Sterling Tubular Gas Fired Direct Spark Propeller Unit Heaters Gg 105 Users Manual S
TUBULAR GAS FIRED DIRECT SPARK PROPELLER UNIT HEATERS GG-75 Sterling-GG-Manual
GG-30 to the manual 13780daf-313c-4c81-a8c1-34a75f6ab23e
2015-02-04
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INSTALLATION INSTRUCTIONS AND PARTS LIST (S) DSGG-IOM-1 J30-08511 TUBULAR GAS FIRED DIRECT SPARK PROPELLER UNIT HEATERS – FOR RESIDENTIAL INSTALLATIONS – ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESEAGREE WITH THOSE AT THE POINT OF INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No.(s) IN THE SPACE PROVIDED. RETAIN FOR FUTURE REFERENCE. Model No. Serial No. FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call your fire department. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Read the installation, operating, and maintenance instruction thoroughly before installing or servicing this equipment. APPROVED FOR USE IN CALIFORNIA Install, operate, and maintain unit in accordance with the manufacturer's instructions to avoid exposure to fuel substances, or substances from incomplete combustion, which can cause death or serious illness. The state of California has determined that these substances may cause cancer, birth defects, or other reproductive harm. INSTALLER'S RESPONSIBILITY Installer Please Note: This equipment has been test fired and inspected. It has been shipped free from defects from our factory. However, shipment and installation problems such as loose wires, leaks, or loose fasteners may occur. It is the installer's responsibility to inspect and correct any problem that may be found. RECEIVING INSTRUCTIONS Inspect shipment immediately when received to determine if any damage has occurred to the unit during shipment. After the unit has been uncrated, check for any visible damage to the unit. If any damage is found, the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with the transportation company. 04/08 HVAC PRODUCTS 260 NORTH ELM ST., WESTFIELD, MA 01085 TEL: (413) 564-5540 FAX: (413) 562-5311 www.sterlinghvac.com MODELS: GG-30, 45, 60, 75, 90, 105, 120 Please utilize this toll free number to contact your local representative 800-490-2290. TABLE OF CONTENTS SPECIFICATIONS Basic Description .................................................... 2 Performance & Specification Data ...................... 4, 5 GENERAL SAFETY INFORMATION Installation Codes ............................................... 2, 3 Special Precautions ............................................ 2, 3 INSTALLATION Locating Units ..................................................... 6, 7 Combustion Air ................................................... 6, 7 Proper Clearances .............................................. 6, 7 Suspension of Units ............................................ 6, 7 Gas Supply Piping .............................................. 8, 9 ELECTRICAL CONNECTIONS ............................10-15 VENTING General .............................................................16-17 Standard Combustion ......................................18-25 Separated Combustion ....................................26-30 OPERATION Explanation of Controls and Operation .................. 31 Main Burner Orifice Schedule ............................... 32 Adjustments .......................................................... 32 High Altitude Operation .................................. 32, 33 MAINTENANCE Servicing & Cleaning ............................................ 33 TROUBLESHOOTING GUIDE .............................34-38 IDENTIFICATION OF PARTS .............................. 39, 40 WARRANTY ............................................................... 41 MODEL NUMBER ..................................................... 42 INSPECTION SHEET................................................. 43 NOTICE: It is the equipment owners responsibility to provide any scaffolding or other apparatus required to perform emergency service or annual/periodic maintenance to this equipment. DESCRIPTION (2nd ed.) “Unit Heaters for Residential Installation”. The designs are certified by ETL as providing a minimum of 80% thermal efficiency, and approved for use in California. Do not alter these units in any way. If you have any questions after reading this manual, contact the manufacturer. The Residential Tubular Gas Fired Unit Heater is a factory assembled, power vented, low static pressure type propeller fan unit heater designed to be suspended within the space to be heated. THESE HEATERS ARE NOT TO BE CONNECTED TO DUCTWORK. These Tubular Unit Heaters are design certified under ANSI Z83.8 for Industrial/Commercial use and IAS .10.96 U.S. Figure 1 - Tubular 30 thru 120 Propeller Unit Heaters GG120 GG030 See Identification of Parts throughout this manual. The following terms are used throughout this manual, in addition to the ETL requirements to bring attention to the presence of potential hazards, or to important information concerning the product: Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury, or substantial property damage. Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury, or substantial property damage. Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or property damage. NOTICE: Used to notify of special instructions on installation, operation, or maintenance which are important to equipment but not related to personal injury. 2 GENERAL SAFETY INFORMATION Failure to comply with the general safety information may result in extensive property damage, severe personal injury, or death. Make certain that the power source conforms to the electrical requirements of the heater. Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing heater. Always disconnect power at main circuit breaker as described above. Failure to do so could result in fatal electric shock. This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts. Installation must be made in accordance with local codes, or in absence of local codes, with the latest edition of ANSI Standard Z223.1 (N.F.P.A. No. 54) National Fuel Gas Code. All of the ANSI and NFPA Standards referred to in these installation instructions are those that were applicable at the time the design of this appliance was certified.The ANSI Standards are available from CSA Information Services 1-800-463-6727. The NFPA Standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Special attention must be given to any grounding information pertaining to this heater. To prevent the risk of electrocution, the heater must be securely and adequately grounded. This should be accomplished by connecting a ground conductor between the service panel and the heater. To ensure a proper ground, the grounding means must be tested by a qualified electrician. Do not insert fingers or foreign objects into heater or its air moving device. Do not block or tamper with the heater in any manner while in operation, or just after it has been turned off, as some parts maybe hot enough to cause injury. If installed in Canada, the installation must conform with local building codes, or in the absence of local building codes, with CGA-B149.1 "Installation Codes for Natural Gas Burning Appliances and Equipment" or CGA-B149.2 "Installation Codes for Propane Gas Burning Appliances and Equipment." These unit heaters have been designed and certified to comply with CGA 2.6. This heater is intended for general heating applications ONLY. It must NOT be used in potentially dangerous locations such as flammable, explosive, chemical-laden, or wet atmospheres. Do not alter the unit heater in any way or damage to the unit and/or severe personal injury or death may occur! Do not attach ductwork to this product or use it as a makeup air heater. Such usage voids the warranty and will create unsafe operation. Disconnect all power and gas supplies before installing or servicing the heater. If the power disconnect is out of sight, lock it in the open position and tag it to prevent unexpected application of power. Failure to do so could result in fatal electric shock, or severe personal injury. In cases in which property damage may result from malfunction of the heater, a back-up system or temperature sensitive alarm should be used. Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply. Ensure that all power sources conform to the requirements of the unit heater, or damage to the unit will result! The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into confined spaces UNLESS precautions are taken as follows: (1) by ventilation of the space, (2) control of the purging rate, (3) elimination of all hazardous conditions. All precautions must be taken to perform this operation in a safe manner! Follow installation instructions CAREFULLY to avoid creating unsafe conditions. All wiring should be done and checked by a qualified electrician, using copper wire only. All gas connections should be made and leaktested by a suitably qualified individual, per instructions in this manual. Also follow procedures listed on "Gas Equipment Start-Up Sheet" located in this manual. Unless otherwise specified, the following conversions may be used for calculating SI unit measurements: 1 foot = 0.305 m 1000 BTU/cu. ft. = 37.5 MJ/m3 1 inch = 25.4 mm 1000 BTU per hour = 0.293 kW 1 gallon = 3.785 L 1 inch water column = 0.249 kPa 1 pound = 0.453 kg liter/second = CFM x 0.472 1 psig = 6.894 kPa meters/second = FPM ÷ 196.8 1 cubic foot = 0.028m3 Use only the fuel for which the heater is designed (see rating plate). Using LP gas in a heater that requires natural gas, or vice versa, will create risk of gas leaks, carbon monoxide poisoning, and explosion. Conversion to a fuel other than that listed on the rating plate is permitted only with a factory supplied, ETL approved conversion kit. 3 Table 1 - Performance and Dimensional Data - Tubular 30 thru 120 Propeller Unit Heater Unit Size PERFORMANCE DATA† Input - BTU/Hr. (kW) Output - BTU/Hr. (kW) Thermal Efficiency (%) Free Air Delivery - CFM (cu. m/s) Air Temperature Rise - Deg. F (Deg. C) Full Load Amps at 120V Maximum Circuit Ampacity MOTOR DATA: Motor HP Motor (kW) Motor Type R.P.M. Motor Amps @ 115V DIMENSIONAL DATA - inches (mm) “A” Jacket Height “B” Overall Height “C” Overall Depth “D1” Center Line Height of Flue* “D2” Center Line Height of Air Intake “E” Fan Diameter “F” Discharge Opening Height “G” Vent Connection Diameter “H1” Center Line of Flue Connection From Side “H2” Center Line of Air Intake From Side Vent Size Requirements - Standard Combustion Category I Horizontal** Category III Horizontal Category I & III Vertical Vent Size Requirements - Separated Combustion Exhaust Diameter** Intake Air Diameter Unit Weight - lbs. (kgs) Shipping Weight - lbs. (kgs) 30 45 60 75 90 105 120 30,000 (8.8) 24,300 (7.1) 81 370 (.175) 60 (15) 3.0 3.5 1/20 (0.04) SP 1650 1.9 45,000 (13.2) 36,450 (10.7) 81 550 (.260) 60 (15) 3.0 3.5 1/20 (0.04) SP 1650 1.9 60,000 (17.6) 48,600 (14.2) 81 740 (.349) 60 (15) 3.7 4.4 1/12 (0.06) SP 1050 2.6 75,000 (22.0) 60,750 (17.8) 81 920 (.434) 60 (15) 4.1 4.8 1/12 (0.06) SP 1050 2.6 90,000 (26.4) 72,900 (21.4) 81 1,100 (.519) 60 (15) 6.4 7.5 1/10 (0.075) SP 1050 4.2 105,000 (30.8) 85,050 (24.9) 81 1,300 (.614) 60 (15) 6.4 7.5 1/10 (0.075) SP 1050 4.2 120,000 (34.2) 97,200 (28.5) 81 1,475 (.696) 60 (15) 6.4 7.5 1/10 (0.075) SP 1050 4.2 12-3/8 (314) 13-1/4 (337) 25-7/8 (632) 8-1/2 (216) 8-1/2 (216) 10 (254) 10-13/16 (275) 4 (102) 7-1/4 (184) 2-3/4 (70) 12-3/8 (314) 13-1/4 (337) 25-7/8 (632) 8-1/2 (216) 8-1/2 (216) 10 (254) 10-13/16 (275) 4 (102) 7-1/4 (184) 2-3/4 (70) 15-7/8 (403) 16-13/16 (427) 26-3/16 (665) 10-3/8 (263) 8 (203) 14 (356) 14-7/16 (367) 4 (102) 7-1/4 (184) 2-3/4 (70) 15-7/8 (403) 16-13/16 (427) 26-3/16 (665) 10-3/8 (263) 8 (203) 14 (356) 14-7/16 (367) 4 (102) 7-1/4 (184) 2-3/4 (70) 22-5/8 (574) 23-9/16 (598) 26-3/8 (670) 13-5/8 (346) 8-5/8 (219) 16 (406) 21-3/16 (538) 4 (102) 7-3/4 (197) 3-1/2 (89) 22-5/8 (574) 23-9/16 (598) 26-3/8 (670) 13-5/8 (346) 8-5/8 (219) 16 (406) 21-3/16 (538) 4 (102) 7-3/4 (197) 3-1/2 (89) 22-5/8 (574) 23-9/16 (598) 26-3/8 (670) 13-5/8 (346) 8-5/8 (219) 16 (406) 21-3/16 (538) 4 (102) 7-3/4 (197) 3-1/2 (89) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 4 (102) 5 (127) 4 (102) 4 (102) 5 (127) 4 (102) 4 (102) 5 (127) 4 (102) 4 (102) 5 (127) 4 (102) 4 (102) 4 (102) 4 (102) 57 (27) 67 (32) 4 (102) 4 (102) 60 (29) 70 (33) 4 (102) 4 (102) 75 (34) 90 (41) 4 (102) 4 (102) 87 (37) 96 (44) 5 (127) 5 (127) 96 (45) 109 (51) 5 (127) 5 (127) 103 (48) 143 (66) 5 (127) 5 (127) 112 (49) 152 (67) * For all installations, the flue collar is included with the unit and should be field installed per the instructions included with the unit. ** 4-5" reducer supplied where required. † Ratings shown are for unit installations at elevations between 0 and 2,000 ft (0 to 610m). For unit installations in U.S.A. above 2,000 ft. (610m), the unit input must be derated 4% for each 1,000 ft. (305m) above sea level; refer to local codes, or in absence of local codes, refer to the latest edition of the National Fuel Gas Code, ANSI Standard Z223.1 (N.F.P.A. No. 54), (also refer to Table 6). 