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Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with instructions could result in personal injury and/or property damage!

Indirect Gas-Fired Heat Modules

1

General Safety Information

These indirect gas-ﬁred furnaces are commonly used
in many different manufacturer’s ventilating products.
For unit-speciﬁc information, refer to the Installation,
Operation and Maintenance manual (IOM) for the unit in
which this furnace is installed.

•

Both the furnace units are listed for installation in the
United States and in Canada.

•

Installation of gas-ﬁred duct furnaces must conform
with local building codes. In the absence of local
building codes, installation must conform to the
National Fuel Gas code, ANSI Z223.1 or in Canada,
CAN/CGA-B149 Installation codes.

•

All electrical wiring must be in accordance with the
regulations of the National Electric Code, ANSI/
NFPA-70.

•

Unit is approved for installation downstream from
refrigeration units. In these conditions, condensate
could form in the duct furnace and provision must be
made to dispose of the condensate.

FOR YOUR SAFETY

If you smell gas:
1. Open windows.
2. Do not touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.

FOR YOUR SAFETY

The use and storage of gasoline or other
flammable vapors and liquids in open
containers in the vicinity of this appliance is
hazardous.

WARNING

Improper installation, adjustment, alteration,
service or maintenance can cause injury or
death. Read the installation, operating and
maintenance instructions thoroughly before
installing or servicing this equipment.

Recognized Component

®

®

Document 474645

Model PVF and PVG

Indirect Gas-Fired Heat Modules

Model PVF

Model PVG

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Содержание PVF

Страница 1: ...l building codes installation must conform to the National Fuel Gas code ANSI Z223 1 or in Canada CAN CGA B149 Installation codes All electrical wiring must be in accordance with the regulations of the National Electric Code ANSI NFPA 70 Unit is approved for installation downstream from refrigeration units In these conditions condensate could form in the duct furnace and provision must be made to ...

Страница 2: ... Unit Identification It is necessary to know the unit model number the burner control turndown and the serial number This information is needed when ordering replacement parts and is available on labels located on the unit Furnace Model Number On the furnace access door or immediately next to the door is a Mylar data label See image below Locate the furnace model number at the top of the label and...

Страница 3: ...r Leaks 14 Gas Pressure Test Ports 14 Sequence of Operation 15 Start Up Standby 15 Heat Mode 15 Recovery from Lockout 15 Performance Data 15 Gas Valves 16 Start Up Furnaces all units 17 4 1 Turndown Electronic Modulation 17 Adjust High Fire and Low Fire Settings 18 Modulating Valve High Fire Setting 18 Modulating Valve Low Fire Setting 18 2 1 Turndown Electronic Modulation 19 8 Stage Combustion 20...

Страница 4: ...ff igniter Typical Furnace Control Logic In all cases refer to the unit speciﬁc wiring diagram located on the unit control center door This illustration is only for a typical 4 1 turndown electronic modulation configuration Temperature Sensor If there is no DDC the sensor is connected to the FX DDC Located in unit main control center FX Controller Input Converter Ignition Controller Call for heat ...

Страница 5: ... The temperature dial and ampliﬁer are installed in the furnace control center Field adjustments include discharge air temperature which is done by means of the Remote Temperature Dial Ampliﬁer Remote Temperature Dial Typical Furnace Electrical and Control Components Microprocessor The microprocessor provides the call for heat to the ignition controller and also monitors the discharge air temperat...

Страница 6: ... valve will modulate the combustion rate continuously dependent on the output from an FX controller With this method all the burners ﬁre at the same time but at a varying capacity The Modulating Valve is used in conjunction with an FX electronic controller and a combination valve which provides an ON OFF function Two Stage Valve The two stage valve is switched electrically from closed to full outp...

Страница 7: ...inator on the exhaust pipe Exhaust transition and vent termination must be purchased from the factory for proper operation Exhaust pipe is by others WARNING The following guidelines must be followed for all indoor units 1 Installation of venting must conform with local building codes In the absence of local codes installation must conform with the National Fuel Gas Code ANSI Z223 1 or in Canada CA...

Страница 8: ...er failure do not locate unit where chlorinated halogenated or acid vapors are present When units are installed in tightly sealed buildings provisions should be made to supply an adequate amount of inﬁltration air from the outside The rule of thumb is that an opening of one square inch should be provided for every 1000 BTUs per hour of input rating Vent terminals must be used Construct the vent sy...

