Mestek NXIM-2 Installation Manual

Page 1
INSTALLATION INSTRUCTIONS AND PARTS IDENTIFICATION
HIGH EFFICIENCY GAS-FIRED PROPELLER UNIT HEATERS
ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT THE POINT OF INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No. (s) IN THE SPACE PROVIDED. RETAIN FOR FUTURE REFERENCE.
NXIM-2
J30-09590
Unit No.
Serial No.
FOR YOUR SAFETY
The use and storage of gasoline or other ammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Don't touch electrical switches.
3. Extinguish any open ame.
4. Immediately contact your gas supplier.
Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Read the installation, operating, and maintenance instruction thoroughly before installing or servicing this equipment.
APPROVED FOR USE IN CALIFORNIA
APPROVED FOR USE IN CALIFORNIA
Install, operate, and maintain unit in accordance with the manufacturer's instructions to avoid exposure to fuel substances, or substances from incomplete combustion, which can cause death or serious illness. The state of California has determined that these substances may cause cancer, birth defects, or other reproductive harm.
Installer Please Note: This equipment has been test fired and inspected. It has been
shipped free from defects from our factory. However, shipment and installation problems such as loose wires, leaks, or loose fasteners may occur. It is the installer's responsibility to inspect and correct any problem that may be found.
RECEIVING INSTRUCTIONS
Inspect shipment immediately when received to determine if any damage has occurred to the unit during shipment. After the unit has been uncrated, check for any visible damage to the unit. If any damage is found, the consignee should sign the bill of lading indicating such damage and immediately le claim for damage with the transportation company.
09/17
INSTALLER'S RESPONSIBILITY
260 NORTH ELM ST., WESTFIELD, MA 01085
TEL: (413) 564-5540 FAX: (413) 562-5311
www.mestek.com
Page 2
TABLE OF CONTENTS
DESCRIPTION ............................................................. 2
GENERAL SAFETY INFORMATION ............................ 3
Installation Codes ....................................................... 3
Special Precautions .................................................... 3
SPECIFICATIONS ........................................................ 4
Performance & Dimensional Data ...........................4-5
INSTALLATION ............................................................6
Locating Units ............................................................. 6
Air for Combustion ...................................................... 6
Clearances ................................................................. 6
Suspension of Units.................................................7-8
INSTALLATION - GAS PIPING .................................... 9
Pipe Sizing..................................................................9
Pipe Installation ........................................................ 10
INSTALLATION - CONDENSATE PIPING .................10
ELECTRICAL CONNECTIONS .................................. 11
Thermostat Wiring and Location ............................... 11
Unit Wiring Diagrams...........................................12-14
VENTING - GENERAL GUIDELINES ........................15
Vent Termination Clearances ....................................15
STANDARD COMBUSTION – HORIZONTALLY
VENTED (CAT. IV) ......................................................16
STANDARD COMBUSTION –
VERTICALLY VENTED (CAT. IV) ............................... 17
SEPARATED COMBUSTION –
TWO PIPE VENTING ............................................18-19
SEPARATED COMBUSTION –
CONCENTRIC VENTING ........................................... 20
Horizontal Sidewall Mounting ..............................20-22
Vertical Roof Mounting .............................................22
GAS CONVERSION ..............................................23-25
OPERATION .............................................................. 26
Explanation of Controls .......................................26-30
Start-Up .................................................................... 30
Shut Down ................................................................ 30
GAS INPUT RATE ..................................................... 31
High Altitude Deration ............................................... 31
MODBUS CONFIGURATION ..................................... 31
PNEUMATIC TUBING SCHEMATIC .......................... 32
UNIT TROUBLESHOOTING GUIDE .....................33-34
LED TROUBLESHOOTING GUIDE ........................... 35
MAINTENANCE ......................................................... 36
WARRANTY ...............................................................37
IDENTIFICATION OF PARTS ................................38-39
Replacement Parts ................................................... 39
APPENDIX A – MODBUS REGISTERS ................40-41
UNIT NUMBER DESCRIPTION ................................. 42
START-UP AND INSPECTION SHEET ...................... 43
NOTICE: It is the equipment owner’s responsibility to provide any scaffolding or other apparatus required
to perform emergency service or annual/periodic maintenance to this equipment.
DESCRIPTION
The High Efciency Gas-Fired Unit Heaters are factory assembled, power vented, low static pressure type propeller fan unit heaters designed to be suspended within the space to be heated. THESE HEATERS ARE NOT TO BE CONNECTED TO DUCTWORK. The designs are certied by ETL as providing a minimum of 96% thermal efciency, and approved for use in California. Do not alter these units in any way. If you have any questions after reading this manual, contact the manufacturer.
The following terms are used throughout this manual, in addition to the ETL requirements to bring attention to the presence of potential hazards, or to important information concerning the product:
Figure 1 - High Efciency Gas-Fired Propeller Unit Heater
situation which, if not avoided, may result in minor injury or property damage.
NOTICE: Used to notify of special instructions on installation, operation, or maintenance which are important to equipment but not related to personal injury.
situation which, if not avoided, will result in death, serious injury, or substantial property damage.
situation which, if not avoided, could result in death, serious injury, or substantial property damage.
Indicates an imminently hazardous
Indicates an imminently hazard-ous
Indicates an imminently hazardous
See IDENTIFICATION OF PARTS, Figures 25 through 29
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GENERAL SAFETY INFORMATION
Failure to comply with the general safety information may result in extensive property damage, severe personal injury, or death.
This product must be install be
a licensed plumber or gas tter when installed
within the Commonwealth of Massachusetts.
Installation must be made in accordance with local codes, or in absence of local codes, with the latest edition of the ANSI Standard Z223.1 (N.F.P.A. No. 54) National Fuel Gas Code. All of the ANSI and NFPA
Standards referred to in these installation instructions are those that were applicable at the time the design of this appliance was certied. The ANSI Standards are available from CSA Information Services, 1-800- 463-6727. The NFPA Standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. These unit heaters are designed for use in airplane hangars when installed in accordance with ANSI/ NFPA No. 409, and in public garages when installed in accordance with NFPA No. 88A and NFPA No.88B.
If installed in Canada, the installation must conform with local building codes, or in the absence of local building codes, with CSA-B149.1 “Installation Codes for Natural Gas Burning Appliances and Equipment” or CSA-B149.2 “Installation Codes for Propane Gas Burning Appliances and Equipment.” These unit heaters have been designed and certied to comply with CSA 2.6. Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES.
Do not alter the unit heater in any way or damage to the unit and/or severe personal injury or death may occur!
Disconnect all power and gas supplies before installing or servicing the heater. If the power disconnect is out of sight, lock it in the open position and tag it to prevent unexpected application of power. Failure to do so could result in fatal electric shock, or severe personal injury.
Ensure that all power sources conform to the requirements of the unit heater, or damage to the unit will result!
Follow installation instructions CAREFULLY to avoid creating unsafe conditions. All wiring should be done and checked by a qualified electrician, using copper wire only. All gas connections should be made and leak­tested by a suitably qualied individual, per instructions in this manual. Also follow procedures listed on GAS EQUIPMENT START-UP AND INSPECTION SHEET located in this manual.
Use only the fuel for which the heater is designed (see rating plate). Using LP gas in a heater that requires natural gas, or vice versa, will create risk of gas leaks, carbon monoxide poisoning, and explosion.
Do not attempt to convert the heater for use with a fuel other than the one intended unless using a factory provided conversion kit. Such conversion is dangerous, as it will create the risks previously listed.
Make certain that the power source conforms to the electrical requirements of the heater.
Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing heater. Always disconnect power at main circuit breaker as described above. Failure to do so could result in fatal electric shock.
Special attention must be given to any grounding information pertaining to this heater. To prevent the risk of electrocution, the heater must be securely and adequately grounded. This should be accomplished by connecting a ground conductor between the service panel and the heater. To ensure a proper ground, the grounding means must be tested by a qualified electrician.
Do not insert fingers or foreign objects into heater or its air moving device. Do not block or tamper with the heater in any manner while in operation, or just after it has been turned off, as some parts may be hot enough to cause injury.
This heater is intended for general heating applications ONLY. It must NOT be used in potentially dangerous locations such as ammable, explosive, chemical-laden, or wet atmospheres.
Do not attach ductwork to this product or use it as a makeup air heater. Such usage voids the warranty and will create unsafe operation.
In cases in which property damage may result from malfunction of the heater, a back-up system or temperature sensitive alarm should be used.
The open end of gas piping systems
being purged shall not discharge into areas where
there are sources of ignition or into conned spaces
UNLESS precautions are taken as follows: (1) by ventilation of the space, (2) control of the purging rate, (3) elimination of all hazardous conditions. All precautions must be taken to perform this operation
in a safe manner!
Unless otherwise specied, the following conversions may be used for calculating SI unit measurements: 1 foot = 0.305 m 1 inch = 25.4 mm 1 gallon = 3.785 L 1 pound = 0.453 kg 1 psig = 6.894 kPa 1 cubic foot = 0.028m
1000 BTU/cu. ft. = 37.5 MJ/m 1000 BTU per hour = 0.293 kW 1 inch water column = 0.249 kPa 1 litre/second = CFM x 0.472 1 meter/second = FPM ÷ 196.8
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3
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CONNECTION
SPECIFICATIONS
Figure 2 - Dimensional Drawing – High Efciency Unit Heater
"U"
"L"
"D"
"P"
FLUE
"E"
"G"
"J"
"W"
"N"
"K"
"A"
"C"
"B"
CONNECTION
"T"
"H"
CAT-10081B
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Table 1 - Performance and Dimensional Data - High Efciency Unit Heater
Unit Capacity (MBH) 100 200 300 400 PERFORMANCE DATA†
Input - BTU/Hr. 100,000 200,000 300,000 400,000
Output - BTU/Hr. 96,000 192,000 285,000 384,000
Thermal Efciency (%) 96 96 95 96 Free Air Delivery - CFM 1,616 3,232 4,848 6,464
Air Temperature Rise - Deg. F 55 55 55 55
Full Load Amps at 120V 10.3 16.3 31.18 31.18 Minimum Circuit Amps at 120V 11.8 17.8 33.93 33.93 Max. Overcurrent Protection at 120V 17.8 23.8 44.93 44.93
MOTOR DATA:
DIMENSIONAL DATA - inches (mm)
"A" Height to Top of Combustion Air Inlet 18-3/4 18-3/4 27-1/8 34-7/8
"B" Jacket Width of Unit 42-13/16 54-13/16 54-13/16 54-13/16
"C" Unit Height 17-1/4 17-1/4 25-11/16 33-7/16
"D" Depth to Rear of Housing 11 11 10-7/8 11-1/2
"E" Hanging Distance Width 27-15/16 38 41-3/4 41-3/4
"F1" Hanging Distance Depth 17-1/4 21-1/4 20 20
"F2" Hanging Distance Depth 17-1/4 21-1/4 26 26
"G" Discharge Opening Width 15 26 26 26
"H" Discharge Opening Height 15-7/8 15-7/8 24-3/8 32-1/8
"J" Side Panel to Centerline Combustion Air 2-13/16 3-3/4 3-3/4 3-3/4
"K" Front Panel to Centerline Combustion Air 4-1/2 5-5/16 5-5/16 5-5/16
"L" Overall Unit Depth 38 42 42 42
"M" Side Depth 27-7/16 31-1/4 31-1/4 31-1/4
"N" Combustion Air Inlet Connection Dia. 2 3 4 4
"P" Flue Connection Diameter 2 2 4 4
"Q" Side Panel to Centerline Gas Connection 2-5/8 2-5/8 2-5/8 2-5/8
"R" Bottom Panel to Centerline Gas Connection 2-1/2 2-1/2 2-1/2 2-1/2
"S" Side Panel to Centerline Flue 5-1/8 6-1/16 5-3/8 5-3/8
"T" Bottom Panel to Centerline Flue 4-5/8 4-5/8 8-1/8 13-1/8
"U" Side to Centerline Condensate Drain Connection 8-1/2 9-1/2 9-1/2 9-1/2
"W" Rear to Centerline Condensate Drain Connection 9-9/16 10-9/16 10-1/8 10-1/8
Combustion Air Inlet Pipe Dia. - in. 2 3 4 4
* Flue Pipe Dia - in. 2 3 4 4
Gas inlet - in. 1/2 1/2 3/4 3/4
Approximate Unit Weight - lb 180 260 323 385
Approximate Ship Weight - lb 228 305 388 460
† Ratings shown are for unit installations at elevations between 0 and 2,000 feet (0 to 610m). For unit installations in U.S.A. above 2,000 feet (610m), the unit input must be eld derated 4% for each 1,000 feet (305m) above sea level; refer to local codes, or in absence of local codes, refer to the latest edition of the National Fuel Gas Code, ANSI Standard Z223.1 (NFPA No. 54).
For installations in Canada, any reference to deration at altitudes in excess of 2,00 0 feet (610m) are to be ignored. At altitudes of 2,000 feet to 4,500 feet (610 to 1372m), the unit must be eld derated and be so marked in accordance with the ETL certication. See HIGH ALTITUDE DERATION section and Table 10 for deration information.
* Field installed PVC ttings provided with unit sizes 200-400 as follows:
- Size 200 units come with a 2" to 3" PVC reducer
- Size 300 units come with a 2" to 4" PVC reducer
- Size 400 units come with a 2" to 4" PVC drain tee tting Reducers/drain tee ttings are to be eld installed per Venting instructions.
LEGEND: ODP = Open Drip Proof, PSC = Permanent Split Capacitor
(kW) (29.3) (58.6) (87.9) (117.2)
(kW) (28.1) (56.3) (83.5) (112.5)
(cu. m/s) (0.763) (1.525) (2.288) (3.050)
(Deg C.) (30.6) (30.6) (30.6) (30.6)
Motor HP (Qty) 1/2 1/2 (2) 1 (2) 1 (2) Motor kW 0.37 0.37 0.74 0.74 Motor Type, ODP PSC PSC PSC PSC RPM 1,500 1,500 1,625 1,625 Amps @ 115V 6.0 12.0 22.0 22.0
(476) (476) (689) (886)
(1087) (1392) (1392) (1392)
(438) (438) (653) (850)
(279) (279) (277) (292)
(710) (965) (1060) (1060)
(438) (540) (508) (508)
(438) (540) (660) (660)
(381) (660) (660) (660)
(403) (403) (619) (816)
(71) (95) (95) (95)
(114) (135) (134) (134)
(965) (1067) (1067) (1067)
(697) (794) (794) (794)
(51) (76) (102) (102)
(51) (51) (102) (102)
(67) (67) (67) (67)
(64) (64) (64) (64)
(130) (154) (137) (137)
(117) (117) (206) (334)
(216) (241) (241) (241)
(243) (268) (257) (257)
(mm) (51) (76) (102) (102)
(mm) (51) (76) (102) (102)
(kg) (81.6) (117.9) (146.5) (174.6)
(kg) (103.4) (138.3) (176.0) (208.6)
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INSTALLATION
Do not install unit heaters in
corrosive or ammable atmospheres! Premature
failure of, or severe damage to the unit will result!
