Schwank P40U, P40U-F, P40U-P, P40U-W, P40U-I Owner's Manual

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Models

P40U, P40U-F,

P40U-P, P40U-W

LOW INTENSITY TUBE TYPE

INFRA RED HEATERS

P40U-I, P40U-I-F,

P40U-IP, P40U-IW

LOW INTENSITY TUBE TYPE

Models

INFRA RED HEATERS

INSTALLATION / OWNER’S MANUAL

WARNING

SAFETY ALERT: This heater must be installed and serviced only by a trained gas service techni-

cian. Failure to comply could result in personal injury, death, fire and/or property damage.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.

Read the installation and operating and maintenance instructions thoroughly before installing or servicing this equipment.

Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other gas fired appliance.

IF YOU SMELL GAS:

 Extinguish any open flame  Do not attempt to light this or any other appliance  Don’t touch any electrical switch, or telephone  Immediately call your gas supplier from a neighbor’s phone  Follow any and all instruction from your gas supplier  If your gas supplier is not available, call the fire department

FIELD CONVERTIBILITY: This appliance is field convertible to LP gas using an optional kit supplied by the manufacturer

Keep this manual in a secure place . Record for future reference:

Model #: Serial #:

(located on heater rating label)

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NOTICE: This manual is current for this product. Occasional revision of the product Certification Stan-

dard may require changes to the product and/or this manual. This publication, or parts thereof, may not be reproduced in any form, without prior written

consent from The Manufacturer. Unauthorized use or distribution of this publication is strictly prohibited.

Schwank Group

5285 Bradco Boulevard Mississauga, Ontario,L4W 2A6

PO Box 988, 2 Schwank Way Waynesboro, Georgia 30830

Customer & Technical Services

Phone: 877-446-3727 Fax: 866-361-0523 e-mail: csr@schwankgroup.com

www.schwankgroup.com

www.infrasave.com

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P40U (-P, -W) / P40U-I (-IP,-IW) SERIES

GAS FIRED INFRARED LOW INTENSITY U-TUBE TYPE

TABLE OF CONTENTS

IMPORTANT INFORMATION - READ FIRST

APPLICATION..............................................4

HEATER EXPANSION ...........................5, 31

GAS CONNECTION ...............................5, 31

VENTING.................................................5, 26

START UP ‘SMOKE’....................................5

THERMOSTAT COMFORT SETTING .........5

CLEARANCE TO COMBUSTIBLES............6

Clearances Figure & Table ........................7

STACKING HEIGHT SIGN .........................8

TOPIC .........PAGE

1. LABOR REQUIREMENTS ...............................9

2. INSTALLATION IN AIRCRAFT HANGARS .....9

3. INSTALLATION IN COMMERCIAL

GARAGES........................................................9

4. INSTALLATIONS OTHER THAN

SPACE HEATING.............................................9

5. PRE-INSTALLATION SURVEY......................10

6. MOUNTING CLEARANCES...........................10

SERVICE CLEARANCE.................................11

7. HEATER PLACEMENT GUIDELINES...........11

8. HEATER INSTALLATION ..............................12

TURBULATORS.............................................15

8A SEISMIC RESTRAINT....................................16

8B HIGH WIND RESTRAINT...............................16

9. FLUE VENTING.............................................17

10. COMBUSTION AIR DUCTING......................20

11. GAS SUPPLY & CONNECTION ................... 21

ORIENTATION OF FLEXIBLE GAS

CONNECTION................................................22

12. GAS CONVERSION.......................................23

13. ELECTRICAL AND THERMOSTAT ..............24

14. HIGH ALTITUDE INSTALLATION..................24

15. LIGHTING INSTRUCTIONS ..........................24

16. RECOMMENDED MAINTENANCE .............. 24

17. WIRING DIAGRAM: FENWAL DSI:

MODELS P40U, P40U-I................................25

18. WIRING DIAGRAM MULTIPLE HEATERS

PER THERMOSTAT .................................... 26

19. FENWAL DSI OPERAT6ION ....................... 27

TOPIC ……...PAGE

20. WIRING DIAGRAM: P40U-P, P40U-W............30

21. SEQUENCE OF OPERATION P40U-P, P40U-W.....31

22. GASLITER MICRO 50N DSI ............................32

23. SPARK IGNITER SET UP................................34

24. TROUBLESHOOTING GUIDE.........................35

25. START– UP / COMMISSIONING SHEET........36

PRODUCT DIMENSIONS & DATA

26. HEATER DIMENSIONS / WEIGHTS ……….39

27. HIGH ALTITUDE & ORIFICE CHART..............40

28. OPTIONAL ACCESSORIES.............................41

29. REPLACEMENT PARTS LIST ........................45

HONEYWELL S87J DSI

WIRING DIAGRAM - S87J...............................48

SEQUENCE OF OPERATION - S87J .............49

FLAME SENSING CIRCUIT - S87J.................50

WARRANTY STATEMENT .................BACK PAGE

FIGURES:

FIG 1 - CLEARANCE TO COMBUSTIBLES ...........7

FIG 2 - SERVICE CLEARANCE.............................11

FIG 3 - TYPICAL MOUNTING HARDWARE..........13

FIG 4 - TYPICAL SUSPENSION...........................14

FIG 5 - HEATER DIMENSIONS & SUSPENSION

ANGLE OPTIONS......................................14

FIG 6 - CLEARANCE TO COMBUSTIBLES

(repeated)...................................................15

FIG 7 - SEISMIC RESTRAINT ...............................16

FIG 8 - HIGH WING RESTRAINT ..........................16

FIG 9 - HEATER EXPANSION - VENT..................18

FIG 10 - HORIZONTAL VENT ...............................18

FIG 11 - ROOF VENT ............................................20

FIG 12 - ORIENTATION OF FLEXIBLE GAS ........22

FIG 13 - INCORRECT FLEXIBLE GAS..................23

DIMENSIONS & WEIGHTS....................................39

WIRING DIAGRAMS: FENWAL DSI.....................25,

MULTIPLE HEATERS PER THERMOSTAT ...26

CHANNEL GASLITER MICRO 50N DSI..........30

HONEYWELL S87J DSI ..................................48

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WARN-

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read and understand this installation and operation manual thoroughly prior to assembly, installation, operation or service to this appliance.

This heater must be installed and serviced only by a trained gas service technician. Do not store or use gasoline or other flammable vapours and liquids in the vicinity of

this or any other gas fired appliance. Failure to comply could result in personal injury, death, fire and/or property damage. Do not store or use gasoline or other flammable vapours and liquids in the vicinity of

this or any other gas fired appliance. This appliance may have sharp edges and corners. Wear protective clothing such

as gloves and protective eye wear when servicing this or any other appliance.

INSPECT PRODUCT UPON RECEIPT

Inspect the carton and heater for concealed damage. Note any damage on the Bill of Lading and make any damage claim to the transport company as soon as possible.

APPLICATION

It is beyond the scope of these instructions to consider all conditions that may be encountered. Installation must conform with local building codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 in the U.S.A. or the Natural Gas and Propane Installation Code, CSA B149.1 in Canada. The latest edition Electrical Code ANSI/NFPA N0 70 in the U.S.A. and PART 1 CSA C22.1 in Canada must also be observed.

Installation of a gas fired tube heater must conform to all heating installation procedures including clearance to combustibles, connection to the gas and electrical supplies, and ventilation.

This heater is not for installation in a Class 1 or Class 2 explosive environment. If the application is in question, consult with local authorities having jurisdiction (Fire Marshall, labor department, insurance underwriter, or other authority).

Revisions to codes and/or standards, may require revision to equipment and installation procedures. In case of discrepancy, the latest codes, standards, and installation manual will take priority over prior releases.

MODELS AVAILABLE in the Schwank P40U & InfraSave P40U-I Series:

Models P40U and P40U-I may be installed for heating of commercial/industrial indoor spaces. Models P40U-P and P40U-IP have a powder coated water resistant burner enclosure and may

be installed for heating of commercial / industrial outdoor spaces and wet indoor environments.

Models P40U-W and P40U-IW have a stainless steel water resistant burner enclosure and may be installed for heating of commercial / industrial outdoor spaces and harsh wet indoor environments.

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WARNING

Heater Expansion

It is a normal condition that during heat-up and cool-down a tube heater will expand and contract. Allowances for heater expansion must be made in the gas connection, venting and combustion air ducting. Improper installation, alteration, or adjustment can result in property damage, injury or death. Refer to Section 11

WARNING

Gas Connection

Improper installation, connection, or adjustment can result in property damage, toxic gases, asphyxiation, injury or death. Using an approved flexible gas connector in the USA or Type 1 hose connector in

Canada, the gas supply to the heater must be connected and tested in accordance with all local, state, provincial, and national codes (ANSI Z223.1/NFPA 54 in USA; B149.1 in Canada) and as indicated in this manual. Refer to Section 11

WARNING

Venting

Inadequate venting of a heater may result in asphyxiation, carbon monoxide poisoning, injury or death. This heater may be directly or indirectly vented from the space. Venting must be in accordance with all local, state, provincial, and national codes (ANSI Z223.1/NFPA 54

in USA; B149.1 in Canada) and as indicated in this manual. Refer to Sections 9 & 10

WARNING

Start-Up ‘SMOKE’ Condition

During start up, the heating of material coatings used in the production process of tubes and reflectors will create smoke during the initial period of operation. This condition is normal and temporary .

Ensure that there is sufficient ventilation to adequately clear any smoke from the space. Notify site and safety personnel to ensure that alarm systems are not unduly activated.

IMPORTANT

THERMOSTAT SETTING FOR COMFORT

Infrared radiant (IR) heating system provide comfort with the effect of radiant heat and ambient air heat.

If your IR system is controlled with a thermostat (TruTemp or ThermoControl Plus) that senses radiant heat, then set the thermostat to the desired comfort temperature (ie: 65°; 68°; 20°C).

If your IR system is controlled with a standard 24V or 120V thermostat that senses only air temperature, then start with a thermostat setting that is 5° to 7°F (3° to 5°C) lower than the desired comfort temperature. Some trial and error setting may be required to ‘fine tune’ the comfort temperature that best suits your site and provides most economical operation.

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WARN-

Clearance to combustibles

Location of flammable or explosive objects, liquids or vapors close to the heater may cause fire or explosion and result in property damage, injury or death. Do not use, store or locate flammable or explosive objects, liquids or vapors in proximity of the heater.

The clearance to combustible material represents the minimum distance that must be maintained between the outer heater surface and a nearby surface. The stated clearance to combustibles represents a surface temperature of 90F° (50C°) above room temperature. It is the installer’s responsibility to ensure that building materials with a low heat tolerance which may degrade at lower temperatures are protected to prevent degradation. Examples of low heat tolerance materials include vinyl siding, fabrics, some plastics, filmy materials, etc.

In locations used for the storage of combustible materials, signs must be posted to specify the maximum permissible stacking height to maintain the required clearances from the heater to the combustibles. Such signs must either be posted adjacent to the heater thermostats or in the absence of such thermostats in a conspicuous location. In addition to stored or stationary material, consideration must also be given to moveable objects such as cranes, vehicles, and overhead doors, and structural objects such as sprinkler heads, electrical and gas lines, and electrical fixtures.

It is beyond the scope of these instructions to consider all conditions that may be encountered. Consult local authorities such as the Fire Marshall, insurance carrier, or safety authorities if you are uncertain as to the safety or applicability of the proposed installation.

Refer to Figure 1 and Table 1 for the certified clearances to combustibles for the appropriate model input/size.