Страница 9: ...hes Combustion Air inches Exhaust inches Combustion Air inches 75 175 4 4 4 6 200 400 6 6 6 8 NOTE Vent piping is supplied by others and not supplied by manufacturer Installation of Concentric Venting Concentric venting allows the exhaust pipe and combustion air pipe to pass through a single hole in the roof or wall of the building A concentric venting adapter CVA is required for concentric ventin...

Страница 10: ...ween the wall and the air intake pipe using an appropriate method Concentric Venting Vertical Refer to the diagram below for venting on vertical concentric systems Maintain at least 12 inches between the top of the combustion air inlet terminals and the bottom of the exhaust terminal Dim B The bottom of the combustion air intake pipe must terminate above the snow line or at least 12 inches above t...

Страница 11: ...o pass through the roof and provide the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake With all required clearances satisﬁed attach the exhaust pipe to the CVA Install Combustion Air Pipe Attach a ﬁeld supplied combustion air pipe to the concentric side of the CVA Be sure to provide enough combustion air piping to pass through the roof and provide...

Страница 12: ...he minimum vent length is 10 feet and the maximum vent length is 70 feet The total equivalent vent length must include elbows The equivalent length of a 4 inch elbow is 6 feet and the equivalent length of a 6 inch elbow is 10 feet Install Exhaust Pipe Run an exhaust pipe from the unit s combustion exhaust through the roof to the outdoors The exhaust pipe must terminate at least 24 inches above the...

Страница 13: ... run must be considered in determining the pipe size to avoid excessive pressure drop Refer to a Gas Engineer s Handbook for gas pipe capacities NOTE Each furnace has a single 3 4 inch connection Installation of Control Wiring Disconnect power supply before making any wiring connections to prevent electrical shock and equipment damage All appliances must be wired strictly in accordance with the wi...

Страница 14: ...fore applying gas to the valves test the gas pressure to make sure it is less than 14 in wg Pressures greater than 14 in wg will damage the gas valves Install Additional Regulator if required If the gas supply pressure exceeds 14 in wg an additional regulator must be installed to reduce the pressure The additional regulator is to be provided and installed by others The regulator must have a listed...

Страница 15: ...dditional tries will be attempted before going into lockout for one hour 4 When a ﬂame is sensed sparking stops immediately The gas valve and combustion blower remain energized 5 Ignition 4 1 Electronic Modulation The burner will light at 100 ﬁre and remain there for up to 30 seconds The main burner gas valve will then modulate from 100 down to a minimum of 25 as needed The combustion blower will ...

Страница 16: ...naces Gas Control Knob ON OFF High Fire Adjusting Screw Overview of typical Two Stage Valve Used in eight stage and two stage furnaces Overview of typical Modulating Valve Used in 4 1 Electronic Modulation Low Fire and High Fire adjustments are made on printed circuit board behind removable cover Low Fire Adjusting Screw High Fire Adjusting Screw Terminal Block Gas Control Knob ON OFF Close up of ...

Страница 17: ...dulating valve that causes the valve to send more or less gas to the furnace The combination valve is normally closed It requires 24 VAC to hold it open With 4 1 Turndown Electronic Modulation Start Up Furnaces all units After the gas piping has been installed and leak tested verify that all ﬁeld installed components such as an air temperature sensor have been installed Verify that ON OFF gas cont...

Страница 18: ...mbination valve is set to the maximum setting Turn the regulator screw all the way in Modulating Valve High Fire Setting 1 Connect a manometer to the test port on the burner manifold 2 Press and hold button 1 until the LED lights solid red Release the button Observe the gas pressure on the manometer 3 Adjust the modulating valve by pushing button 1 to increase the pressure or by pushing button 2 t...

Страница 19: ...ide of the gas valve Low ﬁre gas pressure should be 0 875 in wg for natural gas or 2 5 in wg for LP gas 6 Return the A1092 Controller to normal operation by reconnecting the wire on the modulating valve and turning down the temperature selector 7 Shut down the furnace and then remove the manometer from the manifold and reinstall the plug in the test port 8 Return the furnace to normal operation Fu...

Страница 20: ... manifold pressure must be checked and properly set on each manifold Two Stage Valve Two Stage Valve Split Burner Manifold Remote Temperature Sensor FX Controller Ignition Controller 8 Turn off furnace Reconnect the wire to the high ﬁre terminal Remove manometer and reinstall plug into manifold test port 9 Connect manometer to the other manifold test port and repeat the high ﬁre low ﬁre set up seq...

Страница 21: ...ge Valve Remote Temperature Sensor A350 Controller A350 JOHNSON CONTROLS Ignition Controller With 2 Stage Combustion With Combination Turndown Conﬁgurations There are several different turndown options that may be used in the units that are simply combinations of basic conﬁgurations In all cases all gas valves must be set for high fire and low fire as part of the Start Up process Inspect the furna...

Страница 22: ... Bleed gas line Supply gas pressure too high or too low Check that supply pressure is between 6 and 14 in wg for natural gas and between 11 and 14 in wg for LP gas Loose wire connections Check for tight wire connections No Spark a Spark electrode Ensure spark gap is 1 8 inch and ceramic insulator is not cracked Replace if necessary b Spark cable shorted to ground Replace spark cable c Ignition con...

Страница 23: ...lay RH closed Heat relay RH is not energized Check for loose connections Repair or replace heat relay RH No Yes 24 VAC across W1 and L Heat switch S4 open or not wired Close or replace heat switch S4 No Yes 24 VAC across R and L Main disconnect DS1 open or defective Close repair or replace Main transformer TR1 fault Replace main transformer No Yes Continues on next page DT1 displayed on furnace co...

Страница 24: ...pressure switch PS2 Combustion blower CM not functioning Replace fusing FU7 combustion blower or relay CM Yes No Ignition controller IC red LED blinks 1 time 2 times or 4 times Improper manifold pressure Set high and low manifold pressure refer to 4 1 Electronic Modulation Start Up section Faulty spark rod or spark gap does not equal 1 8 inch Replace spark rod or adjust gap to 1 8 inch Yes No cont...

Страница 25: ...nd C Main disconnect DS1 open or defective Close repair or replace Main transformer TR1 fault Replace main transformer No Yes Ignition controller IC red LED blinks 6 times Combustion blower CM not functioning Replace combustion blower or relay CM Air proving switch PS2 defective Replace air proving switch Yes No Ignition controller IC red LED blinks 1 time 2 times or 4 times Improper manifold pres...

Страница 26: ...ss 22 and 21 Heat transformer TR2 fault Replace heating transformer No No Yes Yes N O contact on heat relay RH closed Heat relay RH is not energized Check for loose connections Repair of replace heat relay RH No Yes 24 VAC across W1 and C Heat switch S4 open or not wired Close or replace heat switch S4 No Yes 24 VAC across R and C Main disconnect DS1 open or defective Close repair or replace Main ...

Страница 27: ...ive combustion blower CM No Yes No Ignition controller IC red LED blinks 1 time 2 times or 4 times No Cycle power to the unit and wait 30 seconds Everything is working properly consult factory Improper manifold pressure Set high and low manifold pressure refer to 8 Staged Start Up section Faulty spark rod or spark gap does not equal 1 8 inch Replace spark rod or adjust gap to 1 8 inch Yes Does the...

Страница 28: ...s Yes 24 VAC across W1 and C Heat Switch S4 open Turn heat switch S4 on No Yes 24 VAC across R and C Main disconnect DS1 open or defective Close repair or replace Main transformer TR1 fault Replace main transformer No Yes Ignition controller IC red LED blinks 6 times Combustion blower CM not functioning Replace combustion blower or relay CR Air proving switch PS2 defective Replace air proving swit...

Страница 29: ...e new setting and return to the Setpoints Menu press the Enter button To return to the Setpoints Menu without saving the change wait 15 seconds To exit Program Mode from the Setpoints Menu wait for 15 seconds Inlet Air Sensor iAS optional The Inlet Air Sensor monitors the temperature of the inlet air If the inlet air is above the setpoint the inlet air sensor shuts off the furnace and continues to...

Страница 30: ...oints Menu and then scroll up or down until the display reads dtS Press the Enter button To edit the settings follow the instructions in Program Mode section Access the Inlet Air Sensor Go to the Setpoints Menu and then scroll up or down until the display reads iAS Press the Enter button Once the display reads iAS the display will change to the Inlet Air Sensor setting To edit the setting follow t...

Страница 31: ...ean the ports with an aerosol degreaser or compressed air c Wipe the inside of the burner clean Cleaning the burner with a degreaser will slow the future buildup of dirt Before reinstalling the burner assembly look down the heat exchanger tubes to make sure they are clear of any debris Reinstall manifold and burner assembly reconnect wire leads and gas supply piping Turn on the electrical power an...

Страница 32: ..._____________________ _________________________________________________ Date ___________________Time _____________ AM PM Notes ___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date ___________________Time ...

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