Avoid locations where extreme drafts can affect burner operation. Unit heaters must not be installed in locations where air for combustion would contain chlorinated, halogenated or acidic vapors. If located in such an environment, premature failure of the unit will occur!
Since the unit is equipped with an automatic gas ignition system, the unit heater must be installed such that the gas ignition control system is not directly exposed to water spray, rain or dripping water.
NOTICE: Location of unit heaters is related directly to the selection of sizes. Basic rules are as follows:
AIRCRAFT HANGARS: Unit Heaters must be installed
in aircraft hangars as follows: In aircraft hangars, unit heaters must be at least 10 feet (3.0 m) above the upper surface of wings or engine enclosures of the highest aircraft to be stored in the hangar, and 8 feet (2.4 m) above the oor in shops, ofces and other sections of the hangar where aircraft are not stored or housed. Refer to current ANSI/NFPA No. 409, Aircraft Hangars. In Canada, installation is suitable in aircraft hangars when acceptable to the enforcing authorities.
PUBLIC GARAGES: In repair garages, unit heaters must be located at least 8 feet (2.4 m) above the oor. Refer to the latest edition of NFPA 88B, Repair Garages.
PARKING STRUCTURES: In parking structures, unit heaters must be installed so that the burner flames are located a minimum of 18 inches (457 mm) above the oor or protected by a partition not less than 18 inches (457 mm) high. Refer to the latest edition of NFPA 88A, Parking structures.
In Canada, installation must be in accordance to the latest edition of CSA B149 “Installation Codes for Gas Burning Appliances and Equipment.”
AIR DISTRIBUTION: Direct air towards areas of maximum heat loss. When multiple heaters are involved, circulation of air around the perimeter is recommended where heated air ows along exposed walls. Satisfactory results can also be obtained where multiple heaters are located toward the center of the area with heated air directed toward the outside walls. Be careful to avoid all obstacles and obstructions which could impede the warm air distribution patterns.
NOTICE: Unit heaters should not be installed to maintain low temperatures and/or freeze protection of buildings. A minimum of 45°F (7.2°C) thermostat setting must be maintained. If the ambient temperature drops to below freezing, it may result in damage to heat exchanger and/or components.
AIR FOR COMBUSTION: The unit heater shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and the maintenance of ambient air at safe limits under normal conditions of use. The unit
heater shall be located in such a manner as not to interfere with proper circulation of air within the confined space. When buildings are so tight that normal inltration does not meet air requirements, outside air shall be introduced per Sections 1.3.4.2 and 1.3.4.3 of ANSI Z223.1 for combustion requirements. A permanent opening or openings having a total free area of not less than one square inch per 5,000 BTU/Hr. (1.5 kW) of total input rating of all appliances within the space shall be provided.
NOTICE: Unit Heater sizing should be based on heat loss calculations where the unit heater output equals or exceeds heat loss.
NOTICE: Unit should be installed in an area where the entering air does not exceed 104°F. Temperatures above 104°F will cause the propeller motor to trip on its thermal overload protection, requiring a cool down period before the motor can reset.
CLEARANCES: Each Gas Unit Heater shall be
located with respect to building construction and other equipment so as to permit access to the Unit Heater. Clearance between vertical walls and the vertical sides of the Unit Heater shall be no less than 6 inches (152 mm). However, to ensure access to the burner and power venter compartments, a minimum of 18 inches (457 mm) is required for the access panel side. A minimum clearance of 6 inches (152 mm) must be maintained between the top of the Unit Heater and the ceiling. The bottom of the Unit Heater must be no less than 6 inches (152 mm) from any combustible. The distance between rear of unit and vertical wall should be no less than 18 inches (457 mm) for the size 100/200 and 36 inches (914mm) for the size 300/400 to maintain inlet air ow. The distance between the ue collector and any combustible must be no less than 6 inches (152 mm). Also see AIR FOR COMBUSTION and VENTING sections.
NOTICE: Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials.
Make certain that the lifting
methods used to lift the heater and the methods
of suspension used in the eld installation of the
heater are capable of uniformly supporting the weight of the heater at all times. Failure to heed this warning may result in property damage or personal injury!
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INSTALLATION (continued)
Make sure that the structure to which the unit heater is to be mounted is capable of safely supporting its weight. Under no circumstances must the gas lines, the venting system or the electrical conduit be used to support the heater; or should any other objects (i.e. ladder, person) lean against the heater gas lines, venting
the suspension of each unit heater is more than adequate for the job. Failure to do so may result in extensive property damage, severe personal injury, or death! Washers should not be used between the unit nutsert and jam nut. Use of a washer may cause
the nutsert to become dislodged from the unit. system or the electrical conduit for support. Failure to heed these warnings may result in property
Refer to Figures 3A through 3E for suspension of units.
damage, personal injury, or death.
For unit sizes 300/400, pay special attention to the
Unit Heaters must be hung level from
side to side and from front to back. Failure to do so
orientation of the angle mounting brackets per Figures 3B and 3E to ensure brackets sit ush on the bottom of the unit.
will result in poor performance and/or premature failure of the unit.
Figure 3A - High Efciency Unit Heater Suspension (for sizes 100/200)
3/8" THREADED SUSPENSION ROD & JAM NUT BY INSTALLER
OUTSIDE JACKET
A
PANEL (UNIT)
Ensure that all hardware used in
A
Figure 3B - High Efciency Unit Heater Suspension (for sizes 300/400)
SECTION A-A
SCALE 1:1
CAT-10084A
CAT-10166A
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Page 8
Figure 3C - Heater Mounting: Steel Construction (for all sizes)
Figure 3D - Heater Mounting: Wood Construction Joists (for sizes 100/200)
:22'&216758&7,21-2,676
JOIST
WASHER & NUT
2" X 6" LAG BOLTED ACROSS JOISTS
3/8'' THREADED
ROD
UNIT HEATER 100/200 SIZES
Figure 3E - Heater Mounting: Wood Construction Joists (for sizes 300/400)
:22'&216758&7,21-2,676
NUT & WASHER
NUT (2) & WASHER
2" X 6" LAG BOLTED ACROSS JOISTS
JOIST
1/2'' THREADED
ROD
THREADED
INSERT
CAT-10065A
LAG BOLT & WASHER
LAG BOLT & WASHER
*Note: Angle mounting brackets are provided by the manufacturer for unit sizes 300/400. All other hanging hardware and wood is not included with the unit and should be eld supplied.
FRONT OF UNIT HEATER 300/400 SIZES
NUT (2) & WASHER
8
CAT-10165A
Page 9
INSTALLATION – GAS PIPING
To avoid damage or possible personal injury, do not connect gas piping to this unit until a supply line pressure/leak test has been completed. Connecting the unit before completing the pressure/leak test may damage
the unit gas valve and result in a re hazard.
Do not rely on a shut-off valve to isolate the unit while conducting gas pressure/ leak tests. These valves may not be completely shut off, exposing the gas valve to excessive pressure and damage.
PIPE SIZING
To provide adequate gas pressure to the gas unit heater, size the gas piping as follows:
1. Find the cu. feet/hr. by using the following formula:
Cu. ft./hr. =
Input BTU/Hr.
1000
2. Refer to Table 2. Match “Length of Pipe in Feet” with appropriate “Gas Input - Cu. Feet/Hr.” gure. This gure can then be matched to the pipe size at the top of the column.
200,000 BTU/Hr 1,000 BTU/cu. ft.
= 200 Cu. ft./hr.
Using Table 2, a 1 inch pipe is needed.
NOTE: See GENERAL SAFETY INFORMATION section for English/Metric unit conversion factors.
NOTICE: If more than one unit heater is to be served by the same piping arrangement, the total cu. ft./hr. input and length of pipe must be considered.
NOTICE: If the gas unit heater is to be red with LP
gas, consult your local LP gas dealer for pipe size information.
NOTICE: HEATER INSTALLATION FOR USE WITH PROPANE (BOTTLED) GAS MUST BE MADE BY A QUALIFIED L.P. GAS DEALER OR INSTALLER. HE/SHE WILL INSURE THAT PROPER JOINT COMPOUNDS ARE USED FOR MAKING PIPE CONNECTIONS; THAT AIR IS PURGED FROM LINES; THAT A THOROUGH TEST IS MADE FOR LEAKS BEFORE OPERATING THE HEATER; AND THAT IT IS PROPERLY CONNECTED TO THE PROPANE GAS SUPPLY SYSTEM.
Example: It is determined that a 67 ft. (20.4m) run of gas
pipe is required to connect a 200 MBTU gas unit heater to a 1,000 BTU/cu ft. (0.29kW) natural gas supply.
Maximum Capacity of Pipe in Cubic Feet of Gas per Hour (Cubic Meters per Hour) for Gas Pressures of 0.5 psig (3.5 kPa) or Less, and a Pressure Drop of 0.5 Inch Water Column (124.4 Pa) (Based on a 0.60 Specic Gravity Gas) Nominal
Iron Internal Length of Pipe, Feet (meters)
Pipe Size Dia. 10 20 30 40 50 60 70 80 90 100 125 150 175 200
in. in. (3.0) (6.1) (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0) 1/2 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35
(4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99) 3/4 0.824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 (10.2) (7.08) (5.66) (4.81) (4.28) (3.91) (3.54) (3.34) (3.11) (2.92) (2.63) (2.38) (2.18) (2.04) 1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 (19.3) (13.2) (10.6) (9.06) (8.07) (7.36) (6.80) (6.23) (5.80) (5.52) (4.96) (4.53) (4.11) (3.82) 1 1/4 1.380 1400 950 770 660 580 530 490 460 430 400 360 325 300 280 (39.6) (26.9) (21.8) (18.7) (16.4) (15.0) (13.9) (13.0) (12.2) (11.3) (10.2) (9.20) (8.50) (7.93) 1 1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 (59.5) (41.3) (33.4) (28.0) (25.5) (22.9) (21.2) (19.5) (18.4) (17.6) (15.6) (14.2) (13.0) (12.2) 2 2.067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800 (112) (77.9) (62.3) (53.8) (47.6) (43.0) (39.6) (36.8) (34.5) (32.6) (28.9) (26.9) (24.1) (22.7) 2 1/2 2.469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280 (178) (123) (99.7) (85.0) (75.0) (68.0) (63.7) (58.0) (55.2) (52.4) (46.7) (42.5) (38.8) (36.2) 3 3.068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280 (311) (218) (177) (150) (135) (122) (110) (105) (97.7) (92.0) (83.5) (75.0) (69.4) (64.6) 4 4.026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600 (651) (447) (362) (309) (275) (249) (229) (212) (204) (190) (170) (156) (142) (130)
1. Determine the required Cu. Ft./Hr. by dividing the input by 1000. For SI/Metric measurements: Convert BTU/Hr. to kilowatts. Multiply the units
inputs (kW) by 0.0965 to determine Cu. Meters./Hr. 2. FOR NATURAL GAS: Select pipe size directly from the table. 3. FOR PROPANE GAS: Multiply the Cu. Ft./Hr. value by 0.633; then, use the table. 4. Refer to the metric conversion factors listed in the General Safety section for SI Unit measurement conversions.
Before any connection is made to the existing line supplying other gas appliances, contact the local gas company to make sure that the existing line is of adequate size to handle the combined load.
Table 2 - Gas Pipe Size
9
Page 10
INSTALLATION – GAS PIPING (continued)
PIPE INSTALLATION
1. Install the gas piping in accordance with applicable local codes.
2. A eld provided lock-up type high pressure regulator must be used to limit the supply pressure to a maximum of 14 inches W.C. (3.5 kPa). All piping should be sized in accordance with the latest edition of ANSI Standard Z223.1 (NFPA 54), National Fuel Gas Code; in Canada, according to CSA B149. See Table 2 for correct gas piping size. If gas pressure is excessive, install a pressure regulating valve in the line upstream from the main shutoff valve.
NOTICE: For proper operation, unit requires a minimum supply gas pressure of 5 inches W.C. (1.2 kPa) for natural gas or 8 inches W.C. (2.0 kPa) for propane (LP) gas.
3. Adequately support the piping to prevent strain on the gas manifold and controls. Supports should be spaced in accordance with the latest edition of ANSI Standard Z223.1 (NFPA 54), National Fuel Gas Code; in Canada, according to CSA B149.
4. To prevent the mixing of moisture with gas, run the take-off piping from the top, or side, of the main.
5. Gas valve has adjustment ports to adjust ow rate. See START-UP section.
6. Provide a drip leg in the gas piping near the gas unit heater. A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing. The manual shutoff valve must be located external to the jacket (See Figure 4).
7. Make certain that all connections have been adequately doped and tightened.
Do not over tighten the inlet gas piping into the valve. This may cause stresses that will crack the valve!
NOTICE: Use pipe joint sealant resistant to the action of
liqueed petroleum gases regardless of gas conducted.
Check all pipe joints for leakage using a soap solution or other approved method. Never use an open flame or severe personal injury or death may occur!
Figure 4 - Pipe Installation, Standard Controls
Never use an open ame to detect
gas leaks. Explosive conditions may exist which may result in personal injury or death!
The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system in excess of 1/2 psig (3.5 kPa).
The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).
INSTALLATION – CONDENSATE PIPING
1. Screw 3/4" adaptor into condensate connection located in the bottom of the unit.
2. Prime and cement together components as shown in Figure 5.
Do not install condensate trap
horizontally. Failure to install the condensate
trap vertically may result in ue gas entering the
condensate piping.
3. A field-provided 3/4" PVC nipple must be primed and cemented between the 3/4" adapter and 3/4" coupler. The nipple length must long enough that the total distance between the bottom of unit and clear ultra trap is equal to or greater than the minimum distance shown in Table 3.
