Sterling TC User Manual

INSTALLATION INSTRUCTIONS AND PARTS IDENTIFICATION

TUBULAR GAS-FIRED BLOWER STYLE UNIT HEATER

ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT THE POINT OF INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No.(s) IN THE SPACE PROVIDED. RETAIN FOR FUTURE REFERENCE.

TBII-3

J30-08867

Unit No.

Serial No.

FOR YOUR SAFETY

The use and storage of gasoline or other ﬂ ammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. Don't touch electrical switches.

3. Extinguish any open ﬂ ame.

4. Immediately contact your gas supplier.

ENERGY

PERFORMANCE

VERIFIED

RENDEMENT

ENERGETIQUE

VERIFIE

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Read the installation, operating, and maintenance instruction thoroughly before installing or servicing this equipment.

APPROVED FOR USE IN CALIFORNIA

Install, operate, and maintain unit in accordance with the manufacturer's instructions to avoid exposure to fuel substances, or substances from incomplete combustion, which can cause death or serious illness. The state of California has determined that these substances may cause cancer, birth defects, or other reproductive harm.

08/13

INSTALLER'S RESPONSIBILITY

Installer Please Note: This equipment has been test fired and inspected. It has been

shipped free from defects from our factory. However, shipment and installation problems such as loose wires, leaks, or loose fasteners may occur. It is the installer's

responsibility to inspect and correct any problem that may be found.

RECEIVING INSTRUCTIONS

Inspect shipment immediately when received to determine if any damage has occurred to the unit during shipment. After the unit has been uncrated, check for any visible damage to the unit. If any damage is found, the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with the transportation company.

260 NORTH ELM ST., WESTFIELD, MA 01085

TEL: (413) 568-9571 FAX: (413) 562-8437

www.mestek.com

TABLE OF CONTENTS

DESCRIPTION………………. ....................................... 2

GENERAL SAFETY INFORMATION Installation Codes………………………………… 2, 3 Special Precautions………………………………. 2, 3

PERFORMANCE AND DIMENSIONAL DATA .............. 4

INSTALLATION Locating Units………………………………………… 5 Combustion Air……………………………………… . 5 Heat Throw Data……………………………………. . 6

Clearances…………………………………….. ......... 7

Suspension of Units………………………………. ....7

Gas Piping……………………………………… ........ 8

Pipe Installation……………………………………. ... 9

BLOWER SET UP AND ADJUSTMENT……………...10

NOTICE: It is the equipment owners responsibility to provide any scaffolding or other apparatus required to perform emergency service or annual/periodic maintenance to this equipment.

MOTOR AND PULLEY .............................................. 11

ELECTRICAL CONNECTIONS…………………. ...12-16

VENTING ..............................................................17-21

OPERATION Explanation of Controls…………………………… . 22

Start-Up, Shut Down………………......…………....22

Main Burner Oriﬁ ce Schedule…………….……….23 Gas Input Rate and Adjustments…………….. 23, 24

TROUBLESHOOTING GUIDE ..............................25-28

LED Indicator Troubleshooting .............................. 29

MAINTENANCE… ...................................................... 30

WARRANTY…............................................................31

IDENTIFICATION OF PARTS ................................32-33

UNIT NUMBER DESCRIPTION ................................. 35

START-UP INSPECTION SHEET ............................... 36

DESCRIPTION

The Power Vented Gas Fired Blower Unit Heaters are factory assembled, high static pressure type, centrifugal blower units designed for heavy duty applications such as continuous operation or where a single unit heater must do the entire heating job in a large area.These blower type unit heaters may be used with the standard adjustable louvers, with short duct runs or discharge

nozzles for spot heating. These blower type unit heaters may be used where low sound levels are required. The designs are certified by ETL as providing a minimum of 83% thermal efficiency, and approved for use in California. Do not alter these units in any way. If you have any questions after reading this manual, contact the manufacturer.

Figure 1 - Tubular Blower Unit Heater

See Identiﬁ cation of Parts, Figures 12 through 18.

The following terms are used throughout this manual, in addition to the ETL requirements to bring attention to the presence of potential hazards, or to important information concerning the product:

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury, or substantial property damage.

Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury, or substantial property damage.

situation which, if not avoided, may result in minor injury or property damage.

NOTICE: Used to notify of special instructions on installation, operation, or maintenance which are important to equipment but not related to personal injury.

Indicates an imminently hazardous

GENERAL SAFETY INFORMATION

Failure to comply with the general safety information may result in extensive property damage, severe personal injury, or

death.

This product must be installed by a licensed plumber or gas ﬁ tter when installed within the Commonwealth of Massachusetts.

Installation must be made in accordance with local codes, or in absence of local codes, with the latest edition of the ANSI Standard Z223.1 (N.F.P.A. No. 54) National Fuel Gas Code. All of the ANSI and NFPA

Standards referred to in these installation instructions are those that were applicable at the time the design of this appliance was certified. The ANSI Standards are available from CSA Information Services, 1-800463-6727. The NFPA Standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. These unit heaters are designed for use in airplane hangars when installed in accordance with ANSI/NFPA No. 409, and in public garages when installed in accordance with NFPA No. 88A and NFPA No.88B.

If installed in Canada, the installation must conform with local building codes, or in the absence of local building codes, with CSA-B149.1 “Installation Codes for Natural Gas Burning Appliances and Equipment” or CSA-B149.2 “Installation Codes for Propane Gas Burning Appliances and Equipment.” These unit heaters have been designed and certiﬁ ed to comply with CSA 2.6. Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES.

Do not alter the unit heater in any way or damage to the unit and/or severe personal injury or death may occur!

Disconnect all power and gas supplies before installing or servicing the heater. If the power disconnect is out of sight, lock it in the open position and tag it to prevent unexpected application of power. Failure to do so could result in fatal electric shock, or severe

personal injury.

Do not attempt to convert the heater for use with a fuel other than the one intended. Such conversion is dangerous, as it will create the risks previously listed.

Make certain that the power source conforms to the electrical requirements of the heater.

Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing heater. Always disconnect power at main circuit breaker as described above. Failure to do so could result in fatal electric shock.

Special attention must be given to any grounding information pertaining to this heater. To prevent the risk of electrocution, the heater must be securely and adequately grounded. This should be accomplished by connecting a ground conductor between the service panel and the heater. To ensure a proper ground, the grounding means must be tested by a qualiﬁ ed electrician.

Do not insert ﬁ ngers or foreign objects into heater or its air moving device. Do not block or tamper with the heater in any manner while in operation, or just after it has been turned off, as some parts may be hot enough to cause injury.

This heater is intended for general heating applications ONLY. It must NOT be used in potentially dangerous locations such as ﬂ ammable, explosive, chemical-laden, or wet atmospheres.

In cases in which property damage may result from malfunction of the heater, a back-up system or temperature sensitive alarm should be used.

The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into confined spaces UNLESS precautions are taken as follows: (1) by ventilation of the space, (2) control of the purging rate, (3) elimination of all hazardous conditions. All precautions must be taken to perform this operation

in a safe manner!

Ensure that all power sources conform to the requirements of the unit heater, or damage to the unit will result!

Follow installation instructions CAREFULLY to avoid creating unsafe conditions. All wiring should be done and checked by a qualiﬁ ed electrician, using copper wire only. All gas connections should be made and leak-tested by a suitably qualiﬁ ed individual, per instructions in this manual. Also follow procedures listed on “Gas Equipment Start-Up Sheet” located in this manual.

Use only the fuel for which the heater is designed (see rating plate). Using LP gas in a heater that requires natural gas, or vice versa, will create risk of gas leaks, carbon monoxide poisoning, and explosion.

Unless otherwise speciﬁ ed, the following conversions may be used for calculating SI unit measurements: 1 foot = 0.305 m 1 inch = 25.4 mm 1 gallon = 3.785 L 1 pound = 0.453 kg 1 psig = 6.894 kPa 1 cubic foot = 0.028m

1000 BTU/cu. ft. = 37.5 MJ/m 1000 BTU per hour = 0.293 kW 1 inch water column = 0.249 kPa 1 litre/second = CFM x 0.472 1 meter/second = FPM ÷ 196.8

