Sterling TF-400, TF-200, TF-175, TF-150, TF-100 User Manual

...

(S) DSTBIM-3

INSTALLATION INSTRUCTIONS AND PARTS LIST

TUBULAR GAS FIRED DIRECT SPARK PROPELLER UNIT HEATERS

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

J30-06935

Model 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.

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.

03/07

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) 564-5540 FAX: (413) 562-5311

www.sterlinghvac.com

MODELS: TF-100, 125, 150, 175, 200, 250, 300, 350, 400 GF-150, 250, 400

Please utilize this toll free number to contact your local representative 800-490-2290.

HVAC PRODUCTS

TABLE OF CONTENTS

SPECIFICATIONS

Basic Description ....................................................2

Performance & Speciﬁ cation Data .......................... 4

GENERAL SAFETY INFORMATION

Installation Codes ............................................... 2, 3

Special Precautions ............................................ 2, 3

INSTALLATION

Locating Units ..................................................... 5, 6

Combustion Air ................................................... 5, 6

Proper Clearances ..............................................5, 6

Suspension of Units ............................................5, 6

Gas Piping .......................................................... 7, 8

ELECTRICAL CONNECTIONS ....................... 9, 10, 11

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.

VENTING ........................................... 12, 13, 14, 15, 16

OPERATION

Explanation of Controls and Operation ..................17

Main Burner Oriﬁ ce Schedule ............................... 18

Adjustments .................................................... 18, 19

TROUBLESHOOTING GUIDE ................20, 21, 22, 23

MAINTENANCE

Servicing & Cleaning ............................................ 24

WARRANTY ...............................................................25

IDENTIFICATION OF PARTS ..............................26, 27

Replacement Parts ................................................27

INSPECTION SHEET ................................................. 28

DESCRIPTION

The Tubular Gas Fired Unit Heaters are a factory assembled, power vented, low static pressure type propeller fan unit heaters designed to be suspended within the space to be heated. THESE HEATERS ARE NOT TO BE CONNECTED TO DUCTWORK. The

designs are certified by ETL as providing a minimum of 80% thermal efficiency, and approved for use in California. Do not alter these units in any way. If you have any questions after reading this manual, contact the manufacturer.

Figure 1 - Tubular Propeller Unit Heater

See Identiﬁ cation of Parts throughout this manual.

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

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

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

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 CGA-B149.1 “Installation Codes for Natural Gas Burning Appliances and Equipment” or CGA-B149.2 “Installation Codes for Propane Gas Burning Appliances and Equipment.” These unit heaters have been designed and certiﬁ ed to comply with CGA 2.6. Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES.

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

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

personal injury.

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

Follow installation instructions CAREFULLY to avoid creating unsafe conditions. All wiring should be done and checked by a 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.

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.

Do not attach ductwork to this product or use it as a makeup air heater. Such usage voids the warranty and will create unsafe operation.

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

The open end of 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!

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 Propeller 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) (43.9) (51.2) (58.6) (73.2) (87.8) (102.5) (117.1) Output - BTU/Hr. 81,000 101,250 121,500 141,750 162,000 202,500 243,000 283,500 324,000 (kW) (23.7) (29.6) (35.6) (41.5) (47.5) (59.3) (71.2) (83.0) (95.0) Thermal Efﬁ ciency (%) 81 81 81 81 81 81 81 81 81 Free Air Delivery - CFM 1,600 2,200 2,400 2,850 3,200 3,450 5,000 5,600 5,800 (cu. m/s) (0.756) (1.039) (1.133) (1.346) (1.511) (1.629) (2.361) (2.644) (2.738) Air Temperature Rise - Deg. F 47 42 47 46 47 54 45 47 51 (Deg. C) (26) (23) (26) (26) (26) (30) (24) (26) (28) Full Load Amps at 120V 5.3 5.8 5.8 8.0 8.0 8.0 11.3 13.5 13.5 MOTOR DATA: Motor HP (Qty.) 1/10 1/4 1/4 1/3 1/3 1/3 (2) 1/4 (2) 1/3 (2) 1/3 Motor kW (0.080) (0.19) (0.19) (0.25) (0.25) (0.25) (0.19) (0.25) (0.25) Motor Type SP PSC PSC PSC PSC PSC PSC PSC PSC R.P.M. 1,050 1,140 1,140 1,140 1,140 1,140 1,140 1,140 1,140 Amps @ 115V 4.2 4.7 4.7 5.8 5.8 5.8 9.4 11.6 11.6 DIMENSIONAL DATA - inches (mm) “A” Overall 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) (831) (831) (831) (1289) (1289) (1289) “C” Width to CL 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 Rear of Housing 11 11 11 11 11 11 12-1/4 12-1/4 12-1/4 (279) (279) (279) (279) (279) (279) (311) (311) (311) “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” 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) “G” Depth to CL 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) “H” 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) “L” 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) *Flue Size Diameter - in. 5 5 5 5 5 5 6 6 6 (Dia.-mm) (127) (127) (127) (127) (127) (127) (152) (152) (152) Fan Diameter - in. (Qty.) 16 16 16 18 18 18 (2) 16 (2) 18 (2) 18 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 - lbs. 133 145 155 191 201 211 307 321 335 (kg) (60) (66) (70) (87) (91) (96) (139) (145) (152) Approximate Ship Weight - lbs. 173 185 195 241 251 261 367 381 395 (kg) (78) (84) (88) (109) (114) (118) (166) (173) (179)

* For all installations, the ﬂ ue collar is included with the unit and should be ﬁ eld installed per the instructions included with the unit.

† Ratings shown are for unit installations at elevations between 0 and 2,000 ft (0 to 610m). For unit installations in U.S.A. above 2,000 ft. (610m), the unit input must be derated 4% for each 1,000 ft. (305m) above sea level; refer to

local codes, or in absence of local codes, refer to the latest edition of the National Fuel Gas Code, ANSI Standard Z223.1 (N.F.P.A. No. 54).

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 derated to 90% of the normal altitude rating,

and be so marked in accordance with the ETL certiﬁ cation.

1-3/8"

(35)

(Hanging)

Flue

11-5/8"

(Hanging)

(295)

32-1/2"

(826)

Electrical Control Panel

D4617

DIMENSIONS .XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS (XXX) MILLIMETERS

Rear View Side View Front View

Gas Valve

(Discharge Opening)

Figure 2 - Dimensional Drawing – Tubular Propeller Unit Heater

(Discharge

Opening)

33"

1" (25)

INSTALLATION

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 feet (2.4m) above the ﬂ oor, measured to the bottom of the unit. At heights above 8 feet (2.4m), less efﬁ cient air distribution will result. If a unit is to be mounted below

8 feet (2.4m) from the ﬂ oor, an OSHA approved fan guard is required on the unit.

AIRCRAFT HANGARS: Unit Heaters must be installed

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

PUBLIC GARAGES: In repair garages, unit heaters must be located at least 8 feet (2.4m) 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 CGA 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.

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.

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

The unit heater shall be located in such a manner as not to interfere with proper circulation of air within the 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.

In parking structures, unit heaters must be installed so that the burner ﬂ ames are located a minimum of 18 in. (457mm) above the ﬂ oor or protected by a partition not less than 18 in. (457mm) high. However, any unit heater mounted in a parking structure less than 8 ft. (2.4m) above the ﬂ oor must be equipped with an OSHA approved fan guard. Refer to the latest edition of NFPA 88A, Parking structures.

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

INSTALLATION (continued)

CLEARANCES: Each Gas Unit Heater shall be

located with respect to building construction and other equipment so as to permit access to the Unit Heater. Clearance between vertical walls and the vertical sides of the Unit Heater shall be no less than 6 inches (152mm). However, to ensure access to the control box, a minimum of 18" (457mm) is required for the control box side. A minimum clearance of 6 inches (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 inches (305mm) from any combustible. The distance between the flue collector and any combustible must be no less than 6 inches (152mm). Also see AIR FOR COMBUSTION and VENTING sections.

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

Make certain that the lifting methods used to lift the heater and the 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!

Figure 3A

Figure 3B - Heater Mounting*

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.

Unit Heaters must be hung level from side to side and from front to back, see Figure 3A, 3B and 3C. 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, 3B and 3C for suspension of units.

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

Figure 3C

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:

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.

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

NOTICE: If more than one unit heater is to be served by the same piping arrangement, the total cu. ft./hr. input and length of pipe must be considered.

NOTICE: If the gas unit heater is to be 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 company to make sure that the existing line is of adequate size to handle the combined load.

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.

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 specified in Table 4. A field LP tank regulator must be used to limit the supply pressure to a maximum of 14 in. W.C. (3.5 kPa). All piping should be sized in accordance with the latest edition of ANSI Standard Z223.1, National Fuel Gas Code; in Canada, according to CGA B149. See Tables 1 & 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!

Figure 4 - Pipe Installation, Standard Controls

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.

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

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

ELECTRICAL CONNECTIONS

HAZARDOUS VOLTAGE!

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

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

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 5a, 5b, 5c, 5d and 5e.

THERMOSTAT WIRING AND LOCATION:

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

Mount the thermostat approximately 5 feet (1.5m) 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.

Figure 5a Low-voltage T Thermostat Wiring Single Stage

Figure 5b - Low-voltage Thermostat Wiring Two Stage

Figure 5c T834H-1009 or T834H-1017 Thermostat Wiring

Honeywell

T834H-1009

T834H-1017

Thermostat

RGW1W2

D6922B

THERMOSTAT HEAT ANTICIPATOR ADJUSTMENTS:

The initial heat anticipator setpoint should equal the thermostat's current amperage draw when the unit is firing. This setpoint should be measured for the best results. Use the recommended ranges for a guide. If further information is needed, consult your thermostat manufacturer's instructions.

Recommended heat anticipator settings:

Unit Size: 30 thru 200 250 thru 400

For Tubular Units: 0.35 Amps 0.65 Amps

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

IMPORTANT: For all wiring connections, refer to the wiring diagram shipped with your unit (either 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.

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