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NOTE: A ‘PEEL & STICK’ SIGN IS SUPPLIED: USE AN INDELIBLE MARKER TO

ENTER VALUES ON THE SIGN: ‘H’ = Calculate (instruction below)

Sides of horizontal heater: ‘S’ = 24 inches (61 cm)

Front of 30° Angle heater: ‘F’ = 36 inches (91.5 cm)

Behind 30° Angle Heater ‘B’ = 24 inches (61 cm)

POST THE SIGN ADJACENT TO THE HEATER THERMOSTAT OR IN A PROMINENT LOCATION.

See next page for details.

FIGURE 1 MINIMUM CLEARANCES TO COMBUSTIBLES* - Table 1 lists values

Suspended at an angle of 30°

FLOOR

Suspended horizontally

24” (61 CM) FROM ‘U’ TUBE

END OF HEATER

FLOOR

Calculate Maximum Stack Height ‘H’: (Enter value ‘H’ on the peel and stick label supplied)

 H = T- 55 inches (140 cm)  ‘T’ is measured on site = distance from the bottom of the heater hanger to the floor  55 inches (140 cm) is the required minimum clearance below the heater

TABLE 1 MINIMUM CLEARANCES TO COMBUSTIBLE SURFACES OR MATERIALS*

MODELS

SUSPENDED HORIZONTALLY

TOP

inches (cm)

P40U / P40U-I P40U-P / P40U-IP P40U-W / P40U-IW

12 (30.5)

Clearance from ‘U’ end of heater (horizontal or angled): 24” (61 cm)

*The clearance to combustible materials represents the minimum distance that must be main-

tained between the heater and a nearby surface. The stated clearance to combustibles represents a surface temperature of 90F° (50C°) above room temperature.

BELOW

inches (cm)

55 (140)

SUSPENDED AT AN ANGLE UP TO 30 DEGREES

SIDES

inches (cm)

TOP

inches (cm)

24 (61) 12 (30.5)

BELOW

inches (cm)

FRONT

inches (cm)

55 (140) 36 (91.5)

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BEHIND

inches (cm)

12 (30.5)

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It is the installer’s responsibility to ensure that building materials with a low heat tolerance which may degrade at lower temperatures are protected to prevent degradation. Examples of low heat tolerance materials include vinyl siding, fabrics, some plastics, filmy materials, some coatings and laminated finishes, etc.

VENT END CLEARANCE: Clearances from the vent pipe are determined by local or national installation codes, but must not be less than 6 inches (15 cm). For ‘unvented’ installation, a minimum distance of 24 inches (61 cm) is required from the end of heater to a combustible surface.

WARNING

In locations used for the storage of combustible materials: Signs must be posted specifying the maximum permissible

stacking height to maintain the required clearances from the heater to the combustibles.

The signs must be posted either adjacent to the IR heating system thermostats or in the ab-

sence of such thermostats, in a conspicuous place.

For your convenience a “peel and stick” sign is provided with this heater. Use a permanent marker to record the required dimensions on the sign.

‘H’ is a value calculated at site: (H = T - C)

 Measure the on site distance between bottom of

the hanger and the floor = ‘T’ inches (cm).

 The minimum clearance to combustibles below

this model heater is 55 inches (140 cm)

 Subtract 55 inches (140 cm) from ‘T’ to get

value ‘H’.

 Enter the calculated value ‘H’ on the sign

For model P40U enter the values for other dimen-

sions are: ‘S’ = 24” (61 cm), ‘F’= 36” (91.5 cm) and

‘B’ = 12” (30.5 cm). See Figure 1 and Table 1

24” 36”

12”

Post this sign as instructed above.

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1. LABOR REQUIRMENTS Two persons are required to safely install this equipment. SHARP EDGES - Wear gloves and

other required safety protection.

2. INSTALLATION IN COMMERCIAL AIRCRAFT HANGARS

Low intensity radiant tube heaters are suitable for use in aircraft hangars when installed in accordance with the latest edition of the Standard for Aircraft Hangars, ANSI/NFPA No 409 in the USA, or the Canadian Natural Gas and Propane Installation Code, B149.1.

A. A minimum clearance of 8 ft (2.4 m) must be maintained from the bottom of the heater to

the floor in other sections of the aircraft hangar, such as offices and shops, which communicate with areas for servicing or storage. Refer to Table 1 for proper mounting clearances to combustibles.

B. Heaters must be located so as to be protected from damage by aircraft and other objects,

such as cranes and movable scaffolding.

C. Heaters must be located so as to be accessible for servicing and adjustment.

3. INSTALLATION IN COMMERCIAL GARAGES AND PARKING STRUCTURES

Low Intensity Heaters are suitable for use in commercial garages when installed in accordance with the latest edition of the Standard for Parking Structures, ANSI/NFPA 88A, or the Standard for Repair Garages, ANSI/NFPA No. 88B, or the Canadian Natural Gas and Propane Installa- tion Code, B149.1.

WARNING

An overhead heater shall be located high enough to maintain

the minimum distance to combustibles, as shown on the heater

rating plate, from the heater to any vehicles parked below the heater. Overhead heaters shall be installed at least 8 ft (2.4 m) above the floor.

4. INSTALLATIONS OTHER THAN SPACE HEATING

Use for process or other applications that are not space heating will void the C.S.A. certification and product warranty. Process application requires field inspection and/or certification by local authorities having jurisdiction.

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WARNING

This heater must be installed and serviced only by a trained gas service technician. Do not store or use gasoline or other flammable vapours and liquids in the vicinity

of this or any other gas fired appliance. Failure to comply could result in personal injury, death, fire and/or property damage. Do not store or use gasoline or other flammable vapours and liquids in the vicinity

of this or any other gas fired appliance.

5. PRE INSTALLATION SURVEY

It is recommended that a full heating design including heat loss calculation be conducted on the structure or area to be heated. Heater sizing and placement must consider available mounting height, sources of greatest heat loss, and the certified clearances to combustibles with respect to stored material, moveable objects (cranes, vehicles, lifts, overhead doors, etc), sprinkler system heads, and other obstructions on the site. Consideration must also be given to vent / duct placement and the allowable combined lengths of vent and duct. Carefully survey the area to be heated, and for best results place burner and combustion chamber in the coldest area(s) .

Installation must conform with all local, state, provincial and national code requirements including the current latest edition ANSI Z223.1 (NFPA 54) in the U.S.A. and B149.1 installation code in Canada, for gas burning appliances and equipment. The latest edition Electrical Code ANSI/ NFPA N0 70 in the U.S.A. and PART 1 CSA C22.1 in Canada must also be observed.

The heating system must have gas piping of the correct diameter, length, and arrangement to function properly. For this reason, a layout drawing is necessary.

6. MOUNTING CLEARANCES

This heater must be mounted with at least the minimum clearances between the heater and combustibles as shown in FIG-1, TABLE 1, Page 7. It is the installer’s responsibility to en-

sure that building materials with a low heat tolerance which may degrade at lower temperatures are protected to prevent degradation. Examples of low heat tolerance materials include vinyl siding, fabrics, some plastics, filmy materials, some coatings and laminated finishes, etc.

Ensure adequate clearance around the air intake at the burner to allow sufficient combustion air supply to the heater.

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Proximity of lights, sprinkler heads, overhead doors, storage areas, gas and electrical lines, parked vehicles, cranes and any other possible obstruction or hazard must be evaluated.

It is recommended that Protective Guard JS-0502-UR-GK be installed on any heater mounted with less than 8 feet from floor to bottom of heater (See Accessories - Page 42).

6A. SERVICE CLEARANCE: The lower ‘jaw’ of the burner cabinet swings down to provide convenient service access to burner components. Provide a minimum clearance from any wall or obstruction of 6 inches (15 cm) to the access end of the burner housing, and a minimum of 24 inches (61 cm) to any ONE side to allow burner service. (see Figure 2 below)

The minimum clearances to combustibles must always be maintained.

FIGURE 2

24” (61 cm)

Min.

6”

(15 cm)

Min.

7. GUIDELINES FOR HEATER PLACEMENT* - SPACE HEATING APPLICATIONS TABLE 2

MODEL

P40U / P40U-I P40U-P / P40U-IP P40U-W / P40U-IW

GUIDELINE *

MOUNTING

HEIGHT

ft (m)

8 – 18

(2.4 - 5.5)

MAXIMUM

BETWEEN

HEATERS

ft (m)

(6)

DISTANCE – HEATER LONG AXIS

PARALLEL TO WALL

HORIZONTAL

ft (m)

5 – 12

(5 - 8)

ANGLE MOUNTED

MINIMUM: COMBUSTIBLE

CLEARANCE BEHIND

(refer to Table 1)

* GUIDELINE MOUNTING HEIGHTS are typical to provide optimum comfort in general space

heating applications. Variance from these typical heights can occur in some applications:

 Higher mounting height due to structure or application requirements  For ‘area’ or ‘spot’ heat, or in areas with greater infiltration rates (near overhead doors,

etc) where more intense heat is needed to provide better comfort then lower mounting heights are recommended (minimum 8 ft [2.4 m] mounting height)

 It is recommended that Protective Guard JS-0502-UR-GK be installed on any heater

mounted with less than 8 feet from floor to bottom of heater (See Accessories - Page 42)

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IMPORTANT: Single or multiple heater placement must be such that continuous operation of heaters will not cause combustible material or materials in storage to reach a temperature in excess of ambient temperature plus 90F° (50C°).

Refer to “Clearance to Combustibles” information on pages 6 to 8, and Figure 1 and Table 1.

8. HEATER INSTALLATION

Inadequate or improper suspension of the tube heater can result in collapse of the system, property damage, and personal injury or death.

It is the installer’s responsibility to ensure that the hardware and structural supports from which the heater is suspended are sound and of adequate strength to support the weight and expansion forces of the heater.

USE CARE & CAUTION WHEN LIFTING HEATER FROM CARTON

1. DO NOT LIFT THE HEAT ER BY THE REFLECTOR

2. CHAINS PROVIDED ARE TO LIFT HEATER FROM CAR-

TON AND FOR HANDLING PURPOSES ONLY

3. WHEN HANDLING FROM BENEATH HEATER - HANDLE BY TUBE NOT REFLECTOR

4. KEEP THE HEATER HORIZONTAL / LEVEL ALONG ITS LENGTH WHILE HANDLING AND INSTALLING

5. AT LEAST 2 PERSONS ARE REQUIRED TO LIFT AND INSTALL THIS HEATER

6. LIFT SAFELY - LIFT WITH YOUR LEGS AND KEEP BACK STRAIGHT DO NOT BEND OR TWIST.

7. BEWARE - SHARP EDGES! WEAR PROTECTIVE GLOVES AND CLOTHING WHEN HANDLING

IMPORTANT: FIRST READ and ensure that installation adheres to the information provided on pages 4 to 8 of this manual, and all national and local codes.

REFER TO PAGES 12 TO 16 IN MANUAL FOR SUSPENSION INSTRUCTIONS

Refer to Figures on next pages for figures and dimensions to assist in installation.

1. Establish the location and install the structural mounting supports and any suspension hardware (chain, etc) prior to removing heater from the carton

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2. Connect to the structure using mechanically sound means to support the weight. Examples of typical hardware are illustrated in FIGURE 3 below.

b) If rigid hardware such as 3/8” threaded rod is used for suspension, swing joints or other means must be provided to allow for system expansion - approximately ½ inch for P40U.

3. P40U Models are packaged with the burner assembled to the tube system at the factory. For many applications a pre-assembled heater simplifies installation.

4. However, for applications where there is constrained access to the installation location, or if the tube/reflector system is to be oriented at a 30° mounting angle (see 8. below), we recommend removal of the burner assembly prior to installation of the tube/reflector assembly. Simply disconnect the spark wire from the igniter and remove the four bolts that fasten the burner to the tube flange. Reinstall the burner after the tube system is installed.