4 Figure 2 - Dimensional Drawing – Tubular 30 thru 120 Propeller Unit Heater DIMENSIONS .XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS (XXX) MILLIMETERS 5 INSTALLATION Do not install unit heaters in corrosive or flammable atmospheres! Premature failure of, or severe damage to the unit will result! AIR FOR COMBUSTION: The unit heater shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and the maintenance of ambient air at safe limits under normal conditions of use. The unit heater shall be located in such a manner as not to interfere with proper circulation of air within the confined space. When buildings are so tight that normal infiltration does not meet air requirements, outside air shall be introduced per Sections 1.3.4.2 and 1.3.4.3 of ANSI Z223.1 for combustion requirements. A permanent opening or openings having a total free area of not less than one square inch per 5,000 BTU/Hr (1.5 kW) of total input rating of all appliances within the space shall be provided. Avoid locations where extreme drafts can affect burner operation. Unit heaters must not be installed in locations where air for combustion would contain chlorinated, halogenated or acidic vapors. If located in such an environment, premature failure of the unit will occur! Since the unit is equipped with an automatic gas ignition system, the unit heater must be installed such that the gas ignition control system is not directly exposed to water spray, rain or dripping water. NOTICE: Unit Heater sizing should be based on heat loss calculations where the unit heater output equals or exceeds heat loss. NOTICE: Location of unit heaters is related directly to the selection of sizes. Basic rules are as follows: CLEARANCES: Each Gas Unit Heater shall be located with respect to building construction and other equipment so as to permit access to the Unit Heater. Clearance between vertical walls and the vertical sides of the Unit Heater shall be no less than 1 inch (25.4mm). However, to ensure access to the control box and fan, a minimum of 18" (457mm) is required for the fan, and control box side. A minimum clearance of 1 inch (25.4mm) must be maintained between the top of the Unit Heater and the ceiling. The bottom of the Unit Heater must be no less than 1 inch (25.4mm) from any combustible. The distance between the flue collector and any combustible must be no less than 1 inch (25.4mm). Also see AIR FOR COMBUSTION and VENTING sections. MOUNTING HEIGHT: If the unit heater is installed in a garage, it must be installed with a minimum clearance above the floor of 18 inches (457mm). AIR DISTRIBUTION: Direct air towards areas of maximum heat loss. When multiple heaters are involved, circulation of air around the perimeter is recommended where heated air flows along exposed walls. Satisfactory results can also be obtained where multiple heaters are located toward the center of the area with heated air directed toward the outside walls. Be careful to avoid all obstacles and obstructions which could impede the warm air distribution patterns. Unit heaters should not be installed to maintain low temperatures and/or freeze protection of buildings. A minimum of 50°F (10°C) thermostat setting must be maintained. If unit heaters are operated to maintain lower than 50°F (10°C), hot flue gases are cooled inside the heat exchanger to a point where water vapor (a flue gas by-product) condenses onto the heat exchanger walls. The result is a mildly corrosive acid that prematurely corrodes the aluminized heat exchanger and can actually drip water down from the unit heater onto floor surface. Additional unit heaters should be installed if a minimum 50°F (10°C) thermostat setting cannot be maintained. NOTICE: Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials. MOUNTING: The Unit Heater may be mounted with the vent outlet, gas and electrical connections to the right or left of the air moving fan. The Unit Heater is shipped with the connections to the right of the fan when looking in the direction of the air flow. If connections to the right are required, remove hanger brackets from face of unit and attach as pictured in Figure 3. If connections to the left are required, invert the heater (180°), mount the hanging brackets as above, and remove, invert, and replace the control access panel and the air discharge louvers. Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and replace any gas control which has been underwater. 6 INSTALLATION (continued) The Unit Heater may be mounted by fastening the hanging brackets directly to ceiling joists or by suspending from four rods. See Figures 3, 4 and 5. Figure 3 - Hanger Bracket Installation Instructions Make certain that the lifting methods used to lift the heater and the method of suspension used in the field installation of the heater are capable of uniformly supporting the weight of the heater at all times. Failure to heed this warning may result in property damage or personal injury! Make sure that the structure to which the unit heater is to be mounted is capable of safely supporting its weight. Under no circumstances must the gas lines, the venting system or the electrical conduit be used to support the heater; or should any other objects (i.e. ladder, person) lean against the heater gas lines, venting system or the electrical conduit for support. Failure to heed these warnings may result in property damage, personal injury, or death. Figure 4 - Heater Mounting (Steel Construction) Unit Heaters must be hung level from side to side and from front to back, see Figures 3, 4 and 5. Failure to do so will result in poor performance and/or premature failure of the unit. Ensure that all hardware used in the suspension of each unit heater is more than adequate for the job. Failure to do so may result in extensive property damage, severe personal injury, or death! Figure 5 - Heater Mounting (Wood Construction) Refer to Figures 3, 4 and 5 for suspension of units. 7 GAS PIPING To avoid damage or possible personal injury, do not connect gas piping to this unit until a supply line pressure/leak test has been completed. Connecting the unit before completing the pressure/leak test may damage the unit gas valve and result in a fire hazard. Do not rely on a shut-off valve to isolate the unit while conducting gas pressure/leak tests. These valves may not be completely shut off, exposing the gas valve to excessive pressure and damage. PIPE SIZING To provide adequate gas pressure to the gas unit heater, size the gas piping as follows: NOTICE: If more than one unit heater is to be served by the same piping arrangement, the total cu. ft./hr. input and length of pipe must be considered. 1. Find the cu. ft./hr. by using the following formula: Input Cu. ft./hr. = BTU 2. Refer to Table 2. Match “Length of Pipe in Feet” with appropriate “Gas Input - Cu. Ft./Hr.” figure. This figure can then be matched to the pipe size at the top of the column. Example: It is determined that a 67 foot (20.4m) run of gas pipe is required to connect a 75 MBTU gas unit heater to a 1,000 BTU/cu ft. (0.29kW) natural gas supply. 75,000 BTU/Hr = 75 Cu. ft./hr 1,000 BTU/cu. ft. . Using Table 2, a 3/4 inch pipe is needed. NOTICE: If the gas unit heater is to be fired with LP gas, consult your local LP gas dealer for pipe size information. NOTICE: HEATER INSTALLATION FOR USE WITH PROPANE (BOTTLED) GAS MUST BE MADE BY A QUALIFIED L.P. GAS DEALER OR INSTALLER. HE WILL ENSURE THAT PROPER JOINT COMPOUNDS ARE USED FOR MAKING PIPE CONNECTIONS; THAT AIR IS PURGED FROM LINES; THAT A THOROUGH TEST IS MADE FOR LEAKS BEFORE OPERATING THE HEATER; AND THAT IT IS PROPERLY CONNECTED TO THE PROPANE GAS SUPPLY SYSTEM. Before any connection is made to the existing line supplying other gas appliances, contact the local gas company to make sure that the existing line is of adequate size to handle the combined load. NOTE: See General Safety Information section for English/Metric unit conversion factors. Table 2 - Gas Pipe Size Maximum Capacity of Pipe in Cubic Feet of Gas per Hour (Cubic Meters per Hour) for Gas Pressures of 0.5 psig (3.5 kPa) or Less, and a Pressure Drop of 0.5 Inch Water Column (124.4 Pa) (Based on a 0.60 Specific Gravity Gas) Nominal Iron Internal Pipe Size Dia. in. 1/2 in. 0.622 3/4 0.824 1 1.049 1 1/4 1.380 1 1/2 1.610 2 2.067 2 1/2 2.469 3 3.068 4 4.026 Length of Pipe, Feet (meters) 10 (3.0) 175 (4.96) 360 (10.2) 680 (19.3) 1400 (39.6) 2100 (59.5) 3950 (112) 6300 (178) 11000 (311) 23000 (651) 20 (6.1) 120 (3.40) 250 (7.08) 465 (13.2) 950 (26.9) 1460 (41.3) 2750 (77.9) 4350 (123) 7700 (218) 15800 (447) 30 (9.1) 97 (2.75) 200 (5.66) 375 (10.6) 770 (21.8) 1180 (33.4) 2200 (62.3) 3520 (99.7) 6250 (177) 12800 (362) 40 (12.2) 82 (2.32) 170 (4.81) 320 (9.06) 660 (18.7) 990 (28.0) 1900 (53.8) 3000 (85.0) 5300 (150) 10900 (309) 50 (15.2) 73 (2.07) 151 (4.28) 285 (8.07) 580 (16.4) 900 (25.5) 1680 (47.6) 2650 (75.0) 4750 (135) 9700 (275) 60 (18.3) 66 (1.87) 138 (3.91) 260 (7.36) 530 (15.0) 810 (22.9) 1520 (43.0) 2400 (68.0) 4300 (122) 8800 (249) 70 (21.3) 61 (1.73) 125 (3.54) 240 (6.80) 490 (13.9) 750 (21.2) 1400 (39.6) 2250 (63.7) 3900 (110) 8100 (229) 80 (24.4) 57 (1.61) 118 (3.34) 220 (6.23) 460 (13.0) 690 (19.5) 1300 (36.8) 2050 (58.0) 3700 (105) 7500 (212) 90 (27.4) 53 (1.50) 110 (3.11) 205 (5.80) 430 (12.2) 650 (18.4) 1220 (34.5) 1950 (55.2) 3450 (97.7) 7200 (204) 100 (30.5) 50 (1.42) 103 (2.92) 195 (5.52) 400 (11.3) 620 (17.6) 1150 (32.6) 1850 (52.4) 3250 (92.0) 6700 (190) 125 (38.1) 44 (1.25) 93 (2.63) 175 (4.96) 360 (10.2) 550 (15.6) 1020 (28.9) 1650 (46.7) 2950 (83.5) 6000 (170) 150 (45.7) 40 (1.13) 84 (2.38) 160 (4.53) 325 (9.20) 500 (14.2) 950 (26.9) 1500 (42.5) 2650 (75.0) 5500 (156) 175 (53.3) 37 (1.05) 77 (2.18) 145 (4.11) 300 (8.50) 460 (13.0) 850 (24.1) 1370 (38.8) 2450 (69.4) 5000 (142) 200 (61.0) 35 (0.99) 72 (2.04) 135 (3.82) 280 (7.93) 430 (12.2) 800 (22.7) 1280 (36.2) 2280 (64.6) 4600 (130) 1. Determine the required Cu. Ft./Hr. by dividing the input by 1000. For SI/Metric measurements: Convert BTU/Hr. to kilowatts. Multiply the units inputs (kW) by 0.0965 to determine Cu. Meters./Hr. 2. FOR NATURAL GAS: Select pipe size directly from the table. 3. FOR PROPANE GAS: Multiply the Cu. Ft./Hr. value by 0.633; then, use the table. 4. Refer to the metric conversion factors listed in the General Safety section for SI Unit measurement conversions. 8 PIPE INSTALLATION 1. Install the gas piping in accordance with applicable local codes. 2. Check gas supply pressure. Each unit heater must be connected to a gas supply capable of supplying its full rated capacity as specified in Table 3. A field LP tank regulator must be used to limit the supply pressure to a maximum of 14 in. W.C. (3.5 kPa). All piping should be sized in accordance with the latest edition of ANSI Standard Z223.1 National Fuel Gas Code; in Canada, according to CGA-B149. See Tables 1 & 2 for correct gas piping size, and also refer to Tables 3, 7 and 8. If gas pressure is excessive on natural gas applications, install a pressure regulating valve in the line upstream from the main shutoff valve. 3. Adequately support the piping to prevent strain on the gas manifold and controls. 4. To prevent the mixing of moisture with gas, run the take-off piping from the top, or side, of the main. 5. Standard Unit Heaters are supplied with a combination valve which includes: a. Manual "A" valve b. Manual "B" valve c. Solenoid valve d. Pressure regulator Pipe directly into the combination valve (see Figure 6). 6. Gas valve has a pressure test post requiring a 3/32" hex head wrench to read gas supply and manifold pressures. Open 1/4 turn counterclockwise to read, turn clockwise to close and reseat. A 5/16" ID hose fits the pressure post. 7. Provide a drip leg in the gas piping near the gas unit heater. A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing. The manual shutoff valve must be located external to the jacket. (See Figure 6) 8. Make certain that all connections have been adequately doped and tightened. Do not over tighten the inlet gas piping into the valve. This may cause stresses that will crack the valve! Table 3 - Gas Piping Requirements The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa). NOTICE: Use pipe joint sealant resistant to the action of liquefied petroleum gases regardless of gas conducted. Check all pipe joints for leakage using a soap solution or other approved method. Never use an open flame or severe personal injury or death may occur! Figure 6 - Pipe Installation, Standard Controls D3631C Never use an open flame to detect gas leaks. Explosive conditions may exist which may result in personal injury or death! The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system in excess of 1/2 psig (3.5 kPa). GAS PIPING REQUIREMENTS* GasType Natural Gas Propane (LP) Gas Manifold Pressure 3.5 in. W.C. (0.9 kPa) 10.0 in. W.C. (2.5 kPa) 14.0 in. W.C. Max. (3.5 kPa) 14.0 in. W.C. Max. (3.5 kPa) 5.0 in. W.C. Min. (1.2 kPa) 11.0 in W.C. Min. (2.7 kPa) Supply Inlet Pressure *For single stage application only at altitudes below 2,001 feet. 9 ELECTRICAL CONNECTIONS THERMOSTAT WIRING AND LOCATION: NOTICE: The thermostat must be mounted on a vertical, vibration-free surface, free from air currents, and in accordance with the furnished instructions. HAZARDOUS VOLTAGE! DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death. Standard units are shipped for use on 115 volt, 60 hertz, single phase electric power. The motor name-plate and electrical rating of the transformer should be checked before energizing the unit heater electrical system. All external wiring must conform to the latest edition of ANSI/NFPA No. 70, National Electrical Code, and applicable local codes; in Canada, to the Canadian Electrical Code, Part 1, CSA Standard C22.1. Do not use any tools (i.e. screwdriver, pliers, etc.) across terminals to check for power. Use a voltmeter. It is recommended that the electrical power supply to each unit heater be provided by a separate, fused, and permanently live electrical circuit. A disconnect switch of suitable electrical rating should be located as close to the gas valve and controls as possible. Each unit heater must be electrically grounded in accordance with the latest edition of the National Electrical Code, ANSI/NFPA No. 70, or CSA Standard C22.1. Refer to Figures 7, 8, 9, 10A, 10B, 10C, 11A, 11B and 11C. Mount the thermostat approximately 5 feet (1.5m) above the floor, in an area where it will be exposed to a free circulation of average temperature air. Always refer to the thermostat instructions, as well as our unit wiring diagram, and wire accordingly. Avoid mounting the thermostat in the following locations: 1. Cold Areas- Outside walls or areas where drafts may affect the operation of the control. 2. Hot Areas- Areas where the sun's rays, radiation, or warm air currents may affect the operation of the control. 3. Dead Areas- Areas where the air cannot circulate freely, such as behind doors or in corners. THERMOSTAT HEAT ANTICIPATOR ADJUSTMENTS: The initial heat anticipator setpoint should equal the thermostat's current amperage draw when the unit is firing. This setpoint should be measured for the best results. Use the recommended ranges for a guide. If further information is needed, consult your thermostat manufacturer's instructions. Recommended heat anticipator setting .35 Amps NOTICE: The start-up fan delay should not exceed 30 seconds from a cold start. IMPORTANT: For all wiring connections, refer to the wiring diagram shipped with your unit (either affixed to the side jacket or enclosed in the installation instructions envelope). Should any original wire supplied with the heater have to be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Figure 7 - Low-voltage Thermostat Wiring Single Stage Figure 8 - Low Voltage Thermostat Wiring Two Stage Figure 9 - T834H or T834N Thermostat Wiring W R R G W1 W2 G D6922C 10 ELECTRICAL CONNECTIONS (continued) Figure 10A - UT Control Board Figure 11A - Honeywell Control Board 11 ELECTRICAL CONNECTIONS (continued) Figure 10B - Tubular Propeller Units 30-120 with Natural and Propane (LP) Gas with Single Stage Gas Control and UT Control Board NOTICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater. If using a standard low voltage thermostat with a sub-base switch for fan control, connect the G terminal of the thermostat to the G terminal of the unit heater. 12 ELECTRICAL CONNECTIONS (continued) Figure 10C - Tubular Propeller Units 60-120 with Natural and Propane (LP) Gas with Optional Two Stage Gas Control and UT Control Board NOTICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater. If using a standard low voltage thermostat with a sub-base switch for fan control, connect the G terminal of the thermostat to the G terminal of the unit heater. 13 ELECTRICAL CONNECTIONS (continued) Figure 11B - Tubular Propeller Units 30-120 with Natural and Propane (LP) Gas with Single Stage Gas Control and Honeywell Control Board NOTICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater. If using a standard low voltage thermostat with a sub-base switch for fan control, connect the G terminal of the thermostat to the G terminal of the unit heater. 14 ELECTRICAL CONNECTIONS (continued) Figure 11C - Tubular Propeller Units 30-120 with Natural and Propane (LP) Gas with Optional Two Stage Gas Control and Honeywell Control Board NOTICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater. If using a standard low voltage thermostat with a sub-base switch for fan control, connect the G terminal of the thermostat to the G terminal of the unit heater. 15 VENTING* All unit heaters must be vented! All Venting installations shall be in accordance with the latest edition of Part 7, Venting of Equipment of the National Fuel Gas Code, ANSI Z223.1, or applicable provisions of local building codes. Refer to notes* below for Canadian installations. Refer to Figures 12-19. CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or flue-like symptoms). When an existing heater is removed or replaced in venting system, the venting system may not be properly sized to vent the attached appliances. An improperly sized vent system can cause formulation of condensate or leakage or spillage of flue gases. The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation: 1. Seal any unused openings in the venting system; 2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition. 3. In so far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace damper. 4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so that the appliance will operate continuously. 5. After it has been determined that each appliance connected to the venting system properly vents when tested as outline above, return doors, windows, exhaust fans, fireplace dampers, and any other gasburning appliance to their previous condition of use. 6. If improper venting is observed during any of the above tests, the venting system must be corrected immediately so that the system conforms with the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the venting system, the venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G of the National Fuel Gas Code, ANSI Z223.1. The unit heater shall be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction. Venting into an unlined masonry chimney is prohibited. ADDITIONAL REQUIREMENTS FOR CANADIAN INSTALLATIONS *The following instructions apply to Canadian installations in addition to installation and operating instructions. 1. Installation must conform with local building codes, or in the absence of local codes, with current CGA-B149.1, Installation Codes for Natural Gas Burning Appliances and Equipment, or CGA-B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment. 2. Any reference to U.S. standards or codes in these instructions are to be ignored and the applicable Canadian standards or codes applied. 16 VENTING - GENERAL GUIDELINES ANSI now organizes vented appliances into four categories. The following guidelines apply to all categories to follow. Venting Categories Table 4 Vent Systems Termination Clearance Requirements Structure Negative Vent Pressure Positive Vent Pressure Minimum Clearances for Termination Locations 4 feet below Door, window or any gravity vent inlet 4 feet horizontally Non Condensing Condensing I II III IV 1 foot above Forced air inlet within 10 ft. 3 feet above Adjoining building or parapet 6 feet Adjacent public walkways 7 feet above grade Electric, gas meters & regulators 4 feet horizontal Category I Includes non-condensing appliances with negative vent pressure, like the traditional atmospheric unit heater. Category II Groups condensing appliances with negative vent pressure. Do not damper or add heat recovery devices to the flue piping. Failure to open such a damper prior to operating the gas unit heater will result in the spillage of flue gas into the occupied space. Category III Appliances are non-condensing and operate with a positive vent pressure. Avoid installing units in areas under negative pressure. When required, a flue vent fan should be installed in accordance with the instructions included with the fan. Category IV Covers condensing appliances with positive vent pressure. NOTICE: Category II and IV do not apply to equipment specified within this manual. Vent connectors serving Category I and Category II heaters shall not be connected into any portion of mechanical draft systems operating under positive vent pressure. Maintain 1-inch (25.4mm) clearance between the vent pipe and combustible materials. ADDITIONAL REQUIREMENT FOR CANADIAN INSTALLATIONS REFER TO SPECIFICATION TABLE AND INSTALLATION MANUAL FOR PROPER USAGE. * T h e fo l l ow i n g i n s t r u c t i o n s a p p l y t o C a n a d i a n installations in addition to installation and operating instructions. 