PTR/ATRA^I Furnace Manual

3. INSTALLATION INSTRUCTIONS

3.1 RECEIVING

3.2 LOCATION

3.3 COMBUSTION AIR AND EFFECT OF NEGATIVE

AIR PRESSURE IN THE BUILDING

3.4 GAS SERVICE FOR GAS MODELS

3.5 ELECTRICAL REQUIREMENTS

3.6 WATER REQUIREMENTS

3.7 OIL SUPPLY FOR OIL BURNER MODELS

3.8 STACK INSTALLATION AND VENTING

3.9 COMPRESSED AIR SUPPLY CONNECTION

 PTR/ATRA^PI Furnace Manual c:\newcpnian\doc3.dip

3. INSTALLATION INSTRUCTIONS

CAUTION: ALL FURNACES EQUIPPED WITH GAS BURNERS HAVE

SMALL ALUMINUM ORIFICE PLATES LOCATED INSIDE THE PIPE
UNIONS JUSTAFTER THE BURNER GAS VALVES. IF THIS UNION IS
UNDONE DURING INSTALLATION OR SERVICE, MAKE SURE THE
ORIFICEPLATESARENOTLOSTORLEFTOUT.'SEEFIGUREBELOW.

(D

Orifice Located
Inside Pipe
Union

1
'J
Fig.3'1 Top View of Gas Burner Showing Orifice Location

3.1 RECEIVING

Most models are shipped completely assembled and crated with only the
larger sizes requiring some assembly. Instructions, diagrams, and
photographs are provided when any assembly is required. Inspectthe ship
ping crate and the furnace carefully when it arrives.

IF THERE IS ANY SIGN OF DAMAGE TO THE CRATE OR FURNACE,

DO NOT SIGN THE DELIVERY RECEIPT UNTIL THE FREIGHT COM
PANY HAS BEEN NOTIFIED AND SUCH DAMAGE HAS BEEN
NOTED ON THE FREIGHT BILL. CLAIMS FOR SHIPPING DAMAGE

Pages -1 Revision 3,3/17/2003

 c:\newcpman\4oc3.chp VTR/ATEUVPl Furnace Manual

MUST BE MADE BY THE CUSTOMER TO THE FREIGHT COMPANY

AND NOT TO THE DISTRIBUTOR OR MANUFACTURER.

Thefurnace weighs upto 11,000 lbs. (5000 kg)depending on model number,

so suitable equipment must be made available to uncrate it, move it off its
wooden shipping pallet, and move it into place. A forklift truck is desirable,
an overhead crane with chains running to the fiimace lifting lugs on top of
the furnace can be used. Pipes used as rollers, and pry bars are satisfactory
if carefully used. Do not leave the fkirnace on the shipping pallet

The cart is held insidethe fumace by shipping bolts which must be removed
before the cart can be moved. The outside track is strapped to the cart or to
the wooden pallet on which the fumace is shipped. The outside track must
be removed and placed in front of the fumace before the cart is moved. For
proper operation due to air movements within the fumace, the cart supplied
must be used and it must not be modified.

3.2 LOCATION

An "Installation Drawing" is located at the end of this chapter. It shows the

exterior dimensions of all the various model sizes with the minimum recom
mended clearances to locate the furnace within your building. Besides the
sheer size and dimensions of the fumace itself, another major factor in
choosing a location are the venting requirements for these furnaces. Each
furnace is supplied with a minimum of nine feet (3 sections) of insulated
chimneyexhauststackwhichconnectsto the top of thefumace. Somemodels
have fifteen feet (5 sections). The insulatedchimney exhaust stack vents the
extremelyhot gases [1400-1600 degreesF (760-871*'C)] from the fumace to
outdoors. Depending on the height of your roof, it may be necessary to
purchase from the factory additional sections of insulated chimney exhaust
stack(eachsection is 3 feetin height). The top of the stack must end 5 feet
or more above the roof. Local, city, or state codes may have different
requirements. If yourstack height exceeds 24 feetfrom thefloor(30feetfor
furnaces with J-121 burners), a draft damper will be required in one of the
insulatedchimneysections. Refer to Section 3.8 in this Chapter for exhaust
stack installation and venting.

Use only factory-supplied insulated chimney sections and accessories.

WARNING: The chimneys fumished by the factory are designed to operate

continuously at internal temperatures of1400-1600°F (760-87rC) and can
withstand temperatures of up to 2300* F (1260* C). The chimney's surface
temperatures run about 210* F @1400inside and 250* @1600. HOT!

Revision 3,3/17/2003 Page 3 - 2

 PTR/ATRATI Furnace Manual c:\newq5nianVdoc3.chp

The simplest and safest way to vent the furnace is straight up through the
roof. However, 45 and 90 degree insulated elbows are available if the stack
mustbe of&et for some reason. See drawing at end of this Chapter. A more
detailed discussion of the venting requirements and recommendations is
covered in section 3.8 in this Chapter entitled "Stack Installation and Vent
ing". Stack mustalways beinstalledby competent individuals experienced
in installing high'temperature venting systemsand who have read all the
installation instructions in this manual Alsoreferto the twopage "Instal
lation Drawing" for more detailsregardingstack installation.Inside installa
tion is preferred for the furnace, although it can be located outdoors if
adequately protected from rain, wind, and freezing weather.

Do not instaU where any solvent fumes, particularly chlorinated ones,

can be drawn into the burners. Such fumes will decompose into acid
fumes which will corrode and destroy the furnace walls.

The fumace should be located to fit in with the flow of work in the shop to
save time and steps in loading and unloading it Thefumace must beplaced
on a levely non-combustible floor (no wood), with a minimum 12 inches
(03M) clearance to combustible material Ifthe floor is uneven, doors may
not close and latch properly. Useshims under one front corner ofthefumace
and thefloor to level base-pan until doors do close and latch properly. The
front of the furnace must be left clear for loading and unloading. The
right-hand side (facing the fumace) must have clearance for reaching and
servicing the bumers and control panel. Adequate clearance must be
provided above the top of the fiirnace to allow the explosion relief door(s) to
open fully if required. Do not obstruct the explosion relief door(s) and do
not place anything on top of these doors. Special order units may have
bumers and controls on the left.

Provision should be made to prevent the fumace from moving out of its
original position as can occur if the fumace is loaded using a forklift. The
best way to keep thefumace in its intended locationis by use of three (3) flat
brackets which can easily be made out of l/2"x2" flat bar or similar material
about 6 to 12 inches long. Positiona bracket near the center of the back and
one on each side of the base of the fumace and bolt the brackets to the floor
of the building. Leave about 3/8" to 1/2" of space between the brackets and
the fumace base in order to allow for thermal expansion ofthe fumace during
operation so as not to warp the furnace basepan (see figure 3-1.5). If you
wish to bolt the fumace directly to the floor, this can be done by welding two
pieces of 3"x3" or 4"x4"angle to the sides of the base-pan and then bolting
these angles to the floor. When using this method, it is important that you
cut the hole for the bolts at least 5/8" larger in diameter than the bolt which

Page 3 - 3 Revision 3,3/17/2003

 c:\newq)man\doc3.chp PTR/ATRA^I Furnace Manual

er TO 12" LONG 1/2"x 2" FLAT BAR

UK BOLTED TO FLOOR

REAR OF
FURNACE

a
TOP RELIEF DOOR 1/2"x 2" FLAT BAR
BOLTED TO FLOOR

v_r
-EXHAUST CHIMNEY
D

[o
CONTROL D9804-02.DWC
BOX
LFURNACE FRONT 1/2"x 2" FLAT BAR
DOORS BOLTED TO FLOOR

PLAN VIEW

FURNACE FRONT
DOOR

BOLT FLAT BAR TO

FLOOR WITH S/fiT
DIAMETER BOLTS

l/2"x 2" FLAT BAR

D9804-02.0WO

-II-3/8" TO 1/2" GAP TO ALLOW

FOR THERMAL EXPANSION OF
FURNACE BASEPAN (TYP.)

