Empire Heating Systems DV-55IPT-1 Quick start guide
Page 1
INSTALLATION INSTRUCTIONS
AND
OWNER'S MANUAL
FAN TYPE
DIRECT VENT
WALL FURNACE
MODEL
DV-55IPT-1
Thisappliancemaybeinstalledinanaftermarket,
permanentlylocated,manufacturedhome(USA
only) or mobile home, where not prohibited by
state or local codes.
This appliance isonly forusewiththetype ofgas
indicated on the rating plate. This appliance is
not convertible for use with other gases, unless
WARNING: If not installed, operated and
maintained in accordance with the manufactur-
er's instructions, this product could expose you
to substances in fuel or from fuel combustion
which can cause death or serious illness.
Installer: Leave this manual with the appli-
ance.
Consumer:Retain this manual for future refer-
ence.
-
ble vapors and liquids in the vicinity of this or
any other appliance.
— WHAT TO DO IF YOU SMELL GAS
use any phone in your building.
neighbor’s phone. Follow the gas suppli-
er’s instructions.
— Installation and service must be performed by
supplier.
WARNING: If the information in these instruc-
may result causing property damage, personal
injury or loss of life.
13281-9-0709Page 2
SECTION PAGE
Important Safety Information ......................................................................................................................3
Vent Kit Information....................................................................................................................................3
Safety Information for Users of LP Gas ......................................................................................................4
Requirements for Massachusetts..................................................................................................................5
Introduction..................................................................................................................................................6
...............................................................................................................................................6
Gas Supply............................................................................................................................................... 7-8
Clearances ...................................................................................................................................................8
Installation Instructions.......................................................................................................................... 9-11
Lighting Instructions .................................................................................................................................12
Pilot Flame Characteristics .......................................................................................................................13
Main Burner Flame Characteristics ..........................................................................................................13
Wiring ........................................................................................................................................................14
Service and Maintenance Suggestions................................................................................................. 15-16
Troubleshooting ................................................................................................................................... 17-18
Parts List ...................................................................................................................................................19
Parts View ..................................................................................................................................................20
Master Parts Distributor List .................................................................................................................... 21
How To Order Repair Parts ...................................................................................................................... 21
Service Notes ....................................................................................................................................... 22-23
TABLE OF CONTENTS
13281-9-0709 Page 3
THIS IS A HEATING APPLIANCE
DO NOT OPERATE THIS APPLIANCE WITHOUT FRONT PANEL INSTALLED.
high surface temperatures and should stay away to avoid
burns or clothing ignition.
are in the same room as the appliance.
on or near the appliance.
appliance must be replaced prior to operating the
appliance.
Installation and repair should be done by a QUALIFIED
SERVICE PERSON. The appliance should be inspected
person. More frequent cleaning may be required due to
excessive lint from carpeting, bedding materials, etc. It
is imperative that control compartments, burners and
circulating air passageways of the appliance be kept
clean.
put anything around the furnace that will obstruct
keep the appliance area clearand free from combustible
material, gasoline and other flammable vapors and
liquids.
examine venting system periodically and replace
damaged parts.
make a periodic visual check of pilot and burners.
Clean and replace damaged parts.
during operation.
use this heater if any part has been under water.
the heater and to replace any part of the control system
and any gas control which has been under water.
Attention: The DV-55IPT direct vent wall furnaces are provided with vent kit, DV4T-59-1 for wall depths of 5" to 9". For wall depths
greater than 9", refer to Accessories, Page 6. Listed below are the vent kits.
Attention: The minimum wall depth for installation of a DV-55IPT MUST BE 5". If the wall depth is less than 5" you can order DV-
822, refer to Accessories, Page 6 or refer to Figure 10 and Figure 11 with accompanying text, Page 11.
NO. PART DESCRIPTION
DV4T-59-1 DV4T-812-1 DV4T-1219-1
1 OUTLET TUBE - INNER 13057 13057 13058
2 GASKET - OUTER COLLAR M-177 M-177 M-177
3 OUTLET TUBE - INNER 13104 13104 13105
4 INLET TUBE - INNER 13062 13062 13063
5 GASKET - INLET COLLAR M-178 M-178 M-178
6 INLET TUBE - INNER 13106 13106 13107
7 INLET TUBE - OUTER 13064 13065 13066
8 OUTLET TUBE - OUTER 13059 13060 13061
9 VENT CAP 13053 13053 16053
HARDWARE KIT 13078 13078 13078
IMPORTANT SAFETY INFORMATION
13281-9-0709Page 4
Some people cannot smell well. Some people cannot smell the
can smell the odorant in propane. Smoking can decrease your
ability to smell. Being around an odor for a time can affect your
sensitivity or ability to detect that odor. Sometimes other odors
in the area mask the gas odor. People may not smell the gas odor
or their minds are on something else. Thinking about smelling a
gas odor can make it easier to smell.
The odorant in LP-gas is colorless, and it can fade under some
circumstances. For example, if there is an underground leak, the
in LP-Gas also are subject to oxidation. This fading can occur if
there is rust inside the storage tank or in iron gas pipes.
The odorant in escaped gas can adsorb or absorb onto or into walls,
masonry and other materials and fabrics in a room. That will take
some of the odorant out of the gas, reducing its odor intensity.
LP-Gas may stratify in a closed area, and the odor intensity could
vary at different levels. Since it is heavier than air, there may be
more odor at lower levels. Always be sensitive to the slightest gas
odor. If you detect any odor, treat it as a serious leak. Immediately
go into action as instructed earlier.
and explosions. In its natural state, propane is odorless and
colorless.You may not know all the following safety precautions
which can protect both you and your family from an accident.
