted where it will be affected by drafts, hot or cold water pipes or air ducts in walls, radiant heat from a RECOMMENDED CLEARANCE GUIDE (Dimensions shown in inches are the minimum clearances furnace design has been certified.) to combustible materials for which the May be 1 Inch when listed Type B -1 Vent Is used. "'Shall not be installed directly on carpeting, tile or other combustible materials, other than wood flooring. 2 fireplace, lamps, the sun, T.V., etc., or on an outside wall. Consult Instruction Sheet packed with thermostat for mounting instructions. ACCESSIBILITY CLEARANCES All servicing and cleaning of these units can be done from the front, and a minimum of 36" horizontal clearance should be allowed. If necessary, these units can be installed at the clearances listed below. However, if access is required to some other piece of equipment, a minimum of 18" should be allowed for passage. In a closet or utility room installation, the door must be large enough to allow replacement of the unit if neces- sary or to permit replacement of any other appliance within the confined space. A minimum of 36" clearance should be allowed at the front of the unit for servicing and cleaning when the closet door is open. In addition adequate clearances must be provided around air openings into the combustion chamber. The furnace should not be installed directly on carpeting, tile or other combustible materials other than wood flooring. If the furnace is installed in a residential garage the unit must be installed so that the burners and the ignition source are located not less than 18 (457 mm) inches above the floor. The furnace must also be located or protected to avoid physical damage by vehicles. THE ACCESSIBILITY CLEARANCES MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEAR- ANCES. o) PROVISIONS FOR COMBUSTI(1.. AIR AND VENTILATION The flow of combustion and ventilating air must not be obstructed from reaching the furnace. Air openings pro- vided in the casing of the furnace must be kept free of obstructions which would restrict air flow, thereby affect- ing efficiency and safe operation of the furnace. Keep this in mind should you choose to remodel the area which contains the furnace. Furnaces must have air for proper performance. WARNING: The air for combustion and ventilation must not come from a corrosive atmosphere. Combustion air must be free of acid forming chemicals; such as sulphur, fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, clean- ing solvents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products. Vapors from these products when burned in a gas flame form acid compounds. The acid compounds increase the dew point temperature of the flue products and are highly corrosive after they condense. in a closet or utility room installation, it will be necessary to provide combustion and ventilation air from an area of adequate air supply. In open basements of normal construction, an adequate supply of air Is obtained from infiltration. Any restricted installation requires two openings in the door or single wall of the closet or utility room. One opening should be located with 12 inches of the top and the other within 12 inches of the bottom of the enclosure. The following minimum free area is required for these openings: a) Openings to interior space —Each opening to in- terior space must have a free area of at least 1 square inch per 1,000 BTU per hour input rating, but not less than 100 square inches. b) Openings to outdoors —Each opening to the out- doors must have a free area of at least 1 square inch per 2,000 BTU per hour input rating If horizon- tal air ducts are used. Air openings in the casing front, return air grilles, and warm air registers must not be obstructed. In all installations provisions for adequate combustion air must be made in accordance with Section 5.3, Air for Section H— INSTALLATION PROCEDURE These units are factory assembled and all the internal wiring and piping has been completed. BOTTOM AIR RETURN if return air is to enter the unit from the bottom, cut opening in bottom, center and level the unit over the return air opening. If necessary, grout around the base to seal leaks between the unit and the floor. Insert air filters into guides cut Into the furnace base. See enclosed sheet 3 Combustion J Ventilation, of the National Fuel Gas Code, ANSI 2223.1 -1984, or applicable provisions of the local building codes. DUCT CONNECTIONS On any job, it is recommended that a flexible duct connection constructed of non - flammable material be used for the return air and discharge connections to prevent transmission of vibration. Never make an installation without a complete return air duct system. The return connection must be made full size to a location outside the utility room. Return air must NEVER be drawn from the inside of a closet, a utility room, or space containing the furnace. In addition, when the furnace is located in an area near or adjacent to the living area, the system should be carefully designed with returns to minimize noise trans- mission through the return air grille. Any blower moving a high volume of air will produce audible noise which could be objectionable when the unit is located very close to a living area. It is often advisable to carry the return ducts under the floor or through the attic. Such designs permit the installation of air return remote from the living area. When a furnace is Installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. ADDITION OF AIR CONDITIONING When a refrigeration coil is used in conjunction with these units. it must be installed in parallel with or in the warm air discharge side of the system to avoid conden- sation in the heating element. With a parallel flow arrangement, dampers must be installed to prevent chilled air from entering the furnace. If manually operated dampers are used, they must be equipped with a means to prevent operation of either unit unless the damper is in full heat or full cool position. HIGH STATIC OPERATION These blowers can be operated against external static pressures up to 0.50" water column, or as indicated on rating plate. for directions. Proceed with duct work. SIDE AIR RETURN If the return air is to enter the unit from the side, it will be necessary to cut the return air opening in the side casing panel. Mark the opening to be cut, using the square embossed knockouts on the casing, if provided, as guides. Or refer to the installation instructions inserted in this booklet. Proceed with duct work. FILTER REQUIREMENTS (HEATING)' AND SIZE FILTER NUMBER INPUT BTU /HR. INTERNAL (STANDARD)" EXTERNAL (OPTIONAL) . " MINIMUM FILTER AREA (SQ. INCH) 40,000 (1) 16 x 25 x 1 (1) 20 x 25x 1 140 60,000 ( 1 ) 16 x 25 x 1 ( 1 ) 2 0 . 