DETAIL VIEW
Figure 3-1.5 Suggested Method for Securing Furnace in Place

you will be using, and tighten the bolts only hand tight in order to allow for
thermal expansion as described above.

When installing the furnace and chimney, please use common sense to
preclude any danger from either the furnace or its chimney stack; keep away
from this equipment and its stack anything flammable or combustible that
may cause a fire. DO NOT ADD EXTRA INSULATIONANYWHERE ON
THE FURNACE OR THE CHIMNEY. Extra insulation restricts normal heat
dispersal into the air forcing furnace walls or chimney walls to operate at
higher temperatures which can be dangerous. Surface temperatures on the
outside ofthefurnace will be about 120-140°Fwhen the furnace isoperating

Revision 3,3117/2003 Page 3-4

 PTR/ATRA^I Furnace Manual c:\newcpman\doc3.cfap

at 800°F on the inside. The furnace can be touched by hand nearly all over,
however, the fiimace frame around the back side of the door will be
somewhat hotter because some heat is conducted directly through the metal
there. WAmiNG: DO NOT TOUCH THERE!

If installed outside, a roof must be installed above the fiimace to protect it

from rain and snow. The side of the fiimace where the bumers and controls
are located must also be protected from blowing rain and snow and the back
side of the fumace must be protected from the wind in order to prevent wind
from blowing directly into the bumer air intakes which can cause problems
with operation and lighting of the bumers. The protection can be a simple
cormgated steel shed with the provision that any plastic or wooden parts of
the stmcture be kept at least 12 inches away from the furnace or its stack. An
outside floor must be non-combustible (no wood), level where the fumace
is but should provide rapid mn-off to prevent water from collecting around
the base and rusting it. Grouting of the base to the floor will prevent seepage
of water under it. Special order units may have control panels for remote
mounting inside the building. If the temperatures fall below freezing, the
water spray lines and system must be protected from freezing by heat tracing
or other means.

3.3 COMBUSTION AIR AND EFFECT OF NEGATIVE AIR

PRESSURE IN THE BUILDING
Every bumer must take in a minimum of 10 times as much air as fuel for
proper combustion, therefore an adequate supply of combustion air must be
assured. Many buildings in which this fumace will be installed will be large
enough to have enough "cracks" and leakage of air to the inside. However,
many buildings now have exhaustfans, spray paint booths, cleaning booths,
sand-blast booths, etc. where air is drawn out much faster than it comes in.
This creates a negative pressure inside the building which is enough to
overcome the natural draft created in the furnace, and the furnace will not
work properly. The effect of the negative pressure is compounded when
dock doors, walk ways, and windows are closed. This is particularly tme in
the winter time. In such situations, the squirrel cage fans of the fumace gas
bumers cannot compete for air with these types ofdevices. Thus, the bumers
may become starved for air. The lower air flows to the bumers may cause
the following undesirable conditions:

1. Lower air flow causes uneven temperatures in the furnace and causes the
combustion temperature of the bumers to rise. The hotter combustion gases
emitted from the primary (lower) burner to heat the fumace may damage the

Page 3 - 5 Revision 3,3/17/2003

 c:\newcpman\doc3.chp PTR/ATRATI FurnaceManual

lower combustion chamber, or parts placed close to the combustion gas

output hole of the chamber.

2. Lowerair flow caused by excess negative buildingpressure mayraisethe

"idle temperature" of the afterburner (upper burner), causing excessive or
needless water spray. This results in longer cycle times and increased
operating costs. Parts also may not come out as clean as desired.

3. When the cleaning cycle ends or when the primary burner cycles off, hot
gases may be drawn backwards through the burner. This may overheat and
damage the burner.

4. Very high building negative pressures may overcome the fiimace natural
negative pressure and draw heat, smoke, and/or odor into the work area.

Where the building negative pressure is fairly small, the furnace will work
just fine as shipped from the Factory or the burners can be "re-tuned" using
the relatively simple procedures described in Section 11-3 of Chapter 11.
The P.C.P.C. Service or Technical Support group can supply help should
"re-tuning" of the burners be required.

In situations where tuning the burners will not correct the problems with
excess building negative pressure, outside air ducting will probably be
required. See the drawingentitled"Combustion Air Duct Details" at the end
of this Chapter. Each bumer needs a minimum of 90 scfin of air to work
properly. For Model 260 and larger furnaces, each bumer requires a mini
mum of 180 scfm of air. There are two recommended methods of ducting
in outside air. One is the manifold type. The other is a direct line.

When the furnace is installed close to an outside wall, a six inch rigid duct
may be mn from the bumer intakes straight through the wall. It is recom
mended that the duct be under ten feet long and as straight as possible.

When the fumace is installed too far away from an outside wall to mn a direct
line, a manifold type of ducting should be used. By mnning a ten-inch
diameter (12 inch for furnaces with J-121 bumers) or equivalent size rectan
gular duct close to the burners, a six-inch diameter rigid duct may be used to
mn from the manifold to each of the bumers or a six-inch diameter non-flam
mable flexible duct hose can be used to connect each bumer to the rigid duct.
Care should be taken to keep the connecting hose as straight and as short as
possible. See drawing at the end of this Chapter. The air ducting system
must flow a minimum of 90 scfm per bumer (180 scfm per bumer for Model
260 and larger fiimaces with J-121 bumers) over the distance of the entire
duct work with negligible pressure loss.

Revision 3,3/17/2003 Page 3 - 6

 PTR/ATR/VPI Fumaoe Manual c:\newq)man\doc3.dip

Outside air ducting is also desirable or beneficial in work areas or installa

tions that have unusually high amountsof dust or particle concentrationsthat
can inhibit the blowerability to draw in air for proper operation, or solvent
fiimes that can corrode the fiimace. "Dirty blower wheels" are the primary
maintenance problems with these furnaces. Blowers should be checked and
cleaned frequently, sometimes daily, even if outside air is used.

A fairly simple, but useful, method of determining how much negative

pressure a building has is to walk inside the furnace at room temperature and
feel for a down draft at the smoke entrance hole of the upper combustion
chamber. If a down draft can not be felt or is very light, the furnace will
work very well or only minor adjustment (tuning) of the burners will be all
that is required. If the downdraft is easily noticeable or severe, then outside
air ducting may be required to optimize the operation of the furnace.

CAUTION: If the furnace is installed in an area with a high negative

pressure, the furnace will not work properly unless outside air is ducted
to the burners. Consult factory if you suspect the installation location
may be subject to excessive negative pressures.

Special adapter air tubes which fit on the gas burner air intake are available
from the factory. Non-combustible flexible tubing from the plenum of the
outside air make-up unit are connected to these air tubes.

In some cases, ifthe negativepressurein the building is extremely high,while

ducting outside air to the burners will allow for proper operation of the
burners and control system, at times smoke may be drawn out of the furnace
around the door gaskets and around the openings where the water spray
pipingenters thefiirnace. In situations suchas this, the furnace shouldeither
be relocated to an area of the building with less negative air pressure, or
make-up air must be added to the building in the area where the fiimace is
located in order to reduce the negative pressure in this area of the building.

3.4 GAS SERVICE FOR GAS MODELS

Both natural gas and propane (LPG or liquefiedpetroleum gases) are very
dangerous whennotproperly installed and controlled. In addition,propane
gases are heavier than air and will sink to the bottom of the room or
enclosure. Installation and service must be done by competent experienced
personnel.

Page 3 - 7 Revision 3,3/17/2003

 c:\newcpman\doc3.chp PTR/ATRATI FurnaceManual

Cleaning Furnaces operate ona "low-pressure "gas supply: 1/2psig (pounds

per square inchgauge pressure) (=8 ounces per sq.in.) (=14"water column)
or less.