Read them carefully now, then review them point by point
with the members of your household. Someday when there
may not be a minute to lose, everyone's safety will depend on
knowing exactly what to do. If, after reading the following
information, you feel you still need more information, please
contact your gas supplier.
Your local LP-Gas
Dealer can give you a "Scratch and Sniff" pamphlet. Use it
that your LP-Gas has a weak or abnormal odor, call your
LP-Gas Dealer.
service, or make adjustments to appliances on the LP-Gas
odor of LP-Gas prior to and while lighting pilot lights or
performing service or making adjustments.
smell that can cover up the LP-Gas odor. Do not try to light
pilot lights, perform service, or make adjustments in an area
where the conditions are such that you may not detect the
odor if there has been a leak of LP-Gas.
of new cylinders and tanks, is possible. Therefore, people
should be particularly alert and careful when new tanks or
cylinders are placed in service. Odor fade can occur in new
have been out of service for a time may develop internal rust
which will cause odor fade. If such conditions are suspected
to exist, a periodic sniff test of the gas is advisable. If you
have any question about the gas odor, call your LP-gas
dealer. A periodic sniff test of the LP-gas is a good safety
measure under any condition.
think you should, assume you have a leak. Then take the same
immediate action recommended above for the occasion when
you do detect the odorized LP-Gas.
-
der no vapor pressure), turn the tank valve off immediately.
If the container valve is left on, the container may draw in
occurs, some new internal rusting could occur. If the valve is
left open, then treat the container as a new tank. Always be
sure your container is under vapor pressure by turning it off
at the container before it goes completely empty or having
phone. Do not do anything that could ignite the gas.
Do that IMMEDIATELY.
as basements. When you have reason to suspect a gas leak,
keep out of basements and other low areas. Stay out until
continue to smell gas, do not turn on the gas again. Do not
re-enter the building, vehicle, trailer, or area.
Finally
gas. Have them air out the area before you return. Properly
trained LP-Gas service people should repair the leak, then
check and relight the gas appliance for you.
SOME POINTS TO REMEMBER
NO ODOR DETECTED - ODOR FADE
LP-GAS WARNING ODOR
If a gas leak happens, you should be able to smell the gas because of the odorant put in the LP-Gas.
That's your signal to go into immediate action!
SAFETY INFORMATION FOR USERS OF LP-GAS
13281-9-0709 Page 5
REQUIREMENTS FOR MASSACHUSETTS
For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
not limited to decks and porches, the following requirements
1. INSTALLATION OF CARBON MONOXIDE
DETECTORS.At the time of installation of the side wall
horizontal vented gas fueled equipment, the installing
carbon monoxide detector with an alarm and battery
equipment is to be installed. In addition, the installing
or hard wired carbon monoxide detector with an alarm
is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the responsibility
licensed professionals for the installation of hard wired
carbon monoxide detectors
a. In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space or
an attic, the hard wired carbon monoxide detector
with alarm and battery back-up may be installed on
b. In the event that the requirements of this subdivision
can not be met at the time of completion of
installation, the owner shall have a period of thirty
period, a battery operated carbon monoxide detector
with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS.
Eachcarbon monoxidedetectorasrequiredin accordance
with the above provisions shall comply with NFPA 720
permanently mounted to the exterior of the building at a
line with the exhaust vent terminal for the horizontally
vented gas fueled heating appliance or equipment. The
inch in size, “GAS VENT DIRECTLY BELOW.
4. INSPECTION. The state or local gas inspector of the
side wall horizontally vented gas fueled equipment shall
not approve the installation unless, upon inspection,
the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of
1. The equipment listed in Chapter 10 entitled
“Equipment Not Required To Be Vented” in the
most current edition of NFPA 54 as adopted by
2. Product Approved side wall horizontally vented
gas fueled equipment installed in a room or
structure separate from the dwelling, building or
structure used in whole or in part for residential
purposes.
When the manufacturer of Product Approved side
wall horizontally vented gas equipment provides a
venting system design or venting system components
with the equipment, the instructions provided by the
manufacturer for installation of the equipment and
the venting system shall include:
1. Detailed instructions for the installation of the
venting system design or the venting system
2. A complete parts list for the venting system
design or venting system.
Approved side wall horizontally vented gas fueled
equipment, all venting instructions, all parts lists
for venting instructions, and/or all venting design
instructions shall remain with the appliance or
equipment at the completion of the installation.
13281-9-0709Page 6
Always consult your local Building Department regarding
regulations, codes or ordinances which apply to the installation
of a direct vent wall furnace.
Instructions to Installer
1. Installer must leave instruction manual with owner after
installation.
supplied with furnace.
3. Installer should show owner how to start and operate furnace
and thermostat.
Warning:
Any change to this furnace or its control can be dangerous.
This is a heating appliance and any panel, door or guard
removed for servicing an appliance must be replaced prior
to operating the appliance.
General Information
National Standard/CSA Standard Z21.86 and CSA 2.32 by the
Canadian Standards Association, as a fan type direct vent wall
furnace to be installed according to these instructions.
Any alteration of the original design, installed other than
as shown in these instructions or use with a type of gas not
shown on the rating plate is the responsibility of the person
and company making the change.
Important
All correspondence should refer to complete Model Number, Serial
Number and type of gas.
Notice:
smoke will occur. To prevent triggering of smoke alarms, ventilate
the room in which the unit is installed.
Installation on Rugs and Tile
If this appliance is installed directly on carpeting, tile or other
be installed on a metal or wood panel extending the full width and
depth of the appliance.
used on wood stoves. The protection is for rugs that are extremely
thick and light colored tile.
Installation in Residential Garages
Gas utilization equipment in residential garages shall be installed
so that all burners and burner ignition devices are located not less
Such equipment shall be located, or protected, so it is not subject
to physical damage by a moving vehicle.
Installation and replacement of gas piping, gas utilization equipment
or accessories and repair and servicing of equipment shall be
person or through a representative is engaged in and is responsible
connection, installation, repair or servicing of equipment, who is
experienced in such work, familiar with all precautions required
and has complied with all the requirements of the authority having
jurisdiction.
State of Massachusetts: The installation must be made by
Massachusetts.
The installation must conform with local codes or, in the absence of
local codes, with the National Fuel Gas Code ANSI Z223.1/NFPA
54* Natural Gas and Propane Installation Code, CSA B149.1.
*Available from the American National Standards Institute, Inc.,
11 West 42nd St., New York, N.Y. 10036.
High Altitudes
above sea level. Canadian High Altitudes for locations having
Model DV-55T
Input- BTU/HR 55,000
Height 82 3/8”
Width 16”
Depth 11 1/2"
CFM 400
Accessories
SOR-1 Register, Side Outlet
SOK-1 Side Outlet Kit, 10" Boot Assembly
*DV-822 Vinyl Siding Vent Kit
DV4T-812-1
DV4T-1219-1
*DV-822, Vinyl vent kit, adds 3" to wall depth. You must include the three
INTRODUCTION
SPECIFICATIONS
13281-9-0709 Page 7
Locating Gas Supply
wall. The gas line opening should be made at this time. Location
and the valve and union used for servicing.
Note:
codes allow copper tubing or galvanized.
Note: Since some municipalities have additional local codes, it is
always best to consult your local authority and installation code.
The use of the following gas connectors is recommended:
— ANSZ21.24ApplianceConnectorsofCorrugated MetalTubing
and Fittings
— ANS Z21.45 Assembled Flexible Appliance Connectors of
Other Than All-Metal Construction
The above connectors may be used if acceptable by the authority
appliance connector cannot exceed three feet in length.
Figure 1
Consult the current National Fuel Gas Code, ANSI Z223.1 CAN/
Installing a New Main Gas Cock
Each appliance should have its own manual gas cock.
A manual main gas cock should be located in the vicinity of
the unit. Where none exists, or where its size or location is not
adequate, contact your local authorized installer for installation
or relocation.
Compounds used on threaded joints of gas piping shall be resistant
checked for leaks by the installer. This should be done with a soap
solution watching for bubbles on all exposed connections, and if
unexposed, a pressure test should be made.
be disconnected from piping at inlet of control valve and pipe
capped or plugged for pressure test. Never pressure test with
A gas valve and ground joint union should be installed in the gas
line upstream of the gas control to aid in servicing. It is required
by the National Fuel Gas Code that a drip line be installed near
the gas inlet. This should consist of a vertical length of pipe tee
connected into the gas line that is capped on the bottom in which
condensation and foreign particles may collect.
Figure 2
Method of Installing a Tee Fitting Sediment Trap
Pressure Testing of the Gas Supply System
plugged tapping, accessible for test gauge connection, must be
placed immediately upstream of the gas supply connection to
the appliance.
2. The appliance 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
3. The appliance must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at test
Attention! If one of the above procedures results in pressures in
it will result in a hazardous condition.
3/4" Recommended Gas Pipe Diameter
Pipe Length
(Feet)
Schedule 20 Pipe
Inside Diameter
Tubing, Type L
Outside Diameter
Nat. L.P. Nat. L.P.
0-10 1//2"
12.7mm
3/8"
9.5mm
1/2"
12.7mm
3/8"
9.5mm
10-40 1/2"
12.7mm
1/2"
12.7mm
5/8"
15.9mm
1/2"
12.7mm
40-100 1/2"
12.7mm
1/2"
12.7mm
3/4"
19mm
1/2"
12.7mm
100-150 3/4"
19mm
1/2"
12.7mm
7/8"
22.2mm
3/4"
19mm
GAS SUPPLY
13281-9-0709Page 8
Figure 3
Checking Manifold Pressure
Both Propane and Natural gas valves have a built-in pressure
regulator in the gas valve. Natural gas models will have a manifold
pressure of approximately 3.5" w.c. at the valve outlet with the
inlet pressure to the valve from a minimum of 5.0" w.c. for the
purpose of input adjustment to a maximum of 7.0" w.c. Propane
gas models will have a manifold pressure approximately 10.0"
w.c. at the valve outlet with the inlet pressure to the valve from a
minimum of 11.0" w.c. for the purpose of input adjustment to a
maximum of 13.0" w.c.
A1/8" N.P.T. plugged tapping, accessible for test gauge connection,
is located on the outlet side of the gas control.
The built-in regulator comes on at approximately 1/4th pressure
and full on in 10 seconds.
Safety Lockout
S8600H module provides 100 percent shutoff, or safety
lockout. If the pilot fails to light within 90 seconds, the
control system will shut down. The control system must
be reset by setting the thermostat below room temperature
for one minute or by turning off power to the module for
one minute.
Clearances
1. In selecting a location for installation, it is necessary to provide
adequate accessibility clearances for servicing and proper
installation.
2. The DV4T-59-1, 5" to 9" wall depth is the standard vent
kit provided with the DV-55IPT. See Accessories Page 6 to
order vent kits for wall depths of 8" to 12" or 12" to 19".
