Table of Contents
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The 2004 edition of the Atwood Furnace Service Manual is a resource created to help
service technicians identify Atwood product by serial number, diagnose service
problems and efficiently and effectively process warranty claims.
Changes to the Hydro Flame furnaces include:
• Ignition boards in the 79, 85 and 89 series furnaces now have the blower relay
incorporated into the PC board. These boards are compatible with previous Hydro
Flame furnaces. There is no longer a remote relay.
• New boards have a diagnostic ability with 4 fault codes.
• Furnaces with no outside access doors (only an exhaust vent) became available in
2003; the initials L/D in the model number identify these models. The gas valve was
re-oriented with a longer inlet manifold to make this possible.
Each of the manuals within this series offers a general overview of the product as well
as more specific product information. For each product within the manual, you will find
model identification, recommended tools and equipment, a sequence of operation,
warnings, annual maintenance procedures, parts and troubleshooting guides, warranty
procedures, flat rate schedules, and replacement part reference charts.
Due to the rapidly changing personal computer revolution we have placed
troubleshooting information in a variety of places to make sure that the most accurate
information is available. The best place to find the current information about Atwood
products is our website: www.atwoodmobile.com. At our website brochures may be
downloaded, trouble shooting guides reviewed and the latest information bulletins can
be read. In addition all Atwood Authorized Service Centers are listed on our site,
accessible via an easy-to-use search system.
Service for all Atwood products is handled out of our Rockford location. Should you
have any questions regarding our products or the information contained in this manual
simply dial 1-800-825-4328. Be sure to have the Model and Serial Number when you call.
Disclaimer: The data presented in this publication is obtained from the most reliable sources, and is believed to be accurate as of the date of publication.
Responsibility for typographical errors or omission of data cannot be assumed by the publishers.
INTRODUCTION
Atwood Service Department
1
September 2003
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Table of Contents
Related Manuals for Atwood 79 Series
Summary of Contents for Atwood 79 Series
- Page 1 September 2003 INTRODUCTION The 2004 edition of the Atwood Furnace Service Manual is a resource created to help service technicians identify Atwood product by serial number, diagnose service problems and efficiently and effectively process warranty claims. Changes to the Hydro Flame furnaces include: •...
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Page 2: Recommended Tools & Equipment
Recommended Tools and Equipment U-Tube Manometer - P/N 34706 - This is the most accurate device for measuring gas pressure. If you use a dial-type manometer, it should be calibrated periodically with this type of manometer. Slack Tube Manometer - P/N 34880 - A more portable U-Tube Manometer. Multi-meter - This is the most effective meter capable of reading voltage, amperage and continuity. -
Page 3: Table Of Contents
85-II 16-20, 85-II 25, 82-II 31-35, 89-I DC, 89-I AC, 89-II DC, 89-II AC, FA 79D, FA 79P, HF 80D, HF 80P ....85-I 16-20, 85-I 25, 85-I 31-35, DC82 25-32, DC82 35-41, AC 82, FA 76D, FA 78 25-32, FA 72D, FA 72P ....Atwood Furnace Installation Parts Atwood Training Tapes and Manuals ORDER BLANK... -
Page 4: 79/80 Series Model Identification
Power Consumption - The 79 series furnace draws only 3.4 amps. However, there is an 8012 series furnace that has a heating capacity of 12,000 BTU’s and only draws 1.8 amps. This furnace is ideal for dry camping. -
Page 5: 79-Ii Directional Air Box Insert
79-II Directional Air Box Insert (PN 36959) An air discharge diverter is now available for all 79 series furnaces. This insert has fins that are set at a 55 degree angle. This will allow you to direct the heat fore or aft in the camper easier. -
Page 6: 85 Series Model Identification
85 Series Model Identification I6-II w/o Therm MODEL DESCRIPTION Model BTU/Hr Rate (Input) 16-IV = 16,000 20-IV = 20,000 25-IV = 25,000 31-IV = 30,000 35-IV = 34,000 Voltage DC Type Gas LP = Propane Gas connection size 6 = 3/8” Flare Options SB = Side/Bottom discharge V = Ventilator... -
Page 7: Model Identification
89 Series Model Identification 35 DC MODEL DESCRIPTION Model BTU/Hr Rate (Input) 35 = 35,000 40 - 40,000 Voltage DC = direct current 12 Volts AC = 120 Volts(120 VAC) Type Gas LP = Propane LC = set at factory for propane but field changeable to natural NC = set at factory for natural but field changeable to propane... -
Page 8: Wiring Diagrams 7900-Ii/8000-Ii Series
Wiring Diagram for 7900-II / 8000-II IMPORTANT If any original wire has to be replaced, it must be replaced with type 105° C or its equivalent. REMOTE Sense Wiring With Blower Control Ignition Board GROUND GROUND MOTOR Black MOTOR Black Black ELECTRODE Black... - Page 9 BLACK / NOIR 115 VAC LINE / Câble 115 VCA WHT / BLANC 115 VAC NEUTRAL / 115 VCA NEUTRE GRN / VERT 115 VAC GROUND / 115 VCA TERRE GRY / GRIS BLACK / NOIR SENSORS / CAPTEURS FREEZE / GEL NOIR NOIR RED –...
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Page 10: 8500 Series
85 Series Wiring Diagrams IMPORTANT: If any original wire has to be replaced, it must be replaced with type 105° C or its equivalent. Terminal Block on 85 Models only. LADDER DIAGRAM WITH DOOR and Blower Control Ignition Board +12v GROUND ELECTRODE +12v GND... - Page 11 85 Series Wiring Diagrams IMPORTANT If any original wire has to be replaced, it must be replaced with type 105° C or its equivalent. 85-III Remote Sense Electrode Motor Circuit breaker Relay Yellow +12V DC Black Yellow Neg. Valve Blue + Thermo Blue Thermo...
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Page 12: 8900-Iii Series & 79 / 85 / 89 With Blower Control Ignition Board
Wiring Diagram for 8900-III DC Wiring Diagram WITHOUT DOOR GROUND IMPORTANT: ELECTRODE MOTOR If any original wire has to be replaced, BLACK YELLOW it must be replaced with type 105° C CIRCUIT ON/OFF or its equivalent. BREAKER SWITCH VALVE + 12V DC YELLOW BLUE +THERMO... -
Page 13: 2-Stage Furnace & Diagnostic Chart
Ignition Failure SOFT Open High Limit SOFT An Excalibur 2-Stage furnace must use an Stuck Sail Switch HARD Atwood Digital Thermostat. Module Fault HARD Two Stage Furnace lockout is a condition that is timed and will make additional NOTE SOFT attempts to correct the problem. -
Page 14: Model 1H2C Digital Thermostat
+/- 1F ......• No operation occurs. Switching Capability A/C....up to 24 VAC (max. 2 AMPs) WIRING REQUIREMENTS FOR ATWOOD THERMOSTAT THERMOSTAT INSTALLATION 7.5 VDC ANALOG A/C SYSTEMS (DOMETIC ® 12 VDC ANALOG A/C SYSTEMS (RVP ® Thermostat is very sensitive. -
Page 15: Model 2H2C Digital Thermostat
MPD 38914 LITERATURE NUMBER hydro flame Model 2H2C Two Stage Furnace Digital Thermostat FOR TWO STAGE FURNACE ENGLISH, FRANCAIS •Installation •Operation (et Canada) Effective 2/4/02 THIS THERMOSTAT HAS BEEN DESIGNED TO OPERATE STANDARD AIR CONDITIONING UNITS IN CONJUNCTION WITH AN EXCALIBUR STAGE FURNACE Screw Mounting Holes THERMOSTAT INSTALLATION... - Page 16 Sequence of Operation - DC Models ( STANDARD ONE STAGE switch allows power to pass to the circuit breaker and the thermostat. WARNING FURNACE PRODUCES HIGH TEMPERATURE • Locate furnace out of traffic and away from furniture and The thermostat controls the operating circuit to the draperies.
