Thomas & Betts UDAS, UDAP User Manual

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Series Fan-Type

Table of Contents

Page

Warnings ........................................ 1

Installation/Operation .............. 2-25

Check/Test/Startup ................. 26-28

Maintenance/Service .............. 28-36

Index (by page)

Burner ................................................... 16, 29

Burner Orifice ............................................ 30

Burner Removal ........................................... 29

California Warning Label .............................. 3

Clearances .................................................... 7

Installation Codes ......................................... 2

Confined Space (UDAP) ............................... 8

Dimensions ................................................ 4-5

Disconnect, Built-in (UDAS) ................ 16, 34

Door Switch (UDAS) ............................19, 33

Downturn Nozzle (Option) ............................4

Electrical Connections ............................... 16

Fan............................................................... 32

Fan Motor...............................................22, 32

Flame Rollout Switch ......................... 18, 34

Gas Piping and Pressures ........................... 12

Gas Valve ...............................................22, 33

General .......................................................... 2

Hanging the Heater ......................................10

Hazard Intensity Levels ............................... 2

Heat Exchanger Maintenance ......................29

High Altitude ............................................ 6, 14

Ignition System ......................................19, 31

Limit Control .........................................18, 33

Location (Heater) ...........................................9

Maintenance Schedule ............................... 28

Pressure Switch (Combustion Air) ....... 17, 33

Replacement Parts ................ See Form P-UD

Sound Data ................................................... 6

Startup ..........................................................26

Suspending Heater ....................................... 4

Technical Data ...............................................6

Thermostat (Option) .................................. 17

Throw (Heater) ..............................................9

Transformer..................................................33

Troubleshooting ................................... 34-36

Uncrating and Preparation ........................... 3

Valve Outlet Pressure ...................................14

Vent System ............................................... 34

Venter Motor ............................................... 32

Venting Model UDAP ........ Use Form I-V-PV

Venting Model UDAP-CV Use Form I-V-CV

Venting Model UDAS ......... Use Form I-V-SC

Warranty.........................................................3

Wiring Diagrams.................................... 23-25

C E R T I F I E D

Unit Heaters

Installation/Operation FORM RZ-NA I-UDA

APPLIES TO: Models UDAP and UDAS

FOR YOUR SAFETY

What to do if you smell gas:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call your fire department.

FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

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.

WARNING: Gas-fired appliances are not designed for use in hazardous atmospheres containing flammable vapors or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in applications with airborne silicone substances. See Hazard Levels, page 2.

WARNING: Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply.

WARNING: Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and replace any gas control that has been under water.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 1

Hazard Levels of Warnings in this Manual

HAZARD INTENSITY LEVELS

1. DANGER: Failure to comply will result in severe personal injury or death and/or property damage.

2. WARNING: Failure to comply could result in severe personal injury or death and/or property damage.

3. CAUTION: Failure to comply could result in minor personal injury and/or property damage.

1. General

BOTH this manual and the correct venting manual are REQUIRED for installation of this heater.

Model UDAP 30 to 125 and Model UDAS 30 to 125 are design certified by the Canadian Standards Association for use in residential, industrial, and commercial installations. Models UDAP 150 to 400 and UDAS 150 to 400 are design certified by the Canadian Standards Association for use in industrial and commercial installations only. All models and sizes are available for use with either natural or propane gas. The type of gas, the input rate and the electrical supply requirement is shown on the heater’s rating plate. Check the rating plate to determine if the heater is appropriate for the intended installation.

Installation requires both this manual AND the venting manual.

Venting Manual by Model

Venting Instruction Look for Matching Label on

Model Manual by Form No. Venting Manual and Heater UDAP Standard Power Vent Label with

Installation (each heater Red Square has its own dedicated vent)

- Form RZ-NA I-V-PV

UDAP-CV Optional Common Vent Label with with Installation (must be inverted Option equipped with Option AV6) Blue Triangle AV6 - Form RZ-NA I-V -CV

Model UDAP-CV is available in Sizes 30, 45, 60, 75, 100 only UDAS Separated Combustion Label with

- Form RZ-NA I-V-SC Green Circle

2. Installation Codes

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 2

Both this installation manual and the appropriate venting manual are shipped with the heater. Verify that the literature is correct for the heater being installed. If either manual is missing or incorrect, contact your distributor before beginning installation.

The instructions in this manual apply only to the models listed. Installation should be done by a qualified agency in accordance with these in-

structions. The qualified service agency installing this heater is responsible for the installation.

These units must be installed in accordance with local building codes. In the absence of local codes, in the United States, the unit must be installed in accordance with the National Fuel Gas Code, ANSI Z223.1. A Canadian installation must be in accordance with the CAN/CGA B149 Installation Codes. These codes are available from CSA Information Services, 1-800-463-6727. Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements.

Special Installations (Aircraft Hangars/ Repair Garages/ Parking Garages)

Installations in aircraft hangars should be in accordance with ANSI/NFPA No. 409 (latest edition), Standard for Aircraft Hangars; in public garages in accordance with ANSI/NFPA No. 88A (latest edition), Standard for Parking Structures; and for repair garages in accordance with ANSI/NFPA No. 88B (latest edition), Standard for Repair Garages. In Canada, installations in aircraft hangars should be in accordance with the requirements of the enforcing authorities, and in public garages in accordance with CAN/CGA B149 codes.

California Warning Label

Massachusetts Requirement

3. Warranty

If the heater is being installed in the state of California, the installer MUST attach a warning label on the outside of the access door. The California Warning label is shipped in the owner’s envelope along with this manual, the warranty form, and any other paperwork that applies.

If installation is in California, select a location on the heater access panel. Be sure the surface is clean and dry and adhere the label.

If the heater is being installed in the Commonwealth of Massachusetts, these units must be installed by a licensed plumber or licensed gas fitter.

Refer to the limited warranty information on the Warranty Card in the "Owner's Envelope".

Warranty is void if ...

a. Wiring is not in accordance with the diagram furnished with the heater. b. The unit is installed without proper clearance to combustible materials. c. A fan model is connected to a duct system or if the air delivery system is

modified.

4. Uncrating and Preparation

This unit was test operated and inspected at the factory prior to crating and was in operating condition. If the heater has incurred any damage in shipment, document the damage with the transporting agency and contact an authorized Reznor Distributor. If you are an authorized Distributor, follow the FOB freight policy procedures as published by Thomas & Betts for Reznor products.

Check the rating plate for the gas specifications and electrical characteristics of the heater to be sure that they are compatible with the gas and electric supplies at the installation site.

Read this booklet and become familiar with the installation requirements of your particular heater. If you do not have knowledge of local requirements, check with the local gas company or any other local agencies who might have requirements concerning this installation.

Before beginning, make preparations for necessary supplies, tools, and manpower. If the installation includes optional vertical louvers, downturn nozzle, ceiling mounting bracket, hanger kit, high altitude kit, multiple heater control, and/or stepdown transformer, install these options before the heater is suspended. Follow the instructions included in the option package; option packages are shipped separately .

Other shipped separate items could include a vent/combustion air kit, high temperature tape, a thermostat bracket kit, a thermostat, and/or a thermostat guard. Be sure all options ordered are at the installation site.

IMPORTANT : Shipping brackets are attached with cabinet screws. When removing shipping brackets, re-insert ALL screws into the cabinet.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 3

5. Dimensions

M and N - Hanger Dimensions for both 2-pt and 4-pt Suspension

P and Q -

Hanger

Dimensions

for 4-pt

Suspension

3/8-16 Female Thread

- all suspension points

TOP VIEW

R - Hanger Dimension for 2-pt Suspension

(30-125 Vertical;

150-400 Horizontal)

Thermostat Connection

Combustion Air Inlet

REAR

FIGURE 1 - Model UDAP,

Power Vented Fan Model

VIEW

Line Voltage

Inlet (connects

at circuit board)

FRONT

VIEW

1-1/4

(32)

External Gas

Connection

RIGHT SIDE

VIEW

(Access Panel)

Vent Collar

(see Technical Data for size)

REZNOR

MODEL UDAP DIMENSIONS (inches ± 1/16)

Size

30, 45 12-1/8 26-5/8 10 13-13/16 26 2 1-9/16 5-3/16 6-1/2 2-11/16 3-7/8 17-3/8 11/16 4-5/16 13 9-9/16

60 15-1/8 2 6-5/8 13 13-13/16 27 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2

75 15-1/8 26-5/8 13 13-13/16 27-5/8 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 100 2 3-1/8 26-5/8 21 13-13/16 28-5/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 125 2 3-1/8 26-5/8 21 13-13/16 29-3/8 21-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2

150, 175,

200

225, 250 26-1/8 38-3/16 22 23 42 35-3/8 13-1/16 8-13/16 9 6-1/2 25-11/16 1-3/8 8-3/16 22-3/16 15-5/8

300, 350,

400

MODEL UDAP DIMENSIONS (mm ± 2)

Size A B C D E F G H J K M N P Q R

30, 45 308 676 254 351 660 548 132 165 6 8 98 441 17 110 330 243

60 384 676 330 351 6 86 548 200 1 65 140 98 441 17 1 10 330 267

75 384 676 330 351 7 02 548 200 1 65 140 98 441 17 110 330 267 100 58 7 676 533 351 727 548 368 165 222 98 441 17 110 330 267 125 58 7 676 533 351 746 548 368 165 222 98 441 17 110 330 267

150, 175,

200

225, 250 664 970 559 584 1067 899 332 2 24 229 165 652 35 208 564 397

300, 350,

400

FIGURE 2 With Optional Downturn Nozzle Dimension “U”

-- Applies to both UDAP and UDAS

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 4

ABC D EF G H J K MNPQ R

20-1/8 38-3/16 16 23 42 35-3/8 8-1/2 8-1/4 5-7/16 6-1/2 2 5-11/16 1-3/8 8-3/16 22-3/16 16-3/8

34-1/8 41 30 23 42 35-3/8 17-1/16 9 11-13/16 7-5/16 27-11/16 1-3/8 8-3/16 22 -3/16 16-3/16

511 970 406 584 1067 899 216 210 138 165 652 35 208 564 416

867 1041 762 584 1067 899 433 229 300 186 703 35 208 564 411

O ption C D3

With Option CD2 or CD4

With Option CD3

Size

O ptions CD2 a nd C D4

inches mm inches mm 30, 45 7-1/8 181 12-3/8 314 60, 75 8-5/8 219 15 381 100, 125 12-5/8 321 21-7/8 556 150, 175, 200 11-1/2 292 19-7/8 505

U U

225, 250 14-1/2 368 25-1/8 638 300, 350, 400 18- 1/2 470 32 813

M and N - Hanger Dimensions

for both 2-pt and 4-pt Suspension

R - Hanger Dimension for 2-pt Suspension

FIGURE 3 - Model UDAS,

Separated Combustion Fan

Combustion Air Connection

(see Technical Data for size)

Model

REAR

VIEW

(Access Panel)

External Gas

Connection

RIGHT SIDE

VIEW

Vent Connection

(see Technical Data for size)

P and Q -

Hanger

Dimensions

for 4-pt

Suspension

Thermostat

Connection

TOP VIEW

3/8-16 Female Thread

- all suspension points

FRONT

VIEW

(30-45, 150-400

Horizontal;

60-125 Vertical)

Line Voltage

Inlet (connects in

sealed electrical box)

1-1/4

(32)

REZNOR

MODEL UDAS DIMENSIONS (inches ± 1/16)

Size

30, 45 12-1/8 26-5/8 10 13-13/16 26 21-9/16 5-3/16 6-1/2 2-11/16 3-7/8 17-3/8 11/16 4-5/16 13 9-9/16 2-15/16 2-15/16

150, 175,

225,

300, 350,

MODEL UDAS DIMENSIONS (mm ± 2)

Size A B C D E F G H J K M N P Q R S T

30, 45 308 676 254 351 660 548 132 165 68 98 441 17 110 330 243

100 125 150, 175,

225,

300, 350,

ABCD EF G H J KMNPQ R S T

60 15-1/8 26-5/8 13 13-13/16 27 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 3-1/4 2-15/16

75 15-1/8 26-5/8 13 13-13/1627-5/8 21-9/16 7-7/8 6-1/2 5-1/2 3-7/8 17-3/8 11/164-5/16 13 10-1/2 3-1/4 2-15/16 100 23-1/8 26-5/8 21 13-13/1628-5/821-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 4-5/8 2-15/16 125 23-1/8 26-5/8 21 13-13/1629-3/821-9/16 14-1/2 6-1/2 8-3/4 3-7/8 17-3/8 11/16 4-5/16 13 10-1/2 4-5/8 2-15/16

20-1/8 38-3/16 16 23 42 35-3/8 8-1/2 8-1/4 5-7/16 6-1/2 25-11/16 1-3/8 8-3/1622-3/16 16-3/8 4-1/8 8-5/16

200

26-1/8 38-3/16 22 23 42 35-3/8 13-1/16 8-13/16 9 6-1/2 25-11/16 1-3/8 8-3/1622-3/16 15-5/8 5-9/16 8-5/16

250

34-1/8 41 30 23 42 35-3/8 17-1/16 9 11-13/16 7-5/16 27-11/16 1-3/8 8-3/1622-3/16 16-3/16 9-1/16 8-9/16

400

75 75

384 676 330 351 686 548 200 165 140 98 441 17 110 330 267 89 75 384 676 330 351 702 548 200 165 140 98 441 17 110 330 267

587 676 533 351 727 548 368 165 222 98 441 17 110 330 267

89 75

117 75

587 676 533 351 746 548 368 165 222 98 441 17 110 330 267 117 75

511 970 406 584 1067 899 216 210 138 165 652 35 208 564 416

200

664 970 559 584 1067 899 332 224 229 165 652 35 208 564 397

250

867 1041 762 584 1067 899 433 229 300 186 703 35 208 564 411

400

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 5

105 211

141 211

230 217

6. Technical Data

(

)

(

)

(

)

TECHNICAL DATA - Sizes 30 - 125

Size 30 45 60 75 100 125

Input Heating Capacity Thermal Efficiency (%) 828383838383

Output Heatin g Capacity

Gas Connection (inches) Vent Connection

Combustion Air Inlet Control Amps (24 volt) 1.0 1.0 1.0 1.0 1.0 1.0 Full Load Amps (115 volt) 1.9 2.4 2.4 3.3 3.9 5.1

Maximum Over Current Protection Normal Power Consumption (watts) 109 155 155 217 276 354 Discharge Air Temperature Rise (°F) 50 55 60 60 60 60

Air Volume

Discharge Air Opening Area

Output Velocity

Fan Motor HP Fan Motor RPM 1550 1550 1550 1550 1050 1050

Fan Diameter (inches) 10 10 12 12 16 16 Sound Level dba @ 15 ft 40 40 40 49 54 55

(inches diameter )

(inches diameter) -

115V)

Data applies to both Models UDAP and UDAS unless noted otherwise.

BTUH 30,000 45,000 60,000 75,000 105,000 120,000

kw 8.8 13.2 17.6 22.0 30.8 35.2

BTUH 24,600 37,350 49,800 62,250 87,150 99,600

kw 7.2 11.0 14.6 18.3 25.6 29.2

Natural 1/2 1/2 1/2 1/2 1/2 1/2

Propane 1/2 1/2 1/2 1/2 1/2 1/2

444444

UDAS onl

CFM 456 629 769 961 1345 1537

minute

FPM 475 656 616 770 668 763

M/minute 145 200 188 238 196 245

Open 0.02 0.03 0.03 0.06 1/30 1/20

Enclosed N.A. N.A. N.A. N.A. 1/4 1/4

444444

15 15 15 15 15 15

12.9 17.8 21.8 27.5 36.7 45.9

0.96 0.96 1.25 1.25 2.01 2.01

0.09 0.09 0.12 0.12 0.19 0.19

TECHNICAL DATA - Sizes 150 - 400

Data applies to bo th Models UDAP and UDAS unless noted othe rwise.

Size 150 175 200 225 250 300 350 4 00

Input Heating Capacity Thermal Efficiency (%) 83838383838383 83 Output Heatin g Capacity

Gas Connection (inches) Vent Connection

Combustion Air Inlet

(inches diameter

(inches diameter) Control Amps (24 volt) 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Full Load Amps (115 volt) 3.8 3.8 4.6 7.5 7.5 10.7 10.7 10.7

Maximum Over Current Protection Normal Power Consumption (watts) 392 392 491 747 747 1086 1086 1086 Discharge Ai r Temperature Rise (°F) 60 60 60 60 60 60 60 60

Air Volume

Discharge Air Opening Area

Output Velocity

Fan Motor HP

Fan Motor RPM 1050 1050 1050 1050 1050 1050 1050 1050 Fan Diameter (inches) 18 18 18 20 20 24 24 24 Sound Level dba @ 15 ft 51 52 53 56 56 59 61 62

CSA ratings for altitudes to 200 0 ft.

Smaller and/or larger vent and combustion air pipe diameters may be permissible. For Model UDAS refer to the Venting Installation Manual for Separated Combustion Units. Fo r Mod el UDAP refer to the Venting Installation Manual for Power Vented units. For a Model UDAP with Option AV6, refer to the Venting Installation Manual for Common Venting.

MOCP = 2.25 x (largest motor FLA) + smallest motor FLA. Answer is rounded to the next lower standard circuit breaker size.

All other information is this table is based on a heater equipped with a s tandard 115 volt open fan motor.

BTUH 150,000 175,000 200,000 225,000 250,000 300,000 350,000 400,000

kw 43.9 51.2 58.6 65.9 73.2 87.8 102.5 117.1

BTUH 124,500 145,250 166,000 186,750 207,500 249,000 290,500 332,000

kw 36.4 42.5 48.6 54.7 60.8 72.9 85.1 97.2

Natural 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4

Propane 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4

5555566 6 6666666 6

15 15 15 15 15 20 20 20

54.4 63.5 72.5 81.6 90.7 108.8 126.9 145.1

2.56 2.56 2.56 3.51 3.51 4.79 4.79 4.79

0.24 0.24 0.24 0.33 0.33 0.45 0.45 0.45

115V)

UDAS onl

CFM 1921 2242 2562 2882 3202 3843 4483 5123

minute

FPM 752 877 1003 820 911 802 936 1069

M/minute 229 267 306 250 278 244 285 326

Open 1/6 1/6 1/6 1/4 1/4 1/2 1/2 1/2

Enclosed 1/4 1/4 1/4 1/4 1/4 1/2 1/2 1/2

Size shown is for gas connection to a single-stage gas valve, not supply line size.

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 6

7. High Altitude

If the heater is being installed at an elevation above 2000 ft (610M), the input rate will have to be derated. This is done by adjusting the valve outlet pressure.

Operation

In addition, if the heater is being installed at an altitude above 6000 ft (1830M), the pressure switch will have to be changed. If ordered with the unit as Option DJ20 or DJ21, the pressure switch is shipped separately.

Gas valve adjustment for high altitude can only be done after heater is operating; see Paragraph 12.

Adjusting the valve outlet pressure is done after the heater is in operation; follow the instructions in Paragraph 12. Capacities and inputs for derated units are also listed in Paragraph 12.

If the pressure switch needs to be changed, do that before the heater is operated; follow the instructions in FIGURE 4.

FIGURE 4 - Installing High Altitude Pressure Switch required above 6000 ft (1830M) elevation

Model UDAP Size 30 45 60 75 100 125 150 175 200 225 250 300 350 400

High Altitude Switch P/N Negative Pressure OFF Setpoint "w.c. Label color

Model UDAP-C V with Option AV6 for Common Venting Size 30 45 60 75 100

High Altitude Switch P/N 197029 197032 196388 Negative Pressure OFF Setpoint "w.c. 0.60 0.45 0.50 Label color Lt Blue Pin

Model UDAS Size 30 45 60 75 100 125 150 175 200 225 250 300 350 400

High Altitude Switch P/N 196388 197030 Differential Pressure OFF Setpoint "w.c. 0.50 0.40 Label color Oran

197031 197032

0.35 0.45

Pur

le Pink

196362

0.55

White

197029

0.60

Lt. Blue

Orange

eGreen

197031

0.35

Pur

197031

Pur

0.35

201160

1.00

Brown

201160 201161

1.00 1.30

Brown

201161

1.30

White

Pressure Switch

8. Clearances

Clearances

Size

30-125 1 25 6 152 18 457 1 25 1 25 18 457

150-400 4 102 6 152 18 457 2 51 1 25 18 457

*Suspend the he ater so that the bot tom is a minimum of 5 feet ( 1 .5M) a bov e t h e floor .

Instructions for Changing Pressure Switch

1. In the control compartment, locate the pressure switch. Sizes 30-125 - On the back wall of the control compartment. Sizes 150-400 - On the bracket on the bottom of the control compartment.

2. Mark and disconnect the two wires attached to the pressure switch.

3. Disconnect the sensing tube from the pressure switch.

4. Locate the two screws holding the switch mounting bracket. Remove the screws (save screws) and the pressure switch.

5. Using the same screws, install the high altitude pressure switch. Attach the sensing tube and wires.

Units must be installed so that the clearances in the table are provided for combustion air space, inspection and service, and for proper spacing from combustible construction. Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface temperature of 90°F above the surrounding ambient temperature is not exceeded.

inches mm inches mm inches mm inches mm inches mm inches mm

Flue Connector Access Panel Non-Access Side

Bottom* Rear

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 7

9. Combustion Air -

applies to Model UDAP and Model UDAP-CV

(Note: For Model UDAS, see Venting Manual for combustion air requirements.)

This heater must be supplied with the air that enters into the combustion process and is then vented to the outdoors. Sufficient air must enter the equipment location to replace that exhausted through the heater vent system. In the past, the infiltration of outside air assumed in heat loss calculations (one air change per hour) was assumed to be sufficient. However , current construction methods using more insulation, vapor barriers, tighter fitting and gasketed doors and windows, weatherstripping, and/or mechanical exhaust fans may now require the introduction of outside air through wall openings or ducts.

The requirements for combustion and ventilation air depend upon whether the unit is located in a confined or unconfined space. An "unconfined space" is defined as a space whose volume is not less than 50 cubic feet per 1000 BTUH of the installed appliance. Under ALL conditions, enough air must be provided to ensure there will not be a negative pressure condition within the equipment room or space.

WARNING: Model UDAP and UDAP-CV power-vented unit heaters are designed to take combustion air from the space in which the unit is installed and are not designed for connection to outside combustion air intake ducts. Connecting outside air ducts voids the warranty and could cause hazardous operation. See Hazard Levels, page 2.

Combustion Air Requirements for a Heater Located in a Confined Space - applies to Model UDAP and Model UDAP-CV

FIGURE 5 - Definition of Confined Space and Required Openings for Combustion Air

Do not install a unit in a confined space without providing wall openings leading

to and from the space. Provide openings near the floor and ceiling for ventilation and air for combustion as shown in FIGURE 5, depending on the combustion air source as noted in Items 1, 2, and 3 below.

Add total BTUH of all appliances in the confined space and divide by figures below for square inch free area size of each (top and bottom) opening.

Confined Space: A space whose volume is less than 50 cubic feet per 1000 BTUH of the installed appliance input rating

1. Air from inside the building -- openings 1 square inch free area per 1000

BTUH. Never less than 100 square inches free area for each opening. See (1) in

FIGURE 5.

2. Air from outside through duct -- openings 1 square inch free area per 2000 BTUH. See (2) in FIGURE 5.

3. Air direct from outside -- openings 1 square inch free area per 4000 BTUH. See (3) in FIGURE 5.

(3)

Confined

Space

(3)

(1)

(2)

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 8

NOTE: For further details on supplying combustion air to a confined space, see

the National Fuel Gas Code ANSI Z223.1a (latest edition).

10. Unit Heater

Location

Use the sound data in Paragraph 6, clearances in Paragraph 8; the combustion air requirements in Paragraph 9; the throw tables, mounting height requirements, and location recommendations below; the weights in Paragraph 11; and the venting requirements in the Venting Manual to determine where to suspend the heater.

Heater Throw

*Louver angle listed in the table is relative to the top of the heater.

FIGURE 6 - Throw for Fan Models UDAP and UDAS

NOTE: Throws listed are with

standard adjustable horizontal louvers at the angles listed (angle is relative to the top of the heater). Throw pattern changes with the addition of optional vertical louvers and/or downturn nozzles.

Dimensions X, Y, and Z (feet) Model UDA P and Model UDAS with Standar d Hor i zontal Lo uver s at Mounting Heights of 5 - 18 ft

5 ft 6 14 30 -21 ° 7 16 40 -20° 8 18 45 - 16° 9 20 57 -14° 9 20 59 -18° 10 22 65 -14°

8 ft 7 13 26 -39 ° 9 16 37 -34° 10 18 42 -29° 12 22 54 -25° 11 21 56 -28° 12 2 3 63 -24° 10 ft 6 11 22 -52° 9 15 33 -43° 10 17 39 -37° 12 22 52 -32° 12 20 52 -36° 13 24 60 -30° 12 ft - - - - 8 12 27 -55° 10 16 34 -46° 12 21 48 -39° 11 19 47 -44° 14 23 57 -36° 14 ft - - - - - - - - 9 14 29 -56° 12 19 44 -46° 11 17 42 -51° 14 22 53 -43° 16 ft - - - - - - - - - - - - 11 17 38 -54° 10 14 34 -58° 13 20 47 -50° 18 ft------------------ - -111740-57°

8 ft 1 3 24 73 -26° 15 28 90 -22° 16 30 93 -20° 14 27 86 -24° 16 29 93 -21° 15 28 94 -24° 17 31 105 -20° 18 34 113 -17° 10 ft 14 24 69 -32° 17 29 87 -27° 17 31 91 -25° 15 27 82 -30° 17 30 90 -26° 16 28 89 -29° 18 32 103 -25° 20 35 110 -21° 12 ft 14 24 64 -39° 18 29 84 -32° 18 31 88 -30° 16 27 78 -35° 18 30 87 -31° 17 28 85 -34° 19 32 98 -30° 21 36 108 -25° 14 ft 14 22 59 -45° 18 28 79 -37° 19 30 84 -34° 16 26 73 -41° 18 30 83 -36° 17 27 80 -40° 20 32 95 -34° 23 35 105 -29° 16 ft 13 20 53 -51° 18 27 74 -42° 19 29 79 -39° 16 24 67 -47° 19 28 78 -41° 17 25 74 -45° 21 31 90 -38° 23 35 101 -33° 18 ft 11 17 44 -58° 17 26 68 -48° 19 28 74 -44° 14 22 60 -53° 18 27 72 -46° 16 24 66 -51° 20 30 85 -43° 23 35 97 -37°

Dimensions X, Y, and Z (mete rs) Model UDAP and Model UDAS with Standard H ori zontal Louvers at Mounting Heights of 1.5 - 5.5M

1.5 M 1.8 4.3 9.1 -21° 2.1 4.9 12.2 -20° 2.4 5.5 13.8 -16° 2.7 6.1 17.4 -14° 2.7 6.1 18.0 -18° 3.0 6.7 19.9 -14°

2.4 M 2.1 4.0 7.9 -39° 2.7 4.9 11.3 -34° 3.0 5.5 12.8 -29° 3.7 6.7 16.5 -25° 3.4 6.4 17.1 -28° 3.7 7.0 19.2 -24°

3.0 M 1.8 3.4 6.7 -52° 2.7 4.6 10.0 -43° 3.0 5.2 11.9 -37° 3.7 6.7 15.8 -32° 3.7 6.1 15.8 -36° 4.0 7.3 18.3 -30°

3.7 M - - - - 2.4 3.7 8.2 -55° 3.0 4.9 10.4 -46° 3.7 6.4 14.6 -39° 3.4 5.8 14.3 -44° 4.3 7.0 17.4 -36°

4.3 M - - - - - - - - 2.7 4.3 8.8 -56° 3.7 5.8 13.4 -46° 3.4 5.2 12.8 -51° 4.3 6.7 16.1 -43°

4.9 M - - - - - - - - - - - - 3.4 5.2 11.6 -54° 3.0 4.3 10.4 -58° 4.0 6.1 14.3 -50°

5.5 M------------------ - -3.45.212.2-57°

2.4 M 4.0 7.3 22.3 -26° 4.6 8.5 27.4 -22° 4.9 9.1 28.0 -20° 4.3 8.2 26.2 -24° 4.9 8.8 28.3 -21° 4.6 8.5 28.7 -24° 5.2 9.4 32.0 -20° 5.5 11.3 34.4 -17°

3.0 M 4.3 7.3 21.0 -32° 5.2 8.8 26.6 -27° 5.2 9.4 27.7 -25° 4.6 8.2 25.0 -30° 5.2 9.1 27.4 -26° 4.9 8.5 27.1 -29° 5.5 9.8 31.4 -25° 6.1 10.7 33.5 -21°

3.7 M 4.3 7.3 19.5 -39° 5.5 8.8 25.6 -32° 5.5 9.4 26.8 -30° 4.9 8.2 23.8 -35° 5.5 9.1 26.5 -31° 5.2 8.5 25.9 -34° 5.8 9.8 29.9 -30° 6.4 11.0 32.9 -25°

4.3 M 4.3 6.7 18.0 -45° 5.5 8.5 24.1 -37° 5.8 9.1 25.6 -34° 4.9 7.9 22.3 -41° 5.5 9.1 25.3 -36° 5.2 8.2 24.4 -40° 6.1 9.8 29.0 -34° 7.0 10.7 32.0 -29°

4.9 M 4.0 6.1 16.2 -51° 5.5 8.2 22.6 -42° 5.8 8.8 24.1 -39° 4.9 7.3 20.4 -47° 5.8 8.5 23.8 -41° 5.2 7.6 22.6 -45° 6.4 9.4 27.4 -38° 7.0 10.7 30.8 -33°

5.5 M 3.4 5.2 13.4 -58° 5.2 7.9 20.7 -48° 5.8 8.5 22.6 -44° 4.3 6.7 18.3 -53° 5.5 8.2 21.9 -46° 4.9 7.3 20.1 -51° 6.1 9.1 25.9 -43° 7.0 10.7 26.9 -37°

30 45

XYZ

150 175 200 225 350 400

XYZ

30 45 60

XYZ

150 175 200 400225 250 300 350

XYZ

le*

XYZ

Louver

le*

XYZ

Louver

le*

XYZ

Louver

le*

XYZ

Louver

le*

XYZ

Louver

le*

XYZ

Louver

le*

XYZ

Louver

le*

XYZ

Louver

Z**

Louver

75 100 125

le*

XYZ

le*

XYZ

75 100 125

le*

XYZ

le*

XYZ

le*

XY Z

Louver

le*

XY Z

Louver

le*

XY Z

Louver

le*

XY Z

Louver

250 300

le*

XY Z

Louver

le*

XY Z

Louver

le*

XY Z

Louver

le*

XY Z

Louver

le* An

Louver

le*

XYZ

Louver

le* An

Louver

le*

XYZ

Louver

**Z is the point when the air velocity drops below 50 feet (15.2M) per minute.

le*

XYZ

Louver

le*

XYZ

Louver

le* An

Louver

le* An

Louver

Location

Locate the heater so that it is a minimum of five feet (1.5M) above the floor and in compliance with the clearances in Paragraph 8.

Recommendations

W ARNING: If touched, the vent pipe and internal heater surfaces that are accessible from outside the heater will cause burns. Suspend the heater a minimum of 5 feet (1.5M) above the floor.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 9

10. Unit Heater Location (cont’d)

NOTE: Venting requirements may affect location. Consult the Venting Manual for this heater before making final determination.

For best results, the heater should be placed with certain rules in mind. In general, a unit should be located from 8 to 12 feet (2.4-3.7M) above the floor . Units should always be arranged to blow toward or along exposed wall surfaces, if possible. Where two or more units are installed in the same room, a general scheme of air circulation should be maintained for best results.

Suspended heaters are most effective when located as close to the working zone as possible, and this fact should be kept in mind when determining the mounting heights to be used. However, care should be exercised to avoid directing the discharged air directly on the room occupants.

Partitions, columns, counters, or other obstructions should be taken into consideration when locating the unit heater so that a minimum quantity of airflow will be deflected by such obstacles.

When units are located in the center of the space to be heated, the air should be discharged toward the exposed walls. In large areas, units should be located to discharge air along exposed walls with extra units provided to discharge air in toward the center of the area.

At those points where infiltration of cold air is excessive, such as at entrance doors and shipping doors, it is desirable to locate the unit so that it will discharge directly toward the source of cold air from a distance of 15 to 20 feet (4.6-6.1M).

CAUTION: Do not locate the heater where it may be exposed to water spray, rain, or dripping water.

Hazards of Chlorine applies to location of Model UDAS heater with regard to combustion air inlet

11. Hanging the Heater

WARNINGS: Check the supporting structure to be used to verify that it has sufficient load carrying capacity to support the weight of the unit. Suspend the heater only from the threaded nut retainers or with a manufacturer provided kit. Do NOT suspend from the heater cabinet.

The presence of chlorine vapors in the combustion air of gas-fired heating equipment presents a potential corrosion hazard. Chlorine found usually in the form of freon or degreaser vapors, when exposed to flame will precipitate from the compound, and go into solution with any condensation that is present in the heat exchanger or associated parts. The result is hydrochloric acid which readily attacks all metals including 300 grade stainless steel. Care should be taken to separate these vapors from the combustion process. This may be done by wise location of the unit vent and combustion air terminals with regard to exhausters or prevailing wind directions. Chlorine is heavier than air. Keep these facts in mind when deter mining installation location of the heater in relation to building exhaust systems.

Before suspending the heater, check the supporting structure to be used to verify that it has sufficient load-carrying capacity to support the weight of the unit.

Model UDAP Size

30 45 60 75 100 125 150 175, 200 225 250 300 350 400

54 59 67 72 96 101 172 187 203 215 269 294 306

lbs

24 27 30 33 44 46 78 85 92 98 122 133 139

Model UDAS Size

30 45 60 75 100 125 150 175, 200 225 250 300 350 400

lbs 55 60 68 73 97 102 173 188 204 216 270 295 307 kg 25 27 31 33 44 46 78 85 93 98 122 134 138

When the heater is lifted for suspension, support the bottom of the heater with plywood or other appropriately placed material. If the bottom is not supported, damage could occur. Before hanging, verify that all screws used for holding shipping brackets were re-installed in the cabinet.

The heater is equipped for either two-point or four-point suspension. A 3/8"-16 threaded nut retainer is located at each suspension point. See Dimensions in Paragraph 5 and the illustration in FIGURE 7A.

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 10

FIGURE 7A - Suspending

the Heater with Rods from the Threaded Nut Retainers (either two or four point suspension)

WARNING: Unit must be level for proper operation. Do not place or add additional weight to the suspended heater. Hazard Levels, page 2.

FIGURE 7B - Swivel Connectors to Suspend the Heater from 1” Pipe, Option CK8 (2-pt) or CK10 (4-pt)

Be sure the threaded hanger rods are locked to the heater as illustrated.

3/8 threaded rod (field supplied)

Add a 3/8 nut and

washer to lock the

hanger rod to the heater.

Recommended maximum hanger rod length is 6 feet (1.8M).

If ordered with swivel connectors for 1” pipe, Option CK8 or CK10, attach the swivels at the threaded nut retainers. Suspend with 1” pipe. (See FIGURE 7B.)

Be sure the threaded swivel connectors are locked to the heater as illustrated.

Lock the swivel

connector to

the heater.

The connector

is threaded for

hanging from

a 1 pipe.

FIGURE 8 - Suspending the Heater using Option CK22, Ceiling Suspension Kit (no hanger rods)

FIGURE 9 - Model UDAS Plug the unused suspension points on the control side of the heater with 3/8”-16 screws and flat washers

If ordered with a ceiling suspension kit, Option CK22, follow the illustrated instructions in the kit. (See FIGURE 8.)

A vailable for Sizes 30-125. Allows the heater to be installed one inch from the ceiling.

NOR

Model UDAS - Whether using the suspension points or the hanger kit, when installing a Model UDAS, the unused suspension points on the control side of the heater MUST be plugged. Plug these holes with the 3/8”-16 bolts and flat washers shipped in the bag with the heater. (See FIGURE 9.)

Plug any unused suspension points on the control side with the 3/8-16 bolts and flat washers provided.

Control Side

Model UDAS

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 11

12. Gas Piping

and Pressures

WARNING: This appliance is equipped for a maximum gas supply pressure of 1/2 pound, 8 ounces, or 14 inches water column. Supply pressure higher than 1/2 pound requires installation of an additional lockup-type service regulator external to the unit.

WARNING: PRESSURE TESTING SUPPLY PIPING

T est Pressur es Above 1/2 PSI: Disconnect the heater and manual valve from the

gas supply line which is to be tested. Cap or plug the supply line. Test Pressures Below 1/2 PSI: Before testing, close the manual valve on the

heater.

Sizing Gas Supply Line

WARNING: All components of a gas supply system must be leak tested prior to placing equipment in service. NEVER TEST FOR LEAKS WITH AN OPEN FLAME. Failure to comply could result in personal injury, property damage or death.

Length Diameter of P ipe

of 1/2" 3/4" 1" 1-1/4" 1-1/2" 2"

Pipe Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane

20’ 92 56 190 116 350 214 730 445 1100 671 2100 1281 30’ 73 45 152 93 285 174 590 360 890 543 1650 1007 40’ 63 38 130 79 245 149 500 305 760 464 1450 885 50’ 56 34 115 70 215 131 440 268 670 409 1270 775 60’ 50 31 105 64 195 119 400 244 610 372 1105 674 70’ 46 28 96 59 180 110 370 226 560 342 1050 641 80’ 43 26 90 55 170 104 350 214 530 323 990 604

90’ 40 24 84 51 160 98 320 195 490 299 930 567 100’ 38 23 79 48 150 92 305 186 460 281 870 531 125’ 34 21 72 44 130 79 275 168 410 250 780 476 150’ 31 19 64 39 120 73 250 153 380 232 710 433 175’ 28 17 59 36 110 67 225 137 350 214 650 397 200’ 26 16 55 34 100 61 210 128 320 195 610 372

Note: When sizing sup ply lines, consider possibilities of future expa nsion and increased requirements.

Capacity of Piping

Cubic Feet per Hour based on 0.3" w.c. Pressure Dr op

Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft)

Specific Gravity for Propane Gas -- 1.6 (Propane Gas -- 2550 BTU/Cubic Ft)

Refer to National Fuel Gas Code for add itional information on line sizing.

All piping must be in accordance with requirements outlined in the National Fuel Gas Code ANSI/Z223.1a (latest edition) or CAN/CGA-B149.1 and B149.2 (See Paragraph 2). Gas supply piping installation should conform with good practice and with local codes. Support gas piping with pipe hangers, metal strapping, or other suitable material; do not rely on the heater to support the gas pipe.

The heater is orificed for operation with natural gas having a heating value of 1000 (± 50) BTUH per cubic ft or propane gas with a heating value of 2500 (± 100) BTUH per cubic ft. If the gas at the installation does not meet these specifications, consult the factory for proper orificing.

Pipe joint compounds (pipe dope) shall be resistant to the action of liquefied petroleum gas or any other chemical constituents of the gas being supplied.

Install a ground joint union and manual shutoff valve upstream of the unit control system, as shown in FIGURE 10. Installation of a trap with a minimum 3" (76mm) drip leg is required.

The unit is equipped with a nipple that extends outside the cabinet. The gas connection is either 1/2” or 3/4”.

Gas Connection Size

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 12

Gas Connection (inches)

30 45 60 75 100 125 150 175 200 225 250 300 350 400

Natural 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4

Propane 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4

Leak-test all connections by brushing on a leak-detecting solution.

FIGURE 10 - Gas connection is at the pipe nipple that extends outside the cabinet

Illustration shows both a vertical and horizontal gas supply; requirements are the same.

Valve Outlet or Orifice Pressure Setting

NOTE: Gas Conversion Kits are available for changing from propane gas to natural gas or natural gas to propane gas. A factoryauthorized conversion kit MUST be used.

Ground

To Gas Valve

Joint Union

(inside the cabinet)

Pipe nipple extending

outside the cabinet.

To Gas Valve (inside the cabinet)

Measuring valve outlet gas pressure cannot be done until the heater is in operation. It is included in the steps of the "Check-Test-Start" procedure in Paragraph

24. The following warnings and instructions apply.

Manual shutoff

Drip Leg

Ground

Joint

Union

From Gas Supply (horizontal or vertical)

Manual shutoff

Drip Leg

WARNING: Valve outlet gas pressure must never exceed 3.5" w.c. for natural gas and 10" w.c. for propane gas.

For Natural Gas: When the heater leaves the factory, the combination gas valve

is set so that the valve outlet gas pressure for a single stage valve or high fire of a two stage valve is regulated to 3.5" w.c. Inlet supply pressure to the valve for natural gas must be a minimum of 5" w.c. or as noted on the rating plate and a maximum of 14" w .c.

For Propane Gas: When the heater leaves the factory , the combination gas valve is set so that the valve outlet gas pressure for a single stage valve or high fire of a two stage valve is regulated to 10" w.c. Inlet supply pressure to the valve for propane gas must be a minimum of 11" w.c. and a maximum of 14" w.c.

Before attempting to measure or adjust valve outlet gas pressure, the inlet supply pressure must be within the specified range both when the heater is in operation and on standby. Incorrect inlet pressure could cause excessive valve outlet gas pressure immediately or at some future time. If natural gas supply pressure is too high, install a regulator in the supply line before it reaches the heater. If natural gas supply pressure is too low, contact your gas supplier.

Check Valve Outlet Pressure (can only be done after heater is operating)

NOTE: If operating at high altitude, outlet pressure requires adjustment. Follow instructions on page 14.

Instructions

1) Locate the 1/8” output pressure tap on the valve (See FIGURE 11, page 14).

With the manual valve turned off to prevent flow to the gas valve, connect a manometer to the 1/8" pipe outlet pressure tap in the valve. NOTE: A manometer (fluid-filled gauge) is recommended rather than a spring type gauge due to the difficulty of maintaining calibration of a spring type gauge.

2) Open the manual valve and operate the heater. (NOTE: On Model UDAS,

depress and hold the door safety switch.) Measure the outlet pressure of the gas valve. Normally when operating at sea level, adjustments should not be necessary to the factory setting. (For high altitude settings, see next paragraph.)

If adjustment is necessary, remove the cap from the adjustment screw(s). Set

pressure to correct settings by turning the regulator screw IN (clockwise) to increase pressure. Turn regulator screw OUT (counterclockwise) to decrease pressure.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 13

12. Gas Piping

and Pressures (cont’d)

Derate by Valve Outlet Pressure Adjustment for High Altitude Operation

This adjustment can only be done after the heater is in operation. It is included in the startup procedures.

NOTE: If elevation is above 6000 ft (1830M), a high altitude pressure switch is required; see Paragraph 7.

FIGURE 11 - Top View of Valves showing Outlet Pressure Tap and Adjustment Locations

Single-Stage Valve

Output

Adjustment

Screw

Inlet

Pressure

Tap

Two -Stage Valve

Adjust High

Pressure

Output

Inlet

Pressure

Tap

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 14

1/8” Output

Pressure Tap

Adjust Low Pressure Output

1/8” Output

Pressure

Tap

Instructions for High Altitude Derate

1. Determine the required valve outlet pressure for the elevation where the heater

will be operating. If unsure of the elevation, contact the local gas supplier.

Valve Outlet Pressure Settings by Elevation

Manifold Pressure Settin

Altitude Natural Gas (inches w.c.) Propane Gas (inches w.c.)

Feet Meters

0-2000 0-610 3.5 1.8 10.0 5.0 2001-3000 611-915 3.1 1.6 8.8 4.4 3001-4000 916-1220 3.0 1.5 8.5 4.2 4001-5000 12 21-1525 2.8 1.5 8.1 4.1 5001-6000 15 26-1830 2.7 1.4 7.7 3.9 6001-7000 18 31-2135 2.6 1.3 7.4 3.7 7001-8000 21 36-2440 2.5 1.3 7.1 3.5 8001-9000 24 41-2745 2.4 1.2 6.7 3.4

9001-10000 2746-3045 2.3 1.2 6.7 3.4

Manifold P ressu re Settin

Altitude Natural Gas (inches w.c.) Propane Gas (inches w.c.)

Feet Meters

0-2000 0-610 3.5 1.8 10.0 5.0 2001-4500 611-1373 2.8 1.5 8.1 4.1

Single Stage and

Two Stage High Fir e

Single Stage and

Two Stage High Fir e

2. Locate the 1/8” output pressure tap on the valve (See FIGURE 11). Turn the

knob on the top of the valve to “OFF”. Connect a manometer to the 1/8" pipe

outlet pressure tap in the valve. Use a water column manometer that is readable

to the nearest tenth of an inch.

3. Single Stage and Two Stage High Fire - Turn the knob on the top of the valve

to “ON”. Remove the cap from the pressure adjusting screw and adjust the gas

train pressure to the pressure selected from the table above. Adjust pressure by

turning the regulator screw IN (clockwise) to increase pressure or OUT (coun-

terclockwise) to decrease pressure.

Two Stage Low Fire - Disconnect the wire from the “HI” terminal on the gas valve and check the low fire pressure. Turn the regulator screw to adjust the low fire outlet pressure to the “Low Fire” pressure selected from the table. Reconnect the wire to the gas valve.

4. Turn up the thermostat. (NOTE: On Model UDAS, depress and hold the door

safety switch.) Cycle the burner once or twice to properly seat the adjustment

spring in the valve.

Re-check the pressure(s). When the outlet pressure is right for the installation,

remove the manometer and replace the cap.

Check for leak at the pressure tap fitting.

5. With the heater operating determine that the inlet pressure to the heater for

natural gas is between 5 and 13.5 inches w.c. and for propane between 10 and

13.5 inches w .c. Take this reading as close as possible to the heater (Heaters are

equipped with gas valves that have an inlet pressure tap.) If the inlet pressure is

not within the specified range, the inlet pressure must be corrected and Steps 3

and 4 repeated.

6. Find the High Altitude Adjustment label in the plastic bag that contained these

instructions. Using a permanent marker, fill-in the appropriate information from

the tables on page 15. Select a location for the label on the outside of the heater

access panel so that it will be conspicuous to anyone operating or servicing the

unit. Be sure the surface is clean and dry and adhere the label.

s by Altitude for the UNITED STATES

Two Stage

Low Fire

s by Altitude for CANADA

Two Stage

Low Fire

Single Stage and

Tw o Stage H igh Fire

Single Stage and

Tw o Stage H igh Fire

Two Stage

Low Fire

Two Stage

Low Fire

High Altitude

Capacity Changes

The input and/or the capacity of the heater changes with the derate. The tables below list inputs and capacities at altitudes from sea level to 10,000 ft (3045M).

BTUH In

ALTITUDE

Feet Meters

uts and Capacities by Altitude in the UNITED STATES for Model UDAP and Model UDAS

Normal

Input

Thermal

Output

Capacity

Minimum

Input

Normal

Input

Thermal

Output

Capacity

Minimum

Input

Normal

Input

Thermal

Output

Capacity

Minimum

Input

Normal

Size 30 Size 45 Size 60

Input

Thermal

Output

Capacity

Size 75

Minimum

Input

0-2000 0-610 3 0000 24600 30000 45000 37350 45000 60000 49800 42000 75000 62250 52500 2001-3000 611-915 28200 23124 28200 42300 35109 42300 56400 46812 39480 70500 58515 49350 3001-4000 916-1220 27600 2 2632 27600 41400 34362 41400 55200 45816 38640 69000 57270 48300 4001-5000 1221-1525 2 7000 22140 27000 40500 33615 40500 54000 44820 37800 67500 56025 47250 5001-6000 1526-1830 2 6400 21648 26400 39600 32868 39600 52800 43824 36960 66000 54780 46200 6001-7000 1831-2135 2 5800 21156 25800 38700 32121 38700 51600 42828 36120 64500 53535 45150 7001-8000 2136-2440 2 5200 20664 25200 37800 31374 37800 50400 41832 35280 63000 52290 44100 8001-9000 2441-2745 2 4600 20172 24600 36900 30627 36900 49200 40836 34440 61500 51045 43050

9001-10000 2746-3045 24000 19680 24000 36000 29880 36000 48000 39840 33600 60000 49800 42000

Feet Meters

Siz e 100 Siz e 125

Siz e 150 Siz e 175

0-2000 0-610 105000 88200 73500 120000 100800 84000 150000 124500 105000 175000 145250 122500 2001-3000 611-915 98700 82908 69090 112800 94752 78960 141000 117030 98700 164500 136535 115150 3001-4000 916-1220 96600 8 1144 67620 110400 92736 77280 138000 114540 96600 161000 133630 112700 4001-5000 1221-1525 9 4500 79380 66150 108000 90720 75600 135000 112050 94500 157500 130725 110250 5001-6000 1526-1830 9 2400 77616 64680 105600 88704 73920 132000 109560 92400 154000 127820 107800 6001-7000 1831-2135 9 0300 75852 63210 103200 86688 72240 129000 107070 90300 150500 124915 105350 7001-8000 2136-2440 8 8200 74088 61740 100800 84672 70560 126000 104580 88200 147000 122010 102900 8001-9000 2441-2745 8 6100 72324 60270 98400 82656 68880 123000 102090 86100 143500 119105 100450

9001-10000 2746-3045 84000 70560 58800 96000 80640 67200 120000 99600 84000 140000 116200 98000

Feet Meters

Siz e 200 Size 250 Size 300

Siz e 225

0-2000 0-610 200000 166000 140000 225000 186750 157500 250000 207500 175000 300000 249000 210000 2001-3000 611-915 188000 156040 131600 211500 175545 148050 235000 195050 164500 282000 234060 197400 3001-4000 916-1220 184000 152720 128800 207000 171810 144900 230000 1 90900 161000 276000 229080 193200 4001-5000 1221-1525 180000 149400 126000 202500 168075 141750 225000 1 86750 157500 270000 224100 189000 5001-6000 1526-1830 176000 146080 123200 198000 164340 138600 220000 1 82600 154000 264000 219120 184800 6001-7000 1831-2135 172000 142760 120400 193500 160605 135450 215000 1 78450 150500 258000 214140 180600 7001-8000 2136-2440 168000 139440 117600 189000 156870 132300 210000 1 74300 147000 252000 209160 176400 8001-9000 2441-2745 164000 136120 114800 184500 153135 129150 205000 1 70150 143500 246000 204180 172200

9001-10000 2746-3045 160000 132800 112000 180000 149400 126000 200000 166000 140000 240000 199200 168000

Feet Meters

Siz e 400Size 350

0-2000 0-610 350000 290500 245000 400000 332000 280000 2001-3000 611-915 329000 273070 230300 376000 312080 263200 3001-4000 916-1220 322000 267260 225400 368000 305440 257600 4001-5000 1221-1525 315000 261450 220500 360000 298800 252000 5001-6000 1526-1830 308000 255640 215600 352000 292160 246400 6001-7000 1831-2135 301000 249830 210700 344000 285520 240800 7001-8000 2136-2440 294000 244020 205800 336000 278880 235200 8001-9000 2441-2745 287000 238210 200900 328000 272240 229600

9001-10000 2746-3045 280000 232400 196000 320000 265600 224000

ALTITUDE

Feet Meters

BTUH In

Normal

Input

uts and Capacit ies by Altitude in CANADA for Models UDAP and UDAS

Thermal

Output

Capacity

Minimum

Input

Normal

Input

Thermal

Output

Capacity

Minimum

Input

Normal

Input

Thermal

Output

Capacity

Minimum

Size 30 Size 45 Size 60

Input

Normal

Input

Thermal

Output

Capacity

Size 75

Minimum

Input

0-2000 0-610 30000 24600 30000 45000 37350 45000 60000 49800 42000 75000 62250 52500 2001-4500 611-1373 27000 22140 27000 40500 33615 40500 54000 44820 37800 67500 56025 47250

Feet Meters

Siz e 150 Siz e 175Siz e 100 Siz e 125

0-2000 0-610 105000 88200 73500 120000 100800 84000 150000 124500 105000 175000 145250 122500 2001-4500 611-1373 94500 79380 66150 108000 90720 75600 135000 113400 94500 157500 132300 110250

Feet Meters

Siz e 200 Siz e 225 Siz e 250 Siz e 300

0-2000 0-610 200000 166000 140000 225000 186750 157500 250000 207500 175000 300000 249000 210000 2001-4500 611-1373 180000 151200 126000 202500 170100 141750 225000 189000 157500 270000 226800 189000

Feet Meters

Siz e 350 Siz e 400

0-2000 0-610 350000 290500 245000 400000 332000 280000 2001-4500 611-1373 315000 264600 220500 360000 302400 252000

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 15

13. Burner

Spark

Transformer

Control

Plug

Fuse

Thermostat

Connections

Fan/Blower

Off

Delay

Status Lights

This heater has a one-piece TCORE to provide controlled flame stability without lifting or flashback with either natu-

ral or propane gas. The burner can be removed as a unit for inspection or service; see Maintenance

Section for removal instructions.

burner assembly (patent pending) designed

14. Electrical Supply and Connections

CAUTION: Route wires so that they do not contact the flue wrapper or venter housing.

CAUTION: 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 105°C, except for limit control, flame rollout, and sensor lead wires which must be 150°C. See Hazard Levels, page 2.

All electrical wiring and connections, including electrical grounding MUST be made in accordance with the National Electric Code ANSI/NFPA No. 70 (latest edition) or, in Canada, with CSA Standard C22.1. In addition, the installer should be aware of any local ordinances or gas company requirements that might apply.

Check the rating plate on the heater for the supply voltage and current requirements. A dedicated line voltage supply with disconnect switch should be run directly from the main electrical panel to the heater. All external wiring must be within approved conduit and have a minimum temperature rise rating of 60°C Conduit must be run so as not to interfere with the heater access panel. If the installation requires a stepdown transformer (Option CG), follow the instructions shipped with the option package for attaching the transformer to the heater.

The electrical supply enters at the rear of the heater (See FIGURE 13). Model UDAS includes a built-in disconnect switch (20A @ 1 15V; 10A @ 230V Rating). Model UDAS supply wiring connects to leads located inside a sealed electrical box. T o maintain the sealing feature of the electrical box, always replace the cover plate. Model UDAP supply wiring connects directly to leads on the integrated circuit board.

The circuit board (See FIGURE 12) is located inside on the bottom of the control compartment. The circuit board is polarity sensitive. It is advisable to check the electrical supply to be certain that the black wire is the “hot” wire and that the white wire is the neutral wire. The supply connection made to “L1” on the circuit board must be the “hot” wire.

FIGURE 12 - Supply Wiring Connections at the Circuit Board (DSI Integrated Control Module)

24V Control Wiring Connections

15. Thermostat

and Connections

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 16

Supply Wiring

Connections

NOTE: Circuit

board is polarity

sensitive; “hot” wire

must be connected

For all models, the terminal strip for 24 volt thermostat connections is located on the outside of the cabinet at the back of the heater (See FIGURE 13). Wires from the terminal strip are factory wired to the circuit board.

Use either an optional thermostat available with the heater or a field-supplied 24volt thermostat. Install according to the thermostat manufacturer's instructions, paying particular attention to the requirements regarding the location of the thermostat.

to T erminal L1.

Make sure that the heat anticipator setting on the thermostat is 0.6 amps (or in accordance with the amperage value noted on the wiring diagram of your heater).

Make thermostat connections at the terminal strip on the back of the heater. The strip has four terminals, R, G, W1, and W2; refer to the wiring diagram.

FIGURE 13 - Terminal Strip for 24-volt wiring is on the outside rear of the heater

NOTE: The size of heater illustrated has a vertical terminal strip. Some sizes have a horizontal terminal strip.

Unit Mounted Thermostat Option CM3

Terminal

Strip

Supply

Wiring

Entrance

Rear View - Model UDAP

R G W1

Disconnect

If the heater was ordered with Option CM3, a kit for mounting the thermostat on the rear of the heater is shipped separately. Follow the instructions in the option package to attach the bracket.

Select a snap-action thermostat when using the unit mounted thermostat bracket. Do not use a mercury switch thermostat because the vibration may cause excessive unit cycling. Be careful with the thermostat leads; shorting the thermostat wires to a metal surface will cause the transformer to fail.

Rear View - Model UDAS

Terminal

Strip

Built-in

Switch

Supply Wiring

Entrance

R G W1 W2

Multiple Heater Control - Option CL31 and Option CL32

16. Combustion Air Proving Switch (Pressure Switch)

If the heater was ordered with a multiple heater control option, one thermostat can be used to control up to six heaters. The option includes a 40VA transformer that replaces the standard transformer in the “master” unit and a relay assembly that attaches to the “slave” unit. Option CL31 provides for control of two heaters. If control of additional heaters is desired (up to six total), Option CL32 which is the relay assembly only must be added to each of the “slave” heaters.

The option packages are shipped separately and include complete instructions on installation and wiring.

The combustion air proving switch is a pressure sensitive switch that monitors air pressure to ensure that proper combustion airflow is available. On Model UDAP, the switch is a single pole/normally open device which closes when a negative pressure is sensed in the venter housing. On Model UDAS, the switch senses the differential pressure between the negative pressure in the venter housing and the pressure in the cabinet. (For switch location, see FIGURE 18, page 31.)

On startup when the heater is cold, the sensing pressure is at the most negative level, and as the heater and flue system warm up, the sensing pressure becomes less negative. After the system has reached equilibrium (about 20 minutes), the sensing pressure levels off.

If a restriction or excessive flue length or turns cause the sensing pressure to be outside the switch setpoint, the pressure switch will function to shutoff the main burner. The main burner will remain off until the system has cooled and/or the flue system resistance is reduced.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 17

16. Combustion Air Proving

The two T ables on the left below list the approximate water column negative pressure readings and switch setpoints for sea level operating conditions for Model UDAP and Model UDAP-CV heaters. The Table on the right lists the approximate water column differential pressure readings and switch setpoints for sea level op-

Switch

(cont’d)

erating conditions for Model UDAS heaters.

DANGER: Safe operation of this unit requires proper venting flow. NEVER bypass combustion air proving switch or attempt to operate the unit without the venter running and the proper flow in the vent system. Hazardous conditions could result. See

Pressure Switch Settings

Model

UDAP

150, 175 0.75 0.65 0.40 0.58 Green 197030 150, 175 0.75 0.60 0.40 0.58 Green 197030 200, 225 2.20 1.50 1.10 1.30 Blue 201158 200, 225 2.20 1.50 1.10 1.30 Blue 201158 250, 300 2.30 1.60 1.10 1.30 Blue 201158 250, 300 2.30 1.60 1.10 1.30 Blue 201158 350, 400 2.60 1.80 1.40 1.60 Red 201159 350, 400 2.60 1.80 1.40 1.60 Red 201159

Model UDAP-CV

with Opt AV6

Startup Equilibrium Setpoint Setpoint Startup Equilibrium Setpoint Setpoint

Cold Hot OFF ON Cold Hot OFF ON

Negative Pressure Measured in " w.c.

30 1.00 0.78 0.40 0.58 Green 1970 30 30 1.00 0.78 0.65 0.83 Yellow 197028 45 0.95 0.75 0.40 0.58 Green 1970 30 45 1.05 0.80 0.65 0.83 Yellow 197028 60 1.00 0.78 0.50 0.68 Orange 196388 6 0 1.10 0.85 0.65 0.83 Yellow 197028

75 1.00 0.85 0.50 0.68 Orange 196388 7 5 1.10 0.85 0.65 0.83 Yellow 197028 100 0.85 0.72 0.50 0.68 Orange 196388 100 0.85 0.72 0.55 0.73 White 196362 125 0.75 0.60 0.40 0.58 Green 197030 125 0.75 0.60 0.45 0.63 Pink 197032

Startup Equilibrium Setpoint Setpoint

Cold Hot OFF ON

Negative Pressure Measured in " w.c.

30 45 60 75

1.10 0.84 0.65 0.83 Yellow

1.10 0.81 0.50 0.68 Orange

0.92 0.75 0.60 0.78 Lt Blue

0.97 0.78 0.60 0.78 Lt Blue

0.88 0.71 0.55 0.73 White100

Hazard Levels, page 2.

Label Color

Switch

P/N

Label Color

Model UDAS

Switch

P/N

197028 196388 197029 197029 196362

Differential Pressure Measured in " w.c.

Label Color

Switch

P/N

17. Limit Control

18. Flame Rollout Switch Sizes 30-125

only

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 18

All units are equipped with a temperature activated auto reset limit control. The control is factory set and is non-adjustable. If the setpoint is reached, the limit control will interrupt the electric supply to the gas valve. This safety device provides protection in the case of motor failure or lack of airflow due to a restriction at the inlet or outlet. (For location, see FIGURE 18, page 31.)

CAUTION: The auto reset limit contr ol will continue to shut down the heater until the cause is corrected. Never bypass the limit control; hazardous conditions could result. See Hazard Intensity Levels, page 2.

Sizes 30-125 are equipped with a temperature activated manually reset flame rollout switch. The flame rollout switch is located at the top of the burner assembly. It is factory set and is non-adjustable. If the setpoint is reached, the flame rollout acts to interrupt the electric supply to the gas valve. If the flame rollout switch activates, identify and correct the cause before resetting the switch. Refer to the Maintenance Section for information on probable causes and instructions on resetting the flame rollout switch. (For location, see FIGURE 18, page 31.)

DANGER: If the manual reset flame rollout switch activates, identify and correct the cause before resetting the switch. Never bypass the flame rollout switch; hazardous conditions could result. See Hazard Intensity Levels, page 2.

19. Door Switch

- Model UDAS only

All sizes of Model UDAS heaters are equipped with a door switch which prevents the heater from operating when the service door panel is open. The service panel of a Model UDAS is equipped with a pliable gasket material that fully seals the door to provide added protection from building air entering the combustion zone of the heater. (For switch location, see FIGURE 18, page 31.)

20. Ignition System

FIGURE 14 – DSI Integrated Control Module (circuit board)

Spark

Transformer

Plug

Control

This heater is equipped with a direct spark integrated control module (circuit board). The module monitors the safety devices and controls the operation of the fan and venter motors and the gas valve between heat cycles.

Fuse

Thermostat

Connections

Status Lights

Control Status - Green LED Codes

Steady ON....... Normal Operation, No call for heat

Fast Flash........ Normal Operation, Call for heat

1 Flash ............ System Lockout, Failed to detect or sustain

flame

2 Flashes ......... Pressure Switch Did Not Close within 30

Seconds of Venter Motor

3 Flashes ......... High Limit or Flame Rollout Switch Open

4 Flashes ......... Pressure switch is closed before venter

motor is energized

Steady OFF ..... Blown Fuse, No Power, or Defective Board

Fan/Blower

Off

Delay

Dip Switch

LED Lights

Flame Status - Yellow LED Codes

Steady ON....... Flame is sensed

Slow Flash ...... Weak flame (current below 1.0

microamps ±50%)

Fast Flash........ Undesired Flame (valve open

and no call for heat)

Fan/Blower OFF Delay Settings (dip switches)

SW-1 SW-2 Time Off Off 120 seconds (factory setting) Off On 90 seconds On Off 160 seconds On On 180 seconds

Normal Heat Cycle Operating Sequence

1) Call for Heat - The thermostat calls for heat by energizing the “W” terminal. The control checks to see that the limit switch is closed and the pressure switch is open. If the limit switch is open, the control responds as defined in the “Abnormal Heat Cycle, Limit Switch Operation”. If the pressure switch is closed, the control will do four flashes on the green LED and wait indefinitely for the pressure switch to open. If the pressure switch is open, the control proceeds to prepurge.

2) Prepurge - The control energizes the venter motor and waits for the pressure switch to close. If the pressure switch does not close within 30 seconds of the venter motor energizing, the control will do two flashes on the green LED. The control will leave the venter motor energized indefinitely as long as the call for heat remains and the pressure switch is open.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 19

20. Ignition System (cont’d)

Normal Heat Cycle Operating Sequence (cont’d)

When the pressure switch is proven closed, the control begins the prepurge time. If flame is present any time while in prepurge, the prepurge time is restarted. If flame is present long enough to cause lockout, the control responds as defined in “Fault Modes, Undesired Flame”.

The control runs the venter motor for a 20 second prepurge time, then proceeds to the ignition trial period.

3) Ignition Trial Period - The control energizes the spark and main gas valve. The venter remains energized. If flame is sensed during the first 16 seconds, the spark is de-energized and the control proceeds to heat fan/blower on delay. If flame has not been sensed during the first 16 seconds, the control de-energizes the spark output and keeps the gas valve energized for an additional one second flame proving period. If flame is not present after the flame proving period, the control de-energizes the gas valve and proceeds with ignition re-tries as specified in “Abnormal Heat Cycle, Ignition Re-try”. If flame is present, the control proceeds to the fan/blower on delay.

4) Fan/Blower On Delay - The control waits for 30 seconds from the time the gas valve opened and then energizes the fan/blower motor. The gas valve and venter motor remain energized. The control proceeds to steady heat mode.

5) Steady Heat - Control inputs are continuously monitored to ensure limit and pressure switches are closed, flame is established, and the thermostat call for heat remains. When the thermostat call for heat is removed, the control de-energizes the gas valve and begins post-purge and fan/blower off delay timing.

6) Post Purge - The venter motor output remains on for a 45 second post-purge period after the thermostat is satisfied.

7) Fan/Blower Off Delay - The fan/blower motor is de-energized after a blower off delay as selected by the dip switches. Timing begins when the thermostat is satisfied. Delay times are as follows:

SW1 SW2 Time

OFF OFF 120 seconds (default when shipped) OFF ON 90 seconds ON OFF 160 seconds ON ON 180 seconds

Abnormal Heat Cycle Functions

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 20

Interrupted Thermostat Call for Heat - If the thermostat demand for heat is

removed before the flame is recognized, the control will run the venter motor for the post purge period and de-energize all outputs.

If the thermostat demand for heat is removed after successful ignition, the control will de-energize the gas valve, run the venter motor through post purge, and run the fan/blower motor on heat speed for the selected delay off time.

Ignition Retry - If flame is not established on the first trial for ignition period, the control de-energizes the gas valve and the venter motor remains energized for an inter-purge period of 10 seconds. The spark and gas valve are then re-energized, and the control initiates another trial for ignition.

If flame is not established on the second trial for ignition, the control de-energizes the gas valve, energizes the fan/blower motor on heat speed, and venter motor remains energized. The fan/blower motor is shut off after the longest selectable fan delay time (180 seconds). When the fan/blower motor de-energizes, the spark and gas valve are re-energized and the control initiates another trial for ignition. (This fan delay is self-healing feature for an open auxiliary limit switch).

If flame is not established on the third trial for ignition period, the control deenergizes the gas valve, and the venter motor remains energized for an inter-pur ge period of 10 seconds. The control then re-energizes the gas valve and spark and initiates another trial for ignition.

If flame is not established on the fourth trial for ignition (initial try plus 3 re-tries), the control de-energizes the gas valve and goes into lockout. The control goes to one flash on the green LED to indicate ignition failure lockout.

Limit Switch Operation - The limit switch is ignored unless a call for heat is present (W energized). If the limit switch is open and a call for heat is present, the control de-energizes the gas valve and turns the fan/blower motor on heat speed and runs the venter motor.

When the switch re-closes or the call for heat is lost, the control runs the venter motor through post purge and runs the blower/fan motor through the selected fan off delay. The control will return to normal operation after fan off delay is completed.

Pressure Switch - If the pressure switch opens before the trial for ignition period, the venter motor will run through the pressure switch recognition delay (2 seconds), the gas valve will be de-energized, and the venter motor will run through the postpurge time. The control will re-start the heat cycle at the pressure switch proving state if the call for heat still exists.

Pressure switch opening for less than 2 seconds during the trial for ignition period shall not interrupt the heat cycle. (Gas valve will de-energize while the pressure switch is open.)

If the pressure switch opens after a successful ignition, the control will de-energize the gas valve. If flame is lost before the end of the 2 second pressure switch recognition delay, the control will respond to the loss of flame. If the pressure switch remains open for 2 seconds and the flame remains, the control de-energizes the gas valve, the venter motor runs through post-purge, and the fan/blower motor runs on heat speed through the selected fan off delay. When the fan off delay is over, the fan/blower motor is de-energized, and a heat cycle is begun if the call for heat still exists.

Continuous Fan Operation

Fault Modes

When the thermostat calls for continuous fan (G) without a call for heat, the fan motor is energized after a .25 second delay. NOTE: This brief on delay is to allow the “G” terminal to energize slightly before “Y” and an external changeover relay to switch from “G” to “W” without causing momentary glitches in the fan/blower output. The fan remains energized as long as the call for fan remains without a call for heat.

If a call for heat (W) occurs during continuous fan, the fan/blower will de-energize.

A call for fan is ignored while in lockout.

Undesired Flame - If flame is sensed longer than 20 seconds while the gas valve is de-energized, the control shall energize the venter motor and fan/blower motor on heat speed. When flame is no longer sensed, the venter motor will run through postpurge, and the fan/blower motor will run through the selected heat fan off delay time. The control will do a soft lockout, but will still respond to open limit and flame. The FLAME (yellow) LED shall flash rapidly when lockout is due to undesired flame.

Gas Valve Relay Fault - If the control senses the gas valve as energized for more than one second when the control is not attempting to energize the gas valve, or the gas valve is sensed as not energized when it is supposed to be energized, then the control will lockout with green LED off. The control assumes either the contacts of the relay driving the gas valve have welded shut, or the sensing circuit has failed. The venter motor is forced off to open the pressure switch to stop gas flow unless flame is present.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 21

20. Ignition System

If the gas valve was sensed as closed when it should be open, and has not deenergized after the venter motor was shutoff for 15 seconds, then the venter motor is re-energized to vent the unburned gas.

(cont’d)

Fault Modes (cont’d)

Lockout

21. Gas Valve

Soft Lockout - The control shall not initiate a call for heat or call for continuous fan while in lockout. The control will still respond to an open limit and undesired flame. Lockout shall automatically reset after one hour. Lockout may be manually reset by removing power from the control for more than one second or removing the thermostat call for heat for more than one and less than 20 seconds.

Hard Lockout - If the control detects a fault on the control board, the status LED will be de-energized, and the control will lockout as long as the fault remains. A hard lockout will automatically reset if the hardware fault clears.

Power Interruption - During a momentary power interruption or at voltage levels below the minimum operating voltage (line voltage or low voltage) the system will self-recover without lockout when voltage returns to the operating range.

Power interruptions of less than 80mS shall not cause the control to change operating states. Power interruptions greater than 80mS may cause the control to interrupt the current operating cycle and re-start.

The main operating gas valve is powered by the 24-volt control circuit through the thermostat and safety controls. The main control valve is of the diaphragm type providing regulated gas flow preset at the factory . (For location, see FIGURE 18, page 31.)

22. Fan Motor

WARNING: The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting the unit to ensure positive closure. See Hazard Levels, page 2.