The use of tubes not supplied by the manufacturer results
in unsatisfactory performance.
3. The DV-55IPT can be attached to the wall or recessed into the
wall up to 4 inches in depth but the minimum 5 inches vent/air
intake system wall depth must be maintained. Example: If
furnace is recessed into the wall at a depth of 4 inches, the
minimum wall depth must be 5 inches behind the furnace.
to the furnace sides and top.
5. When using side discharge registers, SOR-1 or SOK-1, the
furnace cannot be recessed into the wall.
6. Clearance to sidewall or combustible material is 4 inches.
7. Ceiling clearance is 4 inches.
9. Clearance of 18 inches is required to sidewall or combustible
used. See Figure 4.
10. The minimum distance from the center of the vent cap to the
nearest outside corner or obstruction is 24 inches.
The vent terminal of a direct vent appliance with an input over
50,000 BTU per hour shall be located at least 12 inches from any
bottom of the vent terminal and the air intake shall be located at
least 12 inches above grade.
WARNING: The nearest point of the vent cap should
pressure regulator. In case of regulator malfunction, the
six (6) feet distance will reduce the chance of gas entering
the vent cap.
Figure 4
CLEARANCES
13281-9-0709 Page 9
Locating Wall Opening
The furnace is to be located on an outside wall. Locate wall studs so
that wall opening will be located between wall studs. The furnace
is 16 inches in width and normal 16 inches on center studs will
not allow the furnace to be recessed into the wall unless a stud is
repositioned. The wall opening required as shown in Figure 5 is
a diameter of 7 1/2 inches.
A template is provided in furnace carton for positioning furnace
on the wall. Also, refer to Figure 5 for positioning the furnace on
wall and for locating gas line connection.
Installing Optional Side Outlets
Side outlet register, SOR-1 may be installed on one or both sides
of the furnace at the required clearances of 18 inches to adjacent
wall or combustible material as shown in Figure 4.
1. Locate and cut the 5 1/2" square opening in the cabinet side
using the template from the kit, exposing the inner liner
knock-out.
2. Remove the knock-out.
3. Place the register on the 5 1/2" opening with the louvers set
for the desired direction and mark the mounting holes using
the register as a template.
Side outlet kit, 10" boot assembly with register, SOK-1 for warm
air discharge into an adjoining room may be installed on either side
of the furnace at the required clearance of 4 inches to adjacent wall
as shown in Figure 7.
1. Locate and cut the 5 1/2" square opening in the cabinet side
using the template from the kit, exposing the inner liner
knock-out.
2. Remove the knock-out.
3. Using the inner and outer boots as hole templates, mark
cabinet side.
4. Using Figure 7 locate and cut a 6 3/4" square opening through
walls.
Locating Wall Opening).
6. With furnace in place, after checking alignment of side
outlet opening in wall and furnace, place the 9 3/8" x 9 3/8"
side outlet wall plate over outer boot, pass the outer boot
through the wall and attach side outlet wall plate to furnace
screws provided.
x 1/4" screws provided.
9. Locate the register with its louvers positioned for the desired
air discharge direction and mark the mounting holes using
the register as a template.
Figure 5
Figure 6 Figure 7
INSTALLATION INSTRUCTIONS
13281-9-0709Page 10
Using Plastic Expansion Anchors
holes into the wall.
holes.
Figure 9
Figure 9
Attention! The screw holes on the outer casing bottom are off-set
and distort the off-set on the outer casing bottom. Distortion of
the outer casing bottom will not allow the lower front panel to be
attached to the furnace.
Installing Vent Assembly
Attention: DO NOT attempt to cut vent tubes. When you order
appropriate vent kit for measured wall depth the vent tubes will
mounting plate. Use additional caulking to correct uneven wall
surface, such as clapboard.
2. Insert six inch air tube on outside mounting plate INTO six inch
cap OVER
Position the outside mounting plate so that six inch air tube
has a slight downward slope to the outside. The downward
slope is necessary to prevent the entry of rainwater. Attach
screws.
3. Installation is completed.
Figure 8
Locating Electric Supply
A 7/8" diameter knockout is provided at the bottom of the left and
Please remove 7/8" knockout from appropriate side panel when
routing plug assembly to an electrical outlet.
Installation of Three-prong (Grounding) Plug Assembly
2. Remove 7/8" knockout from appropriate side panel.
side panel.
wiring harness.
assembly. Insert 7/8" strain relief bushing into the 7/8" hole in
the side panel.
Attention! The 7/8" strain relief bushing is located within the same
Attaching Furnace to Wall
Align clearance holes on collar with screw holes in combustion
Place collar on six inch air tube against air drop. Align clearance
holes on collar with screw holes in air drop. Attach six inch air
Refer to Figure 5 for the location of the 7 1/2" diameter wall open-
ing for the furnace. After the wall opening has been located and
tubes through wall opening. When attaching furnace to the wall
remove that portion of baseboard and molding on the wall which is
behind the furnace. Attach furnace to wall, at the outer casing top,
13281-9-0709 Page 11
Reassembly And Resealing Vent-Air Intake System
When vent-air intake system is removed for servicing the furnace,
the following steps will assure proper reassembly and resealing of
the vent-air intake assembly.
1. Remove old caulking beneath the collar of the outside mounting
plate. Apply new caulking beneath the collar of the outside
mounting plate. Use additional caulking to correct uneven wall
surface, such as clapboard.