2 5 x 1 200 80,000 (1) 16 x 25 x 1 (1) 20 x 25 x 1 260 100,000 (1) 16 x 25 x 1 (1) 20 x 25 x 1 320 120,000 (1)16x25x1 (1)20x25x1"" 400 When using the external filter rack, cer the filter rack on 'the side panel, flush with bottom edge of the furnace. Mark the fastening holes. Drill the fastening holes in the side panel, and fasten the filter rack in place with sheet metal screws. Proceed with duct work. AIR FILTERS FOR ALL FURNACES: Filters supplied with the external filter rack are of the permanent type. Replacement of either the internal or For cooling requirements consult specification sheet. "Filters rated at 520 FPM or more, permanent type. "'See price book or specification sheet for external filter rack options. " "For quantities over 1700 CFM requires (2) external filters. ELECTRICAL CONNECTIONS These units are 60 HZ wired and require 115 VOLT SINGLE PHASE POWER SUPPLY. Connect 115 Volt power supply and 24 Volt thermostat wires as indicated in the Wiring Diagram, attached to the inside of the blower compartment door, or refer to the diagram inserted in this book. Optional electrical power connections are also shown on the diagram supplied with the furnace. In order to prevent the possibility of electrical shock, this equipment must be electrically grounded in accordance with the latest edition of the National Electrical Code ANSI /NFPA 70 -1984. VENTING Flue vent installations for this series shall be in accor- dance with Part 7, "Venting of Equipment ", of the National Fuel Gas Code, ANSI Z223.1 -1984 or applicable provi- sions of local building codes. Horizontal flue vent requires the use of Stainless Steel vent pipe and our approved horizontal vent kit (4" P/N 8G03005, & 3" P/N 8G03004). A horizontal flue vent system also requires a piped intake combustion air vent from the outside (refer to Installation Instructions for Upflow Forced Draft Furnace Horizontal Venting P/N 7502 -084). We recommend the use of B -1 type flue vent for all vertical vent applications. The B -1 type flue vent referred to is vertical flue vent that starts at the forced draft flue outlet and terminates through the building's roof. The vent must be terminated with a listed cap or roof assembly. If the flue venting is to be done through an existing masonry chimney, it is strongly recommended that when local experience Indicates that flue gases may condense 4 external air filters Culd be of the same size and capacity as the original. Failure to provide adequate filter media, can cause equipment malfunction, uneven room temperature, and excessive fuel usage. Refer to the following table for filter size and minimum filter area required for all furnace sizes. to liquid within the chimney, provisions should be made to provide a suitable metal liner, the chimney should be lined with an approved flue pipe which terminates at or above the top of the chimney, and must be terminated with a listed cap or roof assembly. Proper vent termination is required so that wind from any direction will not create positive pressure in the vicinity of the outlet, to prevent entry of rain water into the flue vent system and to prevent flue restriction by ice build -up during sub - freezing weather conditions. Additionally, provisions must be made, by the installer, for the safe removal of any condensate that might form in the chimney. Failure to provide for safe removal of condensate, could result in water damage to the building. If the flue venting is to be done through an existing chimney and in the installers judgement, it would be impractical or impossible to line the chimney with new B -1 type vent, we recommend the following: 1. The chimney should be inspected for conformance with local and national codes (refer to Article X of the National Building Code or the Standard for Chimney and Vents NFPA 211). 2. If the chimney is of outside construction (not en- closed by the building) the chimney should be lined or relined with a suitable metal liner: a. B -1 type vent with proper terminals, or b. With single wall metal pipe having resistance to heat and corrosion not less than that of gal- vanized sheet steel or aluminum not less than 0.016 inch thick and with proper ends or ter- minations, or c. If permitted by local codes, with stainless steel vent pipe not less than 0.016 inch thick. 0 FURNACE BTUH MINIMUM HEIGHT® FURNACE VENT SIZE MINIMUM COMMON VENT 3" WATER HEATER 4" WATER HEATER 40,000 8 FT 3" 4" 4" 60,000 8 FT 3" 4" 4" 80,000 8 FT 3" 4" 4" 100,000 8 FT 4" 5" 5" 120,000 8 FT 4" 5" 5" FURNACE BTUH VENTED WITH 3" WATER HEATER D.H. VENTED WITH 4" WATER HEATER D.H. 40,000 FIGURE 1 & 2 FIGURE 1 & 2 60,000 FIGURE 1 & 2 FIGURE 1 & 2 80,000 FIGURE 1 & 2 FIGURE 1 & 2 100,000 FIGURE 3 & 4 FIGURE 3 & 4 120,000 FIGURE 3 & 4 FIGURE 3 & 4 • , The chimney liner or flu( ant pipe must be joined together in accordance with the vent pipe manufacturer's instructions, but in any event all joints must be assembled to provide a tight seal for the entire flue system. d. it Is recommended that the vent from the furnace and any other vented appliance be attached to the liner, and that the liner be terminated with an elbow or a closed bottom "T" to trap any conden- sate that may form. 3. If the chimney is located within the building and extends through less than five (5) feet of unin- sulated attic space, then the flue vent connector may connect directly to the chimney and the chim- ney used without a metal liner. The following additional recommendations are made for flue vent systems for Forced Draft furnaces: 1. Select flue connection material that is satisfactory for installation and that meets requirements of local codes. In applications where the flue vent or chimney Is not directly above the flue opening of the furnace, a vent connector of single wall galvanized steel or aluminum of not less than 0.016 inch wall thickness (28 gauge) may be used, where clearances to combustible materials is not less than 6 inches. 2, Flue connection pipe must be at least as large as the diameter of the outlet collar on the furnace. Do not reduce the diameter of the vent connector between the furnace outlet collar and the flue vent. 3. Run flue vent pipe from the vent system or chimney directly to the furnace outlet collar, utilizing the shortest route possible. 4. Frequently, the job requires horizontal vent pipe runs and elbows between the furnace flue collar and the vertical vent. We recommend no more than 4 elbows in vent systems with insulated vent pipe or 3 elbows in vent system with uninsulated vent pipe. In applications where the horizontal run of B -1 type vent passes through an unheated space, the pipe should be insulated with R -7 or equal Insulation. 5. Horizontal runs should slope upward from the furnace not less than 1/4 inch per foot (21 mm /m). 6. Horizontal portions of the vent piping should be supported with hangers or straps every 3 feet to prevent sagging and to insure that there will be no movement after installation. 7. Vertical flue vents should extend high enough above the roof or neighboring structures so that wind from any direction will not create positive pressure in the vicinity of the outlet (refer to ANSI Z223.1-1984 for recommended dimensions). 5 It is always a a able to consult local codes, or in the absence of locdVeodes the National Fuel Gas Code when installing a flue vent system. VENTING (HORIZONTAL) For Horizontal venting, special intake and vent terminals with stainless steel pipe connections must be used. Follow instructions furnished with the Horizontal Venting Kit, or as outlined in Addendum A in this manual. VENTING (COMMON) It is possible for the Forced Draft Furnace to be common vented with another gas burning appliance, such as a gas water heater. However, there are some minimum specifications that are applicable to the common venting system. These are listed below with additional references made to Figures 1 thru 4 as shown: ® MINIMUM VENT HEIGHT MEASURED FROM WATER HEATER OR 9 FT. FROM FURNACE WHICHEVER IS LOWEST. REFER TO THE FOLLOWING FIGURES 1 thru 4 ILLUS- TRATING MiNIMUM COMMON VENTING ARRANGE- MENTS: These illustrations show the minimum pipe sizes and dimensions. Larger pipe sizes and dimensions may be used to accomodate the various furnace and water heater installations. The height of the connector above the furnace will vary from the dimensions shown. Connector height will de- pend on the rise of the water heater connection pipe due to the length of pipe used, height of the water heater and height of the draft hood vent collar above the top of the water heater. For the use of Type B -1 gas vtnt or single wall metal pipe and installation of these vents, refer to Part No. 7, Venting of Equipment, of the National Fuel Gas Code ANSI Z223.1 and these instructions. OTHER CONFIGURA- TIONS MAY BE USED ESPECIALLY 'THOSE FOUND IN PUBLICATIONS BY VARIOUS GAS VENT (B TYPE VENT) MANUFACTURERS AND AS PERMITTED BY LOCAL CODES OR UTILITY COMPANIES. TYPICAL IN:..LATION FOR COMMON VENTING REC..tEMENTS FOR FORCED DRAFT UPFLOW FURNACE 40,000 - 80,000 BTUH 8' 18 52 1 /2" i 'SEE INSTRUCTION INFORMATION TYPICAL INSTALLATION FOR COMMON VENTING REQUIREMENTS FOR FORCED DRAFT UPFLOW FURNACE 40,000.00,000 BTUH OPTIONAL 3' VENT CONNECTION 1 6 8" 62 1/2" TO COLLAR eft L _t FURNACE BTUH 040 060 080 4' PIPE AND TEE FURNACE BTU 040 080 080 WATER HEATER WITH 3" VENT' 3" to 4" INCREASER 4" PIPE' AND TEE '3 1/2" FOR 4" DH _ 3" to 4" INCREASER —3" PIPE WATER HEATER WITH 3' VENT' 3' TO 4' INCREASER 6 WATER HEATER' 4' DH WATER HEATER 4" DH' CONNECTOR RISER • ,,, - r 12' 55 "' 1 \ CONNECTOR ' ) RISER 12" • 4" PIPE 55" 1 1; FIGURE 1 " • r 8' 18 " 52 1/2" TO COLLAR` FURNACE BTUH 100 120 TYPICAL INSTALLATION FOR COMMON VENTING REQUIREMENTS FOR FORCED DRAFT UPFLOW FURNACE 100,000 120,000 BTUH OPTIONAL 4" VENT CONNECTION 8' 18 52 1/2" —4" PIPE, 5" PIPE TEE TYPICAL INSTALLATION FOR COMMON VENTING REQUIREMENTS FOR FORCED DRAFT UPFLOW FURNACE 100,000 - 120,000 BTUH 5" PIPE AND TEE 3 1/2" for 4" DH' _ 4" to 5" 1 I INCREASER 10'3"' INCREASER 4" PIPE 5" PIPE & TEE TO COLLAR` J FURNACE BTUH , 100 f 120 'SEE INSTRUCTION INFORMATION r WATER HEATER 4 " D.H. ; ,•' WATER HEATER WITH 3" VENT' 4" PIPE 4" to 5" • INCREASER 4" PIPE 3 1/2" for 7 CONNECTOR RISER I 12" 4" H.D.• WATER HEATER 4" D•H.• WATER HEATER WITH 3" VENT' 3" TO 5" INCREASER 12 "' 3" DH 3" PIPE 5 1/2 "' I r CONNECTOR RISER - r 12" 55 "' FIGURE 4 'SEE INSTRUCTION INFORMATION FIGURE 3 MANUAL SHUTOFF VALVE SUGGESTED GROUND JOINT UNION GROUND JOINT UNION AND DRIP TRAP LOCATION GAS PIPE DRIP TRAP (SEDIMENT TRAP) GROUND JOINT UNION VENT PIPE JOINTS It is recommended that all the pipe joints be caulked with a high temperature sealant (such as RTV Silicone) to assure a tight seal for the flue system from the furnace to chimney /vent. CAUTION: It is vitally important that the furnace have proper venting. Never attach another appliance or heater to the furnace chimney without proper approval of the installer /servicing mechanic. Any alteration to the flue pipe or chimney must be in accordance with all local and national codes. I I I t . 8 FIGURE 5 GAS PIPING THESE UNITS ARE SHIPPED WITH MANIFOLD AND CONTROLS ASSEMBLED. An opening has been provided on the side for the reception of the piping. Install the gas line from the meter to the unit. Size the pipe as recommended In Table 1 or 3. It is recommended, and many local codes require a manual shut -off valve to be located externally and within 4 feet of the unit. Install a "Tee" in the drop pipe at the same elevation as the gas inlet connection to the unit. At the bottom of the "Tee" install a "drip- trap" (sediment trap). Install a ground joint union at the top of the "Tee" or between "Tee" and furnace as shown In FIGURE 5. A Ye" N.P.T. plugged tap, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the furnace. All gas piping must conform with National and Local Codes and Local Utility requirements. Upon completion of piping, check for leaks' with a soapy solution. NOMINAL IRON PIPE SIZE INCH INTERNAL DIAMETER INCHES LENGTH OF PIPE, FEET 10 20 30 40 50 60 70 80 90 100 125 150 175 200 % .493 95 65 52 45 40 36 33 31 29 27 24 22 20 19 1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 37 35 3 /4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 1 1.049 680 465 375 .320 285 260 240 220 205 195 175 160 145 135 1 1.380 1,400 950 770 660 580 530 490 460 430 400 360 325 300 280 11/2 1.610 2,100 1,460 1,180 990 900 810 750 690 650 620 550 500 460 430 Outside Dia. Inches Length of Tubing (Feet) 10 20 30 40 50 60 70 80 90 100 Ye 39 26 21 19 - -- - - - - '/2 92 62 50 41 37 35 31 29 27 26 We 199 131 107 90 79 72 67 62 59 55 3 /4 329 216 181 145 131 121 112 104 95 90 Ve 501 346 277 233 198 187 164 155 . 146 138 Spec. Gray, Mult. Spec. Gray. Mult. Spec. Gray. 1.00 Mutt. .775 Spec. Gray. 1.60 Mutt. .612 .35 1.31 .65 .962 .40 1.23 .70 .926 1.10 .740 1.70 .594 .45 1.16 .75 .895 1.20 .707 1.80 .577 .50 1.10 .80 .867 1.30 .680 1.90 .565 .55 1.04 .85 .841 1.40 .655 2.00 .547 .60 1.00 .90 .817 1.50 .633 2.10 .535 The furnace and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 /2 PSIG (3.48 kPa). (13.87" Water Column.) The furnace must be isolated from the gas supply piping system by closing its individual manual shutoff valve CAUTION: PRESSURE TESTING TABLE 1 Maximum Capacity of Pipe in Cubic Feet of Gas Per Hour for Gas Pressures of 0.5 PSIG or Less and a Pressure Drop of 0.5 Inch Water Column (Based on 0.60 Specific Gravity Gas) TABLE 2 Multipliers to be used when Specific Gravity Is Other than 0.60 TABLE 3 Capacity of Semi -Rigid Tubing In 1000 BTU Per Hour of Undiluted Liquefied Petroleum Gases of 0.50 Pressure Drop ,9 during any pr . ..ure testing of the gas supply piping system at test pressures equal to or less than 1 /2 PSIG (3.48 kPa). (13.87" Water Column.) CAUTION: DO NOT USE OPEN FLAME TO CHECK FOR GAS LEAKS. CAUTION: USE PIPE COMPOUNDS ON GAS PIPE THREADS THAT ARE RESISTANT TO ALL GASES. { NOTES 1. Allowance has been made for an average number of fittings. 2. When using a gas with a specific gravity other than 0.60, multiply the capacity by the factor given in Table 2. 