1. Installation must conform with local building codes, or in the absence of local codes, with current CGA B149.1, Installation Codes for Natural Gas Burning Appliances and Equipment, or CGA B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment. 2. Any reference to U. S. standards or codes in these instructions are to be ignored, and the applicable Canadian standards or codes applied 17 STANDARD COMBUSTION VERTICALLY VENTED, CATEGORY I - Figure 12 Observe the following precautions when venting the unit: 1. Use flue pipe of the same size as the flue connection(s) on the gas unit heater 4" (102mm). All heaters must be vented with a UL Listed, Type B or single wall vent, a factory built chimney, or a lined brick and mortar chimney that has been constructed in accordance with the National Building Code. All tables and dimensions assume B vent for the flue and single wall pipe or B vent for the connector. 2. E a c h u n i t m u s t h a v e a n individual vent pipe and vent terminal. Unit must not be connected to other vent systems or to a chimney. 3. A minimum vertical rise of 5 feet (1.5m) is required for Category I venting. The top of the vent pipe should extend at least 2 feet (0.61m) above the highest point on the roof. Consideration should be made for anticipated snow depth. Install an Amerivent Americap or Metalbestos vent cap over the vent opening. 4. Slope horizontal runs upward from the gas unit heater at least 1/4-inch per foot (21mm/m) m i n i m u m . H o r i z o n t a l Ve n t Connector length should not exceed 75% of the ver tical height of the vent pipe for single wall, or 100% of the ver tical height for B-Vent connectors. Maximum vent connector length is 10 feet (3m). For exceptions see Ch. 10 of the National Fuel Gas Code, ANSI Z223.1. Horizontal portions of the venting system shall be suppor ted at minimum intervals o f 4 fe e t ( 1 . 2 m ) ( i n Canada, suppor t at 3 foot inter vals (1m) minimum intervals. 5. Use as few elbows as possible. 6. Seal all vent pipe joints and seams to prevent leakage. Use General Electric RTV-108, DowCorning RTV-732, or e q u i va l e n t s i l i c o n e sealant with a temperature rating of 500 deg. F, or 3M #425 aluminum foil tape (or equivalent). 7. Avoid running vent pipe through unheated spaces. When this cannot be avoided, insulate the pipe to prevent condensation of moisture on the walls of the pipe. Insulate vent pipe runs longer than 10 ft (3m). Insulation should be a minimum of 1/2" (12.7 mm) thick foil faced. Figure 12 HORIZONTALLY VENTED, CATEGORY I - Figure 13 Observe the following precautions when venting the unit: 1. Use flue pipe of the size shown on Table 5. All heaters must be vented with a UL Listed, Type B or single wall vent. Refer to Table 5 for dimensional restrictions. 2. E a c h u n i t m u s t h a v e a n individual vent pipe and vent terminal. Unit must not be connected to other vent systems or to a chimney. 3. A m i n i mu m ve r t i c a l r i s e i s required for Category I venting. See Table 5 for specifications. The vent terminal must be at least 3 feet (1m) above grade, or in snow areas, at least 3 feet (1m) above the snow line to prevent blockage by snow. Install a weather cap over the vent opening. An Amerivent Americap or Metalbestos vent cap must be supplied by the customer for each power vented unit. 4. Through the wall venting for these appliances shall not terminate over public walkways, or over an area where the condensate or vapor could create a nuisance, hazard, or could be detrimental to the operation of regulators, relief valves, or other equipment. 5. Seal all vent pipe joints and seams to prevent leakage. Use General Electric RTV-108, DowCorning RTV-732, or equivalent silicone sealant with a temperature rating of 500 deg. F, or 3M # 425 aluminum foil tape (or equivalent). The vent system must be installed to prevent collection of condensate. Pitch 18 horizontal pipes downward 1/4 inch per foot (21mm per meter) toward the outlet for condensate drainage. Install a tee with a condensate drain at the low point of the pipe (see Figure 13). As an alternate, a 3/8 inch diameter hole may be drilled at the low point of the pipe for condensate drainage. 6. Horizontal portions of the venting system shall be supported at minimum intervals of 4 feet (1.2m) to prevent sagging (in Canada, support at 3 foot (1m) minimum intervals). 8. Avoid running vent pipe through unheated spaces. When this cannot be avoided, insulate the pipe to prevent condensation of moisture on the walls of the pipe. Table 5 - Category I Horizontal Venting Requirements - Standard Combustion Vent Diameter (in) Maximum Number Elbows * Maximum Horizontal Vent Length (Ft.) Minimum Vertical Rise (In.) Extension Distance from Wall (In.) 30 4 4 1 2 5 10 8 18 36 36 45 4 4 4 1 1 2 10 15 5 24 24 24 36 36 36 60 4 2 10 18 36 75 5 2 7 24 36 90 5 2 7 24 24 105 5 2 7 24 24 120 5 1 5 24 24 5 2 7 24 24 Unit Size *One elbow is required to make the vertical extension, See Figure 13. Figure 13 - Category I Horizontal Venting Requirements D6838C 19 Figure 14 - Vent Support D- 06839A 20 STANDARD COMBUSTION HORIZONTALLY VENTED, CATEGORY III - Figure 15 Vent Systems Termination Clearance Requirements Structure Minimum Clearances for Termination Locations 4 feet below Door, window or any gravity air inlet 4 feet horizontally 1 foot above Forced air inlet within 10 ft. 3 feet above Adjoining building or parapet 6 feet Adjacent public walkways 7 feet above grade Observe the following precautions when venting the unit: 1. Use flue pipe of the same size as the flue connection(s) on the gas unit heater, 4" (102mm). All heaters must be vented with a single or double wall pipe listed for category III positive pressure vent systems. Type B double wall pipe can be used with limitations as shown in Figure 15B. As illustrated, a single 5 foot (1.52m) section of Type B vent pipe with a draft hood connector may be used between the appliance vent connection and the vent terminal. Use Metalbestos Type B gas vent with a Metalbestos 4RV-DH draft hood connector, or, an Amerivent Type B gas vent with an Amerivent 4EDC draft hood connector. 2. Each unit must have an individual vent pipe and vent terminal. Unit MUST NOT be connected to other vent systems or to a chimney. 3. Category III units are limited to a maximum of 40 feet (12.19m) equivalent length of vent pipe. Equivalent length is the total length of straight sections PLUS 5 feet (1.5m) for each 90 degree elbow and 2.5 feet (.75m) for each 45 degree elbow. 4. If using a single section of Type B vent pipe, seal the annular space between the inner and outer sections of the draft hood connector with a high temperature silicone sealant. Use General Electric RTV-108, DowCorning RTV-732, or equivalent silicone sealant with a temperature rating of 500 deg. F. See Figure 15C. Attach the draft hood connector to the appliance vent connection with screws (3 minimum) and seal the joint with silicone sealant. Install a Type B vent thimble in the wall. Inser t the vent pipe through the thimble and attach it to the adapter on the appliance. Seal the joint with silicone sealant or two wraps of aluminum foil tape. Install a vent cap on the outlet pipe and secure with screws (3 minimum). 5. An Amerivent Americap or Metalbestos vent cap must be supplied by the customer for each power vented unit. The vent pipe diameter must be 4 inches (102mm). 6. Through the wall venting for these appliances shall not terminate over public walkways, or over an area where the condensate or vapor could create a nuisance, hazard, or could be detrimental to the operation of regulators, relief valves, or other equipment, see Figures 15A, 16 and 18. 21 7. The vent terminal must be at least 3 feet (1m) above grade, or in snow areas, at least 3 feet above the snow line to prevent blockage by snow. 8. The vent terminal must be at least 12 inches (305mm) from the exterior of the wall that it passes through to prevent degradation of the building materials by flue gasses. 9. M a i n t a i n 1 - i n c h ( 2 5 . 4 m m ) clearance between the vent pipe and combustible materials. 10. Seal all vent pipe joints and seams to prevent leakage. Use General Electric RTV-108, DowCorning RTV-732, or equivalent silicone sealant with a temperature rating of 500 deg.F, or 3M #425 aluminum foil tape (or equivalent). The vent system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21mm per meter) toward the outlet for condensate drainage. Install a tee with a condensate drain at the low point of the pipe (see Figure 15A). As an alternate, a 3/8 inch diameter hole may be drilled at the low point of the pipe for condensate drainage. 11. Horizontal portions of the venting system shall be supported at minimum intervals of 4 feet (1.2m) to prevent sagging (in Canada, support at 3 foot (1m) minimum intervals). 12. Avoid running vent pipe through unheated spaces. When this cannot be avoided, insulate the pipe to prevent condensation of moisture on the walls of the pipe. STANDARD COMBUSTION VERTICALLY VENTED, CATEGORY III – Figure 17 & 19 Observe the following precautions when venting the unit: 1. Use flue pipe of the same size as the flue connection(s) on the gas unit heater, 4" (102mm). All heaters must be vented with a single or double wall pipe listed for positive pressure vent systems. 2. Each unit must have an individual vent pipe and vent terminal. Unit MUST NOT be connected to other vent systems or to a chimney. 3. Category III units are limited to a maximum of 40 feet (12.19m) equivalent length of vent pipe. Equivalent length is the total length of straight sections PLUS 5 feet (1.5m) for each 90 degree elbow and 2.5 feet (.75m) for each 45 degree elbow. 4. The top of the vent pipe should extend at least 2 feet (0.61m) above the highest point on the roof. Consideration should be made for anticipated snow depth. Install an Amerivent Americap or Metalbestos vent cap over the vent opening. Slope horizontal runs upward from the gas unit heater at least 1/4-inch per foot (21mm/m) minimum. Horizontal portions of the venting system shall be supported at minimum intervals of 4 feet (1.2m) (in Canada, support at 3 feet (1m) minimum intervals). (See Figures 15, 17 and 19) Figure 15 22 5. Seal all vent pipe joints and seams to prevent leakage. Use General Electric RTV-108, DowCorning RTV-732, or equivalent silicone sealant with a temperature rating of 500 deg. F, or 3M #425 aluminum foil tape (or equivalent). 6. Avoid running vent pipe through unheated spaces. When this cannot be avoided, insulate the pipe to prevent condensation of moisture on the walls of the pipe. Figure 15A - Category III Horizontal Venting Requirements Using Single Wall Vent Pipe Figure 15B - Category III Horizontal Venting Requirements Using Type B Double Wall Vent Pipe Figure 15C - Type B Draft Hood Connector 23 VENTING (continued) Figure 16 Figure 17 24 VENTING (continued) Figure 18 Figure 19 25 SEPARARTED COMBUSTION INSTALLATION - VENTING – CATEGORY III COMBUSTION AIR VENTING AND PIPING 5. Long runs of single wall combustion air piping passing through an unheated space may require insulating if condensation becomes noticeable. 