Thomas Betts Patio Heater BE User Manual

Model FE and BE

Gas-Fired, Power-Vented

Unit Heaters

INSTALLATION FORM RGM 436 (Version A)

Obsoletes 436-5

APPLIES TO:

Installation/Operation/Service

Table of Contents

Installation and Operation ......................... Par. 1-23 ......... Pages 1-18

Check Installation and Start-Up ................. Par. 24 .............. Page 19

Optional Equipment .................................. Par. 25-31 ....... Pages 20-22

Service/Maintenance/Troubleshooting ..... Par. 32-42 ....... Pages 23-28

Index by Page

Belt Tension ............................................... 16 Electrical Supply and Connections............ 11

Blower/Filter Cabinet (Optional) ...................22 Fan Blade ................................................... 25

Blower Motor ............................................ 16 Fan Control .......................................... 17, 26

Blower Rotation ........................................ 17 Fan Motor .................................................. 16

Blower Speed Adjustment ......................... 17 Gas Piping and Pressures .......................... 10

Bottom Access ........................................... 23 Guard Options (Blower Model) ................ 22

Burners ................................................ 18, 23 Hanger Kits (Optional) ................................ 7

Burner Air Adjustment .............................. 18 Hazard Intensity Levels ............................... 2

Burner Rack Removal ............................... 23 Heat Exchanger ......................................... 25

Carryover, Flash ........................................ 25 Ignition System .................................... 18, 24

Check Installation and Start-Up ................ 19 Installation Codes ........................................ 2

Clearances.................................................... 5 Limit Control ....................................... 17, 26

Combustion Air Proving Switch ............... 18 Locating the Heater ..................................... 5

Combustion Air ....................................... 5, 6 Louvers, Vertical (Optional) ...................... 20

Confined Space Installation......................... 6 Maintenance .............................................. 23

Dimensional Drawings ................................ 3 Maintenance Schedule ............................... 23

Disconnect Switch (Optional) ................... 11 Multiple Heater Control Option ................ 22

Duct Flange (Blower Model Option) ........ 20

Nozzles, Downturn Air (Optional) ............ 20

Optional Equipment .................................. 20

Operating Sequence ................................... 19

Orifices, Burner and Pilot.......................... 25

Pilot ..................................................... 18, 24

Polytube Adapter (Blower Model Option) ..... 21

Service ....................................................... 23

Spark Gap .................................................. 24

Suspending the Unit .................................... 6

Thermostats ............................................... 11

Troubleshooting ......................................... 27

Uncrating and Preparation ........................... 5

Valve, Gas ............................................ 18, 26

Venter Motor and Relay ............................ 26

Venting................................................... 7, 26

Warranty ...................................................... 2

Wiring Diagrams ................................ 12-15

FOR YOUR SAFETY

If you smell gas:

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.

1. Open windows.

2. Don't touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

WARNING: Gas-fired appliances are not

designed for use in hazardous atmospheres

containing flammable vapors or combustible

dust, in atmospheres containing chlorinated

or halogenated hydrocarbons, or in appli-

cations with airborne silicone substances. See

Hazard Levels, Page 2.

GENERAL

Installation should be done by a qualified agency in accordance

with the instructions in this manual and in compliance with all

codes and requirements of authorities having jurisdiction. The

instructions in this manual apply to the unit heater models shown

on the right.

Model

Fuel

Vent

Power Propeller Fan

Centrifugal Blower (heater

Power may be attached to

ductwork)

Air Delivery

WARNING: Improper installation, adjust-

ment, alteration, service, or maintenance can

cause property damage, injury or death. Read

the installation, operation, and maintenance

instructions thoroughly before installing or

servicing this equipment.

Gas-Fired

Gas -Fired

Mfg P/N 98807 Rev 8, Page 1

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3. Dimensions

Fan-Type, Power-Vented Unit Heater

Dimensions (inches)

Size

Nat Pro

29-25/32 13-9/16 27-1/16 31-7/16 5-27/32 14-7/16 14-1/32

29-25/32 15-9/16 27-1/16 31-7/16 5-27/32 14-7/16 14-1/32

29-25/32 17-9/16 30-7/16 31-7/16 5-27/32 14-7/16 14-1/32

29-25/32 23-5/16 30-7/16 31-7/16 5-27/32 14-7/16 14-1/32

39-15/16 20-5/16 35-7/16 35-15/16 4-7/8 19-15/32 15-23/32 5 14-9/32 24 1/2 1/2 11-11/16 4-19/32

39-15/16 23-5/16 36-3/16 35-15/16 4-7/8 19-15/32 15-23/32 5 14-13/32 24 1/2 1/2 11-11/16 4-19/32

39-15/16 28-13/16 36-3/16 35-15/16 4-7/8 19-15/32 15-23/32 5 12-11/32 24 1/2 1/2 11-11/16 4-19/32

39-15/16 28-13/16 36-11/16 35-15/16 4-7/8 19-15/32 15-23/32 6 12-11/32 24 3/4 1/2 11-11/16 3-19/32

10-9/32 16 1/2 1/2 9-13/16

10-17/32 16 1/2 1/2 10-7/16

12-29/32 16 1/2 1/2 10-7/16

14-7/16 16 1/2 1/2 11-9/16

100

125

165

200

250

300

400

2-5/8

39-15/16 37-1/16 37-5/16 35-15/16 4-7/8 19-15/32 15-23/32 6

24 3/4 1/2 11-11/16 3-19/32

Dimensions (mm)

Size

Nat Pro

756

1014

756

344

395

446

592

516

592

732

941

687

773

900

919

932

948

799

913

148

124

367

498

356

399

102

127

152

261

267

328

367

363

366

314

330

406 13 13

610 13 13

610 19 13

249

265

294

297

117

100

125

165

200

250

300

400

Suspension Notes: Use Dimension "G" for two-point suspension and "E" and "F" for four-

point suspension. (Two-point suspension is standard; four-point is op-

tional. Four-point suspension is available either factory or field installed.)

Mfg P/N 98807 Rev 8, Page 3

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3. Dimensions (cont'd)

Blower-Type, Power-Vented Unit Heater

Dimensions (inches)

Size

‚

„

Hanger

Nat

1/2

3/4

Pro

1/2

29-25/32 13-9/16

29-25/32 15-9/16

29-25/32 17-9/16

29-25/32 23-5/16

39-15/16 20-5/16

39-15/16 23-5/16

39-15/16 28-13/16 66-1/2 35-15/16 4-7/8 19-15/32 76-1/8

39-15/16 37-1/16

43-3/8

47-1/2

31-7/16 5-27/32 14-7/16

31-7/16 5-27/32 14-7/16 65-29/32

35-15/16 4-7/8 19-15/32 76-1/8

61-3/8

10-9/32

10-17/32

12-29/32

14-7/16

14-9/32

14-13/32

12-11/32

100

125

165

200

250

300

400

Size

66-1/2 35-15/16 4-7/8 19-15/32 76-1/8

‚

ꢀ

Hanger

31-7/32

35-3/4

36-11/16

3-23/32 20-15/16 17-3/4

2-23/32 20-15/16 17-3/4

1-23/32 20-15/16 17-3/4

1-11/32 20-15/16 17-3/4

2-27/32 25-15/16 25-1/4

1-11/32 25-15/16 25-1/4

5-29/32 40-9/16

6-25/32 50-9/16

5-1/4

7-1/4

10-3/4

12-3/4

14-3/4

20-1/2

17-1/2 11-7/16

20-1/2 11-7/16

8-7/16

14-3/4

20-1/2

6-3/16

7-15/16

9-13/16

10-7/16

11-9/16

100

125

165

200

250

300

400

2-5/8

11-11/16 4-19/32

11-11/16 3-19/32

25-1/4

11-7/16

34-1/4

34-1/4 11-7/16

Dimensions (mm)

Size

„

Nat

Pro

Hanger

367

495

1559

1674

1934

‚

406

610

756

1014

344

395

446

592

516

592

732

914

1102

1270

1207

1549

1689

799

913

148

124

102

127

152

261

267

328

367

363

366

314

330

100

125

165

200

250

300

400

495

Form 436, Page 4

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Size

‚

ꢀ

Hanger

532

481

641

133

184

273

324

375

521

445

521

660

870

214

291

375

521

660

870

157

202

793

908

932

249

265

294

297

532

100

125

165

200

250

300

400

532

659

117

659

150

172

1030

1284

When equipped with optional blower cabinet.

ꢀUse with 4-point suspension with blower cabinet.

‚When equipped with optional duct flange.

†Contactor is standard on Models 300 and 400; optional on other

ƒDimension includes a 3/4" flange on the rear of the blower

cabinet.

„Use with 4-point suspension without blower cabinet. If

installing hanger kit Option CK19, suspension points

change; see Paragraph 8.

sizes.

‡Contactor location with optional three phase motors on Sizes 50,

75, 100 and 125.

ˆDeduct 6-5/8" on Sizes 50, 75, and 100 when equipped with

direct drive motor.

4. Uncrating and Preparation

oMotor Shipping Plate -- Blower models that are equipped with motors

of 3/4 HP or less have a metal shipping plate attached between the

motor and the blower housing. Remove and discard the shipping plate.

Note: On units factory equipped with an optional belt guard, the belt

guard must be removed in order to reach the shipping plate.

This unit was test operated and inspected at the factory prior to crat-

ing and was in operating condition. If the heater has incurred any

damage in shipment, file a claim with the transporting agency.

Check the rating plate for the gas specifications and electrical char-

acteristics of the heater to be sure that they are compatible with the

gas and electric supplies at the installation site. Read this booklet

and become familiar with the installation requirements of your par-

ticular heater. If you do not have knowledge of local requirements,

check with the local gas company or any other local agencies who

might have requirements concerning this installation. Before begin-

ning, make preparations for necessary supplies, tools, and manpower.

Check to see if there are any field-installed options that need to be

assembled to the heater prior to installation. Each of the option pack-

ages includes a list of components and step-by-step instructions. For

a brief description of optional hanger kits, refer to Paragraph 8. For a

brief explanation of other frequently specified field-installed options,

see Paragraphs 25-31. After becoming familiar with the instructions,

assemble and install the options that are required for your heater.

If the heater was ordered with a vent cap shipped with the heater

(Option BT2), packaging depends on the size of the heater. Sizes 25

and 50 have the vent cap mounted on a shipping tube that is attached

to the venter housing. Remove the vent cap; remove and discard the

shipping tube. Sizes 100, 165, 200, 250, 300 and 400 have the vent

cap attached directly to the venter housing. Size 125 is shipped with

the vent cap mounted on the crate near the gas valve. Remove the

vent cap for field installation at the vent terminal.

5. Unit Heater Location

CAUTION: Avoid installing a unit heater in extremely

drafty areas. Extreme drafts can shorten the life of the

heat exchanger and/or cause safety problems.

For best results, the heater should be placed with certain rules in mind. In

general, a unit should be located from 8 to 12 feet above the floor. Units

should always be arranged to blow toward or along exposed wall sur-

faces, if possible. Where two or more units are installed in the same room,

a general scheme of air circulation should be maintained for best results.

Suspended heaters are most effective when located as close to the work-

ing zone as possible, and this fact should be kept in mind when determin-

ing the mounting heights to be used. However, care should be exercised

to avoid directing the discharged air directly on the room occupants.

Partitions, columns, counters, or other obstructions should be taken into

consideration when locating the unit heater so that a minimum quantity

of airflow will be deflected by such obstacles.

When units are located in the center of the space to be heated, the air

should be discharged toward the exposed walls. In large areas, units should

be located to discharge air along exposed walls with extra units provided

to discharge air in toward the center of the area.

Unless the crate bottom has been removed for option installation,

leave it attached until after the heater has been suspended. If the

crate bottom has been removed, the bottom of the heater must be

supported with plywood or appropriately placed boards. Without

adequate support, the bottom access panel could be damaged.

To protect the unit during shipping, the blower model has special

supports that must be removed before installation. Follow these in-

structions to remove:

oBlower Support Legs -- Remove the two blower support legs and

screws.

oMotor Shipping Block - Remove the wooden block located under

the motor bracket. Find the two rubber pads shipped in the in-

struction envelope. Place these pads on the ends of the motor

bracket bolts.

At those points where infiltration of cold air is excessive, such as at en-

trance doors and shipping doors, it is desirable to locate the unit so that it

will discharge directly toward the source of cold air from a distance of 15

to 20 feet.

Units should not be installed closer than 18 inches from any wall.

CAUTION: Do not locate the heater where it may be

exposed to water spray, rain or dripping water.

6. Clearances & Combustion Air

Units must be installed so that the following clearances are provided for

combustion air space, service and inspection, and for proper spacing from

combustible construction.

Mfg P/N 98807 Rev 8, Page 5

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1. Air from inside the building -- openings 1 square inch free area per

1000 BTUH. Never less than 100 square inches free area for each open-

ing. See (1) in Figure 1.

6. Clearances and Combustion

Air (cont'd)

2. Air from outside through duct -- openings 1 square inch free area

per 2000 BTUH. See (2) in Figure 1.

Model

Size

Required Clearances (inches and mm)

Top

Flue

Sides

Bottom

Rear

3. Air direct from outside -- openings 1 square inch free area per 4000

Collector

BTUH. See (3) in Figure 1.

25-400 6"(152) 6"(152) 18"(457) 12"(305) * 24" (610)**

NOTE: For further details on supplying combustion air to a confined

space, see the National Fuel Gas Code ANSI Z223.1a (latest edition ).

* When supplied with optional downturn nozzle, bottom clearance is

42"(1067mm). For service purposes, on standard units, bottom clear-

ance exceeding minimum (12" or 305mm) is not required but may

be desirable.

8. Suspending the Heater

Before suspending the heater, check the supporting structure to be used

to verify that it has sufficient load-carrying capacity to support the weight

of the unit.

** For servicing purposes only, rear must remain full open.

All fuel-burning equipment must be supplied with the air that enters

into the combustion process and is then vented to the outdoors. Suffi-

cient air must enter the equipment location to replace that exhausted

through the heater vent system. In the past, the infiltration of outside

air assumed in heat loss calculations (one air change per hour) was

assumed to be sufficient. However, current construction methods uti-

lizing more insulation, vapor barriers, tighter fitting and gasketed doors

and windows or weather-stripping, and mechanical exhaust fans may

now require the introduction of outside air through wall openings or

ducts.

Net Weight (lbs and kg)

Model

Type

Fan

Size

25 50 75 100 125 165 200 250 300 400

lbs 76 83 92 101 132 154 175 209 226 281

kg 34 38 42

Blower lbs 97 104 118 130 180 206 240 278 301 395

kg 44 47 54 59 82 93 109 126 137 179

95 103 127

NOTE: If the installation includes an optional stepdown transformer

kit (Option CF or CG), the stepdown transformer bracket is part of the

heater suspension and must be installed prior to hanging the heater.

Follow the instructions on the installation sheet included with the op-

tion kit.

The requirements for combustion and ventilation air depend upon

whether the unit is located in a confined or unconfined space. An "un-

confined space" is defined as a space whose volume is not less than 50

cubic feet per 1000 BTUH of the installed appliance. Under all condi-

tions, enough air must be provided to ensure there will not be a nega-

tive pressure condition within the equipment room or space. For spe-

cific requirements for confined space installation, see Paragraph 7.

A fan-type unit heater is equipped with standard two-point suspen-

sion. A 3/8-16 threaded hanger bracket assembly is located on each

side of the heater. If a fan-type unit has been ordered with optional,

factory-installed, four-point suspension (Option BJ6), it will have two

threaded hanger brackets on each side.

WARNING: These power-vented unit heaters are

designed to take combustion air from the space

in which the unit is installed and are not designed

for connection to outside combustion air intake

ducts. Connecting outside air ducts voids the

warranty and could cause hazardous operation.

See Hazard Levels, Page 2.

A blower-type heater is equipped with standard four-point suspen-

sion. Two 3/8-16 threaded hanger bracket assemblies are located on

each side of the unit. Each hanger bracket assembly is designed for

threaded rod attachment.

For both "standard" and "optional" suspension point dimensions, see

Dimension Tables in Paragraph 3. (Note: If installing Option CK19

hanger kit, suspension points change; see Figure 4B.)

WARNING: Suspend the heater only from the

threaded hanger brackets. Do not suspend from

the heater side panel.

When the heater is lifted for suspension, the bottom must be protected.

If the wooden crate bottom has been removed, the bottom of the heater

will have to be supported with plywood or other appropriately placed

material. If the bottom is not supported, the bottom access panel could

be damaged. Also, when lifting a blower unit, support the blower and

motor to prevent the unit from tipping.

7. Combustion Air Requirements

for a Heater Located in a

Confined Space

Do not install a unit in a confined space without providing wall open-

ings leading to and from the space. Provide openings near the floor

and ceiling for ventilation and air for combustion as shown in Figure

1, depending on the combustion air source as noted in Items 1, 2, and

3 below the illustration.

All blower models have legs that support the blower assembly during

Figure 1 -

shipping. After

the unit is sus-

pended, these

legs should be

removed.

Confined Space: A

space whose volume is

less than 50 cubic feet

per 1000 BTUH of the

installed appliance

input rating

Be sure that the

threaded hanger

rods are locked

to the heater as

Add total BTUH of all appliances in the confined space and divide by

figures below for square inch free area size of each (top and bottom)

opening.

Figure 2 -

shown in Figure

Suspension

Form 436, Page 6

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4) Four-Point Swivel Connectors - Option CK10 (See Figure 4A)

This option package is used on a heater that is already equipped with four-

point suspension to adapt it for suspension from four 1", threaded, station-

ary pipes. The kit includes four swivel hanger connector assemblies and

four lock washers.

WARNING: Unit must be level for proper

operation. Do not place or add additional weight

to the suspended heater. See Hazard Levels, page

If an optional downturn air nozzle is used, the unit must be sus-

pended from four points to ensure level suspension. Two hanger

brackets are included in the downturn option package and must

be field-installed on fan-type units with standard two-point sus-

pension. For additional information, refer to Paragraph 26 and

the instructions that are furnished with the option package.

When blower-type units are equipped with an optional blower/

filter cabinet, there are two suspension points on the blower cabi-

net hanger bar. Suspend a unit equipped with a blower/filter cabi-

net from four points, using the two heater hanger bracket assem-

blies closest to the front of the heater and the two suspension

points on the blower/filter cabinet.

5) Special Four-Point Suspension with Nearly Equal Loading (applies

to blower models only) - Option CK19

This suspension option is designed for special applications when a suspen-

sion system is needed that has nearly equal loading at all four suspension

points. Use this option in installations with spring isolation designed for

seismic protection or when threaded rod hangers are longer than twelve

inches.