3. To convert BTU Input per hour to cubic feet per hour, divide BTU per hour by the heating value of the gas to be used. This can be obtained from your local utility. 4. Piping systems of semi -rigid tubing (Table 3) that are to be supplied with gas of a specific gravity of 1.53 or less can be sized directly from Table 3 unless the authority having jurisdiction specifies that a gravity factor be applied. When the specific gravity of the gas is greater than 1,53, the gravity factor shall be applied. Section III —FINAL ADJUSTMENTS TEMPERATURE RISE The furnace installation is to be adjusted to a tempera- ture rise within the temperature range as specified on the furnace rating plate. PRESSURE REGULATOR ADJUSTMENT A pressure tap has been provided on the gas valve. Attach a pressure gauge to this tap and check the pressure. The pressure should be set as indicated on the rating plate. For most models this figure is normally 3.5 inches W.C. (nat. gas). To adjust the pressure regulator, remove the cap covering the pressure regulator adjusting screw. On valves with more than one adjusting screw, adjust only the screw marked "HI ". Turn the adjusting screw out to decrease the pressure and in to increase the pressure. After the pressure regulator has been adjusted to its proper value, check the gas input by the following formula: INPUT IN BTU /HR = ®Heating value of gas in BTU - Per -CU. ft. x 3600 x CU. ft. gas measured@ @Time in seconds for CU. ft. of gas measured To obtain formula: ®Heating value of gas (BTU /CU. Ft.) is obtained from the Local Gas Utility. Section IV— OPERATION AND MAINTENANCE THERMOSTAT The thermostat is designed to provide the utmost in heating comfort, and is also designed to be attractive in appearance. Please remember that these controls are precision de- vices, and therefore should be handled accordingly. Also, remember that the Thermostat will be affected by any heat source, so do not place lamps, radio, TV, etc., so that heat from these sources can affect the Thermostat operation. TEMPERATURE SELECTION To select the temperature control point, move the tem- perature selection dial until the pointer is in line with the desired point on the temperature scale. The thermometer pointer will not change position on the temperature scale when the temperature selection lever is moved, but will change position as room temperature varies. FAN AND LIMIT CONTROL The Fan and Limit Controls are mounted in their proper location. The limit is set at the correct setting. This setting is the point at which the Limit Switch opens contact. The switch is automatic -reset and will make contact when the temperature of the element drops. On installations with adjustable fan controls, the settings should not exceed 130° on and 90° off. 10 ®To calculate CU. FT. Gas Measured: turn off all other gas appliances and pilots. REMEMBER to turn back on all pilots after test Is completed. @Measure Time (in seconds) for gas meter test dial to complete one revolution (local Utility will provide size of meter). @Measure Gas Input must not exceed gas input on unit rating plate. If the input does not correspond to that shown on the rating plate, adjust the input with the regulator screw of the pressure regulator until the rating plate input is obtained. The pressure in the manifold should not vary more than plus or minus 0.3 inches of water column from the specified valve. Any necessary major changes in the flow should be made by changing the size of the burner orifices. HIGH ALTITUDE INSTALLATION These units may be used at full input rating when installed at altitudes up to 2000 feet. When installed above 2000 feet, the input must be decreased 4% for each 1000 feet above sea level. CAUTION: DO NOT TAMPER WITH THE INTERNAL FAN OR LIMIT CONTROL MECHANISM. BLOWER SPEED ADJUSTMENT (DIRECT DRIVE BLOWER) The multi -speed direct drive motor is wired to the Hi -speed tap for cooling operation and low speed for heating operation. A change to a lower speed may be made at the motor. Heating and cooling models equipped with a blower relay, change speeds automatically. Refer to wiring diagram attached to the furnace. LUBRICATION INSTRUCTIONS For Lubrication Instructions for motor or blower bearings refer to labels attached to blower housing. FILTERS These units are equipped with efficient washable type air filters designed to keep the house cleaner by withholding dirt and other foreign particles from the air circulation. Filters should be cleaned or replaced at least twice a year or at any time they become clogged. Dirty filters will cause the furnace to heat improperly and possibly overheat by holding back air circulation. These furnaces are designed so that the filters may be quickly and easily replaced. Replacement filters must be of the same type and size as originally furnished with the furnace. • PERIbDIC INSPECTION AND FLAiviE REQUIREMENTS This heating system, like anything mechanical, will give the best comfort performance when it is properly ad- justed, correctly operated, and given regular careful maintenance. Because the modern heating plant is so automatic in operation, the owner has a tendency to forget it is in his home. The furnace will require occasional inspection, adjust- ment, and cleaning in order to enable it to provide year after year of indoor comfort at minimum operating ex- pense. This inspection and any required maintenance should be performed at the beginning of the heating season by a qualified serviceman. BURNER FLAME: Burner flame should run the length of the ribbons and be 3" to 4" in height. The flame should be blue in color with a slightly yellow tip. If for any reason the flame should lift from the burner, change color to orange or start rolling out from under the flash shield 'after igni- tion, an adjustment is necessary or the heat exchanger needs to be inspected and cleaned. A periodic visual check of the burner flame should give an indication of the need for further inspection. SEE FIGURE 6 INSPECTION AND CLEANING PROCEDURE NOTE: THIS FURNACE IS EQUIPPED WITH A PRES- SURED COMBUSTION CHAMBER. IT IS MANDATORY TO REPLACE ALL GASKETS THAT ARE REMOVED, ORDER REPLACEMENT GASKET PRIOR TO START- ING SERVICE. CAUTION: Silicon carbide ignitor Is used - extreme care must be exercised in handling the assembly due to the fragile nature of the ignitor assembly. 11 1. Disconnect source to the unit. 2. Remove louver panel from the unit and set aside. See Figure 7. 3. Turn gas supply "off" at the gas valve. Allow a few minutes for unit to cool down. 4. Remove the screws from the front panel of the burner enclosure and set aside. FLASH SHIELD AND �+ VERTICAL FRONT SHIELD PANEL LOUVER PANEL 5. Remove the front panel. 6. Remove the four screws holding the flash shield and vertical shield in place and set aside. 7. On the H.S.I. System, disconnect the sensor lead from the remote sensor (far left burner) and the Ignitor leads at the ignitor disconnect. 