6. The combustion air system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot toward the inlet cap to facilitate drainage. Vertical combustion air pipes should be piped as depicted in Figure 22. 7. The equivalent length of the combustion air system must not be less than 5 feet (1.5m) and must not exceed 30 feet (9m). Equivalent length equals the total length of straight pipe plus 5 feet (1.5m) for each 90° elbow and 2.5 feet (0.76m) for each 45° elbow. Never operate unit heaters without combustion air and flue gas piping in place or severe personal injury or death may occur! CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or flu-like symptoms). NOTICE: For optimum performance keep the combustion air system as straight as possible. 1. The combustion air system installation must be in accordance with the current edition of the National Fuel Gas Code-NFPA 54 or ANSI Z223.1 National Fuel Gas Code. In Canada, installation must be in accordance with CAN/CGA-B149.1 “Installation Code for Natural Gas Burning Appliances and Equipment” and CAN/CGA-B149.2 “Installation Code for Propane Burning Appliances and Equipment”. 2. The concentric vent box, inlet air screen, deflector disk, and vent terminal provided with the unit heater must be installed at the termination point of the combustion air/vent system. See Figures 20, 21, 22, 23 and 24 and Table 6. 3. Each unit heater MUST have its own combustion air system. It MUST NOT be connected to other air intake systems. 4. Use single wall pipe constructed of 26 GA galvanized steel or a material of equivalent durability and corrosion resistance for the vent system. For installations in Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or in the absence of local building codes, with current CAN/CGA-B149.1, Installation Codes for Natural Gas Burning Appliances and Equipment or CAN/CGA-B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment. For residential installations in the United States, vent pipe approved for Category III appliances must be used between the appliance and the concentric vent box unless 33% of the vent run is vertical, then single wall galvanized vent pipe or double wall Type B vent pipe may be used between the appliance and the concentric vent box. A single length of double wall Type B vent pipe must be used to go through the concentric vent box and outside wall to the vent terminal. 8. Each slip joint must be secured with at least three corrosion resistant screws. Two full turns of 3M #425 Aluminum Foil Tape or its equivalent must then be used to seal each joint. General Electric RTV-108, Dow-Corning RTV-732 or an equivalent silicone sealant with a temperature rating of 500°F may be used instead of the tape. 9. For horizontal combustion air systems longer than 5 feet (1.5m), the system must be supported from overhead building structures at 4 foot (1.2m) intervals in the U.S. and at 3 foot (0.91m) intervals in Canada. EXHAUST VENTING NOTICE: Every Separated Combustion unit to be installed MUST use the Factory supplied Concentric Vent Kit. If you do not have this kit, contact the manufacturer ASAP to obtain one prior to installation. Never operate unit heaters without combustion air and flue gas piping in place or severe personal injury or death may occur! 1. Vent system installation must be in accordance with the current National Fuel Gas Code-NFPA 54 or ANSI Z223.1 National Fuel Gas Code. In Canada installation must be in accordance with CAN/CGA-B149.1 “Installation Code for Natural Gas Burning Appliances and Equipment” and CAN/CGA-B149.2. “Installation Code for Propane Burning Appliances and Equipment”. 2. The Concentric Vent Kit (which includes a concentric vent box, air inlet screen, deflector collar, vent terminal and inlet air collar) provided with the heater by the manufacturer MUST be installed at the termination point of the combustion air/vent system. See Figures 20, 21, 22, 23 and 24 and Table 6. 3. Each unit heater MUST have it’s own vent system. It MUST NOT be connected to other vent systems or to a chimney. Never use pipe other than diameter stated in Table 1. Never use PVC, ABS or any other non-metallic pipe for venting! To do so may result in serious damage to the unit and or severe personal injury or death! 26 SEPARATED COMBUSTION VENTING (continued) 4. Use single wall pipe constructed of 26 GA galvanized NOTICE: Increasing the clearance distances may steel or a material of equivalent durability and corrosion be necessary if there is a possibility of distortion or resistance for the vent system. For installations in discoloration of adjacent materials. Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or 11. The top of a VERTICALLY VENTED exhaust system in the absence of local building codes, with current must extend at least 3 feet (0.91m) above the roof CAN/CGA-B149.1, Installation Codes for Natural surface that it passes through. See Figure 22. Gas Burning Appliances and Equipment or CAN/ 12. The point of termination for a HORIZONTALLY CGA-B149.2, Installation Codes for Propane Gas VENTED exhaust system must be at least 12 inches Burning Appliances and Equipment. For residential (0.3m) from the exterior of the wall that it passes installations in the United States, vent pipe approved through. In addition, the termination point must be at for Category III appliances must be used between the least 1 foot (0.3m) above grade or above the snow appliance and the concentric vent box unless 33% of the vent run is vertical, then single wall galvanized line, more than 6 feet (1.8m) from the combustion vent pipe or double wall Type B vent pipe may be used air inlet of another appliance, at least 4 feet (1.2m) between the appliance and the concentric vent box. A below, 4 feet (1.2m) horizontally from, or 1 foot single length of double wall Type B vent pipe must be (0.3m) above any door, window or gravity air inlet used to go through the concentric vent box and outside into any building, and more than 3 feet (0.91m) from wall to the vent terminal. and not directly above, any gas meter or service 5. Any run of single wall vent pipe passing through an regulator. See Figures 23 and 24 and Table 4. unheated space must be insulated with an insulation suitable to 550° F. Table 6 - Concentric Vent Box Dimensions 6. The vent system must be installed to prevent Dimensions - Inches (Nominal) Unit collection of condensate. Pitch horizontal pipes Size A B C D E G downward 1/4 inch per foot (21mm per meter) toward 30 the vent cap to facilitate drainage. Vertical vent pipes 45 should be piped as depicted in Figure 22. 4 6 8 5 12 41/2 7. The equivalent length of the vent system must not be 60 less than 5 feet (1.5m) and must not exceed 30 feet 75 (9m). The equivalent length equals the total length 90 of straight pipe plus 5 feet (1.5m) for each 90° elbow 105 51/2 5 8 12 5 15 and 2.5 feet (0.76m) for each 45° elbow. 120 8. Each slip joint must be secured with at least three corrosion resistant screws. Two full turns of 3M #425 Aluminum Foil Figure 20 - Concentric Vent Box tape or its equivalent must then be used to seal each joint. High temperature silicone sealant may be used instead of the tape. Silicone sealant must be used to seal the joint between the Type B vent pipe and the single wall pipe. 9. For horizontal vent systems longer than 5 feet (1.5m), the system must be supported from overhead building structures at 4 foot (1.2m) intervals in the U.S. and at 3 foot (0.91m) intervals in Canada. 10. The exhaust vent system must remain at a minimum distance of 1 inch (25mm) from all combustible materials. Any part of the vent system that passes through a combustible material must be properly insulated. 27 Figure 21 - Concentric Vent Installation Figure 22 - Vertical Intake/Vent Installation 28 VENTING (continued) Figure 23 - Horizontal Intake/Vent Installation Figure 24 - Horizontal Intake/Vent Installation Building Overhang 3'-0" Min. (0.9M Min.) Adjacent Building 6'-0" Min. (1.8M Min.) Vent Terminal D 3330 29 SEPARATED COMBUSTION VENTING (continued) HORIZONTAL TERMINATION Select a location on outside wall for vent terminal. In most applications, the terminal should be on level with the flue outlet of the unit less a 1/4 inch per foot pitch for condensate drainage toward the outside of the building. See Figure 23. AIR INLET COLLAR Remove screen and mounting plate from air inlet on rear panel of unit by removing 4 screws. Secure inlet collar and gasket to inlet opening re-using the 4 screws removed in step one. EXHAUST AIR COLLAR Secure 5-4” reducer to flue collar on rear panel of unit sizes 090, 105 and 120. Seal per exhaust venting instructions. The location of the vent terminal must be in accordance with the National Fuel Gas Code ANSI Z223.1 in the U.S. or the Natural Gas Installation Code CAN/CGA-B149.1 or the Propane Gas Installation Code CAN/CGA-149.2 in Canada. See Table 4 for minimum clearances. In Canada, a vent shall not terminate above a meter/ regulator assembly within 3 feet (.9m) horizontally of the vertical centerline of the regulator nor within 6 feet (1.8m) of any gas service regulator vent outlet. VERTICAL TERMINATION Select location on roof for vent terminal, ensuring adequate space inside the building/structure for concentric vent box. Terminal must be at least 6 feet (1.8m) from any wall or adjoining building. See Figure 22. Cut a hole through the roof for combustion air pipe. Concentric vent box is to be suspended from the underside of the roof using suitable brackets (field supplied). Before mounting box, cut a length of 6 inch (152mm) (sizes 030-075) or 8 inch (203mm) (sizes 090-120) pipe so that dimension A, Figure 22, is equal to the dimension from the top of the box to the roof surface plus 20 inches or plus maximum expected snow depth, whichever is greater. Fasten pipe to combustion air inlet connection of concentric vent box and seal joint. Insert pipe through roof and fasten vent box in place. Flash and/or caulk pipe to roof. Install inlet air screen assembly and fasten to pipe with screws. Insert a 5 foot length of Type B vent pipe through the concentric vent box opening (detail A, Figure 20) with the "UP" arrow pointing up. Position the pipe to extend 12 inches beyond the inlet air screen. Secure the Type B vent pipe in position by drilling three small equally spaced holes through the collar of the concentric vent box and inserting sheet metal screws. Install deflector disk on Type B vent pipe 2-1/2 inches above inlet air screen and fasten with screws. Seal joint between deflector disk and pipe with silicone sealant. Install vent terminal on top of Type B vent pipe, fasten with screws and seal joint. Cut a hole through the wall for a 6 inch (152mm) sizes (030-075) or 8 inch (203mm) sizes (090-120) combustion air pipe. Install thimble if required by local codes or type of wall construction. Concentric vent box may be fastened directly to wall or spaced away from wall using suitable brackets (field supplied). Cut a length of pipe so that it will protrude 4 inches (102mm) through the wall when the box is mounted in position. Fasten pipe to box with sheet metal screws, using at