THE MAXIMUM GAS LINE PRESSURE SUPPLIED TO THE FUR

NACE SHOULD NOT EXCEED 1/2 PSIG (=8 OZ.) (=14 INCHES
WATER COLUMN).

If gas line pressure is higher than 1/2 psig, an additional gas pressure regulator
must be installed ahead of the fiimace. The local gas company can help
determine service suitability. A gas pressure regulator can be factory sup
plied as an extra cost option when specified on the fiimace purchase order.
The regulator is shipped separate for customer installation.

The gas bumers are suppliedfor either natural gas or propane gas as specified
on the order. Unless otherwise specified, natural gas is assumed to have a
heating valve of 1000 Btu/cubic foot (8.9 kilocalories/cubic meter) and a
specific gravity of 0.6. Propane gas is assumed to have a heating value of
2550 Btu/cu.ft. (22.7 kcal/cu. meter) and a specific gravity of 1.5.

Thegasmeterandgassupply pipingmusthavea sufficientcapacityto supply

all gas burningappliances installed on the premises including the Control
led Pyrolysis Fumace. Fumaces smaller than a Model 260 with J-82 or
SK-225 bumers consume a maximum of 500,000 Btu/hr (500 cu. ft. of
natural gas per hour) (125 kcal/hr; 14.1 cm/hr.). Model 260 and larger
fumaces with J-121 burners consume a maximum of 950,000 Btu/hr (950
cu.ft. of natural gas perhour). All models musthave a minimum of 7 inches
water column gas pressure and a maximum of 14 inches measured on the
gauge at the fumace inlet manual valve when both bumers are on. Model
260and larger fumaces with J-121 bumersrequire a minimum of 11 inches
water column gas pressure. Refer to the front page of this manual, or to the
nameplate tag on the sideof thefumace for the specific gas consumption of
your fumace.

Eachgasbumerhasanadjustable pressure regulator pipedinfrontof itwhich

takes thelinepressure ofbetween 7 and 14 inches, reducing it to exactly 3.5
inches of water column pressure at the bumer. Gas pressure gauges are
supplied on each gas bumer, on the fumace inlet manual valve, and on the
pilotsand high-fire sections for some bumers. The gauges should read 3.5
inches water column, plus or minus 0.25 inches when the gas bumers are on.
The FactoryTest Sheet located in Chapter 11 shows the gas pressure setting
for each bumer when your fumace was tested at the Factory. If the pressure
gauge on either bumer reads less than 3.25 inches water column while the
bumer is mnning, this is an indication that the line pressure to the fumace

Revision 3,3/17/2003 Page 3 - 8

 PTR/ATRA^I Furnace Manual c:\newq)nian\doc3.chp

may be too low. The previous statement applies to the Factory settings for
theregulators andassumes thatthey havenotbeentampered withorchanged.

The size of the gas pipe from the meter to the furnace depends on the gas
pressure available and the distancefrom the meter. The listing below shows
pipe sizes for ordinary installations, based on a pressure drop of 0.5 to 1.0
inch water column between the meter and the fiimace. If there are many
fittings in the supply pipe, increase it one size from that shown. Do not use
flexible gas lines because theyoffer too much resistance to gasflow.

For Furnaces With SK-225 and Incinomite J-82 Burners

0- 10 Ft. (0-3 Meters) 3/4" NPT

11- 30 Ft. (3.5-9 Meters) 1"NPT

31 -120 Ft. (9.5 - 36 Meters) 1 1/4" NPT

121-200 Ft. (37 - 61 Meters) 1 1/2" NPT

201 - 600 Ft. (62 -183 Meters) 2" NPT

For Furnaces With Incinomite J-121 Burners

0 - 60 Ft. (0-18 Meters) 1 1/2" NPT

61 - 200 Ft. (18.5 - 61 Meters) 2" NPT

201 - 400 Ft. (62 -122 Meters) 2 1/2" NPT

When furnished for propanegas, the burners have gas pressure regulators set
at 3.5 inches water column just like the natural gas burners. Each propane
burner has a smaller main orifice. The propane tank supplied by your local
gas company will usually have a regulator set to deliver 11 inches water
column to the building. Please note that most ordinary propane appliances
depend on the 11"water columngas pressure to aspirate combustion air into
the burners. Controlled Pyrolysis® Furnaces use small packaged burners
with electric blower fans for combustion air and do not require 11" water
column gas pressure to operate. They operate at 3.5 inches water column of
gas pressure, the same requirements as for natural gas.

CAUTION: To provide proper vaporization ofthe propane, another regulator

must be installed to reduce the pressure to 7 inches water column measured
at the furnace inlet valve. Locate this regulator outside the building and use

Page 3 - 9 Revision 3,3/17/2003

 c:\newcpmanVIoc3.chp PTR/ATRATI Furnace Manual

pipe, minimum 3/4 inch, to connect from this regulator to the fiimace. The
pipe runmust be at least 10feet in length to allow enough pick-up of heat to
fiilly vaporize the propane. A propane vaporizer may be required in some
cold climates to prevent liquid propane from being carried over into the
burners. The burners are not designed to bum liquid propane, and if liquid
is allowedto reachtheburners, it can upset the combustion processand also
lead to increasedfuel costs due to some of the propane not being burned.Do
not useflexible gas lines because theyoffer too much resistance to gas flow.

3.5 ELECTRICAL REQUIREMENTS

The electrical service to the fumace must be run in conduit. DO NOT USE
RUBBER-COVERED EXTENSION CORD! The supply requirement is
110 to 125 Volts, 50-60 Hertz, 15 Amperes, three 14-gauge or 12-gauge
wires: one hot wire (black), one neutral wire (white) and one equipment
ground wire (green). This circuit must be connected to a separate 15 Amp
circuit breaker or fuse, the supply must have a grounded neutral, and the
green wire must be connected to the grounded metal wireway of the supply.
Actual current usage with both gas burners on is generally about 5 to 8
amperes. A transformer for other voltages can be furnished at extra cost if
specified on the purchase order.

3.6 WATER REQUIREMENTS

The safety of this equipment, its environment, and its proper operation
depend greatly on the water spray systems on thesefurnaces being able to
work correctly at all times. Potable city water is normally acceptable. Do
not use hot water or dirty "process" water such as found in some chemical
plants. The water mist nozzles used in the fumace have very small orifices;
they are easily plugged with trash, other debris or mineral deposits. Some
water suppliesare called "hard", meaningthere are dissolved minerals in the
water that deposit out in the nozzlesand pipes when the water is heated.The
"harder" the water, the sooner a nozzle or pipe will clog; the "softer" the
water, the longer the nozzles can operate before cleaning is needed. Your
local city water department can usually tell the amount of hardness of your
water. It will be expressedas "PPM"(parts per million) of calciumcarbonate.
Dividing this numberby 17 gives a number called "grains per gallon" which
is the way water softeners are rated. Amounts under 120 PPM (7 grains per
gallon) are considered moderate enough not to require further treatment, but
the water spray systems must be tested daily as required for starting the
fumace and the nozzles themselves should be removed and checked at least
monthly until a pattem of necessary cleaning is shown, more often if the

Revision 3,3/17/2003 Page 3 -10

\
 PTR/ATR/VPI Furnace Manual c:\newq)inan\doc3.cfap

water is between 7 to 12grains. If the hardness is over 12grains per gallon

(200 PPM), either a water softener for the whole building (see your yellow
pages) or a small water softener with a replaceable softener cartridge (avail
able from the factory) on just the furnace must be installed to minimize
excessive cleaning of the spray nozzles. Consultthe factory for recommen
dations if your water supply is very hard.