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Page 17: Dc Models (2-Stage Excalibur ™ )
Sequence of Operation - DC Models 2-Stage Excalibur ™ Furnace ONLY The digital thermostat controls the operating circuit to the furnace by reacting to room temperature. When the room temperature is below the thermostat set point by 2°F a heat demand signal will be sent to the controller module (see MPD 38463). -
Page 18: Sequence Of Operation
Sequence of Operation Pilot Models The thermostat controls the operating circuit to the furnace by reacting to room temperature to open and close a set of contact points which allows current to flow to the relay. The relay receives the current and allows current to pass through to the circuit breaker by closing a switch within Thermostat the relay. -
Page 19: Ac Models
Sequence of Operation - AC Models Operating Circuitry 24 VAC The transformer receives 120 VAC which it converts to As power is applied to the electronic ignition circuit 24 VAC for the operating circuitry. board, the system does the following: 1. -
Page 20: Safety & Warnings
WARNING CRITICAL INSTALLATION CRITERIA • Do not install the furnace on material that restricts return air, such as carpet, or any soft material, such as vinyl. • Do not install furnace where clearance to combustibles cannot be maintained. • Do not modify the furnace in any way. •... -
Page 21: Annual Preventative Maintenance Inspection
ANNUAL PREVENTATIVE MAINTENANCE INSPECTION The following preventive maintenance and safety checks should be performed by a qualified RV technician once a year, or more, depending on the use of the furnace. Failure to properly maintain the furnace may void the furnace warranty and can result in unsafe furnace operation. Preventive maintenance is not covered under warranty. -
Page 22: Mechanical Thermostat
Mechanical Thermostat WHAT IS A THERMOSTAT? • It is an ON/OFF switch controlled by a bi-metal coil which opens and closes an electrical contact by sensing changes in the ambient temperature. • With its contacts close, it supplies power to the time delay relay which in turn closes a contact that sends power to the blower motor. -
Page 23: Circuit Breaker & Motor
Circuit Breaker & Motor The circuit breaker is actually a re-settable heat sensitive device designed to protect the blower motor. In a furnace, this heat evidences itself in the form of an amp draw. Therefore, since there are different size motors, there are different amperage ratings on circuit breakers. -
Page 24: Relay
Relay This component is commonly referred to thermostat terminal of the relay. This as a time delay relay. The same relay is voltage heats a coil in the relay body. In used on the 7900, 8500 and 8900 series approximately 20 seconds this heated coil furnaces. -
Page 25: Dual Solenoid Gas Valve
Burner Head, Electrode and Valve Assembly The burner head, electrode and gas valve on the late model 79 series furnace are individually accessible. However, to service these same components on the late model 85 and 89 series, remove the complete assembly. -
Page 26: The 4 Always (Gas Pressure, Voltage, Ducting, Return Air)
The 4 Always Remember that you are working on a heating system and not just a furnace. A majority of furnace problems lie outside of the product itself. Therefore, when trouble-shooting a furnace problem, always check the following items before testing or replacing components. -
Page 27: Return Air
#2 - Voltage See 4 Always previous page. #3 - Minimum Ducting Requirements The various BTU sizes of 85, 89 and 2-stage series furnaces require a minimum number of square inches of heat ducting. The most common size of soft ducting is 4˝ diameter. Therefore, since a 4˝ duct is equal to 12 square inches, we can call out the minimum number of ducts needed for the models of furnaces noted below. - Page 28 NOTES NOTES THIS PAGE INTENTIONALLY LEFT BLANK...
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Page 29: Thermostat
Thermostat TROUBLE SHOOTING GUIDE Effective: 8/10/98 Guides are only intended for use on Atwood ® products by service technicians who have successfully completed Atwood ® training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the product and any applicable Industry Standards. -
Page 30: Electronic Ignition Models
FURNACE -Electronic Ignition Model TROUBLE SHOOTING GUIDE Effective: 8/10/98 Guides are only intended for use on Atwood ® products by service technicians who have successfully completed Atwood ® training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the product and any applicable Industry Standards. -
Page 31: Electronic Ignition Models
FURNACE - ELECTRONIC IGNITION Model (continued) Effective: 8/10/98 CAUSE SOLUTION S O O T I N G (caused by lazy yellow flame) Low gas pressure *Set pressure to a minimum of 11˝ W.C. with all appliances ---------------------------------------------- running. Replace regulator if not obtainable. Low voltage Correct power supply* ------------------------------------------------------... -
Page 32: Pilot Model
FURNACE - Pilot Model TROUBLE SHOOTING GUIDE Effective: 8/10/98 Guides are only intended for use on Atwood ® products by service technicians who have successfully completed Atwood training. This guide should be used in conjunction with the appropriate Instruction Manual provided with the ®... -
Page 33: Pilot Model
FURNACE - Pilot Model (continued) Effective: 8/10/98 CAUSE SOLUTION BLOWER SHUTS OFF AT SAME TIME BURNER SHUTS OFF Faulty relay Replace relay -------------------------------------------------------- Thermostat wired wrong Correct wiring* -------------------------------------- BURNER FAILS TO IGNITE AND - BLOWER FAILS TO RUN No electrical power to the furnace Reconnect or replace power source.* -------------------------- BLOWER VIBRATES OR IS NOISY... -
Page 34: Furnace Terminology
FURNACE TERMINOLOGY Terminology Definition Terminology Definition AC Motor A Motor operating on 120 volts A.C. Fan Switch A normally open switch that closes at a set temperature allowing power flow Adjustable Register A heat outlet capable of being opened to the motor, and allows the motor to and closed. - Page 35 Terminology Definition Terminology Definition Loud Ignition A condition where the air to gas Sooting A black powder that builds up around mixture is off and the burner lights the Burner in the Combustion with a loud noise. Chamber normally caused by an improper air to gas mixture.
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Page 36: Return Goods Policy ( Return Address )
Return Goods Policy 6320 Kelly Willis Road Greenbrier, TN 37073 Effective August 7, 1995, all Atwood defective returns will no longer be repaired at the warehouses and returned to customers. Defective returns will be shipped back to the respective manufacturing facility for problem cause analysis within 30 days of sales. -
Page 37: Warranty
Atwood Mobile Products, Salt 1. For two years from the date of purchase, Atwood will repair or replace any part defective in material or workmanship. This Lake Operations or at an Atwood Authorized Service Center. -
Page 38: Flat Rate Schedule
hydro flame Flat Rate Furnaces Schedule Detectors TIME ALLOWANCE SCHEDULE July 19, 2001 in hours DC89 AC89 8012 II, III & IV I & II & III I & II & III I & II I & II 1522 & 2334 2540 Air Box Extension ............................................ -
Page 39: 7900-Ii/8000-Ii Series
MPD 38137 hydro flame 7900-II / 8000-II Series Furnace Technical Installation Manual ENGLISH, FRANCAIS •Installation (et Canada) Effective 7/01/00 Item # Description of Parts Item # Description of Parts Item # Description of Parts Front Door Motor (79-II) Motor Spacer Electronic Ignition Board Motor (80-II) Small Burner Air Baffle -... -
Page 40: 8500-Iii Series
EXCALIBUR 8500-III October 1997 45-49 SEE PARTS MATRIX PAGES Atwood Furnace Installation Parts Drawing Drawing Description of Parts 8516 8520 8525 8531 8535 Description of Parts 8516 8520 8525 8531 8535 Blower Wheel Electrode Asmbly, Plate & Gasket Electrode Gasket... -