2. Insert six inch air tube on outside mounting plate INTO six
inch air tube attached to air drop. Position the outside mounting
plate so that six inch air tube has a slight downward slope to
the outside. The downward slope is necessary to prevent the
entry of rainwater. Attach outside mounting plate to exterior
OVER
attached to combustion chamber. Attach vent cap to outside
4. Reassembly and resealing vent-air intake system is
completed.
Installing a Vent Near a Window Ledge,
Other Type of Projection or on Siding (vinyl, aluminum, etc.)
Direct vent furnaces are designed to be installed on a uniform
from either side), it must hit the vent cap equally over both the air
such as a door or window casing, which disturbs the wind on one
When the vent cap is to be installed on siding or it appears that
a projection within 6" of any side of the air inlet section could
shield the air inlet section, the entire vent should be supported
away from the wall at least the distance of the projection. 2" x 4"
framing whose outside dimensions match the overall dimensions of
the mounting plate is recommended. The 2" x 4" framing protects
siding from possible warpage or discoloration. All joints can then
be sealed and painted. The wall depth plus the additional depth
of the 2" x 4" framing should not exceed a total depth of 19" for
Vinyl siding vent kit, DV-822, is available from Empire Comfort
Systems, Inc. The depth is 3", which enables the vent cap to be
extended away from siding or projections. The wall depth plus the
additional 3" depth of the vinyl siding vent cap extension should
Warning: When vinyl siding vent kit, DV-822 or 2" x 4"
framing is added to an existing installation (furnace is
outlet tube or air inlet tube. An air tight seal is required for
both tubes. Refer to Parts List, page 19 to order tubes.
Figure 10 Figure 11
INSTALLATION INSTRUCTIONS (continued)
13281-9-0709Page 12
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING:
causing property damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device which
automatically lights the pilot.
Do not try to light the pilot by hand.
B. BEFORE OPERATING smell all around the appliance
WHAT TO DO IF YOU SMELL GAS
do not use any phone in your building.
phone. Follow the gas supplier's instructions.
-
partment.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by
-
explosion.
D. Do not use this appliance if any part has been under water.
the appliance and to replace any part of the control system
and any gas control which has been under water.
1. STOP! Read the safety information
above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot. Do not try
to light the pilot by hand.
5. Remove control access panel (lower front panel).
6. Turn gas control knob clockwise
to "OFF."
7. Wait ten (10) minutes to clear out any gas.
gas, STOP! Follow "B" in the safety information above.
If you don't smell gas, go to the next step.
8. Tur n g as c o nt r o l kn o b co u n t erc l oc k wi s e
to "ON".
9. Replace control acces s panel (low er front
panel).
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
"TO TURN OFF GAS TO APPLIANCE" and call your
service technician or gas supplier.
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance
if service is to be performed .
3. Remove control access panel (lower front
panel).
4. Turn gas control knob clockwise to
"OFF." Do not force.
5. Replace control access panel (lower front
panel).
LIGHTING INSTRUCTIONS
13281-9-0709 Page 13
Figure 12
Electrode and pilot burner must be kept clean. Clean through
pilot access hole with a small brush (toothbrush) and water.
and no ignition with spark stopping after approximately 90 seconds
leakage.
proper. The spark gap must be 1/8". A larger gap can result in the
gap are factory checked and tested.
the furnace has been operating, the burner ports may be blocked by
foreign matter carried in by combustion air. Therefore, cleaning
To clean burner port disconnect the gas supply to the valve, and
remove the eight screws fastening the burner door. After removing
the burner door from the combustion chamber, remove rear burner,
pilot burner and front burner. With front and rear burners removed
from furnace, force water into the ribbon ports and dry with air
pressure. Figure 13
PILOT FLAME CHARACTERISTICS
MAIN BURNER FLAME CHARACTERISTICS
13281-9-0709Page 14
Wiring
The appliance, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with
the NationalElectricalCode,ANSI/NFPA70or Canadian Electrical
Code, CSA C22.1, if an external electrical source is utilized. This
appliance is equipped with a three-prong [grounding] plug for
directly into a properly grounded three-prong receptacle. Do
not cut or remove the grounding prong from this plug. For an
ungrounded receptacle, an adapter, which has two prongs and a
wire for grounding, can be purchased, plugged into the ungrounded
receptacle and its wire connected to the receptacle mounting screw.
With this wire completing the ground, the appliance cord plug can
be plugged into the adapter and be electrically grounded. A 7/8"
hole is provided in the junction box for use with a conduit connector
if local codes require this type of protection.
Thermostat Installation
The thermostat should be installed in the same room as the furnace
stove, hot water heater, etc.) including walls and doorways with
a heat source in an adjoining room. Do Not Install Thermostat
on Outside Wall.
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after servicing.
Figure 14
WIRING
13281-9-0709 Page 15
GENERAL:
fan control, limit control and automatic valve operation. If the furnace
fails to function on initial installation, it is advisable to re-check the
following:
1. 115 volts to the junction box.
2. Inlet gas pressure.
3. The 24 volt system.
4. Type of gas being used and that shown on the rating label.
The Service Department at Empire Comfort Systems, Inc. may
serviceman.
Disconnect the gas supply at the inlet to the control
valve. Then remove the burner door to which the above components
are attached.
Servicing The Fan Motor: The upper front panel, the shroud
surrounding the fan blade and fan blade must be removed.
Replacing Fan and Oiling the Motor
The fan motor should be cleaned and oiled once each heating season.
To reach the motor, withdraw the metal shroud surrounding the fan
blade by removing the screws on each side. Oil holes are located on
the top at each end of the motor. Use a few drops of #10 motor oil.
To clean the motor, blow air through its ventilation openings with a
vacuum cleaner or low pressure air source.