Water service to the furnace should be supplied by either a copper pipe, a

galvanized pipe or other rust-resistant pipe. If a plastic pipe, keep it well
away from the furnace or its stack. If the water pipe is too long or too small,
it will be necessary to go to a larger diameter water pipe to prevent excessive
drop in water pressure when the water spray system comes on. The water
pipe should be protected against freezing including suitable valves to drain
the water from any exposed pipes when freezing is expected. Whendrained,
thefurnace cannot he operated. If you must operate the fiimace in freezing
weather, insulation and heat tracing of the water pipes and control system
can be done, but keep a close check on conditions because stopping the water
for even a short time can have disastrous results. The minimum required
water pressure is 40 psig(2.7 atmospheres) and the maximumallowable water
pressure is ICQ psig (6.8 atmos.). The actual amount of water used is fairly
small. The average flow rate is 0.45 to 0.90 gpm (1.7 to 3.4 liters/min.) and
is intermittent, only on demand from the Water Spray/Stack Temperature
Controller. The maximum flow rate is 7 gpm (26.5 liters/min), also inter
mittent, and this flow will occur only under extreme circumstances if the
primary nozzles are unable to control the temperature for some reason.

The chart below shows the approximate pressure loss in psig (pounds per
square inch gauge pressure)for 100feet of straight standard pipe for various
pipe sizes at various flow rates.

Approx. piping pressure loss for water fpsi per 100 ft of std. pjpel

Water Flow Rate Nominal Pipe Size in inches

(gallons/min) 1/2 3/4 11/4

5.0 12.6 3.1 0.9 0.23

6.0 18.5 4.3 1.23 0.33

7.0 24.7 6.0 1.81 0.46

8.0 31 7.3 2.11 0.55

Page3-11 Revision3,3/17/2003
 c:\newcpman\doc3.chp PTR/ATRATI FurnaceManual

The water pipingto yourfurnacemustbe largeenoughso that when the water

spray is on and using up to 7.0 gpm of water, the water pressuresuppliedto
the furnace does notgo below40 psig evenwhen water is being used to flush
toilets or fill washers, etc. Please keep in mind that the chart above is for
straight pipe and does not accountfor elbows, tees, or other fittings. If your
pipingcontainselbows,tees,or valves, add about 5 to 10feet of straight pipe
for each fitting in order to determine the equivalent length of straight pipe.

No water drain is required inside the furnace because all of the water
sprayed inside the furnace is turned to steam and is exhausted through
the stack.

3.7 OIL SUPPLY FOR OIL MODELS

Only competent and experiencedpersonnel should make oil system installa

tions. Oil burners are supplied for #1 or #2 heating or furnace oil only.
Crank-case oil, waste oil, or gasoline should never be used. A suitable oil
tank located above, on-the-same-level, or no more than 10 feet below the top
of the furnace must be connected to the burners on the furnace with two
continuous runs of heavy wall copper tubing using flare fittings. Two runs
are required because the burners are connected with a return line to the tank
to automatically bleed the air. Specific information on piping, lift
capabilities, and tank installations is provided in the instructions of the fiiel
unit (oil pump) manufacturerin Chapter 12, but for typical installations the
following table will allow selection of copper tubing of an adequate size.

LIFT IN FEET (METERS) LENGTH IN FEET (METERS)

(Fuel Burner Height Above Bottom (Vertical & Horizontal Lengths)

of Oil Tank)

3/3' • CD Tubing 1/2" CD Tubing

0 (0.0) 53 (16.3) 100 (30.8)

3 (1.0) 41 (12.6) 100 (30.8)

6(2.0) 29 (8.9) 100 (30.8)

Revision 3,3/17/2003 Page 3 -12

 PTR/ATRA^I Furnace Manual c:\newq)man\ckx3.chp

3.8 STACK INSTALLATION AND VENTING

GoingStraight upthrough theroofabovethefiimaceis thesimplestandsafest

method of installing the insulated chimney exhaust stack of the fiimace. The
furnace must be installed on a non-combustible floor (no wood) with both
the fumace and the exhaust stack clear of any combustible material. Follow
clearancesfor thefurnace and chimney stack as shown on the drawings at
the end ofthis chapter.

The cleaning fumace is supplied with three sections of insulated chimney

which are included in the cost of the fumace (fiimaces with J-121 bumers
are supplied with 5 sections). These sections snap together and must be
fastened with screws. The Factory Test Sheet located at the end of Chapter
11 should indicate the type of bumers supplied with your fiimace. Necessary
accessories for installing the stack such as an adjustable flashing, a rain cap,
a storm collar, a length ofsealant to seal the storm collar around the chimney,
and a tube of fire-clay mortar to seal chimney joints are included, plus screws
to fasten the chimneys together. Refer to the drawings at the end of this
Chapter for proper fumace and stack installation. Depending on the height
of the fumace model and the height of your roof, it may be necessary to
purchase additional sections of insulated chimney from the Factory to go
through the roof and have adequate clearance. The top of the stack must
end five feet or more above a flat roof, or above the peak of a pitched
roof if the stack is near the peak. Combustible roofs, ceilings, and walls
will require a sheet metal stack thimble available fk'om the factory. Local
or city codes may have additional or different requirements. Consult the
Factory with any questions.

The first three-foot section of stack over the fumace contains a hole for
the stack thermocouple. This section must always be installed first!

When installing the fumace and chimney, please use common sense to
preclude any danger from either the fumace or the exhaust stack; keep away
from this equipment anything flammable or combustible that may cause a
fire. Do not add additional insulation to any part of the fiimace, or to any
part of the chimney stack; clear it away at least 12 inches from the walls, the
roo^ or wherever it may be touching or near the stack. Such insulation
interferes with the natural heat flow and dispersal through the walls of the
fumace and the walls of the chimney and may cause overheating problems
and even a fire. Caution! Do not enclose the exhaust stack or the fiimace
in any type of enclosure without consulting the Factory.

Page 3 -13 Revision 3,3/17/2003

 c:Viewcpman\doc3.chp PTR/ATRATI Furnace Manual

Fig. 3-2 First Stack Section with TC Installed

You must install at least 3 sections (9 feet) of stack on the furnace in

order to provide the required retention time at temperature in the
afterburner to meet EPA guidelines. If your fhmace is equipped with
J-121 burners, you must install a minimum of5 sections (15 feet ofstack)
on the furnace. The EPA requires that the exhaust gases be maintained
at about 1400^ for a minimum of 1/2 second before being exhausted to
atmosphere in order to insure complete destruction of the smoke and
Pyrolysis gases.

WARNING
You must maintain required clearances (air spaces) to combustible
materials. Do not place any type of insulation or combustible material
in the required clearances surrounding the chimney at any point.

Warning: Use only PCPC factory-supplied insulated chimney sections

and accessories. These chimneys are not available from other sources. Use
of other than factory-supplied chimneys will void the warranty on your
furnace and can be a dangerous fire hazard. Do not use any other exhaust
stack, insulated or not, without consulting the Factory.

The chimneys furnished by the Factory are designed to operate continuously

at exhaust gas temperatures of 1400° to 1600°F (760° to 871°C), and can
withstand temperatures ofup to2300°F. Surface temperatures onthe outside
of the chimney will then be about 210^F when 140(fF on the inside and
25(fF when 160(fF on the inside: Do Not Touch!

