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Sterling TF-150 Gas Heater User Manual

1. 24v Gnd oR R O YL H1 GJO wilo 29 TERMINAL BLOCKS TO T STAT Spark EFS i UT 1097 V IGNITION CONTROLLER ALT HL WIRING THRU 90 MBH TO THERMOSTAT SUPPLIED BY OTHERS R e S um wiley 1 aK R ee Fa p11 Ww 2 uto 300 THRU 400 wile end G 6 Un 1 ORBE ME THERMOSTAT T834H THERMOSTAT P1 1 LADDER Eia LINE 120V 1 60 12 7 7 Ee3 e H Fej u2 CMB L1 12 1 1 115 24 10712 50 VA 1 6 pg OR SEE ALT WIRING 24v Hot HL R 1 RD R THERMOSTAT wi 1 2 Bo aW P1 5 Bt oTo BM C NO 1 4 1 3 rg ALTERNATE HIGH LIMIT WIRING FS ce WH ESTSensor 30 thru 90 MBH ZI 1 6 mR in Spark m HL Piel 24v Gnd 4 100 thru 250 MBH P1 6 P1 1 xe Se KEY BY MANUFACTURER TUBULAR PROPELLER 115V 1 60 WIRING DOO Ihr 400 MBH oF MAMUPACRIRER UNIT HEATERS P1 1 vu uio HL HL2 24V WIRING 30 400 NAT amp LP mq SEES BY OTHERS OR OPTIONS 115V 1 60 WIRING UT 1097 LEGEND e BY OTHERS OR OPTIONS IGNITION CONTROLLER Se DRAFTER PRESSURE TERMINAL BLOCK OR FIELD CONNECTION POINT Ho EH LIMIT 2 WIRE CROSSING DIAGRAM RECORD 300 400 MBH ONLY oe esta AUTOMATIC IG
2. designs are certified by ETL as providing a minimum of 80 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 See Identification of Parts throughout this manual The following terms are used throughout this manual in addition to the ETL requirements to bring attention to the presence of potential hazards or to important information concerning the product Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage AWARNING Indicates an imminently hazard ous situation which if not avoided could result in death serious injury or substantial property damage A CAUTION Indicates an imminently hazardous situation which if not avoided may result in minor injury or property damage NOTICE Used to notify of special instructions on installation operation or maintenance which are important to equipment but not related to personal injury GENERAL SAFETY INFORMATION AWARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death A WARNING This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts Installation must be made in accor
3. PON SHUT DOWN 1 Turn the valve selector lever to the OFF position 2 Turn off the electricity 3 To relight follow start up instructions See Figures 10 17 for parts identification Direct Spark Gas Valve D6923B PRIMARY AIR SHUTTER ADJUSTMENT Primary air adjustment is made at the factory No field adjustments are necessary GAS INPUT RATE Check the gas input rate as follows Refer to General Safety Information section for metric conversions A CAUTION Never overfire the unit heater as this may cause unsatisfactory operation or shorten the life of the heater 1 Turn off all gas appliances that use gas through the same meter as the unit heater 2 Turn the gas on to the unit heater 3 Clock the time in seconds required to burn 1 cubic foot of gas by checking the gas meter 4 Insert the time required to burn one cubic foot of gas into the following formula and compute the input rate 3600 Sec per Hr X BTU Cu Ft Input Bate Time Sec For example Assume the BTU content of one cubic foot of gas is 1000 and that it takes 18 seconds to burn one cubic foot of gas 3600 x 1000 18 200 000 NOTICE If the computation exceeds or is less than 95 of the gas BTU hr input rating see Table 2 adjust the gas pressure Adjust the gas pressure as follows 1 NATURAL GAS Best results are obtained when the unit heater is operating at its full rated inpu
4. i 8 E ACB Cool 2 E CMB e 31 Li L2 1 7 115 24 1 2 50 VA P1 6 we OR SEE ALT WIRING HL P1 1 t s124v Hot 1 2 27253 aR DS1 1 5 E i PI 4 _ THERMOSTAT BK P1 3 z ALTERNATE HIGH LIMIT WIRING FS MH ER 30 thru 90 MBH ZI P1 6 s 98 di Spark re el CE e YL un 24v Gnd re e STG 2 100 thru 250 MBH MANUFACTURER 115V 1 60 WIRING BY MANUFACTURER 24V WIRING BY OTHERS OR OPTIONS TUBULAR PROPELLER UNIT HEATERS 50 400 NAT amp LP CONNECTION OR NO CONNECTION SHOULD EXIST LEGEND 115V 1 60 WIRING UT 1097 illae BY OTHERS OR OPTIONS DS1 DRAFTER PRESSURE 24V WIRING IGNITION CONTROLLER SWITCH e TERMINAL BLOCK OR TWO STAGE HL HIGH LIMIT FIELD CONNECTION POINT HL2 HIGH LIMIT 42 WIRE CROSSING DIAGRAM RECORD 300 400 MBH ONLY NO CONNECTION i SANFOR ER WIRE CONNECTION AUTOMATIC IGNITION MV GAS VALVE o WIRE CONNECTION 115V 1 60 M1 DRAFTER MOTOR THERMOSTAT M2 FAN MOTOR COLOR KEY DRAFTOR NOTE BL BLUE OR ORANGE IF AN OPTIONAL COMPONENT IS RD RED YL YELLOW NOT USED WITH RESPECT TO WH WHITE GR GREEN FILE J49 06920 THE COMPONENT TYPE A DIRECT BK BLACK DATE 08 11 2005 Rev G 11 VENTING ANSI now organizes vented Category I Category IV appliances into four categories Includes non condensing Covers condensing appliances wit
5. or gas valve 2 Excessive thermostat heat anticipator setting 3 Unit cycling on high limit Tighten all electrical connections Adjust heat anticipator setting for longer cycles Refer to Electrical Connections Check for proper air supply across heat exchanger and proper gas supply 4 Poor thermostat location 4 Relocate thermostat K Noisy power ventor 1 Power ventor wheel loose 1 Replace or tighten 2 Power ventor wheel is dirty 2 Clean power ventor wheel 3 Power ventor wheel is rubbing on the housing Realign power ventor wheel L Fan will not run M Fan motor turns on and off while burner is operating N Fan will not stop O Not enough heat a Loose electrical connections 2 Defective motor or overload 3 Defective control board Motor overload protection is tripping 2 Loose wiring or connection 3 Control board is defective 1 Control Board is in flame failure mode 2 Fan improperly wired 3 Defective board 1 Incorrect gas input 2 Heater undersized 3 Thermostat malfunction 4 Heater cycling on limit Check and tighten wires on fan circuit Test for 115v on terminal ACB Heat and L2 if voltage is present replace motor Test for 115v on terminal ACB Heat and L2 on the control board if voltage is not present 45 seconds after trial for ignition replace board Check motor amps against motor name plate check
6. 2 3 Special Precautions 2 3 INSTALLATION Locating Units tee niter 5 6 Combustion Air 2 5 6 Proper Clearances 5 6 Suspension of Units 2 5 6 GaS PIPINO pL 7 8 ELECTRICAL CONNECTIONS 9 10 11 ecran 12 13 14 15 16 OPERATION Explanation of Controls and Operation 17 Main Burner Orifice Schedule 18 Adjustments 18 19 TROUBLESHOOTING GUIDE 20 21 22 23 MAINTENANCE Servicing amp Cleaning 24 WARRANTY 5 rra ette oco teda Ke c aiu ER 25 IDENTIFICATION OF PARTS 26 27 Replacement 27 INSPECTION 28 NOTICE It is the equipment owners responsibility to provide any scaffolding or other apparatus required to perform emergency service or annual periodic maintenance to this equipment DESCRIPTION The Tubular Gas Fired Unit Heaters are a factory assembled power vented low static pressure type propeller fan unit heaters designed to be suspended within the space to be heated THESE HEATERS ARE NOT TO BE CONNECTED TO DUCTWORK The Figure 1 Tubular Propeller Unit Heater
7. 39 6 36 8 34 5 32 6 28 9 26 9 24 1 22 7 21 2 2 469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280 178 123 99 7 85 0 75 0 68 0 63 7 58 0 55 2 52 4 46 7 42 5 38 8 36 2 3 3 068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280 311 218 177 150 135 122 110 105 97 7 92 0 83 5 75 0 69 4 64 6 4 4 026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600 651 447 362 309 275 249 229 212 204 190 170 156 142 130 1 Determine the required Cu Ft Hr by dividing the input by 1000 For SI Metric measurements Convert BTU Hr to kilowatts Multiply the units inputs kW by 0 0965 to determine Cu Meters Hr 2 FOR NATURAL GAS Select pipe size directly from the table 3 FOR PROPANE GAS Multiply the Cu Ft Hr value by 0 633 then use the table 4 Refer to the metric conversion factors listed in the General Safety section for SI Unit measurement conversions 7 PIPE INSTALLATION 1 Install the gas piping in accordance with applicable local codes 2 Check gas supply pressure Each unit heater must be connected to a manifold pressure and a gas supply capable of supplying its full rated capacity as specified in Table 4 A field LP tank regulator must be used to limit the supply pressure to a maximum of 14 in W C 3 5 kPa All piping should be sized in accordance with the latest edition o
8. DRILL SCREWS eus 3 8 16 THREADED ROD RECOMMENDED FOR 2 HANGERS D4913A INSTALL THE FLUE COLLAR ADAPTER TO THE POWER VENTER 55 AS SHOWN SECURE IN PLACE USING DRILL SCREWS AS SHOWN Figure 3B Heater Mounting STEEL CONSTRUCTION STD CLAMP NUT A N amp WASHER 0768 3559 THREADED m ROD WASHER amp NUT THREADED ROD MALLEABLE MALLEABLE IRON BOLT IRON BOLT 02788 THREADED PIPE All hanging hardware and wood is not included with the unit To be field supplied Figure 3C WOOD CONSTRUCTION JOISTS JOIST WASHE amp NUT A ZA SZ LAG BOLT amp WASHER X 6 LAG BOLTED ACROSS JOIST D4804 UNIT HE 100 400 SIZES ATER SEE TABLE 1 FOR DIMENSION E GAS PIPING AWARNING until a supply pressure leak A WARNING To avoid damage or possible personal injury do not connect gas piping to this unit line pressure leak test has been completed Connecting the unit before completing the test may damage the unit gas valve and result in a fire hazard Do not rely on a shut off valve to isolate the unit while conducting gas pressure leak tests These valves may not be completely shut off exposing the gas valve to excessive pressure and damage PIPE SIZING To provide adequate
9. Operation 2 Refer to Operation R High limit tripping Unit is over fired Air flow is low Defective switch Defective control board 1 Burner orifices may be too large verify and replace 2 Check for proper voltage ensure fan blade is correct 3 Check operation of switch did the switch open when unit is running or is the switch open during start up 4 Check for 24v on line side of the high limit Constant voltage should be recorded if not control board is suspect Check flash code S Power ventor will not run Loose wiring or connections Motor overload is tripped or bad motor Bad control board 1 Check all wring in the power vent circuit to ensure good connection including Neutral 2 Check for 115v between motor leads and check amp draw of motor Replace if needed 3 Check for continuous 115v on terminal CBM Blower and neutral during call for heat If not present and all checks are normal replace T Power ventor turns on and off during operation Power ventor improperly wired Motor overload cycling or defective motor Defective control board ak Check power ventor circuit per wiring diagram 2 Check motor voltage and amp draw to motor name plate replace if motor found defective 3 Check for continuous 115v on terminal CMB Blower during call for heat replace board if found defective U Power ventor will not sto
10. Table 1 D Dia Flue Opening All unit sizes are factory equipped with the required flue size collar attach in place if not mounted to outlet refer to included vent collar instruction sheet for additional requirements Vent Systems Termination Clearance Requirements Minimum Clearances for Structure Termination Locations 4 feet below Door window or any gravity air inlet 4 feet horizontally 1 foot above 3 feet above 6 feet 7 feet above grade Forced air inlet within 10 ft Adjoining building or parapet Adjacent public walkways The venting system for these appliances shall terminate at least 4 feet 1 2m below 4 feet 1 2m horizontal from or 1 foot 0 3m above any door window or gravity vent air inlet into the building The vent terminal must be at least 12 inches 305mm from the exterior of the wall that it passes through to prevent degradation of the building material by flue gases The vent terminal must be at least 3 feet 1m above grade or in snow areas at least 3 feet above the snow line to prevent blockage by snow Through the wall vent for these appliances shall NOT terminate over public walkways or over an area where the condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment The vent pipe equivalent length must not exceed 50 feet 15 2m Equivalent length is the total l
11. corrosion by chemicals including halogenated hydrocarbons precipitated in the air d to any workmanship of the installer of the Product This limited warranty is conditional upon a advising the installing contractor who in turn notify the distributor or manufacturer b shipment to the Manufacturer of that part of the Product thought to be defective Goods can only be returned with prior written approval of the Manufacturer All returns must be freight prepaid c determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period THIS LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES EITHER EXPRESS OR IMPLIED AND ALL SUCH OTHER WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL SPECIAL OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY JURISDICTION In the interest
12. gas pressure to the gas unit heater size the gas piping as follows 1 Find the cu ft hr by using the following formula burn 1000 Refer to Table 3 Match Length of Pipe in Feet with appropriate Gas Input Cu Ft Hr figure This figure can then be matched to the pipe size at the top of the column Example It is determined that a 67 foot 20 4m run of gas pipe is required to connect a 200 MBTU gas unit heater to a 1 000 BTU cu ft 0 29kW natural gas supply 200 000 BTU Hr 1 000 BTU cu ft Using Table 3 a 1 inch pipe is needed 200 Cu ft hr NOTE See General Safety Information section for English Metric unit conversion factors NOTICE If more than one unit heater is to be served by the same piping arrangement the total cu ft hr input and length of pipe must be considered NOTICE If the gas unit heater is to be fired with LP gas consult your local LP gas dealer for pipe size information NOTICE HEATER INSTALLATION FOR USE WITH PROPANE BOTTLED GAS MUST BE MADE BY A QUALIFIED L P GAS DEALER OR INSTALLER HE SHE WILL INSURE THAT PROPER JOINT COMPOUNDS ARE USED FOR MAKING PIPE CONNECTIONS THAT AIR IS PURGED FROM LINES THAT A THOROUGH TEST IS MADE FOR LEAKS BEFORE OPERATING THE HEATER AND THAT IT IS PROPERLY CONNECTED TO THE PROPANE GAS SUPPLY SYSTEM Before any connection is made to the existing line supplying other gas appliances contact the local gas company to make sure t
13. present Not Applicable Steady Off Internal control fault or no power 1 Line voltage on terminals 120 and C on transformer 2 Low voltage 24V on terminals 24 and C on transformer 3 5 Amp fuse on circuit board Steady On Control internal failure or bad ground Common side of transformer grounded to chassis 2 Loose spark ignitor 2 Flashes In lockout from failed ignitions or flame losses Gas supply off or gas supply pressure too low 2 Flame sense rod contaminated or loose wire 3 Gas valve switch is off or wires are not connected 4 Broken or cracked porcelain on flame probe or spark ignitor 3 Flashes Pressure Switch open with inducer on or closed with inducer off Obstructions or restrictions in appliance air intake or flue outlet are preventing proper combustion airflow 2 Moisture or debris in tubing that connects pressure switch and draft inducer 3 Airflow switch jumpered or miswired 4 Flashes Limit or rollout switch is open 1 Open manual reset rollout switch 2 Gas pressure too high over fire condition 3 Incorrect airflow due to blockage or motor not operating 5 Flashes Flame sensed while gas valve is off Flame probe miswired or shortened 6 Flashes On board microprocessors disagree Thermostat is interfering with control board 23 MAINTENANCE PERIODIC
14. resistant to the action of liquefied petroleum gases regardless of gas conducted A WARNING Check all pipe joints for leakage using a soap solution or other approved method Never use an open flame or severe personal injury or death may occur Figure 4 Pipe Installation Standard Controls A manual shut off valve with 1 8 In plugged tapping Gos accessible for test gage con Supply nection must be installed Line immediately upstream of the gas supply connection to the opp lonce When installed within the Commonwealth of Massachusetts a handle gas cock must be used Ground Joint Union To Controls 3 Min Plugged 76MM Min 1 8 Tn NP T Test Goge Connection 036318 Drip Pocket A WARNING Never use an open flame to detect gas leaks Explosive conditions may exist which may result in personal injury or death The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system in excess of 1 2 psig 8 5 kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 5 kPa Table 4 Gas Piping Requirements SINGLE STAGE GAS PIPING REQUIREMENTS GasType Natural Gas Propane LP Gas Manifold
15. voltage replace if found defective Check for 115v between motor leads Check terminal ACB Heat for voltage if voltage not constant replace board Turn 115v power off to the unit wait 10 seconds and reapply voltage to the unit Check wiring of fan circuit to wiring diagram If unit is not calling for heat and board is not in a flash code mode replace board Refer to Operation Is the heater output sized correctly for heat loss of the space Has the space been enlarged Check thermostat circuit 24v on terminals R and W on terminal strip Check air movement across heat exchanger Check voltage and amps at the fan motor Check gas input to ensure unit is not over fired Check heat exchanger to ensure unit is not dirty 5 Incorrect orifice sizes 5 Check orifice size replace if undersized P Too much heat 1 Unit is over fired 1 Refer to Operation Check orifice size If too big replace 2 Thermostat malfunction 2 Check thermostat for operation to ensure circuit open and closes 3 Heater runs continuously 3 Check wiring per diagram check operation at the gas valve look for a short in thermostat circuit 21 Table 6 Tubular Propeller Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION Q Cold air is delivered during heater operation Incorrect manifold pressure or input Air throughput too high 1 Refer to
16. 03 07 S DSTBIM 3 INSTALLATION INSTRUCTIONS AND PARTS LIST TUBULAR GAS FIRED DIRECT SPARK PROPELLER UNIT HEATERS J30 06935 ATTENTION READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE OR SERVICE THESE UNITS CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT THE POINT OF INSTALLATION RECORD THE UNIT MODEL AND SERIAL No s INTHE SPACE PROVIDED RETAIN FOR FUTURE REFERENCE Model No Serial No 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 Splash FOR YOUR SAFETY If you smell gas 1 Open windows 2 Don t touch electrical switches C US 3 Extinguish any open flame Listed 4 Immediately contact your gas supplier AWARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instruction thoroughly before installing or servicing this equipment APPROVED FOR USE IN CALIFORNIA A WARNING Install operate and maintain unit in accordance with the manufacturer s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness The state of California has determi
17. 1 ft Hi 6 mm 305 mm 10 ft Max 3 05 m Not to Exceed 75 Vertical Flue Height D4796 E Figure 7 Horizontally Vented Tubular Unit Heater Category III e 5 ft 1 52 m Min 1 ft Min 305 mm Approved Vent Terminal P Condensate Drain with 3 ft 091 m Min i Trap if required by Above Highest Snowfa local authorities 4797 ADDITIONAL REQUIREMENT FOR CANADIAN INSTALLATIONS REFER TO SPECIFICATION TABLE AND INSTALLATION MANUAL FOR PROPER USAGE The following instructions apply to Canadian installations in addition to installation and operating instructions 1 Installation must conform with local building codes or in the absence of local codes with current CGA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CGA B149 2 Installation Codes for Propane Gas Burning Appliances and Equipment 2 Any reference to U S standards or codes in these instructions are to be ignored and the applicable Canadian standards or codes applied 14 Figure 8A VENTING continued HORIZONTAL ARRANGEMENT SINGLE WALL VENT SYSTEM TO SINGLE WALL TERMINA
18. 3 5 in W C 10 0 in W C Pressure 0 9 kPa 2 5 kPa 14 0 in W C Max 14 0 in W C Max Supply Inlet 3 5 kPa 8 5 kPa Pressure 5 0 in W C Min 11 0 in WC Min 1 2 kPa 2 7 kPa For single stage application only at normal altitudes ELECTRICAL CONNECTIONS AWARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING Failure to disconnect power before servicing can cause severe personal injury or death Standard units are shipped for use on 115 volt 60 hertz single phase electric power The motor name plate and electrical rating of the transformer should be checked before energizing the unit heater electrical system All external wiring must conform to the latest edition of ANSI NFPA No 70 United States National Electrical Code and applicable local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 A CAUTION Do not use any tools i e screwdriver pliers etc across terminals to check for power Use a voltmeter It is recommended that the electrical power supply to each unit heater be provided by a separate fused and permanently live electrical circuit A disconnect switch of suitable electrical rating should be located as close to the gas valve and controls as possible Each unit heater must be electrically grounded in accordance with the latest edition of the United States National Electrical Code ANSI
19. 3 70 175 ORIFICE DRILL 42 53 7 FT 186 80 200 ORIFICE DRILL 42 53 i FT 233 100 250 ORIFICE DRILL 42 53 10 280 120 300 ORIFICE DRILL 42 53 2 FT 326 140 390 ORIFICE DRILL 42 53 FT 372 160 00 ORIFICE DRILL 42 53 15 This schedule is for units at operating at normal altitudes of 2000 ft 610m or less When installed in Canada any references to deration at altitudes in excess of 2000 ft 610m are to be ignored At altitudes of 2000 to 4500 ft 610 to 1372m the unit heaters must be orificed to 90 of the normal altitude rating and be so marked in accordance with ETL certification TUBULAR UNIT HEATER HIGH ALTITUDE DERATION This Tubular Unit Heater has been manufactured utilizing standard burner orifices and a normal manifold pressure setting as per the specifications shown on your unit rating plate All unit deration must be done through field adjustments by a qualified technician Once the proper adjustments are made in the field attach label J17 06459 to the unit and record adjusted manifold pressure altitude of the unit installation and the technician s name and date on the label using a permanent marker Refer to Installation Instruction section on Adjustments Gas Input Rate for adjusting the manifold pressure 19 Table 5A NATURAL GAS PROPANE LP GAS Heating Manifold
20. E WALL VENT SYSTEM TO DOUBLE WALL TERMINATION BUILDING ADJACENT OVERHANG BUILDING r SEAL JOINT BETWEEN SINGLE WALL VENT AND VENT AND THE ANNULAR SPACE OF Do lo THE B VENT VENT PIPE DIAMETER APPROVED SEE SPECIFICATION TABLE 12 VENT CAP 3 0 MIN N SEE INSTRUCTIONS 0 9 MIN N N 18 MIN 4 n 5 BUILDING MATERIAL SETUP N DEGRADATION FROM FLUE GASES N N a FLUE N DIA N D3661C PITCH FLUE PIPE R N DOWN TOWARD OUTLET 1 4 PER FOOT 21 FLASHING g Foto wa RUN TD ALLOW FOR L 12 INCHES 305MM PLUS 203 254MM CUNDENSATE DRAINAGE MAXIMUM SNOW DEPTH MAX IMUM FOR AREA ABOVE GRADE CLEARANCE TO BE AS SPECIFIED ON TYPE B VENT PIPE Figure 9B SINGLE WALL VENT SYSTEM TO DOUBLE WALL TERMINATION 6 0 MIN 8M MIN APPROVED 4 VENT CAP f ADJACENT BUILDING SEE INSTRUCTIONS 6 INCHES 152MM FIBERGLASS PLUS MAXIMUM SNOW INSULATION DEPTH FOR AREA MIN 2 THICK VERTICAL PIPE EX 51MM MIN TENSION OVER 12 305 MUST INSULATED ROOF ROOF PITCHED i FLASHING FROM 0 TO 45 7 ZZ 14 14 14 03662 14 8 TD 10 CLEARANCE TO BE AS SPECIFIED 203 254MM ON TYPE TENT PIPE MAXIMUM Pie 7 bia VENT PIPE DIAMETER SEE SPECIFICATION TABLE D SEAL JOINT BETWEEN SINGLE WALL VENT 16 AND B THE B VENT AND THE ANNULAR SPACE OF VENT OPERATION P
21. Heating Manifold Altitude Value Pressure Value Pressure Feet BTU Cu ft In W C BTU Cu ft In W C 2 000 948 3 5 2 278 8 6 2 500 931 3 5 2 237 8 5 3 000 914 3 3 2 196 8 4 3 500 897 3 2 2 156 8 4 4 000 881 3 2 2 116 8 3 4 500 865 3 2 2 077 8 2 5 000 849 3 1 2 039 8 1 5 500 833 3 1 2 000 8 0 6 000 818 3 0 1 964 7 9 6 500 802 3 0 1 927 vu 7 000 787 2 9 1 891 7 6 7 500 771 2 9 1 853 7 5 8 000 756 2 8 1 817 7 4 8 500 741 2 8 1 781 7 2 9 000 726 2 7 1 745 7 1 9 500 711 2 7 1 709 6 9 10 000 696 2 6 1 673 6 8 Notes 1 Consult local utility for actual heating value 2 Tables based on heating value of 1 050 BTU Cu ft at sea level Table 6 Tubular Propeller Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION A Flame pops back 1 Burner orifice too small 1 Check with local gas supplier for proper orifice size and replace Refer to Operation B Noisy Flame 1 Irregular orifice causing whistle or resonance 1 Replace orifice 2 Excessive gas input 2 Test and reset manifold pressure C Yellow tip flame some yellow 1 Clogged main burners 1 Clean main burner ports tipping on LP gas is permissible 2 Misaligned orifices 2 Replace manifold assembly 3 Insufficient combustion air 3 Insufficient combustion air 4 Possibly over fired 4 Check gas input and manifold pressures D Floating flame 1 Blocked venting 1 Clean Flue Refer to Inst
22. Installation Codes for Gas Burning Appliances and Equipment AIR DISTRIBUTION Direct air towards areas of maximum heat loss When multiple heaters are involved circulation of air around the perimeter is recommended where heated air flows along exposed walls Satisfactory results can also be obtained where multiple heaters are located toward the center of the area with heated air directed toward the outside walls Be careful to avoid all obstacles and obstructions which could impede the warm air distribution patterns 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 The result is a mildly corrosive acid that prematurely corrodes the aluminized heat exchanger and can actually drip water down from the unit heater onto floor surface Additional unit heaters should be installed if a minimum 50 F 10 C thermostat setting cannot be maintained AIR FOR COMBUSTION The unit heater shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas proper venting and the maintenance of ambient air at safe limits under normal conditions of use The unit heater shall be locat
23. MOSTAT 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 for a guide If further information is needed consult your thermostat manufacturer s instructions Recommended heat anticipator settings Unit Size 30 thru 200 250 thru 400 For Tubular Units 0 35 Amps 0 65 Amps NOTICE The start up fan delay should not exceed 30 seconds from a cold start IMPORTANT For all wiring connections refer to the wiring diagram shipped with your unit either affixed to the side jacket or enclosed in the installation instructions envelope Should any original wire supplied with the heater have to be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Should any high limit wires have to be replaced they must be replaced with wiring material having a temperature rating of 200 C minimum ELECTRICAL CONNECTIONS continued Figure 5d Tubular Units Equipped with Natural Gas and Propane LP Gas PICTORIAL CONTROL PANEL LINE IN 115V AC Heat ACB Cool E 24 Hot 1 SEE ALT HL WIRING HL
24. NFPA No 70 or CSA Standard C22 1 Refer to Figures 5a 5b 5c 5d and 5e THERMOSTAT WIRING AND LOCATION NOTICE The thermostat must be mounted ona vertical vibration free surface free from air currents and in accordance with the furnished instructions Mount the thermostat approximately 5 feet 1 5m above the floor in an area where it will be exposed to a free circulation of average temperature air Always refer to the thermostat instructions as well as our unit wiring diagram and wire accordingly Avoid mounting the thermostat in the following locations 1 Cold Areas Outside walls or areas where drafts may affect the operation of the control 2 Hot Areas Areas where the sun s rays radiation or warm air currents may affect the operation of the control 3 Dead Areas Areas where the air cannot circulate freely such as behind doors or in corners Low voltage Single Stage Thermostat Figure 5a Low voltage T Thermostat Wiring Single Stage R e e D4788 Low voltage Two Stage Thermostat Figure 5b Low voltage Thermostat Wiring wi Two Stage D4790 Honeywell T834H 1009 or Figure 5c T834H 1009 or T834H 1017 _ Thermostat Wiring T834H 1017 Thermostat Oe On o D2 Do D D69228 THER
25. NITION TRANSFORMER WIRE CONNECTION 4 MV GAS VALVE WIRE CONNECTION 1 M1 DRAFTER MOTOR THERMOSTAT M2 FAN MOTOR COLOR KEY DRAFTOR c E EE RD RED GET C T fe Sane 98 GREEN 2 06900 THE COMPONENT TYPE DIRECT BK BLACK DATE 08 9 2005 CONNECTION OR NO CONNECTION REV SHOULD EXIST 10 ELECTRICAL CONNECTIONS continued Figure 5e Tubular Unit Sizes with Optional 2 Stage Ignition PICTORIAL LINE IN 115V AC R RD CONTROL PANEL ACB Heat ACB T Cool BL YL S wijo w2 o H TERMINAL BLOCKS TO T STAT SEE ALT HE WIRING OR YL P1 6 R 1 300 thru 400 MBH Pit am T YL MH FILS 1 1 ee 753 TO THERMOSTAT 3 T SUPPLIED BY OTHERS 9 wi e 7 100 THU 250 MBH 6295 0 8 1 y 9 ae Auto Fa Ww 300 THRU 400 MBH w1 el Ger TAO OR Lek I We THERMOSTAT T834H THERMOSTAT P tt LADDER 11 120 1 60 pL 2 Heat 1
26. OWER VENTED PROPELLER UNITS DIRECT SPARK IGNITION EXPLANATION OF CONTROLS See Figure 10 1 Figure 10 The unit heater is equipped with a power vent system that consists of a power venter motor and blower pressure switch and sealed flue collector in place of the conventional draft diverter The power venter motor is energized by the room thermostat through the integrated control board when a demand for heat is sensed The pressure switch measures the flow through the vent system and energizes the direct spark ignition system beginning the pre purge timing when the flow is correct A WARNING The pressure switch MUST NOT be bypassed The unit MUST NOT be fired unless the power venter is operating An unsafe condition could result The direct ignition system consists of an ignition control module and a gas valve When the pre purge period ends the spark ignition system is energized and the gas valve opens to supply gas to the burners When the thermostat is satisfied the vent system is de energized and the valve closes to stop the flow of gas to the unit The limit switch interrupts the flow of electric current to the control board interrupting the flow of gas to the gas valve if the unit heater becomes overheated Once the thermostat is satisfied or the limit switch interrupts the flow of electric current to the control board the unit will begin a post purge period When the post purge period ends the powe
27. SERVICE NOTICE The heater and vent system should be checked once a year by a qualified technician All Maintenance Service information should be recorded accordingly on the Inspection Sheet provided in this manual AWARNING Open all disconnect switches and disconnect all electrical and gas supplies and secure in that position before servicing unit Failure to do so may result in personal injury or death from electrical shock AWARNING Gas tightness of the safety shut off valves must be checked on at least an annual basis To check gas tightness of the safety shut off valves turn off the manual valve upstream of the appliance combination control Remove the 1 8 inch pipe plug on the inlet side of the combination control and connect a manometer to that tapping Turn the manual valve on to apply pressure to the combination control Note the pressure reading on the manometer then turn the valve off A loss of pressure indicates a leak If a leak is detected use a soap solution to check all threaded connections If no leak is found combination control is faulty and must be replaced before putting appliance back in service Should maintenance be required perform the following inspection and service routine 1 Inspect the area near the unit to be sure that there is no combustible material located within the minimum clearance requirements listed in this manual A WARNING Under no circumstances
28. TION BUILDING OVERHANG ADJACENT SS BUILDING VENT PIPE DIAMETER SEE SPECIFICATION TABLE D APPROVED i VENT 3 0 MIN SEE INSTRUCTIONS 0 9M_MIN gt 12 MIN 4 MIN 305 mm MIN B june AN lt SIMM MIN PREVENT Ran Mn N ALL AROUND BUILDING MATERIAL DEGRADATION FROM FLUE GASES N 1 N N PITCH FLUE PIPE FLASHING DOWN TOWARD OUTLET Et 1 4 PER FOOT 21 2 CLEARANCE FIBERGLASS OF RUN TO ALLOW FOR 51MM 12 INCHES 305MM PLUS TUMBLE INSULATION CONDENSATE DRAINAGE MAXIMUM SNOW DEPTH MIN E Me FOR AREA ABOVE GRADE Figure 8B SINGLE WALL VENT SYSTEM TO SINGLE WALL TERMINATION 6 0 lt 1 8 MIN APPROVED VENT CAP f ADJACENT BUILDING SEE INSTRUCTIONS f 6 INCHES 152MM FIBERGLASS PLUS MAXIMUM SNOW INSULATION DEPTH FOR AREA MIN 2 THICK n VERTICAL PIPE EX 51MM MIN H TENSION OVER 182 305MM MUST BE INSULATED ROOF ROOF PITCHED FLASHING p FROM 0 TO 45 x 4 n 4 036194 4 nu p 2 CLEARANCE 51 8 MIN THIMBLE 5 MIN CALL AROUND FLUE DIA 15 p VENT PIPE DIAMETER SEE SPECIFICATION TABLE 1 VENTING continued Figure 9A SINGL
29. allation 2 Insufficient combustion air 2 Clean combustion air inlet openings 3 Blocked heat exchanger 3 Clean heat exchanger Refer to Installation 4 Air leak into combustion chamber 4 Determine cause and repair accordingly or draft hood E Gas odor 1 Shut off gas supply immediately 1 Inspect all gas piping and repair 2 Leaking gas test port on valve 2 Check to ensure gas test ports are seated 3 Blocked heat exchanger 3 Clean heat exchanger flue 4 Blocked draft hood 4 Clean flue collector 5 Negative pressure in the building 5 See Installation F Delayed ignition 1 Improper ground 1 Check grounding wires and spark bracket connections 2 Bad or broken spark cable 2 Inspect spark cable connections and cuts 3 Faulty control 3 Check to ensure spark is energized after pre purge period 4 Pressure regulator set too low 4 Test and reset manifold pressure refer to Operations 5 Main burner orifices dirty 5 Clean or replace orifices 6 Improper venting 6 Refer to Installation G Failure to ignite Gas supply is off 2 No power supply to unit 1 Open all manual valves check for leaks 2 Turn on power supply check fuses and replace if bad 3 Thermostat not calling 3 Turn up thermostat Check for 24v on terminals R and W1 on terminal strip 4 Defective high limit 4 Check switch for continuity if open with no heat present replace 5 Defective d
30. ation 3 b A CAUTION Never over oil the motor or premature failure may occur 12 Check and test the operational functions of all safety devices supplied with your unit LIMITED WARRANTY Power Vented Tubular Propeller Unit Heaters The Manufacturer warrants to the original owner at original installation site that the above model Gas Fired Heater the Product will be free from defects in material or workmanship for 1 year from the date of shipment from the factory or one and one half 1 1 2 years from the date of manufacture whichever occurs first The Manufacturer further warrants that the complete heat exchanger and burners be free from defects in material or workmanship for a period of ten 10 years from the date of manufacture If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period the manufacturer will repair or replace at its option that part of the Product which is shown to be defective This limited warranty does not apply a if the product has been subjected to misuse or neglect has been accidentally or intentionally damaged has not been installed maintained or operated in accordance with furnished written instructions or has been altered or modified in any way by any unauthorized person b to any expenses including labor or material incurred during removal or reinstallation of the Product c to any damage due to
31. dance with local codes or in absence of local codes with the latest edition of the ANSI Standard Z223 1 N F P A No 54 National Fuel Gas Code All of the ANSI and NFPA Standards referred to in these installation instructions are those that were applicable at the time the design of this appliance was certified The ANSI Standards are available from CSA Information Services 1 800 463 6727 The NFPA Standards are available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 These unit heaters are designed for use in airplane hangars when installed in accordance with ANSI NFPA No 409 and in public garages when installed in accordance with NFPA No 88A and NFPA No 88B If installed in Canada the installation must conform with local building codes or in the absence of local building codes with CGA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CGA B149 2 Installation Codes for Propane Gas Burning Appliances and Equipment These unit heaters have been designed and certified to comply with CGA 2 6 Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES A WARNING Do not alter the unit heater in any way or damage to the unit and or severe personal injury or death may occur A WARNING pisconnect all power and gas supplies before installing or servicing the heater If the power disconnect is out of sight lock it in the open posit
32. ed in such a manner as not to interfere with proper circulation of air within the confined space When buildings are so tight that normal infiltration does not meet air requirements outside air shall be introduced per Sections 1 3 4 2 and 1 3 4 3 of ANSI 2223 1 for combustion requirements A permanent opening or openings having a total free area of not less than one square inch per 5 000 BTU Hr 1 5 kW of total input rating of all appliances within the space shall be provided NOTICE Unit Heater sizing should be based on heat loss calculations where the unit heater output equals or exceeds heat loss INSTALLATION continued CLEARANCES Each Gas Unit Heater shall be located with respect to building construction and other equipment so as to permit access to the Unit Heater Clearance between vertical walls and the vertical sides of the Unit Heater shall be no less than 6 inches 152mm However to ensure access to the control box a minimum of 18 457mm is required for the control box side A minimum clearance of 6 inches 152mm must be maintained between the top of the Unit Heater and the ceiling The bottom of the Unit Heater must be no less than 12 inches 305mm from any combustible The distance between the flue collector and any combustible must be no less than 6 inches 152mm Also see AIR FOR COMBUSTION and VENTING sections NOTICE Increasing the clearance distances may be necessary if there is a possibility of distortion
33. ength of straight sections PLUS 15 feet 4 6m for each 90 elbow and 8 feet 2 44m for each 45 elbow Maintain 6 inches 152mm between the vent pipe and combustible materials The vent terminal must be installed with a minimum horizontal clearance of 4 feet 1 2m from electric meters gas meters regulators and relief equipment Seal all vent pipe joints and seams to prevent leakage Use General Electric RTV 108 Dow Corning RTV 732 silicone sealant or equivalent or 3M 425 aluminum foil tape or equivalent The vent air system must be installed to prevent collection of condensate Pitch horizontal pipes downward 1 4 inch per foot 21mm per meter toward the outlet for condensate drainage Horizontal portions of the venting systems shall be supported at maximum intervals of 4 feet 1 2m to prevent sagging in Canada support at 3 feet 1m maximum intervals Insulate single wall vent pipe exposed to cold air or running through unheated areas Each unit must have an individual vent pipe and vent terminal Each unit MUST NOT be connected to other vent systems or to a chimney VENTING continued Figure 6 Vertically Vented Tubular Unit Heater Category I 9 4 Vent Terminal 1 Use Insulated Stack Outdoors 2 ft Min 0 61 m Min Thimble aoe oo 5 ft Min 1 52 m Min 6 152 mm Min Distance from pipe to ceiling 1 4 Min
34. f ANSI Standard Z223 1 National Fuel Gas Code in Canada according to CGA B149 See Tables 1 amp 3 for correct gas piping size If gas pressure is excessive on natural gas applications install a pressure regulating valve in the line upstream from the main shutoff valve 3 Adequately support the piping to prevent strain on the gas manifold and controls 4 To prevent the mixing of moisture with gas run the take off piping from the top or side of the main 5 Standard Unit Heaters optional two stage units are supplied with a combination valve which includes a Manual A valve b Manual B valve c Solenoid valve d Pressure regulator Pipe directly into the combination valve see Figure 4 6 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 7 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 The manual shutoff valve must be located external to the jacket See Figure 4 8 Make certain that all connections have been adequately doped and tightened A CAUTION Do not over tighten the inlet gas piping into the valve This may cause stresses that will crack the valve NOTICE Use pipe joint sealant
35. h appliances with negative vent positive vent pressure Venting Categories pressure like the traditional Non atmospheric unit heater Condensing Condensing NOTICE Category II and IV do not apply to equipment specified Negative Category II within this manual Vent I Groups condensing appliances Pressure with negative vent pressure Positive Category III Vont n n Appliances are non condensing Pressure pressure and operate with a positive vent All unit heaters must be vented All Venting installations shall be in accordance with the latest edition of Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of local building codes Refer to page 15 for Canadian installations Refer to Figures 6 7 8A 8B 9A and 9B A WARNING CARBON MONOXIDE Your venting system must not be blocked by any snow snow drifts or any foreign matter Inspect your venting system to ensure adequate ventilation exists at all times Failure to heed these warnings could result in Carbon Monoxide Poisoning symptoms include grogginess lethargy inappropriate tiredness or flu like symptoms VERTICALLY VENTED UNIT HEATERS CATEGORY I Observe the following precautions when venting the unit 1 Use flue pipe of the same size as the flue connections on the gas unit heater See Table 1 All heaters should be vented with UL Listed Type B vent a factory built chimney o
36. hat the existing line is of adequate size to handle the combined load Table 3 Gas Pipe Size Maximum Capacity of Pipe in Cubic Feet of Gas per Hour Cubic Meters per Hour for Gas Pressures of 0 5 psig 3 5 kPa or Less and a Pressure Drop of 0 5 Inch Water Column 124 4 Pa Based on a 0 60 Specific Gravity Gas Nominal Iron Internal Length of Pipe Feet meters Pipe Size Dia 10 20 30 40 50 60 70 80 90 100 125 150 175 200 in in 3 0 6 1 9 1 12 2 15 2 18 3 21 3 24 4 27 4 30 5 38 1 45 7 53 3 61 0 1 2 0 622 175 120 97 82 73 66 61 57 53 50 44 40 37 35 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 3 4 0 824 360 250 200 170 151 138 125 118 110 103 93 84 77 72 10 2 7 08 5 66 4 81 4 28 3 91 3 54 3 34 3 11 2 92 2 63 2 38 2 18 2 04 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 19 3 13 2 10 6 9 06 8 07 7 36 6 80 6 23 5 80 5 52 4 96 4 53 411 3 82 11 4 1 380 1400 950 770 660 580 530 490 460 430 400 360 325 300 280 39 6 26 9 21 8 18 7 16 4 15 0 13 9 13 0 12 2 11 3 10 2 9 20 8 50 7 93 1 1 2 1 610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 59 5 41 3 33 4 28 0 25 5 22 9 21 2 19 5 18 4 17 6 15 6 14 2 13 0 12 2 2 2 067 3950 2750 2200 1900 1680 1520 140 1300 1220 115 1020 950 850 800 112 77 9 62 3 53 8 47 6 43 0
37. iameter in Qty 16 16 16 18 18 18 2 16 2 18 2 18 Gas Inlet Natural Gas in 1 2 1 2 1 2 1 2 1 2 3 4 3 4 3 4 3 4 Gas Inlet LP Gas in 1 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 OR 3 4 1 2 4 1 20R3A4 Approximate Unit Weight Ibs 133 145 155 191 201 211 307 321 335 kg 60 66 70 87 91 96 139 145 152 Approximate Ship Weight Ibs 173 185 195 241 251 261 367 381 395 kg 78 84 88 109 114 118 166 173 179 For all installations the flue collar is included with the unit and should be field installed per the instructions included with the unit t Ratings shown are for unit installations at elevations between 0 and 2 000 ft 0 to 610m For unit installations in U S A above 2 000 ft 610m the unit input must be derated 4 for each 1 000 ft 305m above sea level refer to local codes or in absence of local codes refer to the latest edition of the National Fuel Gas Code ANSI Standard Z223 1 N FPA No 54 For installations in Canada any reference to deration at altitudes in excess of 2 000 ft 610m are to be ignored At altitudes of 2 000 ft to 4 500 ft 610 to 1372m the unit mus
38. ion and tag it to prevent unexpected application of power Failure to do so could result in fatal electric shock or severe personal injury A CAUTION Ensure that all power sources conform to the requirements of the unit heater or damage to the unit will result Follow installation instructions CAREFULLY to avoid creating unsafe conditions All wiring should be done and checked by a qualified electrician using copper wire only All gas connections should be made and leak tested by a suitably qualified individual per instructions in this manual Also follow procedures listed on Gas Equipment Start Up Sheet located in this manual Use only the fuel for which the heater is designed see rating plate Using LP gas in a heater that requires natural gas or vice versa will create risk of gas leaks carbon monoxide poisoning and explosion A WARNING Do not attempt to convert the heater for use with a fuel other than the one intended Such conversion is dangerous as it will create the risks previously listed Make certain that the power source conforms to the electrical requirements of the heater A WARNING Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing heater Always disconnect power at main circuit breaker as described above Failure to do so could result in fatal electric shock Special attention must be given to a
39. llowing conversions may be used for calculating SI unit measurements 1 foot 2 0 305 m 1000 BTU cu ft 37 5 MJ m 1 inch 2 25 4 mm 1000 BTU per hour 0 293 kW 1 gallon 3 785 L 1 inch water column 0 249 kPa 1 pound 0 453 kg 1 CFM x 0 472 1 psig 6 894 kPa 1 meter second FPM 196 8 1 cubic foot 0 028m Table 1 Performance and Dimensional Data Tubular Propeller Unit Heater Unit Size 100 125 150 175 200 250 300 350 400 PERFORMANCE DATAT Input BTU Hr 100 000 125 000 150 000 175 000 200 000 250 000 300 000 350 000 400 000 kW 29 3 36 6 43 9 51 2 58 6 73 2 87 8 102 5 117 1 Output BTU Hr 81 000 101 250 121 500 141 750 162 000 202 500 243 000 283 500 324 000 kW 23 7 29 6 35 6 41 5 47 5 59 3 71 2 83 0 95 0 Thermal Efficiency 81 81 81 81 81 81 81 81 81 Free Air Delivery CFM 1 600 2 200 2 400 2 850 3 200 3 450 5 000 5 600 5 800 cu m s 0 756 1 039 1 133 1 346 1 511 1 629 2 361 2 644 2 738 Air Temperature Rise Deg F 47 42 47 46 47 54 45 47 51 Deg C 26 23 26 26 26 30 24 26 28 Full Load Amps at 120V 5 3 5 8 5 8 8 0 8 0 8 0 11 3 13 5 13 5 MOTOR DATA Motor HP Qty 1 10 1 4 1 4 1 3 1 3 1 3 2 1 4 2 1 3 2 1 8 Motor kW 0 080 0 19 0 19 0 25 0 25 0 25 0 19 0 25 0 25 Motor Type SP PSC PSC PSC PSC PSC PSC PSC PSC R P M 1 050 1 140 1 140 1 140 1 140 1 140 1 140 1 140 1 140 Am
40. ned that these substances may cause cancer birth defects or other reproductive harm INSTALLER S RESPONSIBILITY Installer Please Note This equipment has been test fired and inspected It has been shipped free from defects from our factory However shipment and installation problems such as loose wires leaks or loose fasteners may occur It is the installer s responsibility to inspect and correct any problem that may be found RECEIVING INSTRUCTIONS Inspect shipment immediately when ON umm received to determine if any damage has occurred to the unit during d i ERAR L IN shipment After the unit has been HVAC PRODUCTS uncrated check for any visible damage to the unit If any damage is found the consignee should sign the bill of lading indicating such damage and immediately file claim for damage with the transportation company 260 NORTH ELM ST WESTFIELD MA 01085 TEL 413 564 5540 FAX 413 562 5311 www sterlinghvac com MESTEK COMPANY MODELS TF 100 125 150 175 200 250 300 350 400 GF 150 250 400 Please utilize this toll free number to contact your local representative 800 490 2290 TABLE OF CONTENTS SPECIFICATIONS Basic Description 4 4 0222 2 2 Performance amp Specification Data 4 GENERAL SAFETY INFORMATION Installation Codes
41. nless you fully understand the controls GENERAL GAS HEATING With power and gas off With power and gas on L1 Make certain all packing has been removed L1 Inlet gas pressure inW C or kPa o Tighten all electrical terminals and connections L1 Burner ignition L1 Check damper linkages for tightness L1 Manifold gas pressure in W C or kPa 1 Check all fans amp blowers for free movement L1 Cycle on HIGH LIMIT 1 Check all controls for proper settings Cycle firestat and or freezestat Check electronic modulation Set at L1 Cycle and check all other controls not listed 1 Check operation of remote panel 1 Entering air temp F or C Discharge air temp high fire F or C 1 External static pressure in W C Cycle by thermostat or operating control Remarks
42. ny grounding information pertaining to this heater To prevent the risk of electrocution the heater must be securely and adequately grounded This should be accomplished by connecting a ground conductor between the service panel and the heater To ensure a proper ground the grounding means must be tested by a qualified electrician Do not insert fingers or foreign objects into heater or its air moving device Do not block or tamper with the heater in any manner while in operation or just after it has been turned off as some parts may be hot enough to cause injury This heater is intended for general heating applications ONLY It must NOT be used in potentially dangerous locations such as flammable explosive chemical laden or wet atmospheres Do not attach ductwork to this product or use it as a makeup air heater Such usage voids the warranty and will create unsafe operation In cases in which property damage may result from malfunction of the heater a back up system or temperature sensitive alarm should be used A CAUTION The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into confined spaces UNLESS precautions are taken as follows 1 by ventilation of the space 2 control of the purging rate 3 elimination of all hazardous conditions All precautions must be taken to perform this operation in a safe manner Unless otherwise specified the fo
43. of product improvement we reserve the right to make changes without notice 25 IDENTIFICATION OF PARTS PROPELLER UNIT HEATERS Figure 11 Propeller Parts Figure 12 Component Parts Hanger Locations Power Vent Assembly Flue Collector Fan Guard Fan Guard vO 7 AY Motor Electrical Contro Fan Motor Panel Assembly Flame Sensor Baffle Secondary Vestibule Panel Tube Assembly Manifold Burner ssembly n Ale y zz DP T Ignitor Burner Cover Gas Valve Peep Hole Cover Burner D6924A Figure 13 Heat Exchanger Assembly Figure 14 Electrical Control Panel Pressure Switch Pressure Switch Tubing Power Venter Connection Power In Electrical Control Panel Door D6925A Wiring Harness Terminal Block Plate D4785 26 Figure 15 Power Venter Assembly Figure 16 Power Venter Assembly 100 250 Unit Sizes Shown 300 400 Unit Sizes Shown Tinnerman Speed Nuts must be Hose Nipple pushed to this approximate position RS in order to clear blower wheel 7 Locknut Palnut Viet Blower Wheel Ref See detail A Detail A Blower Housing Assembly Blower Wheel Power Venter Assy Machine Screw D4798 Blower Motor Plate Adaptor Self tapping Screw pping Conduit Connecti
44. on Figure 17 Turbulator High Limit Location y Power Venter Assy Turbulator Vestibule Panel Tube Assy Flue Collector Fan Motor Fan Guard Fan D4781 High Limit Ass y HOW TO ORDER REPLACEMENT PARTS Please send the following information to your local representative if further assistance is needed contact the manufacturer s customer service department eModel Number eSerial Number if Part Description and Number as shown in Replacement parts Catalog 27 GAS EQUIPMENT START UP Customer Job Name amp 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 Natural LP Tank Capacity Ibs Rating BTUOG F kg kw X O Are all panels doors vent caps in place O Has the unit suffered any external damage Damage o Does the gas piping and electric wiring appear to be installed in a professional manner Has the gas and electric been inspected by the local authority having jurisdiction Is the gas supply properly sized for the equipment Were the installation instructions followed when the equipment was installed Have all field installed controls been installed o Do you understand all the controls on this equipment If not contact your wholesaler or rep DO NOT START this equipment u
45. or discoloration of adjacent materials AWARNING Make certain that the lifting methods used to lift the heater and the method of suspension used in the field installation of the heater are capable of uniformly supporting the weight of the heater at all times Failure to heed this warning may result in property damage or personal injury A WARNING Make sure that the structure to which the unit heater is to be mounted is capable of safely supporting its weight Under no circumstances must the gas lines the venting system or the electrical conduit be used to support the heater or should any other objects i e ladder person lean against the heater gas lines venting system or the electrical conduit for support Failure to heed these warnings may result in property damage personal injury or death A CAUTION Unit Heaters must be hung level from side to side and from front to back see Figure 3A 3B and 3C Failure to do so will result in poor performance and or premature failure of the unit A WARNING Ensure that all hardware used in the suspension of each unit heater is more than adequate for the job Failure to do so may result in extensive property damage severe personal injury or death Refer to Figures 3A 3B and 3C for suspension of units Figure 3A TUBULAR UNIT HEATERS 100 400 MBH SIZES FLUE COLLAR ADAPTER INSTALLATION INSTRUCTIONS FLUE COLLAR P ADAPTER ea
46. p Power ventor improperly wired Main burner did not light on call for heat Defective control board 1 Check power ventor circuit per wiring diagram 2 Heater is in lockout mode check flash code table for problem 3 No flash codes present along with no call for heat replace control board 22 Table 6 Tubular Propeller Troubleshooting with LED Indicator Assistance No Cycling or appliance power or thermostat call for heat since appliance failure has occured AWARNING Line voltage power can cause product damage severe injury or death Only a trained experienced service technician should perform this trouble shooting 1 Check the system thermo stat to make sure it is call ing for heat Do not cycle the thermostat on and off at this time 2 Remove the appliance burner compartment door Do not interrupt power to the control board by opening any electrically interlocked panels 3 Observe the LED indicator on the control board a greem LED labeled OK indicates system faults check and repair system as noted in the chart to the right NOTICE Air flow proving switch and power ventor hose barbs must be free of any dust or debris at all times Periodically check these openings and or if any problems occur LED STATUS INDICATES CHECK REPAIR Slow Flash Control OK no call for heat Not Applicable Fast Flash Control OK call for heat
47. ps 115V 4 2 4 7 4 7 5 8 5 8 5 8 9 4 11 6 11 6 DIMENSIONAL DATA inches mm A Overall Height to of Flue 33 3 4 33 3 4 33 3 4 33 3 4 33 3 4 33 3 4 34 34 34 857 857 857 857 857 857 864 864 864 B Jacket Width of Unit 20 3 4 20 3 4 20 3 4 32 3 4 32 3 4 32 3 4 50 3 4 50 3 4 50 3 4 527 527 527 831 831 831 1289 1289 1289 C Width to CL Flue 13 3 8 13 3 8 13 3 8 19 3 8 19 3 8 19 3 8 28 3 8 28 3 8 28 3 8 340 340 340 492 492 492 721 721 721 D Depth to Rear of Housing 11 11 11 11 11 11 12 1 4 12 1 4 12 1 4 279 279 279 279 279 279 311 311 311 E Hanging Distance Width 18 5 8 18 5 8 18 5 8 30 5 8 30 5 8 30 5 8 48 5 8 48 5 8 48 5 8 473 473 473 778 778 778 1235 1235 1235 F Discharge Opening Width 18 3 4 18 3 4 18 3 4 30 3 4 30 3 4 30 3 4 48 3 4 48 3 4 48 3 4 476 476 476 781 781 781 1238 1238 1238 Depth to CL Flue 4 3 4 4 3 4 4 3 4 4 3 4 4 3 4 4 3 4 5 1 8 5 1 8 5 1 8 121 121 121 121 121 121 130 130 130 H Discharge Opening Height 24 1 2 24 1 2 24 1 2 24 1 2 24 1 2 24 1 2 24 1 2 24 1 2 24 1 2 622 622 622 622 622 622 622 622 622 L Overall Unit Width 25 1 4 25 1 4 25 1 4 37 1 4 37 1 4 37 1 4 55 1 4 55 1 4 55 1 4 641 641 641 946 946 946 1403 1403 1403 Flue Size Diameter in 5 5 5 5 5 5 6 6 6 Dia mm 127 127 127 127 127 127 152 152 152 Fan D
48. r a lined brick and mortar chimney that has been constructed in accordance with the National Building Code 2 Provide as long a vertical run of flue pipe at the gas unit heater as possible A minimum of 5 feet 1 5m of vertical flue is required The top of the vent pipe should extend at least 2 feet 0 61m above the highest point on the roof Install a weather cap over the vent opening 3 Slope horizontal runs upward from the gas unit heater at least 1 4 inch per foot 21mm m minimum Horizontal runs should not exceed 75 of the vertical height of the vent pipe or chimney above the flue pipe connection up to a maximum length of 10 feet 3m Horizontal portions of the venting system shall be supported at maximum intervals of 4 feet 1 2m See Figure 6 4 Use as few elbows as possible 5 Tape flue pipe joints with high temp RTV or foil face tape 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 Do not damper the flue piping Failure to open such a damper prior to operating the gas unit heater will result in the spillage of flue gas into the occupied space Avoid installing units in areas under negative pressure due to large exhaust fans or air conditioning When required a flue vent fan should be installed in accordance with the instructions included with the fan Vent connectors serving Categor
49. r venter motor is de energized The fan operation is delayed 30 seconds once the thermostat is closed and continues operation for 30 seconds after the thermostat opens NOTICE The start up fan delay must not exceed 30 seconds from a cold start 7 The wall thermostat supplied optionally is a temperature sensitive switch that operates the vent and ignition system to control the temperature of the space being heated The thermostat must be mounted on a vertical vibration free surface free from air currents and in accordance with the furnished instructions also refer to Electrical Section START UP Also refer to lighting instruction plate equipped on the unit 1 Open the manual gas valve in the gas supply line to the unit heater Loosen the union in the gas line to purge it of air Tighten the union and check for leaks A WARNING Never use an open flame to detect gas leaks Explosive conditions may exist which could result in personal injury or death Open the manual valve on the unit heater Turn ON the electrical power The unit should be under the control of the thermostat Turn the thermostat to the highest point and determine that the power venter motor starts and the burners ignite Turn the thermostat to the lowest point and determine that the power venter motor shuts off and the burners are extinguished 5 Turn the thermostat to the desired position 6 See Gas Input Rate and Adjustments sections
50. rafter prove switch 5 Check switch operation to ensure switch closes after draftor purge period If it does not make check tubing connections blockage 6 Loose wiring 6 Check all wiring per diagram 7 Improper ground 7 Check all ground wires and connections 8 Improper thermostat or transformer wiring 8 Check both for wiring according to diagram check for 24V at gas valve terminals during trial for ignition period if present and valve does not open Replace valve H Condensation 1 Improper venting 1 Refer to Installation Venting 2 Unit under fired 2 Check gas supply pressures to unit Refer to Installation 3 Building too cold 3 Refer to Installation 20 Table 6 Tubular Propeller Troubleshooting Guide continued SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION 1 Burners will not shut off Thermostat located incorrectly 2 Improper thermostat wiring 3 Shorted circuit 4 Defective sticking gas valve 5 Excessive gas supply pressure 1 2 3 Relocate thermostat away from outside wall or drafts Check thermostat circuit for open and close on terminal strip on heater R and W Check thermostat circuit for shorts staples piercing wires Check for 24v on gas valve terminals when thermostat is not calling Refer to Installation J Rapid burner cycling 1 Loose electrical connections at thermostat
51. should combustible material be located within the clearances specified in this manual Failure to provide proper clearance could result in personal injury or equipment damage from fire 24 2 Turn off the manual gas valve and electrical power to the unit heater To clean or replace the burners remove burner cover Remove top strip from above burners Lift burners up and pull away from manifold to remove With the burners removed wire brush the inside surfaces of the heat exchanger Remove any dirt dust or other foreign matter from the burners using a wire brush and or compressed air Reassemble the unit heater by replacing all parts in reverse order Check the burner adjustment Check all gas control valves and pipe connections for leaks Check the operation of the automatic gas valve by lowering the setting of the thermostat stopping the operation of the gas duct furnace The gas valve should close tightly completely extinguishing the flame on the burners Inspect and service motor fan assembly To maintain efficient air flow inspect and clean the fan blades and guard to prevent buildup of foreign matter Check lubrication instructions on motor If oiling is required add 3 or 4 drops of electric motor oil as follows a Light Duty After 3 years or 25 000 hours of operation Average Duty Annually after 3 years or 8 000 hours of operation Heavy Duty Annually after 1 year or at least 1500 hours of oper
52. t be derated to 90 of the normal altitude rating and be so marked in accordance with the ETL certification 1 3 8 35 E gt 32 1 2 _ L M Hanging Hanging 11 5 8 826 Flue 295 Hanging 1 H4 IT 4 9 H j H o H U Discharge A gt Opening H H 33 J Ei a 7 Electrical Control Panel Gas Valve F sl La 1 25 Discharge Opening D4617 Rear View Side View Front View DIMENSIONS XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS XXX MILLIMETERS Figure 2 Dimensional Drawing Tubular Propeller Unit Heater 4 INSTALLATION AWARNING Do not install unit heaters in corrosive or flammable atmospheres Premature failure of or severe damage to the unit will result AWARNING Avoid locations where extreme drafts can affect burner operation Unit heaters must not be installed in locations where air for combustion would contain chlorinated halo genated or acidic vapors If located in such an environment premature failure of the unit will occur Since the unit is equipped with an automatic gas ignition system the unit heater must be installed such that the gas ignition control system is not directly exposed to water spray rain or dripping water NOTICE Location of unit heaters is related directly to the selection of sizes Basic rules are as follows MOUNTING HEIGHT Unit Heaters equipped with standard fan guards must be ins
53. t with the manifold pressure of 3 5 inches W C 0 9 kPa Adjustment of the pressure regulator is not normally necessary since it is preset at the factory However field adjustment may be made as follows a Attach manometer at the pressure tap plug adjacent to the control outlet Remove the regulator adjustment screw cap located on the combination gas valve With a small screwdriver rotate the adjustment Screw counterclockwise to decrease pressure or clockwise to increase pressure Replace regulator adjustment screw cap b 2 PROPANE GAS An exact manifold pressure of 10 0 inches W C 2 5 kPa must be maintained for proper operation of the unit heater If the unit is equipped with a pressure regulator on the combination gas valve follow steps a through d above If the unit is not so equipped the propane gas supply system pressure must be regulated to attain this manifold operating pressure The adjusted manifold pressure should not vary more than 1096 from pressure specified in Table 5 Table 5 Main Burner Orifice Schedule TYPE OF GAS NATURAL PROPANE HEATING VALUE 1075 BTU F 2500 BTU F INPUT 40 1 MJ m3 93 1 MJ m N MANIFOLD 22 1000 PRESSURE 3 5 W C 10 W C BURNER BTU 0 87 2 49 ORIFICES FT 93 40 100 ORIFICE DRILL 42 53 FT 116 50 125 ORIFICE DRILL 42 53 9 FT HR 140 60 150 ORIFICE DRILL 42 53 6 16
54. talled at a minimum of 8 feet 2 4m above the floor measured to the bottom of the unit At heights above 8 feet 2 4m less efficient air distribution will result If a unit is to be mounted below 8 feet 2 4m from the floor an OSHA approved fan guard is required on the unit AIRCRAFT HANGARS Unit Heaters must be installed in aircraft hangars as follows In aircraft hangars unit heaters must be at least 10 feet 3 0m above the upper surface of wings or engine enclosures of the highest aircraft to be stored in the hangar and 8 feet 2 4m above the floor in shops offices and other sections of the hangar where aircraft are not stored or housed Refer to current ANSI NFPA No 409 Aircraft Hangars In Canada installation is suitable in aircraft hangars when acceptable to the enforcing authorities PUBLIC GARAGES In repair garages unit heaters must be located at least 8 feet 2 4m above the floor Refer to the latest edition of NFPA 88B Repair Garages In parking structures unit heaters must be installed so that the burner flames are located a minimum of 18 in 457mm above the floor or protected by a partition not less than 18 in 457mm high However any unit heater mounted in a parking structure less than 8 ft 2 4m above the floor must be equipped with an OSHA approved fan guard Refer to the latest edition of NFPA 88A Parking structures In Canada installation must be in accordance to the latest edition of CGA B149
55. y I and Category II heaters shall not be connected into any portion of mechanical draft systems operating under positive pressure HORIZONTALLY VENTED UNIT HEATERS CATEGORY III Horizontal venting arrangements are designed to be used with single wall vent pipe Horizontal venting arrangements must terminate external to the building using either single wall or double wall Type B vent If single wall vent pipe is used it must be constructed of 26 gauge galvanized steel or a material of equivalent durability and corrosion resistance for the vent system For installations in Canada use corrosion resistant and gas tight listed vent pipe conforming with local building codes or in the absence of local building codes with current CAN CGA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CAN CGA B149 2 Installation Codes for Propane Gas Burning Appliances and Equipment See Figures 7 8A and 9A for special installation requirements regarding these venting conditions A WARNING Do not use B double wall vent internally within the building on horizontally vented power vented units If double wall venting is used components which are UL Listed and approved for Category III positive pressure venting systems MUST be used A Breidert Type L Fields Starkap or equivalent vent cap must be supplied by the customer for each power vented unit The vent pipe diameter MUST be as specified in

Sterling TF-150 Gas Heater User Manual

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