5. Survey the available structural supports, considering the system configuration and heat requirements of the area to establish the optimum heater location.

6. Locating a heater directly under joists or beams, and/or installing supplemental steel support rail or angle iron can substantially reduce labor and material costs.

7. The P40U tube system hangers are located 72 inches (183 cm) apart.

8. The tube/reflector system must be level along its length, but can be oriented on the short axis either horizontally, or at an angle up to 30 degrees (vent side of tube must be higher than burner side).

9. When the tube/reflector system is mounted at a 30° angle, the Burner must remain in a horizontal plane. To simplify installation remove burner from tube system prior to installation. The mounting flange on the tube allows for horizontal mounting of the burner when the tube is angled 30° from horizontal.

10. Hardware with a minimum 100 lb. (30 kg) work load must be used at each heater suspension point. A #2 Lion Chain or equivalent is typically used to suspend the heater.

11. The heater must be supported at all four mounting tabs on the hangers. Also install a chain from the eye hook at the upper corner of the burner to maintain system orientation.

12. For seismic and high wind restraint see Sections 8-A & 8-B, page 16.

FIGURE 3 TYPICAL MOUNTING HARDWARE

HOOK OR EYE

BOLT THROUGH

HOLE IN BEAM

BEAM CLAMP

WITH HOOK

HOOK OR

EYE

PIPE RING

OR CLEVIS

HANGER

BAR-JOIST

CLAMP

NOTE: It is the installer’s responsibility to ensure that mounting hardware and fastening to structure are of sufficient strength and integrity to support the system.

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FIGURE 4 TYPICAL SUSPENSION

Use all four suspension points + a chain at burner eye hook. Hardware capable of supporting minimum 100 lbs (45 kg) at each suspension point. For seismic and high wind restraint see Sections 8-A & 8-B.

SERVICE ACCESS: ALLOW A MINIMUM OF 6 INCHES (15 cm) FROM THE ACCESS END OF THE BURNER AND A MINIMUM OF 24 INCHES (60 cm) FROM EITHER SIDE OF THE BURNER TO A WALL OR ANY OBSTRUCTION THAT WOULD RESTRICT OR LIMIT ACCESS TO THE BURNER (SEE

SECTIONS 5 & 6 - PRE-INSTALLATION SURVEY AND MOUNTING CLEARANCES)

”

)

Connect to properly grounded 120V power supply

For 30° angle mount: Remove burner (4 bolts + spark wire); Install the tube system; Reinstall burner to flange using appropriate holes to maintain horizontal orientation of burner.

FIGURE 5 HEATER DIMENSIONS & SUSPENSION ANGLE OPTIONS

Turbulators (factory installed): Burner side tube: 36” (914 mm) .

Vent side tube: 90” (2286 mm)

Vent side

always upper

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Burner always

horizontal

FIGURE 6 P40U MINIMUM CLEARANCES TO COMBUSTIBLES

It is the installer’s responsibility to ensure that building materials with a low heat tolerance which may degrade at lower temperatures are protected to prevent degradation.

Examples of low heat tolerance materials include vinyl siding, fabrics, some plastics, filmy materials, coatings, laminated surfaces, etc.

Turbulators: The system is assembled at the factory with turbulators inside the tube. The turbulators serve

to increase system efficiency and lower the vent temperature. The turbulators must remain in place inside the tube.

Burner side tube: 36” (914 mm) Turbulator (located at elbow, away from burner)

Vent side tube: 90” (2286 mm) Turbulator

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8-A SEISMIC RESTRAINT - LATERAL AND LONGITUDINAL PLANES

FIGURE 7

In areas prone to earthquake, or as specified on a project, install lateral and longitudinal seismic restraints as indicated in Figure 11. If the heater location can be impacted by wind (aircraft hangars, etc) refer to High Wind Restraint section 8-B below.

These instructions indicate attachment of suspension and restraint hardware to the heater. The attachment of suspension hardware to the structure will be as required by site structural conditions, installation codes, and/or local engineering specifications. Other types or systems of restraint that are specified by local or national codes, or by project engineering design specifications may be used .

Schwank / InfraSave offers optional items: #2 Lion Chain 115 lb work load x 200 ft roll (PN: JL0800-XX); and Safety Snap Hooks (PN: JL-0800-SH = pkg 24; JL-0800-SH-B = pkg 100). All other required seismic mounting hardware is field supplied by the installer.

8-B HIGH WIND RESTRAINT - LATERAL, LONGITUDINAL, AND VERTICAL

In areas with wind conditions that can impact the heater (outdoor, aircraft hangers, etc): in ad-

dition to lateral and longi-

FIGURE 8

tudinal restraint the

heater must be re-

strained from vertical movement.

Suspend the heater using 3/8” threaded rod with 3” adjustment turnbuckle at each hanger location to restrain up-anddown movement.

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WARNING

9. FLUE VENTING

Inadequate venting of a heater may result in asphyxiation, carbon monoxide poisoning, injury or death. This heater may use a vent connection or indirect venting system to remove products of combustion from the space. Seal all vent connections with high temperature sealant. Venting must be in accordance with all local, state, provincial, and national codes (ANSI Z223.1/NFPA 54 in USA; B149.1 in Canada) and as indicated below in this manual.

THIS TUBE HEATER IS APPROVED FOR VENTING DIRECTLY TO THE OUTSIDE AND UNVENTED (INDIRECT VENTING)

APPLICATIONS. THE SYSTEM MUST NOT BE OPERATED WITHIN A NEGATIVE AIR CONDITION UNLESS COMBUSTION

AIR IS DUCTED FROM OUTSIDE DIRECTLY TO THE BURNER.

F NEGATIVE PRESSURE IS EXPERIENCED OR ANTICIPATED, OUTSIDE COMBUSTION AIR MUST BE DUCTED

TO THE BLOWER INLET, AND THE ’ATMOSPHERE’ PORT (BARB) ON THE BLOCKED FLUE SWITCH MUST BE CONNECTED

(

PLASTIC HOSE IS FIELD SUPPLIED).

DIRECTLY TO OUTSIDE AIR USING 1/4” PLASTIC HOSE FROM THE SWITCH TO OUTSIDE OF BUILDING

UNVENTED (INDIRECT MECHANICAL VENTING SYSTEM)

Indirect venting must not be used if the building experiences a negative air condition. A minimum 10 inch (25 cm) length of single walled vent pipe is to be installed on the swaged end of the last tube before any Tee, Elbow or Termination Cap is fitted.

USA: Natural or mechanical means shall be provided to supply and exhaust at least 4ft3/ min/1000Btuh (0.38m3/min/kW) input of installed heaters. Some local codes may require an electrical interlock to a dedicated exhaust fan. Exhaust must be located as high as practicable in the structure above the level of the heater(s). Consult your local code and ANSI Z223.1 latest edition for all venting requirements and practices.

Canada: It is required that the heater(s) be electrically interlocked to dedicated exhaust fan(s) by means of an Air Proving Switch. Exhaust fan(s) must be sized to create 300 cfm (8.5 cu m/ min) exhaust for every 100,000 Btuh (30 kW) or any fraction thereof of total input of installed equipment. Exhaust must be located as high as practicable in the structure above the level of the heater(s). Sufficient supply air must be provided. Consult the latest edition of CSA.B149.1 Section 8 for venting system and air supply requirements.

VENTED DIRECTLY TO THE OUTSIDE

It is the sole responsibility of the installer to adhere to all current local codes and/or ANSI Z223.1 / CSA.B149.1 latest editions for all venting requirements, and practices.

It is a normal condition that during heat-up and cool-down a tube heater will expand and contract. Allowances for heater expansion must be made in the venting and combustion air ducting Improper installation can result in property damage, injury or death.

 All vent pipe and adapters are supplied locally by others  All venting must be minimum 26 gauge single wall vent pipe of 4” (10 cm) diameter except

that portion of vent passing through a combustible wall or roof can be 4” type “B” vent as per CSA International’s interim requirement.

 As an Option, two heaters may be vented through an approved common 4" x 4" x 6" Vent

Tee (10 x 10 x 15 cm), supplied by the manufacturer. Vent pipe from each heater does not

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need to be equidistant to the vent Tee, but must comply to requirements below. The two heaters must be controlled by a single common thermostat or “ON/OFF” switch.

 A minimum 12 inch (30 cm) length of minimum 26 gauge single walled 4” (10 cm) diameter

vent pipe is to be installed on the swaged end of the tube before any Tee or Elbow is fitted.

 Seal all vent connections with high temperature sealant. Vent connections must be secured

with three (3) #8 sheet metal screws uniformly spaced around the circumference of the vent pipe.

 When the vent pipe passes through a cold or unheated area where the ambient tempera-

ture is likely to produce condensation of the flue gases, the vent pipe will be insulated with a suitable material as approved and specified by the insulation manufacturer to withstand temperature up to 460°F (238°C).

 The vent system must always be adequately supported to prevent sagging.

FIGURE 9 - Heater Expansion - Suggested Vent Configuration*

* Other means of slip fit installation of the vent and duct are acceptable providing there is adequate allowance for free expansion and contraction of the system, and

All Vent Pipe & Adapters

By Others

free flow of vent gases and combustion air.

FIGURE 10 - Horizontal Vent - ALL vent pipe and adapters by others

Single wall vent from heater

‘C’ to ‘B’ adapter

By Others

HORIZONTAL VENT THROUGH A SIDE WALL:

 Maximum allowable flue vent length is equivalent to 20 feet [6.1 m]  A maximum of two 90°elbows (each equivalent 5 ft [1.5 m]) can be installed in the vent  The flue vent system must slope downwards approximately 1/4" per foot (63 mm / 300 mm)

toward the vent terminal, from the termination of the tube - radiant tube must be level.

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Combustible Overhang

’B’ Vent Through Wall

6”

Min.

18” Min.

These minimum clearance

apply when using the

following Vent Terminal

4” (10 cm) - JA-0528-XX

6” (15 cm) - JA-0529-XX

See notes below

for use of other

approved vent terminations

continued ……..

 Termination Cap Options:

 Use the approved 4" (10 cm) (JA-0528-XX) or 6" (15 cm) (JA-0529-XX) horizontal

wall vent terminal (see FIGURE 20 for applicable clearances)

 OR a high-wind termination cap approved by a recognized certification agency (see

clearance notes below)

 Install any termination cap a minimum of 18 inches (45 cm) from the outside wall to the in-

side edge of terminal opening to alleviate back pressure caused by turbulent wind conditions (See Fig. 19). This also ensures flue gases are directed away from the structure to protect building materials from degradation by the exhausted flue gases.

 Termination cap must be installed to prevent blockage by snow and protect building materi-

als from degradation by flue gases.

Clearances for horizontal flue vent :

 Will not terminate less than 1 ft (30 cm) above grade level, unless its location is adjacent

to public walkways, then it must not terminate less than 7 ft (2.1m) above the walkway.

 Below an overhang:

 As indicated in FIGURE 20 for approved terminations: 4" (10 cm) JA-0528-XX or

6" (15 cm) JA-0529-XX

 For other approved terminations: Will terminate 3 ft (90 cm) or more below a combus-

tible soffit or overhang.

 USA specific horizontal vent requirements:

 The vent terminal of a direct-vent appliance with an input between 10,000 Btu/hr (3 kW)

and 50,000 Btu/hr (14.7kW) shall be installed with a 9 inch (230mm) vent termination clearance from any air opening into a building, and an appliance with an input over 50,000 Btu/hr (14.7kW) shall have at least a 12inch (300mm) vent termination clearance. The bottom of the vent terminal and the air intake shall be located at least 12inches (300mm) above grade.

 A horizontal vent will not terminate:

 Less than 3 ft (90 cm) above a mechanical air inlet located within 10 ft (3.1 m)  Less than 4 ft (1.2 m) below, 4 ft (1.2 m) horizontally from, and 1 ft (0.3 m) above

any window or door that opens, or gravity air inlet to a building

 Less than 4 ft (1.2 m) horizontal clearance from gas and electric meters, regula-

tors and relief equipment

 CANADA specific horizontal vent requirements:

 A horizontal vent will not terminate:

 Within 6 ft (1.8 m) of a mechanical air supply inlet to any building.  Above a ga s utility meter and regulator assembly within 3 ft (0.9 m) horizontally of

the vertical centerline of the regulator vent outlet to a maximum vertical distance of 15 ft (4.5 m).

 Within 3 ft (90 cm) of any gas pressure regulator vent outlet  Within the following distanc es of a window or door that can be opened in any

building, of any non-mechanical air-supply inlet to any building, or of the combustion air inlet of any other appliance:

 12 inches (30 cm) for inputs up to and including 100,000 Btuh (30 kW)  3 ft (90 cm) for inputs exceeding 100,000 Btuh (30 kW)

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VERTICAL VENT THROUGH THE ROOF:

It is the sole responsibility of the installer to adhere to all current local codes and/or ANSI Z223.1 / CSA.B149.1 latest editions for all venting requirements, and practices.

 Use an approved ‘B-vent’ termination cap as

FIGURE 11

Approved Cap

Approved ‘B’ Vent

24”

60 cm

supplied by the manufacturer of the approved ‘B-vent’.

 When vent and combustion air are taken

through the roof, the exhaust vent should always terminate higher than the combustion air intake, to prevent recycling the products of

If roof slope exceeds 9:12 consult NFPA-54 ANSI Z223.1 or CSA-B149.1

combustion back into the heater.

 Maximum allowable 4” [100 mm] diameter vent length equivalent to 20 feet [6 m]  A maximum of three 90° elbows (each equivalent 5 ft) can be installed in a vertical vent

10. COMBUSTION AIR DUCTING

Whenever possible, locate the air intake and vent terminals in a common pressure area. For example on a common wall, or commonly through the roof. Depending upon wind conditions, terminations located in uncommon pressure areas can create intermittent operation problems.

Combustion Air Duct can be 4”, or 5” diameter (reduce to 4” only at connection to blower collar).

4” Dia. Air Duct: Maximum combined total length of flue vent plus combustion air duct equivalent to 35 feet, and neither the 4” diameter vent or duct component can exceed 20 feet.

5” Dia. Air Duct: Maximum combined total length of flue vent plus combustion air duct equivalent to 50 feet. The 4” diameter vent cannot exceed 20 feet; the 5” diameter air duct can-

not exceed 35 feet.

 Total vent and duct length is reduced by five feet for every 90° elbow installed in the vent

and/or duct system

 Exceeding the allowable lengths noted above may cause unreliable operation, create con-

densation or soot conditions, and will void CSA Certification and the heater warranty.

An opening is located on the top surface of the burner housing for combustion air . Ensure adequate clearance around this opening to allow sufficient combustion air supply to the heater. Combustion air duct must be constructed of noncombustible material.

When a tube heater is operated in a negative air condition, or air-born dust or contaminants are present as in woodworking and welding shops, air for combustion must be ducted from outside the negative or contaminated area to the 4 inch (10 cm) diameter intake collar supplied on the blower. See notes above for maximum combined equivalent vent and duct length.

The air intake will not be located less than:

 Three feet above grade  Twelve inches from flue vent terminal of any heater with input up to 100,000 Btu/hr  Three feet from flue vent terminal of any heater over 100,000 Btu/hr

Do not install filters on the combustion air intake. Ensure adequate clearance around the air intake to allow sufficient combustion air supply to the heater.

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continued ...

Optional 4 inch intake terminals are available for this heater:

 Part number: JS-0532-VC Wall mount, bird-screened fresh air intake duct hood  Part number: JS-0530-XX Roof cap

Ensure adequate clearance around the air intake to allow sufficient combustion air supply to the heater. If drawing fresh air from outside, it is recommended that any single wall pipe containing cold air be insulated to prevent or reduce condensation on the pipe.

Do not use flexible dryer hose or any ‘soft wall’ tubing for air inlet duct, the soft corrugated sides of this tubing restrict air flow. A good quality industry approved insulated flex is allowed.

CAUTION: In locations where chlorinated Hydrocarbons are in use, such as Trichloroethyl-

ene or Chloroethylene Nu it is essential that combustion air be brought in from a non-contaminated area. Burning the fumes from these gases will create Hydrochloric acid fumes, which are detrimental to humans, equipment and buildings. Typical sources of other contaminants are paint removers, paints, refrigerants, solvents, adhesives, degreasers, lubricants, pesticides, etc.

The heater manufacturer cannot anticipate all chemical compositions and types of

potential contaminants at project sites. Confer with project site safety, health and engineering staff and/or local authorities having jurisdiction such as the Fire Marshall and Department of Labor for possible contaminants and any conflict with the installation of hot surface heating equipment.

11. GAS SUPPLY - GAS CONNECTION - HEATER EXPANSION

CAUTION: Compensation for expansion of gas supply pipe and radiant tube

heater must be provided. All piping must conform to local and national codes.

This heater will expand up to 1 inch (2.5 cm) in length during operation. To allow for heater expansion the gas supply must be connected using the flexible gas connector that is supplied with this model heater:

 In the USA: a 1/2” x 24” stainless steel Flexible Gas Connector certified for use on an in-

frared radiant tube heater (ANSI Z21.24 CSA 6.10);

 in CANADA: a 1/2” x 36” (±6”) Type 1 Gas Hose Connector (CAN/CGA 8.1).

IMPORTANT: See page 24: Orientation of connector between heater and gas supply.

TEST FOR LEAKS: All gas piping and connections must be tested for leaks after the installation is completed.

Apply soap suds solution to all connections and joints and if bubbles appear, leaks have been detected and must be corrected.

DO NOT USE A MATCH OR OPEN FLAME OF ANY KIND TO TEST FOR LEAKS. NEVER OPERATE THE HEATER WITH LEAKING CONNECTIONS.

Provide a 1/8 in (3.2 mm) NPT plugged tapping, accessible for test gauge connection, immediately upstream of the gas supply connection to the heater.

The supply system should be checked first with heater turned “OFF” followed by another check with heater turned “ON”.

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DO NOT use pressure greater than 1/2 psig to pressure check the heater. During

any pressure testing of the gas piping system each heater must be isolated from the piping system by closing its individual manual shut off valve (field supplied) .

IMPORTANT: Minimum supply line pressure at the inlet to the heater regulator must not be lower than 5.0 inches of water column pressure for natural gas. The supply gas pressure must be checked with all heaters in operation.

Installation of a gas line (trap) “drip leg” is required at the inlet connection tee following the pipe drop to the heater. Failure to provide a “drip leg” could result in condensation and foreign matter passing into the gas valve. Failure to install a “drip leg” in the gas line can cause property damage, injury or death and will void the heater warranty.

TABLE 4

GAS TYPE

LINE PRESSURE

INCHES WATER COLUMN

MINIMUM MAXIMUM

MANIFOLD PRESSURE (tap at gas valve outlet)

INCHES WATER COLUMN

Natural Gas 5.0 14.0 3.5 LP Gas 11.0 14.0 10.0

NOTE: Access to the manifold pressure test port is located on the top of the valve. A 3/16" Al-

len Key is required. A manometer should be used to check the manifold pressure. Gauges which measure in ounces or PSI are not accurate enough to measure or set the pressure.

ORIENTATION OF FLEXIBLE GAS CONNECTOR

The flexible gas connector MUST be installed in the orientation shown below as required by national installation codes and by the certification standard of this heater. This orientation protects the flexible gas connector from damage due to movement during heater expansion.

It is the responsibility of the installer to ensure correct installation of the flexible gas connector. FIGURE 12

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SEE ALSO NEXT PAGE

Orientation of Flexible Gas Connector (continued) FIGURE 13

12. GAS CONVERSION WARNING: Gas conversion must only be performed by a trained gas ser-

vice technician.

Do not convert heater to alternate gas without using one of the kits listed below. Property damage, injury or death could result.

Standard production of this model heater is for use with natural gas. Field conversion between Natural Gas and Propane Gas can be accomplished using field conversion kits available from you local Schwank or InfraSave supplier:

 Part number: JS-0555-XB P40U* - Natural Gas to Propane Gas Conversion Kit  Part number: JS-0555-XA P40U* - Propane Gas to Natural Gas Conversion Kit\

* All models: Schwank P40U, P40U-P, P40U-W; InfraSave P40U-I, P40U-IP, P40U-IW

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13. ELECTRICAL AND THERMOSTAT WIRING (WIRING DIAGRAMS PAGE 26 & 27) The heater must be electrically grounded in accordance with the

NOTICE

National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1.

Appliance and control wiring must be in accordance with all applicable local codes. The total load of all heaters must be considered in determining the required contact rating of the controlling thermostat or switch. Each tube heater requires 120V, 60 HZ electrical power sized for 145VA. The heater includes a 24V/120V relay switch and can be controlled by a 24V Thermostat, a TruTemp Thermostat, a line voltage Thermostat or by an “ON/OFF” switch. Maximum power flow for internal 24V burner components is 21VA.

A maximum night set-back of 9°F (5°C) is recommended for optimum economy and comfort. To maintain satisfactory comfort levels do not turn off the heating system over night/weekends.

14. HIGH ALTITUDE INSTALLATIONS

- also refer to chart in Section 28

When installed above the altitude stipulated below for the USA or Canada, the input must be de-rated by 4% for each 1000 ft above the altitude listed . If your local utility supplies gas with a de-rated heat content, no orifice change is required in the heater . If the gas supply is not de-rated, the orifice must be changed according to the chart in Section 28. Check with your local utility regarding the gas supply and the de-rating of this appliance. Maintain gas supply pressures indicated in Table 4, page 33.

USA: The factory installed orifice for this appliance is approved for altitudes zero to 2000 feet above sea level. When installed above 2000 feet, refer to Section 28.

Canada: The factory installed orifice for this appliance is approved for altitudes zero to 4500 feet above sea level. When installed above 4500 feet, refer to Section 28.

15. LIGHTING INSTRUCTIONS

Refer to the lighting instructions label on the outside of the burner housing. If the unit locks out on safety, main power to the unit must be manually interrupted for a 30 second reset period before the heater can be restarted.

NOTE

: On initial installation, the unit may lock out on safety owing to the length of time

required to bleed air from the gas piping system.

16. RECOMMENDED MAINTENANCE

Improper adjustment, alteration, service or maintenance can cause property damage, injury or death. This heater must be installed and serviced only by a trained gas service technician.

1. Inspect the entire heater system, venting, and gas supply connections at least annually prior to the heating season. Replace worn parts and repair deficiencies.

2. Check the inlet air opening and the blower periodically, cleaning off any lint or foreign matter. It is important that the flow of combustion and ventilation air must not be obstructed.

3. Lubricate Blower motor, by adding several drops of oil to oil ports located on the left hand side of the motor.

THE TUBE HEATER BURNER IS COMPLETELY FACTORY ASSEMBLED AND TESTED. ANY ALTERATION VOIDS THE CSA CERTIFICATION AND MANUFACTURER’S WARRANTY. FOR ADDITIONAL INFORMATION, CONTACT YOUR LOCAL DISTRIBUTOR OR THE MANUFACTURER.