Revision 3,3/17/2003 Page 3 -14

 PTR/ATRA^I Furnace Miinual c:\newcpnian\doc3.chp

Insulated chimneys are 35 3/4 incheslongwith a diameter depending on the

size of the furnace. The outer shell is roll-formed stainless steel and the male
(upper) end of theshellhasa corrugated end and a seriesof catches punched
into that corrugated end. The female (lower) end of the shell has an edge
turned in and flattened for 1/4 inch which snaps over the catches on the male
end. This feature locks the two pieces together when they are installed one
above the other. The female end also has four (4) punched holes to accept
screws and four (4) #10 x 5/8" self-drilling hex headed screws are provided
for each exhaust stack. These screws will either be placed in a plastic bag
and attached to the exhaust stack, or they can be found in the tool box which
is shipped with each furnace. Use these screws to permanently fasten two
sections together. You will also need to use these screws to secure the first
section of chimney to the top outlet of the furnace.
(S)
Each chimney section is insulated with two inches of Kaowool ceramic
fiber blanket insulation wrapped around 3 hard sleeves also made of
Kaowool® but hardened to hold their shape as cylinders with afixed inside
dimension. The insulation-wrapped 3-foot section is trimmed to length,
compressed, and inserted into the outer shell until the end ofthe insert reaches
the male end of the shell. The length of the insert leaves a 1 3/4" void of
insulation at the female end that accepts the male end so that the insulation
in each section will contact each other when the chimneys are installed one
on top of the other. Kaowool is a registered trademark ofThermal Ceramics
Inc.

When you receive and unpackyour insulated chimney and/or insulated elbow
sections, visually check them for damage before installation. If any of the
insulation inside of a chimney or elbow is missing or broken, contact the
Factory before installation to determineif it needs to be replaced. Check that
all of the screws for fastening the stack together have been shipped and also
check to be sure that a tube of fire-clay mortar is in the shipment. The screws
and fire-clay mortar are normally packed in the tool box which is shipped
with each furnace. Any slight cracks in the sleeves can be repaired by use
of the fire-clay mortar to fill the cracks.

The tube of fire clay mortar which is packed in the tool box shipped with the
furnace is provided to seal the seams between the insulated chimneys and/or
elbow sections. To use, run a 1/2" bead of mortar around the top of the hard
sleeve of each section before installing the next section on top of the first
one. Seat each section firmly, making sure the sections latch together. Use
an electric drill to install the 4 screws to make a secure connection between
each section.

Page 3 -15 Revision 3,3/17/2003

 c:\newq)man\doc3.chp PTR/ATRATI FurnaceManual

If the vent stackmustbe offsetfor some reason, 45« and 90-degreeinsulated

elbows are available from the Factory. Insulated elbows are assembled in
thesamemanner as thestraight insulated chimneys and aresecured usingthe
4 screws supplied. See the drawings at the end of this Chapterwhich show
the dimensions of the insulated elbow sections. Do not install a 45- or
90-degree elbow directly on top of die furnace. The first three foot
section of stack on top of the fhmace must be a straight section. One of
the stack sections shipped with your furnace will have a 7/8" diameter hole
pre-drilled in the side about 10" from the female end in order to accept the
stack thermocouple. This section must be installed first Use an electric drill
to install the 4 screws to secure the first section to the top outlet ofthe furnace.
When using 45 or 90 degree elbows, non-combustible supports must be
provided under the elbows themselves and under any long horizontal runs in
order to provide adequate support for the exhaust stack. If you are using 90
degree elbows in your installation, do not run more than 3 sections (9 feet)
of horizontal run without consulting the Factory. The reason for this is that
horizontal runs of exhaust stack typically result in a pressure drop and long
horizontal runs can cause a positive pressure condition inside the fiimace.
This can cause smoke to leak out of the furnace around the door gaskets and
other openings during periods of water spray. The exhaust stack must end
in a verticalpasitiony not facing horizontally in order to prevent wind from
blowing in the open end and afrecting the operation of the furnace.

Depending on the total height and weight of your chimney stack, it may be
necessary to provide lateral support and/or vertical support for the stack
sections. If properly secured with screws at the fiimace and at each chimney
joint, up to 5 straight-up chimneys will be supported laterally both at the
fiimace and at the roof flashing, and the furnace itself can vertically support
the weight of up to 10 chimney sections. Chimney stacks using elbows must
be supported both vertically and laterally. The easiest way to provide lateral
support is to fabricate a 3" wide metal band which can be clamped around
the stack and attach guy wires or rigid supports to this band. See the drawing
at the end of this chapter which shows how this band is made. If you choose
to make your own band, you may make one according to this drawing, or
you may purchase one from the Factory. All stack supports must he
non-combustible. Remember that when using 45- or 90-degree elbows,
non-combustible supports must be provided under the elbows themselves
and under any long horizontal mns in order to provide adequate support for
the exhaust stack.

Other stack accessories included with the furnace are 1) a galvanized roof
flashing adjustable for a flat roof or a pitched roof up to a l-in-12 pitch, 2) a
rain cap, 3) a storm collar to seal the chimney where it goes thm the roof
flashing, and 4) a piece of sealant tape to go on top of the flashing and under

Revision 3,3/17/2003 Page 3 -16

 FTR/ATR/VPI Fumaoe Manual c:\newq>man\doc3.cfap

the storm collar to make a water-proof seal around the chimney. The outer
edges of the roof flashing must be sealed to the roof with silicone rubber or
otherheat-resistant sealant. Combustible material must be kept away from
the chimney.

If the totalstackheight on the fiimace is 24 feet or more above the floor (30
feet for furnaceswith J-121burners), it is necessaryto placea special section
of insulated stack with a draft damper installed in the fourth or fifth section
of stack(sixth or seventh section for fumaceswith J-121burners). The draft
damper section of stack limits the draft achieved inside the furnace to a
reasonable level and must be installed indoors. If unable to install the damper
section in the recommended section of stack, please contact the Factory to
discuss other possible locations or stack arrangements.

CAUTION: DO NOT INSTALL THE DRAFT DAMPER SECTION

IN THE FIRST HFTEEN FEET OF STACK FOR FURNACES WITH
J.121 BURNERS OR IN THE FIRST NINE FEET OF STACK FOR
ALL OTHER MODELS.

Installation of Draft Damper

In order to provide proper control, the damper must be installed in the 4th or
5th section of stack above the fiimace (6th or 7th section for fumaces with
J-121 bumers) and must be in the same room as the fumace. If your fumace
requires a draft damper, it should be shipped with the fumace along with an
installation collar which must be installed first. Follow the instmctions
below, and refer to Figure 3.3 to install the collar.

1. Bend the two ears at the front corners of each collar half outward to 90
degrees, 1/4" behind the single hole in the strap.

2. Insert clamping screws in the ears on the collar and bolt the remainder of
the collar halves together to form a complete collar.

3. Ifyour installation requires a draft damper, one of the stack sections should
already have a hole cut in the side for installation of the collar. Strap the
collar to this stack section at the location of this opening.

4. Bend the tabs on the stack section outward against the inside of the collar
to make a tight joint.

Once the collar has been installed, you are ready to install the draft damper.
For installation in the fumace stack, the damper must be set up as Single-Ac-

Page 3-17 Revision 3,3/17/2003

 c:\newcpinan\doc3.chp PTR/ATRATI Furnace Manual

ting in order to prevent the possibility of any stack gases entering the room.
Follow the instructionsbelow and refer to figure 3.1 to install the damper.

1. Insert the draft control into the collar. The front face of the control must
be plumb. The bearing surfaces must be level whether the control is on a
horizontal, vertical, or sloping stack. Use a spirit level: plumb and level
accurately.

2. Secure the draft control in the collar by tightening the clamping screws.
If the control has any tendency to sag, support it from the ceiling by wire or
by strapping.

3. The control is shipped for installation in a vertical stack. If the control is

installed in a horizontal stack, remove the screw from the upper hole in the
weight lever and insert it in the lower hole.

4. With the damperinstalled, adjustthefurnace draft to the proper level(-0.08

to -0.15 incheswater column)by adding or removing the washer type weights
supported by the two chains. Do not remove the large weights attached
directly to the gate, as they are used only for factory adjustment. In order
to obtain the correct draft setting, the furnace and stack temperatures must
be above certain levels. See the additional instructions below for the correct
temperatures to be used for setting the draft control.