Page 41: 8500-Iv Series
MPD 33940 LITERATURE NUMBER hydro flame 8500-IV Series Furnace 8516, 8520, 8525, MODELS 8531, 8535 Technical Installation Manual ENGLISH, FRANCAIS •Installation •Maintenance (et Canada) Effective 9/1/03 Field Wiring Harness Element Assembly - specify model DRAWING DESCRIPTION Blower Wheel Draft Cap Assembly - Specity model Exhaust Wall Gasket Motor Clamp Electronic Ignition Board... -
Page 42: 8900-Iii Series
MPD 33941 LITERATURE NUMBER hydro flame 8500-IV-LD Series Furnace 8516, 8520, MODELS 8525, 8531, 8535 Technical Installation Manual ENGLISH, FRANCAIS •Installation •Maintenance (et Canada) Effective 9/1/03 Electronic Ignition Board Element Assembly - specify model DRAWING DESCRIPTION Blower Wheel Duct Adapters Exhaust Wall Gasket Motor Clamp Duct Cover Plate... -
Page 43: 2-Stage Model 1522 & 2334
MPD 33938 LITERATURE NUMBER hydro flame 8900-III Series Furnace 8935, 8940 MODELS Technical Installation Manual ENGLISH, FRANCAIS •Installation (et Canada) Effective 9/1/03 Motor DC Motor AC DRAWING DESCRIPTION OF PARTS Sail Switch High Voltage Wire Relay Draft Cap Assembly DC/AC35 Deluxe Door &... -
Page 44: 2-Stage Model 2540
MPD 33939 LITERATURE NUMBER hydro flame 8500-IV 2 Stage Series Furnace 1522, 2334 MODELS Technical Installation Manual Patent No US 6,464,000 Other Patents Pending ENGLISH, FRANCAIS •Installation •Maintenance (et Canada) Effective 9/1/03 HEAT COOL Field Wiring Harness Element Assembly - Specify Model DRAWING DESCRIPTION Blower Wheel... -
Page 45: 85-Iv 16, 85-Iv 20, 85-Iv 25, 85-Iv 31, 85-Iv 35, 1522, 2334 2 - Stage & R-25
MPD 33943 LITERATURE NUMBER hydro flame 8900-III-LD 2 Stage Series Furnace 2540 MODEL Technical Installation Manual Patent No US 6,464,000 Other Patents Pending ENGLISH, FRANCAIS •Installation (et Canada) Effective 9/1/03 HEAT COOL Duct Cover Plate Blower Housing DRAWING DESCRIPTION Blower Wheel Electrode Motor/Combustion Wall Gasket &... -
Page 46: Replacement Part Reference
hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Blowers Wheels & Covers 37605 Blower cover - back (outside) 37606 Blower cover - front (inside) 37607 Blower Venturi Ring 33126 Blower Wheel Kit Burner 36043 Burner Head 35491 Burner Head Burner Orifices 31257 #56 16,000 BTU 31265 1.25MM 18,000 BTU 31267 #54 22,000 BTU... - Page 47 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Heating Elements 37960 Htg Element Kit* 16, 20 (before S/N 1260456) 37961 Htg Element Kit* 25 (before S/N 1260456) 37962 Htg Element Kit* 31, 35 (before S/N 1260456) 37958 Htg Element 16, 20, 25 (after S/N 1260455) 37959 Htg Element 31, 35 (after S/N 1260455) 38282 Htg Element No Longer Available...
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Page 48: 7912-Ii, 7900-Ii 16 & 20, 8012-Ii, 85-Iii 16-20, 85-Iii 25, 85-Iii 31-35, 89-Iii Dc, 89-Iii Ac, 2540 2 - Stage
hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Miscellaneous 37844 Air Intake Tube No Longer Available 32882 Door Screen 31474 Duct Adapter 4” 36688 Duct Adapter 2” 31361 Duct Cover Plate 37410 Gas Inlet Plug 37411 Slide Plate 38248 Transformer... - Page 49 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Blower 33580 Blower Cover 34014 Blower Cover 35881 Blower Wheel 33431 Blower Wheel 34550 Blower Wheel 33126 Blower Wheel Kit Burner 36043 Burner 32811 Burner 33842 Burner 35491 Burner 36147 Secondary Air Baffle 7920 & 7916 (after S/N 0651157) 36438 Secondary Air Baffle 7916 (before S/N 0651156) 36258 Secondary Air Baffle 7912, 8012 Burner Orifices...
- Page 50 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Combustion 35892 Combustion Air Hose 33128 Combustion Wheel Kit 33124 Combustion Wheel Kit 36216 Metal Combustion Wheel 8535-III Use 37107 Door 37912 1/4 Turn Nylatch 36644 Access Grill (Screw-In) No Longer Available 37520 Access Grill (1/4 turn fastener) 37864 Access Grill (1/4 turn Artic White) No Longer Available...