If fan motor is replaced, the silicone rubber gaskets, see Page 19, Index
No. 4, Part No. 712059, should also be replaced. The gaskets must be
and gaskets installed on the motor mounting bars.
S8600H INTERMITTENT IGNITION MODULE
SPECIFICATIONS
Lockout timing is 90 seconds. Ignition timing is until pilot lights or
lockout occurs.
Manual reset required.
ELECTRICAL RATINGS:
Current rating: 0.2 A.
Run Inrush
Pilot 1.0 A 10.0 A
Main 1.0 A 10.0 A
SPARK GENERATOR OUTPUT: 13kV peak at 25 pf load.
THERMOSTAT ANTICIPATOR SETTING: 0.2 A plus pilot valve
rating plus main valve rating.
THERMOSTAT COMPATIBILITY: Standard models compatible with
all open-close switch type 24 Vac thermostats capable of supplying
rated voltage and current to the module.
AMBIENT TEMPERATURE RATING: Minus 40 F to plus 175 F
RELATIVE HUMIDITY RATING: 5 to 90 percent RH at 95 F.
current.
FLAME CURRENT: 1 uA, min.
Check out the gas control system:
1. At initial installation of the appliance.
2. As part of regular maintenance procedures.
4. Any time work is done on the system.
STEP 1: Perform Visual Inspection.
A. With power off, make sure all wiring connections are clean and
tight.
B. Turn on power to appliance and ignition module.
C. Open manual shutoff valves in the gas line to the appliance.
D. Do gas leak test ahead of gas control if piping has been
disturbed.
GAS LEAK TEST: Paint pipe joints with rich soap and water
solution. Bubbles indicate gas leak. Tighten joints to stop leak.
STEP 2: Review Normal Operating Sequence and Module
STEP 3: Reset the Module.
A. Turn the thermostat to its lowest setting.
B. Wait one minute.
As you do Steps 4 and 5, watch for points where operation
deviates from normal. Refer to Troubleshooting Chart to correct
problem.
STEP 4: Check Safety Lockout Operation.
A. Turn gas supply off.
B. Set thermostat above room temperature to call for heat.
C. Watch for spark at pilot burner.
D. Time length of spark operation. Maximum spark time is 90
seconds.
or main burner.
F. Set thermostat below room temperature and wait one minute
before continuing.
STEP 5: Check Normal Operation.
A. Set thermostat above room temperature to call for heat.
B. Make sure pilot lights smoothly when gas reaches the pilot
burner.
D. If gas line has been disturbed, complete gas leak test.
GAS LEAK TEST: Paint gas control gasket edges and all pipe
connections downstream of gas control, including pilot tubing
connections, with rich soap and water solution. Bubbles indicate
gas leaks. Tighten joints and screws or replace component to stop
gas leak.
E. Turn thermostat below room temperature. Make sure main burner
OPERATION
Module operation can be conveniently divided into two phases
for S8600H. The phases are trial for ignition and main burner
operation.
SERVICE & MAINTENANCE SUGGESTIONS
13281-9-0709Page 16
TRIAL FOR IGNITION
Pilot Ignition
electronic spark generator in the module produces a 13,000 volt
at the igniter-sensor that lights the pilot.
1.0 uA and steady, the module will not energize the second main
valve and the main burner will not light.
Safety Lockout
S8600H provides 100 percent shutoff, or safety lockout. A timer
starts timing the moment the trial for ignition starts. Ignition spark
continues only until the timed trial for ignition period ends. Then
the module goes into safety lockout. Lockout de-energizes the
by setting the thermostat below room temperature for one minute
or by turning off power to the module for one minute.
Main Burner Operation
spark generator and energizes the second main valve operator. The
When the call for heat ends, both main valve operators are de-
energized, and both main valves in the gas control close.
START
STAGE 1
TRIAL FOR IGNITION
STAGE 2
MAIN BURNER
OPERATION
END
THERMOSTAT
CALLS FOR HEAT
SPARK GENERATOR POWERED
FIRST VALVE (PILOT)
OPERATOR OPENS
PILOT BURNER OPERATION
PILOT BURNER LIGHTS
MODULE SENSES FLAME CURRENT.
PILOT BURNER DOES NOT LIGHT
OR MODULE RESPONSE
S8600H
AFTER 90SECONDS *PILOT VALVE
CLOSES, SPARK STOPS
*LOCKOUT TIMING IS STAMPED ON MODULE
IF FALME CURRENT SENSED
*SPARK GENERATOR OFF
*SECOND VALVE OPERATOR
(MAIN) OPENS.
MAIN BURNER OPERATION
MODULE MONITORS PILOT
FLAME CURRENT
THERMOSTAT SATISFIED
VALVES CLOSE.
PILOT AND MAIN BURNERS ARE OFF.
POWER INTERRUPTION
SYSTEM SHUT OFF. RESTARTS WHEN
POWER IS RESTORED.
PILOT FLAME FAILURE
SECOND MAIN OPERATOR CLOSES
MODULE STARTS TRIAL FOR IGNITION.
START
STAGE 1
TRIAL FOR IGNITION
STAGE 2
MAIN BURNER
OPERATION
END
THERMOSTAT
CALLS FOR HEAT
SPARK GENERATOR POWERED
FIRST VALVE (PILOT)
OPERATOR OPENS
PILOT BURNER OPERATION
PILOT BURNER LIGHTS
MODULE SENSES FLAME CURRENT.