Table 3 - Minimum Condensate Trap Distance
Size 100 Size 200-400
“X” - Minimum Condensate Trap Distance 2.5" 4.5"
Optional condensate pump and neutralizer should be piped per their separate corresponding installation manuals.
Figure 5 - Condensate Piping
;
SIZE
100 200
2.5" 4.5""X"
CAT-10080A
10
CONDENSATE CONNECTION
3/4" ADAPTOR
FIELD PROVIDED 3/4" PVC NIPPLE
3/4" COUPLER
CLEAR ULTRA TRAP
FIELD PROVIDED 3/4" PVC PIPE TO DRAIN
Page 11
ELECTRICAL CONNECTIONS
HAZARDOUS VOLTAGE!
DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.
Standard units are shipped for use on 115 volt, 60 hertz, single phase electric power. The motor name-plate and electrical rating of the transformer should be checked before energizing the unit heater electrical system. All external wiring must conform to the latest edition of ANSI/NFPA No. 70, United States National Electrical Code, and applicable local codes; in Canada, to the Canadian Electrical Code, Part 1, CSA Standard C22.1.
1. Cold Areas - Outside walls or areas where drafts may affect the operation of the control.
2. Hot Areas - Areas where the sun's rays, radiation, or warm air currents may affect the operation of the control.
3. Dead Areas - Areas where the air cannot circulate freely, such as behind doors or in corners.
Figure 6A - Low-voltage Thermostat Wiring, Single Stage
LOW-VOLTAGE
SINGLE STAGE
THERMOSTAT
G
R
W
R
W1
W2
C
Field installed step-down transformers provided for units with non-standard supply voltage options 2-7 (any voltage other than 115/1/60) cannot be mounted on the unit due to the weight of the transformer. The step-down transformer should be mounted elsewhere and wired to the unit accordingly. Failure to do so could result in fatal electric shock or severe personal injury.
Do not use any tools (i.e. screwdriver, pliers, etc.) across terminals to check for power. Use a voltmeter.
It is recommended that the electrical power supply to each unit heater be provided by a separate, fused, and permanently live electrical circuit. A disconnect switch of suitable electrical rating should be located as close to the gas valve and controls as possible. Each unit heater must be electrically grounded in accordance with the latest edition of the United States National Electrical Code, ANSI/NFPA No. 70, or CSA Standard C22.1.
THERMOSTAT WIRING AND LOCATION:
NOTICE:The thermostat must be mounted on a vertical, vibration-free surface, free from air currents, and in accordance with the furnished instructions.
Mount the thermostat approximately 5 feet (1.5 m) above the oor, in an area where it will be exposed to a free circulation of average temperature air. Always refer to the thermostat instructions, as well as our unit wiring diagram, and wire accordingly. Avoid mounting the thermostat in the following locations:
CAT-10066A
Figure 6B – Low-voltage Thermostat Wiring, Two Stage
W1
R
G
R
W2
W1
W2
C
CAT-10122A
NOTICE: From a cold start, the start-up fan delay should not exceed 30 seconds from after flame sensing.
IMPORTANT: For all wiring connections, refer to the
wiring diagram shipped with your unit (either afxed
inside the control box access panel or enclosed in the installation instructions envelope). Should any original wire supplied with the heater have to be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C.
Should any high limit wires have to be replaced, they must be replaced with wiring material having a temperature rating of 200°C minimum.
11
Page 12
ELECTRICAL CONNECTIONS (continued)
Figure 7A – Unit Wiring Diagram, High Efciency Unit Heater Size 100, Equipped with Natural or Propane
(LP) Gas, Modulating with Outside Air Reset (Master)
12
Page 13
ELECTRICAL CONNECTIONS (continued)
Figure 7B – Unit Wiring Diagram, High Efciency Unit Heater Size 200, Equipped with Natural or Propane
(LP) Gas, Modulating with Outside Air Reset (Master)
13
Page 14
ELECTRICAL CONNECTIONS (continued)
Figure 7C – Unit Wiring Diagram, High Efciency Unit Heater Size 300/400, Equipped with Natural or Propane
(LP) Gas, Modulating with Outside Air Reset (Master)
14
Page 15
VENTING – GENERAL GUIDELINES
ANSI now organizes vented appliances into four categories.
Venting Categories
Non-
Condensing Condensing Negative
Vent I II
Pressure Positive
Vent III IV
Pressure
Category I
Includes non-condensing appliances with negative vent pressure, like the traditional atmospheric unit heater.
Category II
Groups condensing appliances with negative vent pressure.
Category III
Appliances are non-condensing and operate with a positive vent pressure.
Category IV
Covers condensing appliances with positive vent pressure.
NOTICE: Category I, II and III do not apply to equipment specified within this manual. These unit
heaters are Category IV appliances.
All unit heaters must be vented! All Venting installations shall be in accordance with the latest edition of Part 7, Venting of Equipment of the National Fuel Gas Code, ANSI Z223.1 (NFPA 54), or applicable provisions of local building codes.
The following instructions apply to Canadian installations in addition to installation and operating instructions:
1. Installation must conform with local building codes, or in the absence of local codes, with current CSA B149.1,
Installation Codes for Natural Gas Burning Appliances and Equipment, or CSA B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment.
2. Any reference to U.S. standards or codes in these instructions are to be ignored, and the applicable Canadian
standards or codes applied.
CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or
u-like symptoms).
FLUE PIPE REDUCER
Size 200 units ship with a field installed 2" to 3" PVC reducer and size 300 units ship with a field installed 2" to 4" PVC reducer. The reducer must be installed in a horizontal section of the flue pipe system within 12 inches (305 mm) of the unit. All vent pipe joints and seams must be sealed to prevent leakage. All joints must be cleaned prior to assembly. Joints should then be primed in accordance with ASTM F 656. After priming,
Each unit must have an individual vent pipe and vent
joints should be cemented per ASTM D 2564.
terminal! Each unit MUST NOT be connected to other vent systems or to a chimney.
Size 400 units ship with a field installed 2" to 4" PVC
drain tee fitting. The drain tee must be installed in a Do not damper or add heat recovery devices to the ue piping. Failure to open such a damper prior to operating gas unit will result in the spillage of ue gas into the occupied space.
horizontal section of the flue pipe system within 12
inches (305 mm) of the unit with the drain pointing
downward. The condensate tubing will ship connected
to the flue collector coiled inside the power venter
NOTICE: The high efficiency unit heater is likely to produce a vapor plume due to condensation. Surfaces near the vent termination will likely become coated with condensation.
compartment. The tubing should be uncoiled and
connected to the bottom of the condensate drain tee. All
vent pipe joints and seams must be sealed to prevent
leakage. All joints must be cleaned prior to assembly.
Joints should then be primed in accordance with ASTM F
Condensing flue gases can freeze
on exterior building surfaces which may cause
656. After priming, joints should be cemented per ASTM
D 2564.
discoloration and degradation of the surfaces.
Table 4
Structure/Object
Door, window, or gravity vent inlet; combustion air inlet for other appliances
Forced air inlet within 10 ft. Adjoining Building or parapet 10 ft. 10 ft. (3.04m)
Adjacent public walkways
Electric, gas meters & regulators 4 ft. horizontal
Above grade level* 1 ft. 1 ft. (0.3m)
*Minimum above maximum snow depth, or per local code, whichever is greater.
9 in. for 10,000 to 50,000 BTU/Hr input; 12 in. for input exceeding 50,000 BTU/Hr.
3 ft. above 6 ft. (1.8m)
7 ft. above
grade
Vent Systems Termination Clearance Requirements
Minimum Clearance for Termination Locations
USA CANADA
9 in. (230mm) for 10,000 to 50,000 BTU/Hr input; 12 in. (305mm) for input exceeding 50,000 BTU/Hr.
7 ft. (2.1m) above grade
3 ft. (0.9m) horizontally from meter/regulator assembly. 6 ft. (1.8m), any direction, from a gas service regulator vent outlet
15
Page 16
STANDARD COMBUSTION – HORIZONTALLY VENTED UNIT HEATERS
(CATEGORY IV)
This appliance uses a positive pressure venting system. All joints must be sealed completely to prevent leakage of flue products into occupied spaces. Failure to do this may result in severe personal injury, death or major property damage.
1. Horizontal venting arrangements are designed to be used with schedule 40 vent pipe. All heaters should be vented with UL 1738 listed vent pipe. For installations in Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or in the absence of local building codes, with the current CSA-B149.1, Installation Codes for natural Gas Burning Appliances and Equipment or CSA-B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment. Approved vent pipe includes but is not limited to: ULC-S636 PVC or CPVC Vent pipe. Vent pipe must be rated for up to 140°F (60°C) operating temperature. Type B vent should not be used.
Do not use Type B (double wall)
vent internally within the building on high
efciency unit heaters! This can result in death,
serious injury or substantial property damage.
5. The vent system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21 mm/m) toward the unit for condensate drainage.
6. Horizontal portions of the venting systems shall be supported at maximum intervals of 4 feet (1.2 m) to prevent sagging (in Canada, support at 3 feet (1 m) maximum intervals).
7. Seal all vent pipe joints and seams to prevent leakage. All joints must be cleaned prior to assembly. Joints should then be primed in accordance with ASTM F 656. After priming, joints should be cemented per ASTM D 2564.
8. Insulate single wall vent pipe exposed to cold air or
running through unheated areas.
9. Each unit must have an individual vent pipe and
vent terminal! Each unit MUST NOT be connected to other vent systems or to a chimney.
Figure 8 – Horizontal Venting, Standard Combustion
Use of cellular core pipe for any exhaust vent component is prohibited. Use of cellular core pipe may result in severe personal injury, death, or major property damage.
NOTICE: Installations in Canada require compliance with ULC-S636 Standard for Type BH Gas Venting Systems.
2. The vent pipe diameter MUST be as specied (see Table 1). All unit sizes are factory equipped with the required ue size collar; attach in place (if not already factory-mounted to outlet).
3. The vent pipe equivalent length must not exceed 50 feet (15.2 m). Equivalent length is total length of straight sections PLUS 5 feet (1.5 m) for each 90 degree elbow and 2.5 feet (0.76 m) for each 45 degree elbow.
4. The vent terminal must be at least 12 inches (305 mm) from the exterior of the wall that it passes through to prevent degradation of the building material by flue gases. Through the wall vent for these appliances shall NOT terminate over public walkways, or over an area where the condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. See Table 4 for termination clearance requirements.
PITCH PIPE DOWN TOWARDS UNIT 1/4" PER FT. (21 mm/m) OF RUN TO ALLOW FOR CONDENSATE DRAINAGE
ELBOW OR TEE
EXHAUST
CAT-10067A
NOTICE: Increasing the vent termination clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials.
16
Page 17
STANDARD COMBUSTION – VERTICALLY VENTED UNIT HEATERS
(CATEGORY IV)
This appliance uses a positive pressure venting system. All joints must be sealed completely to prevent leakage of flue products into occupied spaces. Failure to do this may result in severe personal injury, death or major property damage.
1. Vertical venting arrangements are designed to be used with schedule 40 vent pipe. All heaters should be vented with UL 1738 listed vent pipe. For installations in Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or in the absence of local building codes, with the current CSA-B149.1, Installation Codes for natural Gas Burning Appliances and Equipment or CSA-B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment. Approved vent pipe includes but is not limited to: ULC-S636 PVC or CPVC Vent pipe. Vent pipe must be rated for up to 140°F (60°C) operating temperature. Type B vent should not be used.
Do not use Type B (double wall)
vent internally within the building on high
efciency unit heaters! This can result in death,
serious injury or substantial property damage.
4. Vent system terminations for these appliances shall NOT terminate in an area where the condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. See Table 4 for termination clearance requirements.
5. The vent pipe equivalent length must not exceed 50 feet (15.2 m). Equivalent length is total length of straight sections PLUS 5 feet (1.5 m) for each 90 degree elbow and 2.5 feet (0.76 m) for each 45 degree elbow.
6. Seal all vent pipe joints and seams to prevent leakage. All joints must be cleaned prior to assembly. Joints should then be primed in accordance with ASTM F 656. After priming, joints should be cemented per ASTM D 2564. The vent system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21 mm/m) toward the unit for condensate drainage.
7. Horizontal portions of the venting systems shall be supported at maximum intervals of 4 feet (1.2 m) to prevent sagging (in Canada, support at 3 feet (1 m) maximum intervals).
Use of cellular core pipe for any exhaust vent component is prohibited. Use of cellular core pipe may result in severe personal injury, death, or major property damage.
NOTICE: Installations in Canada require compliance with ULC-S636 Standard for Type BH Gas Venting Systems
2. The vent pipe diameter MUST be as specied (see Table 1). All unit sizes are factory equipped with the required ue size collar; attach in place (if not already factory-mounted to outlet).
3. The top of the vent pipe should extend at least 2 feet (0.61 m) above the highest point on the roof within 10 feet (3.05 m) of the termination. Consideration should be made for anticipated snow depth.
8. Insulate single wall vent pipe exposed to cold air or
running through unheated areas.
9. Each unit must have an individual vent pipe and
termination. Each unit MUST NOT be connected to other vent systems or to a chimney.
Figure 9 – Vertical Venting, Standard Combustion
ROOF FLASHING
CAT-10068A
FLUE PIPE
17
Page 18
SEPARATED COMBUSTION – TWO PIPE VENTING
NOTE: For non-concentric venting (two wall or two roof penetrations, one for combustion air and a second for ue
pipe), follow the instructions below. For concentric venting (single wall or roof penetration), follow the concentric venting instructions in SEPARATED COMBUSTION – CONCENTRIC VENTING Section.
AIR INLET COLLAR
When unit is to be used in a separated vent system, the inlet collar located on the top panel of the unit will be connected to the combustion air intake pipe. This connection is made by using the appropriate size rubber coupling (eld provided) for each size unit. The coupling is installed so that air inlet pipe can be detached from the unit for serviceability purposes.
COMBUSTION AIR VENTING AND PIPING
CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or flu-like symptoms).
1. The combustion air system installation must be in accordance with the current edition of the National Fuel Gas Code-NFPA 54 or ANSI Z223.1 National Fuel Gas Code. In Canada, installation must be in accordance with CSA-B149.1 “Installation Code for Natural Gas Burning Appliances and Equipment” and CSA-B149.2 “Installation Code for Propane Burning Appliances and Equipment.”
2. Each unit heater MUST have its own combustion air system. It MUST NOT be connected to other air intake systems.
3. Use UL 1738 listed schedule 40 vent pipe for the vent system. For installations in Canada, use UL­S636 listed vent pipe conforming with local building codes, or in the absence of local building codes, with current CSA-B149.1 “Installation Codes for Natural Gas Burning Appliances and Equipment” or CSA-B149.2, “Installation Codes for Propane Gas Burning Appliances and Equipment.”
Do not use Type B (double
wall) vent internally within the building on high
efciency unit heaters! This can result in death,
serious injury or substantial property damage.
Use of cellular core pipe for any exhaust vent component is prohibited. Use of cellular core pipe may result in severe personal injury, death, or major property damage.
NOTICE: Installations in Canada require compliance with ULC-S636 Standard for Type BH Gas Venting Systems.
4. Long runs of single wall combustion air piping passing through an unheated space may require insulating if condensation becomes noticeable.
5. The combustion air inlet system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21 mm/m) toward the inlet cap to facilitate drainage.
6. The equivalent length of the combustion air system must not be less than 5 feet (1.5 m) and must not exceed 50 feet (15.2 m). Equivalent length equals the total length of straight pipe plus 5 feet (1.5 m) for each 90 degree elbow and 2.5 feet (0.76 m) for each 45 degree elbow.
NOTICE: For optimum performance keep the combustion air system as straight as possible.
7. Seal all vent pipe joints and seams to prevent leakage. All joints must be cleaned prior to assembly. Joints should then be primed in accordance with ASTM F 656. After priming, joints should be cemented per ASTM D 2564.
8. For horizontal combustion air systems longer than 5 feet (1.5 m), the system must be supported from overhead building structures at 4 foot (1.2 m) intervals in the U.S. and at 3 foot (0.91 m) intervals in Canada.
EXHAUST VENTING
For ue pipe installation, follow the steps in the STANDARD COMBUSTION VENTING sections.
18
Page 19
Figure 10 - Vertical Two Pipe Separated Combustion Venting, Roof Termination
24" (610 mm) MINIMUM FROM ADJACENT
INLET PIPE
FLUE PIPE COMBUSTION AIR INLET PIPE
ROOF FLASHING
4.5" MINIMUM (115 mm)
AIR INLET TERMINAL
4.5" MINIMUM (115 mm)
WALL OR BUILDING TO COMBUSTION
8" MINIMUM
(204 mm)
ROOF FLASHING REQUIRED AT ALL PENETRATIONS THROUGH THE ROOF
12" (305 mm) MINIMUM
CAT-10075A
FLUE PIPE
COMBUSTION AIR INLET PIPE
ABOVE ROOF OR SNOW LINE
FLUE PIPE
COMBUSTION AIR
CAT-10075A
Figure 11 - Vertical Two Pipe Separated Combustion Venting, Sloped Roof Termination
REQUIRED AT ALL PENETRATIONS THROUGH THE ROOF
4.5" (115 mm) MINIMUM
8" (204 mm) MINIMUM
24" (610 mm) MINIMUM HEIGHT ABOVE HIGHEST POINT OF ROOF WITHIN 10 FT. (3.1 m) RADIUS
CAT-10076A
Figure 12 - Horizontal Two Pipe Separated Combustion Venting, Sidewall Termination
MINIMUM
24" (610 mm)
24" (610 mm) MINIMUM TO ADJACENT WALL OR BUILDING
19
AIR INLET
Page 20
SEPARATED COMBUSTION – CONCENTRIC VENTING
NOTICE: Every Separated Combustion unit to be installed MUST use the factory-available Concentric Vent Kit. If you do not have this kit, contact the manufacturer ASAP to obtain one prior to installation.
AIR INLET COLLAR
When the unit is to be used in a separated vent system, the inlet collar located on the top panel of the unit will be connected to the combustion air intake pipe. This connection is made by using a eld-provided rubber coupling in the appropriate size for each unit capacity. The coupling is installed so that air inlet pipe can de detached from the unit for serviceability purposes.
GENERAL
Concentric venting allows both the intake for combustion air and the exhaust vent to pass through a single standard roof or sidewall opening. This is an alternative to the standard two pipe intake/vent shown in the separated combustion venting instructions. Follow these instructions as well as the separated combustion venting instruction for installation of the intake/vent pipe(s) and all unit heater installation procedures.
IMPORTANT:Concentric venting reduces the allowable intake/vent piping length by 5 feet (1.5 m) from that listed in the venting instructions.
Do not operate the unit until the installation and assembly of the Concentric Vent Kit and all piping are completed. Failure to follow
this warning could result in re, personal injury
or death.
The Concentric Vent Kit contains the following parts: (1) Combustion Air Inlet Cap (1) Air Inlet Pipe (1) Flue Pipe (1) Intake/Vent Concentric “Y”
Figure 13 – Concentric Vent Kit Assembly
In Canada, construct all combustion air and vent pipes for this unit of CSA or ULC certied Schedule 40 PVC, PVC-DWV, or ABS-DWV pipe and pipe cement.
Table 5 – Concentric Vent Kit Component Dimensions
Unit Size
300/400 4" 57-1/4" 5-9/16" 41"
1. Shipping dimension. This may be eld modied by cutting or extending both the intake and exhaust pipes. 12 inches (305 mm) is the minimum allowable length and 60 inches (1.5 m) is the maximum allowable length for this dimension. Only SDR-26 PVC (ASTM D2241) may be used for extending pipes. Do not extend pipes with Schedule 40 PVC or couplings.
2. This dimension will change if the intake/vent pipes are lengthened
or shortened.
Intake/Vent
Nom. Pipe Size
100 2" 34-3/4" 3-1/2" 19-1/2" 200 3" 39-1/8" 4-1/2" 24"
Overall
Assembled
Length
1
Intake Pipe
Outside
Diameter
Air Inlet Pipe
Length
2
NOTICE: Some local code inspectors are not familiar with concentric vents. Be sure to check local code requirements and acceptability prior to installation.
HORIZONTAL SIDEWALL MOUNTING
NOTE: Refer to the following items before horizontal installation:
• Check INSTALLATION section of this manual for allowable clearances and locations.
• Refer to Figures 16 and 17 when venting multiple units using concentric venting.
• Avoid locations with high winds.
• Avoid locations where Concentric Vent Kit is likely to be damaged.
• Avoid locations where vapors are objectionable, or may damage the structure, plants or air conditioning condensing unit.
ASSEMBLED TERMINAL
AIR INLET PIPE
FITTING
FLUE PIPE
Pipe and ttings are required to complete installation (user supplied). The combustion air and vent pipe ttings must conform to ANSI and ASTM standards D1785, F891, D2665, D2241, D2661, or F628. Pipe cement and primer must conform to ASTM standards D2564 or D2235.
COMBUSTION AIR INLET CAP
CAT-10069A
1. Determine correct concentric vent kit size for the unit
capacity selected.
2. Determine the best location for the concentric vent;
refer to Figures 15, 16 and 17. Also refer to Table 4 for vent termination clearance requirements.
3. When installing multiple units with concentric venting,
refer to the following guidelines: a. Do not install multiple concentric vent terminations
directly above one another unless separated by a minimum of 3 feet (0.91 m); see Figure 16.
b. Install multiple concentric vent terminations so
the horizontal distance between the ends of each air intake is 4 inches (102 mm) or less or greater than 24 inches (610 mm); see Figure 17. This will prevent a recirculation of ue gas.
20
Page 21
SEPARATED COMBUSTION – CONCENTRIC VENTING (continued)
T
4. Cut a hole for Concentric Vent kit. a. Cut a 4 inch (102 mm) diameter hole for size 100
unit, 2 inch (51 mm) concentric vent kit.
b. Cut a 5 inch (127 mm) diameter hole for size 200
unit, 3 inch (76 mm) concentric vent kit.
c. Cut a 6 inch (152 mm) diameter hole for size
300/400 unit, 4 inch (102 mm) concentric vent kit.
5. Partially assemble Concentric Vent kit. Follow venting instructions for cleaning and cementing. a. Cement “Y” tting to larger diameter air inlet pipe
(Figure 13).
b. Cement combustion air inlet cap to smaller
diameter ue pipe (Figure 13).
6. Install “Y” tting and pipe assembly through hole.
7. Install combustion air inlet cap and large diameter pipe assembly. Cement and fully insert small diameter pipe in “Y” concentric tting.
8. Secure to structure using metal strapping or equivalent support material (eld supplied); refer to Figure 14.
9. Cement combustion air and vent pipes to concentric vent kit. Refer to Figure 14 for proper pipe attachment.
Figure 15 - Horizontal Sidewall Concentric Venting, Single Termination
ROOF OVERHANG
36" MINIMUM
(915 mm)
CAT-10072A
(25 mm)
COMBUSTION
AIR
MAINTAIN 12" (305 mm) CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LINE OR GRADE
VENT
1"
Figure 16 - Horizontal Sidewall Concentric Venting, Multiple Unit Vertical Layout
ROOF OVERHANG
12" MINIMUM
(305 mm)
10. Check installation by allowing unit to run through one cycle.
Figure 14 - Horizontal Concentric Vent Kit Installation
NOTE: SECURING STRAP MUST BE INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT INSIDE WALL
EXHAUST
COMBUSTION AIR
ELBOW
(FIELD SUPPLIED)
STRAP (FIELD SUPPLIED)
MAX.60"
(1524 mm)
1" (25 mm) COMBUSTION AIR
INLET VANES TO WALL
COMBUSTION AIR
VEN
CAT-10074A
36" MINIMUM
1"
(25 mm)
COMBUSTION
AIR
MAINTAIN 12" (305 mm) CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LINE OR GRADE
VENT
(915 mm)
CAT-10071A
Figure 17 - Horizontal Sidewall Concentric Venting, Multiple Unit Horizontal Layout
4" (102 mm) MAXIMUM OR 24" (610 mm) MINIMUM (BETWEEN END BELL EDGES)
CAT-10073A
1"
(25 mm)
COMBUSTION
AIR
12" (305 mm) MINIMUM
VENT
MAINTAIN 12" (305 mm) CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LINE OR GRADE
21
Page 22
SEPARATED COMBUSTION – CONCENTRIC VENTING (continued)
NOTE: Keep assembly free of insulation during installation.
NOTE: Maintain clearance dimensions as shown in Figures 15, 16 and 17. Also refer to Table 4 for vent termination clearance requirements.
NOTE: If assembly is too short, the two pipes supplied in the kit may be replaced by using same diameter,
eld supplied SDR-26 PVC (ASTM D2241) pipe. Do not
extend pipes with Schedule 40 PVC or couplings. The additional wall thickness will restrict combustion air and may cause operational problems. Do not extend air inlet pipe more than 60 inches (1.5 m); see Figure 14.
Do not use field supplied couplings
to extend pipes; ue gas may leak from the venting
system resulting in unsafe conditions.
If the venting system is not
installed according to these guidelines, ue gas
may recirculate, possibly causing the intake pipe to freeze shut during cold weather operation.
VERTICAL ROOF MOUNTING
NOTE: Roof mounting is recommended as it allows less intake air contaminants and reduces ground-level exhaust.
Figure 18 - Vertical Concentric Vent Kit Installation
MAINTAIN 12" (305 mm) MINIMUM
MAINTAIN 12" (305 mm) MINIMUM (18" (458 mm) FOR CANADA) CLEARANCE ABOVE
(18" (458 mm) FOR CANADA) CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LINE MAXIMUM OF
HIGHEST ANTICIPATED SNOW LINE MAXIMUM OF 24" (610 mm) ABOVE ROOF
24" (610 mm) ABOVE ROOF
COMBUSTION AIR
60" (1524 mm)
MAXIMUM
CAT-10078A
COMBUSTION AIREXHAUST
ROOF WEATHER SEAL/FLASHING (FIELD SUPPLIED)
SUPPORT (FIELD SUPPLIED)
ELBOW (FIELD SUPPLIED)
Figure 19 - Vertical Concentric Venting, Roof Termination
1. Determine correct concentric vent kit size for the unit capacity selected.
2. Determine the best location for the concentric vent.
3. Cut a hole for Concentric Vent Kit. a. Cut a 4 inch (102 mm) diameter hole for size 100
unit, 2 inch (51 mm) concentric vent kit.
b. Cut a 5 inch (127 mm) diameter hole for size 200
unit, 3 inch (76 mm) concentric vent kit.
c. Cut a 6 inch (152 mm) diameter hole for size 300/400
unit, 4 inch (102 mm) concentric vent kit.
4. Partially assemble Concentric Vent kit. Follow venting instructions for cleaning and cementing. a. Cement “Y” tting to larger diameter air inlet pipe
(Figure 13).
b. Cement combustion air inlet cap to smaller
diameter pipe (Figure 13).
5. Install “Y” tting and pipe assembly through hole and roof boot/ashing (eld supplied).
6. Secure to roof using metal strapping or equivalent support material (eld supplied); refer to Figure 18.
7. Install combustion air inlet cap and small diameter pipe assembly into roof. Cement and fully insert small diameter pipe in “Y” concentric tting.
NOTE: Keep assembly free of insulation during installation.
NOTE: Install multiple concentric vent terminations so the horizontal distance between the ends of each air intake is 4 inches (102 mm) or less or greater than 24 inches (610 mm); see Figure 17. This will prevent
a recirculation of ue gas.
NOTE: Termination height must be above roof sur­face or anticipated snow level (minimum 12 inches (305 mm) in U.S. or minimum 18 inches (458 mm) in Canada) as shown in Figures 18 and 19.
NOTE: If assembly is too short, the 2 pipes supplied in the kit may be replaced by using same diameter,
eld supplied SDR-26 PVC (ASTM D2241) pipe. Do not
extend pipes with Schedule 40 PVC or couplings. The additional wall thickness will restrict combustion air and may cause operational problems. Do not extend air inlet pipe more than 60 inches (1.5 m); see Figure 14.
8. Cement combustion air and vent pipes to concentric vent kit. Refer to Figure 14 for proper pipe attachment.
9. Check installation by allowing unit to run through one cycle.
Do not use field supplied couplings
to extend pipes; ue gas may leak from the venting
system resulting in unsafe conditions.
22
Page 23
GAS CONVERSION
This conversion kit shall be installed
by a qualied service agency in accordance with
the manufacturer's instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is
not followed exactly, a re, explosion or production
of carbon monoxide may result causing property
damage, personal injury or loss of life. The qualied
service agency performing this work assumes responsibility for the proper conversion of this appliance with this kit.
1. All work must be performed by a fully qualified, experienced, and trained service technician. It is the responsibility of the installer to follow all instructions. Failure to follow these instructions could result in serious injury or property damage.
2. The qualied agency performing the work assumes responsibility for the conversion.
3. CAUTION: The gas supply should be shut off prior to disconnecting the electrical power. Both the gas and electrical supply must be off prior to starting the conversion.
4. Wear safety glasses.
5. Be sure of ladder placement. Do not allow people to stand below or around the area where the work is being performed. Do not lean ladders or equipment against the heater at any time during the conversion.
Figure 20 - Gas Train Assembly
MIXING CHAMBER
ORIFICE NIPPLE
ELBOW
REPLACE THE ORIFICES (see Figure 20)
6. Remove the four screws holding the access panel and remove the panel.
7. Using the proper size wrench, loosen the 1/2 inch upper ex line union that is attached to the mixing chamber assembly (see Figure 20).
8. Using a Phillips screw driver, remove the 6 screws that attach the mixing chamber to the combustion blower.
9. Place mixing chamber on at surface and unthread the 90 degree elbow from orice nipple. Then unthread the orice nipple from the mixing chamber. Keep the original orice separate from the new orice at all times.
NOTE: Orice should be sizes shown in the Table 6. All Propane (LP) gas orices are painted red.
Table 6 - Main Burner Orice Schedule
Type of Gas Natural Propane
*Input in
1000 BTU
100 Orice Drill Size 0.282 in. 0.213 in. 200 Orice Drill Size 0.282 in. 0.213 in. 300 Orice Drill Size 0.266 in. 0.228 in. 400 Orice Drill Size 0.323 in. 6.6 mm
* This schedule is for units operating at altitudes of 2,000 feet (610 m) or less. See GAS INPUT RATE section and Table 10 for eld deration information.
Heating Value
1,050 BTU/Ft
(39.1 MJ/m3)
3
2,500 BTU/Ft
(93.1 MJ/m3)
3
10. Ensure that the number stamped on the orifice matches the size listed in Table 6. Apply pipe sealant to the threads of the new orice nipple and thread into mixing chamber.
11. Thread the 90 degree elbow and are union onto the orice nipple.
12. Re-install the mixing chamber on the combustion blower ensuring the O-ring gasket is secure in the combustion blower groove. Align and tighten the ex line union to the mixing chamber assembly.
FLEX HOSE
CAT-10119B
OPERATION
13. To adjust gas valve: a. For size 100 and 200 units, using a 2.5mm
wrench turn the set screw on the gas valve high re adjustment clockwise when converting to LP and counter clockwise when converting to natural gas (see Figure 21A).
b. For size 300 and 400 units, remove gas valve
adjustment cover using a at head screwdriver, turn gas valve adjustment counterclockwise to convert to LP gas and clockwise to convert to natural gas (see Figure 21B).
23
Page 24
GAS CONVERSION
Figure 21A – Gas Valve Adjustment Locations (Sizes 100/200)
Low Fire Adjustment
High Fire Adjustment
Figure 21B – Gas Valve Adjustment Location (Sizes 300/400)
Figure 21C – Run% Potentiometer on Control Board
Run % Potentiometer
24
Page 25
GAS CONVERSION
14. Turn the set screw open to the number of turns listed in Table 7. a. For Propane (LP) Gas units:
• For size 100/200 units, turn adjustment clockwise to the number of turns shown.
• For size 300/400 units, turn adjustment counterclockwise to the number of turns shown. Replace gas valve adjustment cover.
b. For Natural Gas units:
• For size 100/200 units, turn adjustment counterclockwise to the number of turns shown.
• For size 300/400 units, turn adjustment clockwise to the number of turns shown. Replace gas valve adjustment cover.
Table 7 - Gas Conversion High Fire Adjustment
Unit Size (MBH)
100 1-3/4 CW 1-3/4 CCW 200 2-1/2 CW 2-1/2 CCW 300 2-1/2 CCW 2-1/2 CW 400 4 CCW 4 CW
Note: “CW” indicates clockwise rotation and “CCW” indicates counterclockwise rotation.
Natural Gas to
Propane (LP) Gas
Propane (LP) Gas to
Natural Gas
Table 8 - CO2 Operation Range
Unit Size
(MBH)
100 7.5 – 8.0% 8.9 – 9.3% 4.2 – 5.0% 5.3 – 5.8% 200 7.5 – 8.0% 8.9 – 9.3% 4.2 – 5.0% 5.3 – 5.8% 300 7.5 – 8.0% 8.6 – 9.0% 4.0 – 4.5% 5.0 – 5.4% 400 7.5 – 8.0% 8.9 – 9.3% 4.2 – 5.0% 5.3 – 5.8%
High Fire - CO2 Range Low Fire - CO2 Range
Natural gas Propane Gas Natural gas Propane Gas
18. Adjust the RUN % potentiometer to 33% for low re. Ensure the low re CO2 is within the range shown in Table 8. NOTE: the low re should not have to
be adjusted if the orice is properly installed. If low re is outside of the range shown in Table 8,
please contact Technical Support to troubleshoot the unit.
19. Check all joints for leaks using a soap solution. Never use an open ame to check for gas leaks.
20. Apply conversion plate and label to inner side of the gas valve access panel. The conversion plate must be installed as closely as possible to the existing heater rating plate.
15. Turn on gas and electrical supply.
16. Fire the unit using the Start-Up procedure in the OPERATION section of this manual.
17. Adjust the RUN % potentiometer to 100% for high re. Ensure the high re CO2 is within the range shown in Table 8.
25
Page 26
OPERATION – HIGH EFFICIENCY PROPELLER UNITS DIRECT SPARK IGNITION
EXPLANATION OF CONTROLS:
1. The unit heater is equipped with a power vent system that consists of a combustion motor and blower, power venter motor and blower, pressure switches, and sealed flue collector in place of the conventional power venter system.
2. The combustion air motor and power venter motor are energized by the room thermostat, or by commands from the Master unit, through the integrated control board when a demand for heat is sensed. During this 35 second pre-purge the pressure switch is made and pressure is increased to the correct ignition point.
The pressure switch MUST NOT
be bypassed. The unit MUST NOT be red unless
the combustion blower and power venter are operating. An unsafe condition could result.
3. The direct spark ignition system consists of an ignition control module and a gas valve. When the pre-purge period ends, the spark ignition system is energized, and the gas valve opens to supply gas to the burners. The trial period for ignition will be 7 seconds. a. If the unit fails to light in the trial period, the unit
will immediately enter the post-purge period. Following the post-purge period, the unit will follow the same pre-purge period and try to light again. If the unit fails to light 3 times in a row, the unit will enter a soft lockout for up to 1 hour. If after 1 hour, the call for heat is still present, the unit will begin the ignition sequence again.
4. Once the ignition is proved, propeller fan is enabled.
5. The burner will maintain a constant firing rate for 60 seconds then modulate according to the control mode selected and/or rate percentage potentiometer.
6. The unit will run single stage, two stage or modulation based on the DIP switch setting on the control board: (See Figure 22 and Tables 9A and 9B) a. 1 Stage Thermostat Operation Stand Alone:
A thermostat will determine how the unit runs. A Fan Only (G) demand will cause the unit to run its propeller fan only. A heat demand (W1) will cause the unit to run at the input set by the Run potentiometer (Run %).
b. 2 Stage Thermostat Operation Stand Alone:
A thermostat will determine how the unit runs. A Fan Only (G) demand will cause the unit run its propeller fan only. A rst stage demand (W1) will cause the unit to run at the minimum input set by the Run potentiometer (Run %). A second stage call (W2) will cause the unit to run at 100%.
c. Thermostat Operation, Networked: A thermostat
will determine how all units run. A Fan Only (G) demand will cause the Master to run its propeller fan only. A rst stage demand (W1) will cause the Master to run at the minimum input. A second stage call (W2) will cause the Master to run at 100%. The Master will broadcast all calls and its re rate to all Members. All Member units will run at the broadcast input level.
• The MASTER Switch must be ON for the Master.
• All units must be connected using the Network communication ports.
• The GLOBAL DIP Switch must be set to ON for Members.
• Each Member uses its own RUN potentiometer (Run %) for the lowest input level.
Note – If the broadcast input level is below any Member’s Run potentiometer setting, that Member will run at its Run potentiometer
setting.
d. Outside Air Reset Operation: A W1 call will
cause the unit to run at an input determined by the outside air temperature and the unit’s selected design temperature. I. OA Reset Standalone: The design temperature
will be set by adjusting the temperature potentiometer (Design T/Space SP). At this temperature (and below) the unit will run at 100% input. When the OA temperature is equal to, or greater than, 65°F (18.3°C) the unit will run at the minimum allowable input. When the OA is between 65°F (18.3°C) and the design temperature, the unit will run at the input corresponding to the linear relationship of these 2 points. A W2 call will cause the unit to run at 100% input.
• The OA DIP Switch must be ON to run in
this OA Reset mode.
• An outdoor air temperature sensor is
required. Note: If the unit was ordered with a modulating gas control with outside air reset (Direct Spark Gas Control [GC] option
1), the outside air temperature sensor is factory provided for eld installation.
• The minimum input is set with the RUN
potentiometer (Run %).
• The Design Temperature is set with the
temperature potentiometer (Design T/Space
SP). Note – If an outdoor air temperature sensor is not installed, or it is faulted, the unit will run at the Run potentiometer (Run%) setting when a W1 call is received.
26
Page 27
OPERATION – HIGH EFFICIENCY PROPELLER UNITS DIRECT SPARK IGNITION
(continued)
II. OA Reset Networked, Global enable
Similar to OA Reset standalone, a W1 call will
cause the Master to run at an input determined by the outside air temperature and the Master’s selected design temperature. The Master will broadcast the W1 call and its calculated input to all Members. All Member units will run at the broadcast input level.
• The Master unit requires an outdoor air temperature sensor. Note: If the unit was ordered with a modulating gas control with outside air reset (Direct Spark Gas Control [GC] options 1 or 2), the outside air temperature sensor is factory provided for eld installation.
• The OA DIP Switch and MASTER DIP Switch must be ON for the Master.
• The GLOBAL DIP Switch must be set to ON for Members.
• Each Member uses its own RUN potentiometer (Run %) for the lowest input level.
• All units must be connected using the Network communication ports.
Note – Only one Master unit is required when networking multiple units together.
Note – If an outdoor air temperature sensor is not installed on the Master, or it is faulted, the Master will run at, and broadcast, its RUN potentiometer (Run %) setting.
Note – If the broadcast input level is below any Member’s RUN potentiometer setting, that Member will run at its Run potentiometer setting.
Note – In this mode all units will run at 100% if the Master is given a W2 call.
Note – In this mode all units will run in fan only mode if the Master is given a G call.
III. OA Reset Networked, Individual enable
The Master unit will broadcast the OA
temperature to all the units. A local W1 call will cause the individual unit to run at an input determined by the broadcasted outside air temperature and its selected design temperature, as in the OA Reset Stand-alone mode.
• The Master unit requires an outdoor air temperature sensor. Note: If the unit was ordered with a modulating gas control with outside air reset (Direct Spark Gas Control [GC] options 1 or 2), the outside air temperature sensor is factory provided for eld installation.
• The OA DIP Switch and Master DIP Switch must be ON for the Master.
• The OA DIP Switch must be ON for all Members.
• All units must be connected using the Network communication ports.
Note – Only one Master unit is required when networking multiple units together.
Note – If an outdoor air temperature sensor is not installed on the Master, or it is faulted, the units will run at the local RUN potentiometer
setting.
e. Indoor Air Reset Operation: The unit offers a
unique approach to output regulation, and energy efciency. With its Indoor Air Reset function, the control monitors its heat demands, watching the demand frequency and duration. Over time, the unit control anticipates the system needs. It sets its input level to provide only as much heat as needed to fine-tune and normalize the heat output. All that is required to enable IAR is to connect thermostat wires to the inputs. The unit control can also be congured for outdoor reset operation, but IAR provides response based on system behavior rather than just looking at outdoor temperature. I. Indoor Air Reset Stand-alone: A W1 call will
cause the unit to run at an input determined by the IAR value calculated by how often, and how long it has recently run.
• The IAR DIP Switch must be ON to run in this mode.
• The minimum input is set with the RUN potentiometer (Run %).
II. Indoor Air Reset Networked, Global enable:
A W1 call will cause the Master to run at an input determined by its IAR value. The Master will broadcast the W1 call and its calculated input to all Members. All Member units will run at the broadcast input level.
• The IAR DIP Switch and MASTER DIP Switch must be ON for the Master.
• The GLOBAL DIP Switch must be set to ON for Members.
• Each Member uses its own RUN potentiometer (Run %) for its lowest input level.
• All units must be connected using the Network communication ports.
Note – If the broadcast input level is below any member’s RUN potentiometer setting, that member will run at its Run potentiometer
setting.
Note – In this mode all units will run at 100% if the Master is given a W2 call.
Note – In this mode all units will run in fan only mode it the master is given a G call.
27
Page 28
OPERATION – HIGH EFFICIENCY PROPELLER UNITS DIRECT SPARK IGNITION
(continued)
f. Space Temperature Operation: The unit
will modulate from 100% fire to the minimum input set by the Run potentiometer (Run %) in order to maintain the setpoint of the space temperature sensor. I. Space Temperature, Stand-alone: A W1
call will cause the unit to run at an input determined by the Space Temperature Setpoint potentiometer (Design T/Space SP), and the current Space Temperature reading. A 4 degree Fahrenheit deadband (+2/-2) and run potentiometer (Run %) control are used to determine when the unit res and the input at which it runs.
• Both the OA DIP and IAR DIP Switch must be ON to run in this mode.
• A space temperature sensor is required. Note: If the unit was ordered with a modulating gas control with room sensing (Direct Spark Gas Control [GC] option 5), the space temperature sensor is factory provided for eld installation.
• The minimum input is set with the RUN potentiometer (Run %).
Note – A W1 Demand is required to enable the unit in this mode.
Note – If a space temperature sensor is not installed, or it is faulted, the unit will run at the RUN potentiometer setting.
II. Space Temperature Networked, Global
enable: A W1 call will cause the Master to run at
an input determined by the Space Temperature Setpoint potentiometer (Design T/Space SP), and the current Space Temperature reading. When the Master determines it should fire based on the setpoint and space temperature, it will broadcast the call and its calculated input to all Members. All Member units will run at the broadcast input level.
• The Master unit requires a space temperature sensor. Note: If the unit was ordered with a modulating gas control with room sensing (Direct Spark Gas Control [GC] option 5), the space temperature sensor is factory provided for eld installation.
• The OA DIP and IAR DIP Switches as well as the MASTER Switch must be ON for the
Master.
• The GLOBAL DIP Switch must be set to ON for Members.
• Each Member uses its own RUN potentiometer (Run %) for the lowest input level.
• All units must be connected using the Network communication ports.
Note – If the broadcast input level is below any Member’s RUN potentiometer setting, that Member will run at its Run potentiometer
setting.
Note – In this mode all units will run at 100% if the Master is given a W2 call.
Note – In this mode all units will run in fan only mode if the Master is given a G call.
g. 2-10 VDC/4-20 mA Input: The ring rate of the
unit can be controlled by a remote 4-20 mA or 2-10 VDC signal.
I. 2-10 VDC/4-20 mA Modulation Stand-alone:
An AUX call will cause the unit to run at an input determined by the 2-10 VDC/4-20 mA input. A value of 10 VDC/20 mA will cause the unit to run at 100% and a value of 2 VDC/4 mA will cause the unit to run at the minimum input.
• The VDC/mA Switch and jumper need to be set for the correct signal type.
• The minimum input is set with the RUN potentiometer (Run %).
II. 2-10 VDC/4-20 mA Modulation Networked:
An AUX call will cause the Master to run at an input determined by the 2-10 VDC/4-20 mA input. A value of 10 VDC/20 mA will cause the unit to run at 100% and a value of 2 VDC/4 mA will cause the unit to run at the minimum input. The Master will broadcast the call and its calculated input to all Members. All Member units will run at the broadcast input level.
• The MASTER Switch must be ON for the
Master.
• The GLOBAL DIP Switch must be set to ON for Members.
• Each Member uses its own RUN potentiometer (Run %) for the lowest input level.
• All units must be connected using the Network communication ports.
Note – If the broadcast input level is below any Member’s RUN potentiometer setting, that Member will run at its Run potentiometer
setting.
Note – In this mode all units will run at 100% if the Master is given a W2 call.
Note – In this mode all units will run in fan only mode if the Master is given a G call.
28
Page 29
OPERATION – HIGH EFFICIENCY PROPELLER UNITS DIRECT SPARK IGNITION
(continued)
h. Modbus Control: The operation of the unit can
be controlled by remote Modbus commands over RS485. See the Modbus Register list (Appendix A) for more information. I. Modbus Control, Stand-alone: By writing to the
BMS Mode data point and the BMS Input data point, a BMS System can control the operation of the unit. The operational status of the unit can also be read using other Modbus data points.
• The unit must be connected to the BMS using the RS485 Modbus port.
• The minimum input is set with the RUN potentiometer (P1).
II. Modbus Control, Networked: Modbus
commands will determine how the all the units will run. By writing to the BMS Mode and BMS Input, a BMS System can control the operation of the Master. The Master will broadcast all calls and its input requests to all the Members. All Member units will run at the broadcast input level. The operational status of the Master can also be read.
• The Master unit must be connected to the BMS using the RS485 Modbus Port.
• The MASTER Switch must be ON for the
Master.
• The GLOBAL DIP Switch must be set to ON for Members.
• Each Member uses its own RUN potentiometer (P1) for the lowest input level.
• All units must be connected using the Network communication ports.
Figure 22 - Control Board, Mode Dip Switches
Dip Switch #1 & 2 = Operation Modes Dip Switch #3 = Master Mode Dip Switch #4 = Global Mode Dip Switch #5 = Analog Input Mode Dip Switch #6-8 = Unit Size
Table 9A - Gas Control Dip Switch Settings
Gas Control Mode
Outdoor Air Reset
(Master)
Outdoor Air Reset
(Network)
Indoor Air Reset 3 Off On Off Off Off
2-10 VDC/4-20mA
Input
Room Sensing 5 On On Off Off Off
Two Stage 6 Off Off Off Off Off
Gas Control Value
(Digit 10)
1 On Off On Off Off
2 On Off Off On Off
4 Off Off Off Off
Dip Switch #1 Dip Switch #2 Dip Switch #3 Dip Switch #4
Table 9B - Dip Switch #6-8, Unit Size
Unit Size Dip Switch #6 Dip Switch #7 Dip Switch #8
100 Off Off Off 200 On Off Off 300 Off On Off 400 On On Off
29
Mode Dip Switches
Dip Switch
#5
Off = 2-10VDC Input
On = 4-20mA Input
Dip Switch
#6-8
See Table 9B
Page 30
OPERATION – HIGH EFFICIENCY PROPELLER UNITS DIRECT SPARK IGNITION
(continued)
7. The high limit switch interrupts the ow of electrical current to the ignition control and gas valve, interrupting the ow of gas to the gas burner if the unit heater becomes overheated.
8. The rollout switch interrupts the flow of the electrical current to the ignition control and gas valve, interrupting the ow of gas to the gas burner if the temperature of the burner compartment exceeds rollout set point. If the rollout switch trips, the combustion, inducer and supply fans will continue to run until the rollout switch is manually reset.
9. The flue temperature limit interrupts the flow of electric current to the ignition control and gas valve, interrupting the ow of gas to the gas burner if the ue temperature exceeds ue temp limit.
10. Once the thermostat is satised, or the high limit or ue temperature limit interrupts the ow of electric current to the control board, the unit will begin a 60 second post-purge period. When the post-purge period ends, the propeller fan, combustion blower and power venter motor are de-energized.
11. The wall thermostat, supplied optionally, is a temperature sensitive switch that operates the vent and ignition system to control the temperature of the space being heated. The thermostat must be mounted on a vertical, vibration-free surface free from air currents and in accordance with the furnished instructions (see also the ELECTRICAL CONNECTIONS section).
START-UP (Also refer to lighting instruction plate equipped on the unit)
1. Open the manual gas valve in the gas supply line to the unit heater. Loosen the union in the gas line to purge it of air. Tighten the union and check for leaks.
Never use an open flame to detect gas leaks. Explosive conditions may exist which could result in personal injury or death.
2. Open the manual valve on the unit heater.
3. Set control mode DIP switches #1-5 to OFF. Discon­nect 2-10 VDC wires, if applicable.
4. Turn ON the electrical power.
6. Set (Run %) potentiometer to 100% on the control board to force the unit to high re. Turn clockwise (100).
7. It may take a few minutes for the unit to modulate, but once in high re, measure the supply gas pressure and record. Supply gas pressure should be 5.0 to 14.0" W.C. for natural gas, 8.0 to 14.0" W.C. for propane (LP) gas.
8. Place a combustion analyzer in the ue pipe. Carbon dioxide (CO2) should be within the range shown in Table
8. Carbon monoxide (CO) values will vary depending on ue pipe length, but CO should always be below 60 PPM. If CO/CO2 values are not within the given range: a . F o r u n i t s i z e s 10 0 / 2 0 0, a d j u s t h i g h  r e a d j u s t m e n t
on gas valve until it is within range. Adjustments should be made with small increments, a quarter (1/4) turn at a time. Clockwise rotation decreases input, counter clockwise increases input.
b. For unit sizes 300/400, adjust gas valve adjustment
on gas valve until it is within range. Adjustments should be made with small increments, a quarter (1/4) turn at a time. Counter clockwise rotation decreases input, clockwise increases input.
9. Turn the (Run %) potentiometer counter clockwise (33) to force the unit to low re.
10. Measure CO/CO2 using a combustion analyzer. CO2 should be within the range shown in Table 8. CO values will vary depending on ue pipe length, but CO should always be below 60 PPM. If CO/CO2 values are not within the given range: a. For unit sizes 100/200, adjust low re adjustment
on gas valve until it is within range. Adjustments should be made with small increments, a quarter (1/4) turn at a time. Clockwise rotation increases input, counter clockwise decreases input.
b. For unit sizes 300/400, adjust gas valve adjustment
on gas valve until it is within range. Adjustments should be made with small increments, a quarter (1/4) turn at a time. Counter clockwise rotation increases input, clockwise decreases input.
11. Remove the call for heat between R and W1.
12. Turn the thermostat to the lowest point and determine that the combustion blower and power venter motors shut off and the burners are extinguished.
5. The unit should be under the control of the thermostat. Turn the thermostat to the highest point and determine that the combustion blower and power venter motors start beginning pre-purge. After 30 seconds, the orange ignition LED should be ashing (on the control board located in the control box), burners will ignite and unit will run at this ignition period for one minute. The orange ignition LED will become solid.
13. Set control mode DIP switches to the desired control mode and turn the thermostat to the desired position. Reconnect 2-10 VDC wires, if applicable.
SHUT DOWN
1. Turn the valve selector lever to the “OFF” position.
2. Turn off the electricity.
3. To relight, follow START-UP instructions.
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Page 31
GAS INPUT RATE
Check the gas input rate as follows (Refer to GENERAL SAFETY INFORMATION section for metric conversions):
Never over-re the unit heater, as this
may cause unsatisfactory operation, or shorten the life of the heater.
1. Turn off all gas appliances that use gas through the same meter as the unit heater.
2. Turn the gas on to the unit heater.
3. Clock the time in seconds required to burn 1 cubic foot of gas by checking the gas meter.
4. Insert the time required to burn one cubic foot of gas into the following formula and compute the input rate.
3600 (Sec. per Hr.) X BTU/Cu. Feet = Input Rate Time (Sec)
For example: Assume the BTU content of one cubic foot of gas is 1000, and that it takes 18 seconds to burn one cubic foot of gas.
3600 X 1000 = 200,000 18
NOTICE: If the computation exceeds, or is less than
95% of the unit’s gas BTU/hr. input rating, adjust the
gas valve.
NOTICE: See Table 6 for gas orice sizes.
HIGH EFFICIENCY UNIT HEATER – HIGH ALTITUDE DERATION
This high efciency unit heater has been manufactured utilizing standard burner orices and gas pressure setting as per the specications shown on the unit rating plate.
The main control board on the unit will automatically adjust for altitude without the need to adjust gas pressure, pressure switches or orice sizes.
Table 10 - High Altitude Deration
Altitude BTU Output
Feet Meters Percentage
0-999 0-305 100%
1,000-1,999 306-610 97% 2,000-2,999 611-914 95% 3,000-3,999 915-1,219 92% 4,000-4,999 1,220-1,524 89% 5,000-5,999 1,525-1,829 86% 6,000-6,999 1,830-2,134 84% 7,000-7,999 2,135-2,439 81% 8,000-8,999 2,440-2,743 78% 9,000-9,999 2,744-3,048 76%
10,000-10,999 3,049-3,353 73%
Note: Table based on heating value of 1,050 BTU/ft3 at sea level (Natural Gas) or 2,500 BTU/ft3 at sea level (Propane). Consult local utility for actual heating value. Derate based on measured and tested values at altitude and reects actual unit performance changes.
MODBUS CONFIGURATION
Figure 23 - Control Board - Modbus Dip Switches
Dip Switch #1 = Memory or DIP Switches Dip Switch # 2 = Baud Dip Switch #3-4 = Data Format Dip Switch #5-8 = Modbus Address
DIP #1 - Memory or DIP Switches
DIP #1 Modbus strings used
OFF Dip Switch Values
ON Values stored in memory – see Modbus Register list
DIP #2 - BAUD
DIP #2 Baud Rate
OFF 19200
ON 38400
DIP #3 & #4 Data Format
DIP #3 - FRMT0 DIP #4 - FRMT1 Data Format
OFF OFF 8E1 OFF ON 8N1
ON OFF 8O1 ON ON 8N2
DIP #5 – #8 Address 1 – 15 Binary (0 is not a valid Modbus address reserved for broadcast)
DIP #5 -
Address0
OFF OFF OFF OFF 0 (not valid) OFF OFF OFF ON 1 OFF OFF ON OFF 2 OFF OFF ON ON 3 OFF ON OFF OFF 4 OFF ON OFF ON 5 OFF ON ON OFF 6 OFF ON ON ON 7
ON OFF OFF OFF 8 ON OFF OFF ON 9 ON OFF ON OFF 10 ON OFF ON ON 11 ON ON OFF OFF 12 ON ON OFF ON 13 ON ON ON OFF 14 ON ON ON ON 15
DIP #6 -
Address1
DIP #7 -
Address2
DIP #8 -
Address3
Modbus Address
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Page 32
PNEUMATIC TUBING TROUBLE SHOOTING SCHEMATIC
T
T
1/8" TUBING TO BULK HEAD
Figure 24 - Pneumatic Tubing Schematic
CAP, FLEX, 3/16"-1/4" OD.
Ø
1/8" TUBING
TO PRESSURE TRANSDUCER
HIGH PRESSURE TAP (FRONT)
TEE, 1/8" X 1/8" X 1/4" ID
Ø
1/8" TUBING
1/8" TUBING
Ø TO BULK HEAD FITTING ON PARTION PANEL
3/16" TUBING
Ø TO POWER VENTER PRESSURE SWITCH, HIGH PRESSURE TAP
TEE, 1/8" X 1/8" X 1/4" ID
Ø FITTING ON FLUE COLLECTOR
Ø 1/8" TUBING
O PRESSURE
RANSDUCER LOW
PRESSURE TAP (BACK)
CAP, FLEX, 3/16"-1/4" OD.
MANIFOLD, AIR
Ø
1/8" TUBING TO GAS VALVE PRESSURE TAP ON SIZE 100-200 UNITS. CONNECTION IS CAPPED ON SIZE 300 - 400 UNITS
Ø 3/16" TUBING
TEE, 1/4" ID
CAT-10120B
Ø 3/16" TUBING TO POWER VENTER
PRESSURE SWITCH,LOW
PRESSURE TAP
3/16
" TUBING
Ø TO BLOCKED INLET
PRESSURE SWITCH
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Page 33
HIGH EFFICIENCY GAS-FIRED UNIT HEATER TROUBLESHOOTING GUIDE
SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION
A. Yellow tip ame (some
yellow tipping on LP gas is permissible).
B. Floating ame. 1. Insufcient combustion air.
C. Gas odor. 1. Shut off gas supply immediately!
D. Delayed ignition. 1. Improper ground.
E. Failure to ignite. 1. Gas supply is off.
F. Burners will not shut off. 1. Thermostat located incorrectly.
G. Rapid burner cycling. 1. Loose electrical connections at thermostat
H. Noisy power venter. 1. Power venter wheel loose.
I. Fan will not run. 1. Loose electrical connections.
J. Fan motor turns on
and off while burner is operating.
1. Clogged air inlet lter.
2. Clogged main burners.
3. Insufcient combustion air.
4. Possibly over red.
2. Air leak into combustion chamber or inducer failure.
2. Leaking port on valve.
3. Blocked heat exchanger.
4. Blocked ue collector.
5. Negative pressure in the building.
2. Bad or broken spark cable.
3. Faulty control.
4. Pressure regulator set too low.
5. Main burner and/or orice dirty.
6. Improper venting.
2. No power supply to unit.
3. Thermostat not calling.
4. Defective high limit.
5. Defective drafter prove switch.
6. Loose wiring.
7. Improper ground.
8. Improper thermostat or transformer wiring.
9. Condensate trap clogged or leaking.
10. Defective ignition control.
11. Cap off pressure tubing
2. Improper thermostat wiring.
3. Shorted circuit.
4. Defective sticking gas valve.
5. Excessive gas supply pressure.
or gas valve.
2. Excessive thermostat heat anticipator
setting.
3. Unit cycling on high limit.
4. Poor thermostat location.
5. An improper ground.
2. Power venter wheel is dirty.
3. Power venter wheel is rubbing on the
housing.
2. Defective motor or overload.
3. Defective control board.
4. Defective fan relay.
1. Motor overload protection is tripping.
2. Loose wiring or connection.
3. Control board is defective.
1. Clean lter.
2. Clean mesh burner.
3. Insufcient combustion air.
4. Check CO2.
1. Clean combustion air inlet openings or lter.
2. Determine cause and repair accordingly.
1. Inspect all gas piping and repair.
2. Check to ensure valve ports are seated.
3. Clean heat exchanger/ue.
4. Clean ue collector.
5. See INSTALLATION.
1. Check grounding wires and spark bracket connections.
2. Inspect spark cable connections and cuts.
3. Check to ensure spark is energized after pre-purge period.
4. Test and reset manifold pressure refer to OPERATION.
5. Clean orice or burners.
6. Refer to INSTALLATION.
1. Open all manual valves “check for leaks”.
2. Turn on power supply, check fuses and replace if bad.
3. Turn up thermostat, Check for 24V on terminals R and W1 on terminal strip.
4. Check switch for continuity if open with no heat present, replace.
5. Check switch operation to ensure switch closes after drafter purge period. If it does not make/check tubing connections/ blockage.
6. Check all wiring per diagram.
7. Check all ground wires and connections.
8. Check both, for wiring according to diagram; check for 24V at gas valve terminals during trial for ignition period if present and valve does not open. Replace valve.
9. Clean condensate trap.
10. Replace ignition control
11. Re-install cap on tubing.
1. Relocate thermostat away from outside wall or drafts.
2. Check thermostat circuit for open and close on terminal strip on heater “R” and “W”.
3. Check thermostat circuit for shorts, staples piercing wires.
4. Check for 24V on gas valve terminals when thermostat is not calling.
5. Refer to INSTALLATION.
1. Tighten all electrical connections.
2. Adjust heat anticipator setting for longer cycles. Refer to ELECTRICAL CONNECTIONS.
3. Check for proper air supply across heat exchanger and proper gas supply.
4. Relocate thermostat.
5. Refer to INSTALLATION.
1. Replace or tighten.
2. Clean power venter wheel.
3. Realign power venter wheel.
1. Check and tighten wires on fan circuit.
2. Test for 115V on terminal ACB Heat and “L2” if voltage is present replace motor.
3. Test for 115V on terminal ACB Heat and “L2” on the control board, if voltage is not present 45 seconds after trial for ignition replace board.
4. Check for 24 volts on terminals 24 and 0. Check for 115V on normally open relay contact when calling.
1. Check motor amps against motor name plate, check voltage, replace if found defective.
2. Check for 115V between motor leads.
3. Check terminal 24 and 0 for 24 volts. If voltage is not constant, replace control board.
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Page 34
SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION
K. Fan will not stop. 1. Control Board is in ame failure mode.
2. Fan improperly wired.
3. Defective board.
4. Defective fan relay.
5. High limit trip.
L. Not enough heat. 1. Incorrect gas input.
M. Too much heat. 1. Unit is over red.
N. Cold air is delivered
during heater operation.
O. High limit tripping. 1. Unit is over red.
P. Power venter will not
run.
Q. Power venter turns
on and off during
operation.
R. Power venter will not
stop.
S. Combustion Blower will
not run.
T. Combustion Blower
turns on and off during
operation.
U. Combustion Blower will
not stop.
V. Flue Temperature
Switch tripping.
2. Heater undersized.
3. Thermostat malfunction.
4. Heater cycling on limit.
5. Incorrect orice size.
2. Thermostat malfunction.
3. Heater runs continuously.
4. Control board congured for incorrect size.
1. Incorrect gas input.
2. Air throughput too high.
2. Air ow is low.
3. Defective switch.
4. Defective control board.
1. Loose wiring or connections.
2. Motor overload is tripped or bad motor.
3. Bad control board.
1. Power venter improperly wired.
2. Motor overload cycling or defective motor.
3. Defective control board.
4. Unit not reaching proper delta pressure.
1. Power venter improperly wired.
2. Main burner did not light on call for heat.
3. Defective control board.
1. Loose wiring or connections.
2. Motor overload is tripped or bad motor.
3. Defective control board.
1. Combustion Blower improperly wired.
2. Motor overload cycling or defective motor.
3. Defective control board.
1. Combustion Blower improperly wired.
2. Main burner did not light on call for heat.
3. Defective control board.
1. Unit over red.
2. Blocked heat exchanger
3. Blocked combustion air or ue vent pipe.
4. Clogged heat exchanger coil.
1. Turn 115V power off to the unit, wait 10 seconds and reapply voltage to the unit.
2. Check wiring of fan circuit to wiring diagram.
3. If unit is not calling for heat and board is not in a ash code mode, replace board.
4. Check for 0 volts on terminals 24 and 0. Check for 0 on normally open relay contact when calling.
5. See High Limit Tripping in troubleshooting section.
1. Refer to OPERATION.
2. Is the heater output sized correctly for heat loss of the space. Has the space been enlarged.
3. Check thermostat circuit, 24V on terminals “R” and “W” on terminal strip.
4. Check air movement across heat exchanger. Check voltage and amps at the fan motor. Check gas input to ensure unit is not over red. Check heat exchanger to ensure unit is not dirty.
5. Check orice size, replace if undersized.
1. Refer to OPERATION. Check orice size. If too big replace.
2. Check thermostat for operation, to ensure circuit open and closes.
3. Check wiring per diagram; check operation at the gas valve, look for a short in thermostat circuit.
4. Check control board dip switch conguration.
1. Refer to OPERATION.
2. Refer to OPERATION.
1. Burner orices may be too large, verify and replace.
2. Check for proper voltage, ensure fan blade is correct and free of debris.
3. Check operation of switch, did the switch open when unit is running or is the switch open during start-up.
4. Check for 24V on line side of the high limit. Constant voltage should be recorded if not control board is suspect. Check ash code.
1. Check all wring in the power vent circuit to ensure good connection, including “Neutral”.
2. Check for 115V between motor leads and check amp draw of motor. Replace if needed.
3. Check for continuous 115V on molex plug on inducer and neutral during call for heat. If not present and all checks are normal, replace.
1. Check power venter circuit per wiring diagram.
2. Check motor voltage and amp draw to motor name plate, replace if motor found defective.
3. Check for continuous 115V on terminal molex plug during call for heat, replace board if found defective.
4. Check pneumatic tubing and vent pipe for blockages. Check condensate trap for proper seal.
1. Check power venter circuit per wiring diagram.
2. Heater is in lockout mode check ash code table for problem.
3. No ash codes present along with no call for heat, replace control board.
1. Check all wring in the power vent circuit to ensure good connection, including “Neutral”.
2. Check for 115V between motor leads and check amp draw of motor. Replace if needed.
3. Check for continuous 115V between black and white wires on molex plug and neutral during call for heat. If not present and all checks are normal, replace.
1. Check Combustion Blower circuit per wiring diagram.
2. Check motor voltage and amp draw to motor name plate, replace if motor found defective.
3. Check for continuous 115V between black and white wires on molex plug of combustion blower during call for heat, replace board if found defective.
1. Check Combustion Blower circuit per wiring diagram.
2. Heater is in lockout mode check ash code table for problem.
3. No ash codes present along with no call for heat, replace control board.
1. Refer to operation section.
2. Clean heat exchanger/ue collector.
3. Clean combustion air or ue vent pipe.
4. Clean heat exchanger coil ns.
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Page 35
HIGH EFFICIENCY GAS-FIRED UNIT HEATER TROUBLESHOOTING WITH LED
INDICATOR ASSISTANCE
No Cycling or appliance power or thermostat call for heat since appliance failure has occured.
Line voltage power can cause product damage, severe injury or death. Only a trained experienced
service technician should perform this trouble-shooting.
1. Check the system thermostat to make sure it is calling for heat. (Do not cycle the thermostat on and off at this time.)
2. Observe the LED indicator on the bottom panel of the unit (red or orange LED off indicates no faults); check and repair system as noted in the chart below.
NOTICE: Air ow proving switch and power venter hose barbs must be free of any dust or debris at all times.
Periodically check these openings and/or if any problems occur.
LED STATUS INDICATES CHECK/REPAIR
Red LED – Off No Faults Not Applicable. Red LED – Solid Ignition Lockout Fault 1. Gas supply off or gas supply pressure too low.
Red LED – 1 Flash Flue Limit Fault 1. Obstruction or restriction in combustion air inlet or ue outlet.
Red LED – 2 Flash Rollout Switch Fault 1. Obstruction or restriction in combustion air inlet or ue outlet.
Red LED – 3 Flash High Limit Switch Fault 1. Gas supply off or gas supply pressure too high.
Red LED – 4 Flash Inlet Pressure Switch Fault 1. Obstruction or restriction in combustion air inlet.
Red LED – 5 Flash Condensate Float Switch Fault 1. Obstruction or restriction in condensate system.
Red LED – 6 Flash Flue Pressure Switch Fault 1. Obstruction or restriction in combustion air inlet or ue outlet.
Red LED – 7 Flash User Interlock Fault 1. Open interlock; broken, or miswired connection.
LED STATUS INDICATES CHECK/REPAIR
Red LED – Solid O r a n g e L E D – 1 F l a s h
Red LED – Solid Orange LED – 2 Flash Red LED – Solid Orange LED – 3 Flash Orange LED – 1 Flash Open OA Sensor Warning 1. Check sensor is properly installed and wired.
Orange LED – 2 Flash Shorted OA Sensor Warning 1. Check sensor is properly installed and wired.
Orange LED – 3 Flash Open Space Sensor Warning 1. Check sensor is properly installed and wired.
Orange LED – 4 Flash Shorted Space Sensor Warning 1. Check sensor is properly installed and wired.
Pressure Transducer Fault 1. Tubing is cracked, broken, or blocked by moisture or debris.
Power Venter Fault 1. Power venter failure.
Combustion Blower Fault 1. Combustion blower failure.
2. Flame Sense rod contaminated or loose wire.
3. Gas valve switch is off or wires are not connected.
4. Broken or cracked porcelain on either sensor or ignitor.
2. Unit is over-red.
3. Control board fault or faulty switch.
4. Power venter is not working properly or producing correct delta pressure.
2. Unit is over-red.
3. Control board fault or faulty switch.
4. Power venter is not working properly or producing correct delta pressure.
2. Unit is over-red.
3. Blocked heat exchanger.
4. Power venter is not working properly.
5. Fan motor(s) or switch(es) failure.
2. Tubing connection to switch is cracked or broken.
3. Faulty power venter or switch.
2. Float switch miswired or failure.
3. If applicable, condensate pump miswired or failure.
2. Tubing is cracked, broken, or blocked by moisture or debris.
3. Blocked heat exchanger.
4. Power venter is not working properly or producing correct delta pressure.
5. Faulty control board, pressure transducer, or switch.
2. Faulty control board.
2. Faulty transducer or control board.
3. Power venter not working properly or producing correct delta pressure.
4. Blockage in ue.
2. Faulty control board.
2. Faulty control board.
2. Sensor failure.
2. Sensor failure.
2. Sensor failure.
2. Sensor failure.
NOTICE: For Rollout Switch Fault, the rollout switch must be manually reset before unit operation can resume. If a Red LED-2 Flash is observed, the red button on the rollout switch will have to be depressed to reset. This switch is located on the top of the burner compartment. The red button should be depressed until an audible "click" is heard.
35
Page 36
MAINTENANCE
PERIODIC SERVICE NOTICE: The heater and vent system should be
checked once a year by a qualied technician.
All Maintenance/Service information should be recorded accordingly on the GAS EQUIPMENT START-UP AND INSPECTION SHEET provided in this manual.
Open all disconnect switches, disconnect all electrical and gas supplies, and secure in that position before servicing unit. Failure to do so may result in personal injury or death from electrical shock.
Gas tightness of the safety shut­off valves must be checked on at least an annual basis. Failure to do so may result in death,
serious injury or substantial property damage.
To check gas tightness of the safety shut-off valves:
1. Turn off the manual valve upstream of the appliance combination control.
2. Turn set screw of test port on gas valve counter clockwise and connect a manometer to that tapping.
3. Turn the manual valve on to apply pressure to the combination control.
4. Note the pressure reading on the manometer, then turn the valve off.
5. A loss of pressure indicates a leak. If a leak is detected, use a soap solution to check all threaded connections.
6. If no leak is found, combination control is faulty and must be replaced before putting appliance back in service.
NOTICE: See separate operation manuals provided with any unit accessories for their maintenance/ service requirements.
Should maintenance be required, perform the following inspection and service routine:
1. Inspect the area near the unit to be sure that there is no combustible material located within the minimum clearance requirements listed in this manual.
Under no circumstances should combustible material be located within the clearances specified in this manual. Failure to provide proper clearance could result in
personal injury or equipment damage from re.
2. Turn off the manual gas valve and electrical power
to the unit heater.
3. To clean or replace the burners, remove burner mounting bracket nuts located in burner compartment. Disconnect union between gas valve and combustion blower. Lift burner assembly up and pull away from heat exchanger to remove.
4. To remove any dirt, dust, or other foreign matter from the burner box mesh, remove burner box cover plate and use compressed air to clean the mesh burners and inlet lter.
NOTICE: Do not use chemical cleaners. Chemical cleaners may damage burner mesh or other components.
5. The condensate trap can be cleaned by loosening the union nut. The spring oat should be cleaned of any debris.
6. Reassemble the unit heater by replacing all parts in reverse order.
7. Check all gas control valves and pipe connections for leaks.
Check all pipe joints for leakage using a soap solution or other approved method. Never use an open flame or severe personal injury or death may occur!
8. Check the operation of the automatic gas valve by lowering the setting of the thermostat, stopping the operation of the unit. The gas valve should close tightly, completely extinguishing the ame on the burners.
9. Inspect and service motor/fan assembly. To maintain efcient air ow, inspect and clean the fan blades and guard to prevent buildup of foreign matter.
36
Page 37
LIMITED WARRANTY
High Efciency Propeller Unit Heaters
1. The "Manufacturer" warrants to the original owner at original installation site that the above model Gas-Fired Heater ("the Product") will be free from defects in material or workmanship for (1) year from the date of shipment from the factory, or one and one-half (1-1/2) years from the date of manufacture, whichever occurs rst. The Manufacturer further warrants that the complete heat exchanger, ue collector, and burners be free from defects in material or workmanship for a period of ten (10) years from the date of manufacture. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the Manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective.
2. This limited warranty does not apply:
a. if the product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has
not been installed, maintained, or operated in accordance with furnished written instructions, or has been
altered or modied in any way by any unauthorized person. b. to any expenses, including labor or material, incurred during removal or reinstallation of the Product. c. to any damage due to corrosion by chemicals, including halogenated hydrocarbons, precipitated in the air. d. to any workmanship of the installer of the Product.
3. This limited warranty is conditional upon: a. advising the installing contractor, who in turn noties the distributor or Manufacturer. b. Shipment to the Manufacturer of that part of the Product thought to be defective. Goods can only be returned
with prior written approval of the Manufacturer. All returns must be freight prepaid. c. determination in the reasonable opinion of the Manufacturer that there exists a defect in material or
workmanship.
4. Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with
respect to such repaired or replaced part beyond the stated warranty period.
5. THIS LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES, EITHER EXPRESS OR IMPLIED, AND
ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY JURISDICTION.
In the interest of product improvement, we reserve the right to make changes without notice.
37
Page 38
Figure 25 - Component Access
T
MACHINE SCREW, (3) M4x6 & (3) M6x6
IDENTIFICATION OF PARTS
Figure 26 - Flue Collector/Drafter Assembly
FLUE COLLECTOR ASSEMBLY
FLUE COLLECTOR GASKET
DRAFTER MOUNTING PLATE
HREADED HEX INSERT, #10-24
DRAFTER GASKET
CAT-10085A
SELF-DRILL SCREW, #8-18
MACHINE SCREW, #10-24
INDUCER
CAT-10089A
Figure 27 - Air Gas Inlet Assembly
MACHINE SCREW, #6-32
AIR-GAS INLET COVER PLATE
INLET AIR
DISTRIBUTOR
HEX NUT, SERRATED FLANGE, 1/4-20
O-RING
COMBUSTION BLOWER GASKET
CAT-10088B
COMBUSTION
BLOWER
NUT, FLANGED, 1/4-20
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Figure 28 - Heat Exchanger Components
TURN COVER
COIL ASSEMBLY
COMBUSTION TUBE
TURBULATOR
COMBUSTION VESTIBULE PANEL
TURN COVER GASKET
Figure 29 - Propeller Motor/Fan Assembly
OSHA FAN GUARD PLATE
OSHA FAN GUARD
RUBBER GROMMET
HARDWARE
TURN VESTIBULE PANEL
HARDWARE
CAT-10086B
FAN BLADE
MOTOR
HOW TO ORDER REPLACEMENT PARTS
Please send the following information to your local representative: if further assistance is needed, contact the manufacturer's customer service department.
• Unit Number
• Serial Number
• Part Description and Number as shown in Replacement parts Catalog
CAT-10079A
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APPENDIX A – MODBUS REGISTERS
Input/Output Variables (Read/Write)
Address Name Raw Data Type Scale Description Valid Values/Range
40001 Modbus Address 8 bit unsigned
40002 Modbus Baud 8 bit unsigned
40003 Modbus Data Format 8 bit unsigned
40004 Modbus Mode 8 bit unsigned
40005 Modbus Input 8 bit unsigned 1.0
This Modbus Address is used if the Communications settings location DIP is set to Memory
This Modbus Baud is used if the Communications settings location DIP is set to Memory
This Modus Data Format is used if the Communications settings location DIP is set to Memory
Modbus Mode. (see BMSTimer) If no wired operating mode demands are present, setting the state member of this variable will put the unit in the corresponding mode. Modbus Input (see BMSTimer) If no wired operating mode demands are present, and the unit is operating per the Modbus Mode variable, the unit will run at this input.
Note – Writing 0 to this variable will allow the unit to run at the input dictated by its local settings. BMS Timer
1 - 247
0 = 1200 1 = 2400
2 = 4800
3 = 9600 4 = 19200
5 = 38400 6 = 56800
7 = 57600
0 = 8E1 1 = 8O1 2 = 8N2 3 = 8N1 0 = Standby 1 = Fan Only (G) 2 = Heating 1 (W1) 3 = Heating 2 (W2)
33% - 100%
0 – Local Control
40006 BMS Timer 16 bit unsigned
The BMS timer is a BMS failsafe feature. This countdown timer should be periodically reloaded with a timeout value (in seconds). If the timer reaches zero, the control assumes that the BMS is no longer operating, and clear the Modbus Mode and Modbus Input values. This is a failsafe feature used to help safeguard the system in case of BMS failure.
0 – 65535 seconds When any Read/Write variable is written, if the BMS Timer is less than 60, it is automatically reloaded with 60.
Writing 0 to the BMS Timer will disable this feature.
Writing non 0 values to this the BMS Timer enables this feature.
Default is ON
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Input Variables (Read Only)
Address Name Raw Data Type Scale Description Valid Values/Range
30001 Outside Temperature 16 bit unsigned 1.0
30002 Space Temperature 16 bit unsigned 1.0
30003 Strat Temperature 16 bit unsigned 1.0
30004 Delta Pressure 16 bit unsigned 0.01 Pressure across the unit 0 – 5 ‘WC
30005 Ignition State 8 bit unsigned Current Ignition State of the unit
30006 Operating Mode 8 bit unsigned The current operating mode of the unit.
30007 Operating Input 8 bit unsigned 1.0 The current operating input of the unit. 33% - 100%
30008 Prop Fan 8 bit unsigned Unit Prop Fan Status
30009 Thermostat Inputs Status 8 bit unsigned These bits indicate the state of the thermostat inputs.
30010 Indoor Air Reset 8 bit unsigned 1.0 Current Indoor Air Rest Limit 33% – 100%
30011 Fault Code 8 bit unsigned Indicates the highest priority Fault set on the unit. See the Fault Code Table.
30012 Inducer Blower RPM 16 bit unsigned 1.0 Current RPMs of the inducer blower 0 – 6500
30013 Combustion Blower RPM 16 bit unsigned 1.0 Current RPMs of the Combustion blower 0 – 11300
Outside air temperature * optional Space temperature * optional Stratication temperature * optional
-40 – 250°F
-52°F if not installed
-40 – 250°F
-52°F if not installed
-40 – 250°F
-52°F if not installed
0 = Standby 1 = Sequence Start 2 = Pre Purge
3 = Ignition Trial
4 = Running 5 = Post Purge 6 = Lockout 0 = Standby 1 = Fan Only (G) 2 = Heating 1 (W1) 3 = Heating 2 (W2)
0 = Prop Fan Off 1 = Prop Fan On See the Thermostat Inputs Flags table.
Status Flags – Thermostat Input Flags
Bit Description Valid Values/Range
0 Thermostat G (Local or Global) 0 = No Signal, 1 = Signal Present
1 Thermostat W1 (Local or Global) 0 = No Signal, 1 = Signal Present
2 Thermostat W2 (Local or Global) 0 = No Signal, 1 = Signal Present
3 Thermostat AUX (Local or Global) 0 = No Signal, 1 = Signal Present
4 Reserved Reserved
5 Reserved Reserved
6 Reserved Reserved
7 Reserved Reserved
System Fault/Warning Codes
Error Code Description
0 No Fault or Warning
1 Flue Limit Switch Trip
2 Roll Out Switch Trip
3 High Limit Trip
4 Inlet Pressure Switch Trip
5 Condensate Float Switch Trip
6 Flue Pressure Switch Error
7 User Interlock Trip
8 Pressure Transducer Error
9 Inducer Blower Fault
10 Combustion Blower Error
11 Ignition Lockout Error
12 Blower Lockout Error
20 Open Outside Air Temperature Sensor
21 Shorted Outside Air Temperature Sensor
22 Open Space Temperature Sensor
23 Shorted Space Temperature Sensor
Faults – The unit cannot run
Warnings – The unit can run
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HIGH EFFICIENCY GAS-FIRED UNIT HEATER
UNIT NUMBER DESCRIPTION
DIGIT N X X X 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 +
ITEM PREFIX UT CA FT FM GT AL GC SV MT MS DL AS
(Internal Use Only)
1, 2 - Unit Type [UT]
HU - High Efciency Unit Heater
3, 4, 5 - Capacity [CA]
100 - 100,000 BTU/HR 200 - 200,000 BTU/HR 300 - 300,000 BTU/HR 400 - 400,000 BTU/HR
6 - Furnace Type [FT]
A - Right Side Access
7 - Heat Exchanger (Furnace) Material [FM]
1 - Stainless Steel Tubes with Aluminum and Brass Fins
Note: Stainless Steel Flue Collector is standard.
8 - Gas Type [GT]
N - Natural Gas P - Propane Gas (LP)
9 - Altitude [AL]
S - 0–11,999 ft.
Note: Installations over 2,000 ft. require gas input deration in the eld.
Refer to unit installation instructions.
10 - Direct Spark Gas Control [GC]
1 - Modulating w/Outside Air Reset (Master) 2 - Modulating w/Outside Air Reset (Network) 3 - Modulating w/Indoor Air Reset 4 - Modulating w/2-10 VDC/4-20 mA Input 5 - Modulating w/Room Sensing 6 - Two Stage
11 - Supply Voltage [SV]
1 - 115/1/60 5 - 230/3/60 2 - 208/1/60 6 - 460/3/60 3 - 230/1/60 7 - 575/3/60 4 - 208/3/60 Z - Special
Note: Supply Voltages [SV] 2-7 include eld mounted step down transformer.
12 - Motor Type [MT]
1 - Open Drip Proof
13 - Blower Motor Sizes [MS]
0 - Not applicable
14 - Design Level [DL]
A - First design level
15+ - Accessories [AS]
0 - Not applicable
† FIELD INSTALLED (AS-____ )
† All Field Installed Accessories are to be entered as a separate line item using the catalog
number which utilizes “AS” as a pre x. i.e: G3 becomes AS-G3.
A7 - High Pressure Regulator A7-1/2-1 - Regulator for PSI range 0.5-10 A7-3/2-1 - Regulator for PSI range 10-20 A7-5/16-1 - Regulator for PSI range 20-35
E9 - Condensate Neutralizer (Inline) EW - Condensate Neutralizer (Wall Mounted)
G1 - 1-Stage T87K Mercury Free Thermostat w/Subbase Kit G2 - 1-Stage T87K Mercury Free Thermostat w/TG511A Guard Kit G3 - 1-Stage T834N Mercury Free Thermostat w/Fan Switch G5 -
2-Stage TH5220D Mercury Free Thermostat
G6 - Locking Thermostat Cover G9 - 1-Stage T822K Mercury Free Thermostat
K8 - Condensate Pump K9 - Condensate Pump Shelf
Y2 - 2" PVC Concentric Vent Kit Y3 - 3" PVC Concentric Vent Kit Y4 - 4" PVC Concentric Vent Kit
w/Subbase
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GAS EQUIPMENT START-UP AND INSPECTION SHEET
Customer ____________________________________ Job Name & Number _________________________
PRE-INSPECTION INFORMATION
With power and gas off.
Type of Equip: Unit Heater Serial Number _________________________ Model Number __________________________
Name Plate Voltage: _____________ Name Plate Amperage: _____________ Type of Gas: Natural LP Tank Capacity _______ lbs. Rating: _ _____ BTU @ ____ °F
_______ kg _ _____ kw @ ____ °C
Are all panels, doors, vent caps in place? ❐ Has the unit suffered any external damage? Damage ______________________________ ❐ Does the gas piping and electric wiring appear to be installed in a professional manner? ❐ Has the gas and electric been inspected by the local authority having jurisdiction? ❐ Is the gas supply properly sized for the equipment? ❐ Were the installation instructions followed when the equipment was installed? ❐ Have all eld installed controls been installed? ❐ Do you understand all the controls on this equipment? If not, contact your wholesaler or rep.
(DO NOT START this equipment unless you fully understand the controls.)
GENERAL
With power and gas off.
Make certain all packing has been removed. Tighten all electrical terminals and connections. Check all fans & blowers for free movement. Check all controls for proper settings.
Inlet gas pressure. ____ in. W.C. or ____ kPa Burner ignition. Cycle and check all other controls not listed. Entering air temp. _____ °F or ____ °C
GAS HEATING
With power and gas on.
Discharge air temp. (High Fire) ____ °F. or ____ °C
FAN
With power and gas off.
Check voltage L1___ L2___ L3___ Check rotation of main fan. Check motor amps L1___ L2(N)___
Remarks: _____________________________________________
Cycle by thermostat or operating control. Combustion Readings (High Fire):
Carbon Monoxide:____ PPM Carbon Dioxide:____ %
Combustion Readings (Low Fire):
Carbon Monoxide:____ PPM Carbon Dioxide:____ %
__________________________________________________ __________________________________________________
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260 NORTH ELM ST., WESTFIELD, MA 01085 TEL: (413) 564-5540 FAX: (413) 562-5311 www.mestek.com
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