OWNER / INSTALLER: For your safety this manual must be carefully and thoroughly read and
understood before installing, operating or servicing this heater.
SIS SERIES:
(50, 75, 100, 125, 150, 175) – N5/L5
SIU SERIES:
(50, 75, 100, 125, 150, 175) – N5/L5
!INSTALLER: This manual is the property of the owner. Please present this manual to the
owner when you leave the job site.
▲WARNING: Improper installation, adjustment, alteration, service, or maintenance can
cause property damage, injury or death. Read the installation, operation and maintenance
instructions thoroughly before installing or servicing this equipment.
IF YOU SMELL GAS:
FOR YOUR SAFETY
! DO NOT try to light any appliance.
! DO NOT touch any electrical switch; DO NOT use any
telephone in your building.
! IMMEDIATELY call your gas supplier from a neighbor's
telephone. Follow the gas supplier's instructions. If you
cannot reach your gas supplier, call the fire department.
DO NOT store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
INSTALLATION AND OPERATION INSTRUCTIONS
INFRARED RADIANT TUBE HEATER
Single Stage Pull Through System (Negative Pressure)
Models:
!IMPORTANT: SAVE THIS MANUAL FOR FUTURE REFERENCE.
Post Office Box 36271 (28236) • 306 West Tremont Avenue (28203) • Charlotte, North Carolina
Phone (704) 372-3486 • Fax (704) 332-5843 • www.sunstarheaters.com • email: info@sunstarheaters.com
SUNSTAR HEATING PRODUCTS, INC.
Form 43343310
Dec 2017
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1.0) Safety ................................................................................................................................................... 2
2.0) Installer Responsibility ...................................................................................................................... 2
3.0) General Information ........................................................................................................................... 2
4.0) Minimum Clearances to Combustibles ........................................................................................... 4
5.0) Specifications...................................................................................................................................... 5
6.0) Packing List ......................................................................................................................................... 5
6.1) Accessory Packages .......................................................................................................................... 8
7.0) Typical Layouts ................................................................................................................................. 10
8.0) Dimensions – SIS Series ................................................................................................................. 11
8.1) Dimensions – SIU Series ................................................................................................................. 12
8.2) Heater Assembly / Joining of Tube Sections ............................................................................... 13
9.0) Typical Suspension Methods .......................................................................................................... 15
9.1) Angle Mounting of Heaters ............................................................................................................. 16
10.0) Assembly of Tube Sections ............................................................................................................. 16
10.1) Assembly of Extension Sections .................................................................................................... 17
10.2) Adding Reflectors ............................................................................................................................. 19
10.3) Adding Optional 90º Elbow (SIS Only) ........................................................................................... 20
10.4) Adding Optional Corner Reflector (SIS Only) ................................................................................ 20
10.5) Adding 180º U-Bend (SIU Only) ...................................................................................................... 21
10.6) Adding Optional U-Bend Reflector (SIU Only) ............................................................................... 21
11.0) Attaching Control Box Assembly .................................................................................................... 22
12.0) Attaching Draft Inducer Assembly ................................................................................................. 23
13.0) Multiple Hanging & Draft Inducer Positions ................................................................................ 24
14.0) Gas Connections and Regulations ................................................................................................. 25
15.0) Instructions for Pressure Test Gauge Connection ....................................................................... 27
16.0) Electrical Connections ..................................................................................................................... 28
16.1) Single Stage (N5/L5) – Internal And Thermostat Connections ................................................ 28
17.0) Venting ............................................................................................................................................... 31
18.0) Air for Combustion ........................................................................................................................... 35
18.1) Direct Outside Air for Combustion ................................................................................................. 35
19.0) Lighting and Shutdown Instructions .............................................................................................. 37
20.0) Sequence of Operation – Single Stage (N5/L5) .......................................................................... 37
21.0) Cleaning and Annual Maintenance ............................................................................................... 38
22.0) Troubleshooting Guide – Single Stage (N5/L5) .......................................................................... 39
23.0) Replacing Parts ................................................................................................................................ 42
23.1) Removing Spark Electrode ............................................................................................................. 42
23.2) Removing Main Burner and Gas Valve ......................................................................................... 43
23.3) Air Switch Pressure Check .............................................................................................................. 44
23.4) Ignition System Checks ................................................................................................................... 44
23.5) Motor and Blower Wheel Check ..................................................................................................... 45
24.0) Installation Data ............................................................................................................................... 45
25.0) Replacement Parts Guide ............................................................................................................... 46
26.0) Warnings Card .................................................................................................................................. 51
This heater complies with ANSI Z83.20 (current standard) and CSA 2.34. Copies of the National Fuel Gas Code (ANSI
Z223.1-latest edition) are available from the CSA at 8501 East Pleasant Valley Road, Cleveland, Ohio 44131 or 55 Scarsdale
Road, Don Mills, Ontario M3B 2R3. All NFPA codes are available from the National Fire Protection Association, Batterymarch
Park, Quincy, Massachusetts 02269.
Form 43343310
Dec 2017 -1-
1.0) SAFETY
Warning instructions must be followed to prevent or avoid hazards which
may cause serious injury, property damage or death.
Caution instructions must be followed to prevent incorrect operation or
installation of the heater which may cause minor injury or property
damage.
This heater is a self-contained infrared radiant tube heater. Safety information required during installation and
operation of this heater is provided in this manual and the labels on the product. The installation, service and
maintenance of this heater must be performed by a contractor qualified in the installation and service of gas
fired heating equipment.
All personnel in contact with the heater must read and understand all safety information, instructions and labels
before operation. The following symbols will be used in this manual to indicate important safety information.
2.0) INSTALLER RESPONSIBILITY
The installer is responsible for the following:
The heater and venting, as well as electrical and gas supplies must be installed in accordance with these
installation instructions and any applicable codes and regulations.
Every heater shall be located with respect to building construction and other equipment so as to permit
access to the heater.
Each installer must follow the clearances to combustible materials for the heaters.
Install the heater so that the supports and hangers are correctly spaced in accordance with these
instructions. The heater must be supported by materials having a working load limit of at least 115lbs.
Supply the owner with a copy of these Installation and Operation Instructions.
Where unvented heaters are used, gravity or mechanical means shall be provided to supply and exhaust at
least 4 CFM per 1,000 Btu/hr input of installed heaters.
Never use the heater as a support for a ladder or other access equipment. Do not hang anyth ing from the
heater.
Supply all installation materials necessary that are not included with the heater.
Check the nameplate to make sure that the burner is correct for the gas type in the building and the
installation altitude.
3.0) GENERAL INFORMATION
This heater is a self-contained infrared radiant tube heater for use in locations where flammable gases or vapors
are not generally present (as defined by OSHA acceptable limits) and is intended for the heating of
nonresidential spaces.
INSTALLATION REQUIREMENTS
The installation must conform to local building codes or in the absence of local codes, with the National Fuel Gas
Code ANSI Z223.1/NFPA54 or the Natural Gas and Propane Installation Code CSA B149.1. Heaters shall be
installed by a licensed contractor or licensed installer. Clearances to combustibles as outlined in this manual
should always be observed. In areas used for storage of combustible materials where they may be stacked
below the heater, NFPA54 requires that the installer must post signs that will “specify the maximum permissible
stacking height to maintain the required clearances from the heater to combustibles.”
Every heater shall be located with respect to building construction and other equipment so as to permit access
to the heater. Each installer shall use quality installation practices when locating the heater and must give
consideration to clearances to combustible materials, vehicles parked below, lights, overhead doors, storage
areas with stacked materials, sprinkler heads, gas and electrical lines and any other possible obstructions or
hazards. Consideration also must be given to service accessibility.
The heater, when installed in aircraft hangars and public garages, must be installed in accordance with
ANSI/NFPA 409-latest edition (Standard for Aircraft Hangars), ANSI/NFPA 88a-latest edition (Standard for
Parking Structures), and ANSI/NFPA 88b-latest edition (Standard for Repair Garages) with the following
clearances:
-2- Dec 2017
Form 43343310
a. At least 10 feet above the upper surfaces of wings or engine enclosures of the highest aircraft that may be
(FOR CANADA ONLY)
a. Installation of this appliance is to be in accordance with latest edition of CSA B149.1 (Natural Gas and
Propane Installation Code).
b. For installation in public garages or aircraft hangars, the minimum clearances from the bottom of the
infrared heater to the upper surface of the highest aircraft or vehicle shall be 50 percent greater than the
certified minimum clearance, but the clearance shall not be less than 8 feet.
This product can expose you to chemicals including ceramic fibers, which
are known to the State of California to cause cancer, and carbon monoxide,
which is known to the State of California to cause birth defects or other
reproductive harm. For more information go to www.p65warnings.ca.gov.
housed in the hangar and at least 8 feet above the floor in shops, offices, and other sections of hangars
communicating with aircraft storage or service areas.
b. At least 8 feet above the floor in public garages. ▲WARNING: Minimum clearances marked on the heater
must be maintained from vehicles parked below the heater.
Although these heaters may be used in many applications other than space heating (e.g., process heating),
SunStar will not recognize the warranty for any use other than space heating.
For indoor installation only. Not for use in residential dwellings.
This heater is for Indoor Installation and Covered Patio Installation only and can be used in either Vented or
Unvented mode. The term Unvented actually means Indirect Vented. While the products of combustion are
expelled into the building, national codes require ventilation in the building to dilute these products of
combustion. This ventilation may be provided by gravity or mechanical means.
This heater is not an explosion proof heater. Where the possibility of exposure to volatile and low flash point
materials exists, it could result in property damage or death. This heater must not be installed in a spray booth
where the heater can operate during the spraying process. Consult your local fire marshal or insurance company.
SIS Series Only: Since straight tube heaters are always hotter at the control end than at the flue terminal end,
always observe the minimum recommended mounting heights shown on the specification sheets in Section 5.0)
of this manual. Use U-tube configuration instead of straight tubes for spot or area heating (e.g., where a single
heater is utilized for space heating).
High Altitude:
Appliances are supplied as standard for altitudes of O to 2,000 feet (0-610 m). High-altitude ratings are obtained
by a change in the orifice size. When ordered for high altitude installations, burners are supplied by the factory
ready for high altitude installation. Check the nameplate for altitude before proceeding with the installation. In
Canada the adjustment for altitude is made in accordance with Standard CGA 2.17, Gas-Fired Appliances for Use
at High Altitudes.
Form 43343310
Dec 2017 -3-
4.0) MINIMUM CLEARANCES TO COMBUSTIBLES
MINIMUM CLEARANCES TO COMBUSTIBLES
Model No.
Mounted Horizontally
Angle Mounted at
45º
Sides
Ceiling*
Below
Ends
45º Front
45º Rear
SIS/SIU 50
24”
6”
40”
15”
40”
12”
SIS/SIU 75
24”
6”
60”
15”
52”
12”
SIS/SIU 100
28”
6”
76” **
15”
60”
12”
SIS/SIU 125
32”
6”
82” **
20”
66”
12”
SIS/SIU 150
36”
6”
87” **
20”
70”
12”
SIS/SIU 175
42”
6”
93” **
20”
77”
12”
Install the warnings card (ordered separately) and complete the blank spaces using the clearances from
combustibles table below. See Section 27 for a printed copy of the warnings card.
Minimum clearances to combustibles shall be measured from the outer surfaces as shown in the following
diagram:
* When used indirect vented, minimum clearance for CEILING must be: 12” for SIS/SIU 50-75 and 18” for
SIS/SIU 100-175. If optional corner and U-bend reflectors are not used, the clearance must be 18”.
** Maximum clearance below reduces by 50% once you are 25 ft. downstream from the burner box.
▲WARNING: Certain materials or objects, when stored under the heater, will be subjected to radiant heat and
could be seriously damaged. Observe the Minimum Clearances to Combustibles listed in the manual and on the
heater at all times.
NOTE:
1. The clearances specified above must be maintained to combustibles and other materials that may be
damaged by temperatures 90ºF above ambient temperature. Clearances to combustibles are posted on the
control box. In areas used for storage of combustible materials where they may be stacked below the heater,
NFPA54 requires that the installer must post signs that will “specify the maximum permissible stacking height
to maintain the required clearances from the heater to combustibles.” SunStar recommends posting these signs
adjacent to the heater thermostat or other suitable location that will provide enhanced visibility.
2. The stated clearance to combustibles represents a surface temperature of 90 ºF (32 ºC) above room
temperature. Building materials with a low heat tolerance (such as plastics, vinyle siding, canvas, tri-ply, etc.)
may be subject to degradation at lower temperatures. It is the installer’s responsibility to assure that adjacent
materials are protected from degradation.
Form 43343310
-4- Dec 2017
5.0) SPECIFICATIONS
Model No.
Btu/hr
Input
Flue Restrictor Plate
I.D. & Part #
Orifice Size
Minimum *
Mounting Height
Natural Gas
Propane Gas
@
Horizontal
@
45º Angle
SIS/SIU 50
50,000
1-1/8”
#42741030
3.3mm
(0.130)
#46
(0.081)
11 ft.
10 ft.
SIS/SIU 75
75,000
1-7/16”
#42741010
#20
(0.161)
#39
(0.099)
13 ft.
12 ft.
SIS/SIU 100
100,000
1-5/8”
#42741060
#14
(0.182)
#33
(0.113)
13 ft.
12 ft.
SIS/SIU 125
125,000
1-7/8”
#42741080
#5
(0.206)
#30
(0.129)
14 ft.
13 ft.
SIS/SIU 150
150,000
2-1/32”
#42741090
5.7mm
(0.224)
#28
(0.140)
15 ft.
14 ft.
SIS/SIU 175
175,000
2-1/4”
#42741100
“C”
(0.242)
3.8mm
(0.150)
15 ft.
14 ft.
Control Option
Suffix
Gas Type
Description
N5
Natural
Single Stage Gas Valve – Single Stage Input
L5
Propane
Single Stage Gas Valve – Single Stage Input
Type
Gas
Gas Pipe
Connection1
Tube
Diameter
Flue
Connection2
Fresh Air
Connection
Electrical
Supply
Current
Rating
Natural
or Propane
½” MPT
(Male)
4”
4” Round
6” Round
120 Volt, 60Hz,
1 Phase
2.6 Amp
Module Electrical Rating:
Ignition System (direct spark):
Fuse : 2 Amp 250V (for 24V Circuit) Input Power
Input-Control: 18-30VAC 60 Hz (class 2 transformer)
Flame Sensitivity: 0.7 uA (microamps) minimum
30 second pre-purge period
21 second trial for ignition period
Single trial for ignition (local sense)
Part Description QTY
Control Box Assembly .............................................................................................................................. 1
Draft Inducer & Junction Box Assembly ................................................................................................ 1
Flue Restrictor Plate (See Section 5.0) for plate I.D. and part no.) ................................................... 1
4” Starting Collar (#40504020) ........................................................................................................... 1
Control Fastener Kit (#42907110) ....................................................................................................... 1
Containing: #8-32 Screws & Nuts (#02166010 & #02127030) .......................................... 2
¼ - 20 Locknuts (#02167010) .............................................................................. 6
Tube Flange Gasket (#42921000) ........................................................................ 2
Draft Inducer Flange (#44015251) ...................................................................................................... 1
Installation & Operation Instructions (#43343310) .......................................................................... 1
Gas connector, 5/8” OD x 36” (#30302360) – US only ..................................................................... 1
NATURAL GAS
PROPANE GAS
MODEL NO. PART NO.
MODEL NO. PART NO.
SIS/U 50-N5 .............#43502030
SIS/U 50-L5 ............. #43502040
SIS/U 75-N5 .............#43502070
SIS/U 75-L5 ............. #43502080
SIS/U 100-N5...........#43503050
SIS/U 100-L5 .......... #43502060
SIS/U 125-N5...........#43503110
SIS/U 125-L5 .......... #43503120
SIS/U 150-N5...........#43503170
SIS/U 150-L5 .......... #43503180
SIS/U 175-N5...........#43503210
SIS/U 175-L5 .......... #43503220
* MOUNT HEATERS AS HIGH AS POSSIBLE. Minimums are shown as a guideline for human comfort and uniform
energy distribution for complete building heating applications. Consult your SunStar representative for the
particulars of your installation requirements.
Model Identification:
6.0) PACKING LIST
A. SIS/SIU Control/Draft Inducer Package
CONTROL/DRAFT INDUCER PACKAGE NUMBERS
Form 43343310
Dec 2017 -5-
B. SIS Body Package Descriptions
System Lengths
15 Ft.
System
20 Ft.
System
30 Ft.
System
40 Ft.
System
50 Ft.
System
SIS 50-175 Body Packages – Aluminized/Hot Rolled
15 Ft. Pkg.
44134000
20 Ft. Pkg.
44135000
30 Ft. Pkg.
44136000
40 Ft. Pkg.
44137000
50 Ft. Pkg.
44138000
Part #
Each Body Package Includes:
Qty.
Qty.
Qty.
Qty.
Qty.
42912180
10 Ft. Tube with 12 Hole Flange (Aluminized)
1 1 1 1 1
41932101
10 Ft. Tube less Flanges (Hot Rolled)
- 1 2 3 4
41932051
5 Ft. Tube less Flanges (Hot Rolled)
1 - - - -
43319100
Reflector, 9’ 11½”
1 2 3 4 5
43319050
Reflector, 4’ 11½”
1 - - - -
30462980
Tube Coupling
1 1 2 3 4
43318000
Tube Hanger/Support Bracket, 13”
2 2 3 4 5
43980010
Wire Hanger
2 2 3 4 5
Body Fastener Kit (included in body packages)
42907190
42907190
42907200
42907210
42907220
42873000
U-Bolt 2 2 3 4
5
02127110
Hex Nut, 5/16-18
5 5 6 8 10
02189020
HWHSM Screw, #10-16 x ½” TEKS
8 8 10
14
18
System Lengths
20 Ft.
System
30 Ft.
System
40 Ft.
System
50 Ft.
System
SIU 50-175 Body Packages – Aluminized/Hot Rolled
20 Ft. Pkg.
44135000
30 Ft. Pkg.
44136010
40 Ft. Pkg.
44137000
50 Ft. Pkg.
44138010
Part #
Each Body Package Includes:
Qty.
