Installation, Operation, and Maintenance Gas Unit Heater High Efficiency Propeller Fan SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.
Warnings, Cautions and Notices Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at appropriate intervals throughout this manual. Warnings are provide to alert installing contractors to potential hazards that could result in death or personal injury. Cautions are designed to alert personnel to hazardous situations that could result in personal injury, while notices indicate a situation that could result in equipment or property-damage-only accidents.
Warnings, Cautions and Notices WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Introduction WARNING Safety Alert! You MUST follow all recommendations below. Failure to do so could result in death or serious injury. For Your Safety The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. If you smell gas: 1. Open windows. 2. Do not touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
Table of Contents Warnings, Cautions and Notices . . . . . . . . . . 2 Model Number Descriptions . . . . . . . . . . . . . . 6 Indoor Gas Heating Units . . . . . . . . . . . . . . . 6 General Information . . . . . . . . . . . . . . . . . . . . . 7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Safety Information . . . . . . . . . . . . . 7 Identification of Parts . . . . . . . . . . . . . . . . . . 8 Unit Dimensions and Weights . . . . . . . . . . .
Model Number Descriptions Indoor Gas Heating Units Digit 13 — Rooftop Heating Unit Motor Selection Note: All units are AGA approved. For CGA approved units, contact Air Handling Product Support.
General Information Description The Power Vented Gas Unit Heater is a factory assembled, power vented, low static pressure type propeller fan heater designed to be suspended within the space to be heated. THESE HEATERS ARE NOT TO BE CONNECTED TO DUCTWORK. The designs are certified by ETL as providing a minimum of 80 percent thermal efficiency, and approved for use in California. Do not alter these units in any way. If you have any questions after reading this manual, contact the manufacturer. Figure 1.
General Information should be done and checked by a qualified electrician, using copper wire only. All external wiring must conform to applicable local codes and to the latest edition of the National Electrical Code ANSI/NFPA No. 70. In Canada, all external wiring must conform to the Canadian Electric Code, Part 1 CSA Standard C22.1. • • All gas connections should be made and leaktested by a suitably qualified individual, per instructions in this manual.
General Information Figure 4. Internal furnace components 1 2 3 1. Flue Collector 2. Heat Exchanger 3. Burner Drawer Figure 5. Component parts (bottom view) 9 1 2 8 3 4 7 5 6 1. Fan/Guard/Motor Assy. 6. 2. “Packaged” Gas Valve 7. Main Burner 3. Pilot Observation Port 8. Junction Box 4. Pilot Burner Assembly Parts 9. Transformer 5.
Unit Dimensions and Weights Table 1. Performance and dimensional data: Power Vented Propeller Unit Heater Unit Size PERFORMANCE DATA(a) Input Output Thermal Efficiency Free Air Delivery CFM Air Temperature Rise Outlet Velocity Full Load Amps at 115V MOTOR DATA: Motor Type RPM Amps @ 115V DIMENSIONAL DATA 100 125 150 175 200 225 250 300 350 400 BTU/Hr (kW) BTU/Hr (kW) % cfm (m3/s) °F (°C) fpm (m/s) 100,000 (29.3) 80,000 (23.4) 80 1,480 (0.699) 50 (28) 775 (3.94) 5.2 125,000 (36.6) 100,000 (29.
Unit Dimensions and Weights Figure 6.
Installation: Mechanical 4.9 m) in order to clear obstacles. When this is the case, it is advisable to use centrifugal blower unit heaters. NOTICE: Equipment Damage! Aircraft Hangers. Unit heaters must be installed in Do not install unit heaters in corrosive or flammable atmospheres! Premature failure of, or severe damage to the unit could result! Avoid locations where extreme drafts can affect burner operation.
Installation: Mechanical Figure 8. Heat throw distances Unit Heater “H” Floor Line NOTICE: Maintain Minimum Thermostat Setting! Unit heaters should not be installed to maintain low temperatures and/or freeze protection of buildings. A minimum of 50°F (10°C) thermostat setting must be maintained. If unit heaters are operated to maintain lower than 50°F (10°C), hot flue gases are cooled inside the heat exchanger to a point where water vapor (a flue gas by-product) condenses onto the heat exchanger walls.
Installation: Mechanical NOTICE: Equipment Damage! Unit heaters must be hung level from side to side and from front to back, see Figure 1, p. 7 and Figure 6, p. 11 through Figure 9, p. 14. Failure to do so could result in poor performance and/or premature failure of the unit. WARNING procedure described in Step 2 using the bottom bracket (P/N 252-07949-00X). 4.
Installation: Mechanical Note: For 90-degree nozzle assemblies, repeat Step 8 to create a second sub-assembly. 9. For 60- and 90-degree nozzle assemblies: Using the enclosed #8-18 x 1/2 screws, attach the sub-assembly created in Step 8 to the 30-degree assembly installed to the unit (in Step 1 through Step 6 of this procedure). Attach the corresponding panels (i.e., top panel to top panel, right side panel to right side panel, etc).
Installation: Piping Gas Supply Piping WARNING Flammable Vapors! When connecting to existing gas lines be sure to valve off the gas supply ahead of connection point. To avoid explosion or possible fire, always purge all residual gas from piping before cutting into existing line or removing threaded fittings. Failure to remove all gas vapors could result in death or serious injury or equipment or property-only damage.
Installation: Piping Table 3. Gas pipe size(a) Nominal Internal 10 Iron Pipe Diameter, Size, in. in. (mm) (3.0) 1/2 Length of Pipe, ft (m) 20 (6.1) 30 40 50 60 70 80 90 100 125 150 175 200 (9.1) (12.2) (15.2) (18.3) (21.3) (24.4) (27.4) (30.5) (38.1) (45.7) (53.3) (61.0) 0.622 175 120 97 82 73 66 61 57 53 50 44 40 37 35 (16) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) (1.25) (1.13) (1.05) (0.99) 0.
Installation: Piping Pipe directly in to combination valve (see Figure 10, p. 18). 5. A 1/8 in. N.P.T. plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the appliance. 6. Provide a drip leg in the gas piping near the gas unit heater. A ground joint union and a manual gas shutoff valve should be installed ahead of the unit heater controls to permit servicing.
Installation: Piping provisions of local building codes for natural or power vented units. Power vented units are designed to be used with single wall vent pipe utilizing horizontal or vertical venting arrangements (see Figure 16, p. 23 through Figure 18). These arrangements may terminate external to the building using either a single wall or double wall vent. See Figure 11, p. 20 through Figure 18, p. 23 for special installation requirements regarding these venting conditions.
Installation: Piping moved to the right horizontal position, the junction box must be rotated 90 degrees CCW to clear the connection. To do this, remove all wires, conduit and conduit connector from the junction box, noting location of wires. Move box, using holes provided. Move 7/8-inch plug from bottom of box to side. Reconnect all wires according to the unit’s wiring diagram. Table 5.
Installation: Piping Figure 12. Horizontal arrangement—single wall vent system to single wall termination Figure 13.
Installation: Piping Figure 14. Horizontal arrangement—single wall vent system to double wall termination Figure 15.
Installation: Piping Figure 16. Horizontal left vent position (rear view of unit heater) To Horizontal Flue Vent Termination Reducer/Increaser Where Applicable Power Venter Tee With Drip Leg & Cleanout Cap At Lowest Point Of Vent System (Typ.) Figure 17. D4072 Horizontal right vent position (rear view of unit heater) Reducer/Increaser Where Applicable To Horizontal Flue Vent Termination Power Venter Tee With Drip Leg & Cleanout Cap At Lowest Point Of Vent System (Typ.) D4073 Figure 18.
Installation: Electrical Electrical Connections WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Installation: Electrical Recommended Heat Anticipator Setting Ranges: 25 ft. (7.6 m) T’stat Wiring 0.85 to 0.90 A 50 ft. (15.2 m) T’stat Wiring 0.90 to 1.1 A Max. Setting on T’stat Fan Time Delay Control Leads from the time delay controls are factory wired to the junction box. The fan control is a time delay relay (approximately 45 seconds ON, 65 seconds OFF). The fan control is rated at 17 amps. Notes: • The start-up fan delay must not exceed 90 seconds from a cold start.
Start-Up Blower Set Up The drive ratio of the motor and blower sheaves has been preset at the factory for a temperature rise of 65°F at 0” wc. If the unit is to be operated under different air flow or pressure requirements, the drive ratio must be altered by means of the adjustable sheave on the blower motor (see Figure 20, p. 26). 1. Ensure that all packing material, support blocks, etc. have been removed from the unit. 2.
Start-Up Operation and ignition systems to control the temperature of the space being heated. Explanation of Controls (see Figure 20, p. 26) Note: The thermostat must be mounted on a vertical, vibration-free surface, free from air currents, and in accordance with the furnished instructions. WARNING Carbon Monoxide! Never operate unit heaters if the power venter is not operable. Your venting system must not be blocked by any snow, snow drifts, or any foreign matter.
Start-Up NOTICE: Additional Devices! The addition of external draft hoods or power venters is not permitted. Addition of such devices could cause severe unit malfunction or failure! b. The indirect spark ignition system consists of an ignition control module, a dual combination gas valve, and a spark-ignited pilot burner. When the pressure switch closes, the pilot valve opens and a spark is generated to light the pilot burner.
Start-Up Burner components—intermittent pilot ignition(a) Figure 21. Burner Drawer Common Parts: 1. 2. 3. 4. 5. 6. 7. Main Burners Burner Manifold Air Shutters Burner Springs Main Burner Orifice Transformer Pilot Tubing 1 Controls: 8A. Main Gas Valve (Honeywell) 8B. Main Gas Valve (White-Rodgers) 9. Honeywell Ignitor 10. Honeywell Pilot Burner 13. High Limit (Safety device located on the rear header plate of the heat exchanger, air inlet side.
Start-Up Gas Input Rate so equipped, the propane gas supply system pressure must be regulated to attain this manifold operating pressure. NOTICE: Overfiring! Never overfire the unit heater, as this could cause unsatisfactory operation, or shorten the life of the heater. 3. The adjusted manifold pressure should not vary more than 10 percent from the pressure specified in Table 6, p. 30. Table 6. Type of Gas Natural Check the gas input rate as follows: 1.
Start-Up or permanent situation when there is insufficient primary air. Figure 22. Main burner flames NORMAL (HARD FLAME) YELLOW TIPPING (MARGINAL) LIFTING (TOO MUCH AIR) YELLOW FLAME (TOO LITTLE AIR) Pilot Adjustment 1. Remove the pilot adjustment cap. 2. Adjust the pilot screw to provide a properly sized flame. 3. A proper pilot flame is a soft steady flame that envelops 3/8- to 1/2-inch (9.5 to 12.7 mm) of the flame sensor. 4. Replace the pilot adjustment cap.
Start-Up Gas Equipment Start-Up Customer _____________________________________________ Job Name & Number _________________________ Pre-Inspection Information with Power and Gas Off Type of Equip: Unit Heater Serial Number: _________________________ Model Number: _____________________________ Name Plate Voltage: ____________________ Name Plate Amperage: ______________________ Type of Gas: Tank Capacity: Natural LP _______ lb Rating: _______ kg _______ Btu @ ____ °F ________ kW @ ____ °C A
Maintenance WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Maintenance 12. Check lubrication instructions on the motor. If oiling is required, add 3 to 4 drops of electric motor oil as follows: a. Light Duty—After 3 years or 25,000 hours of operation. b. Average Duty—Annually after 3 years or 8,000 hours of operation. c. Heavy Duty—Annually after 1 year or at least every 1,500 hours of operation. NOTICE: Equipment Damage! Never over oil the motor or premature failure could occur! 13.
Maintenance Figure 23. Power venter assembly Ref. No. Description Ref. No. Description 1 Blower Housing Assembly 15 Snap Bushing 2 Speed Nut 16 Relay (Motor) 3 Motor 17 Draftor Stack Assembly 4 Washer, Plain 18 Tubing (Aluminum) Formation 5 Plate Adapter 19 Male Connector 6 Blower Wheel (see Note 1) 20 Locknut 7 Mounting Bracket (Pressure Switch) 21 Hole Plug 8 Mounting Bracket (Junction Box) 22 Pressure Switch Cover 9 Screw, S.T.
Maintenance Installation Instructions for Field Replacement of Power Venter Motor Important: This replacement must be performed only by a qualified technician. Note: All hardware (screws, nuts, washers) that will be removed from the unit will be reused for this motor replacement. DO NOT LOSE ANY OF THESE PARTS. Figure 24. Identification of parts Ref. No. Tools and Parts Needed Wire Stripper and Crimper; Slotted Head and #2 Phillips Head Screwdriver; 3/8-in. Wrench; 1/8-in.
Maintenance How to Order Replacement Parts Please send the following information to your local Parts center; If further assistance is needed, contact the manufacturer’s customer service department. • Model number • Serial Number • Part description and Number as shown in the Replacement Parts Catalog.
Diagnostics Troubleshooting WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnect and discharge all energy storing devices such as capacitors before servicing.
Diagnostics Table 7. Troubleshooting guide (continued) Symptoms Possible Cause(s) Corrective Action F. 1. Shut off gas supply immediately! 1. Inspect all gas piping and repair. 2. Blocked heat exchanger/venting. 2. Clean heat exchanger/flue. 3. Drafts around heater. 3. Eliminate drafts. Refer to “Installation: Mechanical,” p. 12. 4. Negative pressure in building. 4. See “Installation: Piping,” p. 16. Clean flue collector. Gas Odor. G. Delayed ignition. H. Failure to ignite. 5.
Diagnostics Table 7. Troubleshooting guide (continued) Symptoms Possible Cause(s) Corrective Action 2. 2. Pilot adjustment screw turned too low on combination/automatic main gas valve. 3. Air in gas line. 3. Purge air from gas supply. 4. Incorrect lighting procedure. 4. Follow lighting instruction label adjacent to gas valve. 5. Dirt in pilot orifice. 5. Remove pilot orifice. Clean with compressed air or solvent. (Do not ream.) 6. Extremely high or low gas pressure. 6.
Diagnostics Table 7. Troubleshooting guide (continued) Symptoms Possible Cause(s) U. No Spark. 1. Thermostat not calling for heat. 1. Close thermostat contacts. 2. No low voltage. 2. Check for 24V across 24V terminals of S8600. 3. Spark gap closed or too wide. 3. Set gap to 0.1. 4. Broken or cracked ceramic on spark electrode. 4. Replace pilot assembly. 1. Loose S8600 connections. 1. Check all connections, term. PV feeds 24V to pilot valve. 2. Improper gas pressure. 2.
Wiring Diagrams Figure 25.
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