Form I-UEAS (Version B) Obsoletes I-UEAS (Version A) 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 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 8.2 24V Control Wiring Connections........28 8.3 Typical Wiring Diagram.......................29 9.0 Controls.............................................
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. WARNING Installation should be done by a qualified agency in accordance with these instructions.
1.0 General (cont’d) 1.4 Installation Codes (cont’d) Special Installations (Aircraft Hangars/ Repair Garages/Parking Garages) 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. Installations in aircraft hangars should be in accordance with ANSI/NFPA No.
Dimensions X, Y, and Z (meters) Model UEAS with Standard Horizontal Louvers at Mounting Heights of 1.5 - 5.5M 130 H 180 260 310 X Y Z Louver Angle* X Y Z Louver Angle* X Y Z Louver Angle* X 2.4 M 4 7 22 -26° 5 9 28 -20° 5 9 29 -24° 3.0 M 4 7 21 -32° 5 9 28 -25° 5 9 27 -29° 3.7 M 4 7 20 -39° 6 9 27 -30° 5 9 26 4.3 M 4 7 18 -45° 6 9 26 -34° 5 8 4.9 M 4 6 16 -51° 6 9 24 -39° 5 5.
3.0 Receiving, Uncrating, and Preparing for Installation (cont’d) IMPORTANT: Shipping brackets are attached with cabinet screws. When removing shipping brackets, re-insert ALL screws into the cabinet. 4.0 Dimensions and Clearances 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.
FIGURE 3 - Dimension “T” With Optional Downturn Nozzle "T" for UEAS Size with Option CD2 with Option CD3 with Option CD4 inches mm inches inches mm mm 130, 180 11-1/2 292 19-7/8 505 14-1/2 368 260, 310 18-1/2 470 32 813 21-1/2 546 Units must be installed so that the clearances in the table are provided for combustion air space, inspection a
6.0 Hanging the Heater (cont’d) If ordered with swivel connectors, Option CK10, for 1” pipe attach the swivels at the threaded nut retainers. Suspend with 1” pipes (FIGURE 4B). FIGURE 4A - Suspending the Heater with Rods from the Threaded Nut Retainers 3/8 threaded rod (field supplied) Add a 3/8 nut and washer to lock the hanger rod to the heater. Be sure the threaded hanger rods are locked to the heater as illustrated. Length of threaded rod extending into the heater MUST NOT exceed 1/2” (13mm).
Sizing Gas Supply Line Capacity of Piping Cubic Feet per Hour based on 0.3" w.c. Pressure Drop Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft) Specific Gravity for Propane Gas -- 1.
7.0 Mechanical (cont’d) 7.1 Gas Piping and Pressure (cont’d) NOTE: A gas conversion kit for changing from natural gas to propane is included with each heater. See Paragraph 7.1.4 for conversion instructions. 7.1.3 Valve Outlet or Orifice Pressure Setting 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 11. The following warnings and instructions apply.
Valve Outlet Pressure Settings by Elevation Altitude Natural Gas Propane Feet Meters inches w.c. Manifold Pressure Settings by Altitude for the UNITED STATES NOTE: This adjustment can only be done after the heater is in operation. High altitude adjustment is included in the startup procedures. 0-2000 2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 7001-8000 8001-9000 9001-10000 0-610 611-915 916-1220 1221-1525 1526-1830 1831-2135 2136-2440 2441-2745 2746-3045 3.5 3.1 3.0 2.8 2.7 2.6 2.5 2.4 2.2 10.
7.0 Mechanical (cont’d) 7.1.3 Valve Outlet or Orifice Pressure Setting (cont’d) Instructions for High Altitude Derate (cont’d) 7.
7.2 Venting and Combustion Air All separated combustion units MUST BE equipped with both combustion air and exhaust piping to the outdoors. The unique concentric adapter box required with this heater allows for both combustion air and exhaust piping with only one horizontal or vertical penetration hole in the building.
7.0 Mechanical (cont’d) 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. INSTALLATION Vertical Vent showing Where to Install the Condensate Drain Connection 7.2 Venting and Combustion Air (cont’d) 7.2.
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 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. This is an acceptable alternate PVC piping arrangement for installations in the United States.
7.2 Venting and Combustion Air (cont’d) 7.2.1 Vent/Combustion Air System Requirements (cont’d) 7.2.1.7 Support 7.2.1.6 Joints (cont’d) 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.
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. 7.2.1.8 Vent Pipe Clearance Vent Pipe - Do not install the vent piping near any high temperature steam lines, radiant heaters, or other sources of heat. 7.2.1.
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) 7.2.
7.2.2 HORIZONTAL VENT TERMINAL Installation - Option CC6 Parts in the Horizontal Vent/Combustion Air Terminal Package (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 17-18.
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) 7.2.2 HORIZONTAL VENT TERMINAL Installation Option CC6 (cont’d) 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.
FIGURE 16 - Typical Installation of a Model UEAS High Efficiency, Separated-Combustion Unit with a Horizontal Vent/Combustion Air Terminal (Option CC6)
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) 7.2.2 HORIZONTAL VENT TERMINAL Installation Option CC6 (cont’d) 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. In the elbow only, enlarge the drilled hole to 7/32”. The elbow will be attached from the outside in Step 8b).
Field-supplied requirements: • Vent pipes and fittings as illustrated in FIGURE 8A, 8B, 9A or 9B on pages 14 and 15 • Combustion air pipes (6” and 8” single-wall galvanized pipe) • Flashing • Sheetmetal screws, tape, primer, cement, and sealant as required 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.
7.0 Mechanical (cont’d) 7.2 Venting and Combustion Air (cont’d) 7.2.3 VERTICAL VENT TERMINAL Installation Option CC2 (cont’d) 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. 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. On the outside, install the combustion air inlet, the rain collar, the bird screen, and fieldsupplied flashing.
7.0 Mechanical (cont’d) 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.
FIGURE 21 - Secondary Heat Exchanger Condensate Drain Trap Model UEAS HEATER NOTE: Bottom of fan guard is removed for better view. See Rear View in FIGURE 2, page 6, for location of condensate drain connection. Minimum Dimensions for Secondary Heat Exchanger Condensate Drain Trap “A” = 3 inches (76mm) minimum “B” = “A” plus at least 5 inches (127mm) Use 1/2” PVC pipe or larger for condensate drain. Continue into sanitary drain.
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, vent temperature limit, and sensor lead wires which must be 150°C. See Hazard Levels, page 2. FIGURE 23 - Supply Wiring Connections at the Circuit Board (DSI Integrated Control Module) 8.
FACTORY WIRING G 115/1/60 R R G BK SEC P3-1 COM L1 NEUTRAL #14 GA G DISCONNECT SWITCH 115 VOLT BR G GRD SCREW NEUTRAL L1 Y G W NEUTRAL P3-2 PR G FAN MOTOR W DOOR INTERLOCK R P3-4 R P3-5 R W R BK W G BR Y W1 BK ATO OR ATC FUSE EAC/BLO P3-3 G BR/W RC R 24V WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W Y #14 GA BK WIRE CONNECTOR TERMINAL STRIP W1 W2 SYSTEM TRANSFORMER #14 GA W OPTIONAL FACTORY
9.0 Controls 9.1 Thermostat 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). Make thermostat connections at the terminal strip on the back of the heater. The strip has four terminals, G, W1, R, and W2; refer to the wiring diagram. IMPORTANT: All units MUST be operated by a 24-volt thermostat. Never use a line voltage disconnect switch as a means of operating the heater.
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 39.
10.0 Ignition System (cont’d) Normal Heat Cycle Operating Sequence Abnormal Heat Cycle Functions 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.
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).
10.0 Ignition System (cont’d) Abnormal Heat Cycle Functions (cont’d) 11.0 Commissioning and Startup Lockout 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.
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. • Leave the building immediately. • Immediately call your gas supplier from a phone remote from the building. 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.
11.0 Commissioning and Startup (cont’d) 11.3 Check Installation After Startup □□ With the unit in operation, measure valve outlet gas pressure. See information and instructions in Paragraph 7.1.3. If operated at high altitude, be sure to adjust outlet gas pressure for altitude. □□ Turn the unit off and on, pausing two minutes between each cycle. Observe for smooth ignition.
• Check the 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 8 for replacement wiring requirements.) NOTE: If replacement parts are required, use only factory-authorized parts. 12.2 Maintenance Procedures 12.2.1 Heat Exchanger Maintenance 3 This heater has a TCORE heat exchanger (patent pending). Remove any external dirt or dust accumulation.
12.0 Maintenance and Service (cont’d) 12.2 Maintenance Procedures (cont’d) 12.2.2 Burner Maintenance (cont’d) 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.
FIGURE 28 - Location of Controls Pressure Switch Disconnect Switch High Temperature Limit Control Flame Sensor Fan Motor Venter Door Switch Gas Valve Ignitor Control Panel Assembly Vent Temperature Limit Switch Time Delay Relay Venter Motor Capacitor Fan Motor Capacitor Transformer DSI Integrated Control Module (Circuit Board) FIGURE 29 - DSI Integrated Control Module (Circuit Board) 12.2.4.
12.0 Maintenance and Service (cont’d) Ignitor 12.2 Maintenance Procedures (cont’d) 12.2.4. Ignition System (cont’d) Ignitor - Refer to FIGURE 28 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 30. 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.
Replacement Instructions FIGURE 32 - Venter Wheel Position on Shaft 1/2” (13mm) from motor plate to wheel Venter Wheel Motor Plate with Gasket Venter Motor 12.2.7 Operating Gas Valve 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. FIGURE 33 - Pressure Tap for Checking Gas Flow Shutoff 1. Turn off the gas and disconnect the electric power. 2.
12.0 Maintenance and Service (cont’d) 12.2 Maintenance Procedures (cont’d) For location of controls, see FIGURE 28, page 39. 12.2.11 Time Delay Relay If it is determined that the time delay relay needs replacing, use only a factory-authorized replacement part that is designed for the heater Time Delay Relay 12.2.12 Transformer Use a voltmeter to verify that there are 24 volts output from the transformer. If the transformer is not functioning, it must be replaced.
12.3 Troubleshooting Trial for Ignition Call for Heat DSI Integrated Control Module (Circuit Board) Trial Troubleshooting Flowchart YES 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.
12.0 Maintenance and Service (cont’d) 12.3 Troubleshooting (cont’d) General Troubleshooting PROBLEM PROBABLE CAUSE REMEDY Venter motor will not start 1. No power to unit. 1. Turn on power; check supply fuses or main circuit breaker. Turn on built-in disconnect switch; replace switch if not operating. 2. No 24 volt power to integrated circuit 2. Turn up thermostat; check control transformer output. board. 3. Integrated circuit board fuse blown. 3. Correct cause.
PROBLEM (cont'd) PROBABLE CAUSE (cont'd) Burner cycle on and 1. Gas pressure too high or too low. off REMEDY (cont'd) 1. Supply pressure should be 5" - 14" w.c. for natural gas or 11" - 14" w.c. for propane. 2. Burner not grounded 2. Make certain integrated circuit board is grounded to ignitor. 3. Circuit board not grounded. 3. Make certain integrated circuit board is grounded to furnace chassis. 4. Faulty integrated circuit board 4.
APPENDIX TECHNICAL DATA Model UEAS Input Heating Capacity 130 180 260 310 BTUH 131,000 175,000 260,000 305,000 kw 38.4 51.2 76.1 89.3 93 91 92 91 BTUH 121,830 159,250 239,200 277,550 Thermal Efficiency (%) Output Heating Capacity A kw 35.7 46.6 70.0 81.3 Natural 1/2 1/2 3/4 3/4 Propane 1/2 1/2 3/4 3/4 Vent Connection Diameter (inches) 4 4 4 4 Combustion Air Inlet Diameter (inches) 6 6 6 6 1.0 1.0 1.0 1.0 6.3 6.3 10.0 10.
INDEX A Abnormal Heat Cycle Functions 32 B Burner Maintenance 37, 38 Burner Orifice 38 Burner Removal Instructions 37 C California Warning Label 4 Check Installation After Startup 36 Check the Installation Prior to Startup 34 Clearance 17 Clearances 7 Combustion Air Inlet 13 Combustion Air Inlet Pipe 13 Combustion Air Pipe Support 17 Combustion Air Pressure Switch 41 Combustion Air Proving (Pressure Switch) 30 Concentric Adapter Box Connections 18 Concentric Adapter Box Dimensions 17, 18 Condensate Dr
INSTALLATION RECORD - to be completed by the installer: Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ ________________________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Contact _______________