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17. FENWAL DSI: WIRING DIAGRAM: 24V OR 120 VOLT THERMOSTAT OPERATION

18. FENWAL DSI: WIRING DIAGRAM: 24V OR 120 VOLT THERMOSTAT OPERATION

SINGLE HEATER PER THERMOSTAT (Multiple Heaters per Thermostat—next page) SINGLE HEATER PER THERMOSTAT (Multiple Heaters per Thermostat—next page)

NOTE: Models produced with FENWAL DSI have model designation: P40U-F & P40U-IF

18. FENWAL DSI: WIRING DIAGRAM: 24V OR 120 VOLT THERMOSTAT OPERATION

SINGLE HEATER PER THERMOSTAT (Multiple Heaters per Thermostat—next page)

OTHER DSI’s: MODELS P40U-P,-W - MICRO 50N - PAGE 31; HONEYWELL S87J - PAGES 59 - 61

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18. MULTIPLE TUBE HEATERS per THERMOSTAT (ALL DSI TYPES)

Each tube heater requires 120V, 60 HZ electrical power sized for 145VA. Maximum power flow for internal 24V burner components is 21VA. See previous page for internal wiring.

The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1.

A maximum night set-back of 9°F (5°C) is recommended for optimum economy and comfort. To maintain satisfactory comfort levels do not turn off the heating system over night/weekends.

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19. FENWAL DSI: SEQUENCE OF OPERATION / FLAME RECOVERY / SAFETY LOCKOUT Power Up / Stand By

Upon applying 24 volts power to 24VAC, the control will reset, perform a self check routine, initiate full time flame sensing, flash the diagnostic LED for up to four seconds, and enter the thermostat scan state.

Heat Mode When a call for heat is received from the thermostat supplying 24 volts to TH, the control checks

the pressure switch for normally open contacts. The combustion blower is then energized and once the pressure switch contacts close, a 30 second purge delay begins. Following the purge period the gas valve is energized and spark commences for the 15 second trial for ignition.

When flame is detected during the trial for ignition, spark is shutoff immediately and the gas valve combustion blower remains energized. The thermostat, pressure switch, and main burner flame are constantly monitored to assure the system continues to operate properly. When the thermostat is satisfied and the demand for heat ends, the main valve is de-energized immediately, the control senses the loss of flame signal and initiates a 30 second post-purge period before de-energizing the combustion blower.

Failure to Light - Lockout (THREE TRIAL MODEL) This three-try control will attempt two additional ignition trials with a 30 second inter-purge be-

tween trials, before going into ‘soft’ lockout. The valve relay will be de-energized immediately, and the combustion blower will be turned off following the 30 second post purge period.

If the thermostat continues to call for heat after one hour the control will automatically reset and attempt to ignite the burner again (three trials).

At any time less than the 1 hour auto-reset, recovery from lockout requires a manual reset by either resetting the thermostat or removing 24 volts for a period of 5 seconds.

Flame Failure - Re-Ignition If the established flame signal is lost while the burner is operating, the control will respond within

0.8 seconds. The HV spark will be energized for a trial ignition period in an attempt to relight the burner. If the burner does not light the control will de-energize the gas valve. Two more attempts will be made to relight the burner. If the burner does not relight the control will go into ‘soft’ lockout as noted above in “Failure to Light”. If flame is re-established, normal operation resumes.

Combustion Airflow Problems -Lockout

Combustion air flow is continually monitored during an ignition sequence by the air flow switch (PSW). If during the initial call for heat the pressure contacts are in the closed position for 30 seconds without an output to the Combustion Blower, an air flow fault will be declared and the control will remain in this mode with the combustion blower off.

If the air flow switch remains open for more than 30 seconds after the combustion blower output (L1 & IND) is energized, an air flow fault will be declared and the control will stay in this mode with the combustion blower on, waiting for the air flow switch to close.

When proper air flow is detected from the air flow switch input (PSW) the control begins the pre-purge period followed with a 15 second ignition sequence.

If the air flow signal is lost while the burner is firing, the control will immediately de-energize the gas valve and the combustion blower will remain on. If the call for heat remains, the control will wait for proper air flow to return. If proper air flow is not detected after 30 seconds an air flow fault signal will be declared. If proper air flow is detected at any time, a normal sequence will begin with the pre-purge period.

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Flame Fault If at any time the main valve fails to close completely and maintains a flame, the full time flame

sense circuit will detect it and energize the combustion blower. Should the main valve later close completely removing the flame signal, the combustion blower will power off following the optional post purge period.

Fault Conditions The LED will flash on for 1/4 sec-

ond, then off for 1/4 second during a fault condition. The pause between fault codes is 3 seconds.

MOUNTING AND WIRING

Error Mode

LED Indication

Internal Control Failure Steady on Air Flow Fault 1 flash Flame with No Call for heat 2 flashes

Ignition Lockout 3 flashes

The Series 35-61 is not position sensitive and can be mounted vertically or horizontally. The case may be mounted on any surface with #6 sheet metal screws. All wiring must be done in accordance with local and national electrical code. Refer to wire diagram page 35 when connecting the Series 35-61 to other components in the burner.

WARNING

The Series 35-61 DSI Control uses voltages of shock hazard potential. Wiring and initial operation must be done by a qualified service technician. The control must be secured in an area that will experience a minimum of vibration and remain below the operating temperature of 160ºF. All connections should be made with UL approved 105ºC rated 18 gauge, stranded, .054 thick insulated wire. Refer to wire diagram page 35 when connecting the Series 35-61 to other components in the burner.

TERMINAL

TH Thermostat Input PSW Pressure Switch Input V1 Valve Power (MV)

IND NC

L1 120/240 VAC Input (Hot) 24 VAC 24 VAC Supply to Processor V2 Valve (MV) GND Valve & System Ground Spark Spark & Local Flame Sense

SPADE

1/4” 1/4” 1/8”

1/4”

1/4” 1/4” 1/8” 1/8” 1/4”

DESIGNATION

Inducer Blower Output Alarm (Not used)

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. A functional checkout of a replacement control is recommended.

PROPER ELECTRODE LOCATION Proper location of the electrode assembly is impor-

tant for optimum system performance. The electrode assembly should be located so that the spark gap is inside the flame envelope about 1 inch (2.5 cm) from the base of the flame at the burner cup.

Electrodes should have a gap spacing of 3/16” (0.188” ± 0.031” or 4.76 mm ± 0.81 mm). If this spacing is not correct, the assembly must be adjusted or replaced. DO NOT adjust the curved igniter/sensor prong. Adjust/bend only the ground prong (More Detail Page 32).

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SERVICE CHECKS

Multipurpose Meter

Flame current passes through the flame from the sensor to ground. The minimum flame current necessary to keep the system from lockout is 0.7 microamps. To measure flame current, connect an analog DC microammeter to the FC- FC+ ter-

Use Microamp

minals per figure at right. Meter should read 0.7 µA or higher. If the meter

reads below “0” on scale, meter leads are reversed. Disconnect power and reconnect meter leads for proper polarity.

TROUBLESHOOTING - FENWAL DSI

(also see Heater Troubleshooting Page 33)

SYMPTOM RECOMMENDED ACTION(S)

A. Miswired - check electrical supply (120Vac ± 5%) B. Transformer bad (24Vac ± 10%)

1. Dead C. Fuse/Circuit breaker bad

D. Bad control (check LED for steady on)

scale

FC- FC+

2. Thermostat on

- no blower output

3. Pressure switch input okay,

but no Trial-for-Ignition after purge delay

4. Valve on, no spark

5. Spark on, no valve

6. Flame ok during TFI, no

flame sense (after TFI)

A. Miswired B. Bad thermostat no voltage @ terminal W C. Bad control (check LED for steady on)

A. Miswired (check PSW terminal voltage: 24Vac ± 10%) B. Flame sense problem (existing flame: check LED - 2

flashes)

C. Bad control (check line voltage between L1 & IND) A. Shorted electrode

B. Open HV cable C. Bad control

A. Valve coil open B. Open valve wire C. Bad control (check 24Vac voltage between V1 & V2)

A. Bad electrode B. Bad HV igniter wire C. Poor ground at burner D. Poor flame (check flame current)

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20. OUTDOOR MODELS: P40U-P, P40U-W WIRING DIAGRAM: 24V OR 120 VOLT THERMO STAT

SINGLE HEATER PER THERMOSTAT

Models P40U, -I …. Page 25 Multiple Heaters/Thermostat … Page 26

Each tube heater requires 120V, 60 HZ electrical power sized for 145VA. The heater includes a 24V/120V relay switch . Maximum power draw for internal 24V burner components is 21VA.

The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1.

A maximum night set-back of 9°F (5°C) is recommended for optimum economy and comfort. To maintain satisfactory comfort levels do not turn off the heating system over night/weekends.

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Maximum Power Draw = 21VA

21. P40U-P (-IP), P40U-W (-IW) SEQUENCE OF OPERATION GASLITER 50N (DSI)

The Gasliter 50N is a three trial ignition control module with a 30 minute soft lockout/reset. It is powered by a 24v transformer that is activated when the thermostat calls for heat. On every call for heat the Gasliter 50N will delay start-up to provide a 30 second system pre-purge. When the Gasliter 50N is activated by a thermostat or call for heat an internal transformer provides power to the electronic generator circuit for Spark Ignition and the retrial/safety lockout timing begins. At the same time, the Gasliter 50N opens the gas control valve allowing gas to flow to the main Burner.

The Gasliter 50N Control Module performs the following basic functions:

· Provides a 30 second system pre-purge

· Supplies power to the electronic pulse-generator circuit for the Spark Igniter (30,000 volts open circuit).

· Allows up to three 20 second Trials For Ignition (TFI) before a ‘soft’ system safety lockout of 30 minutes occurs.

· Three time TFI and soft 30 minute lockout repeat

· Senses the Burner flame for safe lighting

· Shuts off the spark after the Burner is lit.

Burner with direct spark ignition, sequence is as follows :

1a. Line Voltage Thermostat: Upon a call for heat by the line voltage Thermostat or “ON/OFF”

switch, the Blower and the 120/24 volt Transformer are powered simultaneously with 115 volts. …. continue to 2.

1b. 24 Volt Thermostat: 120 volt supply to heater powers the 120v/24v Transformer and the

120V side of the Blower switching relay simultaneously. A call for heat by the 24 volt Thermostat energizes the 24 volt control circuit and the 24v/120 volt relay powering the Blower.

2. The 24 volt control circuit powers the DSI control in series through the normally open Air Pressure Switch (APS) and the normally closed Blocked Flue Switch (BFS).

3. The Blower creates a positive pressure and closes a normally open contact inside the Air Proving Switch (APS).

4. Provided there is no blockage in the system (tube and vent), the Blocked Flue Switch remains in a normally closed position.

5. 24 volts supplied to the DSI control initiates the 30 second pre-purge cycle.

6. After completing the 30 second pre-purge cycle the DSI control generates high voltage to the Spark Igniter, and 24 volts to energize the Gas Valve.

7. The Burner will light and establish a steady flame.

8. Once the flame sensor determines there is a steady flame established, with a minimum flame signal of 1.5 µA the spark igniter is then de-energized.

9. In the event ignition does not occur, the DSI control will retry the ignition sequence up to an additional two trials. If ignition does not occur after the third ignition trial, the system will enter a 30 minute ‘soft’ lock-out. This will reset the ignition module and the operating sequence will restart at step #1 after the 30 minute lock-out period.

10. If there is a loss of flame during the run mode, the unit will energize the spark within 0.8 seconds and perform a T.F.I., without the gas valve being closed first, this is called Spark Restoration. If a flame is not established during Spark Restoration the unit will repeat the process in step number 9 (above).

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22. IGNITION CONTROL: MODELS P40U-P, -W (-IP, -IW) - GASLITER MICRO 50N

The MICRO 50N is a microprocessor-based DSI (Direct Spark Ignition) control which continuously monitors the burner to ensure safe operation under all conditions. The MICRO 50N DSI Control includes specified purge and trial times, multiple ignition attempts, a diagnostic alarm output, and automatic recycle on soft lockout. The polyurethane encapsulated circuit board is suitable for damp and wet environments. The MICRO 50N uses electrode flame sensing.

SPECIFICATIONS

Operating Voltage: 24 VAC, 50/60Hz Power Consumption: 200mA maximum, exclusive of valve/alarm loads High Voltage: 15kV minimum with 50 pF load Spark Gap: 0.150 inches +/- 0.050 inches, 3.8 mm +/- 1.2 mm Spark Rate: 60 sparks per second Ignition Trials: Three (3) Prepurge: 30 seconds Spark Duration: 20 seconds Inter-purge: 30 seconds Soft Lockout / Reset: 30 minutes Gas Valve Output: 2A maximum Alarm Output: 2A maximum, dependent on optional alarm type Operating Temperature: -40°F to +185°F (-40°C to +85°C) Environmental Protection: Polyurethane encapsulated; 500 hour salt spray test to ASTM 117 Mating Connectors: 6 Pin: MOLEX 08-50-8063 or equivalent Timing Specifications: All timings are +/- 10%

NORMAL OPERATING SEQUENCE Power up / Pre-purge

When powered up, the unit performs a series of diagnostic checks to determine if the system is in working order.

Trial for Ignition

After a 30 second pre-purge, the unit will power the valve solenoid and begin a 20 second trial for ignition. The spark will be enabled for the first 80% of the trial period and then suppressed for the last 20% of the trial period to allow the unit to sense weak flame signals.

Run

When a flame is sensed, the unit suppresses the spark and keeps the valve powered. Power is removed from the unit when the thermostat is satisfied.

ABNORMAL CONDITION OPERATING SEQUENCE No Flame Established - Soft Lockout Mode (30 minutes)

If a flame is not established during the trial for ignition, the unit will perform an inter-purge and retrial for ignition. This protocol is followed for three (3) trials. If a flame is not established during the final ignition attempt, the unit will enter the soft lockout mode, which includes a reset delay before another normal trial for ignition series begins.

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continued ….

Loss of Flame - Spark Restoration Retrial

If there is a loss of flame during the run mode, the unit will energize the spark within 0.8 seconds and perform a spark restoration trial for ignition. In this mode, the ignition means is restored without the gas valve being closed. If a flame is not established during the restoration trial, the unit will perform as in “No Flame Established” fault operation above.

Leaking Valve - Hard Lockout Mode

If a flame is present when the gas valve is not energized, the unit will enter the hard lockout mode.

Internal Fault - Hard Lockout Mode

If an internal fault is detected within the unit, the unit will enter the hard lockout mode.

System or External Fault - Hard Lockout Mode

If the unit detects a system fault or an external fault, the unit enters the hard lockout mode.

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23. SPARK IGNITER SET UP

Use the following diagram to check the Igniter gap. If the gap is incorrect all adjustments should be made to the GROUND PRONG/PIN ONLY! DO NOT BEND THE IGNITER

PRONG!!!!

USE THE BLACK BARS BELOW AS A GUIDE FOR ADJUSTMENT. USE THE BARS THAT COINCIDE WITH THE FORMAT & SIZE OF THIS PUBLICATION .

this manual is in

3/16” 1/4”

8.5” x 11” “booklet” format

(pages folded in half)

then use these bars

IF this manual is printed

8.5” x 11” “full page” format use these bars

3/16”

1/4”

ADJUST

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24. TROUBLESHOOTING GUIDE — HEATER OPERATION — FENWAL DSI

Improper adjustment, alteration, service or maintenance can

WARNING

cause property damage, injury or death. This heater must be installed and serviced only by a trained gas service technician

SEQUENCE OF EVENTS (also see DSI Troubleshooting previous page)

APPLY 120 VOLTS - GREEN LIGHT

SET THERMOSTAT TO CALL FOR

COMBUSTION AIR BLOWER

YES

AIR PROVING SWITCH HAS

CLOSED 24 VOLTS IS PRESENT

AT “PSW” AT DSI CONTROL.

YES

BLOCKED FLUE SWITCH IS

CLOSED

24 VOLTS IS PRESENT AT “TH” AT

YES

NO NO

 REMEDY 120 VOLTS SUPPLY FAULT

 CHECK 120V TO DSI AT “L1”  CHECK 120V OUT AT “IND” FROM DSI TO

 FAULTY RELAY SWITCH IN DSI — RE-

PLACE DSI

 CHECK TUBING TO SWITCH IS CON-

NECTED AND NOT BLOCKED OR KINKED

 CHECK AIR PRESSURE WITH MANOME-

TER

 CHECK FOR OBSTRUCTION IN THE AIR

INTAKE

 CHECK TUBING TO SWITCH IS CON-

NECTED AND NOT BLOCKED OR KINKED

 CHECK AIR PRESSURE WITH MANOME-

TER

 CHECK INTEGRITY OF SWITCH

 REPLACE DEFECTIVE SWITCH

SPARK IGNITER / SENSOR

YES

24V TO GAS VALVE - RED LIGHT

CONTINUED

 CHECK DSI CONTROL FUSE FOR CONTI-

NUITY

 VISIBLY CHECK IF IGNITER IS SHORTING

OUT

 CHECK GROUND WIRING  REMOVE AND INSPECT IGNITER AND

LEAD

 CHECK BOOT OF THE IGNITION CABLE

FOR SIGNS OF MELTING OR OVERHEATING

 IF “YES” ... TAKE PROTECTIVE ACTION TO

SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURE; REPLACE ANY DEFECTIVE COMPONENT

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MAIN BURNER LIGHTS

YES

SPARK STOPS WHEN BURNER LIGHTS

YES

 CHECK FOR STRONG SPARK AT IGNITER........

 (SEE PREVIOUS PAGE).  CHECK FOR 24 VAC ACROSS GAS VALVE.  CHECK OUTPUT VOLTAGE FROM CONTROL TER-

MINALS TO GAS VALVE.....IF NO VOLTAGE RE-

PLACE CONTROL.

 CHECK ELECTRICAL WIRING, AND VOLTAGE BE-

TWEEN IGNITION CONTROL AND GAS VALVE.

 IF OK, REPLACE GAS VALVE.

CONTROL IS NOT SENSING FLAME WITHIN THE 21 SECOND TFI AND IS STILL TRYING TO LIGHT

 CHECK CONTINUITY OF SENSOR CABLE AND

GROUND WIRE

 CHECK BURNER FLAME IS COVERING SENSOR.  CHECK FLAME SIGNAL IN SERIES WITH THE

GROUND AND MODULE FOR 1.5UA MINIMUM.

 IF SIGNAL IS LOWER CHANGE IGNITER.

 IF CHECKS ARE OK.......REPLACE CONTROL.

SYSTEM RUNS UNTIL CALL FOR HEAT ENDS

YES

CALL FOR HEAT ENDS:

SYSTEM SHUTS OFF

YES

NOTE: IF IGNITION CONTROLS GOES INTO A LOCKOUT, INTERRUPT POWER AND RESTART.

 CHECK CONTINUITY OF SENSOR CABLE AND

GROUND WIRE AS A POOR GROUND COULD RESULT IN ERRATIC BEHAVIOUR AND NUISANCE SHUTDOWNS EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.

 CHECK FOR EXCESSIVE HEAT AT SENSOR INSU-

LATOR AS TEMPERATURES ABOVE 1000°F(538°C) CAUSES SHORT TO GROUND.

 CHECK FLAME SIGNAL IN SERIES WITH THE

GROUND AND MODULE FOR A MINIMUM 1.5UA.

 IF SIGNAL IS LOWER CHANGE IGNITER.

 IF CHECKS ARE OK.....REPLACE CONTROL.

 CHECK TEMPERATURE CONTROLLER.  CHECK FOR FAULTY WIRING, REMOVE GAS

VALVE LEAD AT CONTROL ,

 IF VALVE CLOSES, RECHECK THE TEMPERATURE

CONTROLLER AND WIRING.

 IF VALVE STAYS OPEN....REPLACE GAS VALVE

TROUBLESHOOTING ENDS

ALSO SEE FENWAL DSI

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25. START-UP / COMMISSIONING SHEET THIS EQUIPMENT HAS BEEN FACTORY FIRED AND TESTED PRIOR TO

SHIPMENT. HOWEVER, THIS APPLIANCE IS NOT “PLUG & PLAY”. IT REQUIRES COMMISSIONING AND FIELD ADJUSTMENT / SPECIFICATIONS CONFIRMATION TO ENSURE SAFE AND EFFICIENT OPERATION.

COMMISSIONING REPORT

AS PER I&O MANUAL AND LOCAL C ODES

CONTRACTOR NAME: ................................................... .............................DATE................................

ADDRESS:............................................................................................................................................

......................................................................... ........................................................... ....... .................

CITY:.................................................................................. ......

PHONE:...................................... .............................................

CELL: ...................................................... ...............................

JOB SITE.............................................. ........................................................CITY................................

HEATER MODE L NUMBER:................................................................................

Located on burner rating plate

HEATER SERIAL NUMBER: ...............................................................................

Located on burner rating plate

TO ENSURE THAT SITE CONDITIONS ARE COMPATIBLE WITH THE HEATER’S PERFORMANCE AND TO ALLEVIATE NUISANCE CALL-BACKS, THE FOLLOWING STARTUP NEEDS TO BE COMPLETED BY THE QUALIFIED GAS INSTALLER.

A TECHNICIAN CALLING FOR TECHNICAL SUPPORT MUST PROVIDE THE

INFORMATION FROM THE COMPLETED COMMISSIONING REPORT ON

THE NEXT PA GE

FAX COMPLETED REPORT TO TECHNICAL SERVICES:

FAX 1-866-361-0523,

VOICE 1-877-446-3727

WARNING

During start up, material coatings used in the production process of tubes and reflectors will “burn off” and create smoke during the first hour of operation. This is temporary and normal.

Please ensure that there is sufficient ventilation to adequately clear the smoke from the space. Notify site and safety personnel to ensure that alarm systems are not unduly activated.