Qty.
Qty.
Qty.
42912180
10 Ft. Tube with 12 Hole Flange (Aluminized)
1 1 1
1
41932101
10 Ft. Tube less Flanges (Hot Rolled)
1 1 3
3
41932051
5 Ft. Tube less Flanges (Hot Rolled)
- 2 -
2
43319100
Reflector, 9’ 11½”
2 2 4
4
43319050
Reflector, 4’ 11½”
- 2 -
2
30462980
Tube Coupling
1 3 3
5
43318000
Tube Hanger/Support Bracket, 13”
2 4 4
6
43980010
Wire Hanger
2 4 4
6
Body Fastener Kit (included in body packages)
42907190
42907200
42907210
42907220
42873000
U-Bolt 2 4 4 5
02127110
Hex Nut, 5/16-18
5 8 8
10
02189020
HWHSM Screw, #10-16 x ½” TEKS
8
14
14
18
U-Bend package
43208020
43208020
43208020
43208020
42913020
U-Bend 1 1 1 1
43318500
31” Tube Support/Hanger Bracket
1 1 1
1
30462980
Tube Coupling
1 1 1
1
02189020
HWHSM Screw, #10-16 x ½” TEKS
2 2 2
2
(Package Part Number is indicated on the outside of each corresponding carton.)
C. SIU Body Package Descriptions
(Package Part Number is indicated on the outside of each corresponding carton.)
-6- Dec 2017
Form 43343310
D. “TOUGH GUY” SIS Body Package Descriptions
System Lengths
15 Ft.
System
20 Ft.
System
30 Ft.
System
40 Ft.
System
50 Ft.
System
SIS 50-175 Body Packages – Aluminized
15 Ft. Pkg.
44134010
20 Ft. Pkg.
44135020
30 Ft. Pkg.
44136020
40 Ft. Pkg.
44137040
50 Ft. Pkg.
44138060
Part #
Each Body Package Includes:
Qty.
Qty.
Qty.
Qty.
Qty.
42912180
10 Ft. Tube with 12 Hole Flange (Aluminized)
1 1 1 1 1
41932100
10 Ft. Tube less Flanges (Aluminized)
- 1 2 3 4
41932050
5 Ft. Tube less Flanges (Aluminized)
1 - - - -
43319100
Reflector, 9’ 11½”
1 2 3 4 5
43319050
Reflector, 4’ 11½”
1 - - - -
30462980
Tube Coupling
1 1 2 3 4
43318000
Tube Hanger/Support Bracket, 13”
2 2 3 4 5
43980010
Wire Hanger
2 2 3 4 5
Body Fastener Kit (included in body packages)
42907190
42907190
42907200
42907210
42907220
42873000
U-Bolt 2 2 3 4
5
02127110
Hex Nut, 5/16-18
5 5 6 8 10
02189020
HWHSM Screw, #10-16 x ½” TEKS
8 8 10
14
18
System Lengths
20 Ft.
System
30 Ft.
System
40 Ft.
System
50 Ft.
System
SIU 50-175 Body Packages – Aluminized
20 Ft. Pkg.
44135020
30 Ft. Pkg.
44136030
40 Ft. Pkg.
44137040
50 Ft. Pkg.
44138070
Part #
Each Body Package Includes:
Qty.
Qty.
Qty.
Qty.
42912180
10 Ft. Tube with 12 Hole Flange (Aluminized)
1 1 1
1
41932100
10 Ft. Tube less Flanges (Aluminized)
1 1 3
3
41932050
5 Ft. Tube less Flanges (Aluminized)
- 2 -
2
43319100
Reflector, 9’ 11½”
2 2 4
4
43319050
Reflector, 4’ 11½”
- 2 -
2
30462980
Tube Coupling
1 3 3
5
43318000
Tube Hanger/Support Bracket, 13”
2 4 4
6
43980010
Wire Hanger
2 4 4
6
Body Fastener Kit (included in body packages)
42907190
42907200
42907210
42907220
42873000
U-Bolt 2 4 4 5
02127110
Hex Nut, 5/16-18
5 8 8
10
02189020
HWHSM Screw, #10-16 x ½” TEKS
8
14
14
18
U-Bend package
43208020
43208020
43208020
43208020
42913020
U-Bend 1 1 1 1
43318500
31” Tube Support/Hanger Bracket
1 1 1
1
30462980
Tube Coupling
1 1 1
1
02189020
HWHSM Screw, #10-16 x ½” TEKS
2 2 2
2
(Package Part Number is indicated on the outside of each corresponding carton.)
E. “TOUGH GUY” SIU Body Package Descriptions
(Package Part Number is indicated on the outside of each corresponding carton.)
Form 43343310
Dec 2017 -7-
6.1) ACCESSORY PACKAGES
A. End Reflector Accessory Package, Part
#43341010
(1 pkg. per SIS Series or 2 pkgs. per SIU Series)
Contains:
End Reflector, #43320000……QTY–2
Speed Clips, #02266010……QTY–4
B. Elbow Accessory Package, Part #43208010
(Option for SIS Series Only)
Contains:
Elbow, #43175000……QTY–1
#10-16 x ½ Self-Drilling Screws, #02189020……QTY–2
Tube Coupling, #30462980……QTY–1
C. Corner Reflector Accessory Package, Part
#43342000
(Option for SIS Series Only)
Contains:
Corner Reflector Assembly, #43345000……QTY–1
Speed Clips, #02266010……QTY–4
D. U-Bend Package, Part #43208020
(Option for SIU Series Only)
Contains:
U-Bend, #42913020……QTY–1
#10-16 x ½ Self-Drilling Screws, #02189020……QTY–2
Tube Coupling, #30462980……QTY–1
31” Tube Support/Hanger Bracket,
#43318500……QTY–1
E. U-Bend Reflector Package, Part #43488000
(Option for SIU Series Only)
Contains:
U-Bend Reflector, #43490000……QTY–1
U-Bend End Reflector, #43490050……QTY–1
Speed Clips, #02266010……QTY–11
#10-16 x ½ Self-Drilling Screws, #02189020……QTY–4
Installation Form, #43489000……QTY–1
-8- Dec 2017
Form 43343310
F. 31” Hanger/Tube Support, Part #43318500
(Option for Angle Mounting of SIU Series)
G. Exhaust Hood Package, Part #42924000
Contains:
Exhaust Hood Assembly, #42925540……QTY–1
#8-18 x ½ Self-Drilling Screws, #02189030……QTY–2
Form 43343310
Dec 2017 -9-
7.0) TYPICAL LAYOUTS
MODEL
EMITTER LENGTH
MODEL
EMITTER LENGTH
Min.
Max.
Min.
Max.
SIS 50
15 Ft.
30 Ft.
SIU 50
20 Ft.
30 Ft.
SIS 75
20 Ft.
30 Ft.
SIU 75
20 Ft.
30 Ft.
SIS 100
30 Ft.
40 Ft.
SIU 100
30 Ft.
40 Ft.
SIS 125
30 Ft.
50 Ft.
SIU 125
30 Ft.
50 Ft.
SIS 150
40 Ft.
50 Ft.
SIU 150
40 Ft.
50 Ft.
SIS 175
40 Ft.
50 Ft.
SIU 175
40 Ft.
50 Ft.
NOTES:
1. In all configurations, the control unit must be connected directly to the 24-hole flange of the 10 ft.
2. Joining of two 90º elbows directly together to form a “Z” shape IS NOT permitted.
3. Any configuration of components not shown in the illustrations may be used except as noted in 1 and 2
aluminized steel start/end body section.
above.
-10- Dec 2017
Form 43343310
8.0) DIMENSIONS – SIS SERIES
Typical Dimensions Up to 50 Ft. Shown.
Form 43343310
Dec 2017 -11-
8.1) DIMENSIONS – SIU SERIES
Typical Dimensions Up to 50 Ft. Shown.
-12- Dec 2017
Form 43343310
8.2) HEATER ASSEMBLY / JOINING OF TUBE SECTIONS
Form 43343310
Dec 2017 -13-
-14- Dec 2017
Form 43343310
9.0) TYPICAL SUSPENSION METHODS
Various means of suspending the heater can be used. See the following drawings for typical examples.
1. Use only noncombustible materials for suspending hangers and brackets.
2. A minimum No. 2 chain with a working load limit of 115 lbs. is required.
3. Turnbuckles can be used with chains to allow leveling of the heater. All “S” hooks and eye bolts must be
manually crimped closed by the installer.
4. When using rigid means for heater suspension (rod, flat bar, etc.) provide sufficient lengths or swing joints to
compensate for expansion. See Figures b and c.
5. Heaters subject to vibration must be provided with vibration isolating hangers.
6. Heaters must not be supported by gas or electric supply lines and must be suspended from a permanent
structure with adequate load capacity.
SunStar recommends that the body sections be suspended using chains with turnbuckles. This will allow slight
adjustments after assembly and heater expansion/ contraction during operation.
If a “trapeze” method is used for tube support/hanger brackets (shown below), the minimum chain length for the
two connecting chains is 36” to minimize any vibration that might be generated by the draft inducer assembly. If
these chains must be less than 36”, then do not use the trapeze method and, instead, use individual chains on
each tube support/hanger bracket.
Form 43343310
Dec 2017 -15-
9.1) ANGLE MOUNTING OF HEATERS
1. Angle mounting can be accomplished by shortening one length of the chain to achieve the desired angle or
using notched section of the wire hanger for angle mounting.
Angle mounting can result in up to 30 % lower radiant output on the floor level and result in lower tube
temperatures when compared to horizontal mounting. Angle mounting of straight tubes for spot or area
heating (e.g. where a single heater is used for space heating) is not recommended unless you have
additional capacity or larger heaters specified/installed. If you are using straight tube heaters, you might
have to install two smaller size tube heaters with burners located at opposite ends, to provide more uniform
energy distribution and improved comfort level on the floor. Consult your Sunstar Representative if you have
any questions prior to the installation concerning particulars of your application.
2. Based on the location of the wire hangers and spacing between the suspension points, it might be necessary
to use additional tube support brackets to support the reflector system. Please order additional Tube Hanger
Support Bracket (#43318000), U-bolt (#42873000), and 2 pieces of Hex Nut (#02127110) for each 10 ft.
length of emitter tube.
10.0) ASSEMBLY OF TUBE SECTIONS
During field assembly of the heater body sections, the recommended procedure is as follows:
1. Before hanging heater sections, first determine the actual layout of the system (see Sections 7.0) & 8.0) for
details). Consideration must also be taken for flue pipe, fresh air ducting, gas piping, clearances to
combustibles, etc. before hanging heater. Typical suspension methods are shown in Section 9.0).
2. Hang each tube section individually. DO NOT attach the heater tube sections together on the ground and
attempt to hang the entire system.
3. The first 10’ tube section must be aluminized steel (with 12-radial hole flange) as the primary heat
exchanger and the control box connected directly to these tube sections. Failure to attach the control box to
the flange end as indicated above will void the manufacturer’s warranty.
4. Place a tube support/hanger bracket on the end of the heat exchanger tube having the mounting flange.
Align the tube such that the welded seam is facing down toward the ground. Failure to assemble the tube
with the seam facing down will VOID the manufacturer’s warranty.
5. Space the tube support/hanger bracket 6 inches from center of its slotted holes to the front face of the
mounting flange. Secure the tube to the support/hanger bracket using a “U” Bolt clamp and two (2) 5/16-18
nuts provided. For U-tube configuration, see typical assembly overview illustration in Section 8.2)
6. Suspend the chain to attach the wire hanger and the tube support bracket. Insert the tube into the wire
hanger and then raise the tube support bracket end up to the suspension chain, use “S” hooks to attach the
wire hanger and tube support bracket to the chain.
Failure to assemble the tube with the seam facing down and installing the first tube support/hanger bracket
more than 6” from the burner box will VOID the manufacturer’ warranty.
-16- Dec 2017
Form 43343310
10.1) ASSEMBLY OF EXTENSION SECTIONS
Form 43343310
Dec 2017 -17-
See typical assembly overview (Section 8.0) for typical complete assembly. Assemble additional extension
The following coupling tightening instructions MUST be followed properly
to ensure the integrity of the tube connections. Two #10 self-drilling
screws MUST be installed at every coupling as shown in the instructions
below. Failure to do so may result in serious injury or property damage.
sections as required for all systems. (See Sections 7.0) and 8.0) for typical layout details.)
Join the tube sections together and secure with tube couplings as described below:
1. Place the compression coupling over the end of the tube.
2. Use the small hole at the centerline of the coupling to check that the coupling is inserted correctly.
3. Partially tighten the bolt nearest the end of the tube (approximately half closed).
4. Slide the next tube into the coupling.
5. Make sure both tube ends are butted together.
6. Finish tightening both bolts to 40-60 ft.lbs. torque to ensure a complete seal.
7. Use the two Self-drilling screws through the pre-punched holes to secure the tubes in the coupling.
-18- Dec 2017
Form 43343310
8. Check to ensure that the hardware is completely closed and the band is seated on the reaction block and
interference pins as illustrated above.
9. Once all the heater body sections are attached, make sure that the heater system is level. If it is not, slight
adjustments can be made using the turnbuckles. (See Section 9.0)
Important: NEVER reuse a coupling.. Always install a new coupling only and torque as per instructions above and
the diagrams below.
10.2) ADDING REFLECTORS
1. Slide the reflectors on the tube support/hanger brackets and through the wire hangers.
2. The tube at the coupling joints must be covered. Slide the reflectors together and provide an overlap of two
(2”) inches for the first reflector overlap after the control unit. All remaining reflector overlaps will be
approximately one (1”) inch. This will allow for the natural expansion and contraction of the heater when in
operation. Note: The heaters can expand and contract up to 1-3/4 inch. See Detail “B” for the correct
installation of reflector overlaps.
3. Secure the reflectors as shown in Detail “A” using #10 x 1/2” self-drilling sheet metal screws at each tube
support/hanger bracket.
Form 43343310
Dec 2017 -19-
10.3) ADDING OPTIONAL 90º ELBOW (SIS ONLY)
1. The optional 90º elbow must be located a minimum of 10 ft. after the control box.
2. Hang the body sections in a 90º ("L") shaped pattern. Allow spacing for the elbow. The distance from one
end of the elbow to the centerline of the opposite leg is 13" as shown.
3. Join the tube ends of the body sections and the elbow together and secure with tube couplings as described
in Section 10.1).
10.4) ADDING OPTIONAL CORNER REFLECTOR (SIS ONLY)
1. Place the corner reflector over the reflectors of both body sections.
2. Secure by sliding speed clips on the reflector edges. One speed clip is required for each side of reflector.
3. The corner reflector can be used only when the long axis of the heater is level and mounted in a horizontal
position.
-20- Dec 2017
Form 43343310
10.5) ADDING 180º U-BEND (SIU ONLY)
1. Hang body sections parallel with each other. The centerline distance from tube at each body section should
be 18” as shown.
2. Join tube ends of body sections and the U-Bend together and secure with tube couplings as described in
Section 10.1).
10.6) ADDING OPTIONAL U-BEND REFLECTOR (SIU ONLY)
1. Place the U-Bend Reflector over the reflectors of each body section with the end resting next to the tube wire
hangers as shown.
2. Slide the speed clips on the reflector edges towards the end of the body section reflectors. Two speed clips
are required for each side of the U-Bend Reflector. Make sure that the speed clips fit tightly over both the UBend Reflector and the reflector on each body section. Use two self-drilling screws to permanently secure
both sides to the reflectors.
3. Place the End Reflector flush with the U-Bend Reflector as shown. Note: Clearance between end of the U-
Bend Reflector and the U-Bend must be a minimum of 1”. Secure by sliding speed clips onto the end
reflector edges. Evenly space the speed clips on the sides (two each side) and top (three each) of the
reflectors to provide a snug fit.
Form 43343310
Dec 2017 -21-
11.0) ATTACHING CONTROL BOX ASSEMBLY
1. Attach the control box and gasket to end of tube flange and secure with 1/4-20 locknuts. NOTE: The control
box must be mounted to a 10 ft. aluminized steel body section regardless of configuration used. Failure to
attach the control box to the flange end as indicated above will void the manufacturer’s warranty.
2. A 3/8" connector is located on the left side of the control cabinet to provide strain relief for field wiring to
the draft inducer junction box (refer to Section 16.0) on Electrical Connections and Connection Wiring
Diagram for wiring between the control box and the draft inducer.)
3. Assemble the end reflector (optional on SIS/SIU series) flush with the end of the main body reflector. Secure
by sliding speed clips onto the reflector edges. Evenly space the speed clips on the sides (one each side) and
top (two required) of the reflectors to provide a snug fit. Leave a 3" space between the end reflector and the
control box assembly.
4. The control box must be mounted with the perforated fresh air plate on top, facing the ceiling.
5. The heater can be mounted horizontally or at an angle of up to 45 degrees maximum from horizontal.
When angle mounting, the control box must be positioned upright as shown below. Failure to install the control
box in an UPRIGHT position will VOID the manufacturer’s warranty. For additional instructions see Section 13.0)
for multiple hanging and draft inducer positions.
6. Control box can be installed in lower side when angle mounting. Please ensure that there is adequate
clearance to open the control box access panel for servicing the heater.
Failure to install the burner box in an upright position and lights facing the floor will void the manufacturer’s
warranty.
-22- Dec 2017
Form 43343310
12.0) ATTACHING DRAFT INDUCER ASSEMBLY
1. Slide the draft inducer flange over the end of tube. Rotate the flange until the tightening brackets are in the
upright position. Secure the flange by tightening the 1/4-20 screw located on the tightening brackets to 66
inlb (5.5 ftlb).
2. Attach the draft inducer assembly and gasket to end of the draft inducer flange and se cure with 1/4-20
locknuts. A flue restrictor plate is attached to the draft inducer weld studs. DO NOT DISCARD RESTRICTOR
PLATE and make sure this remains in place while the draft inducer is being attached to the heater body.
NOTE: The draft inducer can be mounted in a vertical, a 45º, or a horizontal position. Refer to Section 13.0).
3. The 3/8" connector used to hold the SJO cable will remain to provide strain relief for field wiring of the
control box and the draft inducer (refer to the Electrical Connections and Connection Wiring Diagram for
wiring between the control box and the draft inducer in Section 16.0).
4. If the heater is to be VENTED to the outside of the building, place the starting collar on the outlet of the draft
inducer and secure with the #8-32 screws and nuts. Place the flue pipe directly onto the starting collar,
secure with the #8 sheet metal screws, and terminate with an approved vent cap.
5. If the heater is for UNVENTED use, place the exhaust hood (supplied as an accessory) directly onto the outlet
of the draft inducer (starting collar is not necessary for unvented use). Secure with the #8 sheet metal
screws. The exhaust hood must be mounted only in an upright position and directed toward the r eflector
body.
6. Assemble the end reflector (optional on SIS/SIU series) flush with the end of the main body reflector. Secure
by sliding speed clips onto the reflector edges. Evenly space the speed clips on the sides (one each side) and
top (two required) of the reflectors to provide a snug fit. Leave a 3” space between the end reflector and the
draft inducer assembly.
Form 43343310
Dec 2017 -23-
13.0) MULTIPLE HANGING & DRAFT INDUCER POSITIONS
The heater can be mounted horizontally or at an angle of 45º maximum from horizontal. Make sure the long axis
of heater is level.
Multiple draft inducer positions can also be used as shown in the diagrams. This allows for the desired
configuration of flue venting. Regardless of the position chosen, the junction box must remain horizontal as
shown. This may be achieved as follows:
1. Remove the three (3) ¼-20 locknuts securing the motor and blower wheel assembly.
2. Pull the motor and blower wheel assembly with the motor plate slightly from the end of the housing studs.
Use care not to damage the motor leads.
3. Rotate the junction box assembly to the upright position using the multi-hole mounting bracket.
4. Replace the motor and blower assembly. Tighten the locknuts.
5. Horizontal and 45º draft inducer positions can allow the plastic vacuum air tube to sag. The air tube should
be shortened to prevent a downward sag that could allow condensation build-up in the tube.
-24- Dec 2017
Form 43343310
14.0) GAS CONNECTIONS AND REGULATIONS
DO not use an open flame of any kind to test for leaks.
IMPORTANT BEFORE CONNECTING THE GAS TO THE HEATER
1. Connect to the supply tank or manifold in accordance with the latest edition of National Fuel Gas Code (ANSI
Z223.1), and local building codes. Authorities having jurisdiction should be consulted before the installation
is made. (In Canada, refer to the latest edition of CSA B149.1, Natural Gas and Propane Installation Code.)
2. Check that the gas fuel on the burner rating plate matches the fuel for the application.
3. Check that the gas supply piping has the capacity for the total gas consumption of the heaters and any other
equipment connected to the line.
4. Check that the calculated supply pressure with all gas appliances and heaters operating will not drop below
the minimum supply pressure required for these heaters. Check inlet supply pressures on Section 15.0).
5. All gas supply lines must be located in accordance with the required clearances to combustibles from the
heater as listed on the clearances label of the heater and Section 4.0) of this manual.
6. Pipe joint compounds must be resistant to the action of liquefied petroleum gases.
7. Tube heaters will expand/contract during operation. Where local codes do not prohibit, a CSA or U.L.
approved flexible connector supplied with this heater is required for connections between the rigid piping
and the heater. A union should be installed before the control box inlet. An approved shut off valve should be
installed within 6 feet of the union.
8. The gas pipe, flexible hose and connections must be self supporting. The gas pipe work must not bear any of
the weight of the heater or any other suspended assembly.
9. This appliance is equipped with a step-opening, combination gas valve. The maximum supply pressure to the
appliance is 14” W.C. or 1/2 P.S.I. If the line pressure is more than the maximum supply pressure, then a
second stage regulator which corresponds to the supply pressure must be used.
10. After all gas connections have been made, make sure the heater and all gas outlets are turned off before
the main gas supply is turned on slowly. Turn the gas supply pressure on and check for leaks. To check for
leaks, check by one of the methods listed in Appendix D of the National Fuel Gas Code.
11. If a 2nd stage regulator is used, the ball valve down stream in the supply line must be closed when purging
the gas lines to prevent gas seeping through it. If initial gas pressure is higher than 14” w.c. the redundant
combination gas valve is designed to lock out. Pressure build-up in the supply lines prior to the heater must
be released before proper heater operation.
Form 43343310
Dec 2017 -25-
US ONLY: Connector MUST be installed in “” configuration. Use only
the 36” long connector that was furnished with this heater.
US ONLY: A gas connector certified for use on a tubular type infrared heater per the standard for Connectors
for Gas Appliances, ANSI Z21.24/CSA 6.10 is supplied for installation in US only. The gas connector is 36” long
and 1/2” nominal ID, and must be installed as shown above, in one plane, and without sharp bends, kinks or
twists.
CANADA ONLY: A Type I hose connector should be used that is certified as being in compliance with the
Standard for Elastomeric Composite Hose and Hose Couplings for Conducting Propane and Natural Gas
(CAN/CGA 8.1) and is of length of 36+/- 6 in (90+/- 15 cm). The gas connector must be installed as shown
above, in one plane, and without sharp bends, kinks or twists.
-26- Dec 2017
Form 43343310
15.0) INSTRUCTIONS FOR PRESSURE TEST GAUGE CONNECTION
OUTLET GAS PRESSURE CHECK AND ADJUSTMENTS
Gauges that measure pressure in pounds per square inch are not accurate enough to measure or set the
manifold pressure. All measurements MUST BE made when the heater and all other gas burning equipment that
are connectied to the gas supply system are operating at maximum capacity. The combination gas valve is
factory set and should not need adjustment. If gas pressure adjustment is required, follow the instructions:
1. Turn off all electrical power to the system to connect manometer hoses.
2. Turn the pressure test screw (3/32” Hex) in the center of the boss not more than one turn counterclockwise.
Attach a 5/16” hose and manometer over the tapered outlet pressure boss on the valve (see Figures 1 and
2 below). If regulator needs to be adjusted, see instructions below.
TO ADJUST REGULATOR (single stage gas valves):
1. Turn on power and energize the main gas valve. Remove regulator cover screw (see Figure 1 below). Turn
regulator adjustment screw clockwise to increase presure, or counterclockwise to decrease
pressure. Replace regulator cover screw and tighten securely.
DO NOT EXCEED THE PRESSURES SHOWN IN THE GAS PRESSURE TABLE.
2. After testing pressure and adjusting the regulator, turn off all electrical power to the system, remove
manometer hoses, turn outlet test screw (3/32” Hex) clockwise to seal pressure port. Tighten to 7 in lb
minimum. Turn on system power.
GAS PRESSURE TABLE
GAS TYPE
MANIFOLD PRESSURE
SUPPLY PRESSURE
Minimum*
Maximum
Natural Gas
3.5” W.C.
5” W.C.
1
14” W.C.
Propane Gas
10.0” W.C.
11” W.C.
2
14” W.C.
SUPPLY PRESSURE
1. The installer will provide a 1/8” N.P.T. tapped plug, accessible for test gauge connection immediately
upstream of the gas supply connection to the heater.
Form 43343310
Dec 2017 -27-
* Minimum permissible gas supply pressure for purpose of input adjustment.
1
7” W.C. for SIS/U 150-175
16.0) ELECTRICAL CONNECTIONS
1. All electric wiring shall conform to the latest edition of the National Electrical Code (ANSI/NFPA No. 70), or
the code legally authorized in the locality where the installation is made.
2. The unit must be electrically grounded in accordance with the National Electrical Code (ANSI/NFPA No.
70-latest edition). In Canada, refer to current standard C22.1 Canadian Electrical Code Part 1.
3. The wiring providing power to the heater shall be connected to a permanently live electrical circuit, one t hat
is not controlled by a light switch.
4. The power supply to the unit should be protected with a fused disconnect switch or circuit breaker. A service
switch, as required by local codes, shall be located in the vicinity of the heater (check local codes for
allowable distances) and should be identified as Heater Service Switch. All electrical wiring must be located
in accordance with the required Clearances to Combustibles from the heater as listed on the nameplate on
the heater.
5. When connecting the supply circuit to the heater, wiring material having a minimum size of 14 AWG and a
temperature rating of at least 90C shall be used.
6. If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring
material having a temperature rating of at least 105ºC. (18 Ga. CSA 600V Type TEW)
7. A replaceable 2-amp fuse (1-1/4” long) is fitted to the terminal block located inside the junction box
assembly.
16.1) SINGLE STAGE (N5/L5) – INTERNAL AND THERMOSTAT CONNECTIONS
8. SIS SERIES ONLY: The installer will provide type SJO wire cable having minimum size of 18 AWG and
connect the ends to the draft inducer junction box and the control box. Secure with 3/8” connectors as
previously described in the attachment of the control box and draft inducer. Connect wire leads as shown in
the Connection Wiring Diagram. The SJO cable should be located and secured to protect it from mechanical
damage.
-28- Dec 2017
Form 43343310
SINGLE STAGE CONTROLS - INTERNAL CONNECTION WIRING DIAGRAM
SINGLE STAGE CONTROLS - SCHEMATIC WIRING DIAGRAM
SINGLE STAGE CONTROLS - THERMOSTAT WIRING DIAGRAMS
A. LINE VOLTAGE (120V) THERMOSTAT CONNECTIONS – SINGLE HEATER PER THERMOSTAT
Form 43343310
Dec 2017 -29-
B. LINE VOLTAGE (120V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS PER THERMOSTAT
C. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – SINGLE HEATER PER THERMOSTAT
Order 24V Relay Kit (Part No. 43274010) for Low Voltage (24V) thermostat connection.
D. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS PER THERMOSTAT
-30- Dec 2017
Form 43343310
17.0) VENTING
This is a category lll appliance.
A. BASIC FLUE VENTING — Venting must comply with the latest edition of the National Fuel Gas Code (ANSI
Z223.1-latest edition) or the authority having jurisdiction. Other venting references are in the equipment
volume of the ASHRAE Handbook.
SINGLE HEATER VENTING (VERTICAL THROUGH THE ROOF)
1. When venting the heater to outside of building through a roof, use single-wall metal pipe. This is to be
constructed of galvanized sheet metal or other approved noncombustible corrosion-resistant material as
allowed by state or local codes.
2. A vent passing through a combustible roof shall extend through an approved clearance roof thimble. Double-
wall, Type B vent must be used for the portion of the vent system which passes through the combustible roof.
An approved vent cap must be attached to end of the flue.
3. The maximum equivalent length of vent pipe should be carefully observed. A safety switch in the heater is
designed to shut the heater off before excessive flue restriction causes bad combustion. Refer to the Vent
Sizing Table for vent pipe diameter.
Minimum Equivalent Length = 5 ft. of pipe
Maximum Equivalent Length = 100 ft. of 4” pipe
Use the following correction factors to obtain the equivalent length:
Subtract 15 ft. if the run is horizontal. (maximum horizontal length for 4” pipe is 25 ft.)
Subtract 10 ft. for an approved vent cap.
Subtract 10 ft. for each elbow beyond 15 ft. from the heater.
Subtract 15 ft. for each elbow within 15 ft. of the heater.
4. Joints between sections of piping shall be fastened by sheet metal screws or other approved means and
should be sealed to prevent leakage of flue gas into building. Aluminum or Teflon tape suitable for 550ºF
(3M Company tapes 433 or 363) or silicone sealant is recommended.
5. Avoid locating elbows in the first 5’ of vent pipe whenever possible. Limit to (2) 90 elbows. When vent pipe
is in a horizontal run, it must have 1/4 inch per foot rise.
6. All portions of the vent pipe shall be supported to prevent from sagging (6’ spacing is recommended).
7. When the vent pipe passes through areas where the ambient temperature is likely to induce condensation
of the flue gases, the vent pipe should be insulated and a condensation drain should be provided.
8. Minimum clearance for single-wall flue pipe to combustible material shall be 6 inches. This may be reduced
when the combustible material is protected as specified in the National Fuel Gas Code or the authority
having jurisdiction.
9. Single-wall metal pipe shall not originate in any unoccupied attic or concealed space and shall not pass
through any attic, inside wall or concealed space, or through any floor. For the installation of a single -wall
metal pipe through an exterior combustible wall, refer to latest edition of the National Fuel Gas Code or the
authority having jurisdiction.
10. A venting system shall terminate at least 3 ft. above any forced air inlet located within 10 ft.
11. A venting system shall terminate at least 2ft above any possible snow accumulation.
Form 43343310
Dec 2017 -31-
SINGLE HEATER VENTING (HORIZONTAL THROUGH SIDEWALL)
When venting the heater horizontally through a combustible outside sidewall, the same requirements listed
previously for venting Vertical Through The Roof apply except as follows:
1. A vent passing through a combustible wall must pass through an approved clearance thimble (Air-Jet #4VT
or Ameri-Vent #4EWT or other thimbles) that are listed by a nationally recognized testing agency. Doublewall Type B vent must be used for the portion of the vent system which passes through the combustible
sidewall.
2. An approved vent cap (Breidert or equal) must be attached to the end of the vent pipe.
4” vent – 25 ft. maximum with one 90 elbow and vent cap
6” vent – 75 ft. maximum with maximum two 90 elbows and vent cap
If other horizontal vent configurations are required, consult the manufacturer.
NOTE: To minimize problems associated with condensation in long horizontal runs, vent pipe can be insulated.
3. When venting through a sidewall, the horizontal vent pipe shall rise not less than 1/4 inch per foot from the
start of the vent system to the vent terminal. All portions of the vent pipe shall be supported to prevent
sagging. (6’ spacing is recommended)
4. A minimum clearance of 6 inches must be maintained between the outside wall and vent cap (18”
clearance will provide stability under high wind conditions).
5. The horizontal venting system shall not terminate:
Less than 4 ft. (1.2m) below, 4 ft. (1.2m) horizontally from or 1 ft. (30cm) above any door, operable
window or gravity air inlet into any building. The bottom of the vent terminal shall be located at least 7 ft.
(2.1m) above grade or above snow accumulation level as determined by local codes.
Less than 3 ft. (0.9m) from a combustion air inlet.
Less than 3 ft. (0.9m) from any other building opening or any gas service regulator.
Less than 7 ft. (2.1m) above public walkways.
Directly over areas where condensate or vapor could create a nuisance or hazard or be harmful to the
operation of gas utility meters, regulators, relief valves, or other equipment. Building materials should
be protected from flue gases and condensate.
Less than 12” (0.30m) when directly below a combustible overhang.
6. In regions of the country where prevailing winds are consistently higher than 40 mph, it may be necessary to
terminate the vent system above the roof level.
-32- Dec 2017
Form 43343310
MULTIPLE HEATER VENTING (CONNECTIONS INTO A COMMON VENT OR MANIFOLD)
If any heater connected to a common vent system for multiple
heaters is found inoperative, the heater should be disconnected from
the vent system and its entrance into the vent system capped.
Requirements for venting of multiple heaters are the same as described for SINGLE HEATER VENTING except as
follows:
1. The common vent size and total vent height is normally determined by the number of heaters per common
vent, length of horizontal connector runs, and connector rise. Connector lengths should be as short as
possible and have a minimum 1/4 inch per foot rise. Without regard to connector rise and total vent height
due to many possible venting configurations, the following should be observed:
Common vent pipe & vent connector diameter should be no less than that shown in the following Vent
Sizing Table.
A Y-connector must be used to the common vent.
2. Material for connectors and Y-connectors should be constructed of galvanized sheet metal or other approved
noncombustible corrosion resistant material as allowed by state or local codes. All common vent pipe
should be insulated flue pipe or double-wall, Type B vent.
3. Avoid unnecessary bends. Limit to two (2) 90º elbows.
4. The entire length of vent connector shall be readily accessible for inspection, cleaning and replacement.
5. Groups of heaters with a common vent must be controlled by a common thermostat.
Multiple Heater Vertical Venting Arrangement
Form 43343310
Dec 2017 -33-
Multiple Heater Horizontal Venting Arrangement
VENT SIZING TABLE — Multiple Heater Venting
Number of Heaters
1 2 3 4 5
SIS/U50
4”
4”
5”
5”
6”
SIS/U75
4”
5”
6”
6”
7”
SIS/U100
4”
6”
6”
7”
8”
SIS/U125
4”
6”
7”
8”
9”
SIS/U150-175
4”
6”
8”
9”
10”
COMMON VENT DIAMETER
(If a size is not available use the next larger size.)
Multiple Heater Venting (Connections into a Manifold)
THE ABOVE ILLUSTRATIONS AND TABLE OF VENT SIZES FOR COMMON VENTING OF MULTIPLE HEATERS ARE IN
ACCORDANCE WITH THE NATIONAL FUEL GAS CODE ANSI Z223.1-LATEST EDITION, NFPA 54-LATEST EDITION, EQUIPMENT
VOLUME OF 1988 ASHRAE HANDBOOK, CURRENT CAN/CGA-B149.1/2-M86 INSTALLATION CODE, AND AGA PUBLICATION
NO. 10M5.85 2.5-2 ON FUNDAMENTALS OF GAS APPLIANCE VENTING AND VENTILATION-REVISED BUT ARE NOT A PART OF
THE CSA CERTIFICATION.
-34- Dec 2017
Form 43343310
B. INDIRECT VENTING (UNVENTED HEATERS) — This heater requires ventilation in the building to dilute the
products of combustion and provide fresh air for efficient combustion. Where unvented heaters are used,
gravity or mechanical means shall be provided to supply and exhaust at least 4 CFM per 1,000 Btu/hr input
of installed heaters. Exhaust vents must be located at the highest point above and in the vicinity of the
heaters, and the inlet vents must be located below the level of the heaters. An exhaust hood (Part
#42924000) must be placed on the outlet collar of the draft inducer or on the existing 4” starting collar
when used unvented and must be mounted only in an upright position and directed towards the reflector
body as shown.
18.0) AIR FOR COMBUSTION
If indoor combustion air is to be supplied for a tightly enclosed area, one square inch of free area opening shall
be provided below the heater for each 1,000 Btu/hr of heater input. When outside air is used, the opening below
the heater shall be one square inch of free area for each 4,000 Btu/hr of heater input. In contaminated
atmospheres or high humidity areas, optional outside air for combustion is recommended. Adequate clearances
around the air inlet screen must be maintained at all times. In larger open areas of buildings, infiltration
normally is adequate to provide air for combustion.
18.1) DIRECT OUTSIDE AIR FOR COMBUSTION
Outside combustion air should be supplied directly to the heater when the building is subject to negative
pressure, or when contaminants or high humidity are present in the building air. These contaminants include
paints, solvents, corrosive vapors or any other foreign particles that may cause damage to the heater or result in
poor combustion.
Outside combustion air can be brought directly to the heater by a 6” diameter duct less than 50 ft. long or
equivalent. This is attached to the 6” diameter starting collar. The starting collar is fitted to the top of the control
box cabinet after first removing and discarding the perforated cover. An approved vent cap must be placed
directly on the end of the outside combustion air inlet pipe. The combustion air inlet should be not less than 3 ft.
(0.9m), either vertically or horizontally, from the flue vent termination. The air intake terminal must be located
not less than 1 ft. (30cm) above grade. It is good installation practice to supply combustion air from the same
pressure zone as the vent outlet. Avoid bringing combustion air to the heater from an attic space. There is no
guarantee that adequate combustion air will be supplied.
If the heater is installed less than 2 ft. from the ceiling, a flexible transition section (e.g., flexible aluminum duct)
must be provided to allow for expansion/contraction of straight tube heaters (SIS Series).
In colder climates, where necessary, insulate the outside combustion air duct. Avoid locating the outside
combustion air duct directly above the control box. Provide a capped cleanout T as necessary. In high humidity
applications, the control box should be sealed with silicone sealer.
Form 43343310
Dec 2017 -35-
All vent terminations and Combustion Air Intake Terminations must
be at least 6” higher than anticipated snow depth.
In multiple heater applications, the combustion air intake may be ducted individually or common ducted in the
same configuration as shown for venting in Section 17.0). For combustion air intake duct sizing, please refer to
the Vent Sizing Table and use the diameter indicated, based on the number of heaters per duct.
-36- Dec 2017
Form 43343310
19.0) LIGHTING AND SHUTDOWN INSTRUCTIONS
1. Turn on the gas and electrical supply.
2. Set the thermostat to call for heat. The blower motor will energize.
3. Ignition should occur after the 30-second air pre-purge.
4. If ignition fails, the unit will spark for approximately 21 seconds and go into safety lockout. Turn the
thermostat (power) off for 60 seconds to take the system out of lockout.
5. If the heater does not light, manually reset the thermostat or shut off power completely for 5 minutes before
attempting to relight.
6. To permanently shut down the heater, turn off the gas and electrical supply.
NOTE: The lighting and shutdown instructions are also shown on the permanent nameplate label attached to the
heater control box.
20.0) SEQUENCE OF OPERATION – SINGLE STAGE (N5/L5)
The chart below shows the sequence of operation for the normal operating cycle.
If the flame is not sensed during sequence T3 then the burner will automatically begin ignition sequence T2. If
the flame is not re-established the heater will go to lockout.
Form 43343310
Dec 2017 -37-
21.0) CLEANING AND ANNUAL MAINTENANCE
This heater must be cleaned and serviced annually by a qualified contractor before the start of each heating
season and at any time excessive accumulation of dust and dirt is observed. Maximum heating efficiency and
clean combustion will be maintained by keeping the heater clean.
The contractor shall check the following during periodic maintenance.
Clearances to combustibles: Check that clearances are being maintained. Make sure there are no
flammable objects, liquids or vapors near the heater. See also Section 4.0).
Reflectors: Reflectors should be kept clean, at a minimum blow off the reflectors. (Dirty reflectors may
reduce heat output).
Heat exchanger tubes: Inspect the heat exchanger tubes to make sure they are not cracked, sagging or
showing signs of fatigue.
Combustion air intake: Disconnect combustion air intake from the control box and inspect internally using a
flashlight to make sure no foreign material has collected in the tubes and that there is no obstruction
around the air intake openings. Clean any foreign materials. Inspect any joints to make sure they are
completely sealed. See also Section 18.0).
Venting System: Disconnect vent pipe and inspect internally using a flashlight to make sure no foreign
material has collected in the pipes. Check the external vent cap and make sure that there is no obstruction
around the exhaust openings. Clean any foreign materials. Inspect any joints to make sure they are
completely sealed. See also Section 17.0).
Gas lines: Make sure that the gas lines are not leaking. Check the gas connection to the heater for any signs
of damage, fatigue or corrosion. If there are any signs of damage to the gas connection or leaks found in the
gas piping, immediately stop using the heater until the gas pipe and connections have been repaired or
replaced. Check that the gas lines are not bearing the weight of the heater. See also Section 14.0).
Control Box: In order to extend the longevity of the heater, the heat exchanger tube and the burner must be
level. Check that the control box is level; use the turnbuckle on the burner suspension eyebolt to adjust the
level of the burner. See also Section 9.0).
Blower wheel and housing: Check that the blower wheel spins freely, blow out any dust or dirt with
compressed air.
Electrode condition: Visually check that the electrode gap is maintained at 3/16” and that the tips of the
spark electrode are free from deposits. Clean off any deposits. Check that the electrode ceramic is free from
cracks. See Section 23.1).
Suspension system: Check that the suspension system is holding the heater level. Make sure that the heater
is hanging securely, look for any evidence where the heater may have been hit accidentally and tighten any
loose hanging points. Check that S hooks are closed. Check that there is no evidence of wear on the chain at
the connection to the heater and at the ceiling.
Main Burner and Orifice: Check the Main burner and orifice; remove any dirt or debris including spider webs.
See Section 23.1).
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Form 43343310
22.0) TROUBLESHOOTING GUIDE – SINGLE STAGE (N5/L5)
Form 43343310
Dec 2017 -39-
TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED)
-40- Dec 2017
Form 43343310
TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED)
Form 43343310
Dec 2017 -41-
23.0) REPLACING PARTS
Only use genuine SunStar replacement parts. Parts are available from the factory for replacement by a licensed
person. Refer to the Replacement Parts Guide in Section 25.0) for all replacement parts.
23.1) REMOVING SPARK ELECTRODE
The main burner can be inspected without removing the burner housing from the heat exchanger tube.
1. Disconnect electrical supply and open access panel.
2. Pull out the ignition cable hooked to spark electrode.
3. Remove two mounting screws.
4. Take out the spark electrode. Check that the spark gap is 3/16”.
5. Check spark electrode. Spark electrode should be clean and free from debris.
6. Check ceramic on the spark electrode. It should be free from cracks.
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Form 43343310
23.2) REMOVING MAIN BURNER AND GAS VALVE
1. Disconnect electrical supply and gas connection at the restrainer nipple.
2. Open the access panel and disconnect the wires from gas valve.
3. Remove the burner clamp and screws.
4. Remove the burner and gas valve assembly from the cabinet.
5. Unscrew the burner from the manifold.
6. Check the orifice. If the gas valve is to be replaced, the pipe joint compounds must be resistant to the action
of liquefied petroleum gases.
Form 43343310
Dec 2017 -43-
23.3) AIR SWITCH PRESSURE CHECK
Model
Operating Pressure
SIS/U 40 - 175
0.42” W.C. Hot
SIS/U 180 - 250
0.57” W.C. Hot
1. Open hinged access panel.
2. Add tubing to connect the air switch with the connector tee and the existing tubing.
3. Connect plastic tubing of a digital or inclined water manometer with a 0-2” scale onto the connector tees.
4. Turn heater on and wait until blower motor is activated.
5. Observe air pressure from manometer. This should be higher than the set point 0.42” W.C. for correct
operation.
All pressures are with the heater in operation for at least 15 minutes.
23.4) IGNITION SYSTEM CHECKS
TO CHECK IGNITION CABLE.
a. Make sure that the ignition cable does not touch any metal surface.
b. Make sure that connections to the stud terminal and the igniter/sensor are clean and tight.
c. Make sure that the ignition cable provides good electrical continuity.
TO CHECK IGNITION SYSTEM GROUNDING.
(Nuisance shutdowns are often caused by a poor or erratic ground.) A common ground is required for the module,
igniter, flame sensor and main burner.
a. Check for good metal-to-metal contact between the igniter bracket and the main burner.
b. Check the ground lead from the GND (BURNER) terminal on the module to the igniter bracket. Make sure
c. Replace igniter/sensor with factory replacement part if insulator is cracked.
TO CHECK SPARK IGNITION CIRCUIT.
▲WARNING: The ignition circuit generates a 20,000 Volt open circuit and electrical shock can result.
a. Check ignition cable.
b. Check external fuse located inside the draft inducer junction box.
c. Verify power (24V) at module input terminals and output terminal to gas valve.
d. Replace spark module if fuse and power are OK.
connections are clean and tight. If the wire is damaged or deteriorated, replace it.
-44- Dec 2017
Form 43343310
IGNITION MODULE DIAGNOSTICS (Fenwal #35-6087J1-034 module only)
LED Indication
Error Mode
Steady On
Internal Control Fault
2 Flashes
Flame Sense Fault
3 Flashes
Ignition Lockout
Date of
Installation:
# of Heaters in
System:
Serial No.
Model:
SIS or SIU
N = Natural Gas
L = Propane Gas
The LED located on the ignition module will flash ON for ¼ second, then OFF for ¼ second during a fault
condition. The pause between fault codes is 3 seconds.
TO CHECK FLAME SENSOR CIRCUIT (Fenwal #35-6087J1-034 module only)
The flame current is the current that passes through the flame from the sensor to the ground. The minimum
flame current necessary to keep the system from lockout is 0.7 micro-amps.
a. To measure the flame current, connect an analog DC micro-ammeter to the FC- and FC+ terminals
per diagram. The meter should read 0.7 micro-amps or higher when the burner is running full on.
b. If the meter reads below zero, the meter leads are reversed. Disconnect power and reconnect the
meter leads for proper polarity.
c. Remove micro-ammeter. Return system to normal operation.
23.5) MOTOR AND BLOWER WHEEL CHECK
If draft inducer motor fails to run:
a. Check power supply to junction box.
b. Check for loose or broken motor lead wire.
c. Check to see that blower wheel turns freely and is not rubbing housing. Blower wheel may have worked
d. Check for blower wheel damage; replace if necessary. If no damage, readjust blower wheel on shaft &
e. If all above does not correct, replace motor.
24.0) INSTALLATION DATA
Form 43343310
Dec 2017 -45-
loose from shaft and jammed against housing.
retighten set screw.
25.0) REPLACEMENT PARTS GUIDE
DRAFT INDUCER COMPONENTS
Item No.
Part No.
Description
1
42917980
Kit, Draft Inducer Replacement (0.37” W.C.)
1a
42928000
Kit, Motor Replacement
3
03723000
Blower Wheel, Revcor
4
03988120
Plastic Vacuum Air Tube, 12” long
5
42739010
Blower Housing Sub-Assembly
6
42740000
Motor Plate
7
42742000
Sensing Tube Bracket
8
42744000
Sensing Tube, Draft Inducer
9
30347000
Motor Spacer (4 per motor)
10
03868010
3/8” Connector
11
42837050
Kit, Air Switch, set @ 0.37” W.C., #NS2-0306-00
13
30267000
½” Knockout Plug
14
30279000
Transformer
15
30281000
Terminal Block, EK-204
16
30330000
Terminal Block, TFB-323
16a
30202000
Fuse, 2A 250V
17
42709000
Terminal Block Shield
18
42398040
Monitoring Light, Green
19
02175050
Strain Relief
21
42909000
Junction Box
22
42910000
Junction Box Cover
23
42911000
Junction Box Support Bracket
24
42923000
SJO Cable Assembly
25
03721000
Motor
27
43221000
Draft Inducer Gasket
30
42741030
Restrictor Plate, 1-1/8” I.D. (50M Btu/hr)
32
42741010
Restrictor Plate, 1-7/16” I.D. (75M Btu/hr)
34
42741060
Restrictor Plate, 1-5/8” I.D. (100M Btu/hr)
36
42741080
Restrictor Plate, 1-7/8” I.D. (125M Btu/hr)
37
42741090
Restrictor Plate, 2-1/32” I.D. (150M Btu/hr)
38
42741100
Restrictor Plate, 2-1/4” I.D. (175M Btu/hr)
40
40504020
Starting Collar, 4”
Labels
Item No.
Part No.
Description
Qty.
41
42874000
Label, Wire Diagram
1
42
42922020
Label, Sidewall Venting
1
-46- Dec 2017
Form 43343310
Form 43343310
Dec 2017 -47-
CONTROL COMPONENTS
Item No.
Part No.
Description
1
03868010
3/8” Connector
2
30295000
Electrode PSE-GF1 (Igniter/Sensor)
3
30314120
Ignition Cable, 14” long
4
30324000
Terminal Block, EK-104
5
44010010
Kit, Spark Module – Fenwal #35-608711-034
6
42398060
Monitoring Light, Red
7
42398050
Monitoring Light, Amber
8
42447000
Sight Glass
9
9a
10
44010270
Kit, Gas Valve – WR #36J23-203B1 Single Stage (natural gas)
SIS/SIU 100-175
10a
44010280
Kit, Gas Valve – WR #36J23-204B1 Single Stage (propane gas)
SIS/SIU 100-175
10b
44010290
Kit, Gas Valve – WR #36J23-203B1 Single Stage (natural gas)
SIS/SIU 50-75
10c
44010300
Kit, Gas Valve – WR #36J23-204B1 Single Stage (propane gas)
SIS/SIU 50-75
11
42757010
Restrainer Nipple, 4” long
12
42757020
Restrainer Nipple, 4” Long – with center block (for WR valves only)
13
42885000
Spark Module Shield
14
42887100
Burner Clamp
15
42890010
Burner Assembly
16
42899100
Burner Bracket Sub-Assembly
17
42888000
Electrode Bracket
18
42893000
Air Inlet Plate (Perforated)
19
42905000
Access Panel
20
42906100
Cabinet Assembly (for offset burner)
21
42889000
Orifice Fitting – ½” NPT x 9/16-18
22
03258xxx
Orifice for 100M–175M Btu/hr (State Model & Gas Type for Size)
23
03540090
Coupling, ½”
24
42701000
Orifice Fitting – ½” NPT x 7/16-27
25
03259xxx
Orifice for 50M-75M Btu/hr (State Model & Gas Type for Size)
26
42700000
Burner
27
43169000
Burner Clamp
28
43172100
Burner Bracket Sub-assembly
29
43170000
Electrode Bracket
30
03333140
Nipple, ½”x4” long
Labels / Manual
Item No.
Part No.
Description
Qty.
31
43343310
Installation and Operation Instructions (not shown)
1
32
42785000
Label, Wire Diagram (ladder)
1
33
42874000
Label, Wire Diagram
1
34
42875000
Label, Warning
1
35
43269000
Label, 24V Supply
1
36
43270000
Label, Terminal ID (terminals 1 & 2) 24V Supply
1
37
42013010
Label, “SunStar” Logo
1
38
42848010
Label, “SunStar” Nameplate
1
39
43344010
Label, Clearance to Combustibles
1
40
43344050
Label, Gas Connector Warning
1
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Form 43343310
Form 43343310
Dec 2017 -49-
BODY COMPONENTS: SIS/U 50-175
Item
No.
Part No.
Description
1
02266010
Reflector Speed Clip
2
43980010
Wire Hanger
3
42873000
“U” Bolt Clamp, 4” OD Tube
3a
02127110
5/16-18 Hex Nut (2 per “U” Bolt)
4
43318000
Tube Support/Hanger Bracket, 13”
5
43319050
Reflector, 4’-11½” long (5’ section only; 1 per 5 ft. body section)
6
43319100
Reflector, 9’-11½” long (10’ section only; 1 per 10 ft. body section)
7
43320000
End Reflector
8
43342000
Corner Reflector Package
9
42921000
Tube Flange Gasket
10*
44028030
10’ Tube Assembly Kit, 4” OD, ALC steel with one 12-radial hole flange (start tube)
11
44028100
10’ Tube Assembly Kit, 4” OD, HR steel without flanges (extension tube & exhaust tube)
12
44028120
5’ Tube Assembly Kit, 4” OD, HR steel without flanges (extension tube & exhaust tube)
13
43208010
4” O.D. Elbow Package
14
02189020
#10 x ½” Self-Drilling Screw (2 per coupling)
15
30462980
4” OD Tube Compression Coupling w/bolts
16
43208020
4” OD U-Bend (Required for SIU Only)
ALC = Heat Treated, Aluminized Steel
17
43488000
U-Bend Reflector (SIU Option)
HR = Hot Rolled Steel
18
44015251
Tube Flange Assembly (with 1/4-20 x 1” screw)
* Required on all models for mounting of control box.
Note:
1) Screws, Nuts and Washers are standard hardware items and can be purchased at any local hardware store.
2) Please order by PART NUMBER – not by Item Number.
3) Replacement Part Prices are available when ordering.
4) Please refer to complete Model Number when ordering.
ALL ILLUSTRATIONS ARE INTENDED TO GIVE THE GENERAL IMPRESSION OF UNITS ONLY. OTHER
COMBINATIONS OF 5 FT. AND 10 FT. SECTIONS, AND ONES WITH OR WITHOUT THE ELBOW PACKAGE ARE
POSSIBLE. PLEASE CONSULT WITH YOUR SUNSTAR SALES REPRESENTATIVE. WE RESERVE THE RIGHT TO
ALTER ANY SPECIFICATION WITHOUT NOTICE.
-50- Dec 2017
Form 43343310
26.0) WARNINGS CARD
Copies of this card may be ordered at no charge under part no. 43344980 for installation near the heater.
B
Form 43343310
Dec 2017 -51-
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