Installation/Operation/Maintenance Applies to: Model UESA High-Efficiency, Separated-Combustion, Low-Static Unit Heater UESA These appliances meet the following EC Directives: DIR 2009/142/EC:GAD DIR CE 89/336/EEG:EMC DIR 73/23/EEG:LVD DIR 89/392/EEG:MD WARNING Please read this document carefully before commencing installation, commissioning and/or servicing. Leave it with the user or attached to the appliance or gas service meter after installation.
TABLE OF CONTENTS 1. General....................................................................................................................................................3 1.1 Warning 1.2 General information 1.3 Warranty 1.4 Installation codes 2. Unit heater location...............................................................................................................................4 3. Uncrating & preparation..............................................................................
1. GENERAL 1.1 Warnings 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. • Evacuate all personnel. Do not store or use petrol or other flammable vapours and liquids in the vicinity of this or any other appliance. WARNINGS Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.
2. UNIT HEATER LOCATION REMARK Flue requirements may affect location. Consult section 6 before making a final determination. WARNING If touched, the vent pipe and internal heater surfaces that are accessible from outside the heater will cause burns. Suspend the heater such that these components cannot be touched. CAUTION Do not locate the heater where it may be exposed to water.
Units must be installed so that the clearances in table below are provided for combustion air space, inspection and service and for proper spacing from combustible materials. 4. CLEARANCES & DIMENSIONS Suspend the heater so that the bottom is a minimum of 2.5m above the floor. Table 1a: Clearances Attention : The minimum overall clearances to the flue outlet system must be 150mm.
Figure 1b: Dimensions UESA 083 & 102 Rear view Side view Front view Top view Legend 1. Combustion air inlet Ø 130 2. Flue connection Ø 130 with condensate drain tap 3/4” 3. External gas connection 4. Electrical connections 5. Service panel 6.
5. HANGING THE HEATER WARNING Unit must be level for proper operation. Do not place or add additional weight to the suspended heater. 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. Suspend the heater only from the threaded nut inserts. Do not suspend from the heater cabinet. When the heater is lifted for suspension, leave the unit on the pallet.
6. MECHANICAL 6.1 Gas piping & pressures WARNING This appliance is equipped for a maximum gas supply pressure of 50 mbar. 6.1.1 Gas supply WARNING : Pressure testing supply piping Test pressures above 50mbar : 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 50mbar : Before testing, close the manual valve on the heater.
Table 4 Burner jets and pressures Nat. Gas (G20) 035 055 083 102 Burner jet mm 5,30 6,80 7,60 8,90 Burner pressure mbar 8,80 8,10 11,20 8,90 mm 2,90 3,65 4,50 5,00 mbar 36,20 35,80 35,40 34,70 Burner jet Prop. (G31) Burner pressure inlet pressure 20mbar inlet pressure 37mbar Minimum inlet pressure natural gas : 17.0mbar Minimum inlet pressure propane : 35.
The units may be installed as a balanced flue type C heater requiring both a combustion air inlet pipe and a flue pipe or as a power vented heater type B where the combustion air is taken from the space where heater is installed and which requires only a flue pipe exhausting to outdoors. All products of combustion must be flued to outdoor atmosphere.
During operation, condensate is both produced in the heater and collected from the venting system. Therefore, the installaton requires a condensate drain from the secondary heat exchanger and a condensate drain from the flue exhaust pipe. A short flue pipe with 3/4” condensate drain point is supplied with the heater and a PVC collar for PVC tube of dia 32 is provided to drain the condensate from the secondary heat exchanger (see figure 5).
Condensate drain traps : Two condensate drain traps are required. Figure 6 illustrates the trap in the drain attached to the heater and lists the minimum required leg dimensions for that trap. Figure 7 illustrates the flue exhaust pipe drain trap and shows the minimum dimensions for the trap. IMPORTANT : The most important part of fabricating and assembling the traps is the length of the individual legs of the traps.
Figure 7 Flue condensate drain tap Minimum dimensions D = minimum 130mm C = D + at least 50mm (min 185mm) 6.2.2 Flues for power vented installations (type B appliances) If the air heater is to be installed as a type B appliance, air for combustion will be taken from within the space where the heater is installed. Ensure that an adequate air supply for combustion and ventilation is provided within the building in accordance with BS6230/BS5440 plus other relevant regulations & rules in force.
Figure 9 Approved appliances type B. For illustrative purposes only. For actual pipe connections see figure 8. B22 - roof B22 - wall Air supply WARNING When these air heaters are installed as type B appliances, they take their air for combustion from the space in which they are installed. Do not restrict the combustion air intake. It is important to ensure that there is an adequate air supply at all times for both combustion and heating requirements.
Figure 10 Approved appliances type C. For illustrative purposes only. For actual pipe connections see figure 11.