Ideally, the draft inside the fiimace should be about a negative 0.10 inches
of water column, but may range from about -0.08 to -0.15 inches water
column. If the draft is less than this amount, the furnace chamber pressure
might go positive during periods of water spray, causing some smoke to puff
out around the gaskets. At higher negative drafts excess air is pulled into the
furnace. This is detrimental for several reasons. First, the furnace will be
slower to heat up and maintain temperature. Also the "idling temperature"
of the afterburner (upper burner) will be lowered below the optimum region
of about 1400°F because of the excess air. In addition, large amounts of
excess air leakage into the furnace because of high draft dilutes the oxygen-
deficient gases from the primary burner (lower burner), thus raising the
overall oxygen level ofthe furnace atmosphere. Because ofthe above factors,
excessive draft caused by too high a stack can cause difficulty in controlling
the Pyrolysis cleaning process and even possibly lead to a fire inside the
fiimace.

When a Draft Damper section ofstack is installed, the draft inside the fiimace
is controlled by adjustingthe number of washers (weight) on the draft control.
This should be done when the furnace temperature is above about 60(FF
(315°C) and the stacktemperature above about 120(FF(628°C). The simplest

Revision 3,3/17/2003 Page 3 -18

 PTR/ATRA^PI Furnace Manual c:\newcpman\doc3.dip

method of measuring the furnace draft is to loosen the manual high limit
temperature switch which goes through the wall of the fiimace next to the
furnace thermocouple. See Figure 2-4. Pull the temperature switch out of
the fiimace temporarily. A piece of 1/4 inch copperor stainless steel tubing
canbe pushed inside thefumace andconnected toa draftgauge(manometer).
If youdo nothavea draftgauge, an inexpensive manometer can be purchased
from the Factory, or you may purchase a manometer direct from Grainger
Industrial Supply (Dwyer Mark 11 Molded Plastic Manometer, Grainger
stock No. 2T650). Once the draft damper washers are adjusted to give the
proper draft, be sure to replace the high limit temperature switch and
re-tighten its set screw.

3.9 COMPRESSED AIR SUPPLY CONNECTION

Each furnace is equipped with an on-off manual air valve, a coiled air hose,
and an air blow gun mounted to the rear wall of the fumace near the bumers.
Connectyour plantcompressed air supplyof 40 to 100psig to the valve using
a 1/4" pipe. The air blow gun can then be used before each cleaning cycle to
blow out the upper and lower bumer blowers to remove any accumulated
dust, lint, or other material. This daily simple maintenance step will assure
proper operation of the burners for many years.

Page 3-19 Revision 3,3/17/2003

 RELIEF
DQDR

II3V/60HZ

pj

(D INLET

tJ
I
tvj
O

11 C. 28)

SIDE VIEW ERDNT VIEW

4-
12' <.30> MINIMUM TD CDHBUSTIBLE WALL NDTES:

CT :r:::
1. NUMBERS IN BRACKETS ( ) DR UNDER COLUMN ' M' METERS.

TOP RELIEF
PLAN VIEW

REV. D CORRECTED DIM. G FOR 539

REV. C 12-16-96 SEE EIR 145 <CART ROLL OUTS)
REV. B 11-6-96 ADD NEW MODELS t> UPDATE CHART
REV. A 3-15-95 TITLE BLOCK & NOTES

POLLUTION CONTROL

PRODUCTS CO. DALLAS. TEXAS

CLEARANCE TO ROLL
CART OUT.
24'(.6I> MINIMUM TO SET CONTROLS t SERVICE GENERAL INSTALLATION DRAWING
FDR MODEL DC, PTR, ATR, VPI,
PRC, ARC, VRC FURNACES

xam NONE RLB 1-9-95

Ipatk

S9501-05
 OJ^
I pj
tovQ
l-» fl)

A B C D E r G A B C D C F G
MODEL MODEL
M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M
IN.

1. 50 66 1. 68 43 1. 09 101 2. 57 28 . 71 10-1/2 . 27 N/A N/A 330 85 2. 16 169 4. 29 86 2. 19 124 3. 15 38 . 97 16-1/2 . 42 186 4. 73

DC] 59

1. 58 46 1. 17 46 1. 17 69 1. 75 28 . 71 10-1/2 . 27 24 . 61 340 109 2. 77 121 3. 07 97 2. 46 14] 3. 58 38 . 97 16-1/2 . 42 144 3. 66

DC2 62

0C3 1. 73 72 1. 83 55 1. 40 91 2. 31 27 . 69 10-1/2 . 27 54 1. 37 390 109 2. 77 122 3. 10 110 2. 79 162 4. 12 38 . 97 16-1/2 . 42 144 3. 66

68

BC4 68 1. 73 84 2. 13 61 1.63 96 2. 44 27 . 69 10-1/2 . 27 57 1. 49 391 109 2. 77 134 3. 40 97 2. 46 147 3. 74 38 . 97 16-1/2 . 42 156 3. 96

27F 59 1. 50 69 1. 75 43 1. 09 80 2. 03 28 . 71 10-1/2 . 27 54 1. 37 392 121 3. 07 122 3. 10 98 2. 49 148 3. 76 38 . 97 16-1/2 . 42 152 3. 86

52 68 1. 73 72 1. 83 55 1. 40 91 2. 31 27 . 69 10-1/2 . 27 54 1. 37 412 79 2. 01 162 4. 12 117 2. 97 153 3. 89 38 . 97 16-1/2 . 42 170 4. 32

71 68 1. 73 84 2. 13 61 1.55 96 2. 44 27 . 69 10-1/2 . 27 57 1. 49 448 121 3. 07 134 3. 40 98 2. 49 135 3. 43 38 . 97 16-1/2 . 42 164 4. 17

78 68 1. 73 99 2. 52 55 1. 40 91 2. 31 27 . 69 10-1/2 . 27 81 2. 06 449 121 3. 07 122 3. 10 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 152 3. 86

88 71 1. 80 85 2. 16 73 1. 85 113 2. 87 26 . 66 15-1/2 . 65 94 2. 39 450 109 2. 77 134 3. 40 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 156 3. 96

111 77 1. 96 87 2. 21 79 2. 01 117 2. 97 26 . 66 15-1/2 . 39 94 2. 39 482 97 2. 46 170 4. 32 98 2. 49 141 3. 58 38 . 97 16-1/2 . 42 186 4. 73

125 68 1. 73 137 3. 48 55 1. 40 95 2. 41 27 . 69 10-1/2 . 27 108 2. 65 504 109 2. 77 134 3. 40 122 3. 10 160 4. 06 38 . 97 16-1/2 . 42 168 4. 27

Q)
141 83 2. 11 85 2. 16 91 2. 36 129 3. 28 26 . 66 15-1/2 . 39 94 2. 39 512 121 3. 07 134 3. 40 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 164 4. 17

(D
ISO 83 2. 11 97 2. 46 85 2. 16 123 3. 13 26 . 66 15-1/2 . 39 126 3. 20 539 109 2. 77 170 4. 32 98 2. 49 136 3. 46 38 . 97 16-1/2 . 42 192 4. 88

(jj
177 83 2. 11 97 2. 46 97 2. 46 143 3. 63 26 . 66 15-1/2 . 39 126 3. 20 549 121 3. 07 134 3. 40 118 3. 00 155 3. 94 38 . 97 16-1/2 . 42 164 4. 17
1
tsj
188 83 2. 11 85 2. 16 112 2. 85 ISO 3. 81 26 . 66 15-1/2 . 39 94 2. 39 565 131 3. 33 134 3. 40 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 170 4. 32

222 85 2. 16 121 3. 07 85 2. 16 117 2. 97 26 . 66 15-1/2 . 39 138 3. 51 577 121 3. 07 146 3. 71 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 176 4. 47

225S 97 2. 46 109 2. 77 89 2. 26 125 3. 18 26 . 66 15-1/2 . 39 < 1> < 1) 608 121 3. 07 134 3. 40 128 3. 25 166 4. 22 38 . 97 16-1/2 . 42 164 4. 17

226 133 3. 38 93 2. 36 73 1. 85 123 3. 13 26 . 66 15-1/2 . 39 146 3. 71 612 206 5. 23 82 2. 08 117 2. 97 165 4. 19 96 2. 44 40 1. 02 (1> ( 1)

240 109 2. 69 93 2. 36 95 2. 41 133 3. 38 26 . 66 15-1/2 . 39 126 3. 20 622 109 2. 77 166 4. 22 110 2. 80 148 3. 76 38 . 97 16-1/2 . 42 188 4. 78

243 97 2. 46 97 2. 46 103 2. 62 141 3. 58 26 . 66 15-1/2 . 39 126 3. 20 640 121 3. 07 158 4. 01 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 188 4. 78

260 91 2. 31 121 3. 07 97 2. 46 142 3. 61 38 . 97 16-1/2 . 42 138 3. 51 680 121 3. 07 158 4. 01 117 2. 97 154 3. 91 38 . 97 16-1/2 . 42 188 4. 78

290 97 2. 46 121 3. 07 97 2. 46 136 3. 46 38 . 97 16-1/2 . 42 138 3. 51 699 131 3. 33 168 4. 27 98 2. 49 136 3. 46 38 . 97 16-1/2 . 42 204 5. 18

300 85 2. 16 157 3. 99 86 2. 18 124 3. 15 38 . 97 16-1/2 . 42 174 4. 42 714 121 3. 07 164 4. 17 117 2. 97 154 3. 91 38 . 97 16-1/2 . 42 194 4. 93
REV. D 1-27-97 CORRECTED DIM. C FOR 539
306S 9/ 2. 46 109 2. 77 117 2. 97 166 4. 22 38 . 97 16-1/2 . 39 C 1) CD 748 121 3. 0 7 170 4. 32 117 2. 97 154 3. 91 38 . 97 16-1/2 . 42 200 5. 08 REV. C 12-16-96 SEE EIR 145 CCART ROLL OUTS)
REV. B 11-6-96 ADD NEW MODELS & UPDATE CHART
308 91 2. 31 121 3. 0/ 110 2. 80 159 4. 04 38 . 97 16-1/2 . 42 138 3. 51 806D 266 6. 76 118 3. 00 117 2. 97 156 3. 96 126 3. 20 SO 1. 27 < 1> (1) REV. A 3-15-95 t i t l e block 8. NOTES

885 133 3. 38 158 4. 01 132 3. 35 181 4. 60 38 . 97 16-1/2 . 42 194 4. 93

NOTES' POLLUTION CONTROL

< 1> MODELS 225S, 306S 612D, 806D ARE FORK LIFT LOADED. PRODUCTS CO. DALLAS. TEXAS

LOADING AREA IN FRONT OF THE FURNACE IS DETERMINED

GENERAL INSTALLATION DRAWING
BY INSTALLATION SITE CONFIGURATION.
FDR MODEL DC, PTR, ATR, VPI,
NUMBERS UNDER COLUMN IN. =INCHES PRC, ARC, VRC FURNACE S

(3) NUMBERS UNDER COLUMN 'M' =METERS NONE OK. B* RLE BAT* 1-9-95
riu- S990I-09
<4) MODEL vlJPPI IFD WITH A STATIONARY INTERNAL RACK. LAnt- CHMM m mm onoi or DATS
DC I IS
ccc t snoi-03 tsaxT 2 or 2 |o«e. HO. S9501-05
 EXHAUST
cot? EXHAUSV-^.'—^
f<=^ 1 STACK STACK I
I p

n>

12' (300> MIN. TO COMBUSTIBLE WALL

CUC1RICAL

PI AN VIEW
<280)
cdntrdl
BOX

IM.Ct CM

CONTROL BOX

24' (610) HIN. TO SET CONTROLS & SERVICE BURNERS

SIDE VIEW FRDNT VIEW

A B C D E r G H K NDTE!
J
MODEL IN. M IN. M IN. M IN. H IN. M N. M IN. M IN. M IN. M IN. M
NUMBERS UNDER COLUMN 'IN.' = INCHES
NUMBERS UNDER COLUMN 'M' = METERS
54T 46 58 1.47 86 2.19 122 3.10 26 .66 .28 48 1.22 40 1.02 25 .64 65 1.66 NUMBERS IN < ) MILLIMETERS

63T 46 58 1.47 98 2.50 134 3.40 26 .66 .28 48 1.22 43 1.09 25 .64 65 1.66

72T 46 58 1.47 110 2.80 146 3.71 26 .66 .28 48 1.22 46 1.17 25 .64 65 1.66

REV.C 12-12-96 DELETE 1 8. ADJUST H

73T 46 70 1.78 86 2.19 26 .66 .28 48 1.22 40 1.02 33 .84 65 1.66
122 3.10 REV.B 9-19-96 DELETE ROLL OUT CART

84T 46 70 1.78 98 2.50 134 3.40 26 .66 .28 48 1.22 43 1.09 33 .84 65 POLLUTION CONTROL
1.66

PRODUCTS CO. DALLAS. TEXAS

96T 46 70 1.78 110 2.80 146 3.71 26 .66 .28 48 1.22 46 1.17 33 .84 65 1.66

85T 52 26 .66 48 33 .84

INSTALLATION DRAWING
32 70 1.78 86 2.19 122 3.10 .28 1.22 40 1.02 65 1.66
FDR 'TALL BDY' FURNACE.
98T 52 32 70 1.78 98 2.50 134 3.40 26 .66 .28 48 1.22 43 1.09 33 .84 65 1.66
NONE R.S. 4-g3-91
112T 52 ,32 70 1.78 110 2.80 146 3.71 26 .66 48 1.22 46 1.17 33 .84 65 1.66
19505-01
 p SQUARE OPENING
vQ
fl)
CHIMNEY SECTION
u>
INSUUTED CHIMNEY SECTION
I ADJUSTABLE FUSHING
to
LO
1-l/2"(38) CRIMP FITS
INSIDE SECTION ABOVE.
EACH SECTION MAKES
UP TO 34-1/2"(876).

TYPICAL VIEW A-A

36"
(920)
RAIN CAP

STORM COLUR .
60" MIN.
Slide Down Over
(1520)
NOTES: 4-HOLES 1/4" DIA.
2"(51) INSUUTION EVENLY SPACED TO
(•) REFERS TO MODEL 260-680 IGG OR OLDER MASTIC SEALER KAOWOOL SLEEVE SECURE SECTIONS
FURNACES HAVING G2T OR J-80/81/82 BURNERS TOGETHER.
KAOWOOL
NUMBERS IN BRACKETS ( ) OR 60" MIN. \
UNDER COLUMN 'M' = MILLIMETERS (1520) ADJUSTABLE FUSHING KAOWOOL

DIM. C REFERENCES A SQUARE OPENING

OUTER MATERIAL
THROUGH THE INSTALUTION STRUCTURE'S ROOF.
26 GA STAINLESS STEEL
INSTALLER: SQUARE WEIGHT/INSUUTED SECTION
FOR ANY LENGTH LESS THAN 36"(.92)
OPENING 36 LBS. (16.33 KG.)
CUT CHIMNEY SECTION AT BOTTOM.
SQUARE
OPENING
A B C
MODELS
IN. M. IN. M. IN. M.
DC-1/27 INSUUTED STACK
8 200 12 300 19 480 36"(.91) LONG SECTIONS MV.0 *0010 nOMCU WffW IXHOO C» C-57 iUMln
DC-2/SP-13 «rv.e 1-20-OT
SNAPS TOGETHER
«tv.i «cotD virw *-A » lowuii nmii
DC-3, DC-4, FASTENS WITH SCREWS
«cvA w 1*3 (cunnure homaii Mu>it«Aia>
52-150, TALLBOYS 10 250 14 360 21 530
SCTR 6-15
POLLUTION CONTROL
(•)260-680 PRODUCTS CO. DAUAS. TZXAS
FLAT ROOFS PITCHED ROOFS
WITH J-8X OR 12 300 16 410 23 580
G2T BURNERS
EXHAUST STACK TYPICAL INSTALUTION
260 & UP FOR ALL FURNACES, INSTALLED THRU
WITH J-121-3 14 360 18 460 25 630 NON-COMBUSTIBLE ROOFS ONLY
BURNERS
NONE
FURNACES WITH FILE: I9S0SO1D.DWO
LCI500 OR G-57 16 406 20 508 27 686 LAYER: STACINST
burners PLOT DATE; B-24-05 19503-01
 FIGURE 3-3 FIGURE 3-4
CLAMPING SCREWS

DO NOT ADJUST COVER PLATE

THESE WEIGHTS DO NOT REMOVE

WEIGHT LEVER

PLACE SCREW IN
P) UPPER HOLE FOR
INSTALLATION IN
(D VERTICAL STACK
STRAP• OR IN LOWER HOLE
U) FOR INSTALLATION
STOPS (DO NOT IN HORIZONTAL
to FURNACE STACK REMOVE ) STACK

ADJUST FURNACE DRAFT

BY ADDING OR REMOVING
GATE
WEIGHTS
COLLAR HALF

NQIE

SEE SECTIONS 3.8 AND 3.9 OF INSTRUCTION

CLAMPING SCREWS MANUAL FOR DAMPER INSTALLATION

FIGURE 3-5

CHIMNEY SECTION W/HOLE

DRAFT CONTROL COLLAR

DRAFT CONTROL
FILE: I9503-02.DWG
LAYER: DAMPER
PLOT DATE: 9-17-96
CCC# 19503-02

-OPTIONAL- POLLUTION CONTROL

DRAFT-DAMPER CHIMNEY SECTION. NEEDED
IF CHIMNEY HEIGHT GREATER THAN 24 FT PRODUCTS CO. DALLAS. TEXAS

DAMPER TO BE INSTALLED IN FOURTH OR FIFTH CHIMNEY EXHAUST STACK TYPICAL DRAFT DAMPER
SECTION (SIXTH OR SEVENTH CHIMNEY SECTION FOR FURNACES INSTALLATION FOR ALL FURNACES
WITH J-121 BURNERS) AND MUST BE IN SAME ROOM AS FURNACE
NONE RLB MtE 3-23-95
IE B IP*"

'9503-02
 INSULATED
STACK 8. ELBOWS ABCDEFGH I

8DI36(SP-13, DC 1-2) 36 12 2 19 1/2 18 1/2 12 10 8 1/2 12

10DI36(DC-3, DC-4, 52-188) 36 14 2 20 3/4 19 1/2 14 10 1/4 9 14

12DI36<222-243) 36 16 2 21 1/2 20 16 11 9 1/2 16

14DI36<260-UP-J121 BURNERS) 36 18 2 22 23 1/2 18 11 1/2 11 1/2 18

16DI36CINCIN. G-57 BURNERS) 36 20 2 24 25 1/2 20 13 1/2 13 1/2 20

NDTE= ALL DIMENSIONS IN INCHES

TYP.
r C OVERLAP -

_l l_
Xi
OJ REV.C 12-5-96 ELIMINATE ROMAN NUMERALS
REV.B 9-25-96 MODELS 8. APPLICATIONS
0 B REV.A 7-10-96 ADDED 16DI DATA
CO
1 POLLUTION CONTROL
to STACK 90* ELBOW 45* ELBOW
PRODUCTS CO. DALLAS. TEXAS
cn

STACK 8. ELBOV DETAIL DRAWING.

FOR ALL MODELS EXCEPT IGG
AND SCTR FURNACES

FILE' R9e02-02.DVG NONE R.S. 8-12-90

LAYER' STD
PLOT DATE' 18-5-96 CHKB. BY D«T«

CCCIt' R9808-08 surer 1 Of 1 lB»aKo. R92D8-02

 CHIMNEY SIZE

FIND
[ B ]
8DI 10DI 12DI 14DI 16DI
- 1 5/8
9/16 - [ A ] 11-7/8 13-7/8 15-7/8 17-7/8 19-7/8
- 9/16

[ B ] 40-3/4 47 53-1/4 59-1/2 65-3/4

-t-
1/2
[ c ] 12-7/16 14-1/2 16-5/8 18-3/4 20-13/16
1/2 ^

BREAK DOWN 90' 03/8 dia.

FOUR HOLES

BACK TO BACK S.S. 2x2x3 20 GA ANGLES WITH 3/8" DIA. HOLE

FOR GUY WIRES. SPOT WELD IN 6 PLACES TO BAND AND HALVES TO
EACH OTHER. CENTER ANGLE HALVES ON BAND.

3 —
2 -
1/2- 1/2
f9/1,6 1
2 ea. 3/8" DIA. HOLE- o
2
V ±
0[ A ] ID
©
SPOT WELD
6 PLACES

(T>
NOTES:
OJ
1. MATERIAL: 20 GA. S.S. POLLUTION CONTROL PRODUCTS CO.
2877 FREEWOOD ST. DALLAS. TX 76220
NJ 2. PART # = 7027-00. nv

m EXHAUST CHIMNEY
3. ALL DIMENSIONS ARE IN INCHES. wn
SPOT WELD S.S. ANGLE HALVES cew

IN 6 PLACES TO BAND.
GUYWIRE ATTACH COLLAR
CAB rns M9909—05 NONE RLG tm 9—9—99
m ML nora rrt un

•an ^ er 1 jm. n M9909~05

 SK-225

6" X 12" RECTANGULAR

OR 10" DIA. DUCT
( NOT REQUIRED IF 5" DIA.
DUCTS CAN BE EXTENDED
THROUGH WALL WITHOUT
BENDS OR EXCEEDING 10 FT.
IN LENGTH. )

5" DIA. RIGID METAL DUCT

( 10 FT. MAX. )

5 DIA., NON-FLAMMABLE, FLEXIBLE HOSE

0)
RECOMMENDED LENGTH - 6" MAXIMUM.
CD

u> POLLUTION CONTROL PRODUCTS CO.

I 8677 FR8BW00D ST. DAILAS. TX 75880
INJ acv
sv
-J D«f8
COMBUSTION AIR DUCT DETAILS FOR
ceet
FURNACES WITH SK-225 BURNERS
CONTACT ENGINEERING DEPT. FOR ALTERNATE ARRANGEMENTS.
CM nu 09609—02 NONE Ht n RLB MTi9-25-96

9-25-96 •HUT 1 or 1 lorc. m. D9609~02

 J-82 (S^ J-121
6" X 12" RECTANGULAR
OR 10" DIA. DUCT
(NOT REQUIRED IF 6" DIA.
DUCTS CAN BE EXTENDED
THROUGH WALL WITHOUT
BENDS OR EXCEEDING 10 FT
IN LENGTH.)

6 DIA. RIGID METAL DUCT

( 10 FT MAX. )

6 DIA. NON-FLAMMABLE FLEXIBLE HOSE

RECOMMENDED LENGTH - 6" MAXIMUM
(D
POLLUTION CONTROL PRODUCTS CO.
U) 2S77 FfiEEWOOD ST. DALLAS. IX 75220

I
N) COMBUSTION AIR DUCT DETAILS FOR
00 FOR ALTERNATE ARRANGEMENTS. CONTACT THE FACTORY
FURNACES WITH J82 & J121 BURNERS

ew iM D9609-03 iCW» NONE RLB Bm9-25-96

0 fan.

l«n»n9-?5-96 iw. ikl 09609-03