PILOT BURNER DOES NOT LIGHT
OR MODULE RESPONSE
S8600H
AFTER 90SECONDS *PILOT VALVE
CLOSES, SPARK STOPS
*LOCKOUT TIMING IS STAMPED ON MODULE
IF FALME CURRENT SENSED
*SPARK GENERATOR OFF
*SECOND VALVE OPERATOR
(MAIN) OPENS.
MAIN BURNER OPERATION
MODULE MONITORS PILOT
FLAME CURRENT
THERMOSTAT SATISFIED
VALVES CLOSE.
PILOT AND MAIN BURNERS ARE OFF.
POWER INTERRUPTION
SYSTEM SHUT OFF. RESTARTS WHEN
POWER IS RESTORED.
PILOT FLAME FAILURE
SECOND MAIN OPERATOR CLOSES
MODULE STARTS TRIAL FOR IGNITION.
START
STAGE 1
TRIAL FOR IGNITION
STAGE 2
MAIN BURNER
OPERATION
END
THERMOSTAT
CALLS FOR HEAT
SPARK GENERATOR POWERED
FIRST VALVE (PILOT)
OPERATOR OPENS
PILOT BURNER OPERATION
PILOT BURNER LIGHTS
MODULE SENSES FLAME CURRENT.
PILOT BURNER DOES NOT LIGHT
OR MODULE RESPONSE
S8600H
AFTER 90SECONDS *PILOT VALVE
CLOSES, SPARK STOPS
*LOCKOUT TIMING IS STAMPED ON MODULE
MAIN BURNER OPERATION
MODULE MONITORS PILOT
FLAME CURRENT
THERMOSTAT SATISFIED
VALVES CLOSE.
PILOT AND MAIN BURNERS ARE OFF.
POWER INTERRUPTION
SYSTEM SHUT OFF. RESTARTS WHEN
POWER IS RESTORED.
PILOT FLAME FAILURE
SECOND MAIN OPERATOR CLOSES
MODULE STARTS TRIAL FOR IGNITION.
IF FLAME CURRENT SENSED
*SPARK GENERATOR OFF
*SECOND VALVE OPERATOR
(MAIN) OPENS
After 90 seconds* pilot valve
closes, spark stops.
13281-9-0709 Page 17
Important
1. The following service procedures are provided as a general
guide.
2. Meter readings between gas control and ignition module must
be taken within the trial for ignition period. Once the igni-
tion module locks out, the system must be reset by setting the
thermostat down for at least one minute before continuing.
3. If any component does not function properly, make sure it is
correctly installed and wired before replacing it.
4. The ignition module cannot be repaired. If it malfunctions, it
must be replaced.
5. Only trained, experienced service technicians should service
intermittent pilot systems.
Perform the
troubleshooting. Then check TROUBLESHOOTING GUIDE
to pinpoint the cause of the problem. If troubleshooting indicates
an ignition problem, see Ignition System Checks below to isolate
and correct the problem.
Following troubleshooting, perform the procedure
Ignition System Checks
Step 1: Check ignition cable.
Make sure:
A. Ignition cable does not touch any metal surfaces.
B. Ignition cable is no more than 36 inches long.
C. Connections to the ignition module and to the igniter-sensor
are clean and tight.
D. Ignition cable provides good electrical continuity.
Step 2: Check ignition system grounding.
Nuisance shutdowns are often caused by a poor or erratic
ground.
A. Acommon ground, usually supplied by the pilot burner bracket,
is required for the module and the pilot burner/igniter sen-
sor.
burner bracket and the main burner.
the module to the pilot burner. Make sure connections are
clean and tight. If the wire is damaged or deteriorated, replace
it with No. 14-18 gauge, moisture-resistant, thermoplastic
correct position.
cracked.
Step 3: Check spark ignition circuit. You will need a short jumper
wire made from ignition cable or other heavily insulated
wire.
A. Close the manual gas valve.
B. Disconnect the ignition cable at the SPARK terminal on the
module.
WARNING
When performing the following steps, do not touch stripped
generates 13,000 volts at 25 pf load and electrical shock
can result.
C.Energize the module and immediately touch one end of the jumper
of the jumper slowly toward the SPARK terminal until a spark
is established.
D. Pull the jumper slowly away from the terminal and note the
length of the gap when sparking stops. Check table below.
A. Turn off furnace at thermostat.
B. Disconnect main valve wire from the TH or MV terminal on
the gas control.
module.
lead.
module.
ground lead.
E. Set thermostat to call for heat. The spark will light the pilot but
the main burner will not light because the main valve actuator
is disconnected.
at least 1.0 uA.
G. If the reading is less than the minimum or unsteady,
rod.
screw on the gas control clockwise to decrease or counter-
always replace pilot adjustment cover screw and tighten
to ground, and replace igniter-sensor if necessary.
damaged wire with moisture-resistant No. 18 wire rated for
H. Remove meter and reconnect all wires. Return system to
normal operation before leaving job.
ARC LENGTH ACTION
No arc or arc less than 1/8
inch.
Arc 1/8 inch or longer.
Check external fuse, if pro-
vided.
Verify power at module input
terminal.
Replace module if fuse and
power okay.
Voltage output is okay.
TROUBLESHOOTING
13281-9-0709Page 18
S8600HTROUBLESHOOTING GUIDE
Note: Before troubleshooting, familarize yourself with the startup
and checkout procedure.
Check line voltage power low voltage transformer, limit
,
control, thermostat and wiring.
Pull ignition lead
and check spark at
ignition stud.
Spark okay?
Replace module.
No
•Check that all manual gas valves are open. Supply tubing
and pressures are good, and pilot burner orifice is not block
ed.