8. Remove the flash shield, and vertical shield. NOTE: At this point inspect for any loose particles or carbon deposits in the burner area. Using a flashlight and a small mirror, check the upper portions of the heat exchanger for any signs of blockage or dirt accumulation. If any of these conditions are apparent, proceed with the following steps. 9. Remove all burner sections from the unit. This is accomplished by pulling back on the burner sections so that it compresses the spring that Is located between the manifold and the burner. Tilt the burner up into the heat exchanger tube. Slide the burner sections off the orifice and remove from the unit. Make note of location of the burner with the Ignitor for reassembly in the correct position. 10. After each burner section has been taken from the unit, tap the end of the burner that slips over the orifice lightly on the ground, thereby removing any residue from inside the burner. Then run a vacuum hose across the top of the burner to remove any foreign material that might be lodged between the ports. 11. Disconnect the flue pipe from the flue outlet box collar, (. 12. Attach the exhaust end of a high pressure vacuum cleaner (shop vacuum) to the furnace flue outlet to force any loose particles from the upper heat ex- changer into the bottom burner area. 13. With a stiff bristled brush, clean the bottom area of the heat exchanger, brushing into the burner enclo- sure where the vacuum can easily be used to pick up the residue. 14. Reassemble the unit by reversing the above pro- cedure. Make sure all old gaskets are discarded and replaced with new gaskets. NOTE: Extreme care must be taken to protect all new seals and gaskets to assure tightness of the system. Failure to provide tight seals can result in faulty or improper system operation. BALANCING THE SYSTEM There is one adjustment of your heating system that you are In a position to do more satisfactorily than anyone else. This is the balancing of the system to provide equal comfort in every room. Best balancing is done on a typical cold day. Proceed as follows: Be sure that dampers or valves in pipes or register are wide open in all runs to the room or rooms that seem a little cool. 2. It is best to do this balancing in the evening after sundown. 1. 3. The room thermostat should be left at one setting for several hours before you attempt to do any balancing. 4. Check the temperature in all rooms, you can do this with a thermometer. 5. In the room or rooms that are too warm, turn down the register valve. 6. Wait several hours until room comfort balances out at this new setting and then recheck temperature. 7. By doing the adjusting a little at a time, you will accomplish the temperature balance you want. After a pipe damper or register valve has been adjusted it takes time for the temperature to conform with the new setting. By adjusting a little at a time, you will soon accomplish better system balance than can be done by anyone else who does not live in the house. EMERGENCY SERVICE In case of operating difficulty, check the following items before calling for service: 1. Make sure thermostat is set above room temperature. 2. Make sure line switch is "ON" and that fuse is not blown. 3. Make sure air filter is clean. 4. Make sure the Blower Door is properly in place. 5. Make sure there is no blockage of the flue to the outside atmosphere. 12 6. Make sure connections on the safety pressure switch are secure. 7. Make sure all compartments are securely closed and all fasteners are in place. If difficulty still exists, call your Installer. SEQUENCE OF OPERATION — ELECTRIC IGNITION 1. Thermostat calls for heat, energizing the Forced Draft Blower Relay which closes contacts that power the Forced Draft Blower. 2. The rotation of the Forced Draft Combustion Blower will make a centrifugal switch within the motor to prove blower operation and send power from the ignition circuit to the ignition control. 3. The pre -purge mode will delay thirty seconds before applying power to the silicone carbide ignitor. 4. The ignitor is allowed to warm up for approximately 10 seconds. 5. At the end of the warm -up time the valve is ener- gized. 6. The main burner flame must be detected within 7 seconds or the valve Is de- energized and the ignitor turned off. 7. If there is a failure to sense flame on the first attempt, there will be a 60 second delay. The second attempt at lighting the burner flame will duplicate the first attempt with pre - purge, warm -up times and lock -out times identical to those in the first try. Failure to prove on the second attempt will allow yet another 60 second delay and one more complete ignition attempt before complete system lockout. B. Lock -out of the control after the final ignition attempt, will require interruption of the power to the ignition control (either the 24V thermostat or line voltage to the furnace may be interrupted) for 1/20 second or longer to reset the system. 9. The Ignition Sequence will repeat the ignition se- quence for a total of three recycles if flame is lost within the first thirty seconds of establishment. The total of ignition attempts plus the number of recycles cannot exceed three. 10. If flame is established for more than thirty seconds after ignition, the recycle counter will clear. If flame is lost after 30 seconds, there will be a 60 second wait and restart of the ignition sequence. 11. A momentary loss of power or flame to the sensing circuit will cause the valve to be de- energized and a delay of 60 seconds before restarting the ignition sequence. Recycles will begin and the burner will operate normally if the gas supply returns or the fault condition is corrected prior to the last ignition at- tempt. Otherwise the control will lock -out. • 1 i " ') ; INPUT: 60,000 BTUH -1200 CFM (BLOWER 10 X 6) 1100 RPM -3 SPEED 1/4 HP DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER TIP SPEED MULTIPLY RPM BY 2.78 TO = TIP SPEED (FPM) MOTOR SPEED LOW INTERMEDIATE HIGH EXTERNAL STATIC PRESSURE IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE .10 890 950 46 1019 1090 41 1072 1335 33 .15 906 947 47 1024 1085 41 1076 1315 34 .20 922 945 47 1028 1075 41 1080 1300 34 .25 935 943 47 1035 1070 41 1082 1280 35 .30 948 940 47 1038 1050 42 1086 1260 35 .35 961 937 47 1046 1040 43 1089 1245 35 .40 973 935 47 1050 1035 43 1094 1230 36 .45 982 933 48 1056 1030 43 1096 1215 36 .50 995 930 48 1061 1020 43 1100 1195 37 .55 1013 927 48 1068 1010 44 1105 1180 37 .60 1017 925 48 1075 1000 44 1109 1160 38 .65 1027 923 48 1081 990 45 1115 1145 39 .70 1039 920 48 1085 980 45 1119 1130 39 INPUT: 40,000 BTUH -1000 CFM (BLOWER 10 X 6) 1100 RPM -3 SPEED 1/5 HP DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER TIP SPEED MULTIPLY RPM BY 2.78 TO = TIP SPEED (FPM) MOTOR SPEED LOW INTERMEDIATE HIGH EXTERNAL STATIC PRESSURE IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE .10 400 425 70 625 795 37 900 1220 24 .15 450 440 67 660 805 37 910 1205 25 .20 480 450 66 690 810 37 920 1190 25 .25 530 460 64 725 815 