least three screws per joint. Seal joint with silicone sealant. Insert pipe through wall and fasten adapter box in place so that the pipe pitches downward 1/4 inch per foot (21mm/m) toward the outside. Flash and/or caulk pipe on outside wall. Install inlet air screen assembly and fasten to pipe with screws. Insert a 3 foot length of 4 inch (sizes 030-075) or 5 inch (sizes 090-120) Type B vent pipe through the concentric vent box opening (detail A, Figure 20) with the "UP" arrow pointing toward the outside. Position the pipe to extend 12 inches beyond the inlet air screen. Secure the Type B vent pipe in position by drilling three small equally spaced holes through the collar of the concentric vent box and inserting sheet metal screws. Install deflector disk on Type B vent pipe 2-1/2 inches (63.5mm) from inlet air screen and fasten with screws. Install vent terminal on end of Type B vent pipe, fasten with screws and seal joint. Connect flue pipe and combustion air pipe from concentric vent box to unit, following instructions on pages 26 and 27. Joint between Type B vent pipe and single wall vent pipe must be sealed with high temperature silicone sealant. (See Figure 21) Collars on unit and on concentric vent box are sized so that crimped ends of combustion air pipes go toward the unit and crimped ends of flue pipes go away from the unit. Connect flue pipe and combustion air pipe from concentric vent box to unit, following instructions on pages 26 and 27. Joint between Type B vent pipe and single wall vent pipe must be sealed with high temperature silicone sealant. (See Figure 21) Collars on unit and on concentric vent box are sized so that crimped ends of combustion air pipes go toward the unit and crimped ends of flue pipes go away from the unit. 30 OPERATION POWER VENTED PROPELLER UNITS DIRECT SPARK IGNITION EXPLANATION OF CONTROLS (See Figure 25): 1. Each Unit Heater comes equipped with a power vent system that consists of a power venter motor and blower, pressure switch, and sealed flue collector in place of the conventional draft diverter. 2. The power venter motor is energized by the room thermostat through the integrated control board when a demand for heat is sensed. The pressure switch measures the flow through the vent system and energizes the direct spark ignition system beginning the pre-purge timing when the flow is correct. 8. The wall thermostat, supplied optionally, is a temperature sensitive switch that operates the vent system and ignition system to control the temperature of the space being heated. The thermostat must be mounted on a ver tical, vibration-free surface free from air currents and in accordance with the furnished instructions (also refer to Electrical Section). START-UP (Also refer to lighting instruction plate equipped on the unit) 1. Open the manual gas valve in the gas supply line to the unit heater with union connection loose, purge air from the gas line. Tighten the union and check for leaks. The pressure switch MUST NOT be bypassed. The unit MUST NOT be fired unless the power venter is operating. An unsafe condition could result. 3. The direct ignition system consists of an ignition control module and a gas valve. When the pre-purge period ends, the spark ignition system is energized, and the gas valve opens to supply gas to the burner. When the thermostat is satisfied, the vent system is de-energized and the valve closes to stop the flow of gas to the unit. 4. The limit switch interrupts the flow of electric current to the control board, interrupting the flow of gas to the gas valve if the unit heater becomes overheated. 5. The flame roll-out switch interrupts the flow of electric current to the control board, interrupting the flow of gas to the unit heater in the event of sustained flame roll-out from the burner area. If this switch trips, DETERMINE AND CORRECT THE CAUSE of the flame roll-out. 6. Once the thermostat is satisfied, or the limit switch interrupts the flow of electric current to the control board, the unit will begin a post-purge period. When the post-purge period ends, the power venter motor is de-energized. 7. The fan operation is delayed 30 seconds once the thermostat is closed, and continues operation for 30 seconds after the thermostat opens. The start-up fan delay must not exceed 30 seconds from a cold start. 31 Never use an open flame to detect gas leaks. Explosive conditions may exist which could result in personal injury or death. 2. Open the manual valve on the unit heater. 3. Turn ON the electrical power. 4. The unit should be under the control of the thermostat. Turn the thermostat to the highest point and determine that the power venter motor starts and the burner ignite. Turn the thermostat to the lowest point and determine that the power venter motor shuts off and the burner is extinguished. 5. Turn the thermostat to the desired position. 6. See Gas Input Rate and Adjustments sections. SHUT DOWN 1. Turn the valve selector lever to the “OFF” position. 2. Turn off the electricity. 3. To relight, follow “start-up” instructions. See Figure 25 for parts/identification. Figure 25 PRIMARY AIR SHUTTER ADJUSTMENT Primary air adjustment is made at the factory. No field adjustments are necessary. GAS INPUT RATE Check the gas input rate as follows (Refer to General Safety Information section for metric conversions). 2. PROPANE GAS: An exact manifold pressure of 10.0 inches W.C. (2.5 kPa) must be maintained for proper operation of the unit heater. If the unit is equipped with a pressure regulator on the combination gas valve, follow steps "a" through "d" above. If the unit is not so equipped, the propane gas supply system pressure must be regulated to attain this manifold operating pressure. 3. The adjusted manifold pressure should not vary more than 10% from pressure specified in Tables 7 & 8. Never overfire the unit heater, as this may cause unsatisfactory operation, or shorten the life of the heater. 1. Turn off all gas appliances that use gas through the same meter as the unit heater. 2. Turn the gas on to the unit heater. 3. Clock the time in seconds required to burn 1 cubic foot of gas by checking the gas meter. 4. Insert the time required to burn one cubic foot of gas into the following formula and compute the input rate. 3600 (Sec. per Hr.) X BTU/Cu. Ft. Time (Sec.) Table 7 - Main Burner Orifice Schedule* TYPE OF GAS * INPUT IN 1000 BTU = Input Rate 30 45 For example: Assume the BTU content of one cubic foot of gas is 1000, and that it takes 48 seconds to burn one cubic foot of gas. 3600 x 1000 = 75,000 48 60 75 90 105 120 NOTICE: If the computation exceeds, or is less than 95% of the gas BTU/hr. input rating (see Table 1), adjust the gas pressure. NATURAL PROPANE 3 1075 BTU/Ft 2500 BTU/Ft3 (40.1 MJ/m3) (93.1 MJ/m3) MANIFOLD PRESSURE 3.5" W.C. (0.87kPA) 10" W.C. (2.49 kPA) FT 3/HR ORIFICE DRILL FT 3/HR ORIFICE DRILL FT 3/HR ORIFICE DRILL FT 3/HR ORIFICE DRILL FT 3/HR ORIFICE DRILL FT 3/HR ORIFICE DRILL FT 3/HR ORIFICE DRILL 28 38 42 1/8 56 27 70 20 84 16 98 11 112 5 12 52 18 48 24 42 30 37 36 35 42 31 48 1/8 HEATING VALUE NO. OF BURNER ORIFICES 1 1 1 1 1 1 1 *This schedule is for units operating at normal altitudes of 2000 ft. (610m) or less. When installed in Canada, any references to deration at altitudes in excess of 2000 ft. (610m) are to be ignored. At altitudes of 2000 to 4500 ft. (610 to 1372m), the unit heaters must be orificed to 90% of the normal altitude rating, and be so marked in accordance with ETL certification. Adjust the gas pressure as follows: 1. NATURAL GAS: Best results are obtained when the unit heater is operating at its full rated input with the manifold pressure of 3.5 inches W.C. (0.9 kPa). Adjustment of the pressure regulator is not normally necessary since it is preset at the factory. However, field adjustment may be made as follows: a. Attach manometer at the pressure tap plug below the control outlet. b. Remove the regulator adjustment screw cap, located on the combination gas valve. c. With a small screwdriver, rotate the adjustment screw counterclockwise to decrease pressure, or clockwise to increase pressure. d. Replace regulator adjustment screw cap. 32 TUBULAR UNIT HEATER HIGH ALTITUDE DERATION This Tubular Unit Heater has been manufactured utilizing standard burner orifices and a normal manifold pressure setting as per the specifications shown on your unit rating plate (refer to Tables 3, 7 and 8). All unit deration must be done through field adjustments by a qualified technician (refer to Table 8). Once the proper adjustments are made in the field, attach label #J17-06459 to the unit, and record adjusted manifold pressure, altitude of the unit installation and the technician’s name and date on the label using a permanent marker. Table 8 NATURAL GAS Altitude (Feet) 2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 *Heating Value BTU/Cu. ft. 948 931 914 897 881 865 849 833 818 Manifold Pressure (In. W.C.) 3.5 3.5 3.5 3.4 3.4 3.4 3.3 3.3 3.2 PROPANE (LP) GAS *Heating Value BTU/Cu. ft. 2,278 2,237 2,196 2,156 2,116 2,077 2,039 2,000 1,964 NATURAL GAS Manifold Pressure (In. W.C.) Altitude (Feet) 6,500 7,000 7,500 8,000 8,500 9,000 9,500 10,000 10.0 10.0 10.0 10.0 10.0 9.9 9.7 9.6 9.5 *Heating Value BTU/Cu. ft. 802 787 771 756 741 726 711 696 Manifold Pressure (In. W.C.) 3.2 3.1 3.1 3.1 3.0 2.9 2.9 2.8 PROPANE (LP) GAS *Heating Value BTU/Cu. ft. 1,927 1,891 1,853 1,817 1,781 1,745 1,709 1,673 Manifold Pressure (In. W.C.) 9.3 9.2 9.0 8.9 8.7 8.5 8.3 8.1 *Notes: 1. Consult local utility for actual heating value. 2. Tables based on heating value of 1,050 BTU/Cu. ft. at sea level. MAINTENANCE PERIODIC SERVICE NOTICE: The heater and vent system should be checked once a year by a qualified technician. 3. Remove service access panel. 4. To clean or replace the burner, remove retainer from around manifold orifice, disconnect flame sensor and igniter from control board, remove burner assembly mounting screws. See Figure 25. 5. With the burner removed, wire brush the inside surfaces of the heat exchanger. 6. Remove any dirt, dust, or other foreign matter from the burners using a wire brush and/or compressed air. Ensure that all parts are unobstructed. 7. Reassemble the unit heater by replacing all parts in reverse order. 8. Complete the appropriate unit startup procedure as given in the “Operation” section of this manual. (See lighting instruction on the unit nameplate). 9. Check the burner adjustment. 10. Check all gas control valves and pipe connections for leaks. 11 Check the operation of the automatic gas valve by lowering the setting of the thermostat, stopping the operation of the gas unit heater. The gas valve should close tightly, completely extinguishing the flame on the burner. 12. Inspect and service motor/fan assembly. To maintain efficient air flow, inspect and clean the fan blades and guard to prevent buildup of foreign matter. 13. Check lubrication instructions on motor. If oiling is required, add 3 or 4 drops of electric motor oil as follows: a. Light Duty - After 3 years or 25,000 hours of operation. b. Average Duty - Annually after 3 years or 8,000 hours of operation. c. Heavy Duty - Annually after 1 year or at least 1500 hours of operation. All Maintenance/Service information should be recorded accordingly on the Inspection Sheet provided in this manual. Open all disconnect switches and disconnect all electrical and gas supplies and secure in that position before servicing unit. Failure to do so may result in personal injury or death from electrical shock. Gas tightness of the safety shutoff valves must be checked on at least an annual basis. To check gas tightness of the safety shut-off valves, turn off the manual valve upstream of the appliance combination control. Remove the 3/32 hex head plug on the inlet side of the combination control and connect a manometer to that tapping. Turn the manual valve on to apply pressure to the combination control. Note the pressure reading on the manometer, then turn the valve off. A loss of pressure indicates a leak. If a leak is detected, use a soap solution to check all threaded connections. If no leak is found, combination control is faulty and must be replaced before putting appliance back in service. Should maintenance be required, perform the following inspection and service routine: 1. Inspect the area near the unit to be sure that there is no combustible material located within the minimum clearance requirements listed in this manual. Under no circumstances should combustible material be located within the clearances specified in this manual. Failure to provide proper clearance could result in personal injury or equipment damage from fire. Never over oil the motor or premature failure may occur! 14. Check and test the operational functions of all safety devices supplied with your unit. 2. Turn off the manual gas valve and electrical power to the unit heater. 33 Table 9 - Tubular Propeller Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION A. Flame pops back. 1. Burner orifice incorrect. 2. Low manifold Pressure. 1. Check for proper orifice size. Refer to “Operation”. 2. Test and reset manifold pressure. B. Noisy Flame. 1. Irregular orifice causing whistle or resonance. 2. Excessive gas input. 1. Replace orifice. 2. Test and reset manifold pressure. C. Yellow tip flame (some yellow tipping on LP gas is permissible). 1. Clogged burner. 2. Misaligned orifice. 3. Insufficient combustion air. 4. Possibly over fired. 1. Clean main burner ports. 2. Align manifold assembly. 3. Clean combustion air inlet openings. 4. Check gas input and manifold pressures. D. Floating flame. 1. Blocked venting. 2. Insufficient combustion air. 3. Blocked heat exchanger. 4. Air leak into combustion chamber, flue collector or draft hood. 1. Clean Flue. Refer to “Installation”. 2. Clean combustion air inlet openings. 3. Clean heat exchanger. Refer to “Installation”. 4. Determine cause and repair accordingly. E. Gas odor. Shut off gas supply immediately! 1. Gas pipe leak. 2. Leaking gas test port on valve. 3. Blocked heat exchanger. 4. Blocked draft hood. 5. Negative pressure in the building. 1. Inspect all gas piping and repair. 2. Check to ensure gas test ports are seated. 3. Clean heat exchanger/flue. 4. Clean flue collector. 5. See “Installation”. F. Delayed ignition. 1. Improper ground. 1. Check grounding wires and spark bracket connections. 2. Inspect spark cable connections and cuts. 3. Check to ensure spark is energized after pre purge period. 4. Test and reset manifold pressure refer to “Operations”. 5. Clean or replace orifice. 6. Refer to “Installation”. 2. Bad or broken spark cable. 3. Faulty control. 4. Manifold pressure set too low. 5. Main burner orifice dirty. 6. Improper venting. G. Failure to ignite. 1. Gas supply is off. 2. No power supply to unit. 3. Thermostat not calling. 4. Defective high limit. 5. Defective drafter prove switch. 6. Loose wiring. 7. Improper ground. 8. Improper thermostat or transformer wiring. 9. Ignitor defective/damaged. 10. Misaligned ignitor. 11. Defective gas valve. 12. Blown fuse. H. Condensation. 1. Improper venting. 2. Unit under fired. 1. Open all manual valves “check for leaks”. 2. Turn on power supply, check fuses and replace if bad. 3. Turn up thermostat, Check for 24v on terminals R and W1 on terminal strip. 4. Check switch for continuity if open with no heat present, replace. 5. Check switch operation to ensure switch closes after draftor purge period. If it does not make/check tubing connections/blockage. 6. Check all wiring per diagram. 7. Check all ground wires and connections. 8. Check both, for wiring according to diagram. 9. Replace ignitor. 10. Resecure ignitor bracket. 11. Check for 24V at gas valve terminals during trial for ignition period. If present with no manifold pressure. Replace valve. 12. Refer to symptom “Q”. 1. Refer to “Installation, Venting”. 2. Check gas supply pressures to unit. Refer to “Installation”. 3. Refer to “Installation”. 3. Building too cold. 34 Table 9 - Tubular Propeller Troubleshooting Guide (continued) SYMPTOMS I. Burner will not shut off. POSSIBLE CAUSE(S) 1. Thermostat located incorrectly. CORRECTIVE ACTION 5. Excessive gas supply pressure. 1. Relocate thermostat away from outside wall or drafts. 2. Check thermostat circuit for open and close on terminal strip on heater “R” and “W”. 3. Check thermostat circuit for shorts “staples piercing wires”. 4. Check for 24v on gas valve terminals when thermostat is not calling. 5. Refer to “Installation”. J. Rapid burner cycling. 1. Loose electrical connections at thermostat or gas valve. 2. Excessive thermostat heat anticipator setting. 3. Unit cycling on high limit. 4. Poor thermostat location. 1. Tighten all electrical connections. 2. Adjust heat anticipator setting for longer cycles. Refer to “Electrical Connections”. 3. Check for proper air supply across heat exchanger and proper gas supply. 4. Relocate thermostat. K. Noisy power venter. 1. Power venter wheel loose. 2. Power venter wheel is dirty. 3. Power venter wheel is rubbing on the housing. 1. Replace or tighten. 2. Clean power venter wheel. 3. Realign power venter wheel. L. Fan will not run. 1. Loose electrical connections. 2. Defective motor or overload. 1. Check and tighten wires on fan circuit. 2. Test for 115v on terminal ACB Heat and “L2” if voltage is present replace motor. 3. Test for 115v on terminal ACB Heat and “L2” on the control board, if voltage is not present 45 seconds after trial for ignition replace board. 4. Replace fuse. 2. Improper thermostat wiring. 3. Shorted circuit. 4. Defective sticking gas valve. 3. Defective control board. 4. Blown fuse. M. Fan motor turns on and off while burner is operating. 1. Motor overload protection is tripping. 2. Loose wiring or connection. 3. Control board is defective. N. Fan will not stop. 1. Control Board is in flame failure mode. 2. Fan improperly wired. 3. Defective board. O. Not enough heat. 1. Incorrect gas input. 2. Heater undersized. 3. Thermostat malfunction. 4. Heater cycling on limit. 5. Incorrect orifice size. P. Too much heat. 1. Unit is over fired. 2. Thermostat malfunction. 3. Heater runs continuously. Q. Blown fuse. 1. Check motor amps against motor name plate, check voltage, replace if found defective. 2. Check for 115v between motor leads. 3. Check terminal ACB Heat for voltage if voltage not constant, replace board. 1. Turn 115v power off to the unit, wait 10 seconds and reapply voltage to the unit. 2. Check wiring of fan circuit to wiring diagram. 3. If unit is not calling for heat and board is not in a flash code mode, replace board. 1. Refer to “Operation”. 2. Is the heater output sized correctly for heat loss of the space. Has the space been enlarged? 3. Check thermostat circuit, 24v on terminals “R” and “W” on terminal strip. 4. Check air movement across heat exchanger. Check voltage and amps at the fan motor. Check gas input to ensure unit is not over fired. Check heat exchanger to ensure unit is not dirty. 5. Check orifice size, replace if undersized. 1. Refer to “Operation”. Check orifice size. If too big replace. 2. Check thermostat for operation, to ensure circuit open and closes. 3. Check wiring per diagram; check operation at the gas valve, look for a short in thermostat circuit. 1. Refer to wiring diagram. 2. Check grounding wires. 3. Replace. 1. Electrical short. 2. Improper ground. 3. Defective gas valve. 35 Table 9 - Tubular Propeller Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION R. Cold air is delivered during heater operation. 1. Incorrect manifold pressure or input. 1. Refer to “Operation”. S. High limit tripping. 1. Unit is over fired. 1. Burner orifice may be too large, verify and replace. 2. Check for proper voltage, ensure fan blade is correctly positioned 1/3 inside venturi. 3. Check operation of switch, did the switch open when unit is running or is the switch open during start-up. 4. Check for 24v on line side of the high limit. Constant voltage should be recorded if not control board is suspect. Check flash code. 2. Air flow is low. 3. Defective switch. 4. Defective control board. T. Power venter will not run. 1. Loose wiring or connections. 2. Motor overload is tripped or bad motor. 3. Bad control board. U. Power venter turns on and off during operation. 1. Power venter improperly wired. 2. Motor overload cycling or defective motor. 3. Defective control board. V. Power venter will not stop. 1. Power venter improperly wired. 2. Main burner did not light on call for heat. 3. Defective control board. 4. Loss of pressure. Pressure switch not made. 36 1. Check all wring in the power vent circuit to ensure good connection, including “Neutral”. 2. Check for 115v between motor leads and check amp draw of motor. Replace if needed. 3. Check for continuous 115v on terminal “CBM Blower” and neutral during call for heat. If not present and all checks are normal, replace. 1. Check power venter circuit per wiring diagram. 2. Check motor voltage and amp draw to motor name plate, replace if motor found defective. 3. Check for continuous 115v on terminal “CMB Blower” during call for heat, replace board if found defective. 1. Check power venter circuit per wiring diagram. 2. Heater is in lockout mode check flash code table for problem. 3. No flash codes present along with no call for heat, replace control board. 4. Check venting for blockage. Check tubing for blockage or hole. Check spud for blockage. Table 10A - Troubleshooting with LED Indicator Assistance for UT Control Board INDICATES LED STATUS Line voltage power can cause product damage, severe injury or death. Only a trained experienced service technician should perform this troubleshooting. 1. Check the system thermostat to make sure it is calling for heat. (Do not cycle the thermostat on and off at this time.) 2. Remove the access panel. Do not interrupt power to the control board by opening any electrically interlocked panels. 3. Observe the LED indicator on the control board (a green LED labeled “OK” indicates system faults); check and repair system as noted in the chart to the right. *NOTICE: Air flow proving switch and power venter hose barbs must be free of any dust or debris at all times. Periodically check these openings and/or if any problems occur. CHECK/REPAIR Slow Flash Control OK, no call for heat. Not Applicable Fast Flash Control OK, call for heat present. Not Applicable Steady Off Internal control fault, or no power. 1. Line voltage on terminals 120 and C on transformer. 2. Low voltage (24V) on terminals 24 and C on transformer. 3. 5 Amp fuse on circuit board. Steady On Control internal failure or bad ground. 1. Common side of transformer grounded to chassis. 2. Loose spark ignitor. 2 Flashes In lockout from failed ignitions or flame losses. 1. Gas supply off or gas supply pressure too low. 2. Flame sense rod contaminated or loose wire. 3. Gas valve switch is off or wires are not connected. 4. Broken or cracked porcelain on flame probe or spark ignitor. 3 Flashes Pressure Switch open with inducer on or closed with inducer off. 1. Obstructions or restrictions in appliance air intake or flue outlet are preventing proper combustion airflow. 2. Moisture or debris in tubing that connects pressure switch and draft inducer. 3. Airflow switch jumpered or miswired. 4 Flashes Limit or rollout switch is open. 1. Open manual reset rollout switch. 2. Gas pressure too high, over fire condition. 3. Incorrect airflow due to blockage or motor not operating. 5 Flashes Flame sensed while gas valve is off. 1. Flame probe miswired or shortened. 6 Flashes On-board microprocessors disagree. 1. Thermostat is interfering with control board. 37 Table 10B - Troubleshooting with LED Indicator Assistance for Honeywell Control Board STATUS PATTERN CHECK/REPAIR Short Flash Control powered (without call for Heat) Not Applicable Heartbeat Call for Heat: normal operations Not Applicable 2 Pressure Switch failed closed 1. Check pressure switch to see if open to start, if not replace switch. 2. Air flow switch jumpered. Remove jumper and check operation. 3 Pressure Switch failed open 1. Look for obstruction or restrictions in appliance air intake or flue outlet that are preventing proper combustion airflow. 2. Moisture or debris in tube that connects pressure switch and draft inducer. 3. Check spud on power venter housing. Make sure it is clear. 4 Limit circuit open 1. Open manual reset rollout switch. 2. Gas pressure is too high, over fired condition. 3. Incorrect airflow due to blockage or fan motor not operating. 5 Flame sensed out of sequence - flame still present 1. Flame probe miswired or shorted. 6+1 Softlockout: Failed to light in four ignition trials 1. Gas supply off or gas pressure too low. 2. Flame sense rod contaminated or loose wire. 3. Gas valve switch is off or wires are not connected. 4. Broken or cracked porcelain on spark ignitor allowing spark to jump to ground and not between end of probes. 6+2 Softlockout: Limit circuit opened during run (recycle counter at its maximum) 1. Open manual reset rollout switch. 2. Gas pressure too high, over fired condition causing high limit to open. 3. Incorrect airflow due to blockage or fan motor not operating. 6+3 Softlockout: Pressure Switch opened during run; did not reclose within 2 seconds (flame lost and recycle at its maximum) 1. Check pressure from drafter and see if it reads above set point on pressure switch. Replace bad pressure switch. 6+4 Softlockout: Flame failed during run (recycle at its maximum) 1. Check sensor wire and make sure it is connected properly. 6+5 Flame sensed while out of sequence and is now gone 7+1 Lockout: Bad fuse detected. 1. Check for short. If no short replace fuse and start unit. 2. If no short is found, check gas valve for possible over amp. condition. Replace gas valve. 7+2 Lockout: Low voltage on 24VAC input 1. Check transformer for proper voltage. Replace transformer if not correct. 7+4 Lockout: Flame Rod shorted to ground or there is a big leakage from flame rod to ground 1. Switch off power and check flame rod wiring. 7+5 Lockout: Gas Valve fault 1. Turn unit off and back on. If fault code flashes again check gas valve for problem. If problem found replace gas valve. 7+6 Lockout: Internal Hardware error detected 1. Reset board. If code flashes again replace board. 38 IDENTIFICATION OF PARTS RESIDENTIAL TUBULAR 30-120 MBH UNIT SIZES Item No. ItemDescription 39 1 Vestible Panel/Tube Assembly (Heat Exchanger) 2 Bracket/Gas Train 3 Manifold 4 Burner Assembly 5 *Standard Orifice Natural Gas or Propane (LP) Gas 6 Spark Ignitor 7 Flame Sensor 8 Gas Valve Natural or Propane (LP) Gas 9 Manual Rollout Safety Switch 10 Transformer, 50 VA, 115/24 11 Air Pressure Switch 12 Terminal Block Plate 13 High Limit Switch 14 Fan Motor 15 OSHA Fan Guard 16 Standard Fan 17 Fan/Guard/Motor Mount Hardware Kit 18 **Flue Collector 19 Power Venter (Drafter) Assembly 20 Flue Collar Assembly 21 Vinyl Tubing (Pressure Switch) 22 Power Venter Mounting Plate 23 Louver 24 Louver Spring 25 Control Board 26 Access Panel 27 Top Jacket Panel w/Insulation 28 Bottom Jacket Panel w/Insulation 29 Front Jacket Panel 30 Rear Jacket Panel 31 Bracket, Manifold 32 Tube Support Bracket 33 Green Ground Screw 34 Hanger Bracket 35 Manifold Clamp 36 Pipe Nipple 37 Left Side Panel 38 Manifold Support Bracket Kit 39 Spring 40 Grommet 41 Inlet Screen Assembly 42 Burner Box View Port *** The orifice shown are for units operating at normal altitudes of 0 to 2000 ft. (610m). *** When replacing a flue collector, make sure that the flue collector box is sealed completely with factory supplied gasket. IDENTIFICATION OF PARTS RESIDENTIAL TUBULAR 30-120 MBH UNIT SIZES Figure 26 - Propeller Parts Figure 27 - Component Parts Fan Blade Fan Guard Motor Hardware D03339 D03339 Hardware Pressure Switch D4430 NOTE: No rubber grommets are supplied with the 30 and 45 unit sizes. D6963 Gas Valve Figure 28 - Internal Furnace Components Figure 29 - Power Ventor Assembly D4810 40 HOW TO ORDER REPLACEMENT PARTS Please send the following information to your local representative: if further assistance is needed, contact the manufacturer's customer service department. •Model Number •Serial Number •Part Description and Number as shown in Replacement parts Catalog LIMITED WARRANTY Residential Power Vented Tubular Propeller Unit Heaters 1. The "Manufacturer" warrants to the original owner at original installation site that the above model Gas-Fired Heater ("the Product") will be free from defects in material or workmanship for (1) year from the date of shipment from the factory, or one and one-half (1-1/2) years from the date of manufacture, whichever occurs first. The Manufacturer further warrants that the complete heat exchanger, flue collector and burners be free from defects in material or workmanship for a period of ten (10) years from the date of manufacture. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective. 2. This limited warranty does not apply: a. if the product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has not been installed, maintained, or operated in accordance with furnished written instructions, or has been altered or modified in any way by any unauthorized person. b. to any expenses, including labor or material, incurred during removal or reinstallation of the Product c. to any damage due to corrosion by chemicals, including halogenated hydrocarbons, precipitated in the air d. to any workmanship of the installer of the Product 3. This limited warranty is conditional upon: a. advising the installing contractor, who in turn notify the distributor or manufacturer b. shipment to the Manufacturer of that part of the Product thought to be defective. Goods can only be returned with prior written approval of the Manufacturer. All returns must be freight prepaid. c. determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship 4. Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period. 5. THIS LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES, EITHER EXPRESS OR IMPLIED, AND ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY JURISDICTION. In the interest of product improvement, we reserve the right to make changes without notice. 41 Low Profile Tubular Gas-Fired Unit Heater Model Number Description Digit G X Item X X — 1 Prefix 2 UT 3 4 5 CA 6 7 8 9 10 11 12 13 14 15 + FT FM GT AL GC SV MT DL AS (Internal use Only) 1, 2 - Unit Type [UT] 11 - Supply Voltage [SV] GG - Residential Tubular Propeller UH 1 - 115/1/60 4 - 208/3/60 7 - 575/3/60 2 - 208/1/60 5 - 230/3/60 Z - Other 3 - 230/1/60 6 - 460/3/60 Note: Supply Voltage [SV] 2 thru 7 includes a field mounted step down transformer. 3, 4, 5 - Capacity [CA] 030 - 30,000 BTU/HR 045 - 45,000 BTU/HR 060 - 60,000 BTU/HR 075 - 75,000 BTU/HR 090 - 90,000 BTU/HR 105 - 105,000 BTU/HR 120 - 120,000 BTU/HR 12 - Motor Type [MT] 1 - Open Drip Proof (Standard) 2 - Totally Enclosed [Capacities 060 through 120 Only] 13 - Development Level [DL] 6 - Furnace Type [FT] A - Revision Level - Production Onset A - Right Hand Access 14, 15 + - Accessories [AS] 7 - Furnace Material [FM] FACTORY INSTALLED S3 - Stainless Steel Flue Collector Z1 - Special 1 - Aluminized Steel (Standard) 2 - 409 Stainless Steel 8 - Gas Type [GT] FIELD INSTALLED (AS-____) A7 - Pressure Regulator (1/2 - 2 psi) N - Natural Gas P - Propane (LP) Gas G1 - 1 Stage 87K Mercury Free Thermostat G2 - 1 Stage 87K Mercury Free Thermostat w/TG511A Guard Kit G3 - 1 Stage T834N Mercury Free Thermostat/Fan Switch G5 - 2 Stage TH5220D Mercury Free Thermostat w/Subbase G6 - Locking Thermostat Cover G8 - 1 Stage T6169C Line Voltage Thermostat w/Subbase G9 - 1 Stage T822K Mercury Free Thermostat 9 - Altitude [AL] P - Canadian Hi-Alt. 2000-4500 Ft. S - 0-4999 Ft. T - 5000-11,999 Ft. Note: Unit installations over 2000 ft. require gas input deration in the field. Refer to unit installation instructions. P5 - 24V SPST Relay - Specify Purpose 10 - Gas Control [GC] A - Single Stage (Standard) B - Two Stage (CA = 060 through 120 Only) VC-4 - 4" Vent Cap VC-5 - 5" Vent Cap [Capacity 075-120 Category I Horizontal Vent Only] X7-4 - Concentric Vent Kit [Capacities 030-075) X7-5 - Concentric Vent Kit [Capacities 090-120] 42 GAS EQUIPMENT START-UP Customer ____________________________________ Job Name & Number _________________________ PRE-INSPECTION INFORMATION With power and gas off. Unit Heater Type of Equip: Serial Number _________________________ Model Number __________________________ Name Plate Voltage: _____________ Name Plate Amperage: _____________ Type of Gas: Natural Tank Capacity _______ lbs. _______ kg ❐ ❐ ❐ ❐ ❐ ❐ ❐ ❐ LP Are all panels, doors, vent caps in place? Has the unit suffered any external damage? Damage ______________________________ Does the gas piping and electric wiring appear to be installed in a professional manner? Has the gas and electric been inspected by the local authority having jurisdiction? Is the gas supply properly sized for the equipment? Were the installation instructions followed when the equipment was installed? Have all field installed controls been installed? Do you understand all the controls on this equipment? If not, contact your wholesaler or rep. (DO NOT START this equipment unless you fully understand the controls.) GAS HEATING With power and gas on. GENERAL With power and gas off. ❐ ❐ ❐ ❐ ❐ ❐ ❐ ❐ ❐ ❐ Make certain all packing has been removed. Tighten all electrical terminals and connections. Check all fans & blowers for free movement. Check all controls for proper settings. BLOWER With power on and gas off. ❐ ❐ ❐ ❐ ❐ Rating: ______ BTU @ ____ °F ______ kw @ ____ °C Inlet gas pressure. ____ in. W.C. or ____ kPa Burner ignition. Manifold gas pressure. ____ in. W.C. or ____ kPa Cycle on HIGH LIMIT. Cycle and check all other controls not listed. Cycle by thermostat or operating control. Check voltage L1 _____ L2 _____ L3 _____ Check rotation of main blower. Check motor amps L1 _____ L2 _____ L3 _____ Blower RPM _____________ Check air filters. (Record quantity & size.) _____________________________________________ __________________________________________________ __________________________________________________ Remarks: 43 HVAC PRODUCTS 260 NORTH ELM ST., WESTFIELD, MA 01085 TEL: (413) 564-5540 FAX: (413) 562-5311 www.sterlinghvac.com
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