Table 1 - Performance and Dimensional Data - Tubular Blower Unit Heater

Unit Size 100 125 150 175 200 250 300 350 400 PERFORMANCE DATA†

Input - BTU/Hr. 100,000 125,000 150,000 175,000 200,000 250,000 300,000 350,000 400,000 (kW) (29.3) (36.6) (44.0) (51.3) (58.6) (73.3) (87.9) (102.6) (117.2) Output - BTU/Hr. 83,000 103,750 124,500 145,250 166,000 207,500 246,000 290,500 332,000 (kW) (24.3) (30.4) (36.5) (42.6) (48.6) (60.8) (72.1) (85.1) (97.3) Thermal Efﬁ ciency - % 83 83 83 83 83 83 82 83 83 Free Air Delivery - CFM 1,181 1,476 1,771 2,067 2,362 2,953 3,501 4,134 4,724 (cu. m/s) (0.557) (0.697) (0.836) (0.976) (1.115) (1.394) (1.652) (1.951) (2.230) Air Temperature Rise - Deg. F 65 65 65 65 65 65 65 65 65 (Deg. C) (36) (36) (36) (36) (36) (36) (36) (36) (36) Outlet Velocity - FPM 370 463 555 395.0 451.0 564.0 422 498 570 (m/s) (1.879) (2.351) (2.819) (2.006) (2.291) (2.864) (2.143) (2.529) (2.895) Full Load Amps at 115V 7.3 9.4 9.4 14.2 14.2 15.6 15.6 20.8 20.8 Maximum Circuit Ampacity 8.6 11.2 11.2 17.1 17.1 18.9 18.9 25.4 25.4 MOTOR DATA: Motor HP 1/4 1/2 1/2 3/4 3/4 1 1 1-1/2 1-1/2 Motor kW 0.19 0.37 0.37 0.56 0.56 0.75 0.75 1.11 1.11 Motor Type ODP** SPH SPH SPH SPH SPH Cap. Start Cap. Start Cap. Start Cap. Start RPM 1,725 1,725 1,725 1,725 1,725 1,725 1,725 1,725 1,725 Amps @ 115V 5.1 7.2 7.2 11.6 11.6 13.0 13.0 18.2 18.2 DIMENSIONAL DATA - inches (mm) "A" Height to Top of Flue 33-3/4 33-3/4 33-3/4 33-3/4 33-3/4 33-3/4 34 34 34 (857) (857) (857) (857) (857) (857) (864) (864) (864) "B" Jacket Width of Unit 20-3/4 20-3/4 20-3/4 32-3/4 32-3/4 32-3/4 50-3/4 50-3/4 50-3/4 (527) (527) (527) (832) (832) (832) (1289) (1289) (1289) "C" Width to Centerline Flue 13-3/8 13-3/8 13-3/8 19-3/8 19-3/8 19-3/8 28-3/8 28-3/8 28-3/8 (340) (340) (340) (492) (492) (492) (721) (721) (721) "D" Depth to Front Hanger 21 21 21 21 21 21 21 21 21 (533) (533) (533) (533) (533) (533) (533) (533) (533) "E" Hanging Distance Width 18-5/8 18-5/8 18-5/8 30-5/8 30-5/8 30-5/8 48-5/8 48-5/8 48-5/8 (473) (473) (473) (778) (778) (778) (1235) (1235) (1235) "F" Hanging Distance Depth 19 19-1/2 19-1/2 32-3/4 32-3/4 32-3/4 23-1/2 32-3/4 32-3/4 (483) (495) (495) (832) (832) (832) (597) (832) (832) "G" Discharge Opening Width 18-3/4 18-3/4 18-3/4 30-3/4 30-3/4 30-3/4 48-3/4 48-3/4 48-3/4 (476) (476) (476) (781) (781) (781) (1238) (1238) (1238) "H" Depth to Centerline Flue 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4 4-3/4 5-1/8 5-1/8 5-1/8 (121) (121) (121) (121) (121) (121) (130) (130) (130) "L" Discharge Opening Height 24-1/2 24-1/2 24-1/2 24-1/2 24-1/2 24-1/2 24-1/2 24-1/2 24-1/2 (622) (622) (622) (622) (622) (622) (622) (622) (622) "M" Overall Unit Width 25-1/4 25-1/4 25-1/4 37-1/4 37-1/4 37-1/4 55-1/4 55-1/4 55-1/4 (641) (641) (641) (946) (946) (946) (1403) (1403) (1403) "P" Overall Unit Depth 49-3/4 49-3/8 49-3/8 56-1/8 56-1/8 56-1/8 53-3/8 56-1/8 56-1/8 (1264) (1254) (1254) (1426) (1426) (1426) (1356) (1426) (1426) *Flue Size Diameter - in 5 5 5 5 5 5 6 6 6 (mm) (127) (127) (127) (127) (127) (127) (152) (152) (152) Blower Size - inches (Qty) 9 10 10 12 12 12 10 (2) 12 (2) 12 (2) Gas Inlet, Natural Gas - in 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 Gas Inlet, LP Gas - in 1/2 1/2 1/2 1/2 1/2 1/2 OR 3/4 1/2 OR 3/4 1/2 OR 3/4 1/2 OR 3/4 Approximate Unit Weight - lb 171 175 202 245 264 289 370 390 429 (kg) (78) (79) (92) (111) (120) (131) (168) (177) (195) Approximate Ship Weight - lb 256 261 289 381 400 425 520 547 595 (kg) (116) (118) (131) (173) (181) (193) (236) (248) (270)

† Ratings shown are for unit installations at elevations between 0 and 2,000 ft (0 to 610m). For unit installations in U.S.A. above 2,000 ft. (610m), the unit input must be ﬁ eld derated 4%

for

each 1,000 ft. (305m) above sea level; refer to local codes, or in absence of local codes, refer to the latest edition of the National Fuel Gas Code, ANSI Standard Z223.1 (N.F.P.A. No. 54).

For installations in Canada, any reference to deration at altitudes in excess of 2,000 ft. (610m) are to be ignored. At altitudes of 2,000 ft. to 4,500 ft. (610 to 1372m), the unit must be

ﬁ eld derated to 90% of the normal altitude rating, and be so marked in accordance with the ETL certiﬁ cation. See Table 8A for ﬁ eld deration information.

* Flue collar is factory supplied with unit; to be ﬁ eld installed per included instructions. ** LEGEND: SPH = SPLIT PHASE CAP. START = CAPACITOR START ODP = OPEN DRIP PROOF

INSTALLATION

Figure 2 - Dimensional Drawing – Tubular Blower Unit Heater

1 1/8

D8931B

Electrical Control Panel

Rear View

Flue

Gas Valve

Do not install unit heaters in corrosive or ﬂ ammable atmospheres! Premature failure of, or severe damage to the unit will result!

Avoid locations where extreme drafts can affect burner operation. Unit heaters must not be installed in locations where air for combustion would contain chlorinated, halogenated or acidic vapors. If located in such an environment, premature failure of the unit will occur!

Since the unit is equipped with an automatic gas ignition system, the unit heater must be installed such that the gas ignition control system is not directly exposed to water spray, rain or dripping water.

NOTICE: Location of unit heaters is related directly to the selection of sizes. Basic rules are as follows:

MOUNTING HEIGHT: Unit Heaters equipped with

standard fan guards must be installed at a minimum of 8' (2.4m) above the ﬂ oor, measured to the bottom of the unit. For mounting heights above 8', see Table 2 to compare unit height to heat throw distance.

AIRCRAFT HANGARS: Unit Heaters must be installed in aircraft hangars as follows: In aircraft hangars, unit heaters must be at least 10' (3.0m) above the upper surface of wings or engine enclosures of the highest aircraft to be stored in the hangar, and 8' (2.4m) above the floor in shops, offices and other sections of the hangar where aircraft are not stored or housed. Refer to current ANSI/NFPA No. 409, Aircraft Hangars. In Canada, installation is suitable in aircraft hangars when acceptable to the enforcing authorities.

32 1/2

Side View

(Discharge

Opening)

Front View

(Discharge

Opening)

D8931B

PUBLIC GARAGES: In repair garages, unit heaters must be located at least 8' (2.4m) above the ﬂ oor. Refer to the latest edition of NFPA 88B, Repair Garages.

In Canada, installation must be in accordance to the latest edition of CSA B149 “Installation Codes for Gas Burning Appliances and Equipment.”

AIR DISTRIBUTION: Direct air towards areas of maximum heat loss. When multiple heaters are involved, circulation of air around the perimeter is recommended where heated air ﬂ ows along exposed walls. Satisfactory results can also be obtained where multiple heaters are located toward the center of the area with heated air directed toward the outside walls. Be careful to avoid all obstacles and obstructions which could impede the warm air distribution patterns. Heat throw distances are presented in Table 2.

Unit heaters should not be installed to maintain low temperatures and/or freeze protection of buildings. A minimum of 50°F (10°C) thermostat setting must be maintained. If unit heaters are operated to maintain

lower than 50°F (10°C), hot flue gases are cooled inside the heat exchanger to a point where water vapor (a ﬂ ue gas by-product) condenses onto the heat exchanger walls. The result is a mildly corrosive acid that prematurely corrodes the aluminized heat exchanger and can actually drip water down from the unit heater onto ﬂ oor surface. Additional unit heaters should be installed if a minimum 50°F (10°C) thermostat setting cannot be maintained.

INSTALLATION (continued)

Table 2 - Heat Throw Data

Standard Heater 30° Nozzle 60° Nozzle 90° Nozzle

Degree

Nozzle

None 8 60 65 70 75 80 90 105 110 120

90°* 15 30 x 25 35 x 30 40 x 35 45 x 40 50 x 40 60 x 45 70 x 45 80 x 50 100 x 50

* It is not recommended to mount a unit with a 90 nozzle under 10 feet. Notes: 1. All throw data ﬁ gures are approximations. Allowances should be made for optimum performance, altitude, etc.

2. NR - Units not recommended at these mounting heights.

3. 30°, 60° and 90° nozzles are shipped unassembled.

Distance From

Floor to Bottom

of Unit "H" - ft

(m)

(2.4) (18.3) (19.8) (21.3) (22.9) (24.4) (27.4) (32.0) (33.5) (36.6)

10 54 56 60 64 68 78 90 95 100

(3.0) (16.5) (17.1) (18.3) (19.5) (20.7) (23.8) (27.4) (29.0) (30.5)

12 44 46 49 57 61 68 80 84 90

(3.7) (13.4) (14.0) (14.9) (17.4) (18.6) (20.7) (24.4) (25.6) (27.4)

(4.6) (13.7) (14.9) (15.8) (18.3) (21.3) (22.6) (24.4)

(6.1) (14.0) (16.5) (19.2) (20.1) (21.3)

30° 8 65 70 75 80 85 95 115 120 125

(2.4) (19.8) (21.3) (22.9) (24.4) (25.9) (29.0) (35.1) (36.6) (38.1)

10 57 60 64 68 72 86 99 105 110

(3.0) (17.4) (18.3) (19.5) (20.7) (21.9) (26.2) (30.2) (32.0) (33.5)

12 50 54 57 60 64 77 88 94 100

(3.7) (15.2) (16.5) (17.4) (18.3) (19.5) (23.5) (26.8) (28.7) (30.5)

(4.6) (13.7) (14.6) (15.2) (16.2) (19.5) (22.6) (24.1) (25.6)

(6.1) (13.4) (14.3) (17.7) (20.1) (21.6) (22.9)

60° 8 75 80 85 90 95 110 125 130 138

(2.4) (22.9) (24.4) (25.9) (27.4) (29.0) (33.5) (38.1) (39.6) (42.1)

10 65 70 75 79 83 95 109 115 120

(3.0) (19.8) (21.3) (22.9) (24.1) (25.3) (29.0) (33.2) (35.1) (36.6)

12 60 64 68 72 76 84 100 103 108

(3.7) (18.3) (19.5) (20.7) (21.9) (23.2) (25.6) (30.5) (31.4) (32.9)

15 50 54 56 61 65 71 85 88 94

(4.6) (15.2) (16.5) (17.1) (18.6) (19.8) (21.6) (25.9) (26.8) (28.7)

(6.1) (14.9) (15.8) (16.8) (18.0) (19.8) (23.5) (24.7) (25.9)

(4.6) (9.1) (7.6) (10.7) (9.1) (12.2) (10.7) (13.7) (12.2) (15.2) (12.2) (18.3) (13.7) (21.3) (13.7) (24.4) (15.2) (30.5) (15.2)

(6.1) (12.2) (10.7) (17.1) (12.2) (19.8) (12.2) (21.3) (13.7) (24.4) (13.7)

(7.6) (15.2) (10.7) (18.3) (10.7) (19.8) (12.2) (22.9) (12.2)

(9.1) (16.8) (10.7) (18.3) (10.7) (19.8) (12.2)

100,000 125,000 150,000 175,000 200,000 250,000 300,000 350,000 400,000

Approximate Distance of Heat Throw - Feet (Meters)

NR NR

NR NR NR NR

NR NR NR

NR NR NR NR

NR NR NR NR NR

NR NR NR NR NR NR

45 48 50 53 64 74 79 84

49 52 55 59 65 77 81 85

45 49 52 60 70 74 80

UNIT SIZE BTU/Hr

46 54 63 66 70

44 47 58 66 71 75

40 x 35 56 x 40 65 x 40 70 x 45 80 x 45

50 x 35 60 x 35 65 x 40 75 x 40

55 x 35 60 x 35 65 x 40

INSTALLATION (continued)

AIR FOR COMBUSTION: The unit heater shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and the maintenance of ambient temperature at safe limits under normal conditions of use. The unit heater shall be located in such a manner

as not to interfere with proper circulation of air within the conﬁ ned space. When buildings are so tight that normal inﬁ ltration does not meet air requirements, outside air shall be introduced per Sections 1.3.4.2 and 1.3.4.3 of ANSI Z223.1 for combustion requirements. A permanent opening or openings having a total free area of not less than one square inch per 5,000 BTU/Hr (1.5 kW) of total input rating of all appliances within the space shall be provided.

NOTICE: Unit Heater sizing should be based on heat loss calculations where the unit heater output equals or exceeds heat loss.

CLEARANCES: Each Gas Unit Heater shall be

located with respect to building construction and other equipment so as to permit access to the Unit Heater. Clearance between vertical walls and the vertical sides of the Unit Heater shall be no less than 6" (152mm). To ensure access to the control box, a minimum of 18" (457mm) is required for the control box side. A minimum clearance of 6" (152mm) must be maintained between the top of the Unit Heater and the ceiling. The bottom of the Unit Heater must be no less than 12" (305mm) from any combustible. The distance between rear of unit and vertical wall should be no less than 18" to maintain inlet air ﬂ ow. The distance between the ﬂ ue collector and any combustible must be no less than 6" (152mm). Also see AIR FOR COMBUSTION and VENTING sections.

Unit Heaters must be hung level from side to side and from front to back, see Figure 3A and 3B. Failure to do so will result in poor performance and/or premature failure of the unit.

Ensure that all hardware used in the suspension of each unit heater is more than adequate for the job. Failure to do so may result in extensive property damage, severe personal injury, or death!

Refer to Figures 3A and 3B for suspension of units.

Figure 3A - Heater Mounting*

D2788A

*All hanging hardware and wood is not included with the unit (To be ﬁ eld supplied).

Figure 3B - Heater Suspension

NOTICE: Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials.

Make certain that the lifting methods used to lift the heater and the method of suspension used in the ﬁ eld installation of the heater are capable of uniformly supporting the weight of the heater at all times. Failure to heed this warning may result in property damage or personal injury!

Make sure that the structure to which the unit heater is to be mounted is capable of safely supporting its weight. Under no circumstances must the gas lines, the venting system or the electrical conduit be used to support the heater; or should any other objects (i.e. ladder, person) lean against the heater gas lines, venting system or the electrical conduit for support. Failure to heed these warnings may result in property damage, personal injury, or death.

D4804

INSTALLATION (continued)

GAS PIPING

To avoid damage or possible personal injury, do not connect gas piping to this unit until a supply line pressure/leak test has been completed. Connecting the unit before completing the pressure/leak test may damage the unit gas valve and result in a ﬁ re hazard.

Do not rely on a shut-off valve to isolate the unit while conducting gas pressure/leak tests. These valves may not be completely shut off, exposing the gas valve to excessive pressure and damage.

PIPE SIZING

To provide adequate gas pressure to the gas unit heater, size the gas piping as follows:

by the same piping arrangement, the total cu. ft./hr. input and length of pipe must be considered.

1. Find the cu. ft./hr. by using the following formula:

Cu. ft./hr. =

Input BTU/Hr.

1000

2. Refer to Table 3. Match “Length of Pipe in Feet” with appropriate “Gas Input - Cu. Ft./Hr.” ﬁ gure. This ﬁ gure can then be matched to the pipe size at the top of the column.

Example: It is determined that a 67 foot (20.4m) run of gas

pipe is required to connect a 200 MBTU gas unit heater to a 1,000 BTU/cu ft. (0.29kW) natural gas supply.

200,000 BTU/Hr 1,000 BTU/cu. ft.

= 200 Cu. ft./hr.

Using Table 3, a 1 inch pipe is needed.

NOTICE: If the gas unit heater is to be ﬁ red with LP gas, consult your local LP gas dealer for pipe size information.

NOTICE: HEATER INSTALLATION FOR USE WITH PROPANE (BOTTLED) GAS MUST BE MADE BY A QUALIFIED L.P. GAS DEALER OR INSTALLER. HE/SHE WILL INSURE THAT PROPER JOINT COMPOUNDS ARE USED FOR MAKING PIPE CONNECTIONS; THAT AIR IS PURGED FROM LINES; THAT A THOROUGH TEST IS MADE FOR LEAKS BEFORE OPERATING THE HEATER; AND THAT IT IS PROPERLY CONNECTED TO THE PROPANE GAS SUPPLY SYSTEM.

Before any connection is made to the existing line supplying other gas appliances, contact the local gas

NOTE: See General Safety Information section for English/Metric unit conversion factors.

company to make sure that the existing line is of adequate size to handle the combined load.

NOTICE: If more than one unit heater is to be served

Table 3 - Gas Pipe Size

Maximum Capacity of Pipe in Cubic Feet of Gas per Hour (Cubic Meters per Hour) for Gas Pressures of 0.5 psig (3.5 kPa) or Less, and a Pressure Drop of 0.5 Inch Water Column (124.4 Pa) (Based on a 0.60 Speciﬁ c Gravity Gas) Nominal

Iron Internal Length of Pipe, Feet (meters)

Pipe Size

Dia. 10 20 30 40 50 60 70 80 90 100 125 150 175 200

in. in. (3.0) (6.1) (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0) 1/2 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35

(4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99) 3/4 0.824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 (10.2) (7.08) (5.66) (4.81) (4.28) (3.91) (3.54) (3.34) (3.11) (2.92) (2.63) (2.38) (2.18) (2.04) 1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 (19.3) (13.2) (10.6) (9.06) (8.07) (7.36) (6.80) (6.23) (5.80) (5.52) (4.96) (4.53) (4.11) (3.82) 1 1/4 1.380 1400 950 770 660 580 530 490 460 430 400 360 325 300 280 (39.6) (26.9) (21.8) (18.7) (16.4) (15.0) (13.9) (13.0) (12.2) (11.3) (10.2) (9.20) (8.50) (7.93) 1 1/2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 (59.5) (41.3) (33.4) (28.0) (25.5) (22.9) (21.2) (19.5) (18.4) (17.6) (15.6) (14.2) (13.0) (12.2) 2 2.067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800 (112) (77.9) (62.3) (53.8) (47.6) (43.0) (39.6) (36.8) (34.5) (32.6) (28.9) (26.9) (24.1) (22.7) 2 1/2 2.469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280 (178) (123) (99.7) (85.0) (75.0) (68.0) (63.7) (58.0) (55.2) (52.4) (46.7) (42.5) (38.8) (36.2) 3 3.068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280 (311) (218) (177) (150) (135) (122) (110) (105) (97.7) (92.0) (83.5) (75.0) (69.4) (64.6) 4 4.026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600 (651) (447) (362) (309) (275) (249) (229) (212) (204) (190) (170) (156) (142) (130)

1. Determine the required Cu. Ft./Hr. by dividing the input by 1000. For SI/Metric measurements: Convert BTU/Hr. to kilowatts. Multiply the units

inputs (kW) by 0.0965 to determine Cu. Meters./Hr. 2. FOR NATURAL GAS: Select pipe size directly from the table. 3. FOR PROPANE GAS: Multiply the Cu. Ft./Hr. value by 0.633; then, use the table. 4. Refer to the metric conversion factors listed in the General Safety section for SI Unit measurement conversions.

INSTALLATION (continued)

D3631C

PIPE INSTALLATION

1. Install the gas piping in accordance with applicable local codes.

2. Check gas supply pressure. Each unit heater must be connected to a manifold pressure and a gas supply capable of supplying its full rated capacity as speciﬁ ed in Table 4. A ﬁ eld LP tank regulator must be used to limit the supply pressure to a maximum of 14" W.C. (3.5 kPa). All piping should be sized in accordance with the latest edition of ANSI Standard Z223.1 (NFPA54), National Fuel Gas Code; in Canada, according to CSA B149. See Tables 1 & 3 for correct gas piping size. If gas pressure is excessive on natural gas applications, install a pressure regulating valve in the line upstream from the main shutoff valve.

3. Adequately support the piping to prevent strain on the gas manifold and controls.

4. To prevent the mixing of moisture with gas, run the take-off piping from the top, or side, of the main.

5. Standard Unit Heaters, optional two-stage units are supplied with a combination valve which includes:

a. Manual "A" valve b. Manual "B" valve c. Solenoid valve d. Pressure regulator Pipe directly into the combination valve (see Figure

4).

6. Gas valve has a pressure test post requiring a 3/32" hex head wrench to read gas supply and manifold pressures. Open 1/4 turn counterclockwise to read, turn clockwise to close and reseat. A 5/16" ID hose ﬁ ts the pressure post.

7. Provide a drip leg in the gas piping near the gas unit heater. A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing. The manual shutoff valve must be located external to the jacket (See Figure 4).

8. Make certain that all connections have been adequately doped and tightened.

Do not over tighten the inlet gas piping into the valve. This may cause stresses that will crack the valve!

NOTICE: Use pipe joint sealant resistant to the action of liquefied petroleum gases regardless of gas conducted.

Figure 4 - Pipe Installation, Standard Controls

D3631C

Never use an open ﬂ ame to detect gas leaks. Explosive conditions may exist which may result in personal injury or death!

The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system in excess of 1/2 psig (3.5 kPa).

The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).

Table 4 - Gas Piping Requirements

SINGLE STAGE GAS PIPING REQUIREMENTS*

GasType Natural Gas Propane (LP) Gas

Manifold 3.5 in. W.C. 10.0 in. W.C.

Pressure (0.9 kPa) (2.5 kPa)

14.0 in. W.C. Max. 14.0 in. W.C. Max.

Supply Inlet (3.5 kPa) (3.5 kPa) Pressure

(1.2 kPa) (2.7 kPa)

*For single stage application only at normal altitudes.

5.0 in. W.C. Min. 11.0 in W.C. Min.

Check all pipe joints for leakage using a soap solution or other approved method. Never use an open flame or severe personal injury or death may occur!

BLOWER SET UP AND ADJUSTMENT

BLOWER SET UP

BLOWER DRIVE ADJUSTMENT

The drive ratio of the motor and blower sheaves has been preset at the factory for a temperature rise of 65°F at .2" W.C. If the unit is to be operated under different static air ﬂ ow or pressure requirements, the drive ratio must be altered by means of the adjustable sheave on

belt without ﬁ rst disconnecting all electrical power to the unit or severe personal injury may result!

Never attempt to adjust the drive

the blower motor.

1. Ensure that all packing material, support blocks, etc. have been removed from the unit.

2. Adjust the blower drive belt tension by means of the two tension bolts on the blower motor base. When proper tension has been achieved, the mid-point deﬂ ection of the belt will be 3/4" when subjected to a 5 lb. force.

3. Recheck all electrical connections.

4. When power is applied, ensure that the motor and blower are rotating in a counter clockwise direction when viewed from the drive side.

1. Remove the belt guard and loosen the belt tension bolts on the blower motor base.

2. Loosen the set screw on the adjustable half of the motor sheave. To increase the blower speed, turn the adjustable half of the sheave clockwise, counter clockwise to slow the blower. Retighten the set screw.

3. Realign the blower and motor sheaves if necessary.

4. Adjust the belt tension as speciﬁ ed in the BLOWER SET UP section under step 2.

5. Replace the belt guard.

5. Measure the current draw of the motor.

Never operate the unit without

The "at speed" current draw of the

motor must never exceed that specified on the

the belt guard in place or severe personal injury

may result! motor rating plate or severe damage to the motor will result!

6. Check that the air flow of the unit, the rpm and current draw of the blower motor and the temperature rise are within the limits specified in Table 1, the blower motor rating plate and the rating plate on the unit, respectively (also see Motor Data on page 11).

Figure 5 - Motor & Blower Assembly *

* PART DESCRIPTION A. Blower Housing and Wheel C. Blower Shaft D. Bearings E. Drive Pulley F. Driven Pulley G. V-Belt H. Blower Motor I. Blower Housing Support (LH) H. Blower Housing Support (RH)

Never operate the unit beyond the specified limits or severe damage to, and or premature failure of, the unit will result!

D9000

* NOTICE: THE BLOWER ASSEMBLY FOR THE 100/250 UNITS CONSISTS OF 1 WHEEL, 1 HOUSING, 1 SHAFT AND 2 BEARINGS. FOR 300/400 UNITS THE BLOWER ASSEMBLY CONSISTS OF 2 WHEELS, 2 HOUSINGS, 1 SHAFT AND 3 BEARINGS.

MOTOR AND PULLEY

All motor data based on standard ODP Motors.

Table 5

Motor Full Load Amps*

VOLTAGE - PHASE

HP 115-1 208-1 230-1 208-3 230-3 460-3 575-3 1/4 5.1 2.2 2.3 1.7 1.3 0.7 N/A 1/2 7.2 3.7 3.8 2.3 2.2 1.1 0.8 3/4 11.6 5.2 5.0 3.0 3.4 1.7 1.1

1 13.0 6.6 6.5 3.4 3.4 1.7 1.3

1-1/2 18.2 9.1 9.1 5.1 5.2 2.6 1.7

2 21.0 11.3 10.5 6.2 6.0 3.0 N/A

* Average value, all speeds and frequencies.

Table 6

Pulley Table 1725 RPM Motors (1/3 to 2 H.P.)

MOTOR PULLEYS

BLOWER PULLEYS

IVL34

1.9-2.9

Turns Open

5 4-1/2 4 3-1/2 3 2-1/2 2 1-1/2 1 1/2 0

IVL44

2.8-3.8

5 4-1/2 4 3-1/2 3 2-1/2 2 1-1/2 1 1/2 0

AK51

4.7

697 734 771 807 844 880 918 954

991 1027 1064 1101 1137 1174 1211 1247 1284 1321 1357 1394

AK56

5.2

630 663 697 730 763 796 829 863 896 928 962

995 1028 1061 1094 1127 1161 1194 1227 1260

AL64

6.0

546 575 603 633 661 690 719 748 776 805 834 863 891 920 949

978 1006 1035 1064 1093

AL74

7.0

468 493 517 542 567 591 616 641 665 690 715 739 764 789 813 838 863 887 912 936

AL84

8.0

410 431 453 474 496 517 539 560 582 604 625 647 668 690 712 733 755 776 798 819

AL104

10.0

327 345 362 380 397 414 431 448 466 483 500 518 535 552 569 587 604 621 638 656

ELECTRICAL CONNECTIONS

HAZARDOUS VOLTAGE!

DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING. Failure to disconnect power before servicing can cause severe personal injury or death.

Figure 6a Low-voltage Thermostat Wiring Single Stage

D4788

Figure 6b - Low-voltage Thermostat Wiring Two Stage

Standard units are shipped for use on 115 volt, 60 hertz, single phase electric power. The motor name-plate and electrical rating of the transformer should be checked before energizing the unit heater electrical system. All external wiring must conform to the latest edition of ANSI/NFPA No. 70, United States National Electrical Code, and applicable local codes; in Canada, to the Canadian Electrical Code, Part 1, CSA Standard C22.1.

Do not use any tools (i.e. screwdriver, pliers, etc.) across terminals to check for power. Use a voltmeter.

It is recommended that the electrical power supply to each unit heater be provided by a separate, fused, and permanently live electrical circuit. A disconnect switch of suitable electrical rating should be located as close to the gas valve and controls as possible. Each unit heater must be electrically grounded in accordance with the latest edition of the United States National Electrical Code, ANSI/NFPA No. 70, or CSA Standard C22.1. Refer to Figures 6a, 6b, 6c, 6d, 6e, 6f and 6g.

THERMOSTAT WIRING AND LOCATION:

Figure 6c -

D8541

Low-voltage T834H or T834N (or equivalent) Thermostat Wiring Single Stage

D8922C

NOTICE: The start-up fan delay should not exceed 30 seconds from a cold start.

IMPORTANT: For all wiring connections, refer to the wiring diagram shipped with your unit (either afﬁ xed to the side jacket or enclosed in the installation instructions envelope). Should any original wire supplied with the heater have to be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C.

Should any high limit wires have to be replaced, they must be replaced with wiring material having a temperature rating of 200°C minimum.

NOTICE: The thermostat must be mounted on a vertical, vibration-free surface, free from air currents, and in accordance with the furnished instructions.

Mount the thermostat approximately 5' (1.5m) above the floor, in an area where it will be exposed to a free circulation of average temperature air. Always refer to the thermostat instructions, as well as our unit wiring diagram, and wire accordingly. Avoid mounting the thermostat in the following locations:

1. Cold Areas - Outside walls or areas where drafts

may affect the operation of the control.

2. Hot Areas - Areas where the sun's rays, radiation,

or warm air currents may affect the operation of the control.

3. Dead Areas - Areas where the air cannot circulate

freely, such as behind doors or in corners.

ELECTRICAL CONNECTIONS (continued)

Figure 6d - Tubular Blower Units 100-150 with Single Stage Ignition, Natural Gas and Propane (LP) Gas

ELECTRICAL CONNECTIONS (continued)

Figure 6e - Tubular Blower Units 100-150 with Two Stage Ignition, Natural Gas and Propane (LP) Gas

ELECTRICAL CONNECTIONS (continued)

Figure 6f - Tubular Blower Units 175-400 with Single Stage Ignition, Natural Gas and Propane (LP) Gas

ELECTRICAL CONNECTIONS (continued)

Figure 6g - Tubular Blower Units 175-400 with Two Stage Ignition, Natural Gas and Propane (LP) Gas

VENTING

ANSI now organizes vented appliances into four categories.

Category I

Includes non-condensing appliances with negative vent

Venting Categories

Non Condensing Condensing Negative Vent I II Pressure

Positive Vent III IV Pressure

pressure, like the traditional atmospheric unit heater.

Category II

Groups condensing appliances with negative vent pressure.

Category III

Appliances are non-condensing and operate with a positive vent

Category IV

Covers condensing appliances with positive vent pressure.

NOTICE: Category II and IV do not apply to equipment speciﬁ ed

within this manual.

pressure.

All unit heaters must be vented! All Venting installations shall be in accordance with the latest edition of Part 7, Venting of Equipment of the National Fuel Gas Code, ANSI Z223.1 (NFPA54), or applicable provisions of local building codes. Refer to page 19 for Canadian installations. Refer to Figures 7, 8, 9A, 9B, 10A and 10B.

CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or ﬂ u-like symptoms).

Do not damper or add heat recovery devices to the ﬂ ue piping. Failure to open such a damper prior to operating gas unit will result in the spillage of ﬂ ue gas into the occupied space.

VERTICALLY VENTED UNIT HEATERS (CATEGORY I)

Observe the following precautions when venting the unit:

1. Use ﬂ ue pipe of the same size as the ﬂ ue connections on the gas unit heater (See Table #1). All heaters should be vented with double wall or single wall vent, a factory built chimney, or a lined brick and mortar chimney that has been constructed in accordance with the National Building Code. Type B vent should only be used for vertical rise portions of a Category I vent pipe system. Type B vent pipe should not be used for horizontal runs of vent pipe.

2. Provide as long a vertical run of ﬂ ue pipe at the gas unit heater as possible. A minimum of 5' (1.5m) of vertical flue is required. The top of the vent pipe should extend at least 2' (0.61m) above the highest point on the roof. Install a weather cap over the vent opening. Consideration should be made for anticipated snow depth.

3. Slope horizontal runs upward from the gas unit heater at least 1/4" per foot (21mm/m) minimum. Horizontal runs should not exceed 75% of the vertical height of the vent pipe, or chimney, above the ﬂ ue pipe connection, up to a maximum length of 10' (3m). Horizontal portions of the venting system shall be supported at minimum intervals of 4' (1.2m). In Canada, support at minimum intervals of 3' (1m).

5. Seal all vent pipe joints and seams to prevent leakage. Use General Electric RTV-108, Dow Corning RTV-732, or equivalent silicone sealant with a temperature rating of 500 degrees F, or 3M #425 aluminum foil tape (or equivalent).

6. Avoid running vent pipe through unheated spaces.

7. When this cannot be avoided, insulate the pipe to prevent condensation of moisture on the walls of the pipe.

8. Do not damper the ﬂ ue piping. Failure to open such a damper prior to operating the gas unit heater will result in the spillage of flue gas into the occupied space.

9. Avoid installing units in areas under negative pressure due to large exhaust fans or air conditioning. When required, a ﬂ ue vent fan should be installed in accordance with the instructions included with the fan.

10. Vent connectors serving Category I and Category II heaters shall not be connected into any portion of mechanical draft systems operating under positive pressure.

4. Use as few elbows as possible. 17

VENTING (continued)

HORIZONTALLY VENTED UNIT HEATERS

(CATEGORY III)

Horizontal venting arrangements are designed to be used with single wall vent pipe. Horizontal venting arrangements must terminate external to the building using UL 1738 Listed single wall or double wall vent. For installations in Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or in the absence of local building codes, with current CSA-B149.1, Installation Codes for Natural Gas Burning Appliances and Equipment or CSA-B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment. See Figures 8, 9A and 10A for special installation requirements regarding these venting conditions.

Do not use Type B (double wall) vent internally within the building on horizontally vented power vented units! This can result in death, serious injury or substantial property damage.

If double wall venting is used, components which are UL Listed and approved for Category III positive pressure venting systems MUST be used.

A Breidert Type L, Fields Starkap, or equivalent vent cap must be supplied by the customer for each power vented unit. The vent pipe diameter MUST be as specified in Table 1. All unit sizes are factory equipped with the required ﬂ ue size collar; attach in place (if not mounted to outlet); refer to included vent collar instruction sheet for additional requirements.

Table 7

Vent Systems

Termination Clearance Requirements

Minimum Clearance

Structure/Object

Door, window, or gravity vent inlet; combustion air inlet for other appliances

Forced air inlet within 10 feet 3 feet above 6 feet (1.8m)

Adjoining Building or parapet 6 feet 6 feet (1.8m)

Adjacent public walkways

Electric, gas meters & regulators

Above grade level* 1 foot* 1 foot (0.3m)*

*Above maximum anticipated snow depth.

for Termination Locations

USA CANADA

9 inch for 10,000 to 50,000 BTU/Hr input; 12 inch for input exceeding 50,000 BTU/Hr.

7 feet above grade

4 feet horizontal

9 inch (230mm) for 10,000 to 50,000 BTU/Hr input; 12 inch (305mm) for input exceeding 50,000 BTU/Hr.

7 feet (2.1m) above grade

3 feet (0.9m) horizontally from meter/regulator asembly. 6 feet (1.8m), any direction, from a gas service regulator vent outlet

The vent terminal must be at least 12" (305mm) from the exterior of the wall that it passes through to prevent degradation of the building material by ﬂ ue gases.

Through the wall vent for these appliances shall NOT terminate over public walkways, or over an area where the condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

The vent pipe equivalent length must not exceed 50' (15.2m). Equivalent length is the total length of straight sections PLUS 10' (3.05m) for each 90° elbow and 4' (1.22m) for each 45° elbow.

Maintain clearance between the vent pipe and combustible materials according to vent pipe manufacturers instructions

Seal all vent pipe joints and seams to prevent leakage. Use General Electric RTV-108, Dow-Corning RTV-732 silicone sealant or equivalent sealant with a temperature rating of 500° F; or 3M #425 aluminum foil tape (or equivalent). The vent air system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4" per foot (21mm per meter) toward the outlet for condensate drainage.

Horizontal portions of the venting systems shall be supported at maximum intervals of 4' (1.2m) to prevent sagging (in Canada, support at 3' (1m) maximum intervals).

Insulate single wall vent pipe exposed to cold air or running through unheated areas.

Each unit must have an individual vent pipe and vent terminal! Each unit MUST NOT be connected to other

vent systems or to a chimney.

VENTING (continued)

Figure 7 - Vertically Vented Tubular Unit Heater – Category I

Figure 8 - Horizontally Vented Tubular Unit Heater – Category III

D8929

D8930

ADDITIONAL REQUIREMENT FOR CANADIAN INSTALLATIONS

* The following instructions apply to Canadian installations in addition to installation and operating instructions.

1. Installation must conform with local building codes, or in the absence of local codes, with current CSA B149.1, Installation Codes for Natural Gas Burning Appliances and Equipment, or CSA B149.2, Installation Codes for Propane Gas Burning Appliances and Equipment.

2. Any reference to U. S. standards or codes in these instructions are to be ignored, and the applicable Canadian standards or codes applied.

REFER TO SPECIFICATION TABLE AND INSTALLATION MANUAL FOR PROPER USAGE.

Figure 9A

VENTING (continued)

Figure 9B

D3620F

D3619C

Figure 10A

VENTING (continued)

Figure 10B

D3661F

D3662D

OPERATION

POWER VENTED BLOWER UNITS

DIRECT SPARK IGNITION

EXPLANATION OF CONTROLS:

1. The unit heater is equipped with a power vent system

that consists of a power venter motor and blower, pressure switch, and sealed ﬂ ue collector in place of the conventional draft diverter.

2. The power venter motor is energized by the room

thermostat through the integrated control board when a demand for heat is sensed. The pressure switch measures the flow through the vent system and energizes the direct spark ignition system beginning the pre-purge timing when the ﬂ ow is correct.

The pressure switch MUST NOT be bypassed. The unit MUST NOT be ﬁ red unless the power venter is operating. An unsafe condition could result.

3. The direct ignition system consists of an ignition control module and a gas valve. When the prepurge period ends, the spark ignition system is energized, and the gas valve opens to supply gas to the burners. When the thermostat is satisﬁ ed, the vent system is de-energized and the valve closes to stop the ﬂ ow of gas to the unit. (See Figure 11.)

4. The limit switch interrupts the ﬂ ow of electric current to the control board, interrupting the ﬂ ow of gas to the gas valve if the unit heater becomes overheated.

5. Once the thermostat is satisﬁ ed, or the limit switch interrupts the ﬂ ow of electric current to the control board, the unit will begin a post-purge period. When the post-purge period ends, the power venter motor is de-energized.

6. The fan operation is delayed 30 seconds once the thermostat is closed, and continues operation for 30 seconds after the thermostat opens.

7. The wall thermostat, supplied optionally, is a temperature sensitive switch that operates the vent and ignition system to control the temperature of the space being heated. The thermostat must be mounted on a vertical, vibration-free surface free from air currents and in accordance with the furnished instructions (also refer to Electrical Connections).

START-UP (Also refer to lighting instruction plate equipped on the unit)

1. Open the manual gas valve in the gas supply line to the unit heater. Loosen the union in the gas line to purge it of air. Tighten the union and check for leaks.

Never use an open flame to detect gas leaks. Explosive conditions may exist which could result in personal injury or death.

2. Open the manual valve on the unit heater.

3. Turn ON the electrical power.

4. The unit should be under the control of the thermostat. Tur n the thermostat to the highest point and determine that the power venter motor starts and the burners ignite. Turn the thermostat to the lowest point and determine that the power venter motor shuts off and the burners are extinguished.

5. Turn the thermostat to the desired position.

6. See Gas Input Rate and Adjustments sections.

SHUT DOWN

1. Turn the valve selector lever to the “OFF” position.

2. Turn off the electricity.

3. To relight, follow “start-up” instructions.

See Figures 11-17 for parts/identiﬁ cation.

NOTICE: The start-up fan delay must not exceed 30 seconds from a cold start.

Figure 11 - Direct Spark Ignition System, Bottom View

D6923B

OPERATION

PRIMARY AIR SHUTTER ADJUSTMENT

Primary air adjustment is made at the factory. No ﬁ eld adjustments are necessary.

GAS INPUT RATE

Check the gas input rate as follows (Refer to General Safety Information section for metric conversions).

Never overﬁ re the unit heater, as this may cause unsatisfactory operation, or shorten the life of the heater.

1. Turn off all gas appliances that use gas through the

same meter as the unit heater.

2. Turn the gas on to the unit heater.

3. Clock the time in seconds required to burn 1 cubic

foot of gas by checking the gas meter.

4. Insert the time required to burn one cubic foot of

gas into the following formula and compute the input rate.

3600 (Sec. per Hr.) X BTU/Cu. Ft.

= Input Rate

Time (Sec.)

For example: Assume the BTU content of one cubic foot of gas is 1000, and that it takes 18 seconds to burn one cubic foot of gas. 3600 x 1000

= 200,000

NOTICE: If the computation exceeds, or is less than 95% of the gas BTU/hr. input rating (see Table 1), adjust the gas pressure.

Adjust the gas pressure as follows:

1. NATURAL GAS: Best results are obtained when

the unit heater is operating at its full rated input with the manifold pressure of 3.5" W.C. (0.9 kPa). Adjustment of the pressure regulator is not normally necessary since it is preset at the factory. However, ﬁ eld adjustment may be made as follows: a. Attach manometer at the pressure tap plug

adjacent to the control outlet.

b. Remove the regulator adjustment screw cap,

located on the combination gas valve.

c. With a small screwdriver, rotate the adjustment

screw counterclockwise to decrease pressure, or clockwise to increase pressure.

d. Replace regulator adjustment screw cap.

2. PROPANE GAS: An exact manifold pressure of

10.0" W.C. (2.5 kPa) must be maintained for proper operation of the unit heater. If the unit is equipped with a pressure regulator on the combination gas valve, follow steps "a" through "d" above. If the unit is not so equipped, the propane gas supply system pressure must be regulated to attain this manifold operating pressure.

3. The adjusted manifold pressure should not vary more than 10% from pressure speciﬁ ed in Table 8.

Table 8 - Main Burner Oriﬁ ce Schedule*

TYPE OF GAS NATURAL PROPANE

INPUT

HEATING VALUE

1,000

BTU

100

125

150

175

200

250

300

350

400

*This schedule is for units at operating at normal altitudes of 2000 ft. (610m) or less.

When installed in Canada, any references to deration at altitudes in excess of 2000 ft. (610m) are to be ignored. At altitudes of 2000 to 4500 ft. (610 to 1372m), the unit heaters must be ﬁ eld derated to 90% of the normal altitude rating, and be so marked in accordance with ETL certiﬁ cation. See Table 8A for ﬁ eld deration information.

MANIFOLD

PRESSURE

FT3/HR 93 40

ORIFICE DRILL 42 53

FT3/HR 116 50

ORIFICE DRILL 42 53

FT3/HR 140 60

ORIFICE DRILL 42 53

FT3/HR 163 70

ORIFICE DRILL 42 53

FT3/HR 186 80

ORIFICE DRILL 42 53

FT3/HR 233 100

ORIFICE DRILL 42 53

FT3/HR 280 120

ORIFICE DRILL 42 53

FT3/HR 326 140

ORIFICE DRILL 42 53

FT3/HR 372 160

ORIFICE DRILL 42 53

1050 BTU/Ft3

(39.1 MJ/m3)

3.5" W.C. 10" W.C.

(0.87kPA) (2.49kPA)

2500 BTU/Ft3

(93.1 MJ/m3)

NO. OF

BURNER

ORIFICES

OPERATION (continued)

TUBULAR UNIT HEATER HIGH ALTITUDE DERATION

This Tubular Unit Heater has been manufactured utilizing standard burner oriﬁ ces and a normal manifold pressure setting as per the speciﬁ cations shown on your unit rating plate.

are made in the ﬁ eld, attach label #J17-06459 to the unit, and record adjusted manifold pressure, altitude of the unit installation and the technician’s name and date on the label using a permanent marker.

All unit deration must be done through ﬁ eld adjustments by a qualiﬁ ed technician. Once the proper adjustments

Refer to Installation Instruction section on AdjustmentsGas Input Rate for adjusting the manifold pressure.

Table 8A

High Altitude Deration - United States

Altitude

Feet Meters Inches W.C. Pa Inches W.C. Pa Percentage

0-2,000 0-610 3.5 872 10 2,491 100%

2,001-3,000 611-915 3.2 797 9.2 2,292 96%

3,001-4,000 916-1,220 2.9 722 8.4 2,092 92%

4,001-5,000 1,221-1,525 2.7 673 7.7 1,918 88%

5,001-6,000 1,526-1,830 2.4 598 7 1,744 84%

6,001-7,000 1,831-2,135 2.2 548 6.4 1,594 80%

7,001-8,000 2,136-2,440 2 498 5.7 1,420 76%

8,001-9,000 2,441-2,745 1.8 448 5.1 1,270 72%

9,001-10,000 2,746-3,045 1.6 399 4.6 1,145 68%

Notes: 1. Deration based on ANSI Z223.1 (NFPA 54).

2. Table based on heating value of 1,050 BTU/Cu. ft. at sea level.

3. Table based on heating value of 2,500 BTU/Cu. ft. at sea level.

4. Consult local utility for actual heating value.

Natural Gas

Manifold Pressure

Liquid Propane

High Altitude Deration - Canada

Altitude

Feet Meters Inches W.C. Pa Inches W.C. Pa Percentage

0-2,000 0-610 3.5 872 10 2,491 100%

2,001-3,000 611-915 3.2 797 9.2 2,292 96%

3,001-4,000 916-1,220 2.9 722 8.4 2,092 92%

4,001-4,500 1,221-1,371 2.8 697 7.9 1,968 90%

Notes: 1. Deration based on CGA 2.17-M91

2. Table based on heating value of 1,050 BTU/Cu. ft. at sea level.

3. Table based on heating value of 2,500 BTU/Cu. ft. at sea level.

4. Consult local utility for actual heating value.

Natural Gas

Manifold Pressure

Liquid Propane

BTU Output

Table 9 - Tubular Blower Troubleshooting Guide

SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION

A. Flame pops back. 1. Burner oriﬁ ce too small. 1. Check with local gas supplier for proper oriﬁ ce

B. Noisy Flame. 1. Irregular oriﬁ ce causing whistle or resonance.

size and replace. Refer to "Gas Input Rate."

1. Replace oriﬁ ce.

2. Excessive gas input.

C. Yellow tip ﬂ ame (some yellow

tipping on LP gas is permissible).

D. Floating ﬂ ame. 1. Blocked venting.

E. Gas odor 1. Gas leak. Shut off gas supply immediately!

F. Delayed ignition. 1. Improper ground.

1 Clogged main burners.

2. Misaligned oriﬁ ces.

3. Insufﬁ cient combustion air.

4. Possibly over ﬁ red.

2. Insufﬁ cient combustion air.

3. Blocked heat exchanger.

4. Air leak into combustion chamber or ﬂ ue collector.

2. Leaking gas test port on valve.

3. Blocked heat exchanger.

4. Blocked ﬂ ue collector.

5. Negative pressure in the building.

2. Bad or broken spark cable.

3. Faulty control.

2. Test and reset manifold pressure (see Table 4 - "Gas Piping Requirements").

1. Clean main burner ports.

2. Replace manifold assembly.

3. Refer to "Installation - Clearances" and "Venting" to ensure unit is properly mounted and vented.

4. Check gas input and manifold pressures.

1. Clean ﬂ ue. Refer to "Installation."

2. Clean combustion air inlet openings.

3. Clean heat exchanger. Refer to "Installation."

4. Determine leak and repair accordingly.

1. Inspect all gas piping and repair accordingly.

2. Check to ensure gas test ports are sealed.

3. Clean heat exchanger. Refer to "Installation."

4. Clean ﬂ ue collector. Refer to "Installation."

5. See "Installation."

1. Check grounding wires and spark bracket connections.

2. Inspect spark cable connections and cuts. Replace if necessary.

3. Check to ensure spark is energized after prepurge period.

4. Pressure regulator set too low.

5. Main burner oriﬁ ces dirty.

6. Improper venting.

G. Failure to ignite. 1. Gas leak. Shut off gas supply immediately!

2. No power supply to unit.

3. Thermostat not calling.

4. Defective high limit.

5. Defective draftor prove switch.

6. Defective spark ignitor, gas valve, thermostat or transformer.

7. Loose wiring.

8. Improper ground.

9. Improper thermostat or transformer wiring.

4. Test and reset manifold pressure.

5. Clean or replace oriﬁ ces.

6. Refer to "Installation."

1. Open all manual valves, check for leaks.

2. Turn on power supply, check fuses and replace if bad.

3. Turn up thermostat. Check for 24V on terminals R and W1 on terminal strip.

4. Check switch for continuity if open with no heat present; replace.

5. Check switch operation to ensure switch closes after draftor purge period. If it does not make, check tubing connections for blockage.

6. Check for continuity and voltage in safety and control circuits; replace an item where continuity or voltage not found.

7. Check all wiring per diagram.

8. Check all ground wires and connections.

9. Check both for wiring according to diagram; check for 24V at gas valve terminals during trial for ignition period. If present and valve does not open, replace valve.

Table 9 - Tubular Blower Troubleshooting Guide (continued)

SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION

H. Condensation. 1. Improper venting.

2. Unit under ﬁ red.

3. Building/space too cold.

I. Burners will not shut off. 1. Thermostat located improperly.

2. Improper thermostat wiring.

3. Shorted circuit.

4. Defective thermostat.

5. Defective/sticking gas valve.

6. Defective control board.

7. Excessive gas supply pressure.

J. Rapid burner cycling. 1. Loose electrical connections at thermostat or

K. Blower will not run. 1. Loose electrical connections.

L. Blower motor turns on and off while

burner is operating.

M. Blower motor will not stop. 1. Control board is in ﬂ ame failure mode.

gas valve.

2. Excessive thermostat heat anticipator setting.

3. Unit cycling on high limit.

4. Thermostat located improperly.

2. Defective motor or overload.

3. Defective control board.

4. Contactor or starter overload tripped.

5. Broken belt.

1. Motor overload protection is tripping.

2. Loose wiring or connection.

3. Control board is defective.

2. Improperly wired blower circuit.

3. Control board is defective.

1. Refer to "Installation."

2. Check gas supply pressures to unit. Refer to "Installation."

3. Refer to "Installation."

1. Relocate thermostat away from outside wall or drafts.

2. Check thermostat circuit for open and close on heater terminal strip "R" and "W."

3. Check thermostat circuit for shorts or any staples piercing wires.

4. If thermostat is calling after set point has been satisﬁ ed, replace.

5. Check for 24V on gas valve terminals when thermostat not calling. Replace if necessary.

6. Check for 24V at terminals "R" and "W." If not present and board is not in ﬂ ash code mode, replace board.

7. Refer to "Pipe Installation" and Table 4 - "Gas Piping Requirements."

1. Tighten all electrical connections.

2. Adjust heat anticipator setting for longer cycles. Refer to "Electrical Connections."

3. Check for proper air supply across heat exchanger and proper gas supply.

4. Relocate thermostat away from outside wall or drafts.

1. Check and tighten wires on blower circuit.

2. Test for 115V on terminal ACB Heat and "L2." If voltage is present, replace motor.

3. Test for 115V on terminal ACB Heat and "L2." If voltage is not present 45 seconds after trial for ignition, replace board.

4. Test for 115V on coil of contactor. Check if overload has tripped; reset. Check amp draw to motor. Check incoming for power and contactor operation.

5. Replace belt.

1. Check motor amp against the motor name plate, check voltage, replace if found defective.

2. Check for 115V between motor leads.

3. Check terminal ACB Heat for voltage. If voltage not constant, replace board.

1. Turn 115V power off to the unit, wait 10 seconds and reapply voltage to the unit.

2. Check wiring of blower circuit to wiring diagram.

3. If unit is not calling for heat and board is not in ﬂ ash code mode, replace board.

Table 9 - Tubular Blower Troubleshooting Guide (continued)

SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION

N. Not enough heat. 1. Incorrect gas input.

2. Heater undersized.

3. Thermostat malfunction.

4. Heater cycling on limit.

5. Incorrect oriﬁ ce sizes.

O. Too much heat. 1. Unit is over ﬁ red.

2. Thermostat malfunction.

3. Heater runs continuously.

4. Defective gas valve.

5. Excessive gas supply pressure.

6. Excessive static pressure.

P. Noisy blower/motor. 1. Blower wheel loose.

2. Blower wheel is dirty.

3. Blower wheel is rubbing on housing.

4. Bearings are dry.

5. Pulley is loose.

Q. Cold air is delivered during heater

operation.

R. High limit is tripping. 1. Unit is over ﬁ red.

1. Incorrect manifold pressure or input.

2. Air throughput too high.

2. Air ﬂ ow is too low.

3. Defective high limit.

4. Defective control board.

1. Refer to "Gas Input Rate"

2. Is the heater output sized correctly for the heat loss of the space? Has the space been enlarged? Is the heater located in the space properly (see "Installation")?

3. Check thermostat circuit; 24V on terminals "R" and "W" on terminal strip.

4. Check air movement across heat exchanger. Check voltage and amps at the blower motor. Check gas input to ensure unit is not over ﬁ red. Check heat exchanger to ensure unit is not dirty.

5. Check oriﬁ ce size (Refer to "Gas Input Rate"), replace if necessary.

1. Refer to "Gas Input Rate." Check oriﬁ ce size. Replace if too large.

2. Check thermostat for operation, to ensure circuit open and closes.

3. Check wiring per diagram. Check operation at the gas valve. Look for a short in thermostat circuit.

4. Replace valve and check pressure setting (See Table 4 "Gas Piping Requirements").

5. Refer to "Pipe Installation" and Table 4 - "Gas Piping Requirements."

6. Adjust blower sheave to correct RPM - See "Blower Set Up and Adjustment."

1. Replace or tighten.

2. Clean blower wheel.

3. Realign blower wheel.

4. Oil bearings on blower motor. (Refer to label on motor.)

5. Check Blower and Motor pulleys. Replace or tighten as necessary.

1. Test and reset manifold pressure (see Table 4 - "Gas Piping Requirements").

2. Check Blower and Motor pulleys. Replace or tighten as necessary.

1. Refer to "Gas Input Rate." Check oriﬁ ce size. Replace if too large.

2. Check for proper voltage; ensure blower assembly is correct.

3. Check operation of switch. If switch is open during operation, check gas pressure and/ or CFM; adjust accordingly. If switch is open during start-up, replace switch.

4. Check for 24V on line side of high limit. Constant voltage should be recorded. If not, control board is suspect. Check ﬂ ash code.

Table 9 - Tubular Blower Troubleshooting Guide (continued)

SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION

S. Power ventor will not run. 1. No power supply to unit.

2. Thermostat not calling.

3. Loose wiring or connection.

4. Motor overload protection is tripping or bad motor.

5. Defective control board.

T. Power ventor turns on and off

during operation.

U. Power ventor will not stop. 1. Power ventor improperly wired.

V. Noisy power ventor. 1. Power ventor wheel loose.

1. Power ventor improperly wired.

2. Motor overload cycling or defective motor.

3. Defective control board.

2. Main burner did not light on call for heat.

3. Defective control board.

2. Power ventor wheel is dirty.

3. Power ventor wheel is rubbing on housing.

1. Turn on power supply, check fuses and replace if bad.

2. Turn up thermostat. Check for 24V on terminals R and W1 on terminal strip.

3. Check all wiring in the power vent circuit to ensure good connection, including "Neutral."

4. Check for 115V between motor leads and check amp draw of motor. Replace if necessary.

5. Check for continuous 115V on terminal "CBM" Blower" and neutral during call for heat. If not present and all checks are normal, replace.

1. Check power ventor circuit per wiring diagram.

2. Check motor voltage and amp draw to motor name plate, replace if motor found defective.

3. Check for continuous 115V on terminal "CBM" Blower" and neutral during call for heat. If not present and all checks are normal, replace.

1. Check power ventor circuit per wiring diagram.

2. Heater is in lockout mode; check ﬂ ash code table for problem.

3. If no ﬂ ash codes present along with no call for heat, replace control board.

1. Replace or tighten.

2. Clean power ventor wheel.

3. Realign power ventor wheel.

Table 9A - Tubular Blower Troubleshooting with LED Indicator Assistance

No Cycling or appliance power or thermostat call for heat since appliance failure has occured.

Line voltage power can cause product damage, severe injury or death. Only a trained experienced service technician should perform this troubleshooting.

1. Check the system thermostat to make sure it is calling for heat. (Do not cycle the thermostat on and off at this time.)

2. Remove the appliance burner compartment door. Do not interrupt power to the control board by opening any electrically interlocked panels.

3. Observe the LED indicator on the control board (a greem LED labeled “OK” indicates system faults); check and repair system as noted in the chart to the right.

*NOTICE: Air flow proving switch and power ventor hose barbs must be free of any dust or debris at all times. Periodically check these openings and/or if any problems occur.

LED STATUS

Slow Flash

Fast Flash

Steady Off

Steady On

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

INDICATES CHECK/REPAIR

Control OK, no call for heat.

Control OK, call for heat present.

Internal control fault, or no power.

Control internal failure or bad ground.

In lockout from failed ignitions or ﬂ ame losses.

Pressure Switch open with inducer on or closed with inducer off.

Limit or rollout switch is open.

Flame sensed while gas valve is off.

On-board microprocessors disagree.

Not Applicable

1. Line voltage on terminals 120 and C on transformer.

2. Low voltage (24V) on terminals 24 and C on transformer.

3. 5 Amp fuse on circuit board.

1. Common side of transformer grounded to chassis.

2. Loose spark ignitor.

1. Gas supply off or gas supply pressure too low.

2. Flame sense rod contaminated or loose wire.

3. Gas valve switch is off or wires are not connected.

4. Broken or cracked porcelain on ﬂ ame probe or spark ignitor.

1. Obstructions or restrictions in appliance air intake or ﬂ ue outlet are preventing proper combustion airﬂ ow.

2. Moisture or debris in tubing that connects pressure switch and draft inducer.

3. Airﬂ ow switch jumpered or miswired.

1. Open manual reset rollout switch.

2. Gas pressure too high, over ﬁ re condition.

3. Incorrect airﬂ ow due to blockage or motor not operating.

1. Flame probe miswired or shortened.

1. Thermostat is interfering with control board.

MAINTENANCE

PERIODIC SERVICE NOTICE: The heater and vent system should be

checked once a year by a qualiﬁ ed technician.

All Maintenance/Service information should be recorded accordingly on the Inspection Sheet provided in this manual.

Open all disconnect switches and disconnect all electrical and gas supplies and secure in that position before servicing unit. Failure to do so may result in personal injury or death from electrical shock.

Gas tightness of the safety shutoff valves must be checked on at least an annual basis. Failure to do so may result in death, serious injury or substantial property damage.

To check gas tightness of the safety shut-off valves, turn off the manual valve upstream of the appliance combination control. Remove the 1/8" pipe plug on the inlet side of the combination control and connect a manometer to that tapping. Turn the manual valve on to apply pressure to the combination control. Note the pressure reading on the manometer, then turn the valve off. A loss of pressure indicates a leak. If a leak is detected, use a soap solution to check all threaded connections. If no leak is found, combination control is faulty and must be replaced before putting appliance back in service.

Should maintenance be required, perform the following inspection and service routine:

1. Inspect the area near the unit to be sure that there is no combustible material located within the minimum clearance requirements listed in this manual.

Under no circumstances should combustible material be located within the clearances specified in this manual. Failure to provide proper clearance could result in personal injury or equipment damage from ﬁ re.

2. Turn off the manual gas valve and electrical power to the unit heater.

3. To clean or replace the burners, remove burner cover. Remove top strip from above burners. Lift burners up and pull away from manifold to remove.

4. With the burners removed, wire brush the inside surfaces of the heat exchanger.

5. Remove any dirt, dust, or other foreign matter from the burners using a wire brush and/or compressed air.

6. Reassemble the unit heater by replacing all parts in reverse order.

7. Check the burner adjustment.

8. Check all gas control valves and pipe connections for leaks.

9. Check the operation of the automatic gas valve by lowering the setting of the thermostat, stopping the operation of the gas duct furnace. The gas valve should close tightly, completely extinguishing the ﬂ ame on the burners.

10. Inspect and service motor/blower assembly. To maintain efficient air flow, inspect and clean the blower blades and housing to prevent buildup of foreign matter.

11. Check motor lubrication. If oiling is required, add 1 or 2 drops of electric motor oil as follows: a. Light Duty - After 3 years or 25,000 hours of

operation.

b. Average Duty - Annually after 3 years or 8,000

hours of operation.

c. Heavy Duty - Annually after 1 year or at least

1500 hours of operation.

Never over oil the motor or premature failure may occur! Over oiling the motor may result in minor injury or property damage.

12. Check and test the operational functions of all safety

devices supplied with your unit.

LIMITED WARRANTY

Power Vented Tubular Blower Unit Heaters

1. The "Manufacturer" warrants to the original owner at original installation site that the above model Gas-Fired Heater ("the Product") will be free from defects in material or workmanship for (1) year from the date of shipment from the factory, or one and one-half (1-1/2) years from the date of manufacture, whichever occurs ﬁ rst. The Manufacturer further warrants that the complete heat exchanger, ﬂ ue collector, and burners be free from defects in material or workmanship for a period of ten (10) years from the date of manufacture. If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period, the manufacturer will repair or replace, at its option, that part of the Product which is shown to be defective.

2. This limited warranty does not apply:

a. if the product has been subjected to misuse or neglect, has been accidentally or intentionally damaged, has

not been installed, maintained, or operated in accordance with furnished written instructions, or has been

altered or modiﬁ ed in any way by any unauthorized person. b. to any expenses, including labor or material, incurred during removal or reinstallation of the Product c. to any damage due to corrosion by chemicals, including halogenated hydrocarbons, precipitated in the air d. to any workmanship of the installer of the Product

3. This limited warranty is conditional upon: a. advising the installing contractor, who in turn notify the distributor or manufacturer b. shipment to the Manufacturer of that part of the Product thought to be defective. Goods can only be returned

with prior written approval of the Manufacturer. All returns must be freight prepaid. c. determination in the reasonable opinion of the Manufacturer that there exists a defect in material or

workmanship

4. Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with

respect to such repaired or replaced part beyond the stated warranty period.

5. THIS LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES, EITHER EXPRESS OR IMPLIED, AND

ALL SUCH OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY. IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL, SPECIAL, OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER, OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE. THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY JURISDICTION.

In the interest of product improvement, we reserve the right to make changes without notice.

IDENTIFICATION OF PARTS

D8928

BLOWER UNIT HEATERS

Figure 12 - Blower Parts Figure 13 - Component Parts

Flue

Power Vent Assembly

Hanger Locations

Figure 14 - Vestibule Panel / Tube Assembly

D8925B

Motor

Blower

Baffle (Secondary)

Flame Sensor

Manifold Burner Assembly

Burner Cover

Peep Hole Cover (Burner)

Ignitor

Gas Valve

Figure 15 - Electrical Control Panel Assembly

Belt Guard

Electrical Control Panel Assembly

Vestibule Panel/ Tube Assembly

D8927

ccordian Fastener

Pressure Switch

Power Venter Connection

Transformer

Base

Fan Motor Connection

Control Board

Terminal Block

D9064

Electrical Control Panel Door

D9064D8928

IDENTIFICATION OF PARTS (continued)

Figure 16 - Power Venter Assembly (100/250 Unit Sizes Shown)

D4798

Figure 17 - Power Venter Assembly (300/400 Unit Sizes Shown)

D4780

Figure 18 - Turbulator/High Limit Location

Power Venter Ass'y

Flue Collector

Turbulator

D8926

HOW TO ORDER REPLACEMENT PARTS

High Limit Ass'y

Vestibule Panel/ Tube Ass'y

D8926

Please send the following information to your local representative: if further assistance is needed, contact the manufacturer's customer service department.

• Unit Number

• Serial Number

• Part Description and Number as shown in Replacement parts Catalog

NOTES:

TUBULAR BLOWER

UNIT NUMBER DESCRIPTION

Digit X X X X — 1 2 3 4 5 6 7 8 9 10 11 12 13 14 +

Item

Preﬁ x UT CA FT FM GT AL GC SV MT MS AS

(Internal use Only)

Digit #1, 2 - Unit Type [UT]

TC - Tubular Blower

Digit #3, 4, 5 - Capacity [CA]

100 - 100,000 BTU/HR 125 - 125,000 BTU/HR 150 - 150,000 BTU/HR 175 - 175,000 BTU/HR 200 - 200,000 BTU/HR 250 - 250,000 BTU/HR 300 - 300,000 BTU/HR 350 - 350,000 BTU/HR 400 - 400,000 BTU/HR

Digit #6 - Furnace Type [FT]

A - Right Side Access

Digit #7 - Heat Exchanger Construction Material [FM]

1 - Standard (Aluminized) Steel 2 - 409 Stainless Steel

Digit #8 - Gas Type [GT]

N - Natural Gas P - Propane Gas (LP)

Digit #9 - Ignition Control [IC]

S - 0-4,999 ft. T - 5,000-11,999 ft.

Note: Installations over 2,000 ft. require gas input deration in the ﬁ eld. Refer to unit installation instructions.

Digit #10 - Direct Spark Gas Control [GC]

1 - Single Stage 2 - Two Stage 3 - Electronic Modulation w/Room Sensing 4 - Electronic Modulation w/Duct Sensing 5 - Electronic Modulation w/Duct Sensing & Room Ovrd. Stat 6 - Electronic Modulation w/External 4-20 mA Input 7 - Electronic Modulation w/External 0-10 VDC Input

Digit #11 - Supply Voltage [SV]

1 - 115/1/60 5 - 230/3/60 2 - 208/1/60 6 - 460/3/60 3 - 230/1/60 7 - 575/3/60 4 - 208/3/60 Z - Special

Note: Supply Voltages [SV] 2-7 include factory mounted step down transformer.

Digit #12 - Motor Type [MT]

1 - Open Drip Proof (Standard) 2 - Totally Enclosed 3 - Premium Efﬁ ciency, Open Drip Proof 4 - Premium Efﬁ ciency, Totally Enclosed

Digit #13 - Blower Motor Sizes [MS]**

A - 1/4 HP w/Contactor P - 1/2 HP w/Magnetic Starter C - 1/2 HP w/Contactor R - 3/4 HP w/Magnetic Starter D - 3/4 HP w/Contactor S - 1 HP w/Magnetic Starter F - 1 HP w/Contactor T - 1-1/2 HP w/Magnetic Starter G - 1-1/2 HP w/Contactor U - 2 HP w/Magnetic Star ter H - 2 HP w/Contactor W - 1/4 HP w/Magnetic Starter J - 1/4 HP 0 - None/Not Applicable L - 1/2 HP

**Notes: 1. All 3-phase units [SV = 4, 5, 6, 7] include a contactor as standard.

2. All single phase units [SV = 1, 2, 3] include a contactor for units equipped with 3/4 HP. motor or higher [MS = D, F, G, H]

[MS] options J, L only available with [SV] option 1 (115/1/60).

Digit #14 - Accessories [AS]

FACTORY INSTALLED

M8 - Discharge Duct Flange S3 - 409 Stainless Steel Flue Collector S5 - 304L Stainless Steel Burners P4 - Terminal Block Wiring P6 - Summer/Winter Switch

† FIELD INSTALLED (AS-____ )

† Field Installed Accessories are not included in the Unit Number. All Field Installed Accessories are entered as a separate line item using the catalog number which utilizes “AS” as a preﬁ x. i.e: A7 becomes AS-A7.

A7 - Pressure Regulator 1/2-2 psi M2-2 M2-3 -

F1 - 1-Stage T675A Ductstat F2 - 2-Stage T678A Ductstat P5 - 24V SPST Relay-Specify Purpose

G1 - 1-Stage T87K Mercury Free Thermostat X2 - 30 Degree Downturn Nozzle w/Subbase Kit X3 - 60 Degree Downturn Nozzle G2 - 1-Stage T87K Mercury Free Thermostat X4 - 90 Degree Downturn Nozzle w/TG511A Guard Kit X5 - Vertical Louver Kit G3 - 1-Stage T834N Mercury Free Thermostat

w/Fan Switch

2-Stage TH5220D Mercury Free Thermostat

G5 w/Subbase

G6 - Locking Thermostat Cover G8 - 1-Stage T6169C Line Voltage Stat

w/Subbase G9 - 1-Stage T822K Mercury Free Thermostat

Vent Caps (5 inch) (Unit Capacity 100-250) Vent Caps (6 inch) (Unit Capacity 300-400)

GAS EQUIPMENT

START-UP

Customer ____________________________________ Job Name & Number _________________________

PRE-INSPECTION INFORMATION

With power and gas off.

Type of Equip: Serial Number _________________________ Model Number __________________________

Name Plate Voltage: _____________ Name Plate Amperage: _____________ Type of Gas: Natural LP Tank Capacity _______ lbs. Rating: _ _____ BTU @ ____ °F

_______ kg _ _____ kw @ ____ °C

❐ Are all panels, doors, vent caps in place? ❐ Has the unit suffered any external damage? Damage ______________________________ ❐ Does the gas piping and electric wiring appear to be installed in a professional manner? ❐ Has the gas and electric been inspected by the local authority having jurisdiction? ❐ Is the gas supply properly sized for the equipment? ❐ Were the installation instructions followed when the equipment was installed? ❐ Have all ﬁ eld installed controls been installed? ❐ Do you understand all the controls on this equipment? If not, contact your wholesaler or rep.

(DO NOT START this equipment unless you fully understand the controls.)

Unit Heater

GENERAL

With power and gas off.

❐ Make certain all packing has been removed. ❐ Tighten all electrical terminals and connections. ❐ Check all fans & blowers for free movement. ❐ Check all controls for proper settings.

❐ Inlet gas pressure. ____ in. W.C. or ____ kPa ❐ Burner ignition. ❐ Manifold gas pressure. ____ in. W.C. or ____ kPa ❐ Cycle ﬁ restat and/or freezestat.

GAS HEATING

With power and gas on.

❐ Check electronic modulation. Set at: __________

FAN

With power and gas off.

❐ Check voltage L1___ L2___ L3___ ❐ Check rotation of main blower. ❐ Check motor amps L1___ L2___ L3___

❐ Cycle and check all other controls not listed. ❐ Check operation of remote panel. ❐ Entering air temp. _____ °F or ____ °C ❐ Discharge air temp. (high ﬁ re) ____ °F. or ____ °C ❐ External static pressure _________ in. W.C. ❐ Cycle by thermostat or operating control. ❐ Combustion Reading:

Carbon Monoxide:____ PPM Carbon Dioxide:____ %

Remarks:

_____________________________________________ __________________________________________________ __________________________________________________

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Sterling TC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual