Revision: I-UBX-UBZ-UDX-UDZ (04-21) 1034344-0 Supersedes: — (Original Version) UNIT HEATER INSTALLATION/OPERATION/MAINTENANCE MODEL UBX: STANDARD POWER VENT BLOWER TYPE MODEL UBZ: SEPARATED-COMBUSTION BLOWER TYPE MODEL UDX: STANDARD POWER VENT FAN TYPE MODEL UDZ: SEPARATED-COMBUSTION FAN TYPE ⚠ DANGER ⚠ • • • • • • • • • FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
TABLE OF CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Safety Information . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS—CONTINUED ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measure and Adjust Manifold (Outlet) Gas Pressure . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION—CONTINUED References Both this installation/operation manual and the appropriate venting instructions 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. Table 1.
Warranty Refer to the limited warranty form in the literature bag provided with the unit. The warranty is void if: • Wiring is not in accordance with the diagram furnished with the heater. • The unit is installed without proper clearance to combustible materials. • A fan model is connected to a duct system or if the air delivery system is modified. Installation Codes • These units must be installed in accordance with local building codes.
GENERAL INFORMATION—CONTINUED Heater Throw—Continued Z X Y Z 8 10 10 10 9 060 18 45 18 42 17 39 16 34 14 29 14 15 16 16 16 14 — 225 27 86 27 82 27 78 26 73 24 67 22 60 X Y Z 9 12 12 12 12 11 Unit Size 075 20 57 −14° 22 54 −25° 22 52 −32° 21 48 −39° 19 44 −46° 17 38 −54° 9 11 12 11 11 10 20 21 20 19 17 14 100 59 56 52 47 42 34 16 17 18 18 19 18 250 29 93 30 90 30 87 30 83 28 78 27 72 15 16 17 17 17 16 28 28 28 27 25 24 300 94 89 85 80 74 66 X Y 030 045 6 14 30 −21° 7 16 40 7 13 26 −39
Mounting Height Requirements ⚠ WARNING ⚠ 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 (1.5 meters) above the floor. • For best results, the heater should be mounted with certain rules in mind. In general, a unit should be located 8 to 12 feet (2.4 to 3.7 meters) above the floor. Units should always be arranged to blow toward or along exposed wall surfaces, if possible.
GENERAL INFORMATION—CONTINUED Dimensions—Continued L NOTES: 1. * SIZES 150-400 - DIMENSION E VARIES WITH MOTOR SELECTION AND BELT ADJUSTMENT. 2. ** DIMENSIONS H AND K ARE THE HEATER SUSPENSION POINTS.
Table 4.
GENERAL INFORMATION—CONTINUED Dimensions—Continued Table 5.
Table 7.
GENERAL INFORMATION—CONTINUED Combustion Air Requirements—Continued Table 8. Determining Confined Space Combustion Air Requirements Letter* Air Source A Air inside building B Outside air through duct C Direct outside air *See Figure 4.
Table 10. Technical Data for UBX and UBZ Models (Unit Sizes 150–400) Parameter Input heating capacity Thermal efficiency Output heating capacity1 Gas connection, natural2 Unit Size Unit of Measurement 150 175 200 225 250 300 350 400 150,000 175,000 200,000 225,000 250,000 300,000 350,000 400,000 BTUh 43.9 51.2 58.6 65.9 73.2 87.8 102.5 117.1 kW 83 83 83 83 82 % 124,500 145,250 166,000 186,750 207,500 249,000 290,500 328,000 BTUh 36.4 42.5 48.6 54.7 60.8 72.9 85.1 96.
GENERAL INFORMATION—CONTINUED Acoustical Considerations—Continued Table 11. Technical Data for UDX and UDZ Models (Unit Sizes 030–125) Gas connection, natural2 1/2 Unit Size 060 075 60,000 75,000 17.6 22.0 83 49,800 62,250 14.6 18.
Table 12.
INSTALLATION Unpacking and Inspection • The unit was test-operated and inspected at the factory prior to crating and was in operating condition. • It is important to note when uncrating the unit that shipping brackets are attached with cabinet screws. When removing shipping brackets, re-insert ALL screws into the cabinet.
Heater Suspension ⚠ WARNING ⚠ • Before suspending the heater, check the supporting structure to be used to verify that it has sufficient load-carrying capacity to support the weight (refer to Weights section) of the unit. • The heater must be level for proper operation. DO NOT place or add additional weight to a suspended heater. ⚠ CAUTION ⚠ • Before lifting the heater, verify that any screws used for holding shipping brackets were reinstalled in the cabinet.
INSTALLATION—CONTINUED Heater Suspension—Continued Suspension of Heater with Downturn Nozzle Downturn nozzle kits (option CD2, CD3, CD4, or CD5) require four-point suspension. Follow the instructions provided with the kit for downturn nozzle installation. Suspension of Heater Using Option CK8 or CK10 Hanger Kit Options CK8 (two-point suspension) and CK10 (four-point suspension) are for suspending the heater using swivel connectors connected to 1-inch pipe.
Heater Suspension Using Field-Supplied Threaded Rods The heater may be suspended from 3/8-inch threaded rods using either two- or four-point suspension. The recommended maximum rod length is 6 feet (1.8 meters). The length of the threaded rod extending into the heater MUST NOT exceed 1/2 inch (13 mm). Ensure that the threaded rods are locked to the heater as shown in Figure 8. 3/8-INCH THREADED ROD ADD 3/8-INCH NUT AND WASHER TO LOCK ROD TO HEATER Figure 8.
INSTALLATION—CONTINUED Piping Connections—Continued Gas Supply Piping—Continued Table 14.
Table 15. Gas Connection Sizes Natural Gas Unit Size Propane Connection (Inches)* 030–200 225–400 *Connection size for a standard unit (not gas supply line size). 1/2 3/4 1/2 3/4 Electrical Connections ⚠ CAUTION ⚠ • Route wires so that they do not contact the flue wrapper or venter housing.
INSTALLATION—CONTINUED Electrical Connections—Continued Rear View Standard Power Vent Model NOTE: The size of heater illustrated has a vertical terminal strip. Some sizes have a horizontal terminal strip. Rear View Separated Combustion Model C C Figure 10. Supply Wiring Entrance and Control Connection Terminal Strip • The circuit board (see Figure 11) is located inside on the bottom of the control compartment. The circuit board is polarity sensitive.
CONTROLS NOTE: Refer to the Troubleshooting section for probable causes and reset instructions for the following controls. Locations for the following controls are shown in Figure 12. Interlock Door Switch Disconnect Switch Electric Box Circuit Board Circuit Board Figure 12. Component Locations (Typical) Pressure Switch ⚠ DANGER ⚠ Safe operation of this unit requires proper venting flow.
CONTROLS—CONTINUED Pressure Switch—Continued • If a restriction or excessive flue length/turns cause the sensing pressure to be outside the pressure switch setpoint, the switch will function to shut off the main burner. The main burner will remain off until the system has cooled and/or the flue system resistance is reduced. • Pressure switch settings are listed in Table 16. Table 16.
High Temperature Limit Control ⚠ WARNING ⚠ The automatic-reset high temperature limit control will continue to shut down the heater until the cause is corrected. Never bypass this control as hazardous conditions could result. All units are equipped with a temperature-activated, automatic-reset high temperature limit control (see Figure 12 for location). The control is factory-set and is non-adjustable. If the setpoint is reached, the control interrupts the electric supply to the gas valve.
CONTROLS—CONTINUED Thermostat Options NOTES: • IMPORTANT: all units MUST be operated by a 24V thermostat. Never use a line voltage disconnect switch as a means of operating the heater. • The operation of unit sizes 030–125 by means other than by a 24V thermostat may result in the flame rollout switch tripping. • For all availaible thermostat and thermostat accessory options, contact contact an authorized Factory Distributor.
OPERATION ⚠ DANGER ⚠ • 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.
OPERATION—CONTINUED Startup—Continued 3. Open access door and locate gas control (ON/OFF) knob or switch on gas valve (see Figure 13). Top View ON/OFF Switch Figure 13. Gas Valve ON/OFF Control 4. Turn gas control switch to OFF or turn knob clockwise to OFF. 5. Wait 5 minutes to clear out any gas and then smell for gas (including near floor). a. If you smell gas, STOP! and follow steps in DANGER message listed above or on heater operating label. b. If you do not smell gas, proceed to step 6. 6.
Operating Sequences Table 18 describes the heater’s normal operating sequence. Table 19 describes the heater’s abnormal heat cycle functions. Table 20 describes the heater’s fault modes. Refer to Table 17 for LED indications. Table 18. Operating Sequence (Normal Heat Cycle) Step Condition Terminal W is energized 1.
OPERATION—CONTINUED Startup—Continued Operating Sequences—Continued Table 19.
Table 20.
OPERATION—CONTINUED Post-Startup Checklist Check the following after startup: Ensure that vent system has been tested in accordance with Vent System Testing section With unit in operation, measure manifold (outlet) gas pressure in accordance with Measure and Adjust Manifold (Outlet) Gas Pressure section Turn unit OFF and ON, pausing 2 minutes between each cycle; observe for smooth ignition Place literature bag that contains Limited Warranty, this manual, venting instructions, and any control or opti
Measure and Adjust Manifold (Outlet) Gas Pressure If the heater is being installed at an elevation ≤2,000 feet (≤610 meters), adjust the manifold (outlet) gas pressure in accordance with the Measure and Adjust Manifold Gas Pressure—Elevation ≤2,000 Feet (≤610 Meters) section. If the heater is being installed at an elevation >2,000 feet (>610 meters), adjust the manifold (outlet) gas pressure in accordance with the Measure and Adjust Manifold Gas Pressure—Elevation >2,000 Feet (>610 Meters) section.
ADJUSTMENTS—CONTINUED Measure and Adjust Manifold (Outlet) Gas Pressure—Continued REGULATOR SCREW 1/8" OUTLET PRESSURE TAP REGULATOR SCREW INLET PRESSURE TAP INLET PRESSURE TAP 1/8" OUTLET PRESSURE TAP SINGLE-STAGE VALVES HIGH-FIRE REGULATOR SCREW INLET PRESSURE TAP LOW-FIRE REGULATOR SCREW 1/8" OUTLET PRESSURE TAP TWO-STAGE VALVE Figure 15. Gas Valves ⚠ CAUTION ⚠ DO NOT bottom out the gas valve regulator screw.
Measure and Adjust Manifold Gas Pressure—Elevation >2,000 Feet (>610 Meters) For installations at high elevations, measure and adjust the manifold (outlet) gas pressure as follows: 1. If installation is at elevation >6,000 feet (1,830 meters), replace pressure switch in accordance with Pressure Switch Replacement section. ⚠ WARNING ⚠ Manifold gas pressure must never exceed 3.5 IN WC for natural gas or 10 IN WC for propane. 2.
ADJUSTMENTS—CONTINUED Measure and Adjust Manifold (Outlet) Gas Pressure—Continued Table 22.
MAINTENANCE ⚠ WARNING ⚠ If you turn OFF the electrical power supply, turn OFF the gas. ⚠ CAUTION ⚠ • Eye protection is recommended when cleaning unit. • When any service is completed, ensure that the unit is reassembled correctly so that no unsafe conditions are created. • When re-lighting, always follow the lighting instructions on the heater.
MAINTENANCE—CONTINUED Maintenance Procedures—Continued Burner Maintenance—Continued Figure 16. Typical Burner Assembly 1. Remove gas and electric supply: a. Shut OFF gas supply ahead of union at manual valve outside cabinet. b. Turn OFF electric supply. c. Disconnect gas supply at union outside of cabinet. ⚠ WARNING ⚠ Use of eye protectection is recommended. 2. Remove burner assembly (see Figure 16): a. Remove access panel. a. Detach gas train: (1) Mark and disconnect wires at gas valve.
d. Locate burner body supports—depending on size, burner will have two or more supports. e. At each support, remove one screw that secures support to secondary air shield. f. While holding venturi tube, slide entire burner assembly slightly to right to disengage burner from supports on left. g. Rotate open end of venturi tube inward toward heater and carefully pull burner assembly out of cabinet. 3.
MAINTENANCE—CONTINUED Maintenance Procedures—Continued Burner Orifice Maintenance The burner orifice usually needs to be replaced only when installing a gas conversion kit. When ordering a replacement orifice only, provide 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, take care not to damage the venturi tube and/or the bracket.
Maintenance of Fan Motor, Fan Blades, and Fan Guard Inspect and clean the motor, fan guard, and blades. Remove any dirt and grease. Take care when cleaning the fan blades so as prevent causing misalignment or imbalance. Check to ensure that the hub of the fan blades is secure to the shaft. If necessary, replace the assembly as follows: 1. If heater has been installed, turn OFF gas and disconnect electric power. 2.
MAINTENANCE—CONTINUED Maintenance Procedures—Continued Venter Motor and Wheel Assembly Maintenance NOTES: • Venter motor bearings are permanently lubricated. • Keep all hardware removed to be used in reassembling and installing the replacement parts. Remove dirt and grease from the motor casing, venter housing, and venter wheel. Replace the venter motor and wheel assembly as follows: 1. Turn OFF gas and disconnect electric power. 2. Remove burner/control compartment access panel. 3.
Operating Gas Valve Maintenance ⚠ WARNING ⚠ The operating gas 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. Inspect the operating gas valve, carefully remove any external dirt accumulation, and check wiring connections. Check the valve annually to ensure that the valve is shutting off gas flow completely as follows: 1. Turn manual valve OFF to prevent flow to gas valve.
MAINTENANCE—CONTINUED Maintenance Procedures—Continued Flame Rollout Switch Maintenance (Model UDZ Unit Sizes 030–125 Only) • The cause of a flame rollout switch (see Figure 20) activating must be determined. See Figure 12 for flame rollout switch location.
Figure 21. DSI Control Module Troubleshooting Flowchart I-UBX-UBZ-UDX-UDZ (04-21) 1034344-0 45 YES Check connections to flame sensor and/or moisture in the burner assembly. NO Is there minimum flame current at the control module? YES Replace control module. NO YES YES NO YES Reposition spark ignitor. NO Replace gas valve. Check wiring and connections to gas valve. Replace flame sesnsor. Is gas flowing? Is there a spark across gap at ignitor? Clean flame sensor.
TROUBLESHOOTING—CONTINUED General Troubleshooting Refer to Table 25 for general troubleshooting symptoms, probable causes, and remedies. Table 25. General Troubleshooting Symptom Venter motor will not start Probable Cause 1. No power to unit 2. No 24V power to integrated circuit board 3. Integrated circuit board fuse blown 4. No power to venter motor 5. Integrated circuit board defective 6. Defective venter motor Burner will not light 1. Manual valve not open 2. Air in the gas line 3.
Table 25. General Troubleshooting—Continued Symptom Burner cycles ON and OFF Probable Cause 1. Gas pressure too high or too low 2. Burner not grounded 3. Circuit board not grounded 4. Faulty integrated circuit board 5. Pressure switch not closing 6. Faulty pressure switch 7. Flame sensor grounded No heat (heater operating) Fan or venter motor will not run Fan or venter motor turns ON and OFF while burner is operating Fan or venter motor cuts out on overload 8. Cracked ceramic at sensor 9.
INSTALLATION RECORD (TO BE COMPLETED BY INSTALLER) Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ Phone ________________________________________________________ Distributor (company from which the unit was purchased): Company ________________________________________________________ Contact _____