7. ELECTRICAL SUPPLY AND CONNECTIONS 7.1 Electrical supply DANGER : THIS APPLIANCE MUST BE EARTHED. Electrical supply The electrical installation must only be carried out in accordance with the IEE regulations and by an appropriately qualified person. The electrical supply line to the heater should include a main isolating switch. The minimum clearance distance between the contacts must be more than 3 mm.
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8. CONTROLS 8.1 Thermostats 8.2 Gas valve WARNING The main 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 correct sealing. 8.3 Safety controls If it is determined that the pressure switch needs replacing, use only the factory-authorised replacement part that is designed for the model and size of heater being serviced.
WARNING Never bypass the limit controls, hazardous conditions could result. If a limit control needs replacing, use only the factory authorized replacement part for the size of heater. For limit locations, see figure 16a. 8.3.2 Limit controls All units are equipped with temperature activated limit controls. The controls are factory set and non-adjustable. If either setpoint is reached, the corresponding limit control will interrupt the electric power to the gas valve.
9. IGNITION SYSTEM This heater is equipped with a direct spark multi tray burner control relay. The control relay monitors the safety devices and controls the operation of the venter motor and the gas valve between heat cycles. The time line below illustrates a normal heat cycle. Start pre-purge Power to gas valve and ignitor Sensor checks for the presence of a flame Energisation of venter motor. If the differential pressure switch is in normally closed position (start position). End of heat demand.
10. OPERATION 10.1 Check installation Check installation prior to start-up Check suspension. Unit must be secure. Check clearances from combustibles. Requirements are in section 5. Check flue system to ensure it is installed according to the instructions in section 7, flueing requirements. Check piping for leaks and proper gas line pressure. Bleed gas lines of trapped air. Check condensate drain system to be sure that it is installed according to the instructions in part 6.2.
10.4 Check instalation after startup To turn off gas supply at the appliance : • • • • 1) Set thermostat to the lowest possible setting or ‘OFF’ position. 2) Shut off the manual service valve when the fan has stopped. 3) Switch off electric power to the appliance. Check gas pressure as described in detail below. Turn the unit off and on, pausing 2 minutes between each cycle. Observe for smooth ignition. Set the thermostat to the required room temperature.
Figure 16b : Internal control panel assembly located on a removable bracket 13 13) Control relay (ER) 14) Terminal blocks 15) Connector 16) Pressure switch (S3) 14 11.2 Maintenance procedure 15 16 11.2.1 Heat exchanger maintenance This heater has a T-CORE3 TM heat exchanger (patent pending). Remove any external dirt or dust accumulation. Visually check the heat exchanger for cracks and holes. If a crack or hole is observed, replace the heat exchanger.
Figure 17a Figure 18a Figure 17b Figure 18b burner orifice Locking nut Orifice Figure 19 Burner removal steps Remove screws attaching burner Venturi tube : slide right, rotate outward, pull out Disconnect manifold at orifice and outside the heater, slide to the right Inspect and clean the burner With the burner assembly removed, shine a flashlight on the burner ribbons.
Inspect the internal 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 surface of the tube where discoloration is evident. Repeat this procedure with each heat exchanger tube. If any light is observed in these high temperature regions, replace the heat exchanger.
Control relay : See figure 23. The electronic burner relay monitors the operation of the heater including ignition. Do not open the control relay. 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 (DC) as measured by a microam meter.
11.2.6 Venter motor & wheel Remove dirt and grease from the motor casing, the venter housing, and the venter wheel. Venter motor bearings are permanently lubricated. Check for corrosion. Follow these instructions for replacement of the venter motor and wheel assembly. Keep all hardware removed to be used in reassembling and installing the replacement parts. 1.Turn off the gas and disconnect the electric power. 2.Open the control compartment access door. 3.
Trial for ignition Call for heat Is there a spark NO across gap at igniter? Is there line voltage at spark igniter? YES NO Check connection at spark igniter Is there line voltage to the control relay? Replace igniter YES Replace control relay NO Check wiring connections Trial for ignition Call for heat Is there a spark YES across gap at igniter? Does gas ignite? YES Is there min. flame current at the flame sensor? YES NO Is the flame sensor corroded? Is there min.
General troubleshooting PROBLEM PROBABLE CAUSE REMEDY Venter motor will not start 1. No power to unit. 1. Turn on power, check supply fuses or circuit breaker. 2. No power to venter motor. 2. Check connections at burner relay and/or venter motor terminals. 3. Integrated burner relay defective. 3. Replace burner relay. 4. Defective venter motor. 4. Replace venter motor. See Section 26. 5. Fluse blown (F3.1). 5. Replace fuse. 6. Fuse burner relay blown. 6. Replace fuse. 7. LC1 open. 7.
12. SPARE PARTS LIST DESCRIPTION UESA PART NUMBER Control relay all 03 25324 Spark ignitor all 05 25162 Flame sensor all 03 401US 195292 Limit control LC3 all, exc.
ADDENDUM : TECHNICAL DATA Type UESA 035 055 Gas category 083 Comb. Air & Flue, type B (1) B22p Comb.