36 930 1175 25 .30 610 475 62 760 820 36 945 1160 26 .35 645 485 61 785 825 36 960 1145 26 ,40 675 490 60 815 825 36 970 1135 26 .45 715 495 60 835 830 36 985 1120 26 .50 745 500 59 865 830 36 995 1100 27 .55 785 505 59 890 825 36 1010 1085 27 .60 820 510 58 915 820 36 1020 1065 28 .65 850 510 58 935 810 37 1035 1045 28 .70 875 505 59 950 800 37 1045 1020 29 INPUT: 80,000 BTUH -1200 CFM (BLOWER 10 X 8) 1100 RPM -3 SPEED 1/4 HP DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER TIP SPEED MULTIPLY RPM BY 2.78 . TO = TIP SPEED (FPM) MOTOR SPEED LOW INTERMEDIATE HIGH EXTERNAL STATIC PRESSURE IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE .10 646 900 66 754 1090 54 958 1440 41 .15 676 900 66 780 1080 55 965 1415 42 .20 710 895 66 811 1075 55 974 1425 42 .25 742 890 67 825 1070 55 980 1415 42 .30 774 885 67 850 1060 56 989 1400 42 .35 800 885 67 869 1055 56 998 1380 43 .40 827 880 67 890 1045 57 1009 1365 43 .45 850 875 68 913 1035 57 1018 1345 44 .50 877 865 68 930 1025 58 1027 1325 45 .55 900 855 69 953 1010 59 1036 1300 46 .60 928 840 70 970 990 60 1045 1270 47 .65 949 825 72 990 970 61 1055 1215 49 .70 971 800 74 1005 945 63 1063 1195 49 i • DIRECT DRIVE - BLOWER CHAR4, DIRECT DRIVE - BLOWER CHART DIRECT DRIVE - BLOWER CHART ,13 INPUT: 100,000 BTUH --2000 CFM (BLOWER 11.8 X 10.6) 1100 RPM -4 SPEED 3/4 HP DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER TIP SPEED MULTIPLY RPM BY 3.08 TO = TIP SPEED (FPM) MOTOR SPEED LOW LOW INTERMEDIATE HIGH INTERMEDIATE HIGH EXT. STATIC PRESS, IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE .10 820 1675 44 926 1920 38 986 2050 36 1042 2270 33 .15 838 1665 44 937 1895 39 993 2025 36 1048 2240 33 .20 854 1650 45 945 1870 39 1000 2005 37 1052 2210 34 .25 870 1640 45 954 1845 40 1007 1975 37 1057 2180 34 .30 887 1620 46 962 1820 41 1012 1945 38 1063 2150 34 .35 900 1605 46 975 1790 41 1019 1915 39 1069 2120 35 .40 914 1585 47 980 1760 42 1024 1885 39 1075 2090 35 .45 932 1560 47 990 1735 43 1032 1850 40 1079 2055 36 .50 947 1530 48 1000 1705 43 1040 1820 41 1082 2025 37 .55 960 1500 49 1010 1665 44 1046 1780 42 1088 2000 37 .60 976 1465 50 1019 1625 45 1054 1745 42 1090 1970 38 .65 990 1425 52 1032 1570 47 1062 1700 43 1095 1940 38 .70 1008 1375 54 1041 1535 48 1073 1650 45 1096 1910 39 INPUT: 80,000 BTUH -1600 CFM (BLOWER 11.8 X 8) 1100 RPM -3 SPEED 1/2 HP DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER TIP SPEED MULTIPLY RPM BY 3.08 TO = TIP SPEED (FPM) MOTOR SPEED LOW INTERMEDIATE HIGH EXTERNAL STATIC PRESSURE IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE .10 610 1060 56 710 1385 43 910 1800 33 .15 635 1070 55 740 1385 43 920 1785 33 .20 660 1080 55 764 1385 43 932 1765 33 .25 685 1085 55 786 1380 43 944 1750 34 .30 715 1090 54 810 1380 43 953 1735 34 .35 745 1095 54 829 1380 43 967 1715 34 .40 760 1100 54 852 1380 43 978 1695 35 .45 785 1095 54 871 1375 43 989 1680 35 .50 810 1090 54 890 1370 43 1000 1660 36 .55 835 1085 55 911 1365 43 1012 1640 36 .60 860 1085 55 929 1360 43 1025 1620 36 .65 885 1070 55 945 1355 44 1030 1600 37 .70 910 1050 56 961 1345 44 1040 1580 37 INPUT: 100,000 BTUH -1600 CFM (BLOWER 10 X 10) 1100 RPM -3 SPEED 1/3 HP DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER MULTIPLY RPM TO = TIP SPEED TIP SPEED BY 2.78 (FPM) MOTOR SPEED LOW INTERMEDIATE HIGH EXTERNAL STATIC PRESSURE IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE .10 609 1010 73 765 1350 55 943 1795 41 .15 660 1035 72 794 1335 55 958 1770 42 .20 700 1060 70 824 1325 56 972 1745 42 .25 736 1075 69 857 1315 56 986 1725 43 .30 777 1085 68 874 1300 57 1000 1690 44 .35 808 1080 69 905 1290 57 1012 1665 44 .40 842 1075 70 920 1275 58 1024 1640 45 .45 862 1070 69 942 1265 58 1038 1615 46 .50 808 1065 69 960 1250 59 1047 1590 47 .55 918 1060 70 980 1235 60 1059 1565 47 .60 942 1035 71 1000 1225 60 1067 1540 48 .65 969 1020 73 1019 1215 61 1076 1515 49 .70 1000 995 74 1032 1200 62 1085 1490 50 JIRECT DRIVE - BLOWER CHART DIRECT DRIVE - BLOWER CHART DIRECT DRIVE - BLOWER CHART 14 INPUT: 120,000 BTUH -1600 CFM (BLOWER 10 X 10) 1100 RPM -3 SPEED 1/3 HP DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER TIP SPEED MULTIPLY RPM BY 2.78 TO = TIP SPEED (FPM) MOTOR SPEED LOW INTERMEDIATE HIGH EXTERNAL STATIC PRESSURE IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE .10 625 1150 77 705 1340 66 845 1650 54 .15 660 1150 78 735 1340 66 865 1640 54 .20 690 1145 78 765 1335 67 880 1630 55 .25 720 1140 78 790 1335 67 900 1615 55 .30 750 1130 79 820 1330 67 920 1600 56 .35 775 1115 80 840 1320 67 935 1585 56 .40 800 1100 81 865 1305 68 950 1560 57 .45 825 1075 83 890 1290 69 970 1540 58 .50 850 1045 85 910 1275 70 985 1520 58 .55 870 1000 89 925 1250 71 1000 1490 60 .60 890 950 93 945 1220 73 1015 1460 61 .65 920 880 101 965 1185 75 1025 1420 63 .70 935 810 110 980 1145 77 1040 1380 64 INPUT: 120,000 BTUH -2000 1100 RPM -4 SPEED 3/4 HP CFM (BLOWER 11.8 X 10.6) DIRECT DRIVE MOTOR NOTE TO OBTAIN BLOWER TIP SPEED MULTIPLY RPM BY 3.08 TO = TIP SPEED (FPM) MOTOR SPEED LOW LOW INTERMEDIATE HIGH INTERMEDIATE HIGH EXT. STATIC PRESS. IN.W.C. RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMP RISE RPM CFM TEMI RISE .10 755 1725 51 854 1980 45 955 2235 40 1017 2400 37 .15 774 1720 52 867 1960 45 962 2215 40 1025 2380 37 .20 795 1720 52 880 1950 45 969 2190 41 1031 2355 38 .25 817 1715 52 892 1930 46 979 2165 41 1038 2330 38 .30 833 1705 52 904 1915 46 988 2140 41 1044 2305 38 .35 850 1690 52 915 1895 47 996 2115 42 1048 2275 39 .40 866 1675 53 930 1870 47 1003 2085 43 1054 2245 40 .45 879 1655 54 940 1850 48 1010 2060 43 1060 2210 40 .50 888 1635 54 950 1825 49 .1017 2025 44 1064 2180 41 .55 913 1610 55 963 1795 49 1026 2000 44 1070 2145 41 .60 927 1580 56 973 1770 50 1035 1970 45 1075 2105 42 .65 943 1550 57 983 1730 51 1043 1935 46 1082 2070 43 .70 960 1515 58 996 1690 52 1049 1890 47 1085 2025 44 DIRECT DRIVE - BLOWER CH DIRECT DRIVE- BLOWER CHART 15 • REPAIR PARTS ARE AVAILABLE FROM THE FURNACE MANUFACTURER, DEALER OR DISTRIBUTOR. WHEN ORDERING PARTS, REFER TO THAT PART OF THE RATING PLATE, ATTACHED TO THE FURNACE THAT INCLUDES THE COMPLETE FURNACE MODEL NUMBER, SERIAL NUMBER AND LISTED NAME AND ADDRESS WHERE PARTS ARE AVAILABLE. BURNER GROUP GAS MANIFOLD MAIN BURNER ORIFICES MAIN BURNER WITH IGNITOR BRACKET MAIN BURNER WITH SENSOR BRACKET MAIN BURNER (COMMON) MAIN BURNER IGNITOR /SENSOR D.S.I. SYSTEM (ONLY) BLOWER GROUP BLOWER WHEEL BLOWER MOTOR BLOWER MOTOR CAPACITOR BLOWER MOTOR SUPPORT (MOUNT) FORCED DRAFT BLOWER BLOWER MOTOR (COMBUSTION) BLOWER WHEEL (COMBUSTION) AN EXPANDED PARTS LIST, FOR THE PARTICULAR FURNACE MODEL MAY INSTALLATION INSTRUCTION AND OWNER'S MANUAL ENVELOPE. WARNING: IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE. CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY, DEALER, DISTRIBUTOR OR THE GAS SUPPLIER FOR INFORMATION OR ASSISTANCE. FORCED DRAFT BLOWER BURNER STANDARD CARRYOVER' BURNER WITH SENSOR BLOWER MOTOR BLOWER WHEEL RELAY PARTS UST OAS FIRED FORCED DRAFT FURNACE - UPFLOW SERIES 18 CONTROL GROUP GAS VALVE IGNITION CONTROL (ELECTRIC IGNITION) IGNITOR (ELECTRIC IGNITOR) SENSOR- REMOTE (ELECTRIC IGNITION) FAN & LIMIT CONTROL PRESSURE SWITCH PRESSURE SWITCH ORIFICE TRANSFORMER RELAY-MAIN BLOWER RELAY- COMBUSTION BLOWER BLOWER DOOR INTERLOCK SWITCH PRESSURE SWITCH (NORMALLY CLOSED) BLOWER HOUSING PRESSURE SWITCH ORIFICE FAN L LIMIT IGNITION CONTROL GAS VALVE BURNER WITH IGNITOR MANIFOLD TRANSFORMER BE FOUND IN THE FURNACE • 41) A� NDUM A INSTALLATION INSTRUCTIONS FOR UPFLOW FORCED DRAFT FURNACE HORIZONTAL VENTING ITEM NUMBER O [1 w 3" KIT NO.