MANUAL STATES STO TED V I N USSC E U OWNERS COMPANY GRAVITY TYPE DIRECT VENT WALL FURNACE MODEL # 9660 MAY BE INSTALLED IN A MANUFACTURED HOME (MOBILE HOME). WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. – 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.
TABLE OF CONTENTS Introduction...............................................2 Important Information................................2 Gas Specifications....................................2 Furnace Dimensions.................................3 Planning your Furnace Installation........4-5 Installation Instructions for Optional Blower Kit.........................................5 Operation and Maintenance.................6-7 Venting Instructions..............................7-8 Venting Tables.................
GAS FURNACE DIMENSIONS 27 3/8 28 1/4 *TOP VIEW SHOWN WITHOUT FURNACE TRIM FOR CLARITY.
PLANNING YOUR FURNACE INSTALLATION OPENING OF DOOR FRAMING AND FINISHING HEARTH 1. A hearth is not required, but it will improve the appearance and provide added safety. We recommend a noncombustible hearth which extends a minimum of 12 inches in front of the appliance. 2. 1 Remove top grill 2 Lower bottom grill by pulling down knob. 3 Unlatch door and swing door down. 3. 1 Choose furnace location and frame opening as illustrated below in figure 3, 4a & 4b.
THIS APPLIANCE IS FOR USE WITH NATURAL OR PROPANE/LP GAS ONLY AS INDICATED ON RATING PLATE. NOTE: BTU ratings shown on the rating plate area are for elevations up to 2,000 feet. For elevations above 2,000 feet, rating should be reduced at the rate of four (4) percent for each 1,000 feet above sea level. GAS PIPE AND BURNER INSTALLATION Installation must conform to local codes, or in the absence of local codes, to the latest edition of the National fuel Gas Code, ANSI Z 223.1-1992. A.
SHUT-DOWN PROCEDURE OPERATION AND MAINTENANCE WARNING: WHEN PURGING THE 1. To turn off the Main Burner only, use Main Burner switch or turn Valve Knob to "PILOT" position. GAS LINE, THE GLASS FRONT MUST BE REMOVED. 2. For complete shut down, slightly depress Valve Knob, turn to "OFF" position. LIGHTING PROCEDURE (Fig.9) 1. Depress and turn gas valve knob (A) to "off". Wait sufficient time to allow gas which may have accumulated in the burner compartment to escape. (At least 5 minutes.) 2.
GLASS CLEANING VENTING INSTRUCTIONS It will be necessary to clean the glass periodically. During start-up, condensation forms on the inside of the glass and causes dust, lint, etc. to cling to the glass surface. This is normal. Also, initial paint curing can deposit a slight film on the glass. The Model 9660 furnace is designed for direct venting through a side wall or roof. Only venting components specifically approved and labeled for this furnace may be used.
VENTING INSTRUCTIONS If the exterior of the building is non-combustible the following minimum clearances are applicable: If exterior of the building is combustible the following minimum clearances are applicable.
VENTING TABLES V1 VT VT VT V H TABLE B TABLE A H1 TABLE B VT H Min. Max. 1 2 2 4 3 6 4 8 5 8 VT = 40 Max. H = 8' Max. TABLE A VT = 40' Max. H TABLE C TABLE C V Min. 1 2 3 4 5 6 7 8 9 H TABLE D TABLE D H = 12" Min. H = 24" Max. H H H+H 1 V1 Max. Max. Max. 2 2 39 4 4 38 6 6 37 8 8 36 8 10 35 8 12 34 8 14 33 8 16 32 8 16 31 VT = V+V1 = 40' Max. H = 8' Max. TOP VIEW TABLE E TABLE E H = 12" Min. H = 24" Max. TABLE F V H1 H HT TABLE F-1 USSC V Min. 1 2 3 4 5 6 7 8 9 H H+H 1 Max. Max.
INFORMATION ON VENTING ROUTES AND COMPONENTS Since it is very important that the vent system maintain its balance between the combustion air intake and the flue gas exhaust, certain limitation as to vent configurations apply and must be strictly adhered to. • Max. vertical vent run is 40 ft. • Max. horizontal vent run is 16 ft. • A 1/4" rise per foot of horizontal run must be maintained on all horizontal runs.
VERTICAL TERMINATION STEP 1: Set the gas appliance in it's desired location. Drop a plumb bob down from the ceiling to the position of the appliance flue exit, and mark the location where the vent will penetrate the ceiling. Drill a small hole at this point. Next, drop a plumb bob from the roof to the hole previously drilled in the ceiling, and mark the spot where the vent will penetrate the roof. Determine if ceiling joists, roof rafters, or other framing will obstruct the venting system.
STEP 6: Continue to add pipe sections until the height of the Vent Cap meets the minimum building code requirements described in figure 18. Note that for steep roof pitches, the vent height must be increased. In high wind conditions, nearby trees, adjoining rooflines, steep pitched roofs, and other similar factors can result in poor draft, or down-drafting. In these cases, increasing the vent height may solve this problem. Nail Firestop STEP 7: Twist lock the Vent Cap.
GAS PRESSURE REQUIREMENTS The number one cause of all operating problems with gas appliances is improper gas pressure! Such problems as changes in flame color or configuration, gas pilot or burner outages, intermittent operation, changes in heat output, excessive burner noise, etc., are nearly always the result of changes in gas pressure or improper gas pressure at the time of the installation. NATURAL L.P. DESIRED PRESSURE 7.0" W.C. 11.0" W.C.
TESTING MANIFOLD AND INLET PRESSURE GAS CONVERSION To test the Manifold gas pressure and Inlet gas pressure in the field, simply follow the instructions below. 1. Open lower door and locate the 1/4" O.D. tubing connecting the control to the bottom of the pilot. NOTE: Manometer attachment may be accomplished by sliding a rubber tube connected to the manometer to the pressure taps. 2.
TROUBLESHOOTING PROBLEM: POSSIBLE CAUSES: REMEDIES: Piezo sparker won't light pilot. 1. Misaligned electrode. 1. 2. 3. Incorrect wire connections. Defective electrode. 2. 3. 4. 5. Defective push button. No gas present. 4. 5. Realign electrode so it produces spark into pilot hood (approximately 1/8" from pilot hood). Make sure connections are proper. Replace electrode if shorted out or it has cracked porcelain. Replace push button. Turn gas on.
TROUBLESHOOTING (CONT.) PROBLEM: POSSIBLE CAUSES: REMEDIES: Window keeps getting sooty. Unit needs more primary air. 1. Blocked primary air port. 1. 2. 2. 3. Flame impingement on logs or elsewhere. Logs too close to or touching glass. 4. Valve and burner over-fired. 4. PROBLEM: POSSIBLE CAUSES: Dirty window. (White on window). Initial burn off of paint and sealants used to produce unit. 3. Check primary air assembly. Over a period of time dust, lint, pet hair, etc.
TURNING GAS OFF TO APPLIANCE 1. Set the thermostat to lowest setting. 3. Push in gas control knob slightly and turn clockwise to "OFF". Do not force. 2. Turn off all electric power to the appliance if service is to be performed. FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by a piezo ignitor.
MODEL 9660 GENERATOR REPAIR PARTS 1 17 16 3 4 2 10 7 15 18 5 12 11 9 6 8 13 14 21 19 20 22 18 NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE USSC
MODEL 9660 GENERATOR PARTS LIST ITEM DESCRIPTION 1 Control Plate Weldment 2 Burner 3 L.P. Burner Orifice * Natural Gas Burner Orifice 4 Manifold Union 5 1/4" OD Flex Tube 6 3/8" OD Flex Tube 7 Switch Bracket 8 Rocker Switch 9 Adaptor Fitting 10 Control Bracket 11 Piezo Bracket w/Screw 12 Piezo w/ Nut 13 Sit Control 14 16ga. Link Chain 15 Thermopile 16 Sit Thermo-Couple 17 L.P.
MODEL 9660 GAS FURNACE REPAIR PARTS 1 25 24 6 26 31 28 5 30 29 8 9 2 27 3 7 4 11 20 10 21 17 16 7 15 18 19 22 14 13 12 23 20 NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE USSC
MODEL 9660 GAS FURNACE PARTS LIST ITEM 1 2 3 4 5 6 7 DESCRIPTION Unit Top Unit Right Side Unit Left Side Unit Base Unit Back Top Grill Arched Door Frame Full-view Door Frame 8 1-1/4" Flat Rope 9 Glass 10 Lower Grill 11 Brass Door Knob * 10-32x1/2" Machine Screw * Lower Grill Hinge 12 Firebox Bottom 13 Firebox Divider * Flue Outlet 14 Firebox Wrapper * Starting Collar 15 Firebox Shield 16 Firebox Top 17 Latch w/ Keeper 18 Insulation 19 Firebox Front 20 Inner Baffle 21 Baffle Plate 22 Vent Termination Assem
OPTIONAL KITS AVAILABLE MODEL: BDK60 BRASS DOOR TRIM KIT MODEL: B60 BLOWER KIT MODEL: WSK60 WALL SWITCH KIT SKY TEC H INDICATOR SKY ON TEC H OFF NO R E REM OTE M O T E OFF SKYTECH 1001 10 21 32 c 50 60 70 80 90 10 21 32 c 50 60 70 80 90 22 MODEL: RCK60 REMOTE CONTROL KIT MODEL: WTK60 WALL THERMOSTAT KIT MODEL: FVK60 FULL-VIEW DOOR KIT MODEL: CBK60 REFRACTORY CERAMIC BRICK KIT NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE USSC
WIRING DIAGRAM FOR OPTIONAL (MODEL #B60) BLOWER KIT WHITE (Neutral) BLACK (Hot) GREEN (Ground) 1/4" MALE INS. 80377 BLACK ATTACH GROUND TO SIDE OF UNIT WITH SCREW INCLUDED GREEN 2x4 BOX 80377 BLACK 80378 WHITE WHITE 1/4" FEMALE INS. THERMO DISC 1/4" MALE INS. 1/4" FEMALE INS. 80378 BLOWER 1/4" MALE INS.
WIRING GUIDE FOR 9660 The following Wiring Guide is to help assist in the wiring of any combination of the Optional Kit listed below: RCK60 - REMOTE CONTROL KIT WSK60 - WALL SWITCH KIT WTK60 - WALL THERMOSTAT KIT IMPORTANT: Before ordering or installing any to the available kits, remember the following... 1) Not all Optional Kits will work together. Example: The (RCK60) Remote Control Kit, the (WSK60) Wall Switch Kit, and the (WTK60) Wall Thermostat Kit cannot be used at the time.
WIRING WITH THE WSK60 - WALL SWITCH KIT: Remember the Rocker Switch must be turned to "OFF" while using the Wall Switch. WALL SWITCH CONTROL VALVE PILOT TP it TH S ON OFF PILOT A TP TH E ROCKER SWITCH PIGGYBACK DISCONNECT WIRING WITH THE WTK60 - WALL THERMOSTAT KIT AND THE RCK60 - REMOTE CONTROL KIT: Note: When combining these Optional kits, only one kit can be used at a time.
NOTES 26 NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE USSC
NOTES USSC NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE 27
HOW TO ORDER REPAIR PARTS THIS MANUAL WILL HELP YOU OBTAIN EFFICIENT, DEPENDABLE SERVICE FROM YOUR 9660 GRAVITY TYPE VENTED WALL FURNACE, AND ENABLE YOU TO ORDER REPAIR PARTS CORRECTLY. KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE. WHEN WRITING, ALWAYS GIVE THE FULL MODEL NUMBER WHICH IS ON THE NAMEPLATE ATTACHED TO THE HEATER. WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION AS SHOWN IN THIS LIST: 1. THE PART NUMBER 2. THE PART DESCRIPTION 3.
