Nortek Global HVAC CAUA Gas Fired Indoor Heater Owner’s Manual

Nortek Global HVAC CAUA Gas Fired Indoor Heater

Product Information

The Ignition Controller Replacement Kit is designed for gas-fired indoor heaters. It includes various components necessary for replacing the ignition controller of the heater. The kit comes with a DSI control board, a 9-pin wiring harness, a 5-pin wire assembly, an ignition cable, terminals, wire nuts, cable ties, a template, and a wiring diagram label.
DANGER ⚠
To ensure safe and proper operation, read and follow these installation instructions. Failure to do so could result in property damage, personal injury, and/or death.

• These instructions are for replacing an obsolete ignition controller (RAM #3MC4-06, serial number code 76 or J/C #G822KCC-5401D, serial number code 77) with an ignition controller (see Figure 1) replacement kit (PN 258251).
• Refer to the installation manual provided with the heater for important safety information.
• Refer to the replacement parts manual at www.reznorhvac.com for serial number information. All serial number codes apply to original equipment only.
• Ensure that all components before beginning installation.
  

Here are the components included in the Ignition Controller Replacement Kit:

Product Usage Instructions

1. Turn OFF the gas and electric power.

2. Remove the existing ignition controller:

   • Open the control compartment and locate the ignition controller.
   • Disconnect the wiring and existing ignition cable from the controller.
   • Remove the four screws that secure the controller and remove the controller.

3. Install the replacement ignition controller:

   • Position the drill template (5), with the painted side facing up, over the mounting holes for the ignition controller removed in step 2. Justify the holes for the replacement controller toward the bottom of the panel.
   • Mark and drill four 3/16-inch holes.
   • Position the DSI control board (1) so that the spark transformer is located nearest to the spark electrode on the burner. Snap the control board into the holes.

4. Install the replacement ignition cable:

   • Remove the existing ignition cable from the spark electrode on the burner.

   • Connect one end of the replacement ignition cable (6) to the spark electrode on the burner and the other end to the spark transformer on the replacement DSI control board (1).
     Terminal Cross-Reference

     Existing Controller| Replacement Controller
     ACC| EAC/BLO
     24 VAC HOT| SEC
     Ground| COM
     LINE VAC HOT| L1
     CMB BLWR| IND

5. Connect wiring in accordance with replacement wiring diagram label (12):

6. Connect P3 5-pin wire assembly (3) to thermostat terminal strip.

7. Connect P1 9-pin wire assembly (2) as shown in Figure 1. As necessary, shorten wires and install replacement terminals (8).

8. Connect existing wires to DSI control board (1) wire terminals. If terminal on line voltage wire is 3/16 inch, cut off terminal, strip wire, and install quick connect terminal (7). Connect line voltage wire to terminal L1.

9. Connect one end of 24-inch red wire assembly (4) to rollout switch located on burner box top. Connect other end to high limit switch wire lead using wire nut (9).

10. Install cable ties (10) as necessary for routing and for excess wire length.
    NOTE: To cover all applications, connections shown in Figure 2 are for single-stage (AG1) and two-stage (AG2) controls and for both direct and belt drive motors. Make the connections that ap-ply to the options on the unit being serviced.

11. Adhere the wiring diagram label (12) on the left panel inside the burner compartment. Wiring Diagram Label

12. Adhere NOTICE label (11) below wiring diagram label installed in step 6.
    NOTICE Label

13. Turn ON electric power and gas, start up heater, and check for proper operation.

NOTE: Refer to the installation manual at www.reznorhvac.com for operating sequence and troubleshooting information.
Specifications and illustrations subject to change without notice or incurring obligations. Latest version of this manual is available at www.reznorhvac.com.
©2022 Nortek Global HVAC LLC, O’Fallon, MO. All rights reserved.
CAUA-IGN-CNTRL (03-22) 178435-A

References

• Reznor HVAC

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