-8603004 -- 4" KIT NO.-8603005 8G03004 8G03005 3" KIT NO. 4" KIT NO. 0548010001 0548010002 DESCRIPTION INTAKE TERMINAL VENT TERMINAL WITH CLEARANCE SHIELD VENT ADAPTOR FITTING CONDENSATE TRAP TEE (SNAPPY S -902 -3 or -4) CAP WITH DRAIN (SNAPPY S -904 -3 or -4) 8 FT. x 3 /8" DRAIN HOSE HOSE CLAMP INSTALLATION INST. INSTALLER SUPPLIED MATERIALS SEE TABLE 1 FOR VENT LENGTHS Straight sections- , SNAPPY Stainless Steel Pipe NO. S -905 -3 Elbows — Stainless SNAPPY Steel' NO. S -900 -3 Intake - Lightweight Type Plastic (Drain Pipe) ASTM -D 335 -OMS 0548010003 2311 -170 2311 -180 2311 -190 2939 -156 2344 -433 7502 -084 0548010004 2311 -171 2311 -181 2311 -191 2939 -156 2344 -433 7502 -084 SNAPPY NO. S -905 -4 SNAPPY NO. S -900 -4 Type ASTM -D 355 -OMS C PVC Bonding Cement Silicone Sealant (Dow Corning TRV 732 or the equivalent) ID1 Pipe Hangers (Perforated Metal Strapping, Etc.) Stainless Steel Sheet Metal Screws Outlet Pipe Insulation (Optional) Any heavy duty fiberglass pipe Insulation type ASJ may be used, if this option is desired. For the location of the Snappy Pipe Distributor closest to your area call: SNAPPY ' Air Distribution Products A Division of Standex Energy Systems 1090 Legion Road (P.O. Box 1168) Detriot Lakes, MN. 56501 (218) 847 -9258 , . 17 • ` ;'. 1 A:., iii iti,1.10. :1T'C•Id f. INPUT BTUH VENT OR INTAKE DIA. (. ,ULATED VENT PIPE NINSULATED VENT PIPE MAX. LENGTH MAX. ELBOWS CLEARANCE TO COMBUSTIBLE MATERIALS" MAX. LENGTH MAX. ELBOWS CLEARANCE TO COMBUSTIBLE MATERIALS 40,000 3" 10 FT. 4 1" - - 6" 60,000 3" 15 FT. 4 1" 10 FT. 3 6" 80,000 3" 25 FT. 4 1" 15 FT. 3 6" 100,000 4" 25 FT 4 1" 15 FT. 3 6" 120,000 4" 25 FT 4 1" 15 FT. 3 6" 'NATIONAL FUEL GAS CODE, ANSI 2.223.1.1984 INSTALLATION INSTRUCTIONS FOR FURNACE HORIZONTAL VENT WITH OUTSIDE AIR INTAKE For furnace connection to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1 -1984, applicable provisions of local building codes and these instructions. 1. DIRECTION OF VENT FITTINGS All Vent fittings and pipe must be installed with male ends toward the furnace. Longitudinal Vent pipe seams must be on top. All horizontal vent pipe must be pitched up (Downhill toward furnace) at least 1 /4" per foot. All horizontal pipe should be supported to prevent sagging. Place pipe hangers approximately five feet apart for both vent and intake pipe runs. 2. CONDENSATE IN THE VENT Under certain conditions, such as long runs of vent pipe through spaces with relatively cool ambient temperatures, condensate may form inside the flue vent pipe. The prescribed pitch of the pipe and the supplied condensate trap /drain connected in the hori- zontal pipe close to the furnace outlet will allow removal of any accumulation that may occur. STAINLESS STEEL VENT PIPE TO FURNACE OUTLET CAULK ALL JOINTS HOSE CLAMP CONNECT HOSE TO FLOOR DRAIN TRAP MAXIMUM.' F.NGTH OF VENT (HORIZONTAL APPLIC ION INSULATE IF APPLICABLE (OPTIONAL) 12" FIGURE 1 3. SEALING THE PIPE JOINTS Because the forced draft unit produces positive vent pressures when the vent arrangement Is in the horizontal position, it is necessary to seal all joints and connections to prevent the escape of flue products into the surrounding area. Sealing of the pipe joints of both intake and outlet is necessary to prevent pressure losses in the pipe under wind conditions. These losses can produce an imbalance between the intake and exhaust, at the furnace, which could shut down the system. 4. SEALING OF PLASTIC INTAKE PIPING Use a good quality cement on clean, oil free joints. 5. THE STAINLESS STEEL VENT PIPING Use a high temperature silicone sealant (such as Dow - Corning RN 732-400° F or equivalent). All joints to be sealed should be oil and dirt free. Where it is necessary to provide extra strength to a joint in the stainless steel exhaust pipe, the use of stainless steel sheet metal screws is recommended (stainless steel type 304). DO NOT PUT A SCREW IN THE BOTTOM OF THE PIPE. Dab the screw with 5 Ft SEAM II ON TOP ' /," SLOPE TOWARD FURNACE FOR EVERY 12" HORIZONTAL NOTE: REFER TO ITEM NO. 8 FOR INSPECTION AND MAINTENANCE OF HORIZONTAL VENT.' 18 ADEQUATE CLEARANCE VENT / TERMINAL WITH CLEARANCE COLLAR 9 silicone sealant to prevent( akage around the (breads. Screwing the joint together Is not a sub- stitute for sealing the connection with the silicone sealant. 6. LOCATION OF THE VENT TERMINAL The vent terminal must be located at least one foot above grade to avoid blockage by snow or as required to be above snow level. The terminal must be at least three (3) feet above any forced air inlet terminal servicing any other appliance located within 10 feet horizontally. The vent terminal shall be located at least four (4) feet below, four (4) feet horizontally .from, or one (1) foot above any door, window or gravity air inlet into any building. A clearance of four (4) feet Is required to combustible materials opposite the outlet terminal. Should the outlet terminal be located adjacent to a public walkway, it must be not less than seven (7) feet above grade. 7. Vent and intake must be on the same face of the building in order to be in the same pressure zone. The 19 centerline the terminals must be a minimum 16 inches ap rc on a horizontal line. Never install the intake terminal higher than the vent terminal. ) 8. PERIODIC INSPECTION AND MAINTENANCE Under certain wind conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (such as aluminum sheeting) may be required to prevent staining or deterioration. TERMINALS Inspect the intake and outlet terminals at the begin- ning and periodically throughout the heating season to prevent the accumulation of debris at the terminal barrier screens. VENT PIPE Inspect the vent pipe (stainless Steel Pipe) at the beginning and periodically 'throughout the heating season to insure that the joints are leak tight and that the pipe is in proper condition for safe operation. At the same time check the hose /trap from the tee connector to ensure that it is intact and unrestricted. INTAKE TERMINAL , 16 \OW Vow VENT ADAPTOR FITTING TRANSITION BOX CONDENSATE TEE TRAP 1 v ^ VENT TERMINAL WITH CLEARANCE COLLAR a ' FLUE GAS VENT/ ITEM "A" (EXPLODED VIEW) SHOWING THE LONGITUDINAL SEAM OF THE VENT PIPE ON TOP WHEN INSTALLED, READ ASSEMBLY PROCESS THO '1GHLY BEFORE PROCEEDING: • CAUTION: SHUT OFF ALL ELECTRICAL POWER TO THE FURNACE. 