START UP ‘SMOKE’

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QUALIFIED INSTALLER TO COMPLETE THIS TUBE HEATER COMMISSIONING REPORT

TYPE OF GAS: NG LP

DOES BUILDING HAVE A NEGATIVE CONDITION: YES NO

IF THIS IS A HIGH ALTITU D E AR EA WHAT IS THE ALTITUDE ABO VE SEA LEVEL

Feet

DOES APPLICATION REQUIRE FRESH AIR TO BURNER YES NO

IS HEATER EXPOSED TO CHEMICAL OR CO R R OSIVE ATMOSPHERE: YES NO

ARE ACTUAL MINIMUM CLEAR AN C ES AS PER TABLE 3 YES NO

CAN HEATER BE AFFECTED BY OVERHEAD CRANES / VIBRATIO N YES NO

ARE GAS SUPPLY LINES ADEQUATELY SIZED FOR SYSTEM YES NO

GAS LINES AND BRANCHES HAVE BEEN PU R GED OF AIR: YES NO

THIS HEATER FIRED WITHOUT ANY MALFUNCTION: YES NO

INLET GAS SUPPLY PRESSURE WITH HEATER OPERATING : W C "

GAS VALVE OUTLET (M anifold) PRESSURE WITH H EATER OPERATING: WC"

W H AT IS THE LINE VOLTAGE R EAD ING AT THE HEATER VOLTS

WHAT IS T HE VOLTA GE READING AT TH E IGNITION MODULE VOLTS

W H AT IS THE FLAME SIGNAL STR EN GTH IN uA FROM SENSOR: uA (microamps)

IS HEATER CONT R OLLED BY A THERMOSTAT YES NO

IS THE THERMO STAT STRATEGICALY LOCATED YES NO

WHAT IS T OTAL LEN GTH OF INSTALLED THERMOSTAT WIR E FEET

W H AT IS THE GAUGE OF THE THERMOSTAT WIRE GAUGE

W H AT IS THE HEATER T U BE LEN GTH (10ft per Tube section) FEET

W H AT IS THE TOT AL LEN GTH OF TH E VEN T (add 10ft for each bend) FEET

W H AT LENGTH IS COMBU STION AIR INTAKE (add 10ft for each bend) FEET

IF REQUIRED....WHAT IS THE LENG TH OF THE TUR B ULATOR(S) FEET

IF INSTAL L E D....IS TURBULATOR A T FLUE EN D OF SYSTEM YES NO

“MAXIMUM STACKING HEIGHT” SIGN(S) - POSTED AT THERMOSTAT(S)

THIS HEATER MUST BE ELECTRICALLY GOUNDED

FAX COMPLETED REPORT TO TECHNICAL SERVICES: FAX

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1-866-361-0523, VOICE 1-877-446-3727

26. DIMENSIONS AND WEIGHT

Assembled System:

 Weight: 86 pounds (39 kg)  Dimensions: 119.5” L x 20” W x 12” H (3035 mm x 508 mm x 305 mm)

Burner:

 Weight: 26 pounds (11.8 kg)  Dimensions: P40U: 16” L x 10.25” W x 10.75” H (406 mm x 260 mm x 273 mm)

P40U-P,-W: 20” L x 10.25” W x 10.25” H (406 mm x 260 mm x 260 mm)

Tube Reflector System:

 Weight: 70 pounds (27 kg)  Dimensions: 103.5” L x 16.5” W x 7.5” H (2629 mm x 420 mm x 190 mm)

Turbulators (factory installed):

Burner side tube: 36” (914 mm)

Vent side tube: 90” (2286 mm)

FLEXIBLE GAS CONNECTOR (Included in Burner Kit) - MUST INSTALL - see Section 13 USA - Stainless Steel Flexible Gas Connector

130,000 or less: JL-0771-XX - 1/2”x24”

155,000 or more: JL-0771-YY - 3/4”x36”

CANADA - Type 1 Hose Gas Connector 130,000 or less:

JL-0771-RC - 1/2”x36” 155,000 or more:

JL-0771-RB - 3/4”x36”

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27. HIGH ALTITUDE INSTALLATION

When this appliance is installed above the altitude stipulated below, the input must be de-rated by 4% for each 1000 ft . If your local utility supplies gas with a de-rated heat content, no

orifice change is required in the heater . Check with your local utility regarding de-rating.

USA: The factory installed orifice for this appliance is approved for altitudes zero to

2000 feet above sea level. Above 2000 feet, refer to table below. Canada: The factory installed orifice for this appliance is approved for altitudes zero to

4500 feet above sea level. When installed above 4500 feet, refer to the table below

ORIFICE CHART - ALTITUDE CONVERSION

FOR USE AT ALTITUDES ABOVE (FEET)

Gas Orifice Drill Size / Part #

MODEL NO

Supplied

USA Only USA & CANADA*

0 2000 3000 4000 5000 6000 7000 8000

P40U / P40U-I NG

P40U / P40U-I LPG*

31 DMS

JS-0731-DM

49 DMS

JS-0749-DM

3 mm

JS-0730-MM

50 DMS

JS-0750-DM

32DMS

JS-0732-DM

50 DMS

JS-0750-DM

32DMS

JS-0732-DM

50 DMS

JS-0750-DM

33DMS

JS-0733-DM

51 DMS

JS-0751-DM

* Field Conversion Kit required to convert between fuel gas types:

 Part number: JS-0555-XB P40U - Natural Gas to Propane Gas Conversion Kit  Part number: JS-0555-XA P40U - Propane Gas to Natural Gas Conversion Kit

34DMS

JS-0734-DM

51 DMS

JS-0751-DM

7/64

JS-0731-IN

51 DMS

JS-0751-DM

36DMS

JS-0736-DM

52 DMS

JS-0752-DM

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28. OPTIONAL ACCESSORIES

Flue Vent Terminal

4” wall horizontal 6” wall horizontal

JA-0528-XX JA-0529-XX

Air Intake Terminal

4” Wall Intake Terminal (bird screened)

4” roof vertical 6” roof vertical

JA-0532-VC

JA-0530-XX JA-0531-XX

Torctite Coupler (c/w 2 bolts)

Vent Tee 4” X 4” X 6”

(2 couplers optional)

JA-0516-SW

JA- 0514-XX

Clearance Sign - Metal 18” x 6”

- Required in some jurisdictions:

 Vehicle service garages  3/4” high red lettering on white

background

JL-0798-CS

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#2 Lion Chain (115 lb work load)

- 200 ft roll

Safety Snap Hooks - 2” - pkg of 25

- pkg of 100

TruTemp Thermostat True comfort control for radiant heating systems senses and averages ambient and radiant temperatures. Occupancy sensor with auto set-back of 9°F (5°C).

Do not use in wet or corrosive environments

Line Voltage Thermostat:

Dual Scale: °F or °C

Not for use in corrosive or wet environments

JL-0800-XX

JL-0800-SH

JL-0800-SH-B

JM-0150-XX

JL-0772-XX

Low Voltage Digital Thermostat

(24 Volts - °F or °C selectable)

Not for use in corrosive or wet environments

For P40U-P, -W, -IP, -IW: Wet Environments Moisture Proof Thermostat - NEMA 4X

SPDT Line Voltage 40° - 110°F (5° - 40°C) Both °F & °C Scales Voltage: 24 - 277 Vac Differential: 3°F Stainless Steel Bulb UL Listed

24 Volt Option: Control Center

Use when Multiple Tube Heaters are controlled by a single 24V Thermostat or TruTemp (for field mounting)

JS-0569-WR

JS-0570-XX

JM-0303 –KT

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JS-0502-UR-GK PROTECTIVE GUARD SCREEN OPTION – Zinc Plated; Two Piece Kit

– Recommended for heater mounte d with less than 8 feet [2.4 m] between f l oo r an d bottom of

heater or patio heating applications



Two sections make up the protective guard assembly that installs on the underside of the P40-U heater. Near the bottom edge at each side of the reflector are two sets of three holes. Each set of holes has one round hole at the center of the reflector, the other two holes are elongated and positioned between the center and the ends of the reflector. The pins that extend from each side of the two guard sections are inserted into these sets of holes.

Fig. 1

Step 1: On ONE SIDE of the reflector, remove the bottom screws (Qty 3) that fasten the reflector to the

end and center hanger brackets, Fig. 1. Retain screws for re-attachment of reflector .

Step 2: On the side of the reflector that remains securely fastened to the hangers, insert a pin located

at the end of the Protective Guard into one of the 1/8” round holes located at the center of the reflector, Fig. 2

Fig. 3

Fig. 2

Fig. 4

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Fig.5 Fig. 6

STEP 4: On the second side of the reflector, first Insert a guard pin into the center hole, Fig 5.

Insert remaining guard pins in the reflector holes, Fig 6.

Step 5:

Repeat the process with the second guard section.

Holdguardscreen firmlytobendpins

Fig. 7 Fig. 8

Step 6: Re-install the screws at the bottom edge of the reflector into the three hangers, Fig. 7.

Fig. 9 Fig. 10 (Center) Fig. 11 (End)

Notes:

1) To bend the pins, use needle nose pliers to hold the guard screen securely, Fig.8 and another set of pliers to bend the pin sideways, Fig.9.

2) DO NOT bend the pins downwards, it can damage the edge of the reflector.

STEP 7: To secure the guard in place bend the end pins of each guard section sideways and

towards each other, Fig. 10 & 11. The center pin does not require bending.



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29. REPLACEMENT PARTS LIST

P40U BURNER

# PART DESCRIPTION

BURNER HOUSING: Schwank P40U

BURNER CUP

BURNER CUP AIR RESTRICTOR RING

MAIN BURNER ORIFICE NG

BURNER CHAMBER

BURNER AIR RESTRICTOR

EQUALIZER PLATE

BLOWER GASKET

AIR INTAKE ADAPTER / RESTRICTOR

BLOWER

MANIFOLD BUSHING

90 DEGREE ELBOW FITTING 1/2"

GAS VALVE: Natural Gas

4" NIPPLE

TERMINAL BLOCK

STEP DOWN TRANSFORMER

24V/120V RELAY SWITCH

COMPONENT PLATE

COMBUSTION AIR PROVING

SWITCH BLOCKED FLUE PROVING SWITCH

PRESSURE SWITCH TUBING

P40-R & InfraSave P40U-I

Propane

PART #

PART DESCRIPTION PRIMARY SUPPLEMENT

JS-0582-XX Burner housing coated orange JJ-0582-XX Burner housing coated grey JS-0512-UL Burner Cup - Cast Aluminum JS-0596-RA-R Burner Cup Air Restrictor Ring - 2 Holes

JS-0731-DM Gas orifice low intensity HR 31 DMS JS-0749-DM Gas orifice low intensity HR 49 DMS JS-0504-XX Burner Chamber JS-0592-RF Burner air restrictor 40,000

JS-0593-EP-R Outlet equalizer plate 40,000 - 13 Holes JS-0578-XX Blower gasket - Outlet JS-0595-UT Air Intake Adapter/Restrictor - 1-1/4" Hole JS-0579-AA Blower Assembly Tube Burner JM-0589-XX Manifold bushing JS-0588-XX Street elbow fitting 90 deg JL-0701-AA Gas Valve comb 3.5" WC 24VAC VR8 NG JL-0703-AA Gas Valve comb 10" WC 24VAC VR8 LP JS-0590-XX Nipple 4" JM-0455-DD Terminal block - Electrical Connections JA-0775-XX Transformer 120/24V, 20VA AT120B1028 JS-0568-CC 24V/120V Relay Switch JS-0581-SE Component mounting plate SE

JS-0576-UG Air Proving Switch 1.00" WC JS-0577-RR Blocked Flue Switch 0.46" WC

JS-0572-SE Tubing set 2 x 20" PVC SE

P40U-F / P40U-IF I&O Manual

P40U P40U-I; P40-R 40 NG & LP 40 NG & LP

40,000 NG 40,000 LP All 40 NG & LP

40 NG & LP Each P40U NG & LP

40,000 NG 40,000 LP

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Burners with FENWAL IGNITION CONTROL - Models: P40U-F; P40U-I-F

FENWAL DSI CONTROL REPLACEMENT KIT: FENWAL & S87J

IGNITION CABLE

Burners with HONEYWELL S87-J IGNITION CONTROL - Models: P40U; P40U-I

HONEYWELL IGNITION CONTROL

REPLACEMENT KIT: FENWAL CONTROL

IGNITION CABLE HONEYWELL S87J

JA-0567-XX 3-Trial 24Vac with blower relay “-F” Models JA-0568-KT

JS-0518-SA

JA-0568-XX

JA-0568-KT

JS-0518-XX

Fenwal Control + Wire Harness + Cable + Igniter: Replaces Fenwal & S87J

Hi voltage wire (24") STW - 2 x 1/4" Spades

DISCONTINUED - NO LONGER AVAILABLE Fenwal Control + Wire Harness + Cable + Igniter Wire hi voltage (24") S87J Bullet Connection

# PART DESCRIPTION

INDICATOR LAMPS

ELECTRICAL CORD

SIGHT GLASS ASSEMBLY

IGNITER KIT

FLANGE GASKET

FLAME RECTIFIER

PARTS UNIQUE TO:

 P40U-P  P40U-W  P40U-IP  P40U-IW

PART #

PART DESCRIPTION PRIMARY SUPPLEMENT

JW-0519-AM Indicator light amber JW-0519-GR Indicator light green JW-0519-RE Indicator light red JB-0567-XX Cord - electrical 6' JS-0536-XX Sight glass assembly - tube heater JA-0571-KT Spark Igniter & Gasket Kit JS-0591-XX Flange Adapter Gasket JS-0592-RR Flame Rectifier

W27

# PART DESCRIPTION PART # PART DESCRIPTION PRIMARY APPLICABLE

BURNER HOUSING

BURNER HOUSING GASKET SET

AIR INTAKE GASKET

COMBUSTION AIR INLET

SEALTIGHT CONNECTOR

BURNER STABILIZING BRACKET

WATERPROOF GROMMET

W18

COMPONENT PLATE

W22

IGNITION CONTROL

W23

IGNITION CONTROL WIRING HARNESS

W27

IGNITION CABLE - MICRO 50N

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JS-0582-WP-P Powder Coated Burner Housing Wet Environment JS-0582-WP Stainless Steel Burner Housing Harsh Environment JS-0591-WP Housing gasket set JS-0601-WP Air intake gasket JS-0583-WP Powder Coated Combustion air inlet JS-0583-15 Stainless Steel Combustion air inlet JP-2036-XX Connector liquid tight JS-0583-05-P Burner suspension bracket JP-2101-XX Water proof butt connectors JS-0583-41 component mounting plate JB-0568-AA Control - DSI 3 Try potted Gasliter MICRO 50N JB-0568-WH 3 Try potted spark DSI control wiring harness

JS-0518-SA Hi voltage wire (24") STW - 2 x 1/4" Spades

Indoor/Outdoor Indoor/Outdoor

each

P40U TUBE / REFLECTOR SYSTEM - ALL MODELS

SIGHT GLASS ASSEMBLY

IGNITER KIT

TUBE FASTENING BRACKET

PREFORMED U-TUBE

P40U HANGER

P40U REFLECTOR

REFLECTOR END PLATE

P40U TURBULATOR 36"

P40U TURBULATOR 90"

OPTIONAL VENT CAP

JS-0536-XX Sight glass assembly - tube heater JA-0571-KT Spark Igniter & Gasket Kit JS-0502-UV Positions tube in hang er / reflector system JA-0501-UT Preformed U-Tube: 17 ft tube length JS-0506-UH P40U System Hanger JS-0502-UR Reflector for P40U-xx JS-0502-UT Reflector End Plate JS-0533-US 36" Turbulator In Burner Side Tube JS-0533-UT 90" Turbulator In Vent Side Tube JA-0528-XX Horizontal wall 4" vent terminal

Optional Item

P40U-F / P40U-IF I&O Manual

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RL: 4B

HONEYWELL S87-J WIRING DIAGRAM P40U, P40U-I : 24V OR 120 VOLT THERMOSTAT

SINGLE HEATER PER THERMOSTAT

Models P40U-P, -W …. Next Page Multiple Heaters/Thermostat … Page 27

Each tube heater requires 120V, 60 HZ electrical power sized for 145VA. The heater includes a 24V/120V relay switch . Maximum power draw for internal 24V burner components is 21VA.

The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1.

A maximum night set-back of 9°F (5°C) is recommended for optimum economy and comfort. To maintain satisfactory comfort levels do not turn off the heating system over night/weekends.

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HONEYWELL S87J: MODELS P40U, P40U-I SEQUENCE OF OPERATION

The S87 ignition control module is powered by a 24v transformer and activated when the thermostat calls for heat. On every call for heat the S87J will delay start-up to provide a 30 second system pre-purge. When the S87 is activated by a thermostat or call for heat an internal transformer provides power to the electronic generator circuit for Spark Ignition and the safety lockout timing begins. At the same time, the S87 opens the gas controls main valve allowing gas to flow to the main Burner.

The S87 Control Module performs the following basic functions:

· Provides a 30 second system pre-purge

· Supplies power to the electronic pulse-generator circuit for the Spark Igniter (30,000 volts open circuit).

· Allows 21 seconds for Ignition trial (TFI) before system safety lockout occurs.

· Senses the Burner flame for safe lighting

· Shuts off the spark after the Burner is lit.

Burner with direct spark ignition, sequence is as follows :

1a. Line Voltage Thermostat: Upon a call for heat by the line voltage Thermostat or “ON/

OFF” switch, the Blower and the 120/24 volt Transformer are powered simultaneously with 115 volts.

1b. 24 Volt Thermostat: The 120 volt supply to heat er will power the 120v/24v Transformer

and the 120V side of the Blower switching relay simultaneously. A call for heat by the 24 volt Thermostat energizes the 24 volt control circuit and the 24v/120 volt relay powering the Blower.

2. The 24 volt control circuit power s the DSI control in series through the normally open Air Pressure Switch (APS) and the normally closed Blocked Flue Switch (BFS).

3. The Blower creates a positive pressure and closes a normally open contact inside the Air Proving Switch (APS).

4. 24 volts supplied to the DSI control initiates the 30 second pre-purge cycle.

5. After completing the 30 second pre-purge cycle the DSI control generates high voltage to the Spark Igniter, and 24 volts to energize the Gas Valve.

6. The Burner will light and establish a steady flame.

7. Once the flame sensor determines there is a steady flame established, with a minimum flame signal of 1.5 µA the spark igniter is then de-energized.

8. In the event ignition does not occur, the safety circuit will function to interrupt gas flow after approximately 21 seconds and lock the system out. No further gas will flow until the power has been manually interrupted for a period of 30 seconds. This will reset the ignition module and the operating sequence will restart at step #1

9. If the blower does not run, the blower air pressure switch (normally open con tact) does not close and power is not supplied to the ignition control.

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HONEYWELL S87 DSI: MODELS P40U (-I) - FLAME SENSING CIRCUIT

The output of the flame sensing circuit cannot be checked directly on the S87 body. Check the flame sensing circuit directly by checking the flame sensing current from the sensor to the S87 as follows.

1. Connect a meter (dc microammeter scale) in series with the flame signal ground wire as shown below. Using the Honeywell W136A Test Meter or equivalent. Disconnect the ground wire from the S87. Connect the red (positive) meter lead to the free end of the ground wire. Connect the black (negative) meter lead to the quickconnect ground terminal on the S87.

2. Restart the system and read the met er. The flame sensor current must be at least 1.5 uA and steady. If the reading is less than 1.5µA

or unsteady, see LOW OR UNSTEADY

FLAME CURRENT section, below. If a flame is present at sensor and a reading of zero uA is obtained, check for a

secondary ground connection to the 24V (GND) terminal. If secondary connection exists, temporarily remove connection and measure flame current.

1.5 µA DC minimum

and steady

1”

1/4” to 1/2”

A good rectifying flame is achieved with approx 1” of sensor in a strong blue flame, positioned 1/4” to 1/2” away from flame source surface.

LOW/ UNSTEADY FLAME CURRENT

If the current to the S87 flame circuit is less than 1.5 µA or is unsteady, check the burner flame, flame sensor location and electrical connections as follows.

Electrical Connections and Shorts

Connections at the flame sensor must be clean and secure. If wiring needs replacement, use moisture resistant #18 wire rated for continuous duty up to 2210 F [1050 C].

Flame Sensor

The flame signal is best when about 1 in. [25 mm] of flame rod is immersed in the burner flame. A bent flame rod, bent mounting bracket or cracked ceramic insulator will affect flame signal. Replace flame sensor if necessary.

A lazy or weak flame is not a good rectifying flame. Check gas pressure and gas orifice for insects, and spider webs.

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Burner Flame

The flame sensor must be constantly immersed in flame. Check burner flame condition as shown opposite. Observe burner rating plate for the correct gas pressure, and check with a manometer. If gas pressure is correct check line and orifice for obstructions.

LIMITED WARRANTY CERTIFICATE

FOR GAS-FIRED INFRA-RED LOW INTENSITY TUBE HEATERS: P40U (-P, -W)& P40U-I (-IP, -IW) SERIES

The Manufacturer warrants that this product is free from defects in material or workmanship under normal use and service subject to the terms of this document.

THREE YEAR WARRANTY

Subject to the conditions and limitations stated herein, during the term of this limited warranty, we will supply any component part (at our option a new or repaired component part) of the heater as defined below, excluding any labor , which the Manufacturer’s examination determines to be defective in workmanship or material for a period of three years (3 years) from the date of installation, unless otherwise specified below. This warranty applies to the heater’s original owner, and subsequent transferees and only if the unit is installed and operated in accordance with the printed instructions accompanying the unit and in compliance with all applicable installation codes and good trade practices. Warranty is only applicable to Schwank components, other parts are limited to their own Manufacturers warranty period of one year (1 year).

TEN YEAR WARRANTY

The Manufacturer warrants the burner sub-assembly comprising of ceramic and immediate metal tubing, and the radiating tubes (excluding couplings) for a period of ten years (10 years).

WHAT IS NOT COVERED

The Manufacturer shall not be responsible for any expenses, including service, labor, diagnosis, analysis, material or transportation charges incurred during removal or reinstallation of this product, or any of its components or parts. All labor or service charges shall be paid by the owner. This warranty does not cover heating products improperly installed, misused, exposed to or damaged by negligence, accident, corrosive or contaminating atmosphere, water, excessive thermal shock, impact, abrasion, normal wear due to use, alteration or operation contrary to the owner’s manual or if the serial number has been altered, defaced or removed. This warranty shall not apply if the input to the heating product exceeds by more than 2% of the rated input on the rating plate. The Manufacturer shall not be liable for any default or delay in performance by its warranty caused by any contingency beyond its control, including war, government restrictions, or restraints, strikes, fire, flood, acts of God, or short or reduced supply of raw materials or products.

WARRANTY PROCEDURE

To establish the installation date for any purpose under this Limited Warranty, you must retain the original records that can establish the installation date of your unit. If you do not provide such documents, the start date of the term of this Limited Warranty will be based upon the date of unit manufacture, plus thirty (30) days. Failure to maintain the equipment through regular annual service maintenance by a qualified service technici an shall void the warranty.

LIMITATIONS AND EXCLUSIONS

This document contains all warranties made by the Manufacturer and may not be varied, altered or extended by any person. There are no promises, or agreements extending from the Manufacture other than the statements contained herein. THIS WARRANTY IS IN LIEU OF ALL WARRANTIES EXPRESSED OR IMPLIED, TO THE EXTENT AUTHORIZED BY THE LAWS OF THE JURISDICTION, INCLUDING SPECIFICALLY THE WARRANTIES OR MERCHANTIBILITY OF FITNESS FOR A PARTICULAR PURPOSE. It is understood and agreed that the Manufacturer’s obligation hereunder is limited to repairing or replacing parts determined to be defective as stated above. In no event shall the Manufacturer be responsible for any alleged personal injuries or other special, incidental or consequential damages. As to property damages, contract, tort or other claim the Manufacturer’s responsibility shall not exceed the purchase priced paid for the product. All replacement parts will be warranted for the unused portion of the warranty coverage period remaining on the applicable unit.

Some Authorities do not allow certain warranty exclusions or limitations on duration of warranty or the exclusions or limitations of incidental or consequential damages. In such cases, the above limitations or exclusions may not apply to you and are not intended to do so where prohibited by law. This warranty gives you specific legal rights. You may also have other rights which vary by jurisdiction.

SCHWANK GROUP 2 SCHWANK WAY, WAYNESBORO, GEORGIA. 30830 5285 BRADCO BLVD. MISSISSAUGA, ON, L4W 2A6

Ph: 1-877-446-3727 Fax: 1-866-361-0523 www.SchwankGroup.com www.InfraSav e.com

P40U-F / P40U-IF I&O Manual

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Schwank P40U, P40U-F, P40U-P, P40U-W, P40U-I Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual