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19130 59th Dr Ne_BLD821_2026
CITY OF ARLAGTON - ARLINGTON, WA. 98223 238 N. OLYMPIC AVE PHONE; (360) 403-3551 BUILDING PERMIT Address: 19130 59th Avenue NE Permit#: 821 Parcel#:2667632 Valuation: 9500.00 OWNER APPLICANT CONTRACTOR Name: GLOBAL MACHINE WORKS INC Name:Cozy Heating, Inc. Name:COZY HEATING Address: 19130 59TH DR NE Address:20221 67th Avenue NE Address:20221 67th Avenue NE City, State Zip:Arlington,WA 98223 City, State Zip:Arlington,WA 98223 City, State Zip:ARLINGTON, WA 98223 Phone: Phone: 360-435-4904 Phone:360-435-4904 MECHANICAL CONTRACTOR PLUMBING CONTRACTOR Name: Name: Address: Address: City, State,Zip: City, State,Zip: Phone: Phone: LIC#: EXP: LIC#: EXP: JOB DESCRIPTION PERMIT TYPE: Commercial Mechanical CODE YEAR: STORIES: CONST. TYPE: DWELLING UNITS: OCC GROUP: BUILDINGS: OCC LOAD: PERMIT APPROVAL I AGREE TO COMPLY WITH CITY AND STATE LAWS REGULATING CONSTRUCTION AND IN DOING THE WORK AUTHORIZED THEREBY;NO PERSON WILL BE EMPLOYED IN VIOLATION OF THE LABOR CODE OF THE STATE OF WASHINGTON RELATING TO WORKMEN'S COMPENSATION INSURANCE AND RCW 18.27. THIS APPLICATION IS NOT A PERMIT UNTIL SIGNED BY THE BUILDING OFFICIAL OR HIS/HER DEPUTY AND ALL FEES ARE PAID. IT IS UNLAWFUL TO USE OR OCCUPY A BUILDING OR STRUCTURE UNTIL A FINAL INSPECTION HAS BEEN MADE AND APPROVAL OR A CERTIFICATE OF OCCUPANCY HAS BEEN GRANTED. IBC1 IO/IRCI IO. SALES-TAX NOTICE:Sales tax relating to construction and construction materials in the City of Arlington must be reported on your sales tax return Form cod of A ' ton#3101. Signatu Print Name atc Releasell W Date CONDITIONS THIS PERMIT AUTHORIZS ONLY THE WORK NOTED.THIS PERMIT COVERS WORK TO BE DONE ON PRIVATE PROPERTY ONLY. ANY CONSTRUCTION ON THE PUBLIC DOMAIN(CURBS, SIDEWALKS, DRIVEWAYS, MARQUEES, ETC.)WILL REQUIRE SEPARATE PERMISSION. PERMIT FEES Date Description Fee Amount 10/23/2015 Gas Outlets Base Fee 1 to 5 $10.00 10/23/2015 Mechanical Fee(Enter Fixture Fee) $50.00 10/23/2015 Mechanical Permit Base Fee $25.00 10/23/2015 Mechanical Plan Review Fee $200.00 Total Due: $285.00 Total Payment: $285.00 Balance Due: $0.00 CALL FOR INSPECTIONS BUILDING(360)403-3417 When calling For an inspection please leave the following information: Permit Number,Type of inspection being requested, and whether you prefer morning or afternoon I •I ' CC ,4MERCIAL MECF 1%NICAL PRESSURE PIPING INFORMATION Department of Community& Economic Development City of Arlington -.18204 59th Ave NE -Arlington, WA 98223 • Phone (360)403-3551 If gas piping will be installed, this form is required in addition to a Commercial Mechanical Permit Application Pipe Material: Inlet Pressure: 5� i d 1A)C Pressure Drop: tAjC Specific Gravity: 0 Pressure Piping Schematic Show Pipe Size(s)and Length(s)from meter to all appliances. ❑ Scale or ❑ Not to Scale NOTE: any interior pressure regulators CFI PY must indicated NOTE: drip legs/sediment traps are required at all appliances unless integrated in _ _ the listed BUILDING DEPARTMENT appliance APPROVED DATF_44�BY Received NO CHANGES AUTHORIZED w 2 UNLESS APPROVED BY THE ��/t 1 BUILDING INSPECTOR (� I hereby certify that the above information is correct and that the construction on, and the occupancy and the use of the above- described property will be in accordance with the laws, rules and regulation of the State of Washington. Applicants Si ature c6z 1 Date Print A Ti4nts Name ZOTDZIJHA 710 YTIO TMBMTAA93a OV IUJIUS (033VOS99A Ao CM*N4YUA OSOMAM 014 WT Ys 03 O99ge 883J Ml WO )3geW iDAlCJlUa i i 1 � ti o CL l � LLJ CO*) o OZ W W N f-F 2 � Z W om'V H of W w 0 o.� ci c9 CL a` G4 z CL �o O � Q NWT m � Z�m U o I w'� �' 1 �� 1 -u r w �. y. r '-n I-UDA & APD Series (12-14) "OBSOLETES Form 1-UDA(10-14) Installation / Operation Applies to: Standard Power Vent Unit Heaters: Model UDAP 0 Model APD Separated Combustion Unit Heaters: Model UDAS NOTE: Accessories referenced in this installation manual may not apply to all models. DES 1 9h "RO S 'CQS CERi!FE�I ** � _ qT p� �� Y CITY OF ARLINGTON eceived OFFICE COPSUILDING DEPARTMENT CT 2 0 2015 APPROVED WARNING : NO CHANGES AUTHORIZED UNLESS APPROVED BY THE BUILDING INSPECTOR FIRE OR EXPLOSION HAZAR - - - Failure to follow safety warnings exactly could result in serious injury, death, or property damage. Be sure to read and understand the installation, operation, and service instructions in this manual. Improper installation, adjustment, alteration, service, or maintenance can cause serious injury, death, or property damage. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — 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. • Leave the building immediately. • Immediately call your gas supplier from a phone remote from the building. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. — Installation and service must be performed by a qualified installer, service agency, or the gas supplier. Page 1 Table of Contents 1. General .......................................................2-4 7. Electrical Supply and Wiring ................16-22 1.1 Hazard Labels and Notices............................2 7.1 General .......................................................... 16 1.2 General Installation Information....................3 7.2 Supply Wiring................................................ 17 1.3 warranty ..........................................................4 7.3 24V Control Wiring Connections.................17 1.4 Installation Codes...........................................4 7.4 Wiring Diagrams...........................................18 2. Unit Heater Location.............................. 4-6 7.5 Electrical Operating Components...............21 2.1 Heater Throw ..................................................4 8. Controls and Operation.........................22-26 2.2 Location Recommendations..........................5 8.1 Thermostat....................................................22 3. Uncrating and Preparation........................6-7 8.2 DDC Controls, Options D10 and D14..........23 3.1 Uncrating and Inspecting. .............................6 8.3 Ignition System.............................................24 3.2 Preparing for Installation...............................6 9. Commissioning and Startup.................27-28 4. Clearances and Dimensions ....................7-9 9.1 Check the installation prior to startup:.......27 9.2 Heater Startup:..............................................27 4.1 Clearances.......................................................7 9.3 Check installation after startup: 28 4.2 Dimensions .....................................................8 p:.................. 5. Hanging the Heater................................ 10-11 10. Maintenance and Service....................29-36 5.1 Weights.......................................................... 10 10.1 Maintenance Schedule...............................30 5.2 Liftingand Suspending 10 10.2 Maintenance Procedures...........................31 p g................................ 10.3 Troubleshooting ........................................36 6. Mechanical ............................................. 11-16 APPENDIX ....................................................... 38 6.1 Gas Piping and Pressures............................11 Index ................................................................ 39 6.2 Combustion Air-Standard Power Vent and Standard Power Vent with CV Option Models 16 "RINSTALLATION RECORD ..............................40 1.0 General 1"I W42ard labels and Notices There are warning labels on the unit and throughout this manual. For your safety, read the definitions-below and comply with all boxes labeled CAUTION, WARNING, and DANK r� rirtg installation, operation, maintenance, and service of this heater. Definitions of Hazard Intensity Levels in this Manual HAZARD INTENSITY LEVELS 1. DANGER: Failure to comply will result in severe personal injury or death and/or property damage. 2. WARNING: Failure to comply could result in severe personal injury or death and/or property damage. 3. CAUTION: Failure to comply could result in minor personal injury and/or property damage. now"i . - Gas-fired appliances are not designed for use in hazardous atmospheres containing flammable vapors or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in applications with airborne silicone substances. See Hazard Levels, above. . - Should overheating occur, or the gas supply control system fail to shut off the flow of gas, shut off the manual gas valve to the utility heater before shutting off the electrical supply. Page 2 I DO 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 that has been under water. Unit heaters should not be installed in an environment where the ambient temperature is below 50°F. The low space tem- perature may result in condensate forming in the heat ex- changer. 1.2 General 1.2.1 Certification Installation Models 30, 45, 60, 75, 100, and 125 are design certified by the Canadian Standards Information Association for use in residential, industrial, and commercial installations. Utility heat- ers certified for"residential use" are intended for heating of non-living spaces that are attached to, or part of a structure that contains space for family living quarters.They are BOTH this manual not intended to be the primary source of heat in residential applications or to be used and the correct in sleeping quarters. venting manual Models 150, 175, 200, 225,250, 300, 350, and 400 are design certified by the Canadian are REQUIRED for Standards Association for use in industrial and commercial installations only. installation of this All models and sizes are available for use with either natural or propane gas. The type of gas, the gas input rate, and the electrical supply requirement are shown on the heater. heater rating plate. Check the rating plate to verify that the heater is appropriate for the installation site. 1.2.2 Venting Manual Installation requires both this manual AND the venting manual. Venting Manual by Venting Instruction Manual by Look for Matching Label on Model Form No. Venting Manual and Heater Form 1-UD-V-PV, Label with a RED SQUARE Standard Power Vent Installation ' (Each heater has its own dedicated vent.) Form 1-UD-V-CV Label with a BLUE TRIANGLE (Sizes 30, 45, 60, 75 & 100 only) Common Vent Installation (with Option AV6.) Form 1-UD-V-SC, Label with a GREEN CIRCLE, Separated Combustion (with field installed Option CC2, CC6, or CC14 Vent/Combustion Air Kit) Both this installation manual and the appropriate venting manual are shipped with the heater.Verify that the literature is correct for the heater being installed. If either manual is missing or incorrect, contact your distributor before beginning installation. The instructions in this manual apply only to the models listed. Installation should be done by a qualified agency in accordance with these instructions. The qualified service agency installing this heater is responsible for the installation. Page 3 1.0 General 1.3 Warranty (cont'd) Refer to the limited warranty information on the Warranty Card in the"Literature Bag". Warranty is void if... a. Wiring is not in accordance with the diagram furnished with the heater. b. The unit is installed without proper clearance to combustible materials. c. A fan model is connected to a duct system or if the air delivery system is modified. 1.4 Installation These units must be installed in accordance with local building codes. In the absence of Codes local codes, in the United States,the unit must be installed in accordance with the National Fuel Gas Code,ANSI Z223.1.A Canadian installation must be in accordance with the CSA B149 Installation Codes.These codes are available from CSA Information Services, 1-800- 463-6727. Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements. Special Installations Installations in aircraft hangars should be in accordance with ANSI/NFPA No. 409 (latest (Aircraft Hangars/ edition),Standard for Aircraft Hangars; in public garages in accordance with ANSI/NFPA No. Repair Garages/ 88A(latest edition), Standard for Parking Structures; and for repair garages in accordance Parking Garages) with ANSI/NFPA No. 88B (latest edition), Standard for Repair Garages. In Canada, instal- lations in aircraft hangars should be in accordance with the requirements of the enforcing authorities, and in public garages in accordance with CSA B149 codes. California Warning If the heater is being installed in the state of California, the installer MUST attach a warning Label label on the outside of the access door.The California Warning label is shipped in the litera- ture bag along with this manual, the warranty form, and any other paperwork that applies. If installation is in California, select a location on the heater access panel. Be sure the sur- face is clean and dry and adhere the label. Massachusetts If the heater is being installed in the Commonwealth of Massachusetts,these units must be Requirement installed by a licensed plumber or licensed gas fitter. 2.0 Unit Heater Use the sound data in Technical Data table in the APPENDIX (page 38), clearances Location in Paragraph 4.1; the combustion air requirements in Paragraph 6.2; the throw tables, mounting height requirements, and location recommendations in Paragraphs 2.1 and 2.2; the weights in Paragraph 5.1; and the venting requirements in the Venting Manual to determine where to suspend the heater. Unit heaters should not be used in an application where the heated space temperature is below 50°F. Operating under low ambient conditions may cause condensation to form in the heat exchanger. 2.1 Heater Throw *Louver angle listed in the table is relative to the top of the heater. FIGURE 1 -Throw for Fan Models H \ X Y Z** H=Distance from bottom of heater to the floor X=Distance from heater to start of floor coverage Y=Distance to end of floor coverage **Z=point when the air velocity drops below 50 ft(15.2M)per minute NOTE: Throws listed are with standard adjustable horizontal louvers at the angles listed (angle is relative to the top of the heater). Throw pattern changes with the addi- tion of optional vertical louvers and/or downturn nozzles. Page 4 Dimensions X,Y.and Z(feet)Models with Standard Horizontal Louvers at Mounting Heights of 5-18 ft 30 45 60 75 100 125 H `m 0 `w. `w v X Y Z o' X Y Z o X Y Z o X Y Z o W X Y Z o X Y Z o c J Q J Q J Q J Q J Q J Q 5ft 6 14 30 -21° 7 16 40 -200 8 18 45 -160 9 20 57 -14° 9 20 59 -18° 10 22 65 -14- 8 ft 7 13 26 -39° 9 16 37 -34° 10 18 42 -29° 12 22 54 -25° 11 21 56 -28° 12 23 63 -24° 10ft 6 11 22 -52° 9 15 33 -43° 10 17 39 -37° 12 22 52 -32° 12 20 52 -36° 13 24 60 -30° 12ft 8 12 27 -550 10 16 34 -460 12 21 46 -390 11 19 47 -440 14 23 57 -36° 14 ft - 9 14 29 -56. 12 19 44 -46° 11 17 42 -51° 14 22 53 P57- 16 ft 11 17 38 -540 10 14 34 -58° 13 20 47 18 ft 11 17 40 150 175 200 225 250 300 350 400 H `wy `wc X Y Z o X Y Z 'o X Y Z o' X Y 2 'o X Y Z 'o X Y Z o' X Y Z o X Y Z o c J Q J Q J Q J Q J Q J Q J Q J Q 8 ft 13 24 73 1-26° 15 28 90 1-22° 16 30 93 1-20° 14 27 86 -24° 16 29 93 -21- 15 28 1 94 -24° 17 1 31 1 105 -20° 18 34 1 113 1-17° 10 ft 14 24 69 -320 17 29 87 -27° 17 31 91 -25° 15 27 82 -30° 17 30 90 -26° 16 28 89 L-40o 18 32 103 -25° 20 35 110 -21' 12ft 14 24 64 -390 18 29 84 -320 18 31 88 -300 16 27 78 -350 18 30 87 -310 17 28 85 19 32 98 -300 21 36 108 -25° 14 ft 14 22 59 -45° 18 28 79 -37° 19 30 84 -340 16 26 73 -41° 18 30 83 -36° 17 27 80 20 32 95 -34° 23 35 105 -29° 16ft 13 20 53 -51° 18 27 74 -42° 19 29 79 -39° 16 24 67 -47° 19 28 78 -41° 17 25 74 21 31 90 -3B° 23 35 101 -33° 1Bft 11 17 44 -58° 17 26 68 -48° 19 28 74 -44° 14 22 60 -53° 18 27 72 -46° 16 24 66 20 30 85 -430 23 35 97 -370 Dimensions X,Y,and Z(meters)Models with Standard Horizontal Louvers at Mounting Heights of 1.5-5.5M 30 45 60 75 100 125 H a d a d w m a s `w d `m a >- >- >- >- >- >- X Y Z o' X Y Z a X Y Z o X Y Z o X Y Z o W X Y Z o c J Q J Q J Q J Q J Q J Q 1 5 M 1 8 43 91 -21' 21 49 122 -20° 24 55 13.8 -16° 27 6.1 11741 14° 27 61 18.0 -18° 3.0 671 19.9 -14- 2 4 M 21 4 0 7 9 -390 27 49 11 3 -340 30 55 12.6 -29° 37 67 165 -25° 34 64 171 -28° 37 701 192 1-24' 3 0 M 1.8 34 67 -52° 27 46 100 -43° 30 52 11 9 -37° 37 67 15.8 -32° 37 61 15.8 -36° 4 0 7 3 18.3 -30° 37M 24137 8.2 -55° 30 49 104 -46° 37 64 146 -39° 34 5.8 143 -44° 43 70 174 -36° 4 3 M 27 4 3 8.8 -56° 37 58 134 -460 3.4 52 12.8 -51° 4 3 67 16-1 -43° 4 9 M 34 52 11 6 -54° 30 4 3 104 -580 4 0 61 143 -500 5 5 M 1 134 5.2 12.2 -57° 150 175 200 1111 25 111 50 1 300 350 400 H >- >- >- >- >- >- >- >- X Y Z o X Y Z o X Y Z o X Y Z o X Y Z o X Y Z o X Y Z o 0 X Y Z o c J Q J 1 J Q J Q J Q J Q 2 4 M 4 0 73 223 -26° 46 8.5 27.4 -220 4.9 91 28.0 -200 4.3 82 262 -240 49 8,8 28.3 -21° 46 8.5 28.7 -24° 52 94 1320 -20° 55 11 3 344 -17- 3 0 M 4 3 73 210 -320 52 8.8 266 -270 52 94 277 -25° 46 8.2 250 -30° 52 91 274 -26° 49 8.5 27 1 -29° 55 981314 -25° 61 107 335 -21- 3 7 M 43 7 3 195 -39° 55 8.8 256 -320 55 94 268 -300 49 8 2 23.8 -350 5.5 91 265 -310 52 8.5 259 -34° 5.8 9.8 29 9 -30° 64 11 0 329 -25° 4 3 M 43 67 18.0 -45° 55 8 5 24 1 -37° 5.8 91 2561-34°149 7 9 2231-41° 5.5 q82 25.3 -36° 52 8.2 244 -40° 61 9.8 29.0 -340 7 0110 7 32 0 -29° 4 9 M 4 0 6 1 11621-51- 55 8.212261-42° 5.8 8 8124 1 -39° 4 9 7 3 20 4 -47° 5.8 23 B -41° 521761 226 -45°164 94 274 -38° 7 0110 7130.8 -33° 5 5 M 3 4 5 2 13 4 -58° 52 17912071-48°15.818.5122 6 -44°1431 67118.31-53° 55 21 9 -46° 1 4 9 7 3 1 20.1 -51° 6 1 9 1 12591-43° 7 0110.7126 9 -37° 2.2 Location Recommendations NOTE: Venting Locate the heater so that it is a minimum of five feet (1.5M) above the floor and in requirements may compliance with the clearances in Paragraph 4.1. affect location. Consult the Venting Manual for this heater If touched, the vent pipe and internal heater surfaces that are before making final accessible from outside the heater will cause burns. Suspend the determination. heater a minimum of 5 feet (1.5M) above the floor. For best results, the heater should be placed with certain rules in mind. In general, a unit should be located from 8 to 12 feet(2.4-3.7M)above the floor. Units should always be arranged to blow toward or along exposed wall surfaces, if possible. Where two or more units are installed in the same room, a general scheme of air circulation should be maintained for best results. Suspended heaters are most effective when located as close to the working zone as possible, and this fact should be kept in mind when determining the mounting heights to be used. However, care should be exercised to avoid directing the discharged air directly on the room occupants. Partitions, columns, counters, or other obstructions should be taken into consideration when locating the unit heater so that a minimum quantity of airflow will be deflected by such obstacles. Page 5 2.0 Unit Heater Whe,, units are located in the center of the space to be heated, the air should be dis- Location charged toward the exposed walls. In large areas, units should be located to discharge (cont'd) air along exposed walls with extra units provided to discharge air in toward the center of the area. 2.2 Location At those points where infiltration of cold air is excessive, such as at entrance doors and shipping doors, it is desirable to locate the unit so that it will discharge directly toward Recommendations the source of cold air from a distance of 15 to 20 feet(4.6-6.1 M). (cont'd) CAUTION: Do not locate the heater where it may be exposed to water spray, rain, or dripping water. For a location where dirt, dust, or other airborne contaminants are present in the indoor environment, it is recommended to install a separated-combustion unit, Separated Combustion model,that uses outside airfor combustion. Using a separated-combustion unit will reduce the build-up of contaminants on the burner. Any buildup on the burner will adversely affect the combustion process. Hazards of Chlorine - The presence of chlorine vapors in the combustion air of gas-fired heating equipment applies to Separated presents a potential corrosion hazard. Chlorine found usually in the form of freon or Combustion Heaters degreaser vapors, when exposed to flame will precipitate from the compound, and go location with regard to into solution with any condensation that is present in the heat exchanger or associated parts.The result is hydrochloric acid which readily attacks all metals including 300 grade the combustion air inlet stainless steel. Care should be taken to separate these vapors from the combustion process. This may be done by wise location of the unit vent and combustion air terminals with regard to exhausters or prevailing wind directions. Chlorine is heavier than air. Keep these facts in mind when determining installation location of the heater in relation to building exhaust systems. 3.0 Uncrating and 3.1 Uncrating and Inspecting Preparation This unit was test operated and inspected at the factory prior to crating and was in operating condition. If the heater has incurred any damage in shipment, document the damage with the transporting agency and contact an authorized Distributor. If you are an authorized Distributor, follow the FOB freight policy procedures. Check the rating plate for the gas specifications and electrical characteristics of the heater to be sure that they are compatible with the gas and electric supplies at the installation site. 3.2 Preparing for Read this booklet and become familiar with the installation requirements of your par- Installation ticular heater. If you do not have knowledge of local requirements, check with the local gas company or any other local agencies who might have requirements concerning this installation. Before beginning, make preparations for necessary supplies, tools, and manpower. IMPORTANT: Shipping brackets are attached with cabinet screws.When remov- ing shipping brackets, re-insert ALL screws into the cabinet. 3.2.1 Field-Installed Models with Separated Combustion - In the literature bag, find three cap screws, P/N Parts 203311, and three sealing washers, P/N 61658.After attaching the hanging hardware (Paragraph 5.2), these screws and washers must be used to seal the unused holes in the top of the heater. Models with Standard Power Vent- If the installation includes optional vertical louvers, downturn nozzle, ceiling mounting bracket, hanger kit, high altitude kit, multiple heater control, sensor for DDC control, and/or stepdown transformer, install these options before the heater is suspended. Complete instructions are in this form or in the option package; option packages are shipped separately. Other shipped separate items could include a vent cap (Standard Power Vent heaters with Option CC1); a vent/combustion air kit (Separated Combustion heaters with Option CC2 or CC6); a manual gas valve; a thermostat bracket kit; a thermostat; and/ or a thermostat guard. Be sure all options ordered are at the installation site. High Altitude Kit, Option DJ20 or DJ21 If the heater is being installed at an elevation above 2000 ft (610M), the input rate will have to be derated. This is done by adjusting the valve outlet pressure. Page 6 _1 In addition, if the heater is being installed at ai, altitude above 6000 ft (1830M), the pressure switch will have to be changed. If ordered with the unit as Option DJ20 or DJ21, the pressure switch is shipped separately for field installation. Gas valve adjustment Adjusting the valve outlet pressure is done after the heater is in operation; follow the for high altitude can instructions in Paragraph 6.1. Capacities and inputs for derated units are also listed in only be done after Paragraph 6.1. heater is operating; If the pressure switch needs to be changed, do that before the heater is operated; fol- see Paragraph 6.1. low the instructions in FIGURE 2. FIGURE 2 - Standard Power Vent Models Installing High Size 30 1 45 60 1 75 1 100 125 150 175 200 F225 F25OT30013501400 Altitude Pressure High Altitude Switch P/N 197031 197032 197031 201160 Switch required Negative Pressure OFF Setpoint Wc. 035 045 035 1 05 above 6000 ft Label color Purple Pink Purple Brown Standard Power Vent Models with Option AV6 for Common Venting (1830M) elevation Size 1 30 45 60 1 75 100 High Altitude Switch P/N 197029 197032 196362 196388 Negative Pressure OFF Setpoint"w.c. 060 045 0.55 050 {1 Label color Lt Blue Pink White Orange Separated Combustion Models Size 30 45 1 60 LTS 100 125 150 175 200 225 250 300 350 400 High Altitude Switch P/N 197029 196388 197030 197031 201160 Pressure Switch Differential Pressure OFF Setpoint"w c. 060 050 040 035 1 05 Label color Lt Blue Orange Green Purple Brown Instructions for Changing Pressure Switch 1. In the control compartment, locate the pressure switch 2. Mark and disconnect the two wires attached to the pressure switch. 3. Disconnect the sensing tubes from the pressure switch. 4. Locate the two screws holding the switch mounting bracket. Remove the screws and the pressure switch. Save the screws. 5. Using the same screws, install the high altitude pressure switch. Attach the sensing tubes and wires. Downturn Nozzle Kits, Follow the instructions with the kit to install.Additional length beyond the front of the Option CD 2, 3, or 4 unit is shown in FIGURE 3. (Does not apply to Model APD) Downturn nozzles require O tions CD2 and CD4 O tion CD3 FIGURE 3 - 4-pt suspension. Size p p With Optional (n inches mm inches mm Downturn Nozzle c With_----- �' 30,45 7-1/8 181 12-3/8 314 Op tion;' Q Dimension "U" `z CD2 ! With 60,75 8-5/8 219 15 381 tio --Applies to Standard a CD4% a oCD3n 100, 125 12-5/8 321 21-7/8 556 Power Vent(except APD) c a / &Separated Combustion / 150, 175,200 11-1/2 292 19-7/8 505 Models - 225,250 14-1/2 368 25-1/8 638 ��V-' U 300,350,400 18-1/2 470 32 813 4.0 Clearances 4.1 Clearances and Units must be installed so that the clearances in the table are provided for combustion Dimensions air space, inspection and service, and for proper spacing from combustible construc- tion. Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface temperature of 90OF Clearances (50°C) above the surrounding ambient temperature is not exceeded. Size Top Flue Connector Access Panel Non-Access Side Bottom* Rear** inches mm inches mm inches mm inches mm inches mm inches mm 30 - 125 1 25 6 152 18 457 1 25 1 25 18 457 150 -400 1 4 102 6 152 18 457 2 51 1 25 18 457 *Suspend the heater so that the bottom is a minimum of 5 feet(1.5M) above the floor. ** Measure rear clearance from the fan motor. Page 7 4.0 Clearances and Dims-,IIlsions (cont'd) 4.2 Dimensions FIGURE 4 -Standard Power Vent Models N M M and N-Hanger Dimensions for both 2-pt and 4-pt Suspension R-Hanger Dimension for 2-pt Suspension P and Q- Combustion Hanger P Dimensions Air Inlet for 4-pt— R Suspension Thermostat REAR (4-pt is TOP VIEW Connection VIEW required if r (30-125 Vertical, installing 150-400 Horizontal) opnozzle.)tional Q 3/8"-16 Female Thread -all suspension points G � Angular corner l on UDA.Series . Line Voltage 9 K External Vent Collar(For Inlet(connects H Gas size,see Technical at circuit board) Connection Data in the APPENDIX on page 38) B E D F ' (32) FRONT RIGHT SIDE VIEW VIEW A C (Access Panel) Hand Pull-UDA Series ONLY�Q O O "Finger Holes"-APD Series ONLY Standard Power Vent Model Dimensions(inches± 1/16) Size A B C D E F G H J K M N P Q R 30,45 12-1/8 26-5/8 10 13-13/16 26 21-9/16 5-3/16 6-1/2 2-11/16 3-7/8 17-3/8 11/16 4-5/16 13 9-9/16 60 15-1/8 26-5/8 13 13-13/16 27 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 75 15-1/8 26-5/8 13 13-13/16 27-5/8 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 100 23-1/8 26-5/8 21 13-13/16 28-5/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 125 23-1/8 26-5/8 21 13-13/16 29-3/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 150,175,200 20-1/8 38-3/16 16 23 42 35-3/8 8-1/2 8-1/4 5-7/16 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 16-3/8 225,250 26-1/8 38-3/16 22 23 42 35-3/8 13-1/16 8-13116 9 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 15-5/8 300,350,400 34-1/8 41 30 23 42 35-3/8 17-1/16 9 11-13/16 7-5/16 27-11/16 1-3/8 8-3/16 22-3/16 16-3/16 Standard Power Vent Model Dimensions (mm ±2) Size A B C D E F I G H J K M N P Q R 30,45 308 676 254 351 660 548 132 165 68 98 441 17 110 330 243 60 384 676 330 351 686 548 200 165 140 98 441 17 110 330 267 75 384 676 330 351 702 548 200 165 140 98 441 17 110 330 267 100 587 676 533 351 727 548 368 165 222 98 441 17 110 330 267 125 587 676 533 351 746 548 368 165 222 98 441 17 110 330 267 150,175,200 511 970 406 584 1067 899 216 210 138 165 652 35 208 564 416 225,250 664 970 559 584 1067 899 332 224 229 165 652 35 208 564 397 300,350,400 867 1041 762 584 1067 899 433 229 300 186 703 35 208 564 411 Page 8 FIGURE 5 - Separated Combustion Models N M - M and N-Hanger Dimensions for both 2-pt and 4-pt Suspension F-1 R-Hanger Dimension for Combustion Air Connection 2-pt Suspension (For size,see Technical Data in the APPENDIX on page 38.) PandQ- P I-T• Hanger Dimensions— R Thermostat S for 4-pt Connection � REAR Suspension TOP VIEW (30-45,150-40o VIEW (4-pt Is {, Horizontal, required if 60-125 Vertical) installing Q 3/8"-16 Female Thread i optional _all suspension points nozzle.) G J Line Voltage K External Vent Connection Inlet(connects in H Gas (For size,see sealed electrical box) Connection the in e APPENDIX B E on page 38.) ' D 1-1/4 L F - -i (32) e RIGHT SIDE VIEW A C Bi- FRONT (Access Panel) VIEW i LED Viewport Separated Combustion Model Dimensions(inches±1116) Size A B C D E F G H J K M N P Q R S T 30,45 12-1/8 26-5/8 10 13-13/16 26 21-9/16 5-3/16 6-1/2 2-11/16 3-7/8 17-3/8 11/16 4-5/16 13 9-9/16 2-15/16 2-15/16 60 15-1/8 26-5/8 13 13-13/16 27 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 3-1/4 2-15/16 75 15-1/8 26-5/8 13 13-13/16 27-5/8 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 3-1/4 2-15/16 100 23-1/8 26-5/8 21 13-13/16 28-5/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11116 4-5/16 13 10-1/2 4-5/8 2-15/16 125 23-1/8 26-5/8 21 13-13/16 29-3/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 4-5/8 2-15/16 150,175,200 20-1/8 38-3/16 16 23 42 35-3/8 8-1/2 8-1/4 5-7/16 6-1/2 25-11/16 1-3l8 8-3/16 22-3/16 16-3/8 4-1/8 8-5/16 225,250 26-1/8 38-3/16 22 23 42 35-3/8 13-1/16 8-13/16 9 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 15-5/8 5 9/16 8-5/16 300,350,400 34-1/8 41 30 23 42 35-3/8 17-1/16 9 11-13/16 7-5/16 27-11/16 1-3/8 8-3/16 22-3/16 16-3/16 9-1/16 8-9116 Separated Combustion Model Dimensions(mm±2) Size A B C D E F G H J K M N P I Q R S T 30,45 308 676 254 351 660 548 132 165 68 98 441 17 110 330 243 75 75 60 384 676 330 351 686 548 200 165 140 98 441 17 110 330 267 89 75 75 384 676 330 351 702 548 200 165 140 98 441 17 110 330 267 89 75 100 587 676 533 351 727 548 368 165 222 98 441 17 110 330 267 117 75 125 587 676 533 351 746 548 368 165 222 98 441 17 110 330 267 117 75 150,175,200 511 970 406 584 1067 899 216 210 138 165 652 35 208 564 416 105 211 225,250 664 970 559 584 1067 899 332 224 229 165 652 35 208 564 397 141 211 300,360,400 867 1041 762 584 1067 899 1 433 229 300 186 703 35 208 564 411 230 217 Page 9 5.0 Hanging the 5.1 Weights Heater Before suspending the heater, check the supporting structure to be used to verify that it has sufficient load-carrying capacity to support the weight of the unit. Standard Power Vent Model Size 1 30 1 45 1 60 1 75 1 100 1 125 1 150 1175, 200 225 250 300 1 350 1 400 Ibs 54 59 1 67 1 72 96 101 172 187 203 215 269 294 306 kg 1 24 27 1 30 1 33 44 46 78 85 92 98 122 133 139 Separated Combustion Model Size 30 45 60 75 100 125 150 175, 200 225 250 300 350 400 Ibs 55 60 68 73 97 102 173 188 204 216 270 295 307 kg 25 27 31 33 44 46 78 85 93 98 122 134 138 WARNINGS Check the supporting structure to be used to verify that it has sufficient load carrying capacity to support the weight of the unit. Suspend the heater only from the threaded nut retainers or with a manufacturer provided kit. Do NOT suspend from the heater cabinet. 5.2 Lifting and Suspending When the heater is lifted for suspension, support the bottom of the heater with plywood or other appropriately placed material. If the bottom is not supported, damage could occur. Before hanging, verify that any screws used for holding shipping brackets were re-installed in the cabinet. Separated Combustion Models - Whether using the suspension points or a hanger kit, when installing a Separated Combustion Model, any unused suspension points on the control side of the heater MUST be plugged. Plug these holes with the 1/2" long cap screws and flat washers shipped in the bag with the heater. (See FIGURE 6.) FIGURE 6 -Separated Combustion Models Plug any unuse suspension points on the control side with the 1/2"long - Plug the unused _ = cap screws and flat washers provided suspension points on = the control side of the \ heater with the three J '� 1/2" long screws, P/N , 203311, and the three sealing washers, P/N Controj S%de 61658. Find the screws and washers in the literature bag shipped inside the heater. Unit must be level for proper operation. Do not place or add additional weight to the suspended heater. Hazard Levels, page 2. 5.2.1 Two-Point or Four-Point Suspension The heater is equipped for either two-point or four-point suspension.A 3/8"-16 threaded nut retainer is located at each suspension point. NOTE: Four-point suspension is required when installing an optional downturn nozzle. See Dimensions in Paragraph 4.2 and the illustration in FIGURE 7A. Page 10 FIGURE 7A - Be sure the threaded hanger rods are �, Suspending the locked to the heater as illustrated. Heater with Rods from Length of threaded rod extending into the Threaded Nut the heater MUST NOT exceed 1/2" Retainers (either two or (13mm). = 3/8"threaded rod four point suspension) (field supplied) Recommended Add a 3/8°° nut _ - and washerto maximum hanger lock the hanger rod length is rod to the heater. 6 feet (1.8M). 5.2.2 Hanger Kits, Option CK8, CK10, and CK22 If ordered with swivel connectors for 1" pipe, Option CK8 or CK10, attach the swivels at the threaded nut retainers. Suspend with 1" pipe. (See FIGURE 713.) FIGURE 7B - Swivel Be sure the Connectors to Suspend the Heater from 1 threaded swivel Lock the swivel " e, Option CK8 2- t connectors connector to Pipe, p ( p ) are locked to the heaterl or CK10 (4-pt) the heater as The connector{ is threaded for illustrated. hanging from a1" pipe. _- If ordered with a ceiling suspension kit, Option CK22, follow the illustrated instructions in the kit. (See FIGURE 8.) FIGURE 8 - Suspending I the Heater using Available for e Option CK22, Ceiling Sizes 30-125.Allows the Suspension Kit(no han er rods heater to be o e o o g ) installed one inch from the o a ceiling. • • UDA_Series Model Shown 6.0 Mechanical 6.1.1 Gas Supply and Connections 6.1 Gas Piping and ' Pressures This appliance is equipped for a maximum gas supply pressure of 1/2 psi,3.5 kPa, or 14 inches water column.Supply pressure greater than 1/2 psi requires installation of an additional lockup-type service regulator external to the unit. WARNING: PRESSURE TESTING SUPPLY PIPING Test Pressures Above 1/2 PSI: Disconnect the heater and manual valve from the gas supply line which is to be tested. Cap or plug the supply line. Test Pressures Below 1/2 PSI: Before testing, close the manual valve on the heater. Page 11 6.0 Mechanical 6.1 was Piping and Pressures (cont'd) (cont'd) 6.1.1 Gas Supply and Connections (cont'd) Sizing I Capacity of Piping Gas Cubic Feet per Hour based on 0.3"w.c.Pressure Drop Supply Specific Gravity for Natural Gas 0.6(Natural Gas--1000 BTU/Cubic Ft) Line Specific Gravity for Propane Gas--1.6(Propane Gas--2550 BTU/Cubic Ft) Length Diameter of Pipe of 1/2" 3/4" 1" 1-1/4" 1-1/2" 2'' Pipe Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane 20' 92 56 190 116 350 214 730 445 1100 671 2100 1281 30' 73 45 152 93 285 174 590 360 890 543 1650 1007 40' 63 38 130 79 245 149 500 305 760 464 1450 885 50' 56 34 115 70 215 131 440 268 670 409 1270 775 60' 50 31 105 64 195 119 400 244 610 372 1105 674 70' 46 28 96 59 180 110 370 226 560 342 1 1050 641 80' 43 26 90 55 170 104 350 214 1 530 323 990 604 90' 1 40 24 84 1 51 160 98 320 195 490 299 930 567 100, 38 23 79 1 48 150 92 305 186 460 281 870 531 125' 34 21 72 44 130 1 79 275 168 410 250 780 476 150' 31 19 64 39 120 73 250 153 380 232 710 433 175' 28 17 59 36 110 67 225 137 350 214 650 397 200' 26 16 55 34 100 61 210 128 1 320 195 1 610 372 Note:When sizing supply lines,consider possibilities of future expansion and increased requirements. Refer to National Fuel Gas Code for additional information on line sizing. All piping must be in accordance with requirements outlined in the National Fuel Gas Code ANSI/Z223.1a (latest edition) or CSA-B149.1 and B149.2 (See Paragraph 2). Gas supply piping installation should conform with good practice and with local codes. Support gas piping with pipe hangers, metal strapping, or other suitable material; do not rely on the heater to support the gas pipe. The heater is orificed for operation with natural gas having a heating value of 1000 (± 50) BTU per cubic ft or propane gas with a heating value of 2500 (± 100) BTU per cubic ft. If the gas at the installation does not meet these specifications, consult the factory for proper orificing. Pipe joint compounds (pipe dope) shall be resistant to the action of liquefied petroleum gas or any other chemical constituents of the gas being supplied. Install a ground joint union and manual shutoff valve upstream of the unit control sys- tem, as shown in FIGURE 9. Installation of a trap with a minimum 3" (76mm) drip leg is required. The unit is equipped with a nipple that extends outside the cabinet. The gas connection is either 1/2" or 3/4". Leak-test all connections by brushing on a leak-detecting solution. All components of a gas supply system must be leak tested prior to placing equipment in service. NEVER TEST FOR LEAKS WITH AN OPEN FLAME. Failure to comply could result in personal injury, property damage or death. Gas Connection Size Gas Connection inches Size Natural Propane 30 45. 60. 75. 100, 125. 150. 175. 200 1/2 112 225, 250, 300, 350, 400 3/4 3/4 Page 12 FIGURE 9 - Gas Ground Joint Union connection is at To Gas Valve- T `-Manual shutoff (inside thethe pipe nipple that cabinet)extends outside the From Gas Supply (horizontal or vertical) cabinet. +_ Pipe nipple extending outside the cabinet. Manual shutoff Illustration shows both a vertical and To Gas Valve (inside the +-c__ horizontal gas supply; cabinet) -� requirements are the Ground Drip Leg same. Union Measuring valve outlet gas pressure cannot be done until the heater is in operation. It 6.1.2 Valve Outlet is included in the steps of the"Check-Test-Start" procedure in Paragraph 9.The follow- or Orifice Pressure ing warnings and instructions apply. Setting Valve outlet gas pressure must never exceed 3.5" w.c. for natural gas NOTE: Gas Conversion and 10" w.c. for propane gas. Maximum inlet supply pressure for natu- Kits are available ral gas or propane is 14" w.c. Maximum gas pressure can never be for changing from exceded either during operation or static (lock up regulator). propane gas to natural For Natural Gas: When the heater leaves the factory, the combination gas valve is set gas or natural gas to so that the valve outlet gas pressure for a single-stage valve or high fire of a two-stage propane gas. A factory- valve is regulated to 3.5"w.c. Low fire on a two-stage valve is set to 1.8"w.c. Inlet sup- authorized conversion ply pressure to the valve for natural gas must be a minimum of 5" w.c. or as noted on the rating plate and a maximum of 14"w.c. kit MUST be used. For Propane Gas: When the heater leaves the factory, the combination gas valve is set so that the valve outlet gas pressure for a single-stage valve or high fire of a two- stage valve is regulated to 10" w.c. Low fire on a two-stage valve is set to 5.0" w.c. Inlet supply pressure to the valve for propane gas must be a minimum of 11"w.c. and a maximum of 14" w.c. Before attempting to measure or adjust valve outlet gas pressure, the inlet supply pressure must be within the specified range both when the heater is in operation and on standby. Incorrect inlet pressure could cause excessive valve outlet gas pressure immediately or at some future time. If natural gas supply pressure is too high, install a regulator in the supply line before it reaches the heater If natural gas supply pressure Check Valve Outlet is too low, contact your gas supplier. Pressure (can only be Instructions done after heater is NOTE: If operating at high altitude, outlet pressure requires adjustment. Follow operating) instructions on page 14. 1) Locate the 1/8" output pressure tap on the valve (See FIGURE 10). With the man- ual valve turned off to prevent flow to the gas valve, connect a manometer to the 1/8" pipe outlet pressure tap in the valve. NOTE: A manometer(fluid-filled gauge) FIGURE 10 -Top View of Valves showing Outlet Pressure Tap and Adjustment Locations Single-Stage Adjust Outlet 1/8" Outlet Two-Stage Valve Valve Pressure Tap Adjust Low (two styles) Pressure Adjust High Fire Outlet / Fire Outlet Pressure et ,� r� Pressure Inl Pressure Tap ` Vol'- ----- ----- --- - - --- ------ ------------- -- ------ V _ J 10- Adjust Outlet Pressure—�►, T Inlet � &- "' Pressure :-1/8" Outlet Tap 1/8" Outlet Inlet Pressure Tap ' i Pressure Tap Pressure Tap Page 13 6.0 Mechanical is ,acommended rather than a spring type gauge due to the difficulty of maintaining (cont'd) calibration of a spring type gauge. 2) Open the manual valve and operate the heater. (NOTE: On a Separated Combus- 6.1 Gas Piping tion Model, depress and hold the door safety switch.) Measure the outlet pressure and Pressures of the gas valve. To measure low-stage pressure on a unit equipped with a two- (cont'd) stage valve, disconnect the wire from the "HI" terminal on the valve. (Be sure to reconnect the wire.) 6.1.2 Valve Outlet Normally when operating at sea level, adjustments should not be necessary to the or Orifice Pressure factory setting. (For high altitude settings, see next paragraph.) Setting (cont'd) If adjustment is necessary, remove the cap from the adjustment screw(s). Set pressure to correct settings by turning the regulator screw IN (clockwise)to increase pressure. Turn regulator screw OUT(counterclockwise)to decrease pressure. CAUTION: DO NOT bottom out the gas valve regulator adjusting screw. This can result in unregulated manifold pressure causing excess overfire and heat exchanger failure. 6.1.3 Derate by Valve instructions for High Altitude Derate Outlet Pressure 1. Determine the required valve outlet pressure for the elevation where the heater will Adjustment for High be operating. If unsure of the elevation, contact the local gas supplier. Altitude Operation Valve Outlet Pressure Settings by Elevation Manifold Pressure Settings by Altitude for the UNITED STATES This adjustment Altitude Natural Gas(inches w.c.) Propane Gas(inches w.c.) can only be done Feet Meters Single-Stage and Two-Stage Single-Stage and Two-Stage Two-Stage High Fire Low Fire Two-Stage High Fire Low Fire after the heater is in 0-2000 0-610 3.5 1.8 10.0 50 operation. High altitude 2001-3000 611-915 3.1 1.6 1 8.8 4.4 adjustment is included 3001-4000 916-1220 3.0 1.5 8.5 42 in the startup Steps. 4001-5000 1221-1525 2.8 1.5 8.1 4.1 5001-6000 1526-1830 2.7 1.4 7.7 39 NOTE: If elevation is 6001-7000 1831-2135 2.6 1.3 7.4 3.7 above 6000 ft (1830M), 7001-8000 2136-2440 2.5 1.3 7.1 3.5 a high altitude pressure 8001-9000 2441-2745 2.4 1 1.2 1 6.7 3A switch is required; see 9001-10000 1 2746-3045 1 2.3 1 1.2 1 6.7 3.4 Paragraph 3.2.1. Manifold Pressure Settings by Altitude for CANADA Altitude Natural Gas(inches w.c.) Propane Gas(inches w.c.) Feet Meters Single-Stage and Two-Stage Single-Stage and Two-Stage Two-Stage High Fire Low Fire Two-Stage High Fire Low Fire 0-2000 0-610 3.5 1.8 10.0 5.0 2001-4500 611-1373 2.8 1.5 8.1 4.1 2. Locate the 1/8" output pressure tap on the valve (See FIGURE 10, page 13). Turn the knob or switch on the top of the valve to "OFF". Connect a manometer to the 1/8" pipe outlet pressure tap in the valve. Use a water column manometer that is readable to the nearest tenth of an inch 3. Single-Stacie and Two-Stage High Fire -Turn the knob or switch on the top of the valve to"ON". Remove the cap from the pressure adjusting screw and adjust the gas train pressure to the pressure selected from the table above.Adjust pressure by turning the regulator screw IN (clockwise) to increase pressure or OUT(counterclockwise) to decrease pressure. Two-Stage Low Fire - Disconnect the wire from the"HI"terminal on the gas valve and check the low fire pressure. Turn the regulator screw to adjust the low fire outlet pressure to the "Low Fire" pressure selected from the table. Re-connect the wire to the gas valve. 4. Turn up the thermostat. (NOTE: On a Separted Combustion model, depress and hold the door safety switch.) Cycle the burner once or twice to properly seat the adjustment spring in the valve. Re-check the pressure(s). When the outlet pressure is right for the installation, remove the manometer and replace the cap. Check for leak at the pressure tap fitting. Page 14 5. With the heater operating determine that the ,let pressure to the heater for natural gas is between 5 and 13.5 inches w.c. and for propane between 11 and 13.5 inches w.c. Take this reading as close as possible to the heater(Heaters are equipped with gas valves that have an inlet pressure tap.) If the inlet pressure is not within the specified range, the inlet pressure must be corrected and Steps 3 and 4 repeated. 6. Find the High Altitude Adjustment label in the plastic bag that contained these instructions. Using a permanent marker, fill-in the appropriate information from the tables below. Select a location for the label on the outside of the heater access panel so that it will be conspicuous to anyone operating or servicing the unit. Be sure the surface is clean and dry and adhere the label. High Altitude The input and/or the capacity of the heater changes with the Berate The tables below Capacity Changes list inputs and capacities at altitudes from sea level to 10,000 ft(3045M). it BTUH Inputs and Capacities by Altitude in the UNITED STATES for all Models ALTITUDE Normal Thermal Output Minimum Normal Thermal Oulpu[ Minimum Normal Thermal Output Minimum Normal Thermal Output Minimum Input Capacity Input Input Capacity Input Input Capacity Input Input Capacity Input Feet Meters Size 30 Size 45 1 Size 60 Size 75 0-2000 0-610 30000 24600 30000 45000 37350 45000 60000 49800 42000 75000 62250 1 52500 2001-3000 611-915 28200 23124 28200 42300 35109 42300 56400 46812 39480 70500 58515 49350 3001-4000 916-1220 27600 22632 27600 41400 34362 41400 55200 45016 38640 69000 57270 48300 4001-5000'1221-1525 27000 22140 27000 40500 33615 40500 54000 44820 37800 67500 56025 47250 5001-6000 1526-1830 26400 21648 26400 39600 32868 39600 52800 43824 36960 66000 54780 46200 60014000 1831-2135 25800 21156 25800 38700 32121 38700 51600 42828 36120 64500 535. 45150 7001-8000 2136-2440 25200 20664 25200 37800 31374 37800 50400 41832 35280 63000 52290 44100 8001-9000 441-2745 24600 20172 24600 36900 30627 36900 49200 40836 34440 61500 51045 43050 001-1000 746-3045 24000 19680 24000 36000 29880 36000 48000 39840 33600 60000 49800 42000 Feet Meters Size 100 1 Size 125 Size 150 Size 175 0-2000 1 0-610 105000 87150 73500 720M0 99600 84000 JS0Ml 124500 105000 17WW 145250 122500 2001-3000 611-915 98700 82908 69090 '112800 94752 78960 141000 117030 98700 164500 136535 115150 3001-4000 916-1220 96600 81144 67620 110400 92736 77280 138M 114540 96600 181000 133630 112700 - �4001-5000 1221-1525 94500 79380 66150 108000 90720 75600 135000 112050 94500 157500 130725 110250 SOD143000 1626W830 92400 77616 64680 105800 88704 73920 132000 109560 92400 154000 127820 107800 6001-7000 1831-2135 90300 75852 63210 1032M 86688 72240 129000 107070 1 90300 150500 124915 105350 7001-8000 13fi-244(I 88200 7408E 61740 100800 84672 70560 126000 104580 88200 147000 122010 102900 8001-9000 441-2745 86100 72324 60270 98400 62656 6BBB0 123000 102090 86100 143500 119105 100450 1.1 746.3046 84000 1 70560 58800 96000 80640 1672001"M120000 99600 84000 140000 116200 9B000 Feet Meters Size 200 Size 225Size 250 Size 300 0-2000 0-610 00000 166000 140000 186750 207500 175000 DO 249000 210000 2001-3000 611-915 IB8000 156040 131600 11500 175545 35000 195050 164500 82000 234060 197400 3001-4000 '916-1220 IB4000 152720 128600 7000 171610 30000 190900 161000 78000 229080 193200 4001-5000 221-1525'1 B0000 149400 126000 02500 168075 '25000 186750 157500 70DOO 224100 189000 5001-6 000 526-1830176000 146080 123200 198000 164340 00 182600 154000 000 219120 184800 6001-7000 1831-2135'172000 142760 120400 193500 160605 '15000 170450 150500 58000 214140 180600 7001-8000 136-2440 168000 139440 117600 189000 156870 10000 174300 147000 52000 209160 176400 8001-9000 441-2745 164000 136120 114BOO 184500 153135 170150 143500 246000 204180 172200 001-1000 748-304 160000 132800 112000 18000 149400 166000 140000 240DO0 199200 160000 Feet Meters Size 350 Size 400 0-2000 0-610 350000 290500 1245000 400000 332000 280000 2001-3000 611-915 329000=2440202(3)05780000 300 37600D 312080 263200 3001-4000 916-1220 322000400 3680DO 305440 257600 4001-5000 1221-1525:315000500 36000D 298800 252000 5001-6000 1526-183 3080005600 352000 292160 246400 6001-7000 1831-213 301000700 344000 285520 240800 7001-8000 136-244 29400D5800 33600D 278880 235200 6001-9000 441-274 2870001 238210 200900 32=00 272240 229600 001-1000 746-304 280000 232400 196000 320000 265600 224000 BTUH Inputs and Capacities by Altitude in CANADA for all Models ALTITUDE Normal I Thermal Output I Minimum Normal Thermal Output Minimum Normal Thermal Output Minimum Normalffi.,zel Minimum Input Capacity Input Input Capacity Input Input capacity Inoul InputInput Feet Meters Size 30 Size 45 Size 60 0-2000 0-610 30000 24600 30000 45000 37350 45000 60000 49800 42000 7500052500 2001-4500 611-1373 27000 22140 27000 40500 33615 40500 54000 44820 37800 6750047250 Feet Meters Size 100 Size 125 Size 150 0-2000 0-610 105000 87150 73500 120000 99600 1 84000 15000 124500 1 105000 175000 145250 1 122500 2001-4500 611-1373 94500 79380 1 66150 110410001 90720 1 75600 13500 113400 1 94500 1575001 132300 1 110250 Feet Meters Size 200 Size 225 Size 250 Size 300 0-2000 0-610 20DO001 166000 1 140000 2250001 186750 1 157500 2 207500 1 175000 300000 249000 1210000 2001-4500 611-1373 1800001 151200 1 126000 2025OUl 170100 1 141750 225004 189000 1 157500 2700001 226800 1 189000 Feet Meters Size 350 Size 400 0=2000 0-610 13500001 290500 1245000 14000001 332000 280000 20014500 6111-137313150001 264600 1220500 IMM001 302400 252000 Page 15 6.0 Mechanical 6.�. .;ombustion Air - Standard Power Vent Models (cont'd) This heater must be supplied with the air that enters into the combustion process and is then vented to the outdoors. Sufficient air must enter the equipment location to replace (Note: For Separated that exhausted through the heater vent system. In the past, the infiltration of outside air assumed in heat loss calculations (one air change per hour) was assumed to be suf- Combustion Model, ficient. However, current construction methods using more insulation, vapor barriers, see Venting Manual tighter fitting and gasketed doors and windows, weather-stripping, and/or mechanical for combustion air exhaust fans may now require the introduction of outside air through wall openings or requirements.) ducts. The requirements for combustion and ventilation air depend upon whether the unit is located in a confined or unconfined space.An"unconfined space"is defined as a space whose volume is not less than 50 cubic feet per 1000 BTUH of the installed appliance. Under ALL conditions, enough air must be provided to ensure there will not be a negative pressure condition within the equipment room or space. . - Standard Power Vent Model unit heaters are designed to take combustion air from the space in which the unit is installed and are not designed for connection to outside combustion air intake ducts. Connecting outside air ducts voids the warranty and could cause hazardous operation. See Hazard Levels, page 2. Combustion Air Do not install a unit in a confined space without providing wall openings leading to and Requirements fora from the space. Provide openings near the floor and ceiling for ventilation and air for Heater Located in combustion as shown in FIGURE 11, depending on the combustion air source as noted a Confined Space - in Items 1, 2, and 3 below. applies to Standard Add total BTUH of all appliances in the confined space and divide by figures below for Power Vent Models and square inch free area size of each (top and bottom) opening. Standard Power Vent Models with CV Option FIGURE 11 - Definition Confined Space: of Confined Space and A space whose volume is (3) I �� (1) _ (2) - Required Openings for less than 50 cubic feet per Confined Combustion Air 1000 BTUH of the installed Space appliance input rating - - 1.Air from inside the building --openings 1 square inch free area per 1000 BTUH. Never less than 100 square inches of free area for each opening. See (1) in FIGURE 11. 2.Air from outside through duct--openings 1 square inch free area per 2000 BTUH. See (2) in FIGURE 11. 3.Air direct from outside --openings 1 square inch free area per 4000 BTUH. See (3) in FIGURE 11. NOTE: For further details on supplying combustion air to a confined space, see the National Fuel Gas Code ANSI Z223.1 a (latest edition). 7.0 Electrical 7.1 General Supply and All electrical wiring and connections, including electrical grounding MUST be made in accordance with the National Electric Code ANSI/NFPA No. 70 (latest edition) or, in Wiring Canada, with CSA Standard C22.1. In addition, the installer should be aware of any local ordinances or gas company requirements that might apply. CAUTION: Route CAUTION: If any of the original wire as supplied with the appliance must wires so that they do not contact the flue be replaced,it must be replaced with wiring material having a temperature wrapper or venter rating of at least 105°C, except for limit control, flame rollout, and sensor housing. lead wires which must be 150°C. See Hazard Levels, page 2. Page 16 7.2 Supply Wiring Check the rating plate on the heater for the supply voltage and current requirements. A dedicated line voltage supply with disconnect switch should be run directly from the main electrical panel to the heater.All external wiring must be within approved conduit and have a minimum temperature rise rating of 60°C Conduit must be run so as not to interfere with the heater access panel. If the installation requires a stepdown trans- former (Option CG - on some models), follow the instructions shipped with the option package for attaching the transformer to the heater. The electrical supply enters at the rear of the heater (See FIGURE 13). Separated Combustion Models include a built-in disconnect switch (20A @ 115V; 10A @ 230V Rating). The Separated Compustion Model supply wiring connects to leads located inside a sealed electrical box. To maintain the sealing feature of the electrical box, always replace the cover plate. The Standard Power Vent Model supply wiring con- nects directly to leads on the integrated circuit board. The circuit board (See FIGURE 12) is located inside on the bottom of the control com- partment. The circuit board is polarity sensitive. It is advisable to check the electrical supply to be certain that the black wire is the "hot" wire and that the white wire is the neutral wire.The supply connection made to"L1" on the circuit board must be the"hot" wire. FIGURE 12 -Supply Wiring Connections at G)0 MODEL 1097 Z1oCOM � O � the Circuit Board (DSI Spark OOQ- Transformer c g Integrated Control O� O DQQ 3 Module) Supply Wiring CDOOCI Fuse Connections OIN U NOTE: Circuit OJ O Thermostat O 3 board is polarity Q Connections Q sensitive; "hot" wire MUST BE C `a connected to O Terminal L1. Q ' See section 10.3 (;QLo Troubleshooting O F ,p HEAT on pages 36&37 O W O for symptoms. Status��LL MI Lights- Y O O 3 0 0 .SPus 7.3 24V Control For all models, the terminal strip for 24 volt thermostat connections is located on the Wiring outside of the cabinet at the back of the heater(See FIGURE 13). Wires from the ter- Connections minal strip are factory wired to the circuit board FIGURE 13 -Terminal Rear View Standard Rear View Separated Power Vent Model Combustion Model Strip for 24-volt wiring is on the outside rear of the heater. O Terminalso Terminal R Strip oS Strip G1 NOTE: The size of heater 2 0 illustrated has a vertical Built-in terminal strip. Some sizes Disconnect have a horizontal terminal swttch O strip. Suppl Supply e Wiring Wiring Entrance Entrance a Page 17 7.0 Electrical 7.4 vdiring Diagrams Supply and FIGURE 14A -Typical Wiring Diagram for all Single Stage Model or Wiring (cont'd) Recirculation Models ' FACTORY WIRING SYSTEM TRANSFORMER LINEN/H FIELD WIRING .� OPTIONAL FACTORY r WIRING Ny p WIRE CONNECTOR uO G SIR # zo OK o Fg. G � SEC COM L1 NEVTNAt L1 0•�. PR P31 >>Y K� wQ �z Eu1R4E W ` All Y H3L G FAN MOtOR ql EAGSLO BK BK w wl 99 ¢w u 7ti >W < KK N y DOOR INTERLOCK ao 0, 0 (I IDAS ONLY) P3 4 H uLLJW R >R a �i CAPACITOR P3-5 SCENOTE NA >>C LED FLASH CODES GREENLED WIT LIMIT CONTROL R R P1-B ` STEADY ON NORMAL OPERATION NO CALL FOR HEAT 7 FAST FLASH NORMAL OPERATION CALL FOR HEAT 1 FLASH IN LOCKOUT FROM FAILED IGNITIONS OR FLAME LOSSES ` q P1-3 / 2FLASH PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS OF VENTER ENERGIZED FLAME RJ LOUT 3FLASH LIMIT SWITCH OR ROLLOUT SWITCH OPEN (MODELS 3 125 ONLY) 4 FLASH PRESSURE SWITCH IS CLOSED BEFORE VENTER IS ENERGIZE[ f G P1-6 STEADY OFF INTERNALCONTROL FAULTORNOPOWER 1-o , YELLOW LED M 1 `r� PRESSURE SWITCH STEADY ON FLAME SENSED FW1 cs��lul' P1-5 \ SLOW FLASH WEAK FLAME / FAST FLASH UNDESIRED FLAME(VALVE OPEN&NO CALL FOR HEKB rskP1-4 11., OG > Z tw9 w LGA. r: T':. y� O U Y!2 W1 P1-2 FLAME OK LED LED NEUTRAL Z FLAME AP1-7 O O UELECTRODE Q SPARK R Rj P1_g TRANSFORMER CN NOTE V'H 45 DSI CONTROL (SEE NOTE 117) C FLAMEGROUND SPARK GAP or.EMUCL_SEQUILBLE 1 SET THERMOSTAT AT LOWEST SETTING,(FAN SWITCH AT"AUTO"POSITION 2 TURN ON MANUALOASYALVE. FIELD CONTROL WIRING 3.TURN ON POWER TO UNIT 4, SET THERMOSTAT AT DESIRED SETTING TOTAL WIRE DISTANCE FROM MIN RECOMMENDED 5 THERMOSTAT CALLS FOR HEAT,ENERGIZING THE VENTER MOTOR LENGTH UNIT TO CONTROL WIRE GUAGE 6.VENTER PRESSURE SWITCH CLOSES,FIRING UNIT AT FULL RATE 150' 75' N18GA WIRE 7 BURNER FLAME IS SENSED,AND IN 30 SECONDS THE FAN MOTOR IS ENERGIZED 250' 125' N16GA WIRE B.IFTHE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION, 350' 175' N14 GA WIRE THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT (SEE LIGHTING INSTRUCTIONS) 9 SET FAN SWITCH AT"ON"POSITION FOR CONTINUOUS FAN OPERATION NOTES WIRING CODE BLACK-BK 1 THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS THERMOSTAT BROWN-BR 2 DOTTED WIRING INSTALLED BY OTHERS RED-R 3 CAUAPPLTIONANCEIMUST BE REPLACEDNTL UIRING AS ST BEREPLACEIED D WITH WIRING MATERIAL TH THE ORANGE-0 VELLO W-Y ALL SINGLE STAGE or RECIRCULATION HAVING ATEMPERATURE RATING OF AT LEAST 105°C.EXCEPT FOR SENSOR GREEN-G LEAD WIRE,FLAME ROLLOUT AND LIMIT WIRING WHICH MUST BE 150°C BLUE-BL MODELS 4 USE 10 GA WIRE FOR ALL WIRING ON THE UNIT. PURPLE-PR 5 LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OFASIZE TO PREVENT WD# 185139 REV#4 VOLTAGE DROPS BEYOND 5%OF SUPPLY LINE VOLTAGE WHITE-W 6 CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS AG 1-C L 1 or CL22 150-400 AND 20B1230V MODELS 100-400 7.CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150-400 B-VERIFY JUMPER ON CL22 THERMOSTAT TERMINALS RTO RC 9,FAN SWITCH OR LOW STAGE OF CL22 THERMOSTAT ENERGIZES THE BLOWER MOTOR 10.HIGH STAGE OF CL22 THERMOSTAT INITIATES A CALL FOR HEAT Page 18 FIGURE 14B -Typical Wiring Diagram for all Two Stage Gas Valve Models (NOTE: Two Stage Valve circuit ONLY available on UDA_Models) VA � r,Art.TbRT T�wJo y F1EI.D TII FAA A �' WRW YI%iBIIIrT nL r�Cy 1 W d J 3EC CCM � L! 4flUTPAL 17EUTR�1 J I. a P3-1 ll'UTTL1 %V I PS-2 \. F.44 VOTOR o P34 \\ 6 DOOR WV13LDM Irg I 3 r H �:o'`, aaArarale Y BIRO P44 y+wlmrtnn�cor�e {W[IJ9REIHr F a � i 7 WL �vorw� wR+tia.�►1rwn�wsu wr % rAirw�M IrOw�adrwtiTlb�n�u��v 1 HAM MIaOMRlTIi7l�rNi�ItilY11C16dY1LY111AEMb Lr L. Pid 9lLA�r1 ���nvrw�snm�trwm�w / 10now u MnXVLFMuxW"nm r RAirlrr01J.0UT .4m" III�LJMI!lWTCN16d0l��EIrl1lNltllKl'.fV!e7V7Si (IICgVi'U1137OILfj f1O1DYAF MmMLOGM�PJILFiAILT 9R116R4�ik P" \ 1NVOLLa'LID / STEW9N mlKd ALT, HMWYYffiLL HGNEYV40 L %A�RI RE;1597GN P15 MIMlw Ml� 15pRRJYY� rNOYrAGE rA60 STAGe ! > FAIWkAAI IY RMlLWLtlC/tyYLrtlULLAERrlAT] a VALVE [i�kSv" tir. LO I Ibr D I C m (ram BR ! > AJNM LED Ok Y 4II I ED FLAME a 0 a T PTd \ (D ELEC VE 1. chTfuroR Rim CPEPAI o 39MEHM aqwQ 1,SET THUMCKTA7 AT LQX"T SS"V*k CAM fiMTCH AT AU10'P0W W{OPT10N CLTB CNLY►. 2t,TURN ON MWIUAL W VALVE. 4 TM�d1A 0MT�11T 0MRFD�JETTNG. PELD OONT110L Mflik3 G VftKTiiB11TTC� bWlaKHGAT.WO YW70r YDTOR IWALWRE DI6rANCIPPOY IL rdgxl+ D 0. UT7� UTHE L@IOIH 11ffrT000ft17OL NW42f1{t r.IMM FL ME 0 9OOODD.AND IN 90 OCCONM ME CM YDTOR M MNORMEMM w N wilk"WE 8 HWH 6rAM OF TH9MO]9TAT QMM FOR MAW.FlPRI9 LRW AT FU.L RATE, 2w 1YF ftox wm 0.SET FAN lrMTCH AT PC'> 10H"COKI'IM)M FM O PERAT04,OPT"CLIB CNLY, am 1w #"V&WWE To. IFTNE FLAME W 0(T1JOMMI WM W►u N DOM OPOIATION. THE MAltlRIh CJOW04L SYWM=W@ THP MAN VALVEAND bRWB E Pmu iY wowuRnm Pcwm TO THG awnwLCRi7Jfr YI FMCON 0M UONTMG w"RLVw*"Cy w.•.ac-wc 1.THE F A.OVOWO CONTPW AA5 FIELD*aTAu W CF71OFL4:TNEAM0�3rAr �-R O 2 OOTM T1�MTMJI®OV tilts oJOW.Q a CAVW�F ARY OF THEOR1044 A0 vuPPLAEp+mrttl Tt� "�OU '�' APPLIMM MUST N RMACED rr MUST W AFRA 1M Y4N WM MG rM1vSv1L Q7 -° 1~8 A TWP WTUM RACTN3 OF AT WAM 10r A%D G UZWT RJR OFMKX4 MCM-ML UMWM1•RAM IrALLOUrANDLUTYWNG WNW MLW19WbKi%DC P4JWW`Ffl a Uw w Wk MlriM FOR ALL YAROMi ON 7M U r, wFn� T►' & UNRANO PAN UOTORwG11/[H%WleIMEIIDULOBEORASMTDMffmfT Y ALL TWO STAGE GAS VALVE CLTM E OROP9@E1'Ow W%OF awnV1 UMVE 1TAAE IBM"Awa MOVE$110a0L IIIRUOED ONLY p1116V Ai00kL@ 7,OAPAO rtlR O REti!#i MOUMTW M P ff4MVDW*L.Y OM MOOV-S L*-4n MODELS a E00W TAJX�W1CW T0RA 0-.Z CWATORAT0.@ALFBAND WD# 185244 REV AG2-C.22 SECOND BTA.OE AMKYPATOR AT 0.".MIPB. 9. Jubw"TH EMAD T55T TPAI+Atsow ro RG Page 19 7.0 Electrical 7.b. Combustion Air Proving (Pressure) Switch Supply and The combustion air proving switch is a pressure sensitive switch that monitors air pressure to ensure that proper combustion airflow is available. On Standard Power Ventmodels, Wiring (cont d) the switch is a single pole/normally open device which closes when a negative pressure 7.5 Electrical is sensed in the venter housing. On Separated Combustion models, the switch senses Operating the differential pressure between the negative pressure in the venter housing and the pressure in the cabinet. (For switch location, see FIGURE 18, page 30.) Components On startup when the heater is cold, the sensing pressure is at the most negative level, and as the heater and flue system warm up, the sensing pressure becomes less negative. After the system has reached equilibrium (about 20 minutes), the sensing pressure levels off. If a restriction or excessive flue length or turns cause the sensing pressure to be outside the switch setpoint, the pressure switch will function to shutoff the main burner. The main burner will remain off until the system has cooled and/or the flue system resistance is reduced. The Tables on the left below list the approximate water column negative pressure readings and switch setpoints for sea level operating conditions for Standard Power Vent and Model heaters. The Table on the right lists the approximate water column differential pressure readings and switch setpoints for sea level operating conditions for Separated Combustion Model heaters. Safe operation of this unit requires proper venting flow. NEVER bypass combustion air proving switch or attempt to operate the unit without the venter running and the proper flow in the vent Pressure Switch system. Hazardous conditions could result. See Hazard Intensity Settings Levels, page 2. Startup Equilibrium Setpoint Startup I Equilibrium Setpoint Setpoint Std Power Cold Hot Setpoint OFF ON Std Power Cold Hot OFF ON Label Switch Label Switch Vent Vent Models Negative Pressure("w.c.) Color PAN Models Differential Pressure("w.c.) Color PIN 30 10 0.8 0.4 0.6 Green 197030 30 10 0.8 0.65 0.8 Yellow 197028 45 1.0 0.8 0.4 0.6 Green 197030 1 45 1 1.1 0.8 0.65 0.8 Yellow 1 197028 60 1 0 0.8 0.5 0.7 Orange 196388 60 I 1 09 0.65 0.8 Yellow 1 197028 75 1.0 09 0.5 0.7 Orange 196388 75 1.1 0.9 0.65 0.8 Yellow 197028 100 09 07 0.5 0.7 Orange 196388 100 09 07 055 0.7 White 196362 125 0.8 0.6 0.4 0.6 Green 197030 125 0.8 06 0.45 0.6 Pink 197032 150. 175 0.8 0.7 0.4 0.6 Green 197030 150, 175 0.8 0.6 0.40 06 Green 197030 200,225 2.2 1.5 1.1 1.3 Blue 201158 200,225 22 1 5 1.10 1.3 Blue 201158 250,300 2.3 1.6 1 1 1 3 Blue 201158 250.300 2.3 1.6 1 10 1.3 Blue 201158 350.400 2.6 18 1.1 16 Red 201159 350.400 2.6 1.8 1.10 1.6 Blue 201158 Startup Cold Equilibrium Setpoint Setpoint Std Power Vent Hot OFF ON Label Switch Model with Opt AV6 Color P/N Negative Pressure("w.c.) 30 11 0.8 0.65 0.8 Yellow 197028 45 11 0.8 0.50 0.7 Orange 196388 60 09 0.8 0.60 0.8 Lt Blue 197029 75 1 0 0.8 0.60 0.8 Lt Blue 197029 100 09 07 0.55 07 1 White 196362 7.5.2 Limit Control All units are equipped with a temperature activated auto reset limit control. The con- trol is factory set and is non-adjustable. If the setpoint is reached, the limit control will interrupt the electric supply to the gas valve. This safety device provides protection in the case of motor failure or lack of airflow due to a restriction at the inlet or outlet. (For location, see FIGURE 18, page 30.) CAUTION: The auto reset limit control will continue to shut down the heater until the cause is corrected. Never bypass the limit control; hazardous conditions could result. See Hazard Intensity Levels, page 2. Page 20 Sizes 30-125 are equipped with a temperature d manually reset flame rollout switch. The flame rollout switch is located at the top of the burner assembly. It is fac- tory set and is non-adjustable. If the setpoint is reached, the flame rollout acts to inter- rupt the electric supply to the gas valve. If the flame rollout switch activates, identify and correct the cause before resetting the switch. Refer to the Maintenance Section, Paragraph 10.2.10, for information on probable causes and instructions on resetting the flame rollout switch. (For location, see FIGURE 18, page 30.) If the manual reset flame rollout switch activates, identify and correct the cause before resetting the switch. Never bypass the flame rollout switch; hazardous conditions could result. See Hazard Intensity Levels, page 2. 7.5.3 Door Switch All sizes of Separated Combustion Model heaters are equipped with a door switch for Separated which prevents the heater from operating when the service door panel is open. The Combustion Models service panel of a Separated Combustion Models are equipped with a pliable gasket only material that fully seals the door to provide added protection from building air entering the combustion zone of the heater. (For switch location, see FIGURE 18, page 30.) 7.5.4 Gas Valve The main operating gas valve is powered by the 24-volt control circuit through the ther- mostat and safety controls. The main control valve is of the diaphragm type providing regulated gas flow preset at the factory. (For location, see FIGURE 18, page 30.) The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting the unit to ensure positive closure. See Hazard Levels, page 2. 7.5.5 Fan Motor The fan motor is equipped with thermal overload protection of the automatic reset type. Should the motor refuse to run, it may be because of improper current characteristics. Make certain that the correct voltage is available at the motor. NOTE: If the unit is equipped with an optional totally enclosed motor or optional volt- age, the horsepower may be larger than the standard motor. Refer to the motor name- plate to verify horsepower. 7.5.6 Venter Motor The venter motor is assembled to the venter wheel and operates to provide combus- tion airflow. Operation is controlled by the ignition control module (circuit board); refer to ignition system in Paragraph 8.3. 8.0 Controls and 8.1 Thermostat Operation Use either an optional thermostat available with the heater or a field-supplied 24-volt thermostat. Install according to the thermostat manufacturer's instructions, paying par- ticular attention to the requirements regarding the location of the thermostat. Make sure that if there is a heat anticipator setting on the thermostat, it is set at 0.6 amps (or in accordance with the amperage value noted on the heater wiring diagram). Make thermostat connections at the terminal strip on the back of the heater. The strip has four terminals, R, G, W1, and W2; refer to the wiring diagram. IMPORTANT: All units MUST be operated by a 24-volt thermostat. Never use a line voltage disconnect switch as a means of operating the heater. Operating Model Sizes 30-125 by means other than a 24-volt thermostat may result in the flame rollout switch tripping. Multiple Heater Control, Option CL31 and Option CL32 - If the heater was ordered with a multiple heater control option, one thermostat can be used to control up to six heaters. The option includes a 40VA transformer that replaces the standard trans- former in the "controlling" unit and a relay assembly that attaches to the additional unit. Option CL31 provides for control of two heaters. If control of additional heaters is desired (up to six total), Option CL32 which is the relay assembly only must be added to each additional heater. The option packages are shipped separately and include complete instructions on installation and wiring. Page 21 8.0 Controls and Operation If the heater was ordered with Option D10 or D14, it is equipped with a Novar Minio (Cont'd) control module.The Novar control with its accompanying relays and power transformer are mounted in the control compartment of the unit. See FIGURE 15A. This control 8.2 DDC Controls, offers a wide variety of input and output points that can be configured to meet a wide Options D10 and range of building management applications. User-selectable input types are Thermis- D14 (ONLY for tor, 4-20 milliamp, 1-5 volts, or digital. sizes 150-400) FIGURE 15A - •ice DDC Control with Transformer and Relays is Mounted on "` { a Specially Designed ' Bracket in the Control _ Compartment % 1. 7 �J Control Option D10 includes the controller and the sensor to be field mounted at the heater discharge. Option D14 requires a field-supplied sensor that is compatible with the control. For regulatory compliance specifications, and safety precautions, review the control manufacturer's installation instructions in the owner's envelope. The recommended location for mounting the sensor is on the side of a field-installed optional downturn nozzle See FIGURE 1513 for an illustration of the sensor included with Option D10 and dimensions for mounting it on the nozzle side. FIGURE 15B - Recommended Location for Mounting Center the the Sensor is on 1"(25mm) 9/16" 3" sensor hole the Side Panel of a (14mm) �"(76mmj vertically on Discharge Nozzle , L_ a the nozzle (Option CD 2, 3, or 4) 9/161, (14mm) 0(4)111,11 2-1/4" (3mm) (57 m) 01' 2-114" Before installing the (25mm)+ (57mm) discharge nozzle, drill the holes in the side panel as illustrated. a Nozzle flange that connects to the heater outlet. Mount the sensor on the nozzle side. Drill a 7/8" hole in the cabinet top above the controller and install the bushing supplied with the unit for running the sensor wire. Wire the sensor to the controller as illustrated on the wiring diagram on the heater. Sensor wire is field-supplied. Page 22 8.3 Ignition System This heater is equipped with a direct spark intEylated control module (circuit board). The module monitors the safety devices and controls the operation of the fan and ven- ter motors and the gas valve between heat cycles. FIGURE 16 — DSI Integrated Control Module (circuit board) LED lights are visible through a viewport on Separated Combustion Models. Remove door panel to view LED lights on Standard Power Vent Models. •r r•x •r MODEL 1097-710 COn SEC Control Status-Green LED Codes Q+ Spark O Q+ O Q+ Steady ON..........Normal Operation, No call for heat Tranato,mar om QQQ Fast Flash...........Normal Operation, Call for heat -I 0 QQ QQQ = 1 Flash................System Lockout, Failed to detect or OOFuse o O= Q Q U sustain flame OJ 0 2 Flashes............Pressure Switch Did Not Close within 30 Seconds of Venter motor Thermostat O a Connections O 3 Flashes............High Limit or Flame Rollout Switch Open 4 Flashes..... ......Pressure switch is closed before venter s•. Q>, motor is energized Li ?_ Steady OFF........Blown Fuse, No Power, or Defective Board 3 O Flame Status -Yellow LED Codes ILO Steady ON.......Flame is sensed HEAT Slow Flash.......Weak flame (current below 1.0 CO microamps±50%) O M1 Lights' LL Fast Flash........Undesired Flame (valve open and no O+ O+ SP® .0 call for heat) c us LED Lights Normal Heat 1) Call for Heat - The thermostat calls for heat by energizing the "Wa terminal. The Cycle Operating control checks to see that the limit switch is closed and the pressure switch is open. If Sequence the limit switch is open, the control responds as defined in the "Abnormal Heat Cycle, Limit Switch Operation". If the pressure switch is closed, the control will do four flashes on the green LED and wait indefinitely for the pressure switch to open. If the pressure LED lights are visible switch is open, the control proceeds to prepurge. through viewport on 2)Prepurge-The control energizes the venter motor and waits for the pressure switch to close. If the pressure switch does not close within 30 seconds of the venter motor Separated Combustion energizing, the control will do two flashes on the green LED. The control will leave the Models. Remove door venter motor energized indefinitely as long as the call for heat remains and the pres- panel to view LED lights sure switch is open. on Standard Power Vent When the pressure switch is proven closed, the control begins the prepurge time. If Models. flame is present any time while in prepurge, the prepurge time is restarted. If flame is present long enough to cause lockout, the control responds as defined in "Fault Modes, Undesired Flame". The control runs the venter motor for a 20 second prepurge time, then proceeds to the ignition trial period. 3) Ignition Trial Period - The control energizes the spark and main gas valve. The venter remains energized. If flame is sensed during the first 16 seconds, the spark is de-energized and the control proceeds to heat fan/blower on delay. If flame has not been sensed during the first 16 seconds, the control de-energizes the spark output and keeps the gas valve energized for an additional one second flame proving period. If flame is not present after the flame proving period, the control de-energizes the gas valve and proceeds with ignition re-tries as specified in"Abnormal Heat Cycle, Ignition Retry". If flame is present, the control proceeds to the fan/blower on delay. 4) Fan/Blower On Delay - The control waits for 30 seconds from the time the gas valve opened and then energizes the fan/blower motor. The gas valve and venter motor remain energized. The control proceeds to steady heat mode. 5) Steady Heat - Control inputs are continuously monitored to ensure limit and pressure switches are closed, flame is established, and the thermostat call for heat remains. When the thermostat call for heat is removed, the control de-energizes the gas valve and begins post-purge and fan/blower off delay timing. Page 23 8.0 Controls and Noi..ial Heat Cycle Operating Sequence (cont'd) Operation 6)Post Purge-The venter motor output remains on for a 45-second post-purge period (Cont'd) after the thermostat is satisfied. 8.3 Ignition System 7) Fan/Blower Off Delay -The fan/blower motor is de-energized after a fan/blower off (Cont'd) delay (120 seconds). Timing begins when the thermostat is satisfied. Abnormal Heat Cycle Interrupted Thermostat Call for Heat-If the thermostat demand for heat is removed Functions before the flame is recognized, the control will run the venter motor for the post purge period and de-energize all outputs. If the thermostat demand for heat is removed after successful ignition, the control will de-energize the gas valve, run the venter motor through post purge, and run the fan/ blower motor on heat speed for the selected delay off time. Ignition Retry-If flame is not established on the first trial for ignition period, the control de-energizes the gas valve and the venter motor remains energized for an inter-purge period of 10 seconds. The spark and gas valve are then re-energized, and the control initiates another trial for ignition. If flame is not established on the second trial for ignition, the control de-energizes the gas valve, energizes the fan/blower motor on heat speed, and venter motor remains energized. The fan/blower motor is shut off after 120 seconds. When the fan/blower motor de-energizes, the spark and gas valve are re-energized and the control initiates another trial for ignition. (This fan delay is self-healing feature for an open auxiliary limit switch). If flame is not established on the third trial for ignition period, the control de-energizes the gas valve, and the venter motor remains energized for an inter-purge period of 10 seconds. The control then re-energizes the gas valve and spark and initiates another trial for ignition. If flame is not established on the fourth trial for ignition (initial try plus 3 re-tries), the control de-energizes the gas valve and goes into lockout.The control goes to one flash on the green LED to indicate ignition failure lockout. Limit Switch Operation - The limit switch is ignored unless a call for heat is pres- ent (W energized). If the limit switch is open and a call for heat is present, the control de-energizes the gas valve and turns the fan/blower motor on heat speed and runs the venter motor. The control will be in soft lockout and flashing fault code "Y before returning to normal operation. When the switch re-closes or the call for heat is lost, the control runs the venter motor through post purge and runs the blower/fan motor through the selected fan off delay. Pressure Switch - If the pressure switch opens before the trial for ignition period, the venter motor will run through the pressure switch recognition delay (2 seconds), the gas valve will be de-energized, and the venter motor will run through the postpurge time. The control will re-start the heat cycle at the pressure switch proving state if the call for heat still exists. Pressure switch opening for less than 2 seconds during the trial for ignition period shall not interrupt the heat cycle. (Gas valve will de-energize while the pressure switch is open.) If the pressure switch opens after a successful ignition, the control will de-energize the gas valve. If flame is lost before the end of the 2 second pressure switch recogni- tion delay, the control will respond to the loss of flame. If the pressure switch remains open for 2 seconds and the flame remains, the control de-energizes the gas valve, the venter motor runs through post-purge, and the fan/blower motor runs on heat speed through the selected fan off delay. When the fan off delay is over, the fan/blower motor is de-energized, and a heat cycle is begun if the call for heat still exists. When the thermostat calls for continuous fan (G)without a call for heat, the fan motor is energized after a .25 second delay. NOTE: This brief on delay is to allow the"G"termi- nal to energize slightly before "Y" and an external changeover relay to switch from"G" to "W" without causing momentary glitches in the fan/blower output. The fan remains energized as long as the call for fan remains without a call for heat. Page 24 If a call for heat(W) occurs during continuous fan, the fan/blower will de-energize. A call for fan is ignored while in lockout. Continuous Fan Undesired Flame - If flame is sensed longer than 20 seconds while the gas valve is Operation de-energized, the control shall energize the venter motor and fan/blower motor on heat speed. When flame is no longer sensed, the venter motor will run through postpurge, and the fan/blower motor will run through the selected heat fan off delay time. The control will do a soft lockout, but will still respond to open limit and flame. The FLAME (yellow) LED shall flash rapidly when lockout is due to undesired flame. Gas Valve Relay Fault-If the control senses the gas valve as energized for more than Fault Modes one second when the control is not attempting to energize the gas valve, or the gas valve is sensed as not energized when it is supposed to be energized, then the control will lockout with green LED off. The control assumes either the contacts of the relay driving the gas valve have welded shut, or the sensing circuit has failed. The venter motor is forced off to open the pressure switch to stop gas flow unless flame is pres- ent. If the gas valve was sensed as closed when it should be open, and has not de-ener- gized after the venter motor was shutoff for 15 seconds, then the venter motor is re- energized to vent the unburned gas. Soft Lockout - The control shall not initiate a call for heat or call for continuous fan while in lockout. The control will still respond to an open limit and undesired flame. Lockout shall automatically reset after one hour. Lockout may be manually reset by removing power from the control for more than one second or removing the thermostat call for heat for more than one and less than 20 seconds. Hard Lockout-If the control detects a fault on the control board, the status LED will be de-energized, and the control will lockout as long as the fault remains. A hard lockout Lockout will automatically reset if the hardware fault clears. Power Interruption-During a momentary power interruption or at voltage levels below the minimum operating voltage(line voltage or low voltage)the system will self-recover without lockout when voltage returns to the operating range. Power interruptions of less than 80mS shall not cause the control to change operating states. Power interruptions greater than 80mS may cause the control to interrupt the current operating cycle and re-start. Page 25 9.0 Commissioning 9.-, check the installation prior to startup: and Startup ❑ Check to be sure that all screws used to hold shipping brackets were re- installed in the heater cabinet. ❑ Check suspension. Unit must be secure and level. ❑ Check clearances from combustibles. Requirements are in Paragraph 4.1. ❑ Check vent system to be sure that it is installed according to the instructions in the appropriate Vent Installation Manual as listed in Paragraph 2.2. ❑ Check piping for leaks and proper gas line pressure. Bleed gas lines of trapped air. See Paragraph 6.1. ❑Check electrical wiring. Be sure all wire gauges are as recommended. A service disconnect switch should be used. Verify that fusing or circuit breakers are adequate for the load use. ❑ Check polarity. Verify that line voltage exists between the black"L1" and earth ground. ❑ If installed in California, verify that California Warning Label is displayed. 9.2 Heater Startup: For your safety, read before operating. If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. • This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. • Before operating, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. 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. • Leave the building immediately. • Immediately call your gas supplier from a phone remote from the building. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call your fire department. • Use only your hand to turn the gas control ON/OFF knob on the gas valve. Never use tools. If the valve ON/OFF knob will not turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion. • Should overheating occur, or the gas supply control system fail to shut off the flow of gas, turn 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 to replace any part of the control system and any gas control which has been under water. Page 26 Operating Sequence 1. Set thermostat at lowest setting. FIGURE 17 -Gas Valve 2. Turn off all electric power to the appliance. 3. This appliance is equipped with an ignition device which automatically lights the Top view burner. Do not try to light the burner by hand. Open the access door and locate the F. gas control (ON/OFF) knob or switch on the gas valve. (See FIGURE 17.) ® 4. Turn the gas control switch to"OFF' or the knob clockwise to "OFF". 5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the ON/OFF Switch floor. If you smell gas, STOP! and follow the steps in the WARNINGS printed above or on the Operating Label on the heater. If you do not smell gas, proceed to Top View the next step. '—Y-•" 0 6. Turn the gas control switch to"ON" or the knob counterclockwise to"ON". Flow 0 , 7. Close the access door. o ( u o 8. Turn on the electric power to the heater. b 0 F • 9. Set the thermostat to the desired setting. Gas Control NOTE: If the appliance does not operate, follow the instructions "To Turn Off Gas to Knob (shown Appliance" printed below (and on the Operating Label on the heater) and call your in the ON service technician. position) 10. Thermostat calls for heat, energizing the venter motor. Gas 11. Venter pressure switch closes, firing the unit. Flow 12. Burner flame is sensed and in 30 seconds after the gas valve is energized, the F— fan motor is energized. 13. If the flame is extinguished during the main burner operation, the integrated con- Side View trol system closes the main valve and must be reset by interrupting power to the control circuit. (See lighting instructions on the heater.). TO TURN OFF GAS TO THE APPLIANCE 1) Set thermostat to lowest setting 2) If service is to be performed, turn off all electric power to the appliance. 3) Open the access door. 4) Turn the gas control switch to "OFF' or turn knob clockwise to"OFF' (Do not force). 5) Close the access door. 9.3 Check ❑ Vent System Testing Procedure installation after The steps below shall be followed with each heater or utility heater connected to the startup: venting system placed in operation while any other appliance(s) connected to the vent- ing system(s) is not in operation. 1. Seal unused openings(s) in the venting system. 2. Inspect the venting system for proper size and horizontal pitch as required in the National Flue Gas Code,ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1, and the venting manual instructions. Verify that there is no blockage or restriction, leakage, corrosion, and/or other deficiencies that could cause an unsafe condition. 3. In so far as is practical, close all doors, windows, other open spaces within the building, and all doors between the space in which the appliance(s) connected to the venting system is located. Turn on clothes dryers and any exhaust fans (such as range hoods and bathroom exhausts) so they operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Following the lighting instructions, place the utility heater being inspected in operation.Adjust the thermostat so that the utility heater will operate continuously. 5. After it has been determined that each utility heater connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning 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. Page 27 9.0 Commissioning ❑ �_n the unit in operation, measure valve outlet gas pressure. If operated at high and Startup altitude, adjust outlet gas pressure for altitude. (cont'd) See information and instructions in Paragraph 6.1. 9.3 Check ❑ Turn the unit off and on, pausing two minutes between each cycle. Observe for installation after smooth ignition. startup (cont'd) ❑ Place the"Literature Bag" containing the Limited Warranty, this booklet, the venting manual, and any control or optional information in an accessible location near the heater. The gas burner in this gas-fired equipment is designed and equipped to provide safe controlled complete combustion. However, if the installation does not permit the burner to receive the proper supply of combustion air, complete combustion may not occur. The result is incomplete combustion which produces carbon monoxide, a poisonous gas that can cause death. Safe operation of indirect-fired gas burning equipment requires a properly operating vent system that vents all flue products to the outside atmosphere. FAILURE TO PROVIDE PROPER VENTING WILL RESULT IN A HEALTH HAZARD WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH. Always comply with the combustion air requirements in the installation codes and in Paragraph 6.2. Combustion air at the burner should be regulated only by manufacturer-provided equipment. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. Standard Power Vent models units installed in a confined space must be supplied with air for combustion as required by Code and in Paragraph 6.2 of this heater installation manual. MAINTAIN THE VENT OR VENT/COMBUSTION AIR SYSTEM IN STRUCTURALLY SOUND AND PROPER OPERATING CONDITION. 10.0 Maintenance and Service 7Levels,tupra n off the power supply, turn off the gas. See Hazard ge 2. The material contained in the MAINTENANCE AND SERVICE Section of this manual is designed to aid a qualified service person in maintaining and servicing this equip- ment. This heater will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a heater that is operated under normal conditions should be inspected and cleaned at the start of each heating season. If the heater is operating in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent maintenance is recommended. When any service is completed, be careful to reassemble correctly to ensure that no unsafe conditions are created. When re-lighting, always follow the lighting instructions on the heater. Inspect the burner/control compartment annually to determine if cleaning is necessary. Page 28 10.1 Maintenance Maintenance Schedule - The following proce,,u)res should be carried out at least Schedule annually (See FIGURE 18 and Paragraphs 10.2.1 - 10.2.14.): • Clean all dirt, lint, and grease from the combustion air opening (Standard Power Vent) and venter assembly. • Clean all dirt, lint, and grease from the fan blade, fan guard, and motor. • Check the heat exchanger both internally and externally. • Check the burner for scale, dust, or lint accumulation. Clean if needed. • Check gas valve to ensure that gas flow is being shutoff completely. • Check the vent or vent/combustion air system for soundness. Clean openings. Replace any parts that do not appear sound. • Check the wiring for any damaged wire. Replace damaged wiring. (See Paragraph 7 for replacement wiring requirements.) NOTE: If replacement parts are required, use only factory-authorized parts. FIGURE 18 - Location of Controls Flame Rollout Switch a High Temperature Venter Motor(Size 30-75 illustrated. (Sizes 30-125) Sensor Limit Control Pressure Switch Venter motor is in the same location for all models, but appearance is different.) e � o Separated Combustion Unit has a combustion 0 0 0 air pipe(not shown) o ° 0 0 Interlock Door Switch Separated Combustion O O Units only o• C! ® e O U' Fan ur o 0 Q Motor Al e e m c Gas Valve 00 Terminal Board (24V) • ° Disconnect Switch e ° Separated Combustion P.e o , Units only 0 Electric Box-Separated I nitor Combustion units only g Remove cover to connect ago -Transformer Control Panel Assy ( �. supply and access disconnect located on the switch wires. Always replace 8 Control Compartment B 6 cover. Bottom Transformer O Sizes 30-125 O - Sizes 150-400 y _ Venter Motor Capacitor Circuit Board - Circuit Board - Fan Motor (DSllntegrated Optional (DSllntegrated Capacitor Control Module Fan Motor Control Module) _ Capacitor Page 29 10.2 Maintenance Rel. ,,te any external dirt or dust accumulation. Visually check the heat exchanger for Procedures cracks and holes. If a crack or hole is observed, replace the heat exchanger. NOTE: Inspection of the lower portion of the heat exchanger is done with the burner 10.2.1 Heat removed. See the Burner Service section below for information on inspecting the lower Exchanger portion of the heat exchanger. Maintenance 10.2.2 Burner If there is an accumulation of dirt, dust, and/or lint, clean the compartment and follow Maintenance the instructions below to remove and clean the burner. CAUTION: Use of eye protection is recommended. Burner Removal 1. Outside the cabinet, shut the gas supply off at the manual valve ahead of the Instructions (Refer to union. FIGURE 19.) 2. Turn off electric supply. 3. Disconnect the gas supply at the union outside of the cabinet. 4. Remove the access panel. 5. Disconnect and Move the Gas Train -At the gas valve, mark and disconnect the wires. Carefully remove the burner orifice and orifice adapter locking nut. Slide the orifice adapter out through the bracket on the burner pushing the gas train to the right. This will move the gas train out of the way. 6. Move the Control Assembly - Remove the two screws holding the control assembly bracket. Being careful not to disconnect any wires, slide the control assembly to the right. 7. Remove Secondary Air Baffles (Sizes 60-400 only) -Vertical along the right side of the burner, locate the flat plate(s) identified as the secondary air baffle(s). The quantity of baffles could be one to four depending on heater size. Each baffle is held in place by one screw. For re-assembly, on the secondary air shield, mark the location (top and bottom) of each baffle. Remove all baffles. 8. Remove Burner Assembly a) Locate the burner body supports. Depending on the size, the burner will have two or more supports.At each support, remove the one screw that attaches it to the secondary air shield b) Holding the venturi tube, slide the entire burner assembly slightly to the right to disengage the burner from the supports on the left. Then rotate the open end of the venturi tube inward toward the heater. Carefully pull the burner assembly out of the cabinet. FIGURE 19 - Burner Burner Body Support(at least two per unit)-Remove screw attaching Removal (Standard to secondary air shield.Support remains attached to burner. Power Vent model _ illustrated; same Co) , O process for both =C 0 0 Standard Power o—Secondary O o 0 0 Vent and Separated 21 Air Shield Combustion 0 0 m 0, Burner models) a ® o Orifice ° d I O O ' Venturi Tube m Slide right;rotate Gas Valve inward:pull out o v Slide Right Disconnect gas train at orifice and outside _ o a heater;slide to the o o right. Secondary Air Baffle(Qty varies —Orifice Adapter Locking Nut per size.)Mark locations before removing. Control Bracket Screws-Loosen bracket;slide right. Page 30 Inspect and Clean the With the burner assembly removed, shine a fla:. .,rght on the burner ribbons. Look for Burner carbon buildup, scale, dust, lint, and/or anything that might restrict flow through the spaces between the burner ribbons. Holding the burner assembly so that any foreign material will fall away from the burner, use a stiff bristle brush to loosen and remove any foreign material(s). If the burner is excessively dirty, remove one of the burner end caps. Remove the four screws that hold the end cap to the burner housing. Lightly tap the end cap to remove it. Clean all foreign material from the burner and venturi. After the burner is thoroughly clean, replace the end cap making certain that it is tight against the burner housing. NOTE: If any of the burner components are damaged or deteriorated, replace the burner assembly. Inspect the Lower Portion of the Heat Exchanger(with burner assembly removed) At the burner flame entrance of each tube, shine a bright light into each heat exchanger section. With the light shining into the heat exchanger, observe the outside for visible light. Repeat this procedure with each heat exchanger section. If any light is observed, replace the heat exchanger. Re-Install the Burner Instructions to Re-Install the Burner(Refer to FIGURE 19) 1. Attach the Burner Assembly - Holding the venturi tube, slide the entire burner assembly into position.Align the supports on the left side with the slots in the burner shield; sliding the supports into the slots. On the right, re-attach each burner body support to the secondary air shield. 2. Attach the Secondary Air Baffles (Sizes 60400 only) - Re-attach the secondary air baffles as marked. Baffles may be different sizes and each must be attached in the correct location. 3. Attach the Control Assembly - Carefully slide the control assembly into position. Re-attach with the same screws. Check to be sure all wire connections are secure. 4. Attach the Gas Train -Slide the gas train so that the orifice adapter is through the bracket. Fasten the gas train to the bracket with the locking nut. Install the gas orifice. Re-connect the wires to the gas valve. 5. Close the access panel. 6. Reconnect the gas supply at the union outside of the cabinet. Leak test the connection with leak detecting solution. 7. Turn on the electric and the gas. Check for proper operation. 10.2.3 Burner Orifice Burner orifice usually only needs to be replaced when installing a gas conversion kit. If ordering a replacement orifice only, give BTUH content and specific gravity of gas, as well as the model and serial number of the unit. When removing or replacing the burner orifice, be careful not to damage the venturi tube and/or the bracket. 10.2.4 Ignition System DSI Integrated Control Module(circuit board)-See FIGURE 20. The module moni- tors the operation of the heater including ignition. The only replaceable component is the 3 amp Type ATC or ATO fuse. If the fuse is blown, the problem is most likely an external overload. Correct the problem and replace the fuse. FIGURE 20 - DSI Integrated Control r• sst '+g •! Module (Circuit Board) sssr '� ;W •vw � Only replaceable part is a Type ; ATC or ATO 3 ' amp fuse (Color + Code Violet), P/N 201685 Page 31 10.0 Maintenance 10-4 Ignition System (cont'd) and Service Do not attempt to disassemble the control module. However, each heating season (cont'd) check the lead wires for insulation deterioration and good connections. Proper operation of the direct spark ignition system requires a minimum flame signal 10.2 Maintenance of 1.0 microamps as measured by a microampmeter. Procedures For further information and check out procedure on the direct spark ignition system, (cont'd) refer to Paragraph 8.3 and the Troubleshooting Flow Chart in Paragraph 10.3. Ignitor - Refer to FIGURE 18 and locate the ignitor. Disconnect the wire; remove the screw and the ignitor. Clean the ignitor assembly with an emery cloth. Spark gap must be maintained to 1/8". See FIGURE 21. Ignitor wL FIGURE 21 - Ignitor showing required Spark 118 inch Gap measurement (3.2mm)�- CAUTION: Due to high voltage on the spark wire and electrode, do not touch when energized. See Hazard Levels, page 2. Flame Sensor Flame Sensor - Refer to FIGURE 18 and locate the flame sensor. Disconnect the wire; remove the screw and the flame sensor. Clean with an emery cloth. 10.2.5 Fan Motor, Fan Remove dirt and grease from the motor, the fan guard, and blades. Use care when Blades, and Guard cleaning the fan blades to prevent causing misalignment or imbalance. Check that the hub of the fan blades is secure to the shaft. Follow these instructions for replacement of the fan guard, fan motor and/or fan blades. FIGURE 22 - Fan Blade Position on the Shaft by Unit Size and Type of Fan Guard Fan A=Fan S acin Setscrew Blade a Aizes Size (all Models) Standard Wire Fan Guard Option AZ8 Wire Fan Guard Torque tS with .5" 13mm S acin with .334" 8.5mm Spacing in/lbs±10 30-250 30 1" 25 mm 1" 25 mm 0 Motor 45 9/16" 14 mm 1-1/16" 27 mm t I 45-LN 3/4" 19 mm N/A 80 Setscrew 60 1-1/2" 38 mm 1-3/4" 44 mm 75 2-1/8" 54 mm 1-1/2" 38 mm 100 2-3/8" 60 mm 2-3/8" 60 mm 120 A 125 2-5/16" 59 mm 2-1/8" 54 mm Fan 150 2-3/8" 60 mm Blade 300-400 175 2-1/8" 54 mm 200 1-5/8" 41 mm Motor 2251250/300 2" 51 mm N/A 130 Setscrew 350 1-7/8" 48 mm �J 400 1-3/8" 35 mm 1. If the heater is installed, turn off the gas and disconnect the electric power. 2. Open the access door and disconnect the fan motor wires, capacitor wires at the capacitor, and ground screw. 3. Remove the assembled parts (the fan guard, the motor and the fan blade). 4. Disassemble and replace whatever parts are needed and reassemble using whatever part(s) are being replaced and the original parts. Be sure the fan blade is in the proper position on the shaft; refer to the illustration and table in FIGURE 22. Position the assembly on the heater. Attach the fan guard. Rotate the fan blade to check for adequate clearance. If adjustment is required, loosen the mounting screws, re-position the fan guard, and tighten the screws. Rotate the fan blade and re-check for adequate clearance. Repeat this procedure until the assembly is positioned properly. Page 32 5. Reconnect the fan motor wires according to ti—wiring diagram and close the access panel. 6. Restore power to the heater and turn on the gas. Light, following the instructions on the lighting instruction plate. Check for proper operation. 10.2.6 Venter Motor Replacement Instructions and Wheel Remove dirt and grease from the motor casing, the venter housing, and the venter wheel. Venter motor bearings are permanently lubricated. Follow these instructions for replacement of the venter motor and wheel assembly. Keep all hardware removed to be used in re-assembling and installing the replacement parts. 1. Turn off the gas and disconnect the electric power. 2. Open the burner/control compartment access panel. 3. Disconnect the three venter motor wires at the DSI control, capacitor wires at the capacitor(if applicable), and ground screw (located on the control panel). 4. Sizes 30 and 45 - Disconnect the gas train and move it out of the way. Disconnect the gas supply at the union outside of the cabinet.At the gas valve, mark and disconnect the wires. Carefully remove the burner orifice and orifice adapter locking nut. Slide the orifice adapter out through the bracket on the burner pushing the gas train to the right. This will move the gas train out of the way. 5. Holding the venter motor, remove the three or four screws that attach the venter motor mounting plate to the venter housing. Remove the motor and wheel FIGURE 23 -Venter assembly from the heater. Wheel Position on 6. Re-assemble with the replacement venter motor and wheel assembly. See Shaft FIGURE 23. Venter Venter Motor Plate Venter Wheel, Venter Motor Plate Wheel Sizes 30-75 �— Fan Venter Wheel, � Fan Sizes 100-175 Motor Mounting Motor Mounting Bracket Motor Mounting Bracket Bracket t4 - e a Venter n Venter Motor for Venter Motor for Motor for Sizes 1 Sizes 200-400A Sizes 150-175 30-125 a e 5/16"(8mm)inside -�I ��5/16"(8mm)inside I (11mm)inside 7. Follow the wiring diagram to connect the venter wires. 8. Sizes 30 and 45 - Reconnect the gas supply at the union outside of the cabinet. Leak test the connection with leak detecting solution. 9. Replace the access panel. Restore power to the heater and turn on the gas. Light, following the instructions on the lighting instruction plate. Check for proper operation. 10.2.7 Operating Gas Carefully remove external dirt accumulation and check wiring connections. Valve .The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting to the unit to ensure positive closure. See Hazard Levels, page 2. The combination gas valve must be checked annually to ensure that the valve is shut- ting off gas flow completely. Instructions: 1) Locate the 1/8" NPT pressure tap on the combination valve. (See FIGURE 24, page 34. Page 33 10.0 Maintenance 10---l Operating Gas Valve (cont'd) and Service Single-Stage Valves(cont d) 1/8„ Outlet Two -Stage Valve 1/8" Outlet Pressure Tap -; 10.2 Maintenance Pressure Tap Procedures (cont'd) FIGURE 24 - Pressure Tap for Checking Gas Flow Shutoff 1, 1/8 Outlet Pressure Tap NOTE: Operational 2) With the manual valve turned off to prevent flow to the gas valve, connect a pressure settings and manometer to the 1/8" outlet pressure tap in the valve. NOTE: A manometer(fluid- instructions for checking filled gauge) is recommended. pressure settings are in 3) Turn the manual valve to the ON position and the heater OFF. Use your finger to Paragraph 6.1. fully block the main burner orifice for several seconds. Observe the manometer with the orifice blocked, and if any pressure is indicated, the gas valve is leak- ing. A leaking gas valve must be replaced before the heater is put back in operation. 10.2.8 Combustion Air See FIGURE 18, page 30, for location. (NOTE: Depending on date of manufacture and Pressure Switch size, pressure switch may not be in the location indicated. Check the control bracket s_ on the bottom of the compartment or further down on the compartment wall.) If it is determined that the pressure switch needs replacing, use only the factory-authorized replacement part that is designed for the model and size of heater being serviced. r: NOTE:A unit operating above 6000 ft(1830M) elevation requires a high altitude pres- sure switch. See Paragraph 3.2. 10.2.9 Limit If it is determined that the limit control needs replacing, use only a factory-authorized Control replacement part that is designed for the size of heater. For approximate limit location, see FIGURE 18, page 30. 10.2.10 Flame Rollout The cause of a flame rollout switch activating must be determined. Activation of the Switch - Sizes 30-125 manually reset flame rollout switch could be caused by one or more of the following: only • Restricted or plugged heat • Restricted combustion air inlet or exhaust outlet exchanger in combination with a defective pressure switch • Too much building exhaust • Electrical power interruption during operation • Manifold gas pressure too • Unit being operated with a line voltage high disconnect (a 24-volt thermostat is required) If a flame rollout switch trips, inspect the burner/control compartment for signs of excessive heat and burned wiring. For location, see If the compartment appears normal, reset by depressing the red button on the FIGURE 18, page 30. switch. 15 to 20 minutes are required for the switch to cool sufficiently for reset- ting. A distinct click will be felt when the switch resets. Operate the furnace. If the flame rollout switch trips again, determine and correct the cause before resetting the switch. If there is damage to the control compartment, repairs must be made before resetting the switch. If it is determined that the flame rollout switch needs replacing, use only the factory- authorized replacement part that is designed for that size of heater The disconnect switch is located in the sealed electrical box inside the control com- partment with the toggle on the rear of the heater. 10.2.11. Door If it is determined that the door switch needs replacing, use only a factory- Switch - Separtated authorized replacement part that is designed for the heater. Combustion Model For approximate switch location, see FIGURE 18, page 30 only Page 34 10.2.12 Transformer i —ft, See FIGURE 18, page 30, for k ation. Use a voltmeter to verify that i there are 24 volts output from the transformer. If the transformer is not functioning, it must be replaced. Use a replacement transformer identi- cal to the factory-installed model. 10.2.13 Disconnect If it is determined that the disconnect switch needs replacing, use only the Switch - Separated factory-authorized replacement part that is designed for the heater. Always Combustion model +• replace electrical box cover. only 10.2.14 Vent or Vent/ Check the complete system at least once a year. Inspection should include all joints, Combustion Air seams, concentric adapter box(Separated Combustion), inlet air guard or inlet air cap System (Separated Combustion), and the vent terminal cap. Clean openings. Replace any defective parts. 10.3 Troubleshooting The integrated circuit board monitors the operation of the heater and includes two Check the Lights On LED signal lights that indicate normal operation and various abnormal conditions. If g the heater fails to operate properly, check this signal to determine the cause and/or the DSI Integrated to eliminate certain causes. LED is visible through viewport on Separated Combus- Control Module tion models. Remove access panel on Standard Power Vent models. See operating (Circuit Board) sequence in Paragraph 9. Do not attempt to repair the DSI integrated control module(circuit board); the only field replaceable component is the fuse. IMPORTANT: When using a multimeter to troubleshoot Control Status -Green LED Codes the 24 volt circuit, place the Steady ON Normal Operation, No call for heat meter's test leads into the 5 Fast Flash.Normal Operation, Call for heat or 9 pin connectors located 1 Flash......System Lockout, Failed to detect or sustain flame on the ignition control. Do 2 Flashes..Pressure Switch Did Not Close within 30 Seconds of Venter Motor not remove connectors or 3 Flashes..High Limit or Flame Rollout Switch Open terminals from the electri- 4 Flashes . Pressure Switch is Closed Before Venter Motor is Energized cal components. Doing so Steady OFF Blown fuse, No Power, or Defective Board can result in misinterpreted Flame Status -Yellow LED Codes readings due to the ignition Steady ON..Flame is sensed control board's fault mode Slow Flash..Weak flame (current below 1.0 microamps± 50%) monitoring circuits. Fast Flash...Undesired Flame (valve open and no call for heat) DSI Integrated Control Module (Circuit Trial for Ignition Call for Heat Board) Trial Troubleshooting Flowchart YES -- Is there a NO spark across gap at ignitor? YES Does gas -- -,NO Is there YES Check high ignite? spark voltage at voltage wire control? continuity. YES Is there minimum Is the flame YES Clean flame Is there 24V P1-2 YES Replace name current at the sensorcor►oded7 sensor. to power control? control flame sensor? module. Is there 16the sensor Check wiring minimum flame current S Raploee control YES Replace flame at the control module, located inflame sesnsor. I andlor 24VAC module? correctly? transrormer output. O NO Check connections to flame Reposition YES Is gas NO sensor and/or moisture in the burner assembly. flame sensor. flowing? Check gas pressure ES Is the ignitor Replace gas YES Is there and supply voltage. posit Ion correct in the valve. 24VAC at the gas If either are low, gas flow? valve? correct and repeat O startup. O Cheek wiring eml Is there 24VAC Replace Reposition YES from gas valve output on NO ignition spark ignitor. connections to control module to control gas valve. chassis? module. Page 35 10.3 Troubleshooting (coati d) General Troubleshooting PROBLEM PROBABLE CAUSE REMEDY Venter motor will not 1.No power to unit. 1.Turn on power,check supply fuses or circuit breaker. start 2.No 24 volt power to integrated circuit board. 2.Turn up thermostat;check control transformer output. 3.Integrated circuit board fuse blown. 3.Correct cause.Replace fuse(type ATC orATO,32VDC,3A). 4.No power to venter motor. 4.Tighten connections at circuit board and/or motor terminals. 5.Integrated circuit board defective. 5.Replace integrated circuit board. 6.Defective venter motor. 6.Replace venter motor.See Paragraph 29. Burner will not light 1.Manual valve not open. 1.Open manual valve. 2.Air in the gas line 2.Bleed gas line(initial startup only). 3.Gas pressure too high or too low. 3.Supply pressure should be 5"-14"w.c.for natural gas or 11"-14"w.c.for propane. 4.No Spark: 4. a)Loose wire connections a)Be certain all wire connections are solid. b)Transformer failure: b)Be sure 24 volts is available. c)Incorrect spark gap. I c)Maintain spark gap at 1/8". d)Spark cable shorted to ground. I d)Replace worn or grounded spark cable. e)Spark electrode shorted to ground. le)Replace if ceramic spark electrode is cracked or grounded. f)Burner not grounded. If)Make certain integrated circuit board is grounded(Terminal P1-9). g)Circuit board not grounded. I g)Make certain integrated circuit board is grounded to furnace chassis. h)Unit not properly grounded. I h)Make certain unit is properly field grounded to earth ground and properly phased(1-1 to hot lead L2 to neutral). i)Integrated circuit board fuse blown i)Correct cause.Replace fuse(type ATC or ATO,32VDC,3A). j)Faulty integrated circuit board. j)If 24 volt is available to the integrated circuit board and all other causes have been eliminated,replace board. 5.Lockout device interrupting control circuit by 5.Reset lockout by interrupting control at the thermostat or main power. above causes. 6.Combustion air proving switch not closing. 6. a)Make sure unit is properly vented. b)Remove obstructions from vent. c)Replace faulty tubing to pressure switch. 7.Faulty combustion air proving switch. 7.Replace combustion air proving switch. 8.Main valve not operating. 8. a)Defective valve. I a)If 24 volt is measured at the valve connections and valve remains closed, replace valve. b)Loose wire connections b)Check and tighten all wiring connections. 9.Integrated circuit board does not power main 9. valve. a)Loose wire connections I a)Check and tighten all wiring connections. b)Flame sensor grounded b)Be certain flame sensor lead is not grounded or insulation or ceramic is not cracked.Replace as required. c)Incorrect gas pressure. c)Supply pressure should be 5"-14"w.c.for natural gas or 11"-14"w.c.for propane. d)Cracked ceramic at sensor. d)Replace sensor. Burner cycle on and 1.Gas pressure too high or too low. 1.Supply pressure should be 5"-14"w.c.for natural gas or 11"-14"w.c.for off propane. 2.Burner not grounded 2.Make certain integrated circuit board is grounded(Terminal P1-9). 3.Circuit board not grounded. 3.Make certain integrated circuit board is grounded to furnace chassis. 4.Faulty integrated circuit board 4.If 24 volt is available to the integrated circuit board and all other causes have been eliminated,replace board. 5.Combustion air proving switch not closing. 5. a)Make sure unit is properly vented. b)Remove obstructions from vent. c)Replace faulty tubing to pressure switch. 6.Faulty combustion air proving switch. 6.Replace combustion air proving switch. 7.Flame sensor grounded. 7.Be certain flame sensor lead is not grounded or insulation or ceramic is not cracked.Replace as required. 8.Cracked ceramic at sensor. 8.Replace sensor. 9 Incorrect polarity. 9.Reverse line volt leads to integrated circuit board. 10.Pin terminal loose on 9 pin plug 10.Replace wire harness. Page 36 No heat(Heater Op- 1.Incorrect valve outlet pressure or orifice. 1.Check valve outlet pressure.bee Rating plate for manifold pressure. erating) 2.Cycling on limit control. 2.Check air throughput. 3.Improper thermostat location or adjustment. 3.See thermostat manufacturer's instructions. Fan or venter motor 1.Circuit open. 1.Check wiring and connections. will not run 2.Defective integrated circuit board. 2.Replace board. 3.Defective motor or starter. 3.Replace motor or starter. Fan or venter motor 1.Motor overload device cycling on and off. 1.Check motor load against motor rating plate.Replace motor if needed, turns on and off while burner is operating Fan or venter motor 1.Low or high voltage supply. 1.Correct electric supply. cuts out on overload P.Defective motor. 2.Replace motor. 3.Poor airflow. 13.Clean motor,fan,fan guard,filter,and coils Page 37 APPENDIX TECHNICAL DATA-Sizes 30-125(Data applies Lo all Models unless noted otherwise) Size 30 45 60 75 100 125 Input Heating Capacity BTUH 30,000 45.000 60,000 75,000 105,000 120,000 kw 8.8 132 176 220 30.8 35.2 Thermal Efficiency(%) 82 83 83 83 83 83 Output Heating Capacity" BTUH 24,600 37,350 49,800 62,250 87,150 99,600 kw 72 11.0 146 18.3 256 29.2 Natural 112 1/2 1/2 1/2 1/2 1/2 Gas Connection(inches)B Propane 1/2 1/2 1/2 1/2 1/2 1/2 Vent Connection c(inches diameter) 4 4 4 4 4 4 Combustion Air Inlet c(inches diameter)-Separated Combustion only 4 4 4 4 4 4 Control Amps(24 volt) 1 0 1 0 1 0 1 0 1 0 1 0 Full Load Amps(115 volt) 1 9 24 2A 3,3 3-9 5 1 Maximum Over Current Standard 115V 15 15 15 15 15 15 Protection°E Optional 208V or 230V 15 15 15 15 15 15 Normal Power Consumption(watts) 109 155 155 217 276 354 Discharge Air Temperature Rise(°F) 50 55 60 60 60 60 Air Volume CFM 456 629 769 961 1345 1 1537 M'/minute 12.9 17.8 21.8 275 367 459 ftz 1 0 1.0 1,2 1,2 20 2.0 Discharge Air Opening Area Mz 0 1 0.1 0,1 0,1 02 0.2 FPM 475 656 616 770 668 763 Output Velocity Mlminute 145 200 188 238 196 245 Standard Open 00 00 0,0 0 1 1/30 1/20 Fan Motor HP E Optional Enclosed N.A. N.A. N.A. N.A. 1/4 1/4 Fan Motor RPM 1550 1550 1550 1550 1050 1050 Fan Dlameter(Inches) 10 10 12 12 16 16 Sound Level dba @ 15 ft 40 40 40 49 54 55 TECHNICAL DATA-Sizes 150-400(Data applies to all Models unless noted otherwise) Size 150 175 200 225 250 300 350 400 Input Heating Capacity BTUH 150,000 175,000 200,000 225,000 250,000 300,000 350,000 400.000 kw 43.9 51.2 58.6 65,9 732 87.8 102.5 117 1 Thermal Efficiency(%) 83 83 83 83 83 83 83 83 Output Heating Capacity^ BTUH 124,500 145,250 166,000 186,750 207,500 249,000 290,500 332,000 kw 36.4 42.5 48.6 54.7 60.8 729 85.1 97,2 B Natural 1/2 1/2 1/2 3/4 3/4 3/4 3/4 314 Gas Connection(inches) Propane 1l2 1/2 1/2 314 3l4 3l4 3l4 3l4 Vent Connection c(inches diameter) 5 5 5 5 5 6 6 6 Combustion Air Inlet c(inches diameter)-Separated Combustion only 6 6 6 6 6 6 6 6 Control Amps(24 volt) 1 0 1.0 1,0 1 0 1 0 1.o 1 0 1.0 Full Load Amps(115 volt) 3.8 3.8 4.6 75 7,5 10.7 10-7 107 Maximum Over Current Standard 115V 15 15 15 15 15 20 20 20 Protection°e Optional 208V or 230V 15 15 15 15 15 15 15 15 Normal Power Consumption(watts) 392 392 491 747 747 1086 1086 1086 Discharge Air Temperature Rise(°F) 60 60 60 60 60 60 60 60 Air Volume CFM 1921 2242 2562 2882 3202 3843 4483 5123 MI/minute 54.4 63-5 72.5 81.6 907 108.8 1269 1451 ftz 2.6 26 2.6 35 35 4.8 4.8 4.8 Discharge Air Opening Area Mz 0.2 0.2 02 03 0,3 0.5 0.5 OS FPM 752 877 1003 820 911 802 936 1069 Output Velocity M/minute 229 267 306 250 278 244 285 326 Fan Motor HP E Standard Open 1/6 1/6 1/6 1/4 1/4 1/2 1/2 1/2 Optional Enclosed 1/4 1/4 1/4 1/4 1/4 1/2 1/2 1/2 Fan Motor RPM 1050 1050 1050 1050 1050 1050 1050 1050 Fan Diameter(inches) 1 18 18 18 20 20 24 24 24 Sound Level dba @ 15 ft 51 52 53 56 56 59 61 62 A CSA ratings for altitudes to 2000 ft. e Size shown is for gas connection to a single-stage gas valve, not supply line size. c Smaller and/or larger vent and combustion air pipe diameters may be permissible. For Separated Combustion models refer to the Venting Installation Manual for Separated Combustion Units. For Standard Power Vent models refer to the Venting Installation Manual for Power Vented units.For a Standard Power Vent model with Option AV6, refer to the Venting Installation Manual for Common Venting. °MOCP=2.25 x(largest motor FLA)+smallest motor FLA.Answer is rounded to the next lower standard circuit breaker size. E Except where indicated, information in this table is based on a heater equipped with a standard 115 volt open fan motor. Page 38 INDEX A Gas Supply 11 Power Interruption 25 Abnormal Heat Cycle Functions 24 Gas Supply Line 12 Preparing for Installation 6 Aircraft Hangars 4 Gas Valve 21, 33 Prepurge 23 Control Amps 38 Gas Valve ON/OFF Control Knob 27 Pressure Switch 24 Full Load Amps 38 H Pressure Switch Settings 20 APPENDIX 38 Hanger Kits 11 PRESSURE TESTING SUPPLY PIP- B Hanging the Heater 10 ING 11 Clean the Burner 31 HAZARD INTENSITY LEVELS 2 S Burner Maintenance 30 Hazard Labels and Notices 2 Mounting the Sensor 22 Burner Orifice 31 Heat Exchanger Maintenance 30 Sound Level 38 Burner Removal 30 High Altitude Capacity 15 Spark Gap 32 C High Altitude Derate 14 Startup 26 California Warning Label 4 High Altitude Kit 6, 7 Stepdown transformer 6 Ceiling Suspension Kit 11 1 Supply Wiring 17 Certification 3 Ignition System 23, 31 Suspending 10 Check installation after startup 27 Ignition Trial Period 23 Suspending the Heater with Rods 11 Check the installation prior to startup Ignitor 32 Suspend the Heater from 1" Pipe 11 26 Input Heating Capacity 38 Swivel Connectors 11 Check the Lights 35 Installation Codes 4 T Chlorine 6 L TECHNICAL DATA 38 Clearances 7 Leak-test 12 Thermostat 21 LED Codes 23, 35 Lifting 10 Unit Mounted Thermostat 21 Combustion Air 16 LED lights 23 Throw 4 Combustion Air Inlet 38 Limit Control 20, 34 Transformer 35 Combustion Air Pressure Switch 34 Limit Switch 24 Troubleshooting 35, 36 Combustion Air Proving Literature Bag 28 Troubleshooting Flowchart 35(Pressure)Switch 20 Location 5 TURN OFF GAS TO THE APPLIANCE 27 Commissioning 26 Unit Heater Location 4 Confined Space 16 Location of Controls 29 U Contact 40 Lockout 25 Uncrating and Inspecting 6 Control Wiring 17 Optional vertical louvers 6 V Conversion Kits 13 M Valve Outlet Pressure 13 D Maintenance Procedures 30 Vent 35 DDC Controls 22 Maintenance Schedule 29 Vent/Combustion Air 35 Dimensions 8 Massachusetts Requirement 4 Vent/Combustion Air Kit 3 Disconnect Switch 35 Fan Motor 32 Vent/combustion air kit 6 Door Switch 34 Venter Motor 33 Vent cap 6 Door Switch-Separated Combustion Motor HP 38 Vent Connection 38 Model only 21 Multiple Heater Control 22 Venter Wheel 33 Downturn Nozzle Kits 7 N Venting Manual 3, 5 DSI Integrated Control Module 23, 31 Vent System Testing Procedure-Stand Normal Heat Cycle 23 E Power Vent Model 27 Thermal Efficiency 38 W Electrical Supply 16 Operating Sequence 27 Warranty 4 F Option CC1 6 Weights 10 Option C2 or 3,6 WHAT TO DO IF YOU SMELL GAS 26 Continuous Fan Operation 25 Option CDD 2, 3,, or or 4 7 Fan/Blower Off Delay 24 Wiring Connections 17 Option CK8, CK10, and CK22 11 Wring Diagram for all Single Stage Fan/Blower On Delay 24 Option CL31 22 g g g Fan Blades 32 Models 18 Option CL32 22 Fan Motor 21 Wiring Diagram for all Two Stage Gas Fault Modes 25 Option CM3 21 Valve 19 Option DJ20 or DJ21 6 Wiring Diagrams 18 Field-Installed Parts 6 Options D10 and D14 22 Flame Rollout Switch 34 Orifice Pressure 13 Flame Sensor 32 Output Heating Capacity 38 G P Garages 4 Plug the unused suspension points 10 Gas Connection 38 Post Purge 24 Gas Connection Size 12 Page 39 INSTALLATIOk, RECORD - to be completed by the installer: Installer: Name Company Address Phone Distributor(company from which the unit was purchased): Company Contact Address Phone Model Serial No. Date of Installation SPECIFIC INSTALLATION NOTES: (i.e. Location,Amps, Gas Pressure, Temperature, Voltage,Adjustments, Warranty, etc.) BUILDING OWNER OR MAINTENANCE PERSONNEL: For service or repair • Contact the installer listed above. • If you need additional assistance, contact the Distributor listed above. • For more information, contact your Local Representative. Specifications&illustrations subject to change without notice of incurring obligatons. ©2014 Nortek RCH Group. All rights reserved. NOROYYNE All marks are the property of their respective organizations. O'Fallon, MO I Printed in U S.A.(12/14) COMPLETE COMFORT,GENUINE VALUE. D300519 SKU 320E-1214 Form 1-UDA&APD Series,PN 195673R25 Page 40 ca.5 PIPE � o, •= �Ll+.wl f C-E- Z o• = 1..1►11'� K���Rs�z� So_ao Permit Information Date 10/20/2015 Permit Number 821 Project Name Global Machine Works Applicant Name Cozy Heating, Inc. Applicant Address 20221 67th Avenue NE City, State,Zip Arlington,WA 98223 Contact Kyle Taylor Phone 360-435-4904 Email kyle91879@aol.com Permit Type Commercial Mechanical Site Address 19130 59th Avenue NE Valuation 950000 Status Applied Permit Issued Permit Expires Square Feet 0 Type of Construction/Occupancy Load Number of Stories 0 Proposed Use Install 2 unit heaters with gas piping Assigned To Launa Peterson Property Information Owner Information Parcel#:2667632 GLOBAL MACHINE WORKS INC GLOBAL MACHINE WORKS INC 19130 59TH DR NE 19130 59TH DR NE Arlington,WA 98223 Contractors Contractor Primary Phone Email Contractor Type License License# Name Contact .,OZY ince Willett 360-435- info@cozyheatinginc.comMECHANICAL Labor& COZYHI 122MM HEATING 904 CONTRACTOR Industries Review Date Type Description Target Date Completed Date Assigned To Status 10/20/2015 Commercial Mechanical 10/27/2015 JKevin Olander In Review Uploaded FileUpload File Date File 10/20/2015 2:58:09 PM lReznor Specs Install Manua�pdf i '`. � I1 ' � �, � y .� + � CGiviMERCIAL MECK LAICAL PERMIT APPLICATION Department of Community& Economic Development City of Arlington •18204 59th Ave NE • Arlington, WA 98223 • Phone (360) 403-3551 THIS APPLICATION MUST BE ACCOMPANIED BY TWO(2) SETS OF CONSTRUCTION DRAWINGS AND ALL OTHER INFORMATION OUTLINED IN THE MECHANICAL PERMIT SUBMITTAL REQUIREMENTS, IFAPPLICABLE. Type of Permit: ✓❑ New Installation ❑ Replacement ❑ Alteration Project Address: 19130 59th Ave NE Parcel #. Install (2) Unit Heaters and Gas Piping Project Description: Valuation:9,500 Owner:Global Machine Works, Inc Phone#: 360-403-8432 Address: 19130 59th Ave NE City: Arlington State: WA Zip: 98223 Email Address: brentgglobalmachineworks.com Brent @ Global Machine Contact Person: Phone#: 360-403-8432 Address: 19130 59th Ave NE City: Arlington State: WA Zip 98223 Email Address:Brent @ Global Machine Contractor Name:Cozy Heating, Inc Phone#:360-435-4904 Contractor Address:20221 67th Ave NE City:Arlington State:WA Zip:98223 Email:kyle91879C@aol.com Contractor License Number: 114 Expiration: 06/30/2016 Please indicate type of number of appliances: FURNACE CONDENSING UNIT GAS PIPING OUTLET 2 BOILER HEAT PUMP (multi-split) UNIT HEATER 2 CHILLER HEAT PUMP (mini-split) PAINT BOOTH COOLER HEAT PUMP (other) TYPE I HOOD AC(air cooled) HEAT REJECTION EQUIP TYPE II HOOD AC(water cooled) VENTILATION SYSTEM AST AC (evaporator) PACKAGED UNIT UST AC (VRF) DRYER OTHER I hereby certify that the above information is correct and that the construction on, and the occupancy and the use of the above- described property will be in accordance with the laws, rules and regulation of the State of Washington. Applicants Signature Date 10/20/2015 Applicants Printed Name Kyle Taylor Keceived J FOR STAFF USE ONLY OCT 2 0 2015 Permit rt Ac ed By Amount Received Receipt# Date Received ' COMMERCIAL MECHANICAL PRESSURE PIPING INFORMATION Department of Community & Economic Development City of Arlington •.18204 59th Ave NE • Arlington, WA 98223 • Phone (360)403-3551 If gas piping will be installed, this form is required in addition to a Commercial Mechanical Permit Application Pipe Material: IQ.C(� ('�� Inlet Pressure: 4� ill (A)'C Pressure Drop: (AjC Specific Gravity: C% Pressure Piping Schematic Show Pipe Size(s) and Length(s) from meter to all appliances. ❑ Scale or ❑ Not to Scale NOTE: any interior pressure regulators must be indicated NOTE: drip legs/sediment traps are required at all appliances unless integrated in the listed appliance I hereby certify that the above information is correct and that the construction on, and the occupancy and the use of the above- described property will be in accordance with the laws, rules and regulation of the State of Washington. /O� —� Applicants Si atur P/ n/ Date CZ CLVI�!l�l Print A lit, nls Name 1 1 --- �) � -- � -\ - .. � 1 --- �o �, -� � � --- _ �-- - � - — � C _ w -- �� (�1 - - � -- - - i 1 -- �� --_ __ � i � i �� . �� � � � . - _ . ..- -- - � 1 �_ � -- - -- - -- �I � N� -� - - — i � Permit#: 821 Permit Date: 10/20/15 Permit Type: COMMERCIAL MECHANICAL Project Name: Global Machine Works Applicant Name: Cozy Heating, Inc. Applicant Address: 20221 67th Avenue NE Applicant, City, State, Zip: Arlington,WA 98223 Contact: Kyle Taylor Phone: 360-435-4904 Email: kyle91879@aol.com Scope of Work: Install 2 unit heaters with gas piping Valuation: 9500.00 Square Feet: 0 Number of Stories: 0 Construction Type: Occupancy Group: ID Code: Permit Issued: 10/23/2015 Permit Expires: Form Permit Type: Status: COMPLETE Assigned To: Launa Black Property Parcel# Address Legal Description Owner Name Owner Phone Zoning GLOBAL 2667632 19130 59TH DR NE MACHINE WORKS INC Contractors Contractor Primary Contact Phone Address Contractor Type License License# COZY HEATING Vince Willett 360-435-4904 20221 67TH AVE CONSTRUCTIONNE CONTRACTOR City of Arlington 601 088 561 COZY HEATING Vince Willett 360-435-4904 20221 67TH AVE CONSTRUCTION LABOR&COZYHI*122MM NE CONTRACTOR INDUSTRIES Inspections Date Inspection Type Description Scheduled Date Completed Date Inspector Status R00.FURNACE 2 Reznor unit heaters 10/30/2015 FINAL bracing and installation 10/30/2015 10/30/2015 BUILDING Approved approved. 10/26/2015 R09.GAS PIPING 10/26/2015 BUILDING Approved ROUGH-IN Plan Reviews Date Review Type Description Assigned To Review Status 10/20/2015 COMMERCIAL BUILDING MECHANICAL Fees Fee Description Notes Amount Gas Piping/Units Enter#of units $10.00 Mechanical Base Permit Fee $25.00 Mechanical Fee(Enter Fixture Fee) $50.00 Mechanical Commercial Plan Review Table 4-1 $200.00 Total $285.00 Attached Letters Date Letter Description 10/23/2015 Building Permit Payments Date Paid By Description Payment Type Accepted By Amount 10/23/2015 Prina Taylor 56690905 cc $285.00 Outstanding Balance $0.00 Uploaded Files Date File Name 10/20/2015 1331214-Reznor Specs&Install Manual.pdf 10/20/2015 1331212-Gas Piping App .pdf 10/20/2015 1331213-Mechanical Permit Application 1FYHBOg7v sRMN.pdf COMMERCIAL MECHANICAL PERMIT APPLICATION Department of Community& Economic Development City of Arlington •18204 59th Ave NE • Arlington, WA 98223 • Phone (360) 403-3551 THIS APPLICATION MUST BE ACCOMPANIED BY TWO (2) SETS OF CONSTRUCTION DRAWINGS AND ALL OTHER INFORMATION OUTLINED/N THE MECHANICAL PERMIT SUBMITTAL REQUIREMENTS, IF APPLICABLE. Type of Permit: a New Installation Replacement 7 Alteration Project Address: 19130 59th Ave NE Parcel #: Install (2) Unit Heaters and Gas Piping Project Description: Valuation:9,500 Owner:Global Machine Works, Inc Phone#: 360-403-8432 Address: 19130 59th Ave NE City: Arlington State: WA Zip: 98223 Email Address: brent@globalmachineworks.com Brent @ Global Machine Contact Person: Phone#: 360-403-8432 Address: 19130 59th Ave NE City: Arlington State: WA Zip: 98223 Email Address:Brent @ Global Machine Contractor Name:Cozy Heating, Inc Phone#:360-435-4904 Contractor Address:20221 67th Ave NE City:Arlington State:WA Zip: 98223 Email:kyle91879@aol.com Contractor License Number: 114 Expiration: 06/30/2016 Please indicate type of number of appliances: FURNACE CONDENSING UNIT GAS PIPING OUTLET 2 BOILER HEAT PUMP (multi-split) UNIT HEATER 2 CHILLER HEAT PUMP (mini-split) PAINT BOOTH COOLER HEAT PUMP (other) TYPE I HOOD AC(air cooled) HEAT REJECTION EQUIP TYPE II HOOD AC(water cooled) VENTILATION SYSTEM AST AC (evaporator) PACKAGED UNIT UST AC (VRF) DRYER OTHER I hereby certify that the above information is correct and that the construction on. and the occupancy and the use of the above- described property will be in accordance with the laws. rules and regulation of the State of Washington. Applicants Signature � � I`'�a��� Date 10/20/2015 Applicants Printed Name Kyle Taylor FOR STAFF USE ONLY Permit# Accepted By Amount Received Receipt# Date Received Form I-UDA&APD Series (12-14) OBSOLETES Form 1-UDA(10-14) Installation / Operation Applies to: Standard Power Vent Unit Heaters: Model UDAP 0 Model APD Separated Combustion Unit Heaters: Model UDAS NOTE: Accessories referenced in this installation manual may not apply to all models. g 1 e� PROFS �J11 Ago:. s Cos CERTITtEO ® O . O A WARNING : FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage. Be sure to read and understand the installation, operation, and service instructions in this manual. Improper installation, adjustment, alteration, service, or maintenance can cause serious injury, death, or property damage. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — 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. • Leave the building immediately. • Immediately call your gas supplier from a phone remote from the building. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. — Installation and service must be performed by a qualified installer, service agency, or the gas supplier. Page 1 Table of Contents 1. General .......................................................2-4 7. Electrical Supply and Wiring ................16-22 1.1 Hazard Labels and Notices............................2 7.1 General .......................................................... 16 1.2 General Installation Information.................... 3 7.2 Supply Wiring................................................ 17 1.3 Warranty..........................................................4 7.3 24V Control Wiring Connections................. 17 1.4 Installation Codes...........................................4 7.4 Wiring Diagrams........................................... 18 2. Unit Heater Location..................................4-6 7.5 Electrical Operating Components...............21 2.1 Heater Throw ..................................................4 8. Controls and Operation.........................22-26 2.2 Location Recommendations.......................... 5 8.1 Thermostat....................................................22 3. Uncrating and Preparation........................6-7 8.2 DDC Controls, Options D10 and D14..........23 3.1 Uncrating and Inspecting............................... 6 8.3 Ignition System.............................................24 3.2 Preparing for Installation............................... 6 9. Commissioning and Startup.................27-28 4. Clearances and Dimensions ....................7-9 9.1 Check the installation prior to startup:.......27 9.2 Heater Startup:..............................................27 4.1 Clearances....................................................... 7 g.3 Check installation after startup:..................28 4.2 Dimensions .....................................................8 5. Hanging the Heater................................ 10-11 10. Maintenance and Service....................29-36 5.1 Weights 10 10.1 Maintenance Schedule............................... 30 5.2 Liftingand Suspending 10 10.2 Maintenance Procedures........................... 31 p g"""""""""""""""" 10.3 Troubleshooting 36 6. Mechanical ............................................. 11-16 APPENDIX ....................................................... 38 6.1 Gas Piping and Pressures............................11 Index ................................................................ 39 6.2 Combustion Air- Standard Power Vent and Standard Power Vent with CV Option Models 16 INSTALLATION RECORD .............................. 40 1.0 General 1.1 Hazard Labels and Notices There are warning labels on the unit and throughout this manual. For your safety, read the definitions below and comply with all boxes labeled CAUTION, WARNING, and DANGER during installation, operation, maintenance, and service of this heater. Definitions of Hazard Intensity Levels in this Manual HAZARD INTENSITY LEVELS 1. DANGER: Failure to comply will result in severe personal injury or death and/or property damage. 2. WARNING: Failure to comply could result in severe personal injury or death and/or property damage. 3. CAUTION: Failure to comply could result in minor personal injury and/or property damage. Gas-fired appliances are not designed for use in hazardous atmospheres containing flammable vapors or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in applications with airborne silicone substances. See Hazard Levels, above. Should overheating occur, or the gas supply control system fail to shut off the flow of gas, shut off the manual gas valve to the utility heater before shutting off the electrical supply. Page 2 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 that has been under water. Unit heaters should not be installed in an environment where the ambient temperature is below 50°F. The low space tem- perature may result in condensate forming in the heat ex- changer. 1.2 General 1.2.1 Certification Installation Models 30, 45, 60, 75, 100, and 125 are design certified by the Canadian Standards Information Association for use in residential, industrial, and commercial installations. Utility heat- ers certified for"residential use" are intended for heating of non-living spaces that are attached to, or part of a structure that contains space for family living quarters.They are BOTH this manual not intended to be the primary source of heat in residential applications or to be used and the correct in sleeping quarters. venting manual Models 150, 175,200,225,250,300,350,and 400 are design certified by the Canadian are REQUIRED for Standards Association for use in industrial and commercial installations only. installation of this All models and sizes are available for use with either natural or propane gas. The type of gas, the gas input rate, and the electrical supply requirement are shown on the heater. heater rating plate. Check the rating plate to verify that the heater is appropriate for the installation site. 1.2.2 Venting Manual Installation requires both this manual AND the venting manual. Venting Manual by Venting Instruction Manual by Look for Matching Label on Model Form No. Venting Manual and Heater Form 1-UD-V-PV, Label with a RED SQUARE Standard Power Vent Installation (Each heater has its own dedicated vent.) 0 Form 1-UD-V-CV Label with a BLUE TRIANGLE (Sizes 30, 45, 60, 75 & 100 only) Common Vent Installation (with Option AV6.) Form I-UD-V-SC, Label with a GREEN CIRCLE Separated Combustion (with field installed Option CC2, CC6, or CC14 Vent/Combustion Air Kit) Both this installation manual and the appropriate venting manual are shipped with the heater.Verify that the literature is correct for the heater being installed. If either manual is missing or incorrect, contact your distributor before beginning installation. The instructions in this manual apply only to the models listed. Installation should be done by a qualified agency in accordance with these instructions. The qualified service agency installing this heater is responsible for the installation. Page 3 1.0 General 1.3 Warranty (cont'd) Refer to the limited warranty information on the Warranty Card in the "Literature Bag". Warranty is void if... a. Wiring is not in accordance with the diagram furnished with the heater. b. The unit is installed without proper clearance to combustible materials. c. A fan model is connected to a duct system or if the air delivery system is modified. 1.4 Installation These units must be installed in accordance with local building codes. In the absence of Codes local codes, in the United States,the unit must be installed in accordance with the National Fuel Gas Code,ANSI Z223.1.A Canadian installation must be in accordance with the CSA B149 Installation Codes.These codes are available from CSA Information Services, 1-800- 463-6727. Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements. Special Installations Installations in aircraft hangars should be in accordance with ANSI/NFPA No. 409 (latest (Aircraft Hangars/ edition),Standard for Aircraft Hangars;in public garages in accordance with ANSI/NFPA No. Repair Garages/ 88A(latest edition), Standard for Parking Structures; and for repair garages in accordance Parking Garages) with ANSI/NFPA No. 88B (latest edition), Standard for Repair Garages. In Canada, instal- lations in aircraft hangars should be in accordance with the requirements of the enforcing authorities, and in public garages in accordance with CSA B149 codes. California Warning If the heater is being installed in the state of California,the installer MUST attach a warning Label label on the outside of the access door.The California Warning label is shipped in the litera- ture bag along with this manual, the warranty form, and any other paperwork that applies. If installation is in California, select a location on the heater access panel. Be sure the sur- face is clean and dry and adhere the label. Massachusetts If the heater is being installed in the Commonwealth of Massachusetts,these units must be Requirement installed by a licensed plumber or licensed gas fitter. 2.0 Unit Heater Use the sound data in Technical Data table in the APPENDIX (page 38), clearances Location in Paragraph 4.1; the combustion air requirements in Paragraph 6.2; the throw tables, mounting height requirements, and location recommendations in Paragraphs 2.1 and 2.2; the weights in Paragraph 5.1; and the venting requirements in the Venting Manual to determine where to suspend the heater. Unit heaters should not be used in an application where the heated space temperature is below 50°F. Operating under low ambient conditions may cause condensation to form in the heat exchanger. 2.1 Heater Throw *Louver angle listed in the table is relative to the top of the heater. FIGURE 1 - Throw for I Fan Models H E X - Y Z** H=Distance from bottom of heater to the floor X=Distance from heater to start of floor coverage Y=Distance to end of floor coverage **Z=point when the air velocity drops below 50 ft(15.2M)per minute NOTE: Throws listed are with standard adjustable horizontal louvers at the angles listed (angle is relative to the top of the heater). Throw pattern changes with the addi- tion of optional vertical louvers and/or downturn nozzles. Page 4 Dimensions X,Y,and Z(feet)Models with Standard Horizontal Louvers at Mounting Heights of 5-18 ft 30 45 60 75 100 125 F1 `m m `m m `w w `m m `m*v `m v X Y Z 3 a X Y Z m X Y Z X Y Z 3 m X Y Z F. X Y Z �m J Q J Q J Q J Q J Q J Q 5ft 6 14 30 -21° 7 16 40 -20° 8 18 45 -16° 9 20 57 -14° 9 20 59 -18° 10 22 65 -14° 8ft 7 13 26 -39° 9 16 37 -34° 10 18 42 -29° 12 22 54 -25° 11 21 56 -28° 12 23 63 -24° 10ft 6 11 22 -52° 9 15 33 -43° 10 17 39 -370 12 22 52 -320 12 20 52 -36° 13 24 60 -30. 12ft - - - - 8 12 27 -55° 10 16 34 1-46° 12 21 48 -39° 11 19 47 -44° 14 23 57 -36° 14 ft 9 14 29 -56' 12 19 44 -460 11 17 42 -510 14 22 53 -430 16ft - - - - - - - - - - - - 11 17 38 -54° 10 14 34 -58° 13 20 47 -50° 18ft 11 17 40 -570 150 175 200 225 250 300 350 400 F1 > ad `> d'v `vy `va > m"v >- >- >- >- >- >- >- >- X Y Z ii � X Y Z 'o � X Y Z 'o � X Y Z ii � X Y Z ii � X Y Z ii � X Y Z 'o � X Y Z o c J Q J Q J Q J Q J Q J Q J Q J Q 8ft 13 24 73 -260 15 28 90 -220 16 30 93 -200 14 27 86 -24° 16 29 93 -21° 15 28 94 -24° 17 31 105 -20° 18 34 113 -170 10ft 14 24 69 -320 17 29 87 -27' 17 31 91 -25° 15 27 82 -300 17 30 90 -26° 16 28 89 -29° 18 32 103 -25° 20 35 110 -21° 12ft 14 24 64 -390 18 29 84 -320 18 31 88 -300 16 27 78 -35° 18 30 87 -31° 17 28 85 -34° 19 32 98 -30° 21 36 108 -25° 14ft 14 22 59 -450 18 28 79 -37° 19 30 84 -34' 16 26 73 -410 18 30 83 -36° 17 27 80 -40° 20 32 95 -34° 23 35 105 -29° 16ft 13 20 53 -51° 18 27 74 -42° 19 29 79 -390 16 24 67 -47° 19 28 78 -41° 17 25 74 -45° 21 31 90 -38° 23 35 101 -33° 18ft 11 17 44 -58° 17 26 68 -48° 19 28 74 -440 14 22 -- -53° 18 27 72 46° 16 24 66 -51° 20 30 85 -43° 23 35 97 -37° Dimensions X,Y,and Z(meters)Models with Standard Horizontal Louvers at Mounting Heights of 1.5-5.5M 30 45 60 75 100 125 ry --[ >d d d >d d d `v`y `>'- X Y Z "m X Y Z � m X Y Z m X Y Z m X Y Z X Y Z J Q J Q J Q J Q J Q J Q 1.5 M 1.8 4.3 9.1 -210 2.1 4.9 12.2 -200 2.4 5.5 13.8 -160 2.7 6.1 17.4 -140 2.7 6.1 18.0 -180 3.0 6.7 19.9 -140 2.4 M 2.1 4.0 7.9 -390 2.7 4.9 11.3 -340 3.0 5.5 12.8 -290 3.7 6.7 16.5 -25° 3.4 6.4 17.1 -28° 3.7 7.0 19.2 -24° 3.0 M 1.8 3.4 6.7 -52° 2.7 4.6 10.0 -43° 3.0 5.2 11.9 -37° 3.7 6.7 15.8 -32° 3.7 6.1 15.8 -36° 4.0 7.3 18.3 -30° 3.7 M - - - - 2.4 3.7 8.2 -55° 3.0 4.9 10.4 -46° 3.7 6.4 14.6 -39° 3.4 5.8 14.3 -440 4.3 7.0 17.4 -36° 4.3 M - - - - - - - - 2.7 4.3 8.8 -560 3.7 5.8 13.4 -46° 3.4 5.2 12.8 -51° 4.3 6.7 16.1 -43° 4.9 M - - - - - 3.4 5.2 111.6 -54° 3.0 14.3 10.4 -58° 4.0 6.1 14.3 -50° 5.5 M - - - - - - - - - - - I - - - I - I - - I - - - 3.4 5.2 12.2 -57° 150 175 200 225 250 300 350 400 M d'v > `vy dd `vy `va and m"v >- >- >- >- >- >- >- >- XTYTZ o � X Y Z o � X Y Z 'o � X Y Z 0 X Y Z 0 X Y Z 'o c X Y Z 'o X Y Z o c J Q J Q J. J Q J Q J Q J Q J Q 2.4 M 4.0 7.3 22.3 -26° 4.6 8.5 27.4 -22° 4.9 9.1 28.0 -20' 4.3 8.2 26.2 -240 4.9 8.8 28.3 -210 4.6 8.5 28.7 -24° 5.2 9.4 32.0 -20° 5.5 11.3 34.4 -17° 3.0 M 4.3 7.3 21.0 -32° 5.2 8.8 26.6 -270 5.2 9.4 27.7 -25° 4.6 8.2 25.0 -30° 5.2 9.1 27.4 -26° 4.9 8.5 27.1 -29° 5.5 9.8 31.4 -25° 6.1 10.7 33.5 -21° 3.7 M 4.3 7.3 19.5 -390 5.5 8.8 25.6 -320 5.5 9.4 26.8 -30° 4.9 8.2 23.8 -350 5.5 9.1 26.5 -310 5.2 8.5 25.9 -34° 5.8 9.8 29.9 -30° 6.4 11.0 32.9 -250 4.3 M 4.3 6.7 �18. -45° 5.5 8.5 24.1 -37° 5.8 9.1 25.6 -34° 4.9 7.9 22.3 -41° 5.5 9.1 25.3 -36° 5.2 8.2 24.4 -40° 6.1 9.8 29.0 -34° 7.0 10.7 32.0 -29° 4.9 M 4.0 6.1 -51° 5.5 8.2 22.6 -42° 5.8 8.8 24.1 -39° 4.9 7.3 20.4 -47° 5.8 8.5 23.8 -41° 5.2 7.6 22.6 -45° 6.4 9.4 27.4 -38° 7.0 10.7 30.8 -33° 5.5 M 3.4 5.2 -58° 5.2 7.9 20.7 -48° 5.8 8.5 22.6 -44° 4.3 6.7 18.3 -53° 5.5 8.2 21.9 -46° 4.9 7.3 20.1 -51° 6.1 9.1 25.9 -43° 7.0 10.7 26.9 -37° 2.2 Location Recommendations NOTE: Venting Locate the heater so that it is a minimum of five feet (1.5M) above the floor and in requirements may compliance with the clearances in Paragraph 4.1. affect location. Consult the Venting Manual for this heater If touched, the vent pipe and internal heater surfaces that are before making final accessible from outside the heater will cause burns. Suspend the determination. heater a minimum of 5 feet (1.5M) above the floor. For best results, the heater should be placed with certain rules in mind. In general, a unit should be located from 8 to 12 feet(2.4-3.7M)above the floor. Units should always be arranged to blow toward or along exposed wall surfaces, if possible. Where two or more units are installed in the same room, a general scheme of air circulation should be maintained for best results. Suspended heaters are most effective when located as close to the working zone as possible, and this fact should be kept in mind when determining the mounting heights to be used. However, care should be exercised to avoid directing the discharged air directly on the room occupants. Partitions, columns, counters, or other obstructions should be taken into consideration when locating the unit heater so that a minimum quantity of airflow will be deflected by such obstacles. Page 5 2.0 Unit Heater When units are located in the center of the space to be heated, the air should be dis- Location charged toward the exposed walls. In large areas, units should be located to discharge (cont'd) air along exposed walls with extra units provided to discharge air in toward the center of the area. 2.2 Location At those points where infiltration of cold air is excessive, such as at entrance doors and shipping doors, it is desirable to locate the unit so that it will discharge directly toward Recommendations the source of cold air from a distance of 15 to 20 feet(4.6-6.1 M). (cont'd) CAUTION: Do not locate the heater where it may be exposed to water spray, rain, or dripping water. For a location where dirt,dust,or other airborne contaminants are present in the indoor environment, it is recommended to install a separated-combustion unit, Separated Combustion model,that uses outside airfor combustion. Using a separated-combustion unit will reduce the build-up of contaminants on the burner.Any buildup on the burner will adversely affect the combustion process. Hazards of Chlorine - The presence of chlorine vapors in the combustion air of gas-fired heating equipment applies to Separated presents a potential corrosion hazard. Chlorine found usually in the form of freon or Combustion Heaters degreaser vapors, when exposed to flame will precipitate from the compound, and go location with regard to into solution with any condensation that is present in the heat exchanger or associated parts.The result is hydrochloric acid which readily attacks all metals including 300 grade the combustion air inlet stainless steel. Care should be taken to separate these vapors from the combustion process. This may be done by wise location of the unit vent and combustion air terminals with regard to exhausters or prevailing wind directions. Chlorine is heavier than air. Keep these facts in mind when determining installation location of the heater in relation to building exhaust systems. 3.0 Uncrating and 3.1 Uncrating and Inspecting Preparation This unit was test operated and inspected at the factory prior to crating and was in operating condition. If the heater has incurred any damage in shipment, document the damage with the transporting agency and contact an authorized Distributor. If you are an authorized Distributor, follow the FOB freight policy procedures. Check the rating plate for the gas specifications and electrical characteristics of the heater to be sure that they are compatible with the gas and electric supplies at the installation site. 3.2 Preparing for Read this booklet and become familiar with the installation requirements of your par- Installation ticular heater. If you do not have knowledge of local requirements, check with the local gas company or any other local agencies who might have requirements concerning this installation. Before beginning, make preparations for necessary supplies, tools, and manpower. IMPORTANT: Shipping brackets are attached with cabinet screws. When remov- ing shipping brackets, re-insert ALL screws into the cabinet. 3.2.1 Field-Installed Models with Separated Combustion - In the literature bag, find three cap screws, P/N Parts 203311, and three sealing washers, P/N 61658.After attaching the hanging hardware (Paragraph 5.2), these screws and washers must be used to seal the unused holes in the top of the heater. Models with Standard Power Vent- If the installation includes optional vertical louvers, downturn nozzle, ceiling mounting bracket, hanger kit, high altitude kit, multiple heater control, sensor for DDC control, and/or stepdown transformer, install these options before the heater is suspended. Complete instructions are in this form or in the option package; option packages are shipped separately. Other shipped separate items could include a vent cap (Standard Power Vent heaters with Option CC1); a vent/combustion air kit (Separated Combustion heaters with Option CC2 or CC6); a manual gas valve; a thermostat bracket kit; a thermostat; and/ or a thermostat guard. Be sure all options ordered are at the installation site. High Altitude Kit, Option DJ20 or DJ21 If the heater is being installed at an elevation above 2000 ft (610M), the input rate will have to be derated. This is done by adjusting the valve outlet pressure. Page 6 In addition, if the heater is being installed at an altitude above 6000 ft (1830M), the pressure switch will have to be changed. If ordered with the unit as Option DJ20 or DJ21, the pressure switch is shipped separately for field installation. Gas valve adjustment Adjusting the valve outlet pressure is done after the heater is in operation; follow the for high altitude can instructions in Paragraph 6.1. Capacities and inputs for derated units are also listed in only be done after Paragraph 6.1. heater is operating; If the pressure switch needs to be changed, do that before the heater is operated; fol- see Paragraph 6.1. low the instructions in FIGURE 2. FIGURE 2 - Standard Power Vent Models Installing High Size 30 1 45 60 1 75 1 100 125 1 150 175 200 225 1 250 1 300 1 350 400 Altitude Pressure High Altitude Switch P/N 197031 197032 197031 201160 Switch required Negative Pressure OFF Setpoint"w.c. 0.35 0.45 0.35 1.05 above 6000 ft Label color Purple Pink Purple Brown Standard Power Vent Models with Option AV6 for Common Venting (1830M) elevation Size 30 45 60 75 100 High Altitude Switch P/N 197029 197032 196362 196388 Negative Pressure OFF Setpoint"w.c. 0.60 0.45 0.55 0.50 �, Label color Lt Blue Pink White Orange Separated Combustion Models Size 30 45 60 75 100 125 150 175 200 225 250 300 350 400 High Altitude Switch P/N 197029 196388 197030 197031 201160 Pressure Switch Differential Pressure OFF Setpoint"w.c. 0.60 0.50 0.40 0.35 1.05 Label color Lt.Blue Orange Green Purple Brown Instructions for Changing Pressure Switch 1. In the control compartment, locate the pressure switch. 2. Mark and disconnect the two wires attached to the pressure switch. 3. Disconnect the sensing tubes from the pressure switch. 4. Locate the two screws holding the switch mounting bracket. Remove the screws and the pressure switch. Save the screws. 5. Using the same screws, install the high altitude pressure switch.Attach the sensing tubes and wires. Downturn Nozzle Kits, Follow the instructions with the kit to install.Additional length beyond the front of the Option CD 2, 3, or 4 unit is shown in FIGURE 3. (Does not apply to Model APD) Downturn nozzles require Options CD2 and CD4 Option CD3 FIGURE 3 - 4-pt suspension. Size p p With Optional inches mm inches mm co Downturn Nozzle o With a 30,45 7-1/8 181 12-3/8 314 „ O tion p ,� Dimension U c92 with 60,75 8-5/8 219 15 381 --Applies to Standard a co C op 100,125 12-5/8 321 21-7/8 556 Power Vent(except APD) o a 150,175,200 11-1/2 292 19-7/8 505 &Separated Combustion D 225,250 14-1/2 368 25-1/8 638 Models U U 300,350,400 18-1/2 470 32 813 4.0 Clearances 4.1 Clearances and Units must be installed so that the clearances in the table are provided for combustion Dimensions air space, inspection and service, and for proper spacing from combustible construc- tion. Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface temperature of 90°F Clearances (50°C) above the surrounding ambient temperature is not exceeded. Size Top Flue Connector Access Panel Non-Access Side Bottom* Rear** inches mm inches mm inches mm inches mm inches mm inches mm 30 - 125 1 25 6 152 18 457 1 25 1 25 18 457 150 -400 1 4 102 6 152 1 18 457 1 2 51 1 1 25 1 18 457 *Suspend the heater so that the bottom is a minimum of 5 feet(1.5M)above the floor. ** Measure rear clearance from the fan motor. Page 7 4.0 Clearances and Dimensions (cont'd) 4.2 Dimensions FIGURE 4 - Standard Power Vent Models N M M and N-Hanger Dimensions for both 2-pt and 4-pt Suspension R-Hanger Dimension for 2-pt Suspension PandQ- Hanger P Combustion Dimensions Air Inlet for 4-pt— R Suspension t Thermosta1(,?CkLR AR (4-pt isI t TOP VIEW ConnectioEW required if ` (30-125 Vertica installing 150-400 Horizonta optional Q 3/8"-16 Female Thread � nozzle.) i -all suspension points G � Angular corner on UDA Series Line Voltage For Inlet connects External size,t eellarTechn al at circuit board) H Connection Data in the APPENDIX on page 38.) B I E D 1-114 . F (32) FRONT VIEW RIGHT SIDE VIEW A C (Access Panel) Hand Pull-UDA Series ONLYyO O O "Finger Holes"-APD Series ONLY Standard Power Vent Model Dimensions (inches± 1/16) Size A B C D E F G H J K M N P Q R 30,45 12-1/8 26-5/8 10 13-13/16 26 21-9/16 5-3/16 6-1/2 2-11/16 3-7/8 17-3/8 11/16 4-5/16 13 9-9/16 60 15-1/8 26-5/8 13 13-13/16 27 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 75 15-1/8 26-5/8 13 13-13/16 27-5/8 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 100 23-1/8 26-5/8 21 13-13/16 28-5/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 125 23-1/8 26-5/8 121 13-13/16 29-3/8 21-9/16 14-1/2 1 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 150,175,200 20-1/8 38-3/16 16 23 t42 35-3/8 8-1/2 8-1/4 5-7/16 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 16-3/8 225,250 26-1/8 38-3/16 22 23 35-3/8 13-1/16 8-13/16 9 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 15-5/8 300,350,400 34-1/8 41 30 23 35-3/8 17-1/16 9 11-13/16 7-5/16 27-11/16 1-3/8 8 3/16 22-3/16 16-3/16 Standard Power Vent Model Dimensions (mm ±2) Size A B C D E F G H J K M N P Q R 30,45 308 676 254 351 660 548 132 165 68 98 441 17 110 330 243 60 384 676 330 351 686 548 200 165 140 98 441 17 110 330 267 75 384 676 330 351 702 548 200 165 140 98 441 17 110 330 267 100 587 676 533 351 727 548 368 165 222 98 441 17 110 330 267 125 587 676 533 351 746 548 368 165 222 98 441 17 110 330 267 150,175,200 511 970 406 584 1067 899 216 210 138 165 652 35 208 564 416 225,250 664 970 559 584 1067 899 332 224 229 165 652 1 35 1 208 564 397 300,350,400 867 1041 762 584 1067 899 433 229 300 186 703 1 35 1 208 564 411 Page 8 FIGURE 5 - Separated Combustion Models N • M M and N-Hanger Dimensions for both 2-pt and 4-pt Suspension R-Hanger Dimension for Combustion Air Connection 2-pt Suspension (For size,see Technical Data in the APPENDIX on page 38.) PandQ- P �.T. Hanger Dimensions— R Thermostat S for 4-pt Connection --L REAR Suspension TOP VIEW (30-45,150-400 VIEW (4-pt Is Horizontal; required if 60-125 Vertical) installing(� 3/8"-16 Female Thread i optional nozzle.) i all suspension points Line Voltage K External Vent Connection Inlet(connects in H Gas (For size,see sealed electrical box) Connection Technical Data in the APPENDIX D B 1-1/4 on page 38.) � (32)� F E , RIGHT SIDE rrrrrrc VIEW A C FRONT (Access Panel) VIEW i LED Viewport Separated Combustion Model Dimensions(inches±1/16) Size A B C D E F G H J K M N P Q R S T 30,45 12-1/8 26-5/8 10 13-13/16 26 21-9/16 5-3/16 6-1/2 2-11/16 3-7/8 17-3/8 11/16 4-5/16 13 9-9/16 2-15/16 2-15/16 60 15-1/8 26-5/8 13 13-13/16 27 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 3-1/4 2-15/16 75 15-1/8 26-5/8 13 13-13/16 27-5/8 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 3-1/4 2-15/16 100 23-1/8 26-5/8 21 13-13/16 28-5/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 4-5/8 2-15/16 125 23-1/8 26-5/8 21 13-13/16 29-3/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 4-5/8 2-15/16 150,175,200 20-1/8 38-3/16 16 23 42 35-3/8 8-1/2 8-1/4 5-7/16 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 16-3/8 4-1/8 8-5/16 225,250 26-1/8 38-3/16 22 23 42 35-3/8 13-1/16 8-13/161 9 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 15-5/8 5-9/16 8-5/16 300,350,400 34-1/8 41 1 30 23 42 35-3/8 17-1/16 9 Ill-13/16 7-5/16 27-11/16 1-3/8 8-3/16 22-3/16 16-3/16 9-1/16 8-9/16 Separated Combustion Model Dimensions(mm±2) Size A B C D E F G H J K M N P Q R S T 30,45 308 676 254 351 660 548 132 165 68 98 441 17 110 330 243 75 75 60 384 676 330 351 686 548 200 165 140 98 441 17 110 330 267 89 75 75 384 676 330 351 702 548 200 165 140 98 441 17 110 330 267 89 75 100 587 676 533 351 727 548 368 165 222 98 441 17 110 330 267 117 75 125 587 676 533 351 746 548 368 165 222 98 441 17 110 330 267 117 75 150,175,200 511 970 406 584 1067 899 216 210 138 165 652 35 208 564 416 105 211 225,250 664 970 559 584 1067 899 332 224 229 165 652 35 208 564 397 141 211 300,350,400 867 1041 762 584 1067 899 433 229 300 186 703 35 208 564 411 230 217 Page 9 5.0 Hanging the 5.1 Weights Heater Before suspending the heater, check the supporting structure to be used to verify that it has sufficient load-carrying capacity to support the weight of the unit. Standard Power Vent Model Size 30 45 60 75 100 125 150 175, 200 225 250 300 350 400 Ibs 54 59 67 72 96 101 172 187 203 215 269 294 306 kg 24 27 30 33 44 46 78 85 92 98 122 133 139 Separated Combustion Model Size 30 45 60 75 100 125 150 175, 200 225 250 300 350 400 Ibs 55 60 68 73 97 102 173 188 204 216 270 295 307 kg 25 27 31 33 44 46 78 85 93 98 122 134 138 . - Check the supporting structure to be used to verify that it has sufficient load carrying capacity to support the weight of the unit. Suspend the heater only from the threaded nut retainers or with a manufacturer provided kit. Do NOT suspend from the heater cabinet. 5.2 Lifting and Suspending When the heater is lifted for suspension, support the bottom of the heater with plywood or other appropriately placed material. If the bottom is not supported, damage could occur. Before hanging, verify that any screws used for holding shipping brackets were re-installed in the cabinet. Separated Combustion Models - Whether using the suspension points or a hanger kit, when installing a Separated Combustion Model, any unused suspension points on the control side of the heater MUST be plugged. Plug these holes with the 1/2" long cap screws and flat washers shipped in the bag with the heater. (See FIGURE 6.) FIGURE 6 - Separated Combustion Models Plug any unusedsuspension points on the control side with the 1/2"long - Plug the unused _ - cap screws and flat washers provided m� suspension points on _ the control side of the heater with the three 1/2" long screws, P/N 203311, and the three sealing 61658.E Find the sscrews Control Side and washers in the literature bag shipped inside the heater. moor. - Unit must be level for proper operation. Do not place or add additional weight to the suspended heater. Hazard Levels, page 2. 5.2.1 Two-Point or Four-Point Suspension The heater is equipped for either two-point or four-point suspension.A 3/8'A 6 threaded nut retainer is located at each suspension point. NOTE: Four-point suspension is required when installing an optional downturn nozzle. See Dimensions in Paragraph 4.2 and the illustration in FIGURE 7A. Page 10 FIGURE 7A- Be sure the threaded hanger rods are Suspending the locked to the heater as illustrated. Heater with Rods from Length of threaded rod extending into the Threaded Nut the heater MUST NOT exceed 1/2" Retainers (either two or (13mm). 3/8"threaded rod four point suspension) (field supplied) Recommended Add a 3/8" nut and washer to maximum hanger lock the hanger rod length is rod to the heater. 6 feet (1.8M). 5.2.2 Hanger Kits, Option CK8, CK10, and CK22 If ordered with swivel connectors for 1" pipe, Option CK8 or CK10, attach the swivels at the threaded nut retainers. Suspend with 1" pipe. (See FIGURE 713.) FIGURE 7B - Swivel Be sure the --- Connectors to Suspend threaded swivel Lock the swivel 0 the Heater from 1" e, Option CK8 2- t connectors connector to Pipe, ( p ) are locked to the heater. or CK10 (4-pt) the heater as The connecto is threaded for illustrated. hanging from a 1" pipe. If ordered with a ceiling suspension kit, Option CK22, follow the illustrated instructions in the kit. (See FIGURE 8.) FIGURE 8 - Suspending the Heater using Sizes Available for Option CK22, Ceiling Allows the 5 I e Suspension Kit (no o hanger rods) heater to be installed one I inch from the ceiling. 1 1 a UDA_Series Model Shown 6.0 Mechanical 6.1.1 Gas Supply and Connections 6.1 Gas Piping and Pressures This appliance is equipped for a maximum gas supply pressure of 1/2 psi, 3.5 kPa, or 14 inches water column. Supply pressure greater than 1/2 psi requires installation of an additional lockup-type service regulator external to the unit. WARNING: PRESSURE TESTING SUPPLY PIPING Test Pressures Above 1/2 PSI: Disconnect the heater and manual valve from the gas supply line which is to be tested. Cap or plug the supply line. Test Pressures Below 1/2 PSI: Before testing, close the manual valve on the heater. Page 11 6.0 Mechanical 6.1 Gas Piping and Pressures (cont'd) (cont'd) 6.1.1 Gas Supply and Connections (cont'd) Sizing Capacity of Piping Gas Cubic Feet per Hour based on 0.3"w.c.Pressure Drop Supply Specific Gravity for Natural Gas--0.6(Natural Gas--1000 BTU/Cubic Ft) Line Specific Gravity for Propane Gas 1.6(Propane Gas--2550 BTU/Cubic Ft) Length Diameter of Pipe of 1/2" 3/4" V 1-1/4" 1-1/2" 2" Pipe Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane 20' 92 56 190 116 350 214 730 445 1100 671 2100 1281 30, 73 45 152 93 285 174 590 360 890 543 1650 1007 40' 63 38 130 79 245 149 500 305 760 464 1450 885 50' 56 34 115 70 215 131 440 268 670 409 1 1270 775 60' 50 31 105 64 195 119 400 244 610 372 1105 674 70' 46 28 96 59 180 1 110 370 226 560 342 1050 641 80' 43 26 90 55 170 104 350 214 530 323 990 604 90, 40 24 84 51 160 98 320 195 490 299 930 567 100, 38 23 79 48 150 92 305 186 460 281 870 531 125' 34 21 72 44 130 79 275 168 410 250 1 780 476 150' 31 19 64 39 120 73 250 153 380 232 710 433 175' 28 17 59 36 110 67 225 137 350 214 650 397 200' 26 16 55 34 100 61 210 128 320 195 610 372 Note:When sizing supply lines,consider possibilities of future expansion and increased requirements. Refer to National Fuel Gas Code for additional information on line sizing. All piping must be in accordance with requirements outlined in the National Fuel Gas Code ANSI/Z223.1a (latest edition) or CSA-B149.1 and B149.2 (See Paragraph 2). Gas supply piping installation should conform with good practice and with local codes. Support gas piping with pipe hangers, metal strapping, or other suitable material; do not rely on the heater to support the gas pipe. The heater is orificed for operation with natural gas having a heating value of 1000 (± 50) BTU per cubic ft or propane gas with a heating value of 2500(± 100) BTU per cubic ft. If the gas at the installation does not meet these specifications, consult the factory for proper orificing. Pipe joint compounds (pipe dope)shall be resistant to the action of liquefied petroleum gas or any other chemical constituents of the gas being supplied. Install a ground joint union and manual shutoff valve upstream of the unit control sys- tem, as shown in FIGURE 9. Installation of a trap with a minimum 3" (76mm) drip leg is required. The unit is equipped with a nipple that extends outside the cabinet.The gas connection is either 1/2" or 3/4". Leak-test all connections by brushing on a leak-detecting solution. . - All components of a gas supply system must be leak tested prior to placing equipment in service. NEVER TEST FOR LEAKS WITH AN OPEN FLAME. Failure to comply could result in personal injury, property damage or death. Gas Connection Size Gas Connection inches Size Natural Propane 30 45 60 75 100 125 150 175 200 1/2 1/2 225, 250, 300, 350, 400 3/4 3/4 Page 12 FIGURE 9 - Gas Ground Joint union connection is at To Gas Valve-. Manual shutoff (inside the the pipe nipple that cabinet) o Drip From Gas Supply extends outside the Leg (horizontal or vertical) cabinet. + Pipe nipple extending outside the cabinet. —Manual shutoff Illustration shows both a vertical and To Gas Valve (inside the 'q- horizontal gas supply; cabinet) requirements are the Groun Leg Drip same. union Measuring valve outlet gas pressure cannot be done until the heater is in operation. It 6.1.2 Valve Outlet is included in the steps of the"Check-Test-Start'procedure in Paragraph 9.The follow- or Orifice Pressure ing warnings and instructions apply. Setting 0 V M. Valve outlet gas pressure must never exceed 3.5" w.c. for natural gas and 10" w.c. for propane gas. Maximum inlet supply pressure for natu- Kits are available NOTE: Gas Conversion ral gas or propane is 14" w.c. Maximum gas pressure can never be for changing from exceded either during operation or static (lock up regulator). propane gas to natural For Natural Gas:When the heater leaves the factory,the combination gas valve is set gas or natural gas to so that the valve outlet gas pressure for a single-stage valve or high fire of a two-stage propane gas.A factory- valve is regulated to 3.5"w.c. Low fire on a two-stage valve is set to 1.8"w.c. Inlet sup- ply pressure to the valve for natural gas must be a minimum of 5"w.c. or as noted on authorized conversion the rating plate and a maximum of 14"w.c. kit MUST be used. For Propane Gas: When the heater leaves the factory, the combination gas valve is set so that the valve outlet gas pressure for a single-stage valve or high fire of a two- stage valve is regulated to 10" w.c. Low fire on a two-stage valve is set to 5.0" w.c. Inlet supply pressure to the valve for propane gas must be a minimum of 11"w.c. and a maximum of 14"w.c. Before attempting to measure or adjust valve outlet gas pressure, the inlet supply pressure must be within the specified range both when the heater is in operation and on standby. Incorrect inlet pressure could cause excessive valve outlet gas pressure immediately or at some future time. If natural gas supply pressure is too high, install a regulator in the supply line before it reaches the heater. If natural gas supply pressure Check Valve Outlet is too low, contact your gas supplier. Pressure (can only be Instructions done after heater is NOTE: If operating at high altitude, outlet pressure requires adjustment. Follow operating) instructions on page 14. 1) Locate the 1/8"output pressure tap on the valve (See FIGURE 10). With the man- ual valve turned off to prevent flow to the gas valve, connect a manometer to the 1/8" pipe outlet pressure tap in the valve. NOTE:A manometer(fluid-filled gauge) FIGURE 10 - Top View of Valves showing Outlet Pressure Tap and Adjustment Locations Single-Stage Adjust Outlet 1/8" Outlet Two-Stage Valve Valve Pressure Pressure Tap Adjust Low (two styles) Adjust High Fire Outlet 4` Fire Outlet Pressure Pressure Inlet — " Pressure Tap CI Adjust Outlet Pressure— Inlet ' u IE Pressure � ►•-1/8" Outlet Tap 1/8" Outlet Inlet Pressure Tap y Pressure Tap Pressure Tap Page 13 6.0 Mechanical is recommended rather than a spring type gauge due to the difficulty of maintaining (cont'd) calibration of a spring type gauge. 2) Open the manual valve and operate the heater. (NOTE: On a Separated Combus- 6.1 Gas Piping tion Model, depress and hold the door safety switch.) Measure the outlet pressure and Pressures of the gas valve. To measure low-stage pressure on a unit equipped with a two- (cont'd) stage valve, disconnect the wire from the "HI"terminal on the valve. (Be sure to reconnect the wire.) 6.1.2 Valve Outlet Normally when operating at sea level, adjustments should not be necessary to the or Orifice Pressure factory setting. (For high altitude settings, see next paragraph.) Setting (cont'd) If adjustment is necessary, remove the cap from the adjustment screw(s). Set pressure to correct settings by turning the regulator screw IN (clockwise)to increase pressure. Turn regulator screw OUT(counterclockwise)to decrease pressure. CAUTION: DO NOT bottom out the gas valve regulator adjusting screw. This can result in unregulated manifold pressure causing excess overfire and heat exchanger failure. 6.1.3 Derate by Valve Instructions for High Altitude Derate Outlet Pressure 1. Determine the required valve outlet pressure for the elevation where the heater will Adjustment for High be operating. If unsure of the elevation, contact the local gas supplier. Altitude Operation Valve Outlet Pressure Settings by Elevation Manifold Pressure Settings by Altitude for the UNITED STATES This adjustment Altitude Natural Gas(inches w.c.) Propane Gas(inches w.c.) can only be done Feet Meters Single-Stage and Two-Stage Single-Stage and Two-Stage Two-Stage High Fire Low Fire Two-Stage High Fire Low Fire after the heater is in 0-2000 0-610 3.5 1.8 10.0 5.0 operation. High altitude 2001-3000 611-915 3.1 1.6 8.8 4.4 adjustment is included 3001-4000 916-1220 3.0 1.5 8.5 4.2 in the startup Steps. 4001-5000 1221-1525 2.8 1.5 8.1 4.1 5001-6000 1526-1830 2.7 1.4 7.7 3.9 NOTE: If elevation is 6001-7000 1831-2135 2.6 1.3 7.4 3.7 above 6000 ft (1830M), 7001-8000 2136-2440 2.5 1.3 7.1 3.5 a high altitude pressure 8001-9000 2441-2745 2.4 1.2 6.7 3.4 switch is required; see 1 9001-10000 1 2746-3045 1 2.3 1 1.2 1 6.7 1 3.4 Paragraph 3.2.1. Manifold Pressure Settings by Altitude for CANADA Altitude Natural Gas(inches w.c.) Propane Gas(inches w.c.) Feet Meters Single-Stage and Two-Stage Single-Stage and Two-Stage Two-Stage High Fire Low Fire Two-Stage High Fire Low Fire 0-2000 0-610 3.5 1.8 10.0 5.0 2001-4500 611-1373 2.8 1.5 8.1 4.1 2. Locate the 1/8"output pressure tap on the valve (See FIGURE 10, page 13). Turn the knob or switch on the top of the valve to"OFF". Connect a manometer to the 1/8" pipe outlet pressure tap in the valve. Use a water column manometer that is readable to the nearest tenth of an inch. 3. Single-Stage and Two-Stage High Fire -Turn the knob or switch on the top of the valve to "ON". Remove the cap from the pressure adjusting screw and adjust the gas train pressure to the pressure selected from the table above.Adjust pressure by turning the regulator screw IN (clockwise)to increase pressure or OUT(counterclockwise)to decrease pressure. Two-Stage Low Fire - Disconnect the wire from the "HI"terminal on the gas valve and check the low fire pressure. Turn the regulator screw to adjust the low fire outlet pressure to the "Low Fire" pressure selected from the table. Re-connect the wire to the gas valve. 4. Turn up the thermostat. (NOTE: On a Separted Combustion model, depress and hold the door safety switch.) Cycle the burner once or twice to properly seat the adjustment spring in the valve. Re-check the pressure(s). When the outlet pressure is right for the installation, remove the manometer and replace the cap. Check for leak at the pressure tap fitting. Page 14 5. With the heater operating determine that the inlet pressure to the heater for natural gas is between 5 and 13.5 inches w.c. and for propane between 11 and 13.5 inches w.c. Take this reading as close as possible to the heater(Heaters are equipped with gas valves that have an inlet pressure tap.) If the inlet pressure is not within the specified range, the inlet pressure must be corrected and Steps 3 and 4 repeated. 6. Find the High Altitude Adjustment label in the plastic bag that contained these instructions. Using a permanent marker, fill-in the appropriate information from the tables below. Select a location for the label on the outside of the heater access panel so that it will be conspicuous to anyone operating or servicing the unit. Be sure the surface is clean and dry and adhere the label. High Altitude The input and/or the capacity of the heater changes with the derate. The tables below Capacity Changes list inputs and capacities at altitudes from sea level to 10,000 ft(3045M). BTUH Inputs and Capacities by Altitude in the UNITED STATES for all Models ALTITUDE Normal I Thermal Output Minimum Normal Thermal Output Minimum Normal Thermal Out Minimum Normal Thermal Output Minimum Input Capacity Input Input Capacity Input Input Capacity Input Input Capacity Input Feet Meters Size 30 Size 45 Size 60 Size 75 0-2000 0-610 30000 24600 30000 45000 37350 45000 60000 49800 42000 75000 62250 52500 2001-3000 611-915 28200 23124 28200 42300 35109 42300 56400 46812 39480 70500 58515 49350 3001-4000 916-1220 27600 22632 27600 41400 34362 41400 55200 45816 38640 69000 57270 48300 4001-5000 1221-1525 27000 22140 27000 40500 33615 40500 54000 44820 37800 67500 56025 47250 5001-6000 1526-1830 26400 21648 26400 39600 32868 39600 52800 43824 36960 66000 54780 46200 6001-7000 1831-2135 258001 21156 25800 38700 32121 38700 51600 42828 36120 645001 53535 45150 7001-8000 136-2440 25200 20664 25200 137800 1 31374 37800 50400 41832 35280 63000 52290 44100 8001-9000 441-2745 24600 20172 24600 36900 30627 36900 49200 40836 34440 61500 51045 43050 9001-10000 746-3045 24000 19680 24000 36000 1 29880 36000 48000 39840 33600 60000 49800 42000 Feet Meters Size 100 Size 125 Size 150 Size 175 0-2000 0-610 105000 87150 73500 120000 99600 84000 150000 124500 105000 175000 145250 122500 2001-3000 611-915 98700 82908 69090 112800 94752 78960 141000 117030 98700 164500 136535 115150 30014000 916-1220 96600 81144 67620 110400 92736 77280 138000 114540 96600 1161000 133630 112700 4001-5000 1221-1525 94500 79380 66150 108000 90720 75600 135000 112050 94500 157500 130725 110250 5001-6000 1526-1830 92400 77616 64680 105600 88704 73920 132000 109560 92400 154000 127820 107800 6001-7000 1831-2135 90300 75852 63210 103200 86688 72240 129000 107070 90300 150500 124915 105350 7001-8000 136-2440 88200 1 74088 L�8800 100800 84672 70560 126000 104580 88200 147000 122010 102900 8001-9000 441-2745 86100 72324 98400 82656 68880 123000 102090 86100 143500 119105 100450 001-10000 746-3045 84000 70560 96000 80640 67200 1200001 99600 84000 140000 116200 98000 Feet Meters Size 200 Size 225 Size 250 Size 300 0-2000 0-610 200000 166000 140000 225000 186750 157500 250000 207500 175000 300000 249000 210000 2001-3000 611-915 188000 156040 131600 211500 175545 148050 235000 195050 164500 282000 234060 197400 3001-4000 916-1220 184000 152720 128800 207000 171810 144900 230000 190900 161000 276000 229080 193200 4001-5000 1221-1525 180000 149400 126000 202500 168075 141750 1225000 186750 157500 270000 224100 189000 5001-6000 1526-1830 176000 146080 123200 198000 164340 138600 220000 182600 154000 264000 219120 184800 6001-7000 1831-2135 172000 142760 120400 193500 160605 135450 215000 178450 150500 258000 214140 180600 7001-8000 136-2440 1680001 139440 117600 189000 156870 132300 10000 174300 147000 252000 209160 176400 8001-9000 441-2745 164000 136120 114800 184500 153135 129150 205000 170150 143500 246000 204180 172200 9001-100002746-3045 160000 132800 112000 1800001 149400 126000 2000001 166000 1 140000 12400001 199200 168000 Feet Meters Size 350 Size 400 0-2000 0-610 350000 290500 245000 400000 332000 280000 2001-3000 611-915 329000 273070 230300 376000 312080 263200 3001-4000 916-1220 322000 267260 225400 368000 305440 257600 4001-5000 1221-1525 315000 261450 220500 360000 298800 252000 5001-6000 1526-1830 308000 255640 215600 352000 292160 246400 6001-7000 1831-2135 301000 249830 210700 344000 285520 240800 7001-8000 2136-2440 294000 244020 205800 13360001 278880 235200 8001-9000 274512870001 238210 1200900 13280001 272240 1229600 9001-100002746-304512800001 232400 1196000 13200001 265600 1224000 BTUH Inputs and Capacities by Altitude in CANADA for all Models ALTITUDE Normal Thermal Out Minimum Normal Thermal Output Minimum Normal Thermal Output Minimum Normal Thermal Output Minimum Input Capacity Input Input I Capacity Input Input Capacity Input Input Capacity Input Feet Meters Size 30 Size 45 Size 60 Size 75 0-2000 0-610 30000 24600 30000 45000 37350 1 45000 60000 49800 1 42000 75000 62250 1 52500 2001-4500 611-1373 27000 22140 1 27000 40500 33615 1 40500 540001 44820 1 37800 67500 56025 1 47250 Feet Meters Size 100 Size 125 Size 150 Size 175 0-2000 0-610 105000 87150 73500 120000 99600 1 84000 150000 124500 1 105000 175000 145250 1 122500 2001-4500 511-1373 94500 79380 1 66150 108000 90720 1 75600 1350001 113400 1 94500 1575001 132300 1 110250 Feet 1 Meters Size 200 Size 225 Size 250 Size 300 0-2000 0-610 200000 166000 140000 225000 186750 1 157500 250000 207500 1 175000 300000 249000 1 210000 2001-4500 611-1373 1800001 151200 1 126000 202500 170100 1 141750 2250001 189000 1 157500 2700001 226800 1 189000 Feet Meters Size 350 Size 400 0-2000 0-610 13500001 290500 1245000 14000001 332000 280000 2001-4500 611-1373 315000 264600 220500 360000 302400 252000 Page 15 6.0 Mechanical 6.2 Combustion Air - Standard Power Vent Models (cont'd) This heater must be supplied with the air that enters into the combustion process and is then vented to the outdoors. Sufficient air must enter the equipment location to replace (Note: For Separated that exhausted through the heater vent system. In the past, the infiltration of outside air assumed in heat loss calculations (one air change per hour) was assumed to be suf- Combustion Model, ficient. However, current construction methods using more insulation, vapor barriers, see Venting Manual tighter fitting and gasketed doors and windows, weather-stripping, and/or mechanical for combustion air exhaust fans may now require the introduction of outside air through wall openings or requirements.) ducts. The requirements for combustion and ventilation air depend upon whether the unit is located in a confined or unconfined space.An"unconfined space"is defined as a space whose volume is not less than 50 cubic feet per 1000 BTUH of the installed appliance. Under ALL conditions, enough air must be provided to ensure there will not be a negative pressure condition within the equipment room or space. Standard Power Vent Model unit heaters are designed to take combustion air from the space in which the unit is installed and are not designed for connection to outside combustion air intake ducts. Connecting outside air ducts voids the warranty and could cause hazardous operation. See Hazard Levels, page 2. Combustion Air Do not install a unit in a confined space without providing wall openings leading to and Requirements fora from the space. Provide openings near the floor and ceiling for ventilation and air for Heater Located in combustion as shown in FIGURE 11, depending on the combustion air source as noted a Confined Space - in Items 1, 2, and 3 below. applies to Standard Add total BTUH of all appliances in the confined space and divide by figures below for Power Vent Models and square inch free area size of each (top and bottom) opening. Standard Power Vent Models with CV Option FIGURE 11 - Definition Confined Space: of Confined Space and A space whose volume is �(3) (1)� _ -(?)- - Required Openings for less than 50 cubic feet per Ij Confined Combustion Air 1000 BTUH of the installed Space appliance input rating ; (3) (1); 1.Air from inside the building --openings 1 square inch free area per 1000 BTUH. Never less than 100 square inches of free area for each opening. See (1) in FIGURE 11. 2.Air from outside through duct--openings 1 square inch free area per 2000 BTUH. See (2) in FIGURE 11. 3.Air direct from outside --openings 1 square inch free area per 4000 BTUH. See (3) in FIGURE 11. NOTE: For further details on supplying combustion air to a confined space, see the National Fuel Gas Code ANSI Z223.1a (latest edition). 7.0 Electrical 7.1 General Supply and All electrical wiring and connections, including electrical grounding MUST be made in accordance with the National Electric Code ANSI/NFPA No. 70 (latest edition) or, in Wiring Canada, with CSA Standard C22.1. In addition, the installer should be aware of any local ordinances or gas company requirements that might apply. CAUTION: Route CAUTION: If any of the original wire as supplied with the appliance must wires so that they do not contact the flue be replaced, it must be replaced with wiring material having a temperature wrapper or venter rating of at least 105°C, except for limit control, flame rollout, and sensor housing. lead wires which must be 150°C. See Hazard Levels, page 2. Page 16 7.2 Supply Wiring Check the rating plate on the heater for the supply voltage and current requirements. A dedicated line voltage supply with disconnect switch should be run directly from the main electrical panel to the heater.All external wiring must be within approved conduit and have a minimum temperature rise rating of 60°C Conduit must be run so as not to interfere with the heater access panel. If the installation requires a stepdown trans- former (Option CG - on some models), follow the instructions shipped with the option package for attaching the transformer to the heater. The electrical supply enters at the rear of the heater (See FIGURE 13). Separated Combustion Models include a built-in disconnect switch (20A @ 115V; 10A @ 230V Rating). The Separated Compustion Model supply wiring connects to leads located inside a sealed electrical box. To maintain the sealing feature of the electrical box, always replace the cover plate. The Standard Power Vent Model supply wiring con- nects directly to leads on the integrated circuit board. The circuit board (See FIGURE 12) is located inside on the bottom of the control com- partment. The circuit board is polarity sensitive. It is advisable to check the electrical supply to be certain that the black wire is the "hot" wire and that the white wire is the neutral wire.The supply connection made to"L1"on the circuit board must be the"hot" wire. FIGURE 12 - Supply 109)-03-]IOX xSCI Wiring Connections at Q MODEL 1097-210 CD OO e0Q the Circuit Board (DSI Spark o OOa` Transformer u Integrated Control O =' DOO oa Module) Supply Wiring O OOQ Fus - Connections 0= Q, NOTE: Circuit OJ O Thermostat O 3 board is polarity Q _ Connections O sensitive; "hot" Q wire MUST BE C;;) 3} connected to O Terminal L1. O See section 10.3 E;QLD Troubleshooting O MEeT I on pages 36&37 O W COOL = for symptoms. O =©� nl Status LL Lights<�o x O O [��u 7.3 24V Control For all models, the terminal strip for 24 volt thermostat connections is located on the Wiring outside of the cabinet at the back of the heater(See FIGURE 13). Wires from the ter- Connections minal strip are factory wired to the circuit board. FIGURE 13 - Terminal Rear View Standard Rear View Separated Power Vent Model Combustion Model Strip for 24-volt wiring is on the outside rear of the heater. ° TerminalSeO Terminal- Strip �® R Strip �® G NOTE: The size of heater o® W1 illustrated has a vertical �® W2 Built-in terminal strip. Some sizes Disconnect ° have a horizontal terminal switch strip. Supply Supply Wiring Wiring Entrance Entrance Page 17 7.0 Electrical 7.4 Wiring Diagrams Supply and FIGURE 14A- Typical Wiring Diagram for all Single Stage Model or Wiring (cont'd) Recirculation Models LINE/1/60 FACTORYWIRING SYSTEM TRANSFORMER Y < — FIELD WIRING Y Z R m —M--M--M--M--K— OPTIONAL FACTORY r WIRING M J N J II w WIRE CONNECTOR o o� BR 3 ZOO GIRD U SCREW BK 0 Y G r G - SEC COM L1 NEUTRAL NEUTRAL L1 O am PR P3 1 o >>Y Q � EUTRAL W z W1 Y P3-2 A Q G FAN MOTOR Ny W — EAC/BLO BK BK�w. i [—� W P3-3 W O G ¢w y y DOOR INTERLOCK ao 0, m Z (UDAS ONLY) P3-4 O ULL R R R R 4 ti CAPACITOR �3 P3-5 `` J J C LED FLASH CODES (SEE NOTE#6) // GREEN LED W2 LIMIT CONTROL R P1-8 STEADY ON NORMAL OPERATION NO CALL FOR HEAT R FAST FLASH NORMAL OPERATION CALL FOR HEAT 1 FLASH IN LOCKOUT FROM FAILED IGNITIONS OR FLAME LOSSES R R P1J \ 2 FLASH PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS / OF VENTER ENERGIZED FLAME ROLLOUT 3FLASH LIMIT SWITCH OR ROLLOUT SWITCH OPEN (MODELS 30-125 ONLY) 4 FLASH PRESSURE SWITCH IS CLOSED BEFORE VENTER IS ENERGIZED Q.. G P1-6 STEADY OFF INTERNAL CONTROL FAULT OR NO POWER N 1 YELLOW LED n PRESSURE SWITCH STEADY ON FLAME SENSED SLOW FLASH WEAK FLAME Sul / FAST FLASH UNDESIRED FLAME(VALVE OPEN 8 NO CALL FOR HEAT) ~w P7-4 w~O BL \ IND BK Z / VENTER U'W �r�IGAS VALVE MOTOR O V W2 W� LB_ BR P1-2 FLAME E W BKLED LED NEUTRAL O O G N Z FLAME R P1-� zC U u ELECTRODE OF RC SPARK m 3 R R� P1-9 TRANSFORMER CAPACITOR DSI CONTROL (SEE NOTE#7) FLAMEGROUND SPARK GAP OPERATING SEQUENCE 1.SETTHERMOSTATAT LOWEST SETTING,(FAN SWITCH AT"AUTO"POSITION. 2.TURN ON MANUAL GAS VALVE. FIELD CONTROL WIRING 3.TURN ON POWER TO UNIT. 4.SET THERMOSTAT AT DESIRED SETTING. TOTAL WIRE DISTANCE FROM MIN.RECOMMENDED 5.THERMOSTAT CALLS FOR HEAT,ENERGIZING THE VENTER MOTOR. LENGTH UNIT TO CONTROL WIRE GUAGE 6.VENTER PRESSURE SWITCH CLOSES,FIRING UNITAT FULL RATE. 150' 75' #18 GA.WIRE 7.BURNER FLAME IS SENSED,AND IN 30 SECONDS THE FAN MOTOR IS ENERGIZED. 250' 125' #16 GA.WIRE 8.IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION, 350' 175' #14 GA.WIRE THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT (SEE LIGHTING INSTRUCTIONS). 9.SET FAN SWITCH AT"ON"POSITION FOR CONTINUOUS FAN OPERATION. NOTES WIRING CODE BLACK-BK 1.THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS:THERMOSTAT BROWN-SR 2.DOTTED WIRING INSTALLED BY OTHERS. RED-R 3.CAUTION:IF OF THE ORIGINAL WIRING REPLACED WIRING ORANGE-O ALL SINGLE STAGE or RECIRCULATION APPLIANCE MUST BE REPLACED,IT MUST BE REPLACED WITH WIRING MATERIAL YELLOW-Y HAVING A TEMPERATURE RATING OF AT LEAST 105'C.EXCEPT FOR SENSOR GREEN-G MODELS LEAD WIRE,FLAME ROLLOUT AND LIMIT WIRING WHICH MUST BE 150-C. BLUE-BL 4.USE 18 GA.WIRE FOR ALL WIRING ON THE UNIT. PURPLE-PR 5.LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT WHITE-W WD# 185139 REV#4 VOLTAGE DROPS BEYOND 5%OF SUPPLY LINE VOLTAGE. 6.CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS AG1-CL1 or CL22 150-400 AND 208/230V MODELS 100400. 7.CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150-400. 8.VERIFY JUMPER ON CL22 THERMOSTAT TERMINALS R TO RC. 9.FAN SWITCH OR LOW STAGE OF CL22 THERMOSTAT ENERGIZES THE BLOWER MOTOR. 10.HIGH STAGE OF CL22 THERMOSTAT INITIATES ACALL FOR HEAT. Page 18 FIGURE 14B - Typical Wiring Diagram for all Two Stage Gas Valve Models (NOTE: Two Stage Valve circuit ONLYavailable on UDA_ Models) 30 VA 2 TY4T0M 7RAH3PORIWR FACTORY MWW V FI ElD wRl13 WRNG yalc WA Lx ri � Y SW1 .. SEC CCVA I j] L1 `IEUTR41 NEUTK•�L _I H J P11 \\ Y lLU I K•'L Q FHII'�'O-GR P33 \ r Ce r rn.q »JR NTE:;L.^.CK C I R \ R / •c m I OAPADITOR I I LP3-6 \\ •rx1Am RIOH roEee Ail1�NOTE r61 hC C "T COYTFt:( WTVG/UN IIa1M%Q-V%VKI IIp 90"PQR WT rIWIRAM. wiOY rwtiT1imd PMM NLOoxuTT7MPFi®ISIY,.716oRevraoeuf L. H pt2 \ 2K.1w I.sWA7TRrC"PMPWT9wfsMRWf►ncuw 7- / Elw. ALAME PoOLLOUt 4RAM R7�t1M[LM'ATCi1NtlOEmlStlll leHia K!`llEYfl® IM OM*129ONLY) rrorovaa< frtounLvoM*Ru�l�Tor!nostr� P Yrhla0lr ttm fT[IDY OH RAIL tIf11C M.PYR " NRK R�'M lu?VCr ,ELL HONEYWal P r' AJd&NALleOMiPCtkuh'RH?An .._.•L GAS VALVE (.,v x W w P14 TCSt ta: WiILv YT7 r--2 FLAME d( MOTOR I, C aq ID > LED L T EiECTPCOE AI! �1 $PAKVM P r n 0HI .> DOCONTI� TIlMl1PdC'AI IpTE� 1 pc C-4 Fz Akk 7- t .`►RK OAr �7 CPI31ATPQ 395ZUEPOQE 1,SET T}OWDSTATATLOW59TiTiTnHQ,4FMIUNfiglAT-AIJF0rF0wT K0VnC14CLIBCNLY► Z.TV H 04 My GAS VALVE, 3.7LRM ON POWERTO Uwr. IwLD COlftfl0l 1'IIIL*h] d-RET THMM0MTAT OMLIED ffrF*A F. WW STAOECF7l EMMATCMLS FORHGAT.LLVWWWh17 Tiff VWWR M TM TOTAL WFit DISTAMOE PR M kw IIEODLIlIJDeD 0.YE NTM PRE WAII1 11 0.09E1111,FM O LLMTAT LOW FOTE. 11,91afH Uw TO 00"TROL- NIIR!Q~ r. MOTOR W MF�i9M. t50 7S II18 QJL yfL� S.HIGH GTAft Of THLFMOUTAT CAli6 FOR MRT.FIRMS LRTT AT Fill RATE. WY 127 #M OA",M 0.SET FAN sfYATCM AT'Olr POSLTION FW COHTM IJOW FAN OPERATgH OPPON 01.0 O0*LY. 359 177 s/4 flA rf 70. F 11-C FLAME IS 00 0I01010 CIUR114110 MAN DUra4111M OPERATVON, TI'r IHLE@I VMb OAIIINOI SYSTEM CLOAM THI•MAST VALL!AND vn cOD� MIST LIE IWMU BY MEWLVFM IQM1 TO TH G OOFITROL CRW IT tea LIO~OMTNUCTI0110:1, BLACK-NK MOTLS SLIOWN•w lam7-THE POLLOA 110 004TFi0l9 ARE FIELD ILISTALLED OPTWIa4:T►ErOAO6TAT cot R 2 ®WID OW MTAUM DY G11LLM�. ��'E•U 3.CA11T M IF AsN OF THECRIO�IAL riNENO A8 bUP Ft lEC TM4H THE YELLOWY APMIl"HLl,Yt 6E 11o1JR,'�R PIC BE 111P1/IJ'SMTH MlIRi16 WTI FA LL- ��-O INYIHB A TEl�1PSiM1TURE WITIIO OF Air LMW 1=11 G.L-7. WH 8041BOR KILN.FL LEAD WIRI.MAME ROl11011/rA1ID LUST rLIL*IO WwM MUST"WASO C. Pllrif LE•PN +. UIEWOXWGIEFORALLWIWMON7MUNT. YhiiE-» b. UIICM O PAN MOTOR IMWWH 11ffilil S SNOULD BE OF A SI ZI TO IMPEVIEW NFCLTA7EOROPSeEMWW%OfVLMVLIMVMTAW- ALL TWO STAGE GAS VALVE 4,('JSPACfTQiIGR�A0iEM0UfT�/NL7LM0.UDEDRILYON776VM70EL8 T,Gb0APAC ATlsb 216p 9WOMED Mo U T+EaDAh D MLLIAW QLY ON MOEB 4A-400 MODELS S. BErT15Is MATRFZW UFA09 ANTEWATOR AT CA AAAPSMID 6EO0W#TA2EAMI0PAT0RAT0. AMft WD# 185244 REV#4 AG2-GL22 S.JI.�lL71 TrOWOSTfLTle11WYALs 101 TO RC. Page 19 7.0 Electrical 7.5.1 Combustion Air Proving (Pressure) Switch Supply and The combustion air proving switch is a pressure sensitive switch that monitors air pressure to ensure that proper combustion airflow is available. On Standard Power Ventmodels, Wiring (cont d) the switch is a single pole/normally open device which closes when a negative pressure 7.5 Electrical is sensed in the venter housing. On Separated Combustion models, the switch senses Operating the differential pressure between the negative pressure in the venter housing and the pressure in the cabinet. (For switch location, see FIGURE 18, page 30.) Components On startup when the heater is cold, the sensing pressure is at the most negative level, and as the heater and flue system warm up, the sensing pressure becomes less negative. After the system has reached equilibrium (about 20 minutes), the sensing pressure levels off. If a restriction or excessive flue length or turns cause the sensing pressure to be outside the switch setpoint, the pressure switch will function to shutoff the main burner. The main burner will remain off until the system has cooled and/or the flue system resistance is reduced. The Tables on the left below list the approximate water column negative pressure readings and switch setpoints for sea level operating conditions for Standard Power Vent and Model heaters. The Table on the right lists the approximate water column differential pressure readings and switch setpoints for sea level operating conditions for Separated Combustion Model heaters. Safe operation of this unit requires proper venting flow. NEVER bypass combustion air proving switch or attempt to operate the unit without the venter running and the proper flow in the vent Pressure Switch system. Hazardous conditions could result. See Hazard Intensity Settings Levels, page 2. Startup Equilibrium Setpoint Startup Equilibrium Setpoint Setpoint Std Power Cold Hot Setpoint OFF ON Std Power Cold Hot OFF ON Label Switch Label Switch Vent Vent Models Negative Pressure("w.c.) Color P/N Models Differential Pressure("w.c.) Color P/N 30 1.0 0.8 0.4 0.6 Green 197030 30 1.0 0.8 0.65 0.8 Yellow 197028 45 1.0 0.8 0.4 0.6 Green 197030 45 1.1 0.8 0.65 0.8 Yellow 197028 60 1.0 0.8 0.5 0.7 Orange 196388 60 1.1 0.9 0.65 0.8 Yellow 197028 75 1.0 0.9 0.5 0.7 Orange 196388 75 1.1 0.9 0.65 0.8 Yellow 197028 100 0.9 0.7 0.5 0.7 Orange 196388 100 0.9 0.7 0.55 0.7 White 196362 125 0.8 0.6 0.4 0.6 Green 197030 125 0.8 0.6 0.45 0.6 Pink 197032 150, 175 0.8 0.7 0.4 0.6 Green 197030 150, 175 0.8 0.6 0.40 0.6 Green 197030 200,225 2.2 1.5 1.1 1.3 Blue 201158 200,225 2.2 1.5 1.10 1.3 Blue 201158 250,300 2.3 1.6 1.1 1.3 Blue 201158 250,300 2.3 1.6 1.10 1.3 Blue 201158 350,400 2.6 1.8 1 1.1 1.6 Red 201159 350,400 2.6 1 1.8 1.10 1 1.6 Blue 201158 Startup Cold Equilibrium Setpoint Setpoint Std Power Vent P Hot OFF ON Label Switch Model with Opt AV6 Color P/N Negative Pressure("w.c.) 30 1.1 0.8 0.65 0.8 Yellow 197028 45 1.1 0.8 0.50 0.7 Orange 196388 60 0.9 0.8 0.60 0.8 Lt Blue 197029 75 1.0 0.8 0.60 0.8 Lt Blue 197029 100 0.9 0.7 0.55 0.7 White 196362 7.5.2 Limit Control All units are equipped with a temperature activated auto reset limit control. The con- trol is factory set and is non-adjustable. If the setpoint is reached, the limit control will interrupt the electric supply to the gas valve. This safety device provides protection in the case of motor failure or lack of airflow due to a restriction at the inlet or outlet. (For location, see FIGURE 18, page 30.) CAUTION: The auto reset limit control will continue to shut down the heater until the cause is corrected. Never bypass the limit control; hazardous conditions could result. See Hazard Intensity Levels, page 2. Page 20 Sizes 30-125 are equipped with a temperature activated manually reset flame rollout switch. The flame rollout switch is located at the top of the burner assembly. It is fac- tory set and is non-adjustable. If the setpoint is reached, the flame rollout acts to inter- rupt the electric supply to the gas valve. If the flame rollout switch activates, identify and correct the cause before resetting the switch. Refer to the Maintenance Section, Paragraph 10.2.10, for information on probable causes and instructions on resetting the flame rollout switch. (For location, see FIGURE 18, page 30.) If the manual reset flame rollout switch activates, identify and correct the cause before resetting the switch. Never bypass the flame rollout switch; hazardous conditions could result. See Hazard Intensity Levels, page 2. 7.5.3 Door Switch All sizes of Separated Combustion Model heaters are equipped with a door switch for Separated which prevents the heater from operating when the service door panel is open. The Combustion Models service panel of a Separated Combustion Models are equipped with a pliable gasket only material that fully seals the door to provide added protection from building air entering the combustion zone of the heater. (For switch location, see FIGURE 18, page 30.) 7.5.4 Gas Valve The main operating gas valve is powered by the 24-volt control circuit through the ther- mostat and safety controls. The main control valve is of the diaphragm type providing regulated gas flow preset at the factory. (For location, see FIGURE 18, page 30.) The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting the unit to ensure positive closure. See Hazard Levels, page 2. 7.5.5 Fan Motor The fan motor is equipped with thermal overload protection of the automatic reset type. Should the motor refuse to run, it may be because of improper current characteristics. Make certain that the correct voltage is available at the motor. NOTE: If the unit is equipped with an optional totally enclosed motor or optional volt- age, the horsepower may be larger than the standard motor. Refer to the motor name- plate to verify horsepower. 7.5.6 Venter Motor The venter motor is assembled to the venter wheel and operates to provide combus- tion airflow. Operation is controlled by the ignition control module (circuit board); refer to ignition system in Paragraph 8.3. 8.0 Controls and 8.1 Thermostat Operation Use either an optional thermostat available with the heater or a field-supplied 24-volt thermostat. Install according to the thermostat manufacturer's instructions, paying par- ticular attention to the requirements regarding the location of the thermostat. Make sure that if there is a heat anticipator setting on the thermostat,it is set at 0.6 amps (or in accordance with the amperage value noted on the heater wiring diagram). Make thermostat connections at the terminal strip on the back of the heater. The strip has four terminals, R, G, W1, and W2; refer to the wiring diagram. IMPORTANT: All units MUST be operated by a 24-volt thermostat. Never use a line voltage disconnect switch as a means of operating the heater. Operating Model Sizes 30-125 by means other than a 24-volt thermostat may result in the flame rollout switch tripping. Multiple Heater Control, Option CL31 and Option CL32 - If the heater was ordered with a multiple heater control option, one thermostat can be used to control up to six heaters. The option includes a 40VA transformer that replaces the standard trans- former in the "controlling" unit and a relay assembly that attaches to the additional unit. Option CL31 provides for control of two heaters. If control of additional heaters is desired (up to six total), Option CL32 which is the relay assembly only must be added to each additional heater. The option packages are shipped separately and include complete instructions on installation and wiring. Page 21 8.0 Controls and Operation If the heater was ordered with Option D10 or D14, it is equipped with a Novar Minio (Cont'd) control module.The Novar control with its accompanying relays and power transformer are mounted in the control compartment of the unit. See FIGURE 15A. This control 8.2 DDC Controls, offers a wide variety of input and output points that can be configured to meet a wide Options D10 and range of building management applications. User-selectable input types are Thermis- D14 (ONLY for tor, 4-20 milliamp, 1-5 volts, or digital. sizes 150-400) FIGURE 15A- DDC Control with Transformer and Relays is Mounted on a Specially Designed Bracket in the Controllow , Compartment - _ / Control Option D10 includes the controller and the sensor to be field mounted at the heater discharge. Option D14 requires a field-supplied sensor that is compatible with the control. For regulatory compliance specifications, and safety precautions, review the control manufacturer's installation instructions in the owner's envelope. The recommended location for mounting the sensor is on the side of a field-installed optional downturn nozzle. See FIGURE 15B for an illustration of the sensor included with Option D10 and dimensions for mounting it on the nozzle side. FIGURE 15B - Recommended ° Location for Mounting Center the the Sensor is on 1" 25mmsensor hole the Side Panel of a (14m7j) (76mm) vertically on Discharge Nozzle o the nozzle side. (Option CD 2, 3, or 4) 9/1619 +(14mm) 0(4)1/8" 2-1/4" (3mm) (57mm) *1, 2-1/4" Before installing the (25+>+ (57mm) discharge nozzle, drill the holes in the side panel as illustrated. Nozzle flange that connects to the heater outlet. Mount the sensor on the nozzle side. Drill a 7/8" hole in the cabinet top above the controller and install the bushing supplied with the unit for running the sensor wire. Wire the sensor to the controller as illustrated on the wiring diagram on the heater. Sensor wire is field-supplied. Page 22 8.3 Ignition System This heater is equipped with a direct spark integrated control module (circuit board). The module monitors the safety devices and controls the operation of the fan and ven- ter motors and the gas valve between heat cycles. FIGURE 16 — DSI Integrated Control Module (circuit board) LED lights are visible through a viewport on Separated Combustion Models. Remove door panel to view LED lights on Standard Power Vent Models. 10 a3-Z1GX xSCI MODEL 1097-210 EOM SEC Control Status - Green LED Codes Spark CD O Q+ Steady ON..........Normal Operation, No call for heat Transformer o QOQ` Fast Flash...........Normal Operation, Call for heat Q� Ea DOO Q" 1 Flash................System Lockout, Failed to detect or O OQ Fuse 4 i = sustain flame QQ" 2 Flashes............Pressure Switch Did Not Close within 30 O� Seconds of Venter motor Thermostat O 3 Q Connections O x 3 Flashes............High Limit or Flame Rollout Switch Open = 3 4 Flashes............Pressure switch is closed before venter Q motor is energized Ll Steady OFF........Blown Fuse, No Power, or Defective Board L Flame Status -Yellow LED Codes �D Steady ON.......Flame is sensed HEAT SlowSlow Flash.......Weak flame (current below 1.0 =O = microamps±50%) O Lights`s- �LL Fast Flash........Undesired Flame (valve open and no Light O+ O+ co 6 call for heat) E us LED Lights Normal Heat 1) Call for Heat - The thermostat calls for heat by energizing the "W" terminal. The Cycle Operating control checks to see that the limit switch is closed and the pressure switch is open. If Sequence the limit switch is open, the control responds as defined in the "Abnormal Heat Cycle, Limit Switch Operation". If the pressure switch is closed,the control will do four flashes on the green LED and wait indefinitely for the pressure switch to open. If the pressure switch is open, the control proceeds to prepurge. LED lights are visible Combustion 2)Prepurge-The control energizes the venter motor and waits for the pressure switch through vi to close. If the pressure switch does not close within 30 seconds of the venter motor Separated Combuss tion energizing, the control will do two flashes on the green LED. The control will leave the Models. Remove door venter motor energized indefinitely as long as the call for heat remains and the pres- panel to view LED lights sure switch is open. on Standard Power Vent When the pressure switch is proven closed, the control begins the prepurge time. If Models. flame is present any time while in prepurge, the prepurge time is restarted. If flame is present long enough to cause lockout, the control responds as defined in "Fault Modes, Undesired Flame". The control runs the venter motor for a 20 second prepurge time, then proceeds to the ignition trial period. 3) Ignition Trial Period - The control energizes the spark and main gas valve. The venter remains energized. If flame is sensed during the first 16 seconds, the spark is de-energized and the control proceeds to heat fan/blower on delay. If flame has not been sensed during the first 16 seconds, the control de-energizes the spark output and keeps the gas valve energized for an additional one second flame proving period. If flame is not present after the flame proving period, the control de-energizes the gas valve and proceeds with ignition re-tries as specified in "Abnormal Heat Cycle, Ignition Retry". If flame is present, the control proceeds to the fan/blower on delay. 4) Fan/Blower On Delay - The control waits for 30 seconds from the time the gas valve opened and then energizes the fan/blower motor. The gas valve and venter motor remain energized. The control proceeds to steady heat mode. 5) Steady Heat - Control inputs are continuously monitored to ensure limit and pressure switches are closed, flame is established, and the thermostat call for heat remains. When the thermostat call for heat is removed, the control de-energizes the gas valve and begins post-purge and fan/blower off delay timing. Page 23 8.0 Controls and Normal Heat Cycle Operating Sequence (cont'd) Operation 6) Post Purge-The venter motor output remains on for a 45-second post-purge period (cont'd) after the thermostat is satisfied. 8.3 Ignition System 7) Fan/Blower Off Delay-The fan/blower motor is de-energized after a fan/blower off (cont'd) delay (120 seconds). Timing begins when the thermostat is satisfied. Abnormal Heat Cycle Interrupted Thermostat Call for Heat- If the thermostat demand for heat is removed Functions before the flame is recognized, the control will run the venter motor for the post purge period and de-energize all outputs. If the thermostat demand for heat is removed after successful ignition, the control will de-energize the gas valve, run the venter motor through post purge, and run the fan/ blower motor on heat speed for the selected delay off time. Ignition Retry-If flame is not established on the first trial for ignition period,the control de-energizes the gas valve and the venter motor remains energized for an inter-purge period of 10 seconds. The spark and gas valve are then re-energized, and the control initiates another trial for ignition. If flame is not established on the second trial for ignition, the control de-energizes the gas valve, energizes the fan/blower motor on heat speed, and venter motor remains energized. The fan/blower motor is shut off after 120 seconds. When the fan/blower motor de-energizes, the spark and gas valve are re-energized and the control initiates another trial for ignition. (This fan delay is self-healing feature for an open auxiliary limit switch). If flame is not established on the third trial for ignition period, the control de-energizes the gas valve, and the venter motor remains energized for an inter-purge period of 10 seconds. The control then re-energizes the gas valve and spark and initiates another trial for ignition. If flame is not established on the fourth trial for ignition (initial try plus 3 re-tries), the control de-energizes the gas valve and goes into lockout.The control goes to one flash on the green LED to indicate ignition failure lockout. Limit Switch Operation - The limit switch is ignored unless a call for heat is pres- ent (W energized). If the limit switch is open and a call for heat is present, the control de-energizes the gas valve and turns the fan/blower motor on heat speed and runs the venter motor. The control will be in soft lockout and flashing fault code "3" before returning to normal operation. When the switch re-closes or the call for heat is lost, the control runs the venter motor through post purge and runs the blower/fan motor through the selected fan off delay. Pressure Switch - If the pressure switch opens before the trial for ignition period, the venter motor will run through the pressure switch recognition delay (2 seconds), the gas valve will be de-energized, and the venter motor will run through the postpurge time. The control will re-start the heat cycle at the pressure switch proving state if the call for heat still exists. Pressure switch opening for less than 2 seconds during the trial for ignition period shall not interrupt the heat cycle. (Gas valve will de-energize while the pressure switch is open.) If the pressure switch opens after a successful ignition, the control will de-energize the gas valve. If flame is lost before the end of the 2 second pressure switch recogni- tion delay, the control will respond to the loss of flame. If the pressure switch remains open for 2 seconds and the flame remains, the control de-energizes the gas valve, the venter motor runs through post-purge, and the fan/blower motor runs on heat speed through the selected fan off delay. When the fan off delay is over, the fan/blower motor is de-energized, and a heat cycle is begun if the call for heat still exists. When the thermostat calls for continuous fan (G)without a call for heat,the fan motor is energized after a .25 second delay. NOTE: This brief on delay is to allow the"G"termi- nal to energize slightly before "Y" and an external changeover relay to switch from "G" to "W" without causing momentary glitches in the fan/blower output. The fan remains energized as long as the call for fan remains without a call for heat. Page 24 If a call for heat (W)occurs during continuous fan, the fan/blower will de-energize. A call for fan is ignored while in lockout. Continuous Fan Undesired Flame - If flame is sensed longer than 20 seconds while the gas valve is Operation de-energized, the control shall energize the venter motor and fan/blower motor on heat speed. When flame is no longer sensed, the venter motor will run through postpurge, and the fan/blower motor will run through the selected heat fan off delay time. The control will do a soft lockout, but will still respond to open limit and flame. The FLAME (yellow) LED shall flash rapidly when lockout is due to undesired flame. Gas Valve Relay Fault- If the control senses the gas valve as energized for more than Fault Modes one second when the control is not attempting to energize the gas valve, or the gas valve is sensed as not energized when it is supposed to be energized, then the control will lockout with green LED off. The control assumes either the contacts of the relay driving the gas valve have welded shut, or the sensing circuit has failed. The venter motor is forced off to open the pressure switch to stop gas flow unless flame is pres- ent. If the gas valve was sensed as closed when it should be open, and has not de-ener- gized after the venter motor was shutoff for 15 seconds, then the venter motor is re- energized to vent the unburned gas. Soft Lockout - The control shall not initiate a call for heat or call for continuous fan while in lockout. The control will still respond to an open limit and undesired flame. Lockout shall automatically reset after one hour. Lockout may be manually reset by removing power from the control for more than one second or removing the thermostat call for heat for more than one and less than 20 seconds. Hard Lockout- If the control detects a fault on the control board,the status LED will be de-energized, and the control will lockout as long as the fault remains. A hard lockout Lockout will automatically reset if the hardware fault clears. Power Interruption-During a momentary power interruption or at voltage levels below the minimum operating voltage(line voltage or low voltage)the system will self-recover without lockout when voltage returns to the operating range. Power interruptions of less than 80mS shall not cause the control to change operating states. Power interruptions greater than 80mS may cause the control to interrupt the current operating cycle and re-start. Page 25 9.0 Commissioning 9.1 Check the installation prior to startup: and Startup ❑ Check to be sure that all screws used to hold shipping brackets were re- installed in the heater cabinet. ❑ Check suspension. Unit must be secure and level. ❑ Check clearances from combustibles. Requirements are in Paragraph 4.1. ❑ Check vent system to be sure that it is installed according to the instructions in the appropriate Vent Installation Manual as listed in Paragraph 2.2. ❑ Check piping for leaks and proper gas line pressure. Bleed gas lines of trapped air. See Paragraph 6.1. ❑ Check electrical wiring. Be sure all wire gauges are as recommended. A service disconnect switch should be used. Verify that fusing or circuit breakers are adequate for the load use. ❑ Check polarity. Verify that line voltage exists between the black "L1" and earth ground. ❑ If installed in California, verify that California Warning Label is displayed. 9.2 Heater Startup: For your safety, read before operating. If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. • This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. • Before operating, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. 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. • Leave the building immediately. • Immediately call your gas supplier from a phone remote from the building. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call your fire department. • Use only your hand to turn the gas control ON/OFF knob on the gas valve. Never use tools. If the valve ON/OFF knob will not turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion. • Should overheating occur, or the gas supply control system fail to shut off the flow of gas, turn 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 to replace any part of the control system and any gas control which has been under water. Page 26 Operating Sequence 1. Set thermostat at lowest setting. FIGURE 17 - Gas Valve 2. Turn off all electric power to the appliance. 3. This appliance is equipped with an ignition device which automatically lights the Top View burner. Do not try to light the burner by hand. Open the access door and locate the gas control (ON/OFF) knob or switch on the gas valve. (See FIGURE 17.) 4. Turn the gas control switch to"OFF" or the knob clockwise to"OFF". 5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the ON/OFF Switch floor. If you smell gas, STOP! and follow the steps in the WARNINGS printed above or on the Operating Label on the heater. If you do not smell gas, proceed to Top View the next step. V;OF ° 6. Turn the gas control switch to"ON" or the knob counterclockwise to "ON". Flow 7. Close the access door. ®c8. Turn on the electric power to the heater. 9. Set the thermostat to the desired setting. Gas Control NOTE: If the appliance does not operate, follow the instructions 'To Turn Off Gas to Knob Appliance" printed below (and on the Operating Label on the heater)and call your (shown in the ON 0 service technician. position) 10. Thermostat calls for heat, energizing the venter motor. Gas 11. Venter pressure switch closes, firing the unit. Flow 12. Burner flame is sensed and in 30 seconds after the gas valve is energized, the ow fan motor is energized. 13. If the flame is extinguished during the main burner operation, the integrated con- Side View trol system closes the main valve and must be reset by interrupting power to the control circuit. (See lighting instructions on the heater.). TO TURN OFF GAS TO THE APPLIANCE 1) Set thermostat to lowest setting 2) If service is to be performed, turn off all electric power to the appliance. 3) Open the access door. 4) Turn the gas control switch to "OFF" or turn knob clockwise to "OFF' (Do not force). 5) Close the access door. 9.3 Check ❑ Vent System Testing Procedure installation after The steps below shall be followed with each heater or utility heater connected to the startup: venting system placed in operation while any other appliance(s)connected to the vent- ing system(s) is not in operation. 1. Seal unused openings(s) in the venting system. 2. Inspect the venting system for proper size and horizontal pitch as required in the National Flue Gas Code,ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1, and the venting manual instructions. Verify that there is no blockage or restriction, leakage, corrosion, and/or other deficiencies that could cause an unsafe condition. 3. In so far as is practical, close all doors, windows, other open spaces within the building, and all doors between the space in which the appliance(s)connected to the venting system is located. Turn on clothes dryers and any exhaust fans (such as range hoods and bathroom exhausts)so they operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Following the lighting instructions, place the utility heater being inspected in operation.Adjust the thermostat so that the utility heater will operate continuously. 5. After it has been determined that each utility heater connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning 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. Page 27 9.0 Commissioning — With the unit in operation, measure valve outlet gas pressure. If operated at high and Startup altitude, adjust outlet gas pressure for altitude. (cont'd) See information and instructions in Paragraph 6.1. 9.3 Check ❑ Turn the unit off and on, pausing two minutes between each cycle. Observe for smooth ignition. installation after startup (cont'd) ❑ Place the "Literature Bag" containing the Limited Warranty, this booklet, the venting manual, and any control or optional information in an accessible location near the heater. 0I The gas burner in this gas-fired equipment is designed and equipped to provide safe controlled complete combustion. However, if the installation does not permit the burner to receive the proper supply of combustion air, complete combustion may not occur. The result is incomplete combustion which produces carbon monoxide, a poisonous gas that can cause death. Safe operation of indirect-fired gas burning equipment requires a properly operating vent system that vents all flue products to the outside atmosphere. FAILURE TO PROVIDE PROPER VENTING WILL RESULT IN A HEALTH HAZARD WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH. Always comply with the combustion air requirements in the installation codes and in Paragraph 6.2. Combustion air at the burner should be regulated only by manufacturer-provided equipment. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. Standard Power Vent models units installed in a confined space must be supplied with air for combustion as required by Code and in Paragraph 6.2 of this heater installation manual. MAINTAIN THE VENT OR VENT/COMBUSTION AIR SYSTEM IN STRUCTURALLY SOUND AND PROPER OPERATING CONDITION. 10.0 Maintenance and Service 7Leyvels,tuprage n off the power supply, turn off the gas. See Hazard 2. The material contained in the MAINTENANCE AND SERVICE Section of this manual is designed to aid a qualified service person in maintaining and servicing this equip- ment. This heater will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a heater that is operated under normal conditions should be inspected and cleaned at the start of each heating season. If the heater is operating in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent maintenance is recommended. When any service is completed, be careful to reassemble correctly to ensure that no unsafe conditions are created. When re-lighting, always follow the lighting instructions on the heater. Inspect the burner/control compartment annually to determine if cleaning is necessary. Page 28 10.1 Maintenance Maintenance Schedule - The following procedures should be carried out at least Schedule annually (See FIGURE 18 and Paragraphs 10.2.1 - 10.2.14.): • Clean all dirt, lint, and grease from the combustion air opening (Standard Power Vent) and venter assembly. • Clean all dirt, lint, and grease from the fan blade, fan guard, and motor. • Check the heat exchanger both internally and externally. • Check the burner for scale, dust, or lint accumulation. Clean if needed. • Check gas valve to ensure that gas flow is being shutoff completely. • Check the vent or vent/combustion air system for soundness. Clean openings. Replace any parts that do not appear sound. • Check the wiring for any damaged wire. Replace damaged wiring. (See Paragraph 7 for replacement wiring requirements.) NOTE: If replacement parts are required, use only factory-authorized parts. FIGURE 18 - Location of Controls Flame Rollout Switch— S High Temperature Venter Motor(Size 30-75 illustrated. Sensor(Sizes 30-125) Limit Control Pressure Switch Venter motor is in the same location for all models, but appearance is 0 o different.) e o Separated Combustion Unit has a combustion 0 0 o air pipe (not shown) 0 ° 0 0 Interlock Door Switch 21 Separated Combustion -0 O O O O Units only o� m ® 0 0 cn Fan � O o Q Motor L O O L � 'E4 as Valve m Terminal Board (24V) • ° Disconnect Switch 0 o Separated Combustion • • O Units only -A--A / Electric Box-Separated Combustion units only Ignitor Remove cover to connect • • Transformer Control Panel Assy • Oo supply and access disconnect located on the switch wires. Always replace B B Control Compartment B B cover. Bottom Transformer O Sizes 30-125 _0Im - � Sizes 150-400 mmm1p. u Venter Motor Capacitor Circuit Board - Circuit Board Fan Motor - Optional (DSI Integrated (DSllntegrated • Capacitor Control Module) _ Fan Motor Control Module) _ Capacitor Page 29 10.2 Maintenance Remove any external dirt or dust accumulation. Visually check the heat exchanger for Procedures cracks and holes. If a crack or hole is observed, replace the heat exchanger. NOTE: Inspection of the lower portion of the heat exchanger is done with the burner 10.2.1 Heat removed. See the Burner Service section below for information on inspecting the lower Exchanger portion of the heat exchanger. Maintenance 10.2.2 Burner If there is an accumulation of dirt, dust, and/or lint, clean the compartment and follow Maintenance the instructions below to remove and clean the burner. CAUTION: Use of eye protection is recommended. Burner Removal 1. Outside the cabinet, shut the gas supply off at the manual valve ahead of the Instructions (Refer to union. FIGURE 19.) 2. Turn off electric supply. 3. Disconnect the gas supply at the union outside of the cabinet. 4. Remove the access panel. 5. Disconnect and Move the Gas Train -At the gas valve, mark and disconnect the wires. Carefully remove the burner orifice and orifice adapter locking nut. Slide the orifice adapter out through the bracket on the burner pushing the gas train to the right. This will move the gas train out of the way. 6. Move the Control Assembly- Remove the two screws holding the control assembly bracket. Being careful not to disconnect any wires, slide the control assembly to the right. 7. Remove Secondary Air Baffles (Sizes 60-400 only) -Vertical along the right side of the burner, locate the flat plate(s) identified as the secondary air baffle(s). The quantity of baffles could be one to four depending on heater size. Each baffle is held in place by one screw. For re-assembly, on the secondary air shield, mark the location (top and bottom) of each baffle. Remove all baffles. 8. Remove Burner Assembly a) Locate the burner body supports. Depending on the size, the burner will have two or more supports.At each support, remove the one screw that attaches it to the secondary air shield b) Holding the venturi tube, slide the entire burner assembly slightly to the right to disengage the burner from the supports on the left. Then rotate the open end of the venturi tube inward toward the heater. Carefully pull the burner assembly out of the cabinet. FIGURE 19 - Burner Burner Body Support(at least two per unit)-Remove screw attaching Removal (Standard r to secondary air shield.Support remains attached to burner. Power Vent model ° _ nor L illustrated; same o , ° process for both =C 0 0 Standard Power Secondary 0 o 0 0 Vent and Separated 21 Air Shield Combustion ° o 0 m Burner models) a ® Orifice ° 0 0 L F O O op Venturi Tube Slide right; rotate Gas Valve inward; Dull out o Slide Right Disconnect gas train at orifice and outside 0 e heater;slide to the 0 0 right. o Secondary Air Baffle(Qty varies —Orifice Adapter Locking Nut per size.)Mark locations before removing. Control Bracket Screws-Loosen bracket;slide right. Page 30 Inspect and Clean the With the burner assembly removed, shine a flashlight on the burner ribbons. Look for Burner carbon buildup, scale, dust, lint, and/or anything that might restrict flow through the spaces between the burner ribbons. Holding the burner assembly so that any foreign material will fall away from the burner, use a stiff bristle brush to loosen and remove any foreign material(s). If the burner is excessively dirty, remove one of the burner end caps. Remove the four screws that hold the end cap to the burner housing. Lightly tap the end cap to remove it. Clean all foreign material from the burner and venturi. After the burner is thoroughly clean, replace the end cap making certain that it is tight against the burner housing. NOTE: If any of the burner components are damaged or deteriorated, replace the burner assembly. Inspect the Lower Portion of the Heat Exchanger (with burner assembly removed) At the burner flame entrance of each tube, shine a bright light into each heat exchanger section. With the light shining into the heat exchanger, observe the outside for visible light. Repeat this procedure with each heat exchanger section. If any light is observed, replace the heat exchanger. Re-Install the Burner Instructions to Re-Install the Burner (Refer to FIGURE 19) 1. Attach the Burner Assembly- Holding the venturi tube, slide the entire burner assembly into position.Align the supports on the left side with the slots in the burner shield; sliding the supports into the slots. On the right, re-attach each burner body support to the secondary air shield. 2. Attach the Secondary Air Baffles (Sizes 60-400 only) - Re-attach the secondary air baffles as marked. Baffles may be different sizes and each must be attached in the correct location. 3. Attach the Control Assembly- Carefully slide the control assembly into position. Re-attach with the same screws. Check to be sure all wire connections are secure. 4. Attach the Gas Train - Slide the gas train so that the orifice adapter is through the bracket. Fasten the gas train to the bracket with the locking nut. Install the gas orifice. Re-connect the wires to the gas valve. 5. Close the access panel. 6. Reconnect the gas supply at the union outside of the cabinet. Leak test the connection with leak detecting solution. 7. Turn on the electric and the gas. Check for proper operation. 10.2.3 Burner Orifice Burner orifice usually only needs to be replaced when installing a gas conversion kit. If ordering a replacement orifice only, give BTUH content and specific gravity of gas, as well as the model and serial number of the unit.When removing or replacing the burner orifice, be careful not to damage the venturi tube and/or the bracket. 10.2.4 Ignition System DSI Integrated Control Module (circuit board)-See FIGURE 20. The module moni- tors the operation of the heater including ignition. The only replaceable component is the 3 amp Type ATC or ATO fuse. If the fuse is blown, the problem is most likely an external overload. Correct the problem and replace the fuse. FIGURE 20 - DSI Integrated Control ��f Module (Circuit Board) Only replaceable s part is a Type ATC orATO 3 amp fuse (Color • Code Violet), P/N 201685 .Ilr4 p iw��. Page 31 10.0 Maintenance 10.2.4 Ignition System (cont'd) and Service Do not attempt to disassemble the control module. However, each heating season (cont d) check the lead wires for insulation deterioration and good connections. Proper operation of the direct spark ignition system requires a minimum flame signal 10.2 Maintenance of 1.0 microamps as measured by a microampmeter. Procedures For further information and check out procedure on the direct spark ignition system, (cont'd) refer to Paragraph 8.3 and the Troubleshooting Flow Chart in Paragraph 10.3. Ignitor- Refer to FIGURE 18 and locate the ignitor. Disconnect the wire; remove the screw and the ignitor. Clean the ignitor assembly with an emery cloth. Spark gap must be maintained to 1/8". See FIGURE 21. Ignitor FIGURE 21 - Ignitor showing required Spark 1/8 inch Gap measurement (3.2mm) CAUTION: Due to high voltage on the spark wire and electrode, l do not touch when energized. See Hazard Levels, page 2. Flame Sensor Flame Sensor - Refer to FIGURE 18 and locate the flame sensor. Disconnect the wire; remove the screw and the flame sensor. Clean with an emery cloth. 10.2.5 Fan Motor, Fan Remove dirt and grease from the motor, the fan guard, and blades. Use care when Blades, and Guard cleaning the fan blades to prevent causing misalignment or imbalance. Check that the hub of the fan blades is secure to the shaft. Follow these instructions for replacement of the fan guard, fan motor and/or fan blades. FIGURE 22 - Fan Blade Position on the Shaft by Unit Size and Type of Fan Guard Fan A Size all A=Fan Spacing Setscrew Blade Models) Standard Wire Fan Guard Option AZ8 Wire Fan Guard Torque sizes with .5" 13mm S acin with .334" 8.5mm Spacing in/lbs±10 30-250 30 1" 25 mm 1" 25 mm 0 Motor 45 9/16" 14 mm 1-1/16" 27 mm 45-LN 3/4" 19 mm N/A 80 Setscrew 60 1-1/2" 38 mm 1-3/4" 44 mm 75 2-1/8" 54 mm 1-1/2" 38 mm 100 2-3/8" 60 mm 2-3/8" 60 mm A 120 125 2-5/16" 59 mm 2-1/8" 54 mm Fan 150 2-3/8" 60 mm Blade Sizes 175 2-1/8" 54 mm 300-400 o Motor 200 1-5/8" 41 mm N/A 130 225/250/300 2" 51 mm Setscrew I 350 1-7/8" 48 mm 400 1-3/8" 35 mm 1. If the heater is installed, turn off the gas and disconnect the electric power. 2. Open the access door and disconnect the fan motor wires, capacitor wires at the capacitor, and ground screw. 3. Remove the assembled parts (the fan guard, the motor and the fan blade). 4. Disassemble and replace whatever parts are needed and reassemble using whatever part(s)are being replaced and the original parts. Be sure the fan blade is in the proper position on the shaft; refer to the illustration and table in FIGURE 22. Position the assembly on the heater.Attach the fan guard. Rotate the fan blade to check for adequate clearance. If adjustment is required, loosen the mounting screws, re-position the fan guard, and tighten the screws. Rotate the fan blade and re-check for adequate clearance. Repeat this procedure until the assembly is positioned properly. Page 32 5. Reconnect the fan motor wires according to the wiring diagram and close the access panel. 6. Restore power to the heater and turn on the gas. Light, following the instructions on the lighting instruction plate. Check for proper operation. 10.2.6 Venter Motor Replacement Instructions and Wheel Remove dirt and grease from the motor casing, the venter housing, and the venter wheel.Venter motor bearings are permanently lubricated. Follow these instructions for replacement of the venter motor and wheel assembly. Keep all hardware removed to be used in re-assembling and installing the replacement parts. 1. Turn off the gas and disconnect the electric power. 2. Open the burner/control compartment access panel. 3. Disconnect the three venter motor wires at the DSI control, capacitor wires at the capacitor(if applicable), and ground screw (located on the control panel). 4. Sizes 30 and 45- Disconnect the gas train and move it out of the way. Disconnect the gas supply at the union outside of the cabinet.At the gas valve, mark and disconnect the wires. Carefully remove the burner orifice and orifice adapter locking nut. Slide the orifice adapter out through the bracket on the burner pushing the gas train to the right. This will move the gas train out of the way. 5. Holding the venter motor, remove the three or four screws that attach the venter motor mounting plate to the venter housing. Remove the motor and wheel FIGURE 23 -Venter assembly from the heater. Wheel Position on 6. Re-assemble with the replacement venter motor and wheel assembly. See Shaft FIGURE 23. Venter Venter Motor Plate Venter Wheel, _ Venter Wheel, Venter Motor Plate Wheel Sizes 30-75 Fan Sizes 100-175 -Fan Motor Mounting Motor Mounting Bracket Motor Mounting Bracket Bracket e a e a Venter o Venter Motor for Venter Motor for Motor for Sizes 12 Sizes 200-400A Sizes o 0 30-125 a 150-175 e e e 5/16"(8mm)inside ->I ��5/16"(8mm)inside 16"(11mm)inside 7. Follow the wiring diagram to connect the venter wires. 8. Sizes 30 and 45- Reconnect the gas supply at the union outside of the cabinet. Leak test the connection with leak detecting solution. 9. Replace the access panel. Restore power to the heater and turn on the gas. Light, following the instructions on the lighting instruction plate. Check for proper operation. 10.2.7 Operating Gas Carefully remove external dirt accumulation and check wiring connections. Valve 11111111111q 1111qThe operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting to the unit to ensure positive closure. See Hazard Levels, page 2. The combination gas valve must be checked annually to ensure that the valve is shut- ting off gas flow completely. Instructions: 1) Locate the 1/8" NPT pressure tap on the combination valve. (See FIGURE 24, page 34. Page 33 10.0 Maintenance 10.2.7 Operating Gas Valve (cont'd) and Service Single-Stage Valves, „ (cont'd) 1/8 Outlet Two -Stage Valve 1/8" Outlet Pressure Tap 10.2 Maintenance Pressure Tap Procedures - (cont'd) FIGURE 24 - Pressure ''o ► -1 0 �- . Tap for Checking Gas Flow Shutoff _ ,. 1/8" Outlet Pressure Taa NOTE: Operational 2) With the manual valve turned off to prevent flow to the gas valve, connect a pressure settings and manometer to the 1/8"outlet pressure tap in the valve. NOTE:A manometer(fluid- instructions for checking filled gauge) is recommended. pressure settings are in 3) Turn the manual valve to the ON position and the heater OFF. Use your finger to Paragraph 6.1. fully block the main burner orifice for several seconds. Observe the manometer with the orifice blocked, and if any pressure is indicated, the gas valve is leak- ing. A leaking gas valve must be replaced before the heater is put back in operation. 10.2.8 Combustion Air See FIGURE 18, page 30,for location. (NOTE: Depending on date of manufacture and Pressure Switch size, pressure switch may not be in the location indicated. Check the control bracket on the bottom of the compartment or further down on the compartment wall.) If it is determined that the pressure switch needs replacing, use only the factory-authorized replacement part that is designed for the model and size of heater being serviced. NOTE:A unit operating above 6000 ft(1830M) elevation requires a high altitude pres- sure switch. See Paragraph 3.2. 10.2.9 Limit If it is determined that the limit control needs replacing, use only a factory-authorized Control replacement part that is designed for the size of heater. For approximate limit location, see FIGURE 18, page 30. 10.2.10 Flame Rollout The cause of a flame rollout switch activating must be determined. Activation of the Switch - Sizes 30-125 manually reset flame rollout switch could be caused by one or more of the following: only • Restricted or plugged heat • Restricted combustion air inlet or exhaust outlet exchanger in combination with a defective pressure switch • Too much building exhaust • Electrical power interruption during operation • Manifold gas pressure too • Unit being operated with a line voltage high disconnect(a 24-volt thermostat is required) If a flame rollout switch trips, inspect the burner/control compartment for signs of excessive heat and burned wiring. For location, see If the compartment appears normal, reset by depressing the red button on the FIGURE 18, page 30. switch. 15 to 20 minutes are required for the switch to cool sufficiently for reset- ting.A distinct click will be felt when the switch resets. Operate the furnace. If the flame rollout switch trips again, determine and correct the cause before resetting the switch. If there is damage to the control compartment, repairs must be made before resetting the switch. If it is determined that the flame rollout switch needs replacing, use only the factory- authorized replacement part that is designed for that size of heater. The disconnect switch is located in the sealed electrical box inside the control com- partment with the toggle on the rear of the heater. 10.2.11. Door If it is determined that the door switch needs replacing, use only a factory- Switch - Separtated 4-1 authorized replacement part that is designed for the heater. Combustion ModelFor approximate switch location, see FIGURE 18, page 30. only Page 34 10.2.12 Transformer See FIGURE 18, page 30, for location. Use a voltmeter to verify that there are 24 volts output from the transformer. If the transformer is not functioning, it must be replaced. Use a replacement transformer identi- cal to the factory-installed model. 10.2.13 Disconnect If it is determined that the disconnect switch needs replacing, use only the Switch - Separated ��� factory-authorized replacement part that is designed for the heater.Always Combustion model replace electrical box cover. only 10.2.14 Vent or Vent/ Check the complete system at least once a year. Inspection should include all joints, Combustion Air seams, concentric adapter box(Separated Combustion), inlet air guard or inlet air cap System (Separated Combustion), and the vent terminal cap. Clean openings. Replace any defective parts. 10.3 Troubleshooting The integrated circuit board monitors the operation of the heater and includes two LED signal lights that indicate normal operation and various abnormal conditions. If Check the Lights on the heater fails to operate properly, check this signal to determine the cause and/or the DSI Integrated to eliminate certain causes. LED is visible through viewport on Separated Combus- Control Module tion models. Remove access panel on Standard Power Vent models. See operating (Circuit Board) sequence in Paragraph 9. Do not attempt to repair the DSI integrated control module (circuit board);the only field replaceable component is the fuse. IMPORTANT: When using a multimeter to troubleshoot Control Status - Green LED Codes the 24 volt circuit, place the Steady ON Normal Operation, No call for heat meter's test leads into the 5 Fast Flash.Normal Operation, Call for heat or 9 pin connectors located 1 Flash......System Lockout, Failed to detect or sustain flame on the ignition control. Do 2 Flashes..Pressure Switch Did Not Close within 30 Seconds of Venter Motor not remove connectors or 3 Flashes..High Limit or Flame Rollout Switch Open terminals from the electri- 4 Flashes....Pressure Switch is Closed Before Venter Motor is Energized cal components. Doing so Steady OFF Blown fuse, No Power, or Defective Board can result in misinterpreted Flame Status -Yellow LED Codes readings due to the ignition Steady ON..Flame is sensed control board's fault mode Slow Flash..Weak flame (current below 1.0 microamps ±50%) monitoring circuits. Fast Flash...Undesired Flame (valve open and no call for heat) DSI Integrated Control Module (Circuit Trial for Ignition Call for Heat Board) Trial Troubleshooting Flowchart YES Is there a NO spark across gap at ignitor? Is there Check high YES Does gas NO YES ignite? spark voltage at voltage wire control? continuity. O YES Is there minimum NO Is the flame YES Clean flame Is there 24V P1-2 YES Replace flame current at the sensor corroded? sensor. to power control. control flame sensor? module. NO NO Is there Is the sensor Check wiring minimum flame current ES Replace control YES Replace flame at the control module. located in flame sesnsor. and/or 24VAC module? correctly? transformer output. NO NO Check connections to flame Reposition YES Is gas NO sensor and/or moisture in the flame sensor. flowing? burner assembly. Is the ignitor Is there Check gas pressure YES Replace gas YES position correct in the 24VAC at the gas and supply voltage. gas flow? valve' valve? If either are low, correct and repeat O startup. NO Check wiring and Is there 24VAC Replace Reposition YES from gas valve output on NO ignition spark ignitor. connections to control module to control gas valve. chassis? module. Page 35 10.3 Troubleshooting (cont'd) General Troubleshooting PROBLEM PROBABLE CAUSE REMEDY Venter motor will not 1.No power to unit. 1.Turn on power,check supply fuses or circuit breaker. start 2.No 24 volt power to integrated circuit board. 2.Turn up thermostat;check control transformer output. 3.Integrated circuit board fuse blown. 3.Correct cause.Replace fuse(type ATC orATO,32VDC,3A). 4.No power to venter motor. 4.Tighten connections at circuit board and/or motor terminals. 5.Integrated circuit board defective. 5.Replace integrated circuit board. 6.Defective venter motor. 6.Replace venter motor.See Paragraph 29. Burner will not light 1.Manual valve not open. 1.Open manual valve. 2.Air in the gas line. 2.Bleed gas line(initial startup only). 3.Gas pressure too high or too low. 3.Supply pressure should be 5"-14"w.c.for natural gas or 11"-14"w.c.for propane. 4.No Spark: 14. a)Loose wire connections Ia)Be certain all wire connections are solid. b)Transformer failure.: I b)Be sure 24 volts is available. c)Incorrect spark gap. Ic)Maintain spark gap at 1/8". d)Spark cable shorted to ground. Id)Replace worn or grounded spark cable. e)Spark electrode shorted to ground. Ie)Replace if ceramic spark electrode is cracked or grounded. f)Burner not grounded. If)Make certain integrated circuit board is grounded(Terminal P1-9). g)Circuit board not grounded. Ig)Make certain integrated circuit board is grounded to furnace chassis. h)Unit not properly grounded. h)Make certain unit is properly field grounded to earth ground and properly phased(1-1 to hot lead L2 to neutral). i)Integrated circuit board fuse blown. I i)Correct cause.Replace fuse(type ATC or ATO,32VDC,3A). j)Faulty integrated circuit board. j)If 24 volt is available to the integrated circuit board and all other causes have been eliminated,replace board. 5.Lockout device interrupting control circuit by 5.Reset lockout by interrupting control at the thermostat or main power. above causes. 6.Combustion air proving switch not closing. 6. Ia)Make sure unit is properly vented. b)Remove obstructions from vent. c)Replace faulty tubing to pressure switch. 7.Faulty combustion air proving switch. 7.Replace combustion air proving switch. 8.Main valve not operating. 8. a)Defective valve. I a)If 24 volt is measured at the valve connections and valve remains closed, replace valve. b)Loose wire connections b)Check and tighten all wiring connections. 9.Integrated circuit board does not power main 9. valve. a)Loose wire connections. Ia)Check and tighten all wiring connections. b)Flame sensor grounded. I b)Be certain flame sensor lead is not grounded or insulation or ceramic is not cracked.Replace as required. c)Incorrect gas pressure. c)Supply pressure should be 5"-14"w.c.for natural gas or 11"-14"w.c.for propane. d)Cracked ceramic at sensor. d)Replace sensor. Burner cycle on and 1.Gas pressure too high or too low. 1.Supply pressure should be 5"-14"w.c.for natural gas or 11"-14"w.c.for off propane. 2.Burner not grounded 2.Make certain integrated circuit board is grounded(Terminal PI-9). 3.Circuit board not grounded. 3.Make certain integrated circuit board is grounded to furnace chassis. 4.Faulty integrated circuit board 4.If 24 volt is available to the integrated circuit board and all other causes have been eliminated,replace board. 5.Combustion air proving switch not closing. 5. a)Make sure unit is properly vented. b)Remove obstructions from vent. c)Replace faulty tubing to pressure switch. 6.Faulty combustion air proving switch. 6.Replace combustion air proving switch. 7.Flame sensor grounded. 7.Be certain flame sensor lead is not grounded or insulation or ceramic is not cracked.Replace as required. 8.Cracked ceramic at sensor. 8.Replace sensor. r9.Incorrect polarity. 9.Reverse line volt leads to integrated circuit board. 10.Pin terminal loose on 9 pin plug. 10.Replace wire harness. Page 36 No heat(Heater Op- 1.Incorrect valve outlet pressure or orifice. 1.Check valve outlet pressure.See Rating plate for manifold pressure. erating) 2.Cycling on limit control. 2.Check air throughput. 3.Improper thermostat location or adjustment. 3.See thermostat manufacturer's instructions. Fan or venter motor 1.Circuit open. 1.Check wiring and connections. will not run 2.Defective integrated circuit board. 2.Replace board. 3.Defective motor or starter. 3.Replace motor or starter. Fan or venter motor 1.Motor overload device cycling on and off. 1.Check motor load against motor rating plate.Replace motor if needed. turns on and off while burner is operating Fan or venter motor 1.Low or high voltage supply. 1.Correct electric supply. cuts out on overload 2.Defective motor. 2.Replace motor. 3.Poor airflow. 13.Clean motor,fan,fan guard,filter,and coils Page 37 APPENDIX TECHNICAL DATA-Sizes 30-125(Data applies to all Models unless noted otherwise.) Size 30 45 60 75 100 125 Input Heating Capacity BTUH 30,000 45,000 60,000 75,000 105,000 120,000 kw 8.8 13.2 17.6 22.0 30.8 35.2 Thermal Efficiency(%) 82 83 83 83 83 83 Output Heating Capacity" BTUH 24,600 37,350 49,800 62,250 87,150 99,600 kw 7.2 11.0 14.6 18.3 25.6 29.2 Gas Connection(inches)a Natural 1/2 1/2 1/2 1/2 1/2 1/2 Propane 1/2 1/2 1/2 1/2 1/2 1/2 Vent Connection I(inches diameter) 4 4 4 4 4 4 Combustion Air Inlet D(inches diameter)-Separated Combustion only 4 4 4 4 4 4 Control Amps(24 volt) 1.0 1.0 1.0 1.0 1.0 1.0 Full Load Amps(115 volt) 1.9 2.4 2.4 3.3 3.9 5.1 Maximum Over Current Standard 115V 15 15 15 15 15 15 Protection D E Optional 208V or 230V 15 15 15 15 15 15 Normal Power Consumption(watts) 109 155 155 217 276 354 Discharge Air Temperature Rise(°F) 50 55 60 60 60 60 Air Volume CFM 456 629 769 961 1345 1537 MI/minute 12.9 17.8 21.8 27.5 36.7 45.9 ftz 1.0 1.0 1.2 1.2 2.0 2.0 Discharge Air Opening Area Mz 0.1 0.1 0.1 0.1 0.2 0.2 FPM 475 656 616 770 668 763 Output Velocity M/minute 145 200 188 238 196 245 Fan Motor HP E Standard Open 0.0 0.0 0.0 0.1 1/30 1/20 Optional Enclosed N.A. N.A. N.A. N.A. 1/4 1/4 Fan Motor RPM 1550 1550 1550 1550 1050 1050 Fan Diameter(inches) 10 10 12 12 16 16 Sound Level dba @ 15 ft 40 40 40 49 54 55 TECHNICAL DATA-Sizes 150-400(Data applies to all Models unless noted otherwise.) Size 150 175 200 225 250 300 350 400 Input Heating Capacity BTUH 150,000 175,000 200,000 225,000 250,000 300,000 350,000 400,000 kw 43.9 51.2 58.6 65.9 73.2 87.8 102.5 117.1 Thermal Efficiency(%) 83 83 83 83 83 83 83 83 Output Heating Capacity" BTUH 124,500 145,250 166,000 186,750 207,500 249,000 290,500 332,000 kw 36.4 42.5 48.6 54.7 60.8 72.9 85.1 97.2 e Natural 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 Gas Connection(inches) Propane 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 Vent Connection D(inches diameter) 5 5 5 5 5 6 6 6 Combustion Air Inlet I(inches diameter)-Separated Combustion only 6 6 6 6 6 6 6 6 Control Amps(24 volt) 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Full Load Amps(115 volt) 3.8 3.8 4.6 7.5 7.5 10.7 10.7 10.7 Maximum Over Current Standard 115V 15 15 15 15 15 20 20 20 Protection D E Optional 208V or 230V 15 15 15 15 15 15 15 15 Normal Power Consumption(watts) 392 392 491 747 747 1086 1086 1086 Discharge Air Temperature Rise(°F) 60 60 60 60 60 60 60 60 CFM 1921 2242 2562 2882 3202 3843 4483 5123 Air Volume MI/minute 54.4 63.5 72.5 81.6 90.7 108.8 126.9 145.1 Discharge Air Opening Area ftz 2.6 2.6 2.6 3.5 3.5 4.8 4.8 4.8 Mz 0.2 0.2 0.2 0.3 0.3 0.5 0.5 0.5 FPM 752 877 1003 820 911 802 936 1069 Output Velocity M/minute 229 267 306 250 278 244 285 326 Fan Motor HP E Standard Open 1/6 1/6 1/6 1/4 1/4 1/2 1 1/2 1/2 Optional Enclosed 1/4 1/4 1/4 1/4 1/4 1/2 1/2 1/2 Fan Motor RPM 1050 1050 1050 1050 1050 1050 1050 1050 Fan Diameter(inches) 18 18 18 20 20 24 24 24 Sound Level dba @ 15 ft 51 52 53 56 56 59 61 62 A CSA ratings for altitudes to 2000 ft. "Size shown is for gas connection to a single-stage gas valve,not supply line size. °Smaller and/or larger vent and combustion air pipe diameters may be permissible. For Separated Combustion models refer to the Venting Installation Manual for Separated Combustion Units. For Standard Power Vent models refer to the Venting Installation Manual for Power Vented units. For a Standard Power Vent model with Option AV6,refer to the Venting Installation Manual for Common Venting. D MOCP=2.25 x(largest motor FLA)+smallest motor FLA.Answer is rounded to the next lower standard circuit breaker size. E Except where indicated,information in this table is based on a heater equipped with a standard 115 volt open fan motor. Page 38 INDEX A Gas Supply 11 Power Interruption 25 Abnormal Heat Cycle Functions 24 Gas Supply Line 12 Preparing for Installation 6 Aircraft Hangars 4 Gas Valve 21, 33 Prepurge 23 Control Amps 38 Gas Valve ON/OFF Control Knob 27 Pressure Switch 24 Full Load Amps 38 H Pressure Switch Settings 20 APPENDIX 38 Hanger Kits 11 PRESSURE TESTING SUPPLY PIP- B Hanging the Heater 10 ING 11 Clean the Burner 31 HAZARD INTENSITY LEVELS 2 S Burner Maintenance 30 Hazard Labels and Notices 2 Mounting the Sensor 22 Burner Orifice 31 Heat Exchanger Maintenance 30 Sound Level 38 Burner Removal 30 High Altitude Capacity 15 Spark Gap 32 C High Altitude Derate 14 Startup 26 California Warning Label 4 High Altitude Kit 6, 7 Stepdown transformer 6 Ceiling Suspension Kit 11 1 Supply Wiring 17 Certification 3 Ignition System 23, 31 Suspending 10 Check installation after startup 27 Ignition Trial Period 23 Suspending the Heater with Rods 11 Check the installation prior to startup Ignitor 32 Suspend the Heater from 1" Pipe 11 26 Input Heating Capacity 38 Swivel Connectors 11 Check the Lights 35 Installation Codes 4 T Chlorine 6 L TECHNICAL DATA 38 Clearances 7 Leak-test 12 Thermostat 21 LED Codes 23, 35 Lifting 10 Unit Mounted Thermostat 21 Combustion Air 16 LED lights 23 Throw 4 Combustion Air Inlet 38 Limit Control 20, 34 Transformer 35 Combustion Air Pressure Switch 34 Limit Switch 24 Troubleshooting 35, 36 Combustion Air Proving Literature Bag 28 Troubleshooting Flowchart 35(Pressure)Switch 20 Location 5 TURN OFF GAS TO THE APPLIANCE Commissioning 26 Unit Heater Location 4 27 Confined Space 16 Location of Controls 29 U Contact 40 Lockout 25 Uncrating and Inspecting 6 Control Wiring 17 Optional vertical louvers 6 V Conversion Kits 13 M Valve Outlet Pressure 13 D Maintenance Procedures 30 Vent 35 DDC Controls 22 Maintenance Schedule 29 Vent/Combustion Air 35 Dimensions 8 Massachusetts Requirement 4 Vent/Combustion Air Kit 3 Disconnect Switch 35 Fan Motor 32 Vent/combustion air kit 6 Door Switch 34 Venter Motor 33 Vent cap 6 Door Switch-Separated Combustion Motor HP 38 Vent Connection 38 Model only 21 Multiple Heater Control 22 Venter Wheel 33 Downturn Nozzle Kits 7 N Venting Manual 3, 5 DSI Integrated Control Module 23, 31 Normal Heat Cycle 23 Vent System Testing Procedure-Stand E Power Vent Model 27 Thermal Efficiency 38 W Electrical Supply 16 Operating Sequence 27 Warranty 4 F Option CC1 6 Weights 10 Option C2 or 3, 6 WHAT TO DO IF YOU SMELL GAS 26 Continuous Fan Operation 25 Option CDD 2, 3,, or or 4 7 Fan/Blower Off Delay 24 Option CK8, CK10, and CK22 11 Wiring Connections 17 Fan/Blower On Delay 24 Option CL31 22 Wiring Diagram for all Single Stage Fan Blades 32 Models 18 Option CL32 22 Wiring Diagram for all Two Stage Gas Fan Motor 21 Option CM3 21 Valve 19 Fault Modes 25 Option DJ20 or DJ21 6 p Wiring Diagrams 18 Field-Installed Parts 6 Options D10 and D14 22 Flame Rollout Switch 34 Orifice Pressure 13 Flame Sensor 32 Output Heating Capacity 38 G P Garages 4 Plug the unused suspension points 10 Gas Connection 38 Post Purge 24 Gas Connection Size 12 Page 39 INSTALLATION RECORD - to be completed by the installer: Installer: Name Company Address Phone Distributor(company from which the unit was purchased): Company Contact Address Phone Model Serial No. Date of Installation SPECIFIC INSTALLATION NOTES: (i.e. Location,Amps, Gas Pressure, Temperature, Voltage,Adjustments, Warranty, etc.) BUILDING OWNER OR MAINTENANCE PERSONNEL: For service or repair • Contact the installer listed above. • If you need additional assistance, contact the Distributor listed above. • For more information, contact your Local Representative. Specifications&illustrations subject to change without notice of incurring obligatons. ©2014 Nortek RCH Group. All rights reserved. NORDYNE All marks are the property of their respective organizations. O'Fallon, MO I Printed in U.S.A.(12/14) COMPLETECOMFORT.GENUINE VALUE. D300519 SKU 320E-1214 Form I-UDA&APD Series, PN 195673R25 Page 40