The fan motor is equipped with thermal overload protection of the automatic reset type. Should the motor refuse to run, it may be because of improper current characteristics. Make certain that the correct voltage is available at the motor.

NOTE: If the unit is equipped with an optional totally enclosed motor or optional voltage, the horsepower may be larger than the standard motor . Refer to the motor nameplate to verify horsepower.

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 22

23. Wiring Diagrams

FIGURE 15A - Typical Wiring Diagram for Model UDAP or Model UDAS, Single Stage

(OPT CL3) T874F OR (OPT CL1) W.R.

(OPT CL2) W.R. 1C30-341 THERMOSTAT

1C30-341 THERMOSTAT (SEE NOTE #8)

W-S23-6 SUBBASE (SEE NOTE #8)

30 VA

SYSTEM TRANSFORMER

24V

SW1

FUSE

3.0 AMP ATO OR ATC

LED FLASH CODES

GREEN LED

NORMAL OPERATION NO CALL FOR HEATSTEADY ON

FAST FLASH

1 FLASH

2 FLASH

3 FLASH

4 FLASH

STEADY OFF

SLOW FLASH WEAK FLAME

NORMAL OPERATION CALL FOR HEAT

IN LOCKOUT FROM FAILED IGNITIONS OR FLAME LOSSES

PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS OF VENTER ENERGIZED

LIMIT SWITCH OR ROLLOUT SWITCH OPEN

PRESSURE SWITCH IS CLOSED BEFORE VENTER IS ENERGIZED

INTERNAL CONTROL FAULT OR NO POWER

YELLOW LED

FLAME SENSEDSTEADY ON

UNDESIRED FLAME (VALVE OPEN & NO CALL FOR HEAT)FAST FLASH

LAY

FF D

S W 1

DSI CONTROL

120

160

180

VOLT

115/208/230

L1 NEUTRAL NEUTRAL L1COMSEC

LED

TEST

OKFLAME

LED

FACTORY WIRING

FIELD WIRING

OPTIONAL FACTORY WIRING

WIRE NUT

P3-1

P3-2

P3-3

P3-4

P3-5

P1-8

P1-3

P1-6

P1-5

P1-4

P1-2

P1-7

P1-9

TERMINAL STRIP

DOOR INTERLOCK

(UDAS ONLY)

LIMIT CONTROL

R R

FLAME ROLLOUT

(MODELS 30-125 ONLY)

PRESSURE SWITCH

GAS VALVE

FLAME

ELECTRODE

FLAME

GROUND

LINE/1/60

(UDAS ONLY)

DISCONNECT SWITCH

BK BK

NEUTRAL

EAC/BLO

IND

NEUTRAL

SPARK

TRANSFORMER

GRD

SCREW

FAN MOTOR

CAPACITOR

(SEE NOTE #6)

(SEE NOTE #7)

SPARK GAP

BR/W

VENTER MOTOR

BR/W

CAPACITOR

1. SET THERMOSTAT AT LOWEST SETTING, (FAN SWITCH AT "AUTO" POSITION, OPTION CL2 ONLY).

2. TURN ON MANUAL GAS VALVE.

3. TURN ON POWER TO UNIT.

4. SET THERMOSTAT AT DESIRED SETTING.

5. THERMOSTAT CALLS FOR HEAT, ENERGIZING THE VENTER MOTOR.

6. VENTER PRESSURE SWITCH CLOSES, FIRING UNIT AT FULL RATE.

7. BURNER FLAME IS SENSED, AND IN 30 SECONDS THE FAN

8. IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION, THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT (SEE LIGHTING INSTRUCTIONS).

9. SET FAN SWITCH AT "ON" POSITION FOR CONTINUOUS FAN OPERATION, OPTION CL2 ONLY.

1. THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS: THERMOSTAT

2. DOTTED WIRING INSTALLED BY OTHERS.

3. CAUTION: IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C. EXCEPT FOR SENSOR LEAD WIRE, FLAME ROLLOUT AND LIMIT WIRING WHICH MUST BE 150° C.

4. USE 18 GA. WIRE FOR ALL WIRING ON THE UNIT.

5. LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5% OF SUPPLY LINE VOLTAGE.

6. CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS 150-400 AND 208/230V MODELS 100-400.

7. CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150 - 400.

8. SET THERMOSTAT ANTICIPATOR AT 0.6 AMPS.

OPERATING SEQUENCE

MOTOR IS ENERGIZED.

NOTES

FIELD CONTROL WIRING

TOTAL WIRE

LENGTH

150' 250' 350'

DISTANCE FROM UNIT TO CONTROL

WIRING CODE

BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W

75' 125' 175'

UDAP & UDAS SERIES

WD# 185139 REV #1 AG1

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 23

MIN. RECOMMENDED

WIRE GAUGE

#18 GA. WIRE #16 GA. WIRE #14 GA. WIRE

23. Wiring Diagrams (cont’d)

FIGURE 15B - Typical Wiring Diagram for Model UDAP or Model UDAS, Single Stage with Optional Air Recirculation

(OPT CL18) T874F THERMOSTAT

Q674C SUBBASE (SEE NOTES #8 AND #9)

TERMINAL STRIP

DOOR INTERLOCK

(UDAS ONLY)

R R

LIMIT CONTROL

R R

FLAME ROLLOUT

(MODELS 30-125 ONLY)

FLAME

ELECTRODE

FLAME

GROUND

PRESSURE SWITCH

GAS VALVE

FACTORY WIRING

FIELD WIRING

OPTIONAL FACTORY WIRING

WIRE NUT

P3-1

P3-2

P3-3

P3-4

P3-5

P1-8

P1-3

P1-6

P1-5

P1-4

P1-2

P1-7

P1-9

SYSTEM TRANSFORMER

3.0 AMP

FAST FLASH

1 FLASH

2 FLASH

3 FLASH

4 FLASH

STEADY OFF

SLOW FLASH WEAK FLAME

FAN O

TIM

120

160

180

30 VA

24V

SW1

FUSE

ATO OR ATC

LED FLASH CODES

GREEN LED

NORMAL OPERATION NO CALL FOR HEATSTEADY ON

NORMAL OPERATION CALL FOR HEAT

IN LOCKOUT FROM FAILED IGNITIONS OR FLAME LOSSES

PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS OF VENTER ENERGIZED

LIMIT SWITCH OR ROLLOUT SWITCH OPEN

PRESSURE SWITCH IS CLOSED BEFORE VENTER IS ENERGIZED

INTERNAL CONTROL FAULT OR NO POWER

YELLOW LED

FLAME SENSEDSTEADY ON

UNDESIRED FLAME (VALVE OPEN & NO CALL FOR HEAT)FAST FLASH

FF DELAY

DSI CONTROL

VOLT

115/208/230

L1 NEUTRAL NEUTRAL L1COMSEC

LED

TEST

OKFLAME

LED

LINE/1/60

(UDAS ONLY)

DISCONNECT SWITCH

BK BK

NEUTRAL

EAC/BLO

IND

NEUTRAL

SPARK

TRANSFORMER

GRD

SCREW

FAN MOTOR

CAPACITOR

(SEE NOTE #6)

SPARK GAP

BR/W

VENTER MOTOR

BR/W

CAPACITOR

(SEE NOTE #7)

1. SET THERMOSTAT AT LOWEST SETTING, FAN SWITCH AT "AUTO" POSITION.

2. TURN ON MANUAL GAS VALVE.

3. TURN ON POWER TO UNIT.

4. SET THERMOSTAT AT DESIRED SETTING.

5. LOW STAGE OF THERMOSTAT CALLS FOR HEAT, ENERGIZING THE FAN MOTOR.

6. HIGH STAGE OF THERMOSTAT CALLS FOR HEAT, ENERGIZING THE VENTER MOTOR.

7. VENTER PRESSURE SWITCH CLOSES, FIRING UNIT AT FULL RATE.

8. SET FAN SWITCH AT "ON" POSITION FOR CONTINUOUS FAN OPERATION.

9. IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION, THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT (SEE LIGHTING INSTRUCTIONS).

1. THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS: THERMOSTAT

2. DOTTED WIRING INSTALLED BY OTHERS.

4. USE 18 GA. WIRE FOR ALL WIRING ON THE UNIT.

5. LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5% OF SUPPLY LINE VOLTAGE.

6. CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS 150-400 AND 208/230V MODELS 100-400.

7. CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150 - 400.

8. SET THERMOSTAT SECOND STAGE ANTICIPATOR AT 0.6 AMPS. AND FIRST STAGE ANTICIPATOR AT MINIMUM.

9. JUMPER THERMOSTAT TERMINALS G TO W1 AND RH TO RC IF FAN CONTROL FROM THERMOSTAT FAN SWITCH IS DESIRED.

OPERATING SEQUENCE

NOTES

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 24

TOTAL WIRE

LENGTH

150' 250' 350'

FIELD CONTROL WIRING

DISTANCE FROM UNIT TO CONTROL

75' 125' 175'

WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W

UDAP & UDAS SERIES

WD# 185306 REV#2

MIN. RECOMMENDED

WIRE GAUGE

#18 GA. WIRE #16 GA. WIRE #14 GA. WIRE

FIGURE 15C - Typical Wiring Diagram for Model UDAP or Model UDAS, Two Stage Gas Valve

FACTORY WIRING

(OPT CL7) T874F THERMOSTAT

Q674G SUBBASE (SEE NOTE #8)

(OPT CL18) T874F THERMOSTAT

Q674C SUBBASE (SEE NOTE #8 AND #9)

ALT.

HONEYWELL

TWO STAGE GAS VALVE

STG

LOW

STG

HIGH

1. SET THERMOSTAT AT LOWEST SETTING, (FAN SWITCH AT "AUTO" POSITION, OPTION CL18 ONLY).

2. TURN ON MANUAL GAS VALVE.

3. TURN ON POWER TO UNIT.

4. SET THERMOSTAT AT DESIRED SETTING.

5. LOW STAGE OF THERMOSTAT CALLS FOR HEAT, ENERGIZING THE VENTER MOTOR.

6. VENTER PRESSURE SWITCH CLOSES, FIRING UNIT AT LOW RATE.

7. BURNER FLAME IS SENSED, AND IN 30 SECONDS THE FAN

8. HIGH STAGE OF THERMOSTAT CALLS FOR HEAT, FIRING UNIT AT FULL RATE.

9. SET FAN SWITCH AT "ON" POSITION FOR CONTINUOUS FAN OPERATION, OPTION CL18 ONLY.

10. IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION, THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT (SEE LIGHTING INSTRUCTIONS).

1. THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS: THERMOSTAT

2. DOTTED WIRING INSTALLED BY OTHERS.

4. USE 18 GA. WIRE FOR ALL WIRING ON THE UNIT.

5. LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5% OF SUPPLY LINE VOLTAGE.

6. CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS

150-400 AND 208/230V MODELS 100-400.

7. CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150 - 400.

8. SET THERMOSTAT FIRST STAGE ANTICIPATOR AT 0.6 AMPS AND SECOND STAGE ANTICIPATOR AT 0.2 AMPS.

9. JUMPER THERMOSTAT TERMINALS RH TO RC.

TERMINAL STRIP

HONEYWELL

OPERATING SEQUENCE

R R

TWO STAGE GAS VALVE

STG

LOW

STG

HIGH

NOTES

DOOR INTERLOCK

(UDAS ONLY)

LIMIT CONTROL

FLAME ROLLOUT

(MODELS 30-125 ONLY)

ELECTRODE

FIELD WIRING

OPTIONAL FACTORY WIRING

WIRE NUT

R R

PRESSURE SWITCH

FLAME

GROUND

MOTOR IS ENERGIZED.

P3-1

P3-2

P3-3

P3-4

P3-5

P1-8

P1-3

P1-6

P1-5

P1-4

P1-2

P1-7

P1-9

SYSTEM TRANSFORMER

TIM

120

160

180

30 VA

24V

VOLT

115/208/230

SW1

L1 NEUTRAL NEUTRAL L1COMSEC

NEUTRAL

EAC/BLO

FUSE

3.0 AMP ATO OR ATC

LED FLASH CODES

GREEN LED

NORMAL OPERATION NO CALL FOR HEATSTEADY ON

FAST FLASH

1 FLASH

2 FLASH

3 FLASH

4 FLASH

STEADY OFF

SLOW FLASH WEAK FLAME

FAST FLASH

FAN O

NORMAL OPERATION CALL FOR HEAT

IN LOCKOUT FROM FAILED IGNITIONS OR FLAME

PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS OF VENTER ENERGIZED

LIMIT SWITCH OR ROLLOUT SWITCH OPEN

PRESSURE SWITCH IS CLOSED BEFORE VENTER IS ENERGIZED

INTERNAL CONTROL FAULT OR NO POWER

YELLOW LED

FLAME SENSEDSTEADY ON

UNDESIRED FLAME (VALVE OPEN & NO CALL FOR HEAT)

ELAY

FF D

S W

DSI CONTROL

TOTAL WIRE

LED

LENGTH

150' 250' 350'

TEST

OKFLAME

LED

WIRING CODE

BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W

NEUTRAL

SPARK

TRANSFORMER

FIELD CONTROL WIRING

DISTANCE FROM UNIT TO CONTROL

UDAP & UDAS SERIES

WD# 185244 REV #3 AG2

LINE/1/60

GRD

(UDAS ONLY)

BK BK

SCREW

FAN MOTOR

CAPACITOR

(SEE NOTE #6)

SPARK GAP

DISCONNECT SWITCH

IND

75' 125' 175'

BR/W

VENTER MOTOR

(SEE NOTE #7)

MIN. RECOMMENDED

#18 GA. WIRE #16 GA. WIRE #14 GA. WIRE

BR/W

CAPACITOR

WIRE GUAGE

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 25

24. Check Installation and Startup

Check the installation prior to startup:

o Check to be sure that all screws used to hold shipping brackets were re-

installed in the heater cabinet.

o Check suspension. Unit must be secure and level. o Check clearances from combustibles. Requirements are in Paragraph 8.

o Check vent system to be sure that it is installed according to the instructions

in the appropriate Vent Installation Manual as listed in Paragraph 1.

o Check piping for leaks and proper gas line pressure. Bleed gas lines of

trapped air. See Paragraph 12.

o Check electrical wiring. Be sure all wire gauges are as recommended. A

service disconnect switch should be used. Verify that fusing or circuit breakers are adequate for the load use.

o Check polarity. Verify that line voltage exists between the black “L1” and

earth ground.

o If installed in California, verify that California Warning Label is displayed

Heater Startup:

WARNINGS: For your safety, read before operating. If you do not follow these instructions exactly, a fire or explosion may

result causing property damage, personal injury, or loss of life.

• This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

• Before operating, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call your fire department.

• Use only your hand to turn the gas control ON/OFF knob on the gas valve. Never use tools. If the valve ON/OFF knob will not turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Operating Instructions and Operating Sequence

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 26

• Should overheating occur, or the gas supply fail to shut off, turn off the manual gas valve to the appliance before shutting off the electrical supply.

• Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

1. Set thermostat at lowest setting.

2. Turn off all electric power to the appliance.

3. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. Open the access door and locate the gas control (ON/OFF) knob on the gas valve. (See FIGURE 16.)

FIGURE 16 - Gas Valve ON/OFF Control Knob

Top V iew

Gas Control

Knob

(shown in the

ON position)

Gas Flow

Side View

Gas Flow

4. Turn the gas control knob clockwise to "OFF".

5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near

the floor. If you smell gas, ST OP! and follow the steps in the WARNINGS printed above or on the Operating Label on the heater. If you do not smell gas, proceed to the next step.

6. Turn the gas control knob counterclockwise to "ON".

7. Close the access door.

8. Turn on the electric power to the heater.

9. Set the thermostat to the desired setting. NOTE: If the appliance does not operate, follow the instructions "To Turn Off

Gas to Appliance" printed below (and on the Operating Label on the heater) and call your service technician.

10. Thermostat calls for heat, energizing the venter motor.

11. Venter pressure switch closes, firing the unit.

12. Burner flame is sensed and in 30 seconds after the gas valve is energized, the fan motor is energized.

13. If the flame is extinguished during the main burner operation, the integrated control system closes the main valve and must be reset by interrupting power to the control circuit. (See lighting instructions on the heater.).

Check installation after startup:

TO TURN OFF GAS TO THE APPLIANCE

1) Set thermostat to lowest setting

2) If service is to be performed, turn off all electric power to the appliance.

3) Open the access door.

4) Turn the gas control knob clockwise to "OFF". Do not force.

5) Close the access door.

o Vent System Testing Procedur e - Model UDAP

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1 or CAN/CGA B149.1 and B149.2, Installation Code for Gas Burning Appliances and Equipment, and the venting installation manual. Determine that there is no blockage or restriction, leakage, corrosion or other deficiencies that could cause an unsafe condition.

3. In so far as practical, close all building doors and windows and all doors between the space where the heater is and other spaces of the building. Turn on clothes dryers and exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4. Light the heater following the lighting instructions. Adjust the thermostat for continued operation. Verify that combustion products are venting properly. After determining that the heater vents properly, return doors, windows, exhaust fans, and fireplace dampers to their previous conditions. If improper venting is observed, the venting system must be corrected.

o With the unit in operation, measure valve outlet gas pressure. If operated at

high altitude, adjust outlet gas pressure for altitude. See information and instructions in Paragraph 12.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 27

24. Startup

o Turn the unit off and on, pausing two minutes between each cycle. Observe

for smooth ignition.

(cont’d)

o Place the "Owner's Envelope" containing the Limited Warranty, this booklet,

and any control or optional information in an accessible location near the heater. Follow the instructions on the envelope.

DANGER: The gas burner in this gas-fired equipment is designed and equipped to pr ovide safe controlled complete combustion. However, if the installation does not permit the burner to receive the proper supply of combustion air, complete combustion may not occur. The result is incomplete combustion which produces carbon monoxide, a poisonous gas that can cause death. Safe operation of indirect-fired gas burning equipment requir es a pr operly operating vent system that vents all flue products to the outside atmosphere. FAILURE TO PROVIDE PROPER VENTING WILL RESULT IN A HEALTH HAZARD WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH.

Always comply with the combustion air requirements in the installation codes and in Paragraph

9. Combustion air at the burner should be regulated only by manufactur er-provided equipment. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. Model UDAP units installed in a confined space must be supplied with air for combustion as required by Code and in Paragraph 9 of this heater installation manual. MAINTAIN THE VENT OR VENT/COMBUSTION AIR SYSTEM IN STRUCTURALLY SOUND AND PROPER OPERATING CONDITION.

MAINTENANCE AND SERVICE

25. Maintenance Schedule

NOTE: If replacement parts are required, use only factory-authorized parts.

WARNING: If you turn off the power supply, turn off the gas. See Hazard Levels, page 2.

The material contained in the MAINTENANCE AND SERVICE Section of this manual is designed to aid a qualified service person in maintaining and servicing this equipment. This heater will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a heater that is operated under normal conditions should be inspected and cleaned at the start of each heating season. If the heater is operating in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent maintenance is recommended. When any service is completed, be careful to reassemble correctly to ensure that no unsafe conditions are created. When re-lighting, always follow the lighting instructions on the heater.

Maintenance Schedule - The following procedures should be carried out at least annually (See FIGURE 18 and Paragraphs 26-39.):

• Clean all dirt, lint, and grease from the combustion air opening (UDAP) and venter assembly .

• Clean all dirt, lint, and grease from the fan blade, fan guard, and motor.

• Check the heat exchanger both internally and externally.

• Check the burner for scale, dust, or lint accumulation. Clean if needed.

• Check the vent or vent/combustion air system for soundness. Clean openings. Replace any parts that do not appear sound.

• Check the wiring for any damaged wire. Replace damaged wiring. (See Paragraph 14 for replacement wiring requirements.)

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 28

26. Heat Exchanger Maintenance

27. Burner

Maintenance

This heater is equipped with a TCORE Remove any external dirt or dust accumulation. V isually check the heat exchanger

for cracks and holes. If a crack or hole is observed, replace the heat exchanger. NOTE: Inspection of the lower portion of the heat exchanger is done with the

burner removed. See the Burner Service section below for information on inspecting the lower portion of the heat exchanger.

This heater is equipped with a TCORE Inspect the burner/control compartment annually to determine if cleaning is nec-

essary . If there is an accumulation of dirt, dust, and/or lint, clean the compartment and follow the instructions below to remove and clean the burner.

heat exchanger (patent pending).

burner (patent pending).

CAUTION: Use of eye protection is recommended.

Burner Removal Instructions (Refer to FIGURE 17.)

FIGURE 17 - Burner Removal (UDAP illustrated; same process for both UDAP and UDAS)

1. Outside the cabinet, shut the gas supply off at the manual valve ahead of the

union.

2. Turn off electric supply.

3. Disconnect the gas supply at the union outside of the cabinet.

4. Remove the access panel.

5. Disconnect the Gas Train and Move Out of the Way - At the gas valve,

mark and disconnect the wires. Carefully remove the burner orifice and orifice adapter locking nut. Slide the orifice adapter out through the bracket on the burner pushing the gas train to the right. This will move the gas train out of the way.

6. Move the Control Assembly - Remove the two screws holding the control

assembly bracket. Being careful not to disconnect any wires, slide the control assembly to the right.

7. Remove Secondary Air Baffles (Sizes 60-400 only) - Vertical along the right

side of the burner, locate the flat plate(s) identified as the secondary air baffle(s). The quantity of baffles could be one to four depending on heater

Burner Body Support (at least two per unit) - Remove screw attaching to secondary air shield. Support remains attached to burner.

Secondary Air Shield

Burner

Orifice

Burner Assembly

Secondary Air Baffle (Qty varies per size.) Mark locations before removing.

Venturi Tube

Slide right; rotate inward; pull out

Slide Right

Control Bracket Screws Loosen bracket; slide right.

Gas Valve

Disconnect gas train at orifice and outside the heater; slide to the right.

Orifice Adapter Locking Nut

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 29

27. Burner Maintenance (cont’d)

Burner Removal (cont’d)

size. Each baffle is held in place by one screw. For re-assembly, on the secondary air shield, mark the location (top and bottom) of each baffle.

Remove all baffles.

8. Remove Burner Assembly

a) Locate the burner body supports. Depending on the size, the burner will

have two or more supports. At each support, remove the one screw that attaches it to the secondary air shield

b) Holding the venturi tube, slide the entire burner assembly slightly to the

right to disengage the burner from the supports on the left. Then rotate the open end of the venturi tube inward toward the heater. Carefully pull the burner assembly out of the cabinet.

Inspect and Clean the Burner

Re-Install the Burner

With the burner assembly removed, shine a flashlight on the burner ribbons. Look for carbon buildup, scale, dust, lint, and/or anything that might restrict flow through the spaces between the burner ribbons. Holding the burner assembly so that any foreign material will fall away from the burner, use a stiff bristle brush to loosen and remove any foreign material(s). If the burner is excessively dirty, remove one of the burner end caps. Remove the four screws that hold the end cap to the burner housing. Lightly tap the end cap to remove it.

Clean all foreign material from the burner and venturi. After the burner is thoroughly clean, replace the end cap making certain that it is tight against the burner housing. NOTE: If any of the burner components are damaged or deteriorated, replace the burner assembly.

Inspect the Lower Portion of the Heat Exchanger (with burner assembly removed)

At the burner flame entrance of each tube, shine a bright light into each heat exchanger section. With the light shining into the heat exchanger, observe the outside for visible light. Repeat this procedure with each heat exchanger section. If any light is observed, replace the heat exchanger.

Instructions to Re-Install the Burner (Refer to FIGURE 17)

1. Attach the Burner Assembly - Holding the venturi tube, slide the entire

burner assembly into position. Align the supports on the left side with the slots in the burner shield; sliding the supports into the slots. On the right, reattach each burner body support to the secondary air shield.

2. Attach the Secondary Air Baffles (Sizes 60-400 only) - Re-attach the

secondary air baffles as marked. Baffles may be different sizes and each

must be attached in the correct location.

3. Attach the Control Assembly - Carefully slide the control assembly into

position. Re-attach with the same screws. Check to be sure all wire connections are secure.

4. Attach the Gas Train - Slide the gas train so that the orifice adapter is

through the bracket. Fasten the gas train to the bracket with the locking nut. Install the gas orifice. Re-connect the wires to the gas valve.

5. Close the access panel.

6. Reconnect the gas supply at the union outside of the cabinet. Leak test the

connection with leak detecting solution.

7. Turn on the electric and the gas. Check for proper operation.

28. Burner Orifice

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 30

Burner orifice usually only needs to be replaced when installing a gas conversion kit. If ordering a replacement orifice only, give BTUH content and specific gravity of gas, as well as the model and serial number of the unit. When removing or replacing the burner orifice be careful not to damage the venturi tube and/or the bracket.

FIGURE 18 - Location of Controls

Flame Rollout Switch

(Sizes 30-125)

Burner Assembly

Ignitor

Transformer

Circuit Board (DSI Integrated Control Module)

Flame Sensor

Pressure Switch

- Sizes 30-125

Control Panel Assy

located on the

Control Compartment

Bottom

Sizes 30-125

Sizes 150-400

Optional Fan Motor Capacitor

High Temperature Limit Control

Gas Valve

Transformer

Circuit Board (DSI Integrated Control Module)

Venter Motor (Size 30-75 illustrated. Venter motor is in the same location for all models, but appearance is different.)

Model UDAS has a collar for combustion air pipe (not illustrated)

Interlock Door Switch - UDAS only

Fan Motor

Terminal Board (24V)

Disconnect Switch

- UDAS only

Electrical Box - UDAS only Remove cover to connect supply and access disconnect switch wires . Always replace cover.

Pressure Switch (Sizes 150-400)

Venter Motor Capacitor

Fan Motor Capacitor

29. Ignition System

FIGURE 19 - DSI Integrated Control Module (Circuit Board)

DSI Integrated Control Module (circuit board) - See FIGURE 19. The module

monitors the operation of the heater including ignition. The only replaceable component is the 3 amp Type ATC or ATO fuse. If the fuse is blown, the problem is most likely an external overload. Correct the problem and replace the fuse.

Do not attempt to disassemble the control module. However, each heating season check the lead wires for insulation deterioration and good connections.

Proper operation of the direct spark ignition system requires a minimum flame signal of 1.0 microamps as measured by a microampmeter.

For further information and check out procedure on the direct spark ignition system, refer to Paragraph 20 and the Troubleshooting Flow Chart in Paragraph 40.

Only replaceable part is a Type ATC or ATO 3 amp fuse (Color Code Violet), P/N 201685

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 31

29. Ignition System

Ignitor - Refer to FIGURE 18 and locate the ignitor. Disconnect the wire; remove the screw and the ignitor. Clean the ignitor assembly with an emery cloth.

Spark gap must be maintained to 1/8". See FIGURE 20.

(cont’d)

Ignitor

Flame Sensor

30. Fan Motor, Fan Blades, and Guard

FIGURE 21 - Fan Blade Position on the Shaft

Dimension A

Size

inches mm

30 45 60

75 100 125 150 175 200

225, 250,

300 350 400

125

9/16 14 1-1/2 38 2-1/8 54 2-3/8 60

2-5/16 59

2-3/8 60 2-1/8 54 1-5/8 67

251

1-7/8 48 1-3/8 35

Fan Blade

FIGURE 20 - Ignitor showing required Spark Gap

1/8 inch

(3.2mm)

measurement

IMPORTANT: When re-assembling, the brown ground wire must remain attached

to the ignitor .

CAUTION: Due to high voltage on the spark wire and electrode, do not touch when energized. See Hazard Levels, page 2.

Flame Sensor - Refer to FIGURE 18 and locate the flame sensor. Disconnect the

wire; remove the screw and the flame sensor. Clean with an emery cloth.

Remove dirt and grease from the motor, the fan guard, and blades. Use care when cleaning the fan blades to prevent causing misalignment or imbalance. Check that the hub of the fan blades is secure to the shaft. Follow these instructions for replacement of the fan guard, fan motor and/or fan blades.

1. If the heater is installed, turn off the gas and disconnect the electric power.

2. Open the access door and disconnect the fan motor wires, capacitor wires at the capacitor, and ground screw.

3. Remove the assembled parts (the fan guard, the motor and the fan blade).

Fan

Motor

tioned properly .

5. Reconnect the fan motor wires according to the wiring diagram and close the access panel.

6. Restore power to the heater and turn on the gas. Light, following the instructions on the lighting instruction plate. Check for proper operation.

4. Disassemble and replace whatever parts are needed and reassemble using whatever part(s) are being replaced and the original parts. Be sure the fan blade is in the proper position on the shaft; refer to the illustration and table in FIGURE 21. Position the assembly on the heater. Attach the fan guard. Rotate the fan blade to check for adequate clearance. If adjustment is required, loosen the mounting screws, re-position the fan guard, and tighten the screws. Rotate the fan blade and re-check for adequate clearance. Repeat this procedure until the assembly is posi-

31. Venter Motor and Wheel

Replacement Instructions

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 32

Remove dirt and grease from the motor casing, the venter housing, and the venter wheel. Venter motor bearings are permanently lubricated. Follow these instructions for replacement of the venter motor and wheel assembly. Keep all hardware removed to be used in re-assembling and installing the replacement parts.

1. Turn off the gas and disconnect the electric power.

2. Open the burner/control compartment access panel.

3. Disconnect the three venter motor wires at the DSI control, capacitor wires at the capacitor (if applicable), and ground screw (located on the control panel).

4. Sizes 30 and 45 - Disconnect the gas train and move it out of the way . Disconnect the gas supply at the union outside of the cabinet. At the gas valve, mark and disconnect the wires. Carefully remove the burner orifice and orifice adapter locking nut. Slide the orifice adapter out through the bracket on the burner pushing the gas train to the right. This will move the gas train out of the way.

FIGURE 22 - Venter Wheel Position on Shaft

5. Holding the venter motor, remove the three or four screws that attach the venter motor mounting plate to the venter housing. Remove the motor and wheel assembly from the heater.

6. Re-assemble with the replacement venter motor and wheel assembly . See FIG- URE 22.

7. Follow the wiring diagram to connect the venter wires.

8. Sizes 30 and 45 - Reconnect the gas supply at the union outside of the cabinet. Leak test the connection with leak detecting solution.

9. Replace the access panel. Restore power to the heater and turn on the gas. Light, following the instructions on the lighting instruction plate. Check for proper operation.

V enter Wheel, Sizes 30-75

32. Operating Gas Valve

Venter Motor Plate

Fan

Motor Mounting Bracket

Motor Sizes 30-75

5/16” (8mm) inside

The gas valve requires no field maintenance except careful removal of external dirt accumulation and checking of wiring connections. Instructions for testing pressure settings re in Paragraph 12.

WARNING: The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting to the unit to ensure positive closure. See Hazard Levels, page 2.

33. Combustion

Air Pressure Switch

V enter Wheel, Sizes 100-175*

Single

Stage

Gas

Valve

Venter Motor Plate

Fan

Motor Mounting Bracket

Motor Sizes 100-400

*Venter wheel has different appearance on Sizes 200-400. Motor spacing is the same.

5/16” (8mm) inside

Optional

Two

Stage

Gas

Valve

See FIGURE 18, page 31, for location. If it is determined that the pressure switch needs replacing, use only the factory-authorized replacement part that is designed for the model and size of heater being serviced.

NOTE: A unit operating above 6000 ft elevation requires a high altitude pressure switch. See Paragraph 7.

34. Limit Control

35. Door Switch

- UDAS only

36. Transformer

If it is determined that the limit control needs replacing, use only a factory-authorized replacement part that is designed for the size of heater.

For approximate limit location, see FIGURE 18, page 31.

If it is determined that the door switch needs replacing, use only a factory-authorized replacement part that is designed for the heater.

For approximate switch location, see FIGURE 18, page 31.

See FIGURE 18 , page 31, for location. Use a voltmeter to verify that there are 24 volts output from the transformer. If the transformer is not functioning, it must be replaced. Use a replacement transformer identical to the factory-installed model.

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 33

37. Flame Rollout Switch Sizes 30-125

only

For location, see FIGURE 18, page 31.

The cause of a flame rollout switch activating must be determined. Activation of the manually reset flame rollout switch could be caused by one or more of the following:

• Restricted or plugged heat exchanger

• Pressurization of the heat exchanger

• Restricted combustion air inlet or exhaust outlet in combination with a defective pressure switch

• Building exhaust

• Electrical power interruption during operation

If a flame rollout switch trips, inspect the burner/control compartment for signs of excessive heat and burned wiring.

If the compartment appears normal, reset by depressing the red button on the switch. 15 to 20 minutes are required for the switch to cool sufficiently for resetting. A distinct click will be felt when the switch resets. Operate the furnace. If the flame rollout switch trips again, determine and correct the cause before resetting the switch. If there is damage to the control compartment, repairs must be made before resetting the switch.

If it is determined that the flame rollout switch needs replacing, use only the factory-authorized replacement part that is designed for that size of heater.

38. Disconnect Switch UDAS only

39. Vent or Vent/ Combustion

Check the complete system at least once a year. Inspection should include all joints, seams, concentric adapter box (UDAS), inlet air guard or inlet air cap (UDAS), and the vent terminal cap. Clean openings. Replace any defective parts.

Air System

40. Troubleshooting

DSI Integrated Control Module (Circuit Board) Trial Troubleshooting Flowchart

Is there

minimum flame current

at the control

module?

Check connections to flame

sensor and/or moisture in the

burner assembly.

Is there minimum

YES NO

flame current at the

flame sensor?

YES

Replace control

module.

YES NO

Does gas

ignite?

Is the flame

sensor corroded?

Is the sensor

located in flame

correctly?

Reposition

flame sensor.

The disconnect switch is located in the sealed electrical box inside the control compartment with the toggle on the rear of the heater. If it is determined that the disconnect switch needs replacing, use only the factory-authorized replacement part that is designed for the heater. Always replace electrical box cover.

Trial for Ignition

Call for Heat

Is there a

spark across gap at

ignitor?

YES NO

Is gas

flowing?

Is there

spark voltage at

control?

Is there 24V P1-2

to power control?

Check wiring

and/or 24VAC

transformer output.

YES

Check high

voltage wire

continuity.

Replace

control

module.

YES

Clean flame

sensor.

Replace flame

sesnsor.

YES NO

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 34

Check gas pressure

and supply voltage.

If either are low,

correct and repeat

startup.

YES

position correct in the

Is the ignitor

gas flow?

Reposition

spark ignitor.

Replace gas

valve.

Check wiring and

connections to

gas valve.

YES

YES NO

Is there

24VAC at the gas

valve?

Is there 24VAC

from gas valve output on

control module to

chassis?

Replace ignition

control

module.

Check the Lights on

ght

)

the DSI Integrated Control Module (Circuit Board)

IMPORTANT: When using a multimeter to troubleshoot the 24 volt circuit, place the meter’s test leads into the 5 or 9 pin connectors located on the ignition control. Do not remove connectors or terminals from the electrical components. Doing so can result in misinterpreted readings due to the ignition control board’s fault mode monitoring circuits.

The integrated circuit board monitors the operation of the heater and includes two LED signal lights that indicate normal operation and various abnormal conditions. If the heater fails to operate properly , check this signal to determine the cause and/ or to eliminate certain causes. See operating sequence in Paragraph 20.

Do not attempt to repair the DSI integrated control module; the only field replaceable component is the fuse.

Control Status - Green LED Codes

Steady ON..Normal Operation, No call

for heat

Fast Flash...Normal Operation, Call for

heat

1 Flash........System Lockout, Failed to

detect or sustain flame

2 Flashes ....Pressure Switch Did Not

Close within 30 Seconds of Venter Motor

3 Flashes ....High Limit or Flame

Rollout Switch Open

General Troubleshooting

PRO BLEM PROBA BLE C AUSE REMEDY Venter motor

will n ot start

Burner will not li

1. No powe r to unit. 1. T urn on powe r; check s up pl y fuses or main c i rcuit br e a ke r. Turn on built-in disconnect switch (Model UDAS only); replace switch if not oper ating.

2. No 24 volt pow e r to integr a t ed c i rcuit board. 2. Turn up ther mostat; c he c k c ontrol tr a ns form e r output.

3. Integrated cir cuit board f use blown. 3. Corr ect caus e. Replace f use (type AT C or ATO, 32VDC, 3A).

4. No powe r to venter motor. 4. Tighten conne c t ions at cir c uit boa rd and/or m ot or terminals.

5. Integrated circuit board defective. 5. Replace intergrated circuit board.

6. D efective venter motor. 6. Replace venter motor. See Paragr aph 31.

1. Manual valve n ot open. 1. Open m anual valve.

2. Air in the gas line. 2. Bleed gas line (initial startup only).

3. Gas pressu re too high or too low. 3. Supply pre ssure should be 5" - 14" w.c. for nat ural gas or 11" - 14" w.c. for propane gas.

4. No Spa rk: 4.

a) L oose wire connec ti ons. a) B e c e rtain all wire c onn e c tion s are s oli d. b) Trans former failure . b) B e s ure 24 volts is available . c) Incorrect spark gap. c) Maintain spark gap at 1/8". d) Spark c a bl e s horted to gr oun d. d) R e pla ce worn or gr ounde d spark c abl e . e) Spark electrode shorted to ground. e) Replace if ceram ic spar k electrode is cracked or grounded. f) Bur ner not grounded. f) Make c ertain integrated circ ui t board is grounded t o ign i t or. g) C ircuit board not grounde d. g) M ake c e rtain integrated c ircuit board is gr ounde d to furnace chassis. h.) Unit no t properl y grounded. h.) Make ce rtain unit is proper ly field gr ounde d t o e a rth ground a nd

prop e rly phase d (L1 to hot lea d L 2 to ne utral) .

i) I ntegrated circuit board fuse blown. i) Correct cause. Replace f use ( type AT C or ATO, 32VDC, 3A). j.) Faulty inter gr a ted cir c uit boar d. j) If 24 volt is availa ble to the integrated cir c uit board and all other caus es

have been eliminated, replace board.

5. Lockout devic e interrupting control circuit

by above causes.

6. Interlock door switch open (UD AS only). 6. Close access door or r eplace sw itch.

7. Combustion air proving switch 7.

not clos i ng. a) Ma ke sure unit is properly vented.

8. Faulty combustion air proving switch. 8. Replace combustion air proving switch.

9. M ain valve not operating. 9.

a) Defective valve. a) If 24 volt is measured at the valve connections and valve remains

Loos e wire c onn ec t ions b) Check and tighten all wiring connec tions.

5. Reset lockout by interrupting cont rol at the thermostat or main po wer.

b) Rem ove obs tructions from vent. c) Replace f aulty tubing to press ure switch.

closed, replace valve.

4 Flashes ....Pressure Switch is Closed

Before Venter Motor is Energized

Steady OFF Blown fuse, No Power, or

Defective Board

Flame Status - Yellow LED Codes

Steady ON..Flame is sensed Slow Flash .Weak flame (current below

1.0 microamps ± 50%)

Fast Flash ...Undesired Flame (valve

open and no call for heat)

Form RZ-NA I-UDA, Mfg #195673 Rev 5, Page 35

40. Troubleshooting (cont’d)

PROBLEM (cont’d) PROBABLE CAUSE (cont’d) R EMEDY (cont’d) Burner will n ot light (cont’d)

Burner cycle on and of f

No h eat (Heater Operating)

Fan or ve nter motor will not run

Fan or venter motor t urns on and off while burner is o Fan or venter motor cuts out on overload

erating

10. I ntegrated circuit board does not power main valve. a) Loose wire connections. a) Check and tighten all wir ing connections. b) F la m e s e ns or grounded. b) Be ce rtain flame s e ns or lead is not grounded or ins ulation or

c) Incorrect gas pressure. c) Supply pressure should be 5" - 14" w.c. for natural gas or 11" - 14"

d) Cracked cer amic at sensor. d) Replace sensor.

1. Gas pres sure too high or too low. 1. Supply pr e s sure should be 5" - 14" w.c. for natural gas or 11" - 14"

2. Burner not grounded 2. Ma ke c e rtain integrated c ircuit board is grounded to ignitor.

3. Circuit board not grounded. 3. Make certain integrated circuit board is grounded to furnace chass is.

4. Faulty integrated circuit board 4. If 24 volt is ava ila ble to the integrated circuit board and all other

5. Combustion air pr oving s witch 5. not closing. a) Ma ke s ure unit is proper ly vented.

6. Faulty combustion air proving switch. 6. Replace combustion air proving switch.

7. Flam e sensor grounded. 7. Be certain flame sensor lead is not grounded or insulation or ceramic

8. Cracked ceram ic at sensor . 8. Replace sensor.

9. Incorrect polarity. 9. Reverse line volt leads to inte grated circuit board.

1. Incorr ec t valve outlet press ur e or orifice. 1. Check valve outlet pressur e. See Rating plate for manifold press ure.

2. Cycling on limit control. 2. Check air throughput.

3. Im pr oper therm os tat location or adjustment. 3. S ee therm ostat m anufacturer’s instructions.

1. Circuit o

2. D efective integrated circuit board. 2. Replace board.

3. Defective motor or starter. 3. Replace motor or starter .

1. Motor overload device cycling on and off. 1. Check motor load against motor rating plate. Replace motor if

1. Low or high voltage supply. 1. Correct electr ic supply.

2. D efective motor. 2. Replace motor.

3. P oor air flow. 3. Clean motor, fan, fan guard, filter, and coils .

4. Defective bearing or lubrication. 4. Lubricate bearings (motor permitting) or r eplace motor.

en. 1. Check wiring and connections.

10.

ceramic is not cr acked. Replace as required.

w. c. for propane gas.

causes have been eliminated, replace board.

b) Remove ob struc tions f rom vent. c) Replace faulty tubing to pressure switch.

is not cracked. Replace as r equired.

needed.

FOR SERVICE OR REPAIR, FOLLOW THESE STEPS IN ORDER:

FIRST: Contact the Installer

Name __________________________________________________________ Address_________________________________________________________

__________________________________________________________ __________________________________________________________

Phone _____________________________________

SECOND: Contact the nearest distributor (See Yellow Pages). If no listing,

contact Authorized Factory Representative, 1-800-695-1901 (Press 1).

THIRD: Contact REZNOR

/ Thomas & Betts Corporation 150 McKinley Avenue Mercer, PA 16137 Phone: (724) 662-4400

Date of

Model No. ______________Unit Serial No._____________________________ Installation _______________

(800) 695-1901; www.ReznorOnLine.com

Trademark Note: Reznor®, TCORE2® , and are trademarks of Thomas & Betts.

Form RZ-NA I-UDA, P/N 195673 Rev 5, Page 36

1/03 YL Form RZ-NA I-UDA (Version .5)

Thomas & Betts UDAS, UDAP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual