Page 2 / IM 685
General
Warranty Exclusion ........................................................ 3
Ventilation and Flue Pipe Requirements ........................ 3
Factory Mounting .......................................................... 3
Factory Checkout ........................................................... 3
Installation
General ........................................................................... 3
Flue Box ......................................................................... 4
Wind Deflector .............................................................. 4
Electrical ......................................................................... 5
Gas Pressure Requirements ............................................. 5
Gas Piping ...................................................................... 5
Valve and Regulator Venting .......................................... 6
Normally Open Vent Valve ............................................ 6
Gas Piping Routing Into Unit
On-the-Roof Piping (Models 020-140) ...................... 7
Through-the-Curb Piping (Models 020-140) ............. 7
Typical Piping Connections ........................................ 7
Gas Piping (Models 150-200) ..................................... 8
Gas Piping Within the Vestibule ................................ 8
Field Gas Piping Required .......................................... 8
Condensate Drain ....................................................... 8
Vestibule (Models 150-200) ....................................... 8
Start-up & Operating Procedures
Start-up Responsibility ................................................... 9
Start-up Procedure.......................................................... 9
Before Start-up ............................................................... 9
About This Burner ......................................................... 9
Prepurge is Low-High-Low ......................................... 9
Low Fire Start ............................................................. 9
“Pilot” is Main Flame Modulated Down
to Pilot Rate ............................................................ 9
Set Control System to Enable Heating ......................... 10
Start-up Preliminary ..................................................... 10
Preliminary "Dry" Run................................................. 10
Flame Start-up .............................................................. 11
Modulate Firing Rate ................................................... 11
Combustion Tests ........................................................ 11
Cycle the Unit .............................................................. 11
Record Data ................................................................. 11
References
Typical Electrical Schematic ......................................... 12
Typical Sequence of Operation..................................... 12
Typical Piping Schematic ............................................. 13
Typical Burner Control Box ......................................... 14
Table of Contents
When writing to McQuay for service or replacement parts, refer to the model number of the unit as stamped on the serial plate,
attached to the unit. If there is an in-warranty failure, state the date of installation of the unit and the date of failure along with
an explanation of the malfunctions and the description of the replacement parts required. Parts are warranted for ninety (90)
days unless covered by original unit warranty.
Flame Safeguard
Keyboard Display Module ............................................ 14
Operation ..................................................................... 14
LED Display................................................................. 15
Service
General ......................................................................... 16
Gun Assembly .............................................................. 16
Gun Assembly Removal and Installation ...................... 16
Flame Rod Adjustment ................................................. 16
Flame Rod Installation ................................................. 17
Ignition Electrode Adjustment ..................................... 17
Air and Gas Adjustments .............................................. 17
Gas Supply Pressure...................................................... 17
High Pressure Regulator ............................................... 17
Gas Adjustment ............................................................ 17
Air Adjustment ............................................................. 17
Air and Gas Control Linkage ........................................ 18
Actuator Crankarm....................................................... 19
Switch Adjustment ....................................................... 19
Altitude Considerations ................................................ 19
Gas Valve Pressure Regulator Adjustment .................... 19
Adjustment Procedure for Parallel Valves ................. 20
Check Manifold Pressure at Minimum Rate ............. 20
Combustion Testing ..................................................... 21
Verify Input Rate .......................................................... 21
Check CO
2
, CO and Stack Temperature ..................... 21
Cleaning Heat Exchanger (Models 032-020) ............... 21
Cleaning Heat Exchanger (Models 020-025) ............... 22
Leakage Symptoms ....................................................... 22
Checking for Leaks ....................................................... 23
Causes of Failures ......................................................... 23
Replacing Heat Exchanger ............................................ 23
Furnace Condensation .................................................. 24
Rear Cleanout Port ....................................................... 24
Combination Fan and Limit Control ........................... 25
Maintenance
Monthly, Twice Yearly, Yearly ..................................... 25
Troubleshooting Guide ............................................. 26
Typical Parts List – 60 Hz ....................................... 28
Capacities & Adjustments Table ............................ 29
Performance & Service History ............................ 30
Installer: Leave this manual with owner. It is to be posted and maintained in legible condition.
SERVICED BY:
TELEPHONE NO: INSTALLATION DATE: