Empire Products FAW-40-1IP, FAW-40-1SPP If Electrode Does Not Produce Spark, IP-Model Pilot

SERVICE AND MAINTENANCE SUGGESTIONS

CALL SERVICEMAN

GENERAL: All furnaces have been fire-tested to check for proper op- eration. This includes, main burner flame, pilot flame, fan operation, 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 be contacted to assist in servicing furnace.

Standing Pilot Model

Servicing the Pilot and Main Burners, Pilot Orifice, Thermocouple, and Main Burner Orifices: Disconnect the gas supply at the inlet to the control valve. Then remove the burner door to gain access to the above listed components.

Spark Igniter Does Not Light Pilot: With air in the gas line, such as when the furnace is first installed or was off all summer, the pilot flame may be too lean to ignite on the first few trials. Turn the control valve knob to pilot position and depress the red reset button. Holding the button down continually to bleed the line;.

1.Use lighter rod to light pilot with a match.

2.Use the piezo ignitor at 30 second intervals until it lights.

If Electrode Does Not Produce Spark:

1.Check wire connections.

2.Check gap for pilot burner to the electrode tip. Should be between 1/8" (3mm) and 3/16" (5mm). Electrode wire and tip must be more than 1/4" (6mm) away from all other metal components.

If Pilot Does Not Light By Any Means:

1.Check valve knob for being in the "Pilot" position.

2.Check pilot adjustment for being full open (counterclockwise to open).

3.If gas is available in the supply tubing, the pilot orifice and/or pilot burner is probably restricted by a spider web. Clean pilot assembly and relight.

If Pilot Does Not Remain On After Releasing Knob:

1.Follow instructions and hold button down longer and harder.

2.Determine if pilot flame extends past thermocouple; if not, adjust input or clean pilot burner.

3.Replace thermocouple if millivolts read less than 15 millivolts.

Main Gas Valve Does Not Open When Thermostat Is Turned To On:

1.Check for 24 volts to valve by removing one wire and touching to the SAME TERMINAL it was on. Terminal should have a light spark.

DO NOT SHORT ACROSS TERMINALS, AS IT WILL BURN OUT THE WALL THERMOSTAT.

2.Thermostat wires at the wall may be shorted, so check for a faulty thermostat.

3.To check for line voltage to furnace, remove front panel and short across two-terminal fan control to allow fan to operate (Figure 14).

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

IP-Model Pilot

This heater is using a Honeywell "Smart Valve" system for intermittent pilot ignition.

On a call for heat by the thermostat this control turns on a 24 volt mini hot surface ignitor which lights a pilot that in turn lights the main burner. The gas valve used in this system is a step opening which opens at a lower pressure for ignition and then steps to a full inlet pressure of 4" H2O pressure on Natural gas and 10" H20 pressure on LP gas.

Pilot Flame Adjustment

The pilot flame should envelop 3/8 to 1/2 inch (10 to 13mm) of the tip of the flame rod. See Figure 10.

To adjust:
1.	Remove the pilot adjustment cover screw.
2.	Turn the inner adjustment screw clockwise		to decrease
	or counterclockwise	to increase pilot flame. Pilot adjust-
	ment is shipped at full flow rate. Turn the inner adjustment screw
	clockwise	if the inlet pressure is too high.

3.Replace the cover screw after the adjustment to prevent gas leak- age.

Figure 15

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