•Check electrical connections between module and pilot
operator on gas control.
•Check for 24VAC across PV— MV/PV terminals on module.
If voltage is okay, replace gas control. If not, replace module.
•Note: If S8600H goes into lockout, reset system.
•Check continuity of ignition cable and ground wire.
•Check that pilot flame covers electrode.
•Adjust pilot flame current. Minimum signal should read 1.0
microamp.
•If problem persists, replace module.
•Check ignition cable, ground wiring, ceramic insulator
and gap, and correct.
•Check boot of the ignition cable for signs of melting or
buckling. Take protective action to shield cable and boot
from excessive temperatures.
•Check for 24VAC across MV-MV/PV terminals. If no voltage,
replace module.
•Check electrical connections between module and gas control.
If okay, replace gas control.
Note: If S8600H goes into lockout, reset system.
•Check continuity of ignition cable and ground wire. Note: If
ground is poor or erratic, shutdowns may occur occasionally
even though operation is normal at the time of checkout.
•If checks are okay, replace module.
•Check for proper thermostat operation.
•Remove MVlead at module: If valve closes, recheck
thermostat and wiring. If not, replace gas control.
No
No
No
No
No
No
No
Repeat procedure until troublefree operation is obtained.
Yes
Yes
Yes
Yes
Yes
Yes
Yes
START
Turn gas supply off.
Turn thermostat
to call for heat.
Spark stops when
pilot is lit?
Power to module.
(24 VAC nominal)
Spark across
Igniter/sensor gap.
Turn gas supply on.
Pilot burner lights?
Main burner lights?
System runs until
call for heat ends?
Call for heat ends.
System shuts off?
Troubleshooting ends.
Yes
13281-9-0709 Page 19
PLEASE NOTE: When ordering parts, it is very important that part number and description of part coincide.
PARTS LIST
INDEX
NO
PART NO DESCRIPTION
1 11762 OUTER CASING TOP
2 R-618
3 11764 MOTOR MOUNTING BAR - 2 RE-
4 M-147
5 R-619 MOTOR
6 11787 FAN BLADE
7 11766 FAN HOUSING
8 DV-558 FRONT PANEL- UPPER
9 11759 SIDE PANEL
10 DV-613 INNER SHIELD - RIGHT
11 13057 OUTLET TUBE - INNER ASSEMBLY
12 M-177 GASKET - OUTLET COLLAR
13 13104 OUTLET TUBE - INNER WELDED
ASSEMBLY
14 13062 INLET TUBE - INNER ASSEMBLY
15 M-178 GASKET - INLET COLLAR
16 13106 INLET TUBE - INNER WELDED AS-
SEMBLY
17 13064 INLET TUBE - OUTER ASSEMBLY
18 13059 OUTLET TUBE - OUTER ASSEMBLY
19 13053 VENT CAP WELDED ASSEMBLY
20 13110 AIR DROP WELDED ASSEMBLY
21 M-176 GASKET - FLUE OUTLET FLANGE
22 13113 COMBUSTION CHAMBER WELDED
ASSEMBLY
23 R-1536 BUSHING
24 11765 SWITCH COMPARTMENT
25 R-630 LIMIT CONTROL
26 R-1941 FAN CONTROL
27 DV-832 SWITCH COMPARTMENT COVER
28 DV-562 FRONT PANEL - LOWER
29 DV-826 REAR BURNER ASSEMBLY
30 R-1617 SPARK PLUG WIRE
31 R-714-L PILOT WITH ORIFICE - LPG GAS
31 R-714-N PILOT WITH ORIFICE - NAT GAS
32 DV-808 PILOT TUBING
33 DV-824 FRONT BURNER ASSEMBLY
34 P-88-41
34 P-88-53
35 DV-687 MANIFOLD
36 M-148 GASKET - MANIFOLD
37 M-155 GASKET-OBSERVATION HOLE
COVER
38 DV-781 LIGHTING HOLE COVER ASSEMBLY
39 DV-064 COVER PLATE-OBSERVATION HOLE
40 DV-691 SEAL BRACKET
41 M-147 GASKET - TUBING SEAL
42 DV-847 BURNER DOOR - NAT GAS
42 DV-972 BURNER DOOR - LPG GAS
43 DV-779 GASKET - BURNER DOOR
44 P-112 MANIFOLD UNION
45 R-2147 GAS VALVE - LPG GAS
45 R-2149 GAS VALVE - NAT GAS
46 UH-810 TRANSFORMER MOUNTING BRACK-
ET
47 R-1995 TRANSFORMER
48 UH-451
49 11760 OUTER CASING BOTTOM
50 R-1515 BUSHING
51 R-690-B CORD SET
52 DV-571 CONTROL COMPARTMENT DIVIDER
53 DV-671 MANIFOLD SUPPORT
54 DV-765 GASKET - CHAMBER AIR INLET
55 DV-764 GASKET - CHAMBER AIR INLET
56 DV-692 MODULE MOUNTING BRACKET
57 R-721 WIRE HARNESS - CONTROL MOD-
ULE
58 R-1616 CONTROL MODULE
59 R-1404 BUSHING
60 DV-614 INNER SHIELD - LEFT
61 11759 SIDE PANEL
NOT
SHOWN
R-9832 WIRING ASSEMBLY UPPER
NOT
SHOWN
R-9833 WIRING ASSEMBLY LOWER
NOT
SHOWN
R-6389 THERMOSTAT
NOT
SHOWN
R-734 LIGHTER ROD
INDEX
NO
PART NO DESCRIPTION
13281-9-0709Page 20
PARTS VIEW
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