1. Assembly of Outside Intake /Vent Terminals FOLLOW ALL THE CONDITIONS DESCRIBED EAR- LIER IN THESE INSTRUCTIONS WITH REGARD TO CLEARANCES AND POSITIONING WHEN DETER- MINING THE LOCATION OF THE INTAKE AND OUTLET VENT TERMINALS. INTAKE TERMINAL: a. The hole made in the wall through which the terminal is installed, should be one inch (1 ") larger than the outside diameter of the terminal pipe. b. Insert the terminal through the hole from the outside and secure it in place with the proper type of anchor for the type of construction to which it is being attached. c. From the outside, caulk around the edge of the mounting plate to provide a tight seal against exterior elements. d. From the inside, caulk around the pipe as it comes out of the wall. VENT TERMINAL: a. If the surface through which the outlet terminal is protruding is of combustible material, the hole in the construction must be made large enough to allow the fitting of the concentric clearance collar around the outlet terminal. b. Slip the terminal in place from the outside and secure it with the appropriate anchoring device. c. Caulk around the perimeter of the mounting plate. d. From the inside, caulk around the pipe, (or clear- ance collar if used). 2. PIPE ASSEMBLY Before hanging the intake and outlet pipe per- manently, assemble the pipe from the terminal to the furnace and cut the lengths necessary to give the positioning required in final assembly. Start the intake plastic pipe so the unflared (male) end Is at the furnace connection. Start the vent system assembly by placing the vent adaptor fitting on the furnace. Assemble the stainless steel vent pipe and fittings with the male ends toward the vent adaptor fitting. All other pipe sections and fittings must be oriented in the same direction to insure condensate drainage toward the vent drain tee. The drain tee should be installed as close to the furnace as possi- ble, (within 18" laterally). ASSEMBLY INSTRUCTIONS: 20 9. h. DO NOT allow the metal outlet pipe to come within six inches of combustible construction. See National Fuel Gas Code, ANSI Z- 223.1 -1984. (One inch clearance is required from the outer surface of an insulation wrapped pipe.) Allow 1/4" per foot drop toward furnace, for the vent pipe. To obtain desired piping length: Final trim on the pipe may be accomplished at either the furnace end or the terminal end. If it is necessary to trim the pipe at points between the furnace and terminal ends, use the following procedure: 1. Trim only the unflared end at these points. 2. Do not trim drain tee. 3. FINAL ASSEMBLY Vent Pipe a. Begin at the vent terminal —NOTE: LONGITU- DINAL SEAM OF THE VENT PIPE MUST BE ON TOP WHEN INSTALLED. (See FIGURE 2 IN- SERT A.) b. Seal each piping joint as you assemble the con- nections by spreading at least a 1 /e inch thick bead of silicone sealant one (1) inch in from the end of the male connection. After the connection is pushed together, check that there is no gapping in the seal. Reseal any gaps or open seams. c. Support the pipe as you go along to prevent excess movement at the joints. •d. Where screws are needed for rigidity (stainless steel screws) be sure to seal around the screw to prevent leakage. e. At the furnace connection, caulk around the base of the collar at the vent box collar with silicone. Then install the Vent adaptor fitting Into the silicone caulking and check for a good perimeter seal. f. Seal the joint at the vent terminal with silicone and make one final inspection of each pipe joint seal. Wrap the areas requiring insulation. Attach the condensate drain hose to the fitting on the drain tee cap and secure with the plastic tie provided. The looped end of the hose, which will act as a trap in the line, must be attached at the tee drain. The free end should then be run to, or as close as possible to a floor drain. 4. FRESH AIR INTAKE PIPE ASSEMBLY a. Beginning at the intake terminal, slip the pipe end Over the terminal pipe. b. Connect the pipe back towar( ) furnace, cement- .. ! ing each joint with standard plastic cement and support the structure with pipe hangers as needed. BE SURE JOINTS ARE CLEAN AND DRY BE , FORE CEMENTING. c. At the furnace connection, lay a bead of silicone at the base of the collar on the intake transition box. Then slip the final connection into place to com- plete the joint. d. Caulk the joint at the terminal connection with silicone, forcing the silicone Into the gap between the pipes. Check the assembly for integrity of seal. CAUTION: The Horizontal Vent Kit is designed for use with a Forced Draft Gas Furnace. As a natural part of the unit's operation, normal products of combustion, Including FINAL INSPECTION QUESTIONNAIRE System now should be operated and the following items checked: 1. All vent fittings MUST be installed with male ends toward furnace (pitched at least V4 inch per foot). 2. Have Vent Pipe and Vent Terminals been installed with seams on top? 3. Have all Joints from furnace to terminals been ade- quately sealed? 21 water vapor a iented to the atmosphere. Since the outside air temperature can be well below 32° F., it is possible that the water vapor in the exhaust will freeze, causing an ice buildup around the discharge opening of the pipe. During periods of extremely cold weather and prolonged operation of the furnace, this ice build -up could become quite large. The manufacturer does not recom- mend the installation of these units in locations above frequent vehicular and /or pedestrian traffic. The ice build -up could present a potentially hazardous situation if it becomes dislodged. The manufacturer will NOT be held responsible for any injury or property damage resulting from any improper installation. Figure 2 is a recommended installation to prevent prop- erty or personal injury. 4. Make sure that hose with condensate trap is properly attached to tee and unrestricted. 5. Have Terminals been adequately caulked to prevent leakage? 6. Make sure these instructions are kept available for your periodic .inspection and maintenance of the system. ; ■.l CITY OF TUKWILA 6200 SOUTIICENTER BOULEVARD, TUKWILA, IVASIIINGTON98188 September 11, 1991 Dear Ms Cross: Sincerely, 1.\ 4 . Ken Nelsen Plans Examiner PHONE # (206) 433.1800 Jeannie Cross Sunlok, Inc. 11630 Slate Ave. S.E. Kirkland, WA 98034 RE: Byron 'Bankskfurnace and water heater conversion Plan check number 91- 162 -M The mechanical permit application for subject residence, received September 3, 1991 to this office did not include all required subtitle information. Please address the following comments. 1. Provide heat loss calculations of this residence to qualify the proposed sized furnace per the Washington State Energy Code. 2. Provide the manufactures installation instruction for all appliance to be installed. Please confirm you have received these comments by contacting this office and /or submit revisions within ten working days. Feel free to call me if there are any questions, 8 :30 a.m. to 4:30 p.m. at 431 -3670. Cary L. VanDasen, Mayor