- Page 51 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 33566 Outlet Manifold (before S/N 0654748) 35936 Outlet Manifold (before S/N 0651156) No Longer Available 31043 Brass Inlet Fitting Use with Part #’s 37392/37391 32173 Brass Inlet Elbow (before S/N 0654748) Motor 35122 Motor AC 34039 Motor Capacitor AC 36122 Motor PF20066Q...
- Page 52 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 37383 White Rodgers Valve (DC) (After Serial #0657715) 34006 White Rodgers Valve (AC) (Before Serial #0657716) 25M18V-701 37384 White Rodgers Valve (AC) (After Serial #0657715) 25M18V-711 34515 White Rodgers Coil (AC) 37973 2-Stage Gas Valve W/R 25M05V-701 Vent Kit 35955 79A-II 4 inch 35956 79B-II 8 inch...
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Page 53: 85-Ii 16-20, 85-Ii 25, 82-Ii 31-35, 89-I Dc, 89-I Ac, 89-Ii Dc, 89-Ii Ac, Fa 79D, Fa 79P, Hf 80D, Hf 80P
hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Blower 33580 Blower Cover 33431 Blower Wheel 33618 Blower Wheel 33619 Blower Wheel 34550 Blower Wheel Burner 32149 Burner No Longer Available 32811 Burner 33842 Burner 34000 Burner (Use Kit 38548) 35491 Burner Burner Orifice 31268 #59 12,000 BTU 31257 #56 16,000 BTU... - Page 54 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 33853 Recess Pan 01 White 33854 Recess Pan 02 Colonial White 33856 Recess Pan 04 White 33863 Recess Pan 11 White 35063 Recess Pan 12 Grey 35104 Recess Pan 22 White 35105 Recess Pan 23 White 33847 Door Catch Screw Type (set) 33620 Door Hinge - inner (set) 31145 Roller Door Catch...
- Page 55 hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Pilot 32466 1/4 x 7 Pilot Tube w/ fittings 33830 Jade Orifice .008 31307 Jade Thermal Couple 14˝ 33831 Jade Pilot Assembly J721013CLP (Use 31299) 36038 Piezo Igniter Kit Relay 31017 Klixon Relay Switches 31023 Limit Switch L170 35132 Limit 130 Switch...
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Page 56: 85-I 16-20, 85-I 25, 85-I 31-35, Dc82 25-32, Dc82 35-41, Ac 82, Fa 76D, Fa 78 25-32, Fa 72D, Fa 72P
hydro flame Furnace REPLACEMENT PART REFERENCE September 2003 Blower 31135 Blower Wheel NLA 31139 Blower Wheel 32775 Blower Wheel 32776 Blower Wheel Burner 32002 Burner 32112 Burner 32149 Burner No Longer Available 32811 Burner Burner Orifice 31270 #66 Orifice 31268 #59 Orifice 31257 #56 16,000 BTU 31265 1.25mm 18,000 BTU 31267 #54 25,000 BTU... - Page 57 hydro flame Furnace REPLACEMENT PART REFERENCE September 2002 Motor 31039 Motor JA25065N (AC) 31036 Motor PF2040Q 31037 Motor PE2423Q 31038 Motor PE2627Q 32330 Motor PF23129Q 32774 Motor PF23175Q 33219 Motor PF2055Q 32870 Motor Bracket Pilot 31292 ITT Pilot Assembly 26C1762 33829 ITT TV Orifice .010 32417 ITT TV Orifice .008 31299 Jade Pilot Assembly J72C2426CL...
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Page 58: Atwood Furnace Installation Parts
Atwood Furnace Installation Parts Series 85 and 2-Stage Furnaces Part # Appearance Description 34438 Floor plate and (3) adapters for 4" ducts to rear of furnace. 36278 Adapter plate for bottom discharge - with foam seals on both sides. 36277 Adapter plate for bottom discharge - no seals but with alignment tabs. - Page 59 This manual has been provided courtesy of My RV Works, Inc. www.myrvworks.com You can find more RV service manuals here: www.myrvworks.com/manuals Over the years of running a mobile RV repair service, having a dedicated place to access service manuals for all the different appliances and components found on RVs was something that I always had a desire to create.