Installation, Operation, and Maintenance Gas Unit Heater Tubular Gas-Fired Direct Spark Propeller Unit Heater 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. Do not try to light any appliance. 2. Do not touch electrical switches; do not use any phone in your building. 3. Immediately call your gas supplier from a neighbor’s phone.
Table of Contents Warnings, Cautions and Notices . . . . . . . . . . 2 Model Number Descriptions . . . . . . . . . . . . . . 6 Indoor Gas Heating Units . . . . . . . . . . . . . . . 6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .46 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . .50 General Information . . . . . . . . . . . . . . . . . . . . . 7 Description . . . . . . . . . . . . . . . . . . . . . . . .
Model Number Descriptions Indoor Gas Heating Units Note: All units are AGA approved. For CGA approved units, contact Air Handling Product Support.
General Information Description The Tubular Gas-Fired Unit Heater is a factory assembled, power vented, low static pressure type propeller fan unit 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.
General Information • • Turn off the gas supply and disconnect all electric power, including remote disconnects before servicing unit. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized and the gas can not be inadvertently turned on. Failure to turn off gas or disconnect power before servicing could result in death or serious injury. • Do not attach ductwork to this product or use it as a makeup air heater.
General Information Figure 3. Unit sizes 30–120: Unit parts # 1. 2. Description Vestible Panel/Tube Assembly (Heat Exchanger) Bracket/Gas Train 3. Manifold 4. 5. Burner Assembly Standard Orifice (a) Natural Gas or Propane (LP) Gas Spark Ignitor 6. 7. 8. 9. Flame Sensor Gas Valve Natural or Propane (LP) Gas Manual Rollout Safety Switch 10. Transformer, 50 VA, 115/24 11. Air Pressure Switch 12. Terminal Block Plate 13. High Limit Switch 14. Fan Motor 15. OSHA Fan Guard 16. Standard Fan 17.
General Information Figure 4. Unit sizes 30–120: Component parts Figure 6. Unit sizes 30–120: Power venter assembly Figure 7. Unit sizes 150–400: Component parts D03 Pressure switch Figure 5.
General Information Figure 8. Figure 9. Unit sizes 150–400: Heat exchanger assembly Figure 10. Unit sizes 150–250: Power venter assembly Figure 11. Unit sizes 300–400: Power venter assembly Unit sizes 150–400: Electrical control panel Figure 12.
Unit Dimensions and Weights Table 1.
Unit Dimensions and Weights Figure 13.
Unit Dimensions and Weights Table 2.
Unit Dimensions and Weights Figure 14.
Installation: Mechanical NOTICE: Equipment Damage! 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. Unit heaters must not be installed in locations where air for combustion would contain chlorinated, halogenated or acidic vapors.
Installation: Mechanical WARNING Overheating or Flooding Could Cause Fire or Explosion! Overheating or flooding (where any part of the unit heater has been under water) could result in fire or explosion. Should overheating occur, or the gas supply fails to shut off, shut off the manual gas valve to the unit heater before shutting off the electrical supply. Do not use the unit heater if any part has been under water.
Installation: Mechanical WARNING Figure 16. Unit sizes 30–120: Heater mounting (steel construction) Heavy Objects! Ensure that all hardware used in the suspension of each unit heater is capable of supporting the unit weight. Failure to do so could result in unit falling off its mounting location, which could result in death or serious injury. Unit sizes 30–120 only: The unit heater may be mounted with the vent outlet, gas and electrical connections to the right or left of the air moving fan.
Installation: Mechanical to temporarily attach the top bracket (P/N 252-07948-00X). Figure 18. Unit sizes 150–400: Flue collar adapter installation a. Using the holes in the top bracket as a guide, predrill a 1/8” (0.125”) hole at each location across the front panel of the unit heater. b. Using the enclosed screws, permanently attach the top bracket. 3. Remove the upper two (2) screws from the lower section on the front of the unit heater.
Installation: Mechanical larger holes are facing the unit heater, create a sub-assembly by attaching the top panel (P/N 251-07942-00X) and the bottom panel (P/N 251-07943-00X) to the left side panel (P/N 251-07945) and to the right side panel (P/N 251-07947). 10. Install the louvers and cone springs. Note: The top and bottom panels must be attached so that the sides with the larger holes are facing the unit heater; this makes the assembly easier.
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. All unit sizes: Gas pipe size 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 21, p. 23). 5. Gas valve has a pressure test post requiring a 3/32” hex head wrench to read gas supply and manifold pressures. Open 1/4 turn counterclockwise to read, turn clockwise to close and reseat. A 5/16” ID hose fits the pressure post. 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 Table 5. exhaust fans, fireplace dampers, and any other gasburning appliance to their previous condition of use. All unit sizes: Venting categories Non Condensing Condensing Negative Vent Pressure I II Positive Vent Pressure III IV Category I Includes non-condensing appliances with negative vent pressure, like the traditional atmospheric unit heater. Category II Groups condensing appliances with negative vent pressure.
Installation: Piping Standard Combustion All Unit Sizes: Vertically Vented Unit Heaters (Category I) WARNING Carbon Monoxide! Never operate unit heaters without combustion air and flue gas piping in place. Each unit heater MUST have its own combustion air system and MUST NOT be connected to other vent systems or to a chimney. Your venting system must not be blocked by any snow, snow drifts, or any foreign matter.
Installation: Piping Figure 22. All unit sizes: Vertical venting (Category I) Approved Vent Terminal 2 feet Min. (0.61 m Min.) Use Insulated Stack Outdoors Thimble Roof 5 feet Min. 1.52 m Min. Unit sizes 30–120: 1” (25.4 mm) minimum distance from pipe to ceiling Unit sizes 150–400: 6” (152 mm) minimum distance from pipe to ceiling 1/4” Min. (6 mm)* 1 foot (305 mm)* *1/4” per foot (21 mm per m) 10 feet Max. (3.
Installation: Piping hazard, or could be detrimental to the operation of regulators, relief valves, or other equipment: • Unit sizes 30–120: Refer to Figure 23, p. 28, • Unit sizes 150–400: Refer to Figure 26, p. 28. • All unit sizes: Refer to Figure 28, p. 30 and Figure 30, p. 31. • Unit sizes 30–120: Use 4” (120 mm) flue pipe. • Unit sizes 150–400: Refer to Table 2, p. 14. All heaters must be vented with a single or double wall pipe listed for Category III positive pressure vent systems.
Installation: Piping • Unit sizes 150–400: Insulate single wall vent pipe exposed to cold air or running through unheated areas. Figure 26. Unit sizes 150–400: Horizontally-vented tubular unit heater (Category III) Figure 23. Unit sizes 30–120: Horizontal venting requirements using single wall vent pipe (Category III) Unit Sizes 30–120 Only: Vertically Vented Unit Heaters (Category III) Figure 24.
Installation: Piping rating of 500°F, or 3M #425 aluminum foil tape (or equivalent). 6. Avoid running vent pipe through unheated spaces. When this cannot be avoided, insulate the pipe to prevent condensation of moisture on the walls of the pipe. Figure 27.
Installation: Piping Figure 28. All unit sizes: Horizontal arrangement, single wall vent system to single wall termination Building overhang Vent pipe diameter Unit sizes 30–120: See Table 1, p. 12 Unit sizes 150–400: See Table 2, p. 14 Adjacent building Approved vent cap (see instructions) 3’-0” min. (0.9 m min.) 12” min. (305 mm min.) To prevent building material degradation from flue gases. 2” min. (51 mm min.) all around 6’-0” min. (1.8 m min.) Flue dia.
Installation: Piping Figure 30. All unit sizes: Horizontal arrangement, single wall vent system to double wall termination Building overhang Adjacent building Seal joint between single wall vent and double wall vent and the annular space of the double wall vent Vent pipe diameter Unit sizes 30–120: See Table 1, p. 12 Unit sizes 150–400: See Table 2, p. 14 Approved vent cap (see instructions) 3’-0” min. (0.9 m min.) 12” min. (305 mm min.) To prevent building material degradation from flue gases.
Installation: Piping Separated Combustion For installations in the United States, vent pipe approved for Category III appliances must be used between the appliance and the concentric vent box unless 33% of the vent run is vertical, then single wall galvanized vent pipe or double wall Type B vent pipe may be used between the appliance and the concentric vent box. A single length of double wall Type B vent pipe must be used to go through the concentric vent box and outside wall to the vent terminal.
Installation: Piping Z223.1 National Fuel Gas Code. In Canada installation must be in accordance with CAN/CGA-B149.1 “Installation Code for Natural Gas Burning Appliances and Equipment” and CAN/CGA-B149.2. “Installation Code for Propane Burning Appliances and Equipment”. 2.
Installation: Piping Figure 33. Unit sizes 30–120: Concentric vent installation Figure 34. Unit sizes 30–120: Vertical intake/vent installation Figure 35.
Installation: Piping Figure 36. Unit sizes 30–120: Horizontal intake/vent installation Building Overhang 3'-0" Min. (0.9M Min.) Adjacent Building 6'-0" Min. (1.8M Min.) Vent Terminal D 3330 Air Inlet Collar Remove screen and mounting plate from air inlet on rear panel of unit by removing 4 screws. Secure inlet collar and gasket to inlet opening re-using the 4 screws removed in step one. underside of the roof using suitable brackets (field supplied).
Installation: Piping Install thimble if required by local codes or type of wall construction. Concentric vent box may be fastened directly to wall or spaced away from wall using suitable brackets (field supplied). Cut a length of pipe so that it will protrude 4 inches (102 mm) through the wall when the box is mounted in position. Fasten pipe to box with sheet metal screws, using at least three screws per joint. Seal joint with silicone sealant.
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 Figure 38. All unit sizes: Low-voltage thermostat wiring (Two stage) Figure 39. All unit sizes: T834H or T843N Thermostat wiring W R R G W1 W2 G D6922C Thermostat Heat Anticipator Adjustments. The initial heat anticipator setpoint should equal the thermostat’s current amperage draw when the unit is firing. This setpoint should be measured for the best results. Use the recommended ranges as a guide.
Start-Up All Unit Sizes: Operation Power Vented Propeller Units—Direct Spark Ignition Explanation of Controls 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 3. Turn on the electrical power. The unit heater should now be under the control of the thermostat. Set the thermostat to its highest setting; the power venter motor should start and burner ignition occur. Turn the thermostat to its lowest setting; the power venter motor shuts off and the burner(s) should extinguish. Reset the thermostat to the desired operational setting. Note: For more information, refer to “Gas Input Rate,” p. 40 and “Gas Pressure Adjustments,” p. 40. Shut-Down 1.
Start-Up b. Remove the regulator adjustment screw cap, located on the combination gas valve. c. With a small screwdriver, rotate the adjustment screw counterclockwise to decrease or clockwise to increase pressure. d. Replace regulator adjustment screw cap. 2. PROPANE GAS: An exact manifold pressure of 10.0 inches wc (2.5 kPa) must be maintained for proper operation of the heater. If the unit is equipped with a pressure regulator on the combination gas valve, follow Step a through Step d (above).
Start-Up Table 10. All unit sizes: Tubular unit heater high altitude manifold pressure Natural Gas Propane (LP) Gas Manifold Pressure (in. wc) Manifold Pressure (in. wc) Heating(a Heating(a) Unit Sizes Unit Sizes ) Value Value Altitude (Btu/ ft3) 30–120 150–400 (Btu/ ft3) 30–120 150–400 (ft) 2,000 948 3.5 3.5 2,278 10.0 8.6 2,500 931 3.5 3.5 2,237 10.0 8.5 3,000 914 3.5 3.3 2,196 10.0 8.4 3,500 897 3.4 3.2 2,156 10.0 8.4 4,000 881 3.4 3.2 2,116 10.0 8.3 4,500 865 3.
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 close tightly, completely extinguishing the flame on the main burner(s). 12. Inspect and service the motor/fan assemblies. To maintain efficient air flow, inspect and clean the fan blades and guard to prevent buildup of foreign matter. 13. 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.
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 11. Troubleshooting guide (continued) Symptoms Possible Cause(s) Corrective Action G. Failure to ignite. 1. Gas supply is off. 1. Open all manual gas valves. Check for leaks. 2. Lack of power at unit. 2. Replace fuse or turn on power supply. 3. Thermostat not calling for heat. 3. Turn up thermostat. Check for 24 volts at terminals “R” and “W1” on terminal strip. 4. Defective high limit. 4. Check limit switch with continuity tester.
Diagnostics Table 11. Troubleshooting guide (continued) Symptoms Possible Cause(s) Corrective Action N. Fan will not stop. 1. Control board is in flame failure mode. 1. Turn 115V power off to the unit, wait 10 seconds, and reapply voltage to the unit. 2. Fan improperly wired. 2. Check wiring of fan circuit per wiring diagram. 3. Defective board. 3. If unit is not calling for heat and board is not in a flash code mode, replace board. 1. Incorrect gas input. 1.
Diagnostics WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. 1.
Wiring Diagrams Figure 42.
Wiring Diagrams Figure 43. Unit sizes 30–120: Natural & propane (LP) gas with single-stage gas control & UT control board Figure 44. Unit sizes 60–120: Natural and propane (LP) gas with optional two-stage gas control and UT control board Note: Refer to Figure 37, p. 37 through Figure 39, p. 38, Figure 43, p. 51, and Figure 44, p. 51 for connecting the thermostat to the unit heater.
Wiring Diagrams Figure 45. Unit sizes 150–400: Natural and propane (LP) gas 52 Figure 46.
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