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heatco EMA Series Installation, Operation And Maintenance Instructions

Gas-fired duct furnace
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INSTALLATION, OPERATION
MAINTENANCE INSTRUCTIONS
HIGH EFFICIENCY DUCT FURNACE
ANSI Z83.8 (2016) – CSA 2.6 (2016) Gas-Fired Duct Furnace
MP5157
WARNING:
!
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury ,
death or property damage .
Be sure to read and understand the installation , operation and service
instructions in this manual .
Improper installation , adjustment , alteration , service or maintenance
can cause serious injury , death or property damage .
Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance .
WHAT TO DO IF YOU SMELL GAS
·
Do not try to light any appliance
·
Do not touch any electrical switch ; do not use any phone in your
building
·
Leave the building immediately
·
Immediately call your gas supplier from a phone remote from the
building. Follow the gas supplier's instructions .
·
If you cannot reach your gas supplier , call the fire department .
Installation must be performed by a qualified installer , service agency or
gas supplier .
This manual must be kept with the appliance for future reference.
Heatco Inc.
50 Heatco Court
Cartersville, GA 30120
EM (A, G) SERIES
AND
3035443
EM-IOM-E-2016-13

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  • Page 1 If you cannot reach your gas supplier , call the fire department . Installation must be performed by a qualified installer , service agency or gas supplier . This manual must be kept with the appliance for future reference. Heatco Inc. 50 Heatco Court Cartersville, GA 30120 EM-IOM-E-2016-13...

  • Page 2: Table Of Contents

    Table of Contents Dimensions and Ratings. 3 – 4 Safety Rules and Precautions. . III. Installation Requirements. 6 – 7 a. Direction of Airflow. b. Application Guidelines. Duct Installation. 7 – 8 Combustion Air Supply. Venting – General. 9 – 10 a.

  • Page 3: Dimensions And Ratings

    (Across Air Area Ht. / Blank Min. Depth Min. Max. Min. Max. Width (No. of Tubes) Btuh Btuh EMA Series - Horizontal or Vertical Airflow 720,000 46.00 45.76 55.93 17.77 669,600 6200 20667 EMA720 (16) 211,010 1168 1162 1421 1.65 196,240 1.63...
  • Page 4 EMG Series...

  • Page 5: Safety Rules And Precautions

    II. Safety Rules and Precautions The installation, operation and maintenance instructions in this manual must be followed to provide safe and efficient operation of the furnace. Particular care must be exercised regarding special precautions noted throughout this manual. Failure to address critical areas and situations noted could result in PROPERTY DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH.

  • Page 6: Installation Requirements

    III. Installation Requirements All unit installations must be in accordance with the National Fuel Gas Code ANSI Z223.1 (NFPA 54) in the United States and Can/CGA-B149 Installation Code in Canada, and all other applicable local codes and ordinances. These requirements include but are not limited to: ...

  • Page 7: Application Guidelines

    WARNING ! Be sure the furnace/airflow configuration selected is appropriate for application based on entering air temperature. Failure to install unit with proper airflow direction may result in property damage, personal injury or death. Application Guidelines Parallel installations are acceptable with all configurations. Duct Furnace Airflow...
  • Page 8 Figure 3 –Duct Access Panels A circulating airflow proving switch must be installed in duct upstream of duct furnace to prove circulating airflow. See “Controls” section for additional information on locating air probe. Airflow Distribution Uniform air distribution over the heat exchanger is essential to proper operation and optimum unit efficiency. Use of baffles and/or turning vanes may be required to provide uniform air flow though the heating unit.

  • Page 9: Combustion Air Supply

    V. Combustion Air Supply The duct furnace needs an ample supply of air for proper and safe combustion of the fuel gas. Do not block or obstruct air openings to the area where the heating unit is installed. Locate unit to insure an adequate supply of fresh air to replace air used in the combustion and ventilation process.

  • Page 10: Outdoor Installations

    The vent and combustion air piping must be properly supported. A 10ft. long section of schedule 40 PVC pipe weighs approximately 14 lbs for 3 in. diameter and 20 lbs. for 4 in. diameter. Horizontal sections must be installed with an upward pitch of not less than ¼...
  • Page 11 Figure 5 – Outdoor Venting a) Side Discharge 12.0" (0.3m) Min. 18.0" (0.45m)Max. or 90 Elbow Install Term ination Vent Pipe Screen 18" (.45m) Minimum above grade or expected snow level b) Top Discharge...

  • Page 12: Indoor Installations

    Indoor Installations Installations with Ambient Combustion Air Supply In this type of installation, duct furnaces will draw their combustion air from the space surrounding the heating unit. Combustion air openings must be provided in the access panel to the burner vestibule area with openings properly sized as outlined in Section V.
  • Page 13 b) Top Discharge Note: For top discharge exhaust orientations, a flue exhaust drain coupling is provided and must be installed for proper condensate drainage of the venting system. See Section VII for condensate drain connections to furnace and vent pipe. Vertical vents should terminate as shown in Figure 7.
  • Page 14 For horizontally vented installations, select a location that limits vent length to the maximum in Table 2. Allow for ¼” (6mm) upward pitch of vent pipe from the heater to the termination for proper condensate draining. Vent pressures in horizontally vented furnaces are positive and therefore are classified as Category IV venting systems in accordance with ANSI standards.
  • Page 15 Table 3 – Clearances to Horizontal Vent Terminal Min. Clearances to Vent Terminal Structure (all directions unless specified) Combustion air inlet of another appliance 6 ft. (1.8m) Forced air inlet within 10 ft. (3.1m) 3 ft. (0.9m) above 4ft. (1.2m) horizontally Door, window or gravity air inlet 4 ft.
  • Page 16 Figure 11 – Non-Combustible Material Wall Installations with Outdoor Combustion Air Supply –Separated Combustion This duct furnace installation requires a two (2) pipe separated combustion vent system with separate air intake and vent. Models with inputs of 400,000 Btuh or greater employ two furnace sections and require an individual vent pipe from each section to discharge flue gases.
  • Page 17 Table 4 – Vent and Combustion Air Pipe Sizing for Separated Combustion. Max. Vent Combustion Air Inlet Flue Exhaust (Vent Pipe) Model Input (Btuh) Pipe Size Diameter Material Diameter Material Length 90,000 3" 3" 35’ 135,000 3" 3" 180,000 4" 4"...
  • Page 18 Vertical Vent System This section applies to vertically vented two-pipe vent systems in addition to the instructions provided under “General”. All venting and drain components, except for condensate traps, are provided by others. Vertical vent systems terminate vertically up. Install a Tee fitting with drip leg and cleanout trap as shown in Figure 12.
  • Page 19 Indoor Horizontal Vent System This section applies to horizontally vented two-pipe vent systems in addition to the instruction provided under “General”. All venting and drain components, except for condensate traps, are provided by others. Horizontal vent systems terminate horizontally. Install a Tee fitting with drip leg and cleanout trap as shown in Figure 14. Vent and combustion air piping must be terminated as shown in Figure 15.

  • Page 20: Condensate Drains - General

    VII. Condensate Drains Condensate is produced in furnace sections during heating operation. Installation requires an individual condensate drain system for each duct furnace section and may be combined to a common condensate drain line after condensate trap(s). Waterless condensate valve/trap kits are provided with each duct furnace. The condensate drain system must include a waterless valve/trap for each furnace section for proper system performance.
  • Page 21 Figure 16 – Condensate Drain Connections for Outdoor Installation a) Condensate Piping- Typical Certain induced draft fan orientations require an additional condensate drain hose(es) to remove condensate from fan housing as shown in following illustrations. b) Side Discharge...
  • Page 22 c) Two (2) Inducer Fan Systems (See Figure 17 for Common Manifold Piping) d) Top Discharge...

  • Page 23: Common Condensate Manifold

    The drains must be extended through the heater base and into the heated space below to prevent freezing of condensate in the drain piping. Waterless valve/trap must be located in a heated space or protected to avoid freezing. Locate Waterless Trap as close to duct furnace as possible. Where condensate drains are located outside a heated space or in a space where temperatures may fall below freezing, the drain line must be protected.
  • Page 24 Figure 18 – Condensate Drains for Indoor Installations – Vertical Vent For top discharge exhaust, the induced draft fan requires a drain connection to the fan housing. A drain hose (of proper temperature rating) is provided and should be attached as shown below. For installations where the building drain lines are above the level of the duct furnace drain system, a condensate pump is required.

  • Page 25: Condensate Neutralization

    Figure 19 – Condensate Drains for Indoor Installation –Horizontal Vent Disposal of condensate is subject to local codes and ordinances. In some locals the condensate drain system may be connected to a sanitary drain within the building. VIII. Condensate Neutralization Some municipalities require that the acidic condensate produced be neutralized before being discharged into a sewer or drain.

  • Page 26: Gas Supply Piping And Connections

    Gas Supply, Piping and Connections Installation of piping must conform with local building codes and ordinances, or in the absence of local codes with ANSI Z223.1 the National Fuel Gas Code. In Canada, installation must be in accordance with CAN/CGA –B149.1 for Natural Gas and B149.2 for Propane units.
  • Page 27 WARNING ! 1) All gas piping, including furnace connections, must be pressure tested prior to operation. NEVER use an open flame. Use a soap solution or equivalent for testing. 2) Gas pressure to furnace controls must NEVER exceed 14” w.c. (1/2 PSI) WARNING ! 1.

  • Page 28: Electrical Supply And Ratings

    Electrical Supply and Ratings All electrical equipment must be grounded and wired in accordance with the National Electric Code (ANSI/NFPA 70) in the United States, and the Canadian Electric Code (CSA C22.1), in Canada. The furnace control system requires both line voltage and low voltage circuits with correct polarity, and clean neutral and ground.

  • Page 29: Airflow Proving Switch

    Airflow Proving Switch An airflow proving switch must be installed in the duct furnace application. The airflow proving switch prevents operation of the gas heater in the event of failure or restriction of the circulating air fan. An airflow probe should be installed upstream of the heating section to detect a positive pressure when the circulating air fan is operating during heating cycle.
  • Page 30 Figure 22 – White Rodgers 36H55 Gas Valve Failure to Ignite On the initial start-up, or after unit has been off long periods of time, the first ignition trial may be unsuccessful due to the need to purge air from manifold at start-up. If ignition does not occur on the first trial, the gas and spark are shut-off by the ignition control and the control enters an inter-purge period of 15 seconds, during which the draft inducer continues to run.

  • Page 31: Operating And Safety Controls

    1. The burner flame should be predominately blue in color, well defined and centered at the tube entry as shown in Figures above. Distorted flame or yellow tipping of natural gas flame, or a long yellow flame on propane, may be caused by lint and dirt accumulation inside burner or at burner ports, at air inlet between burner and manifold pipe, or debris in the main burner orifice.

  • Page 32: Periodic Seasonal Maintenance And Inspection

    High Limit Switches Two high limit switches are provided on all duct furnace configurations. One limit control is mounted in the air stream and will shut-off the gas supply in the event of overheating due to reduced airflow over the heat exchanger. This limit is an automatic reset type and will cycle the burners back on when the temperature drops below the preset differential.

  • Page 33: Annual Maintenance And Inspection

    Check the appearance of the burner flame (See Figure 22A and 22B on Page 27. Be sure circulating air fan is operating and verify proper airflow through duct furnace Verify proper flow of condensate from drain system Return thermostat or heat controller to normal setting. Heatco Inc. 50 Heatco Court Cartersville, Ga. 30120...

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