Form I-UEAS (Version C.1) Obsoletes I-UEAS (Version C) Installation / Operation / Maintenance Applies to: Model UEAS, High-Efficiency, SeparatedCombustion, Low-Static Unit Heater T N P M TY UA E RO LITY SYST RA DU R CT WA Q C U S TO M E R CQS STA RT-UP AG C S PROC CY E EN VERGE S N N O ! WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
Table of Contents 1.0 General....................................................2-4 1.1 Hazard Labels and Notices......................... 2 1.2 General Information.................................... 3 1.3 Warranty..................................................... 3 1.4 Installation Codes....................................... 3 2.0 Unit Heater Location .............................4-5 8.2 24V Control Wiring Connections............... 27 8.3 Typical Wiring Diagram............................. 28 9.
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. WARNING Installation should be done by a qualified agency in accordance with these instructions. The qualified service agency installing this high efficiency separatedcombustion system is responsible for the installation. 1.
1.0 General (cont’d) 1.4 Installation Codes (cont’d) dance with the requirements of the enforcing authorities, and in public garages in accordance with CSA B149 codes. California Warning Label 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. Find the California Warning label, P/N 196977, in the plastic bag with this installation manual. Select a location on the heater access panel.
Location Recommendations 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 4.2. WARNING Internal heater surfaces that are accessible from outside the heater will cause burns if touched. Suspend the heater a minimum of 5 feet (1.5M) above the floor. 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.
3.0 Receiving, Uncrating, and Preparing for Installation (cont’d) If the installation includes optional vertical louvers, downturn nozzle, and/or a hanger kit, install these options before the heater is suspended. Instructions are in this form or in the option package; option packages are shipped separately. Other shipped-separate items could include a thermostat bracket kit, a thermostat, and/or a thermostat guard. Be sure all options ordered are at the installation site.
4.2 Clearances Clearances 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 (50°C) above the surrounding ambient temperature is not exceeded.
7.0 Mechanical WARNING This appliance is equipped for a maximum gas supply pressure of 1/2 psi, 3.5 kPa, or 14 inches water column. Supply pressure greater than 1/2 psi requires installation of an additional lockup-type service regulator external to the unit. WARNING: PRESSURE TESTING SUPPLY PIPING 7.1 Gas Piping and Pressure 7.1.1 Gas Supply Test Pressures 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.
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. FIGURE 5 - 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.
7.0 Mechanical (cont’d) Normally when operating on natural gas 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. 7.
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.
7.0 Mechanical (cont’d) 7.1 Gas Piping and Pressure (cont’d) 7.2 Venting and Combustion Air 7.1.4 Converting from Natural Gas to Propane (cont’d) 4. Fill in the information required on the gas conversion tape. Select a location near the rating plate. Be sure the surface is clean and dry and affix the conversion tape and propane label to the heater. 5. During heater startup, follow the instructions in Paragraph 7.1.3 to check the valve outlet pressure.
See Paragraph 7.2.1.6, page 14, for making vent pipe joints. The vent pipe drain connects into the heater condensate drain. Refer to Paragraph 7.3, page 25, for condensate drain installation instructions. FIGURE 8A - U.S. INSTALLATION ONLY - Vertical Vent showing Where to Install the Condensate Drain Connection using factoryprovided 4” PVC Cap FIGURE 8B CANADIAN OR U.S.
7.0 Mechanical (cont’d) FIGURE 9B CANADIAN OR U.S. INSTALLATION Horizontal or Vertical Vent showing Where to Install the Condensate Drain Connection in the Horizontal Vent Run 7.2.1.4 Vent Pipe Diameter and Length 7.2 Venting and Combustion Air (cont’d) 7.2.1 Vent/Combustion Air Requirements (cont’d) THIS PVC PIPING ARRANGEMENT APPLIES TO ALL CANADIAN INSTALLATIONS. In Canada, all PVC vent pipe must be approved to ULC S636. All venting and drain parts in this illustration are field supplied.
2. Check for Proper Fit With light pressure, test the fit. A dry pipe should go one-half to one-third of the way into the fitting hub. Do not use pipe or fittings that are too tight or too loose. 3. Primer, Cement, and Applicator Requirements a) Primer for joints should conform to ASTM F 656. b) Cement for joints should conform to ASTM D 2564. c) Use a 2-3” applicator brush for the 4” pipe and fittings. 4.
7.0 Mechanical (cont’d) 7.2.1 Vent/Combustion Air System Requirements (cont’d) 7.2.1.7 Support (cont’d) 7.2 Venting and Combustion Air (cont’d) Combustion Air Pipe Support - Support a single-wall metal horizontal combustion air run every six feet (1.8M). Support a vertical single-wall metal combustion air pipe in accordance with accepted industry practices. The heater and concentric adapter box may be used to support a vertical combustion air pipe. 7.2.1.
FIGURE 13 - Concentric Adapter Box Airflow FIGURE 14 - Concentric Adapter Box Connections
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) Parts in the Horizontal Vent/Combustion Air Terminal Package (Option CC6) 7.2.2 HORIZONTAL VENT TERMINAL Installation - Option CC6 Components Required - Factory and Field Complete Horizontal Vent/Combustion Air Terminal Kit (Same as Option CC6), P/N 221247 Qty P/N Description Concentric Adapter Box with Silicone Sealing Ring (See Paragraph 7.2.1.9, pages 16-17.
Clearances to Horizontal Vent Terminal Structure Minimum Clearances for Vent Terminal Location (all directions unless specified) Forced air inlet within 10 ft (3.1M)* 3 ft (0.9M) above Combustion air inlet of another appliance 6 ft (1.8M) 4 ft (1.2M) horizontally Door, window, or gravity air inlet (any building opening) 4 ft (1.2M) below 1 ft (305mm) above Electric meter, gas meter ** and relief equipment U.S. - 4 ft (1.2M) horizontally Canada - 6 ft (1.8M) Gas regulator ** 3 ft (0.
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) 7.2.
6b) Drill a hole to attach the elbow at the end and install the pipe. Being sure the vent pipe is in the proper flow direction, temporarily fit the elbow on the exhaust end of the vent pipe. For easier future service, the elbow is being attached using one field-provided 3/4” long sheetmetal screw. Using a drill that is a size smaller than the 3/4” long sheetmetal screw, with the elbow pointing down, drill a pilot hole through the top center of the elbow socket and the vent pipe. Remove the elbow.
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) 7.2.3 VERTICAL VENT TERMINAL Installation - Option CC2 (cont’d) Before beginning, verify that the kit is at the site and that all components are correct for the installation. Be sure all required field-supplied parts are available. Installation Instructions for Vertical Vent/ Combustion Air Kit Option CC2 (in compliance with requirements on pages 12-17) Minimum Vent Terminal Spacing when Installing more than one Heater 1.
6. Determine the length and install the “terminal end” vent pipe. 6a) Refer to FIGURE 17 and determine the required length of the continuous section of vent pipe. The length of the vent pipe extending through the box, through the combustion air inlet pipe, and the height required above the combustion air inlet air pipe must be one piece of pipe without joints.
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) 7.2.3 VERTICAL VENT TERMINAL Installation (cont’d) 7. Attach the indoor combustion air pipe. Use field-supplied sheetmetal screws to attach the single-wall combustion air pipe run to the collar on the concentric adapter box. Seal with tape or sealant. FIGURE 19 - Install Combustion Air Inlet, Rain Collar, and Bird Screen THIRD, Attach the bird guard on the exhaust (vent) terminal with the sheetmetal screws provided. 8.
7.3 Condensate Drain System The installer must provide a condensate drain system. A 4” PVC cleanout cap (FIGURE 22) that is drilled and tapped for a 1/2” NPT fitting is furnished with the heater for the vent drain. All other material must be field supplied. During operation, condensate is both produced in the heater and collected from the venting system.
7.0 Mechanical (cont’d) 7.3 Condensate Drain System (cont’d) • FIGURE 22 illustrates the vent pipe drain trap and lists the required length difference for the trap legs. FIGURE 22 - Vent Pipe Condensate Drain Trap HEATER Minimum Dimensions for Vent Pipe Condensate Drain Trap “C” = to suit the installation “D” = “C” plus at least 1-1/2 inches (38mm) Use 1/2” PVC pipe or larger for condensate trap.
The circuit board (See FIGURE 23) 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.
FACTORY WIRING G 115/1/60 R G SEC P3-1 COM L1 NEUTRAL #14 GA G DISCONNECT SWITCH BK G GRD SCREW NEUTRAL L1 Y G W NEUTRAL P3-2 PR G FAN MOTOR W Y DOOR INTERLOCK R P3-4 R P3-5 R W R BK W G BR W1 P3-3 BK ATO OR ATC FUSE EAC/BLO CAPACITOR (SEE NOTE #7) LED FLASH CODES C GREEN LED R LIMIT CONTROL R R W2 R P1-8 P1-3 R FLUE LIMIT CONTROL Y PRESSURE SWITCH Y Y P1-6 STEADY ON NORMAL OPERATION NO CALL FOR HEAT FAST FLASH NORMAL OPERATION CALL FOR HEAT 1 FLASH
9.0 Controls 9.1 Thermostat 9.2 Gas Valve The main operating gas valve is powered by the 24-volt control circuit through the thermostat and safety controls. The main control valve is a diaphragm type providing regulated gas flow preset at the factory. (For location, see FIGURE 28, page 37.) If the thermostat has an anticipator setting, make sure it is set to 0.6 amps (or in accordance with the amperage value noted on the wiring diagram of your heater).
9.0 Controls (cont’d) 9.3 Safety Controls (cont’d) 9.3.2 Limit Control 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 28, page 37.
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 switches are closed and the pressure switch is open. If one of the limit switches 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.
10.0 Ignition System (cont’d) 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. Abnormal Heat Cycle Functions (cont’d) Limit Switch Operation - The limit switch is ignored unless a call for heat is present (W energized).
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.
11.0 Commissioning and Startup (cont’d) 11.2 Heater Startup (cont’d) FIGURE 26 - Gas Valve Top View ON/OFF Switch 11.3 Check Installation After Startup Operating Instructions and Operating Sequence 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.
Always comply with the combustion air requirements in the installation codes. Combustion air at the burner should be regulated only by manufacturerprovided equipment. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. MAINTAIN THE VENT/COMBUSTION AIR SYSTEM IN STRUCTURALLY SOUND AND PROPER OPERATING CONDITION. 12.0 Maintenance and Service WARNING If you turn off the power supply, turn off the gas. See Hazard Levels, page 2. 12.
12.0 Maintenance and Service (cont’d) Burner Removal Instructions (continued.) 5. Disconnect and Move the Gas Train - 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.
Re-Install the Burner Instructions to Re-Install the Burner (Refer to FIGURE 27) 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, re-attach each burner body support to the secondary air shield. 2. Attach the Secondary Air Baffles - Re-attach the secondary air baffles as marked.
12.0 Maintenance and Service (cont’d) 12.2 Maintenance Procedures (cont’d) Ignitor 12.2.4. Ignition System (cont’d) 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.
12.2.7 Operating Gas Valve WARNING The operating valve is the prime safety shutoff. To ensure positive closure, clean all dirt and scale from gas supply lines before connecting to the unit. See Hazard Levels, page 2. FIGURE 33 - Pressure Tap for Checking Gas Flow Shutoff FIGURE 32 - Venter Wheel Position on Shaft 1/2” (13mm) from motor plate to wheel Motor Plate with Gasket Venter Wheel 3.
12.0 Maintenance and Service (cont’d) For location of controls, see FIGURE 28, page 37. Vent Temperature Limit Switch Disconnect Switch 12.2 Maintenance Procedures (cont’d) 12.2.12 Vent Temperature Limit Switch The vent temperature limit switch is located on the discharge of the combustion air blower (venter) and its purpose is to prevent the vent gas temperature from exceeding a temperature that will harm the PVC vent pipe.
DSI Integrated Control Module (Circuit Board) Trial Troubleshooting Flowchart YES Trial for Ignition Call for Heat Is there a spark across gap at ignitor? YES NO Is there spark voltage at control? NO Does gas ignite? YES Check high voltage wire continuity. NO Is there minimum flame current at the flame sensor? YES NO Is the flame sensor corroded? YES Clean flame sensor. YES Replace control module. Is the sensor located in flame correctly? Check wiring and/or 24VAC transformer output.
12.0 Maintenance and Service (cont’d) PROBLEM Burner will not light (cont’d) 12.3 Troubleshooting (cont’d) General Troubleshooting (cont’d) PROBABLE CAUSE (cont'd) 10. Integrated circuit board does not power main valve. a) Loose wire connections. b) Flame sensor grounded. c) Incorrect gas pressure. d) Cracked ceramic at sensor. 11. Faulty time delay relay. (applies to units manufactured prior to 12/12) Burner cycle on 1. Gas pressure too high or too low. and off 2. Burner not grounded 3.
Operating Principle showing Combustion Airflow and Supply Airflow Room Supply Air Intake Outside Combustion Air to the Burner Flue Gas Outlet Cooler flue gas temperature requires a condensate drain in the vent. Warm Air Discharge Condensate drain connection from the secondary heat exchanger This unit heater is a high efficiency appliance designed to extract part of the latent heat from the products of combustion.
INSTALLATION RECORD - to be completed by the installer: Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ ________________________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Contact _______________