Suspension points change with the addition of hanger kit Option CK19; see

Figure 4B.

Figure 4B - Suspension Dimensions (inches and mm) for

Model BE Heater with Hanger Kit Option CK19

Size

If one of the optional, field-installed hanger kits has been ordered

for your heater, it will have been shipped separately. Each option

package includes a list of components and complete, step-by-step

assembly instructions.

25-50 11-7/8 (302) 9-1/8 (232)

13-7/8 (352) 11-1/8 (283)

15-7/8 (403) 13-1/8 (333)

21-5/8 (549) 18-7/8 (479)

18-5/8 (473) 15-7/8 (403)

21-5/8 (549) 18-7/8 (479)

27-1/8 (689) 24-3/8 (618)

35-3/8 (897) 32-5/8 (829)

100

125

165

200

250

300

400

Optional, Field-Installed Hanger Kits:

1) Four-Point Suspension (fan models only) - Option CK7

This option kit is designed to convert a fan-type heater from stan-

dard two-point suspension to four-point suspension. The kit con-

tains two additional hanger brackets.

2) Two-Point Swivel Connectors (fan models only) - Option

CK8 (See Figure 3.)

The purpose of this option kit is to adapt the standard hanger

bracket so that the heater can be suspended from 1", threaded,

stationary pipe. The swivel connector screws "into" the threaded

hanger bracket on the heater and "onto" the 1" threaded pipe used

for hanging the heater. The kit includes two swivel hanger con-

nector assemblies and two lock washers.

Figure 3 - Two-

Point Suspension

with Swivel

Connections

(fan models

only)

9. Venting

These power-vented unit heaters are designed to operate safely and effi-

ciently with either a horizontal or vertical vent. (Horizontal vent run is rec-

ommended for maximum fuel savings.)

3) Four-Point with Swivel Connectors (fan-models only) -

Option CK9 (See Figure 4A)

WARNING: Units installed in multiples require

individual vent pipe runs and vent caps. Manifolding

of vent runs is not permitted due to possible

recirculation of combustion products into the

building and possible back pressure effects on the

combustion air proving switch.

This option package is designed to convert a fan-type heater from

standard two-point suspension to four-point suspension with

swivel connectors. By installing this kit the standard fan-type heater

can be hung from four 1", threaded, stationary pipes. The kit in-

cludes two hanger bracket assemblies, four swivel hanger con-

nector assemblies and four lock washers.

Figure 4A - Four-Point Suspension with Swivel

Connections (Applies to both fan

and blower models)

Specific Venting Requirements (read all before

installing)

1. Venter (Flue) Outlet

Venter Outlet Size:

Model Size Outlet Diameter

25-100

125-250

300-400

4" (102 mm)

5" (127 mm)

6" (152 mm)

Mfg P/N 98807 Rev 8, Page 7

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Table 2: Optional Maximum Permissible Vent Lengths

(Requires an increase in vent pipe diameter.)

9. Venting (cont'd)

Venter Outlet Attachment Requirements:

Vent Pipe

Model Diameter

- " (mm)

Maximum

Vent Length*

- ft (m)

Equivalent Straight

Length** - ft (m)

90^oElbows 45^oElbows

•

If the pipe used in the vent run is larger than the diameter of the

venter outlet (See Vent Length Table 2), make the transition at

the venter outlet.

100

165

200

250

300

400

5" (127)

6" (152)

7" (178)

60 ft (18.3 m)

70 ft (21.3 m)

90 ft (27.4 m)

8' (2.4 m)

10' (3.0 m)

12' (3.7 m)

8' (2.4 m)

13' (4.0)

4.0' (1.2 m)

5.0' (1.5 m)

6.0' (1.8 m)

4.0' (1.2 m)

6.5' (2.0 m)

7.0' (2.1)

•

A minimum of 12" of straight pipe is required at the venter

outlet (or transition fitting) before installing an elbow in the

vent system. An elbow should never be attached directly to the

venter. An elbow attached to the straight pipe can be in any

position at or above horizontal. See Figure 5.

14' (4.3)

Figure 5 - Alternate Vent

Directions (vent in any

position above horizontal;

minimum of 12" of straight

*Note 1: If the system contains all vertical pipe or a combination of horizontal

and vertical vent pipe, the Maximum Permissible Vent Length shown in Tables 1

and 2 may be increased one foot for each foot vertical rise up to a maximum

increase of 10 feet for model sizes 25 thru 100 and up to 20 feet for model sizes

125 thru 400.

pipe

**Reduce the maximum vent length by the amount indicated for each elbow.

required

before

4. Vent System Joints

Vent system joints depend on the installation and the type of pipe being

elbow)

used.

•

If using single wall, 26-gauge or heavier galvanized pipe, secure slip-

fit connections using sheet metal screws or rivets. Seal pipe joints ei-

ther with tape suitable for 550^oF (such as Option FA1, P/N 98266) or

high-temperature silicone sealant.

If using Category III vent pipe, follow pipe manufacturer's instructions

for joining pipe sections. When attaching Category III pipe to the ven-

ter outlet or the vent cap, make secure, sealed joints following a proce-

dure that best suits the style of Category III pipe being used.

If using double-wall (Type B) vent pipe (allowed only if 1/2 of the

equivalent vent length is vertical), follow pipe manufacturer's instruc-

tions for joining pipe sections. For joining double-wall pipe to the ven-

ter outlet collar, single-wall pipe, and/or the vent cap, follow the in-

structions below.

2. Vent Pipe

If installed with a horizontal vent run, use either vent pipe approved

for a Category III heater or appropriately sealed 26-gauge galva-

nized steel or equivalent single-wall pipe.

If at least half of the equivalent length of the vent system is verti-

cal, vent pipe approved for a Category I heater may be used. Single-

wall pipe or double-wall (Type B) vent pipe are suitable for use

with a Category I heater.

Use only one of the flue pipe diameters listed in the Vent Length

Tables for the furnace size being installed.

Instructions for attaching double-wall (Type B) vent pipe to the venter out-

let, a single-wall pipe run, or to the vent cap (use these instructions for ei-

ther full length double-wall or terminal only):

Hardware and Sealant Required: 3/4" long sheetmetal screws; and a tube of RTV

1) Look for the "flow" arrow on the vent pipe; attach according to the arrow.

Slide the pipe so that the venter outlet, the single-wall pipe, or the vent cap is

inside the double-wall pipe.

2) Drill a hole through the pipe into the outlet collar, the single-wall pipe, or the

vent cap. (Hole should be slightly smaller than the sheet metal screw being used.)

Using a 3/4" long sheet metal screw, attach the pipe. Do not overtighten. Repeat,

drilling and inserting two additional screws evenly spaced (120^oapart) around

the pipe.

3) Use RTV to seal any gaps. If there is an annular opening, run a large bead of

RTV in the opening. The bead of RTV must be large enough to seal the opening,

but it is not necessary to fill the full volume of the annular area.

2A. Vent Pipe Diameter Reduction

If at least half of the equivalent length of the vent system is verti-

cal, the vent pipe diameter may be reduced one inch from the stan-

dard diameter listed in Vent Length Table 1. Only single-wall pipe

is suitable for use when reducing the pipe diameter. A taper-type

reducer must be used. The maximum allowable vent length remains

the same. If required, double wall pipe may be used at the terminal

end as shown in Figure 6. (Use the equivalent length for elbows as

shown in Vent Length Table 1 for the standard vent pipe diameter.

All elbows used in the vent system must be considered.)

5. Vent System Support

3. Vent Length Tables

Table 1: Maximum Permissible Vent Lengths

Vent Pipe Maximum

Model Diameter Vent Length*

Support lateral runs every six feet, using a non-combustible material such

as strap steel or chain. Do not rely on the heater for support of either hori-

zontal or vertical vent pipe

Equivalent Straight

Length** - ft (m)

6. Condensation

-" (mm)

4"(102)

5"(127)

6"(152)

- ft (m)

90^oElbows 45^oElbows

Single wall vent pipe exposed to cold air or run through unheated areas

must be insulated. Where extreme conditions are anticipated, install a means

of condensate disposal.

100

125

165

200

250

300

400

30 ft (9.1 m)

40 ft (12.2 m)

50 ft (15.2 m)

3.5' (1 m)

5' (1.5 m)

7' (2.1 m)

5' (1.5 m)

9' (2.7 m)

8' (2.4 m)

10' (3.0 m)

1.8' (.5 m)

2.5' (.8 m)

3.5' (1.1 m)

.5' (.8 m)

4.5' (1.4 m)

4.0' (1.2 m)

5' (1.5 m)

7. Vent Terminal (Pipe and Vent Cap)

The vent system must be terminated with a suitable vent cap that is the

same size as the vent run.

Heaters installed in Canada must be equipped with the vent cap sup-

plied as optional equipment by the heater manufacturer (Option CC1 or

Option BT2). Heaters installed in the United States must be equipped

with the heater manufacturer's vent cap, a Type L Breidert Air-x-hauster^®

vent cap, or equivalent. Use of a vent cap supplied by the pipe manufac-

11' (3.4 m) 5.5' (1.7 m)

15' (4.6 m) 7.5' (2.3 m)

Form 436, Page 8

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turer is not permitted; the vent cap must be the type approved for use

with this heater. A different style vent cap could cause nuisance prob-

lems or unsafe conditions.

See the illustrations in Figures 6 and 7 for requirements of both verti-

cal and horizontal vent termination. The vent terminal section may be

either single-wall or double-wall (Type B) vent pipe. If double-wall

pipe is used in the vent terminal with a single-wall vent run, follow the

instructions in No. 4, Vent System Joints, to attach the vent cap and to

connect the double-wall pipe to the single-wall vent pipe run.

Figure 6 - Vertical Vent Terminals

Figure 7 - Horizontal Vent Terminals

Horizontal Vent Terminal Clearances:

Structure

Minimum Clearances for Vent Termination

Location (all directions unless specified)

3 ft (0.9m) above

6 ft (1.8m)

The location of the termination of the hori-

zontal vent system must be in accordance with

National Fuel Gas Code Z223.1. Required

Forced air inlet within 10 ft (3.1m)

Combustion air inlet of another appliance

minimum clearances are listed on the right.

Products of combustion can cause discolora-

tion of some building finishes and deteriora-

tion of masonry materials. Applying a clear

silicone sealant that is normally used to pro-

tect concrete driveways can protect masonry

materials. If discoloration is an esthetic prob-

lem, relocate the vent or install a vertical vent.

Door, window, or gravity air inlet

(any building opening)

4 ft (1.2m) horizontally

4 ft (1.2m) below

3 ft (0.9m) above

Electric meter, gas meter * and relief equipment 4 ft (1.2m) horizontally

Gas regulator *

Adjoining building or parapet

Grade (ground level)

*Do not terminate the vent directly above a gas meter or service regulator.

3 ft (0.9m)

6 ft (1.8m)

7 ft (2.1m) above

Mfg P/N 98807 Rev 8, Page 9

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10. Gas Piping and Pressures

WARNING

This appliance is equipped for a maximum gas

supply pressure of 1/2 pound, 8 ounces, or 14

inches water column. Supply pressure higher

than 1/2 pound requires installation of an

additional service regulator external to the unit.

PRESSURE TESTING SUPPLY PIPING

Test Pressures Above 1/2 PSI: Disconnect the heater and manual

valve from the gas supply line which is to be tested. Cap or

plug the supply line.

Figure 8 - Supply

Piping Connection

Test Pressures Below 1/2 PSI: Before testing, close the manual

valve on the heater.

All piping must be in accordance with requirements outlined in the

National Fuel Gas Code ANSI/Z223.1a (latest edition), published by

the American Gas Association or CAN/CGA-B149.1 and B149.2, pub-

lished by the Canadian Gas Association (See Paragraph 1). Gas supply

piping installation should conform with good practice and with local

codes.

WARNING: All components of a gas supply

system must be leak tested prior to placing

equipment in service. NEVER TEST FOR

LEAKS WITH AN OPEN FLAME. Failure to

comply could result in personal injury, property

damage or death.

Unit heaters for natural gas are orificed for operation with gas having a

heating value of 1000 (+ or - 50) BTUH per cubic ft. If the gas at the

installation does not meet this specification, consult the factory for

proper orificing.

Manifold or Orifice Pressure Settings

Pipe joint compounds (pipe dope) shall be resistant to the action of

liquefied petroleum gas or any other chemical constituents of the

gas being supplied.

Measuring manifold gas pressure cannot be done until the heater is in

operation. It is included in the steps of the "Check-Test-Start" proce-

dure in Paragraph 24. The following warnings and instructions apply.

Install a ground joint union and manual shut-off valve upstream of the

unit control system, as shown in Figure 8. The 1/8" plugged tapping in

the shut-off valve provides connection for supply line pressure test

gauge. The National Fuel Gas Code requires the installation of a trap

with a minimum 3" drip leg. Local codes may require a minimum drip

leg longer than 3" (typically 6").

WARNING: Manifold gas pressure must never

exceed 3.5" w.c. for natural gas and 10" w.c. for

propane gas.

For Natural Gas: Manifold gas pressure is regulated by the combina-

tion valve to 3.5" w.c. Inlet pressure to the valve must be a minimum of

5" w.c. or as noted on the rating plate and a maximum of 14" w.c.

Gas connection sizes are included in the Dimensional Tables in Para-

graph 3. After all connections are made, disconnect the pilot supply at

the control valve and bleed the system of air. Reconnect the pilot line

and leak-test all connections by brushing on a soap solution.

For Propane Gas: Manifold gas pressure is regulated by the combina-

tion valve to 10" w.c. Inlet pressure to the valve must be a minimum of

11" w.c. and a maximum of 14" w.c.

Sizing a Gas Supply Line

C apac ity of P ipin g

C u b ic F eet p er H o u r b as ed o n 0 .3 " w .c. P res s u re D ro p

Sp ecific G rav it y fo r N at u ral G as -- 0 .6 (N at u ral G as -- 1 0 0 0 B T U /C u b ic F t )

Sp ecific G rav it y fo r P ro p an e G as -- 1 .6 (P ro p an e G as -- 2 5 5 0 B T U /C u b ic F t )

Le n g th

o f

D ia me te r o f P ip e

1/2"

3/4"

1-1/4"

1-1/2"

P ip e

2 0 '

3 0 '

4 0 '

5 0 '

6 0 '

7 0 '

8 0 '

9 0 '

1 0 0 '

1 2 5 '

1 5 0 '

1 7 5 '

2 0 0 '

N a tu ra l P ro p a n e N a tu ra l P ro p a n e N a tu ra l P ro p a n e N a tu ra l P ro p a n e N a tu ra l P ro p a n e N a tu ra l P ro p a n e

9 2

7 3

6 3

5 6

5 0

4 6

4 3

4 0

3 8

3 4

3 1

2 8

2 6

5 6

4 5

3 8

3 4

3 1

2 8

2 6

2 4

2 3

2 1

1 9

1 7

1 6

1 9 0

1 5 2

1 3 0

1 1 5

1 0 5

9 6

9 0

8 4

7 9

7 2

1 1 6

9 3

7 9

7 0

6 4

5 9

5 5

5 1

4 8

4 4

3 9

3 6

3 4

3 5 0

2 8 5

2 4 5

2 1 5

1 9 5

1 8 0

1 7 0

1 6 0

1 5 0

1 3 0

1 2 0

1 1 0

1 0 0

2 1 4

1 7 4

1 4 9

1 3 1

1 1 9

1 1 0

1 0 4

9 8

9 2

7 9

7 3

6 7

7 3 0

5 9 0

5 0 0

4 4 0

4 0 0

3 7 0

3 5 0

3 2 0

3 0 5

2 7 5

2 5 0

2 2 5

2 1 0

4 4 5

3 6 0

3 0 5

2 6 8

2 4 4

2 2 6

2 1 4

1 9 5

1 8 6

1 6 8

1 5 3

1 3 7

1 2 8

1 1 0 0

8 9 0

7 6 0

6 7 0

6 1 0

5 6 0

5 3 0

4 9 0

4 6 0

4 1 0

3 8 0

3 5 0

3 2 0

6 7 1

5 4 3

4 6 4

4 0 9

3 7 2

3 4 2

3 2 3

2 9 9

2 8 1

2 5 0

2 3 2

2 1 4

1 9 5

2 1 0 0

1 6 5 0

1 4 5 0

1 2 7 0

1 1 0 5

1 0 5 0

9 9 0

9 3 0

8 7 0

7 8 0

7 1 0

1 2 8 1

1 0 0 7

8 8 5

7 7 5

6 7 4

6 4 1

6 0 4

5 6 7

5 3 1

4 7 6

4 3 3

3 9 7

3 7 2

6 4

5 9

5 5

6 5 0

6 1 0

6 1

N o t e: W h en s iz in g s u p p ly lin es , co n s id er p o s s ib ilit ies o f fu t u re exp an s io n an d in creas ed req u irem en t s .

R efer t o N at io n al F u el G as C o d e fo r ad d it io n al in fo rm at io n o n lin e s iz in g.

Form 436, Page 10

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spring type gauge due to the difficulty of maintaining calibration of a

spring type gauge.

2) Open the valve and operate the heater. Measure the gas pressure to the

manifold. Normally adjustments should not be necessary to the factory

preset regulator.

Before attempting to measure or adjust manifold gas pressure,

the inlet (supply) pressure must be within the specified range for

the gas being used both when the heater is in operation and on

standby. Incorrect inlet pressure could cause excessive manifold

gas pressure immediately or at some future time.

If adjustment is necessary, set pressure to correct settings by turning the regu-

lator screw IN (clockwise) to increase pressure. Turn regulator screw OUT

(counterclockwise) to decrease pressure.

Instructions to Check Manifold Pressure:

1) With the manual valve (on the combination valve) positioned

to prevent flow to the main burners, connect a manometer to

the 1/8" pipe outlet pressure tap in the valve. NOTE: A ma-

nometer (fluid-filled gauge) is recommended rather than a

Consult the valve manufacturer's literature provided with the heater for more

detailed information.

11. Electrical Supply and Connections

All electrical wiring and connections, including electrical ground-

Figure 9B

WARNINGS: On a heater with

ing MUST be made in accordance with the National Electric

Code ANSI/NFPA No. 70 (latest edition) or, in Canada, the Ca-

nadian Electrical Code, Part I-C.S.A. Standard C22.1. In addi-

tion, the installer should be aware of any local ordinances or gas

company requirements that might apply.

Check the rating plate on the heater for the supply voltage and

current requirements. A separate line voltage supply with fused

disconnect switch should be run directly from the main electri-

cal panel to the heater. All external wiring must be within ap-

proved conduit and have a minimum temperature rise of 60^oC.

Conduit from the disconnect switch must be run so as not to

interfere with the service panels of the heater.

The electrical supply connects at the top back of the heater in the

left corner (left when facing the back of the heater). A threaded

hole is provided for a standard 1/2" electrical fitting.

The wiring access panel is easily removed for field connections.

Consult the wiring diagram supplied with your heater. Replace

the panel after the wiring connections are made.

a unit disconnect switch (Option

AI-1), if the power is turned off

at the switch, the supply lead in

the electrical supply junction

box (Figure 9A) remains

energized. If service is to be

done in the supply junction box,

turn off the power at the remote

disconnect switch.

If equipped

with unit-

mounted

disconnect

switch, on/

off toggle

switch is

near access

panel to

electrical

supply

junction

box.

If you turn off the power supply,

turn off the gas.

Circuit

The operating sequence of the heater can be

found on the heater wiring diagram and is pub-

lished in Paragraph 24, Check Installation and

Start-Up. Typical wiring diagrams are on the

next four pages, showing standard single-

stage heating with spark pilot with and with-

out lockout.

breaker

button for

Option AI-1

unit-

If the heater has field-installed options that require electrical con-

nections, consult the instruction sheet and wiring diagram sup-

plied in the option package.

mounted

disconnect

switch

A fan-type heater may be equipped with a built-in fused discon-

nect switch (Option AI-1). If the heater is equipped with a built-

in disconnect switch, a two-position toggle (on/off) switch is

located near the electrical supply access panel (See Figures 9A

and 9B). This switch may be used to disconnect the power when

servicing the heater other than in the supply junction box.

Specific wiring diagrams that include standard and factory-in-

stalled options are included with the heater. Check the wiring

diagram to identify optional equipment.

CAUTION: If any of the original wire as

supplied with the appliance must be replaced, it must be replaced with

wiring material having a temperature rating of at least 105^oC, except for

limit control and sensor lead wires which must be 150^oC. See Hazard

Levels, page 2.

12. Thermostat and Thermostat

Connections

A thermostat is not standard equipment but is an installation requirement.

Use either an optional thermostat available with the heater or a field-supplied

thermostat. Install according to the thermostat manufacturer's instructions.

Make sure that the heat anticipator setting on the thermostat is in accordance

Field Wiring

from Disconnect

in Conduit

with the amperage value noted on the

Figure 10 -

wiring diagram of your heater.

Two Screw

Threaded

Hole for

Standard 1/2"

Fitting

Terminal Strip Connections - The

standard heater is equipped with a two-

screw terminal connector strip (See Fig-

ure 10) for easy connection to the low

voltage controls (24V). When factory-

installed options require two-stage

thermostat control, the heater is

equipped with a SP-ST relay and a

Terminal

Connector

Strip for

24-volt

Wiring

Note: Fan-type

heaters with optional

built-in disconnect

switch, have an on/off

switch located near

the electrical supply

access panel.

Figure 11 -

Four Screw

Remove

Access

Panel to

make

four-screw terminal connector strip

(See Figure 11).

Terminal

Connector

Strip for 24-

Volt Wiring

If your heater requires field instal-

lation of the four-screw terminal

strip and the relay, follow the in-

structions packaged with the relay

or thermostat option.

connections

Figure 9A - Electrical

Connections

(Paragraph 12 continued on page 16.)

Mfg P/N 98807 Rev 8, Page 11

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TYPICAL WIRING DIAGRAMS -- Pages 12 - 15

Field Control Wiring Length and Gauge

CAUTION: If any of the original wire as supplied with

the appliance must be replaced, it must be replaced with

wiring material having a temperature rating of at least

105^oC, except for limit control and sensor lead wires

which must be 150^oC. See Hazard Levels, page 2.

Total Wire

Length

Distance from MinimumRecommended

Unit to Control

Wire Gauge

#18 gauge

#16 gauge

#14 gauge

150' (45.7 m)

250' (76.2 m)

350' (106.7 m)

75' (22.9 m)

125' (38.1 m)

175' (53.3 m)

Fan-Type, Power-Vented Model

with Intermittent Spark Pilot,

Single-Stage Heating,

Natural or Propane

OPERATING SEQUENCE

1. SET THERMOSTAT AT LOWEST SETTING.

2. TURN ON MAIN AND PLOT MANUAL GAS VALVES.

3. TURN ON POWER TO UNIT

4. SET THERMOSTAT AT DESIRED SETTING.

5. THERMOSTAT CALLS FOR HEAT ENERGIZING THE VENTER MOTOR.

6. VENTER PRESSURE SWITCH CLOSES FIRING UNIT AT FULL RATE AFTER PILOT

PROVING SEQUENCE.

7. FAN CONTROL SENSES HEAT EXCHANGER TEMPERATURE, ENERGIZING THE

FAN MOTOR.

8. IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION THE SAFETY SWITCH

CLOSES THE MAIN VALVE AND RECYCLES THE SPARK GAP

ON UNITS EQUIPPED

WITH THE G77ONGC-4 LOCKOUT CONTROL, IF PILOT IS NOT ESTABLISHED WITHIN 120

SECONDS (APPROX.) UNIT LOCKS OUT AND THE UNIT MUST BE RESET BY

INTERRUPTING POWER TO CONTROL CIRCUIT (SEE LIGHTING INSTRUCTIONS).

NOTES

1. THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS:

THERMOSTAT

2. THE FOLLOWING CONTROLS ARE FACTORY INSTALLED OPTIONS:

S/W SWITCH

3. DOTTED WIRING INSTALLED BY OTHERS.

4. CAUTION: IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE APPLIANCE MUST BE

REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING

TEMPERATURE

RATING OF AT LEAST 105 DEGREES C., EXCEPT FOR SENSOR LEAD AND

LIMIT WIRING WHICH MUST BE 150 DEGREES C.

5. USE #18 GA WIRE FOR ALL WIRING EXCEPT FAN MOTOR CIRCUIT

6. LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF

DROPS BEYOND 5% OF SUPPLY LINE VOLTAGE.

SIZE TO PREVENT VOLTAGE

7. ON 230V.

UNITS THE CONTROL TRANSFORMER HAS

DUAL VOLTAGE PRIMARY

FOR 230V

UNITS USE BLACK AND YELLOW LEADS (CAP RED).

UNITS USE BLACK AND RED LEADS (CAP YELLOW).

FOR 208V

ON 115V

UNITS THE CONTROL TRANSFORMER IS

SINGLE VOLTAGE PRIMARY

FOR 115V.

UNITS USE BLACK AND YELLOW LEADS.

8. SEE INSTALLATION INSTRUCTIONS FOR GREATER DETAIL.

FACTORY WIRING

FIELD WIRING

WIRING CODE

BLACK

BROWN

OPTIONAL FACTORY WIRING

WIRE NUT

RED

ORANGE

YELLOW

GREEN

CRIMP TERMINAL

BLUE

PURPLE

WHITE

115/1/60, 208/1/60 OR 230/1/60

(COM)

(HOT)

VENTER MOTOR

VENTER RELA

CONTACTS

GRD

FAN MOTOR

OPTIONAL

S/W SWITCH

FAN CONTROL

LINE VOLT

CONTROL

TRANSFORMER

24V

GROUND TERMINAL

(TERMINAL STRIP)

VENTER RELAY

COIL

GRND.

STRIP

G67BG-5

RECYCLE

G770NGC-4

LOCKOUT

TR OR

PV-MV

IGNITION

CONTROLLER

FLAME SENSING

PROBE

PRESSURE

SWITCH

LIMIT

CONTROL

IGNITOR

GRND

CHASSIS GRND.

TH-TR

OR PV

FE 25-400 OPT.

AH2/AH3 WD #97302 REV #8

Form 436, Page 12

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Blower-Type, Power-Vented Model Sizes 25-100 with

Intermittent Spark Pilot,

Single-Stage Heating,

Natural or Propane,

Direct Drive

Use these Two Motor Wires

Speed

*Medium *Blue and White

Model Size

Low

Red and White

*Black and White

Blue and White

Black and White

*High

Medium

High

*Medium *Blue and White

Low

Red and White

*Black and White

Blue and White

Red and White

*High

Medium

Low

100

*Factory-wired speed

Mfg P/N 98807 Rev 8, Page 13

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Blower-Type, Power-Vented Model Sizes 50-250 with Intermittent Spark Pilot, Single-Stage Heating,

Natural or Propane, Belt Drive (NOTE: Belt drive is standard on Sizes 125-250; optional on Sizes 50-

100.)

Form 436, Page 14

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Blower-Type, Power-Vented Model Sizes 165-400 with Intermittent Spark Pilot, Single-stage

Heating, Natural or Propane, Belt Drive, Motor Contactor (NOTE: Motor contactor is

standard on Sizes 300 and 400; optional on other sizes.

Mfg P/N 98807 Rev 8, Page 15

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12. Thermostat Connections (cont'd)

There are some unique wiring requirements with the installation of the optional controls (relay and two-stage). Figure 12 illustrates the wiring of the

relay and the connections required for optional thermostat control.

575/3/60

Figure 12 - Wiring Diagrams for Optional Controls

Multiple Heater Control - These unit heaters are not designed for multiple unit connection to one thermostat. If you require that more than one unit

be controlled by a single thermostat, it will be necessary to use relays in the circuit. Options CL31 and CL32 provide the necessary parts and

instructions for multiple heater control. For more information on these options, see Paragraph 30.

13. Fan Motor

Fan motors are equipped with thermal overload protection of the auto-

matic reset type. Should the motor refuse to run, it may be because of

improper current characteristics. Make certain that the correct voltage

is available at the motor.

NOTE: If the unit is equipped with an optional totally enclosed motor,

the horsepower may be larger than the standard motor. Refer to the

motor nameplate to verify horsepower.

Figure 13 -

Adjusting Belt

Tension

14. Blower Motor

Blower Model Sizes 25-100 are standardly equipped with a direct drive

motor; an optional belt drive motor is available on Sizes 50-100. Blower

Model Sizes 125-400 have an adjustable belt drive motor.

motor and sealed. No change should be made to starter set unless the

original motor is replaced.

As part of the Check/Test/Start (Paragraph 24), check the belt for proper

tension. Proper belt tension is important to the long life of the belt and

Starters are supplied from the factory for manual reset operation. If an

overload condition is experienced, the condition must be corrected,

and the starter must be manually reset.

motor. A loose belt will cause wear and slippage. Too much tension

will cause excessive motor and blower bearing wear. Adjust the belt

tension by turning the adjusting screw on the motor base until the belt

can be depressed 1/2-3/4". (See Figure 13.) After correct tension is

achieved, re-tighten the locknut on the adjusting screw.

After the installation is complete including all ductwork, the amp draw

of the motor should be checked with an amp meter to verify that the

motor amp rating on the motor nameplate is not being exceeded. Amps

may be adjusted downward by reducing blower speed for by increas-

ing the duct system static pressure. The temperature rise must be within

the range specified on the unit rating plate.

Most blower motors are equipped with thermal overload protection of

the automatic reset type. If a motor is not equipped with thermal over-

load protection, the unit will be equipped with a starter. The adjustable

setting on the starter will be factory set to match the amp draw of the

Form 436, Page 16

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speed, increasing the outlet temperature, turn the adjustable half

of the pulley outward. One turn of the pulley will change the speed

8-10%.

15. Blower Speed Adjustment

The blower speed may be adjusted to achieve the desired outlet tem-

perature, as long as the adjustment is within the temperature rise and

the static pressure limits shown on the heater rating plate. Direct drive

motors are factory set as indicated in the chart below. Belt drive mo-

tors are factory set at the mid-point between maximum and minimum

blower speeds.

5. Tighten the set screw on the flat portion of the pulley shaft.

6. Replace the belt and adjust the belt tension. Adjust tension by turn-

ing the adjusting screw on the motor base until the belt can be de-

pressed 1/2-3/4". (See Figure 13.) Re-tighten the lock nut on the

adjusting screw.

If the duct resistance is low, the blower may deliver too high an air

volume; or if the heater is operated without ductwork, it may deliver

sufficient excess air to overload the motor, causing the overload pro-

tector to cycle the motor. Reducing the blower speed will correct these

conditions. If ductwork is added to an installation, it may be necessary

to increase the blower speed. Decreasing blower speed will increase

outlet temperature; increasing blower speed will decrease outlet tem-

perature.

7. Turn on the gas and electric. Light the heater following the instruc-

tions on the lighting instruction plate.

8. Check the motor amps with an amp meter. The maximum motor

amp rating on the motor nameplate must not be exceeded.

CAUTION: An external duct system static

pressure not within the limits shown on the rating

plate or improper adjustment of the motor pulley

or belt may overload the motor.

Blower Model Sizes 25-100 with Direct

Drive

Direct drive blower motors have multi-speed taps for speed adjust-

ment. If your installation requires an adjustment of the blower speed,

the motor may be re-wired to an alternate tap by following these in-

structions.

16. Blower Rotation

Each blower housing is marked for proper rotation. Rotation may be

changed on single-phase motors by re-wiring in the motor terminal

box. Three-phase motors may be reversed by interchanging two wires

on the 3-phase supply connections.

1. Turn off the gas and the electric power.

2. Remove the left (left when facing the back of the unit) outer side

panel of the heater to reveal the wiring connections.

17. Fan Control

3. Consult the wiring diagram on the heater and follow the below chart

to choose the wire for the desired adjustment. The asterisk(*) indi-

cates the factory-wired speed.

1. A fan control provides the following:

(a) Delay of fan or blower operation to prevent the discharge of

cold air.

(b) Fan or blower operation as long as the unit is hot.

2. The fan control provides additional safety by keeping the fan or

blower in operation in the event that the gas valve fails to close

when the thermostat is satisfied.

3. To be sure that the fan or blower can continue to operate, the power

supply to the heater MUST NOT be interrupted except when ser-

vicing the unit.

4. If the customer wants the heater off at night, the gas valve circuit

SHOULD BE OPENED by a single pole switch wired in series

with the thermostat. Some thermostats are provided with this fea-

ture.

Model Size

Speed

*Medium

Low

Use these Two Motor Wires

*Blue and White

Red and White

*High

Medium

High

*Black and White

Blue and White

Black and White

*Blue and White

Red and White

*Medium

Low

*High

Medium

Low

*Black and White

Blue and White

100

Multiple units controlled from a single thermostat are shut off in the

same manner. For proper operation, be sure the fan control wiring

is observed.

Red and White

4. Cut the crimped cap from the end of the wire that you intend to use

and strip the insulation.

WARNING: If you turn off the power supply,

turn off the gas. See Hazard Levels, page 2.

5. Disconnect the factory-wired connection and re-wire, using the

newly stripped wire.

NOTE: Low ambient temperatures (less than 40^oF) may cause false

cycling of the fan/blower. To prevent this, a time delay relay can be

added to the unit (available with single-stage gas valve only) to acti-

vate the fan/blower electrically independent of the heat exchanger or

the room temperature. The low ambient fan control relay can be fac-

tory installed; Option BF8 will appear on the heater wiring diagram.

Or, the relay can be field installed; order Option CQ3 (P/N 112779).

This relay is in addition to the fan control The fan control is a safety

device and should never be removed from the heater circuit.

6. Put a wire nut on the end of the blower motor wire that was discon-

nected.

7. Replace the heater side panel and turn on the gas and the electric.

Blower Model Sizes 50-400 with Belt Drive

The belt drive on these units is equipped with an adjustable pulley

which permits adjustment of the blower speed. Follow these instruc-

tions to adjust the blower speed.

1. Turn off the gas and the electric power.

18. Limit Control

2. Loosen belt tension and remove the belt.

All models are equipped with an automatic, non-adjustable reset limit

control that acts to interrupt the electric supply to the redundant main

operating valve in case of motor failure or lack of airflow due to re-

3. Loosen the set screw on the side of the pulley away from the motor.

4. To increase the blower speed, decreasing outlet temperature, turn

strictions at the inlet or outlet.

the adjustable half of the pulley inward. To decrease the blower

Mfg P/N 98807 Rev 8, Page 17

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is imposed on that metal probe which is electrically isolated from

ground. When the pilot flame impinges on the flame sensing probe,

the flame acts as a conduction path to ground. The pilot flame recti-

fies and completes the DC circuit. The ignition controller acknowl-

edges the flame and energizes the main gas valve.)

19. Combustion Air Proving

Switch

The combustion air proving switch is a pressure sensitive switch that

monitors air pressure to ensure that proper combustion air flow is avail-

able. The switch is a single pole - normally open - device which closes

when a decreasing pressure is sensed in the outlet duct of the flue gas

collection box.

22. Burners

These unit heaters have individually formed steel burners with accu-

rately die-formed ports to give controlled flame stability without lift-

ing or flashback with either natural or propane gas. The burners are

lightweight and factory mounted in an assembly which permits them

to be removed as a unit for inspection or service.

On start-up when the heater is cold, the sensing pressure is at the most

negative level, and as the heater and flue system warm up, the sensing

pressure becomes less negative. After the system has reached equilib-

rium (about 20 minutes), the sensing pressure levels off.

If a restriction or excessive flue length or turns cause the sensing pres-

sure to become less than the switch setpoint, the pressure switch will

function to shut off the main burners. The main burners will remain off

until the system has cooled and/or the flue system resistance is reduced.

The Table on the right lists the approximate water column negative pres-

sure readings and switch setpoints for sea level operating conditions.

23. Burner Air Adjustment

All sizes of these unit heaters that are equipped with standard alumi-

nized burners are designed to operate without burner air shutters when

fueled with either natural or propane gas. However, Sizes 165 through

400 equipped with optional stainless steel burners (Option AD2) re-

quire air shutters (Option AE1) when used with propane gas (Option

AA2).

Model

Size

Start-Up

Cold

Equilibrium Set Point

"OFF"

Set Point

"ON"

Optional air shutters, either factory or field installed, are available for

any size model for use where unusual conditions cause excess pri-

mary aeration.

25-400 -1.0" w.c.

-0.60" w.c.

-0.47" w.c. -0.64"w.c.

Before making any adjustments to the air shutters, allow the heater to

operate for about fifteen minutes. The air shutter adjustment screws

can be reached by opening the bottom panel. (Remove the two screws

located at the rear of the bottom panel and allow the panel to hinge

down from the front.) The adjustment screws for the air shutters are

visible at the rear of the burner rack . See Figure 14.

DANGER: Safe operation of this unit requires

proper venting flow. NEVER bypass combustion

air proving switch or attempt to operate the unit

without the venter running and the proper flow

in the vent system. Hazardous conditions could

result. See Hazard Levels, page 2.

When making the adjustment, close the air shutters no more than is

necessary to eliminate the problem condition.

Observe the flame for yellow-tipping. A limited amount of yellow-

tipping is permissible for liquefied petroleum gases. Other fuels should

not display any yellow-tipping.

20. Gas Valve

Main operating valve is powered by the 24-volt control circuit through

thermostat and safety controls. The main control valve is of the dia-

phragm type with magnetic pilot servo bleed operators, providing regu-

lated gas flow preset at the factory. The valve body also incorporates a

magnetic valve providing pilot gas control for the electronic ignitor sys-

tem and redundant or dual valve safety shutoff function.

Two adjustment screws are used (See Figure 14). Rotating the screws

clockwise closes the shutters, reducing the primary air supply. Coun-

terclockwise rotation opens the shutters, increasing the primary air

supply. The two adjustment screws should be rotated alternately to

open or close the shutters. Attempting to gain adjustment by not alter-

nating between the two screws may cause the shutters to bind.

WARNING: The operating valve is the prime

safety shutoff. All gas supply lines must be free of

dirt or scale before connecting the unit to ensure

positive closure. See Hazard Levels, page 2.

After proper adjustment has been completed, eliminating the problem

condition, close the bottom panel and replace the retaining screws.

Figure 14 - Air Shutter Adjustment Screws -- Alternate

Turning Screws When Adjusting Shutter

21. Pilot and Ignition System

These unit heaters are equipped with a spark ignited intermittent safety

pilot system that shuts off the pilot gas flow between heat cycles. In

addition, propane units are equipped with a spark pilot system that in-

corporates a lockout device that stops the gas flow to the pilot if the

pilot fails to light in 120 seconds. The spark pilot with 100% lockout

requires manual reset by interruption of the thermostat circuit. Propane

units require the lockout; natural gas units may be equipped with either

standard spark pilot or spark pilot with lockout (Option AH3). Refer to

the wiring diagram with your heater for pilot system identification and

proper wiring.

The ignition controller in the spark pilot system provides the high volt-

age spark to ignite the pilot gas and also acts as the flame safety device.

After ignition of the pilot gas, the control electronically senses the pilot

flame. (A separate solid metal probe in the pilot burner assembly is

employed for the flame sensing function. A low voltage electrical signal

DANGER: Failure to install and/or adjust air

shutters according to directions could cause

property damage, personal injury, and or death.

Form 436, Page 18

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24. Check Installation and Start-Up

Check the installation prior to start-up:

o Check suspension. Unit must be secure and level.

5. Thermostat calls for heat, energizing the venter motor.

6. Venter pressure switch closes, firing the unit, after pilot prov-

ing sequence.

o Blower Model - Check to be sure that all shipping supports

have been removed. Rubber feet must be on the motor bracket

bolts. See Paragraph 4.

7. Fan control senses heat exchanger temperature, energizing

the fan or blower motor.

8. If the flame is extinguished during the main burner opera-

tion, the safety switch closes the main valve and recycles the

spark gap.

o Check clearances from combustibles. Requirements are shown

in Paragraph 6.

o Check vent system to be sure that it is installed according to

On units equipped with lockout device, if the pilot is not es-

tablished within 120 seconds, the unit locks out and must be

reset by interrupting power to the control circuit. (See light-

ing instructions on the heater.)

the instructions in Paragraph 9.

o Check piping for leaks and proper gas line pressure. Bleed

gas lines of trapped air. See paragraph 10.

o Check electrical wiring. Be sure all wire gauges are as rec-

ommended. A service disconnect switch should be used.

Verify that fusing or circuit breakers are adequate for the load

use.

Check installation after start-up:

o With the unit in operation, measure manifold gas pressure.

Manifold pressure for natural gas should be 3.5" w.c. and

10" w.c. for propane gas. See Paragraph 10.

o Check that any field-installed options have been included in

o Turn the unit off and on, pausing two minutes between each

the installation.

cycle. Observe for smooth ignition.

o Blower Model - Check belt tension. See Paragraph 14.

o Blower Model - Check motor amps with an amp meter. The

maximum amp rating on the motor nameplate must not be

exceeded.

Start-Up -- Typical Operating Sequence:

1. Set thermostat at lowest setting.

2. Turn on main and pilot manual gas valves.

3. Turn on the power to the unit.

o Place 'Owner's Envelope" containing Limited Warranty Card,

this booklet, and any optional information in an accessible

location near the heater. Follow the instructions on the enve-

lope.

4. Set the thermostat to desired setting.

DANGER: The gas burner in this gas-fired equipment is designed and equipped to provide safe

and economically controlled complete combustion. However, if the installation does not permit

the burner to receive the proper supply of combustion air, complete combustion may not occur.

The result is incomplete combustion which produces carbon monoxide, a poisonous gas that can

cause death. Safe operation of indirect-fired gas burning equipment requires a properly operating

vent system which vents all flue products to the outside atmosphere. FAILURE TO PROVIDE

PROPER VENTING WILL RESULT IN A HEALTH HAZARD WHICH COULD CAUSE

SERIOUS PERSONAL INJURY OR DEATH.

Always comply with the combustion air requirements in the installation codes and in Paragraphs

6 and 7. Combustion air at the burner should be regulated only by manufacturer-provided

equipment. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION

AIR TO ANY HEATER. Indoor units installed in a confined space must be supplied with air for

combustion as required by Code and in Paragraph 7 of this heater installation manual. MAINTAIN

THE VENT SYSTEM IN STRUCTURALLY SOUND AND PROPERLY OPERATING

CONDITION.

Mfg P/N 98807 Rev 8, Page 19

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OPTIONAL EQUIPMENT

This section contains a brief description of the more frequently specified field-installed options. All option packages include complete assembly

and installation instructions.

25. Optional Vertical Louvers -

Option CD1

26. Optional Downturn Air Nozzles

- Options CD2, CD3, CD4, & CD5

The purpose of the addition of optional vertical louvers is to in-

crease the air pattern spread. The vertical louver assembly is de-

signed to be field assembled and installed. Refer to the instructions

packaged with Option CD1 for a list of components and step-by-

step installation instructions (Do not add optional vertical louvers to

a fan-type heater with downturn nozzle Option CD3. See Paragraph

26.)

Sizes

"A"

Range of

Air Deflection

25-125

9" (229mm)

25^o-65^o

165-400 13" (330mm)

CAUTION: To avoid getting burned, adjust

louvers prior to heater operation. If louvers

need re-adjusting after start-up, wear

protective gloves.

Figure 16 - Optional

Downturn Nozzles

Sizes

"A"

Range of

Air Deflection

Figure 15 -

Optional

Vertical

25-125 16-1/2" (419mm)

165-400 23-1/2" (597mm)

50^o-90^o

Louvers

Unit heaters may be specified with optional downturn air nozzles to direct

the discharge tempered air. The nozzles are shipped separately for field

assembly and installation. The horizontal louvers are removed from the

heater and re-installed into the outlet of the downturn nozzle.

The addition of a downturn nozzle requires four-point heater suspension.

Two hanger brackets are included with downturn nozzle options and must

be added to fan-type heaters with standard two-point suspension. Suspen-

sion point dimensions are found in Dimension Charts in Paragraph 3. On

fan-type heaters, do not install Option CD5 or use vertical louvers with

Option CD3.

27. Optional Duct Flange - Option CD9 (Blower Models only)

Blower-type unit heaters may be connected to ductwork. The duct flange option is designed to adapt

the heater outlet (supply side) for connection to ductwork.

Ductwork connection sizes are shown in the chart below.

Follow the installation instructions included with the option package.

Model BE

Size

Height

Duct Connection Sizes (inches and mm) with Optional Duct Flange

25-50

15-7/8 15-7/8

403 403

10-3/4 12-3/4

273 324

100

15-7/8

403

14-3/4

375

125

165

200

250-300

400

15-7/8 23-7/8 23-7/8 23-7/8 23-7/8

403

20-1/2 17-1/2 20-1/2

521 445 521

606

660

606

34-1/4

870

Width

Form 436, Page 20

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28. Optional Polytube Adapter - Options CD6, CD8, and CD11

(Blower Models only)

The polytube adapter option is designed to adapt this blower-

type heater for use with polytube ductwork. The use of

polytubes for air distribution is common in greenhouse appli-

cations and some industrial applications. A polytube distribu-

tion system delivers warm air to a specific area, reducing the

need for complete area heating. The polytube adapter is avail-

able in three installation designs making it adaptable to many

applications and building structures.

Figure 17 - Polytube Adapter

Illustration shows Option

CD8, Polytube Adapter

for Floor-Mounted

Heater. Options CD6 and

CD11 are for Suspended

Heaters.

WARNINGS: This adapter is to be used

only on units equipped with a blower. At

no time should the free area in the polytube

be less than the listed minimum. Failure to

comply with these warnings could result

in severe personal injury, death and/or

property damage.

The following chart shows specification information covering the use of polytubes with these blower-type unit heaters.

CFM at Polytube M inimum Free

Size .25" Diameter Area (square

Suggested Hole Sizes and Locations

Length of Polytube

Holes

ESP

(inches)

Inches)

50 Ft

75 Ft

100 Ft

125 Ft

150 Ft

Number

37pairs 75 pairs 75 pairs

Diameter 1-1/2"

Spacing 16"

12"

16"

925

110

Number 50 pairs 50 pairs 100 pairs 94 pairs

Diameter 1-1/2"

Spacing 12"

1-1/2"

18"

12"

16"

100 1235

125 1540

130 1600

165 2035

200 2465

250 3085

300 3700

400 4935

145

185

190

240

300

360

425

550

Number 40 pairs 60 pairs 60 pairs 125 pairs

Diameter 1-7/8"

Spacing 15"

1-1/2"

15"

1-1/2"

20"

12"

Number 40 pairs 60 pairs 60 pairs 125 pairs

Diameter 1-7/8"

Spacing 15"

1-1/2"

15"

1-1/2"

20"

12"

Number 50 pairs 50 pairs 75 pairs 75 pairs 75 pairs

Diameter 1-7/8"

Spacing 12"

1-7/8"

18"

1-1/2"

16"

1-1/2"

20"

1-1/2"

24"

Number 42 pairs 42 pairs 60 pairs 60 pairs 100 pairs

Diameter 2-1/4"

Spacing 14"

2-1/4"

21"

1-7/8"

20"

1-7/8"

25"

1-1/2"

18"

Number 40 pairs 60 pairs 60 pairs 60 pairs 60 pairs

Diameter 2-1/2"

Spacing 15"

15"

20"

25"

30"

Number 75 pairs 75 pairs 75 pairs 75 pairs 75 pairs

Diameter

Spacing

12"

16"

20"

24"

Number 60 pairs 60 pairs 60 pairs 100 pairs 100 pairs

Diameter 2-1/2"

Spacing 10"

2-1/2"

15"

2-1/2"

20"

1-7/8"

15"

1-7/8"

18"

The polytube adapter option package does not include polytubing.

Polytubing can be obtained from a supply distributor such as FOF

Products, Inc., P. O. Box E, 1505 Racine Street, Delevan, WI

53115; ACME Engineering Co., P.O. Box 978, Muskogee, OK

74402; or any local greenhouse supply distributor. Some local

code authorities require the polytube material to be a listed mate-

rial. Consult code authority having jurisdiction and the polytube

supplier to determine the appropriate polytube material and rec-

ommended methods of suspension.

Conversion Table (Diameter to Area)

Diameter of the Hole

Area of the Hole

(inches)

2-1/2

2-1/4

(sq in)

4.91

3.98

3.14

1-7/8

1-1/2

2.76

1.76

0.785

Mfg P/N 98807 Rev 8, Page 21

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29. Optional Guards -

Options CD10 & CD12

(Blower Models only)

These guard options are designed to provide complete pro-

tection from the rotating drive and/or blower components.

Option CD12 is designed for use with Sizes 25-100 with

standard direct drive motor. This kit includes only the blower

inlet guard.

30. Optional Multiple Heater Control -

Options CL31 & CL32

The multiple heater control options are designed to permit the control of up to six

heaters (one master and five slave units) with a single thermostat or a time clock

and single/multiple thermostats.

For maximum safety, the multiple control is one in the low voltage circuit. These

multiple heater control options may not be used with two-stage gas valves.

Figure 19 - Multiple Heater Control Wiring with Options CL31

and/or CL32

Option CD10 is designed for use on Sizes 50-400 with a

belt driven motor and includes both the belt guard and the

blower inlet guard.

Figure 18 - Optional Guards

Optional

Belt

Guard

Installed

Optional

Blower Inlet

Guard

Installed

31. Optional Blower/Filter Cabinet -

Options CW1, CW2, or CW3

(Blower Models Only)

The blower/filter cabinet option is available for all sizes. The blower/filter cabi-

net is shipped separately for field assembly and installation. The cabinet is adapt-

able for use with either 1" or 2" filters and may be connected to a return air duct

(includes 3/4" duct flange). Option CW1 does not include filters; CW2 includes

1" permanent aluminum filters; and CW3 includes 2" permanent aluminum

filters.

Model

Size

Filter

Size

Replacement P/N

1" Filter 2" Filter

101608 101621

101609 101622

101610 101623

101607 101620

101608 101621

101609 101622

101610 101623

Qty

25-125

165-200

20 x 20

16 x 25

20 x 25

16 x 20

20 x 20

16 x 25

20 x 25

250-300

400

Figure 20 - Optional Field-Installed Blower/Filter Cabinet

Blower Cabinet with

Filters (Option CW2

or CW3) -- side panel

removed to illustrate

interior of cabinet

Blower Cabinet

without Filters

(Option CW1)

Form 436, Page 22

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visible. Do the

following:

SERVICE AND MAINTENANCE

(a) Disconnect the

pilot tubing from the

pilot burner.

WARNING: If you turn off the power supply,

turn off the gas. See Hazard Levels, page 2.

(b) Disconnect the

flame sensing wire

and high tension

(spark) lead from

the ignition control-

ler.

This unit will operate with a minimum of maintenance. To ensure long

life and satisfactory performance, a heater that is operated under nor-

mal conditions should be inspected and cleaned at the start of each

heating season. If the heater is operating in an area where an unusual

amount of dust or soot or other impurities are present in the air, more

frequent maintenance is recommended.

Flame

Sensor Lead

Pilot

Tubing

Figure 22 - Spark Pilot Location

The following procedures should be carried out at least annually (See

Paragraphs 32-41 for specific instructions.):

1. Clean all dirt and grease from the primary and secondary combus-

tion air openings.

2. Fan Models - Clean the fan blade, fan guard, and motor.

3. Blower Models - Clean the blower, the belt guard, the inlet guard,

and motor of all dirt and grease. Check the blower belt for tension

and wear. Replace a worn belt that may fail before the next sched-

uled maintenance check.

4. Clean the heat exchanger both internally and externally.

5. Check the pilot burner and main burners for scale, dust, or lint ac-

cumulation. Clean as needed.

7A. Heaters manufactured beginning 8/91 (Serial No. Date Code

AQH) - The burner rack is indexed as illustrated in Figure 23. While

supporting the burner rack, remove the screws (two or three) that

hold the burner rack support. (For screw location, refer to Figure

23.) Remove the burner rack support allowing the burner rack as-

sembly to swing down (See Figure 24).

Burner Rack Support

with Indexing

6. Check the vent system for soundness. Replace any parts that do not

appear sound.

7. Check the wiring for any damaged wire. Replace damaged wiring.

(See Paragraph 11 for replacement wiring requirements.)

Burner Rack

Support on units

manufactured

prior to 8/91 was

not indexed

Screws

NOTE: Use only factory-authorized replacement parts.

Figure 23 - Burner Rack Support and Retaining Screws

7B. Heaters manufactured prior to 8/91 (Serial No. Date Code AQH)

Loosen the sheet metal screws (two or three) located at the front of

the burner rack assembly. See Figures 23. These screws retain the

burner rack support. While supporting the burner rack assembly,

slide the burner rack support and remove it from the screws, allow-

ing the burner rack assembly to swing down (See Figure 24).

8. To Remove the Burner Rack -- With the burner rack assembly

"hanging" down, lift up on the rear and slide the assembly up and

out of the manifold support brackets.

32. Burner Rack Removal

These unit heaters have a convenient bottom access panel. The pilot is

attainable with the bottom panel open. With the access panel removed,

the burner rack assembly will hinge down for removal. Use the follow-

ing step-by-step instructions for removal of the bottom access panel

and the complete burner rack assembly.

Instructions for Burner Rack Removal (See

Figures 21-24.)

1. Shut the gas supply off ahead of the combination valve.

2. Turn off electric supply.

3. Remove the two sheet metal screws located at the rear of the bot-

tom panel.

4. Allow bottom

panel to hinge

down from the

front.

Figure 24 -

Burner Rack

Hinged Down

Pilot

Location

5. Push in one of

the two spring-

loaded hinge pins

Push

hinge

located at the

pin to

front of the bot-

remove

tom panel (in-

bottom

side), and com-

panel

pletely remove

the

bottom

panel.

6. The bottom of

Figure 21- Bottom Access Panel Open

the pilot is now

Mfg P/N 98807 Rev 8, Page 23

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moval, Paragraph 32. The pilot can be removed to check the wiring,

the spark gap, or to remove the orifice for cleaning. When the pilot is

re-installed, be sure to include the pilot hole cover plate.

32. Burner Rack Removal (cont'd)

Figure 25

Burner Orifices

Pilot Hole

Cover

Plate

Burner Assembly Support Brackets

Figure 26 -

Figure 28 - Pilot Removal

Burner Rack

Completely

Removed

Spark gap must be maintained to .100". (See Figure 29.)

Figure 29 -

Pilot Burner

Spark Gap

9. To remove the individual burners:

a. Remove the flash car-

ryover (one screw per

burner).

Figure 27 - Individual Burners

In the event the pilot

flame is short and/or

yellow, check the pi-

lot orifice for block-

age caused by lint or

dust accumulation.

b. With the burner rack

upside down, remove

the sheet metal screws

(located at the rear)

that retain the burner

holddown.

c. Lift the rear of the

burner upward slightly

and pull back, remov-

ing the individual

burners.

Figure 30 -

Pilot

Assembly

Remove the pilot ori-

fice and clean with air

pressure. Check and

clean the aeration slot

in the pilot burner.

d. To replace individual burners, reverse the above procedure.

10. To replace the burner rack assembly and the bottom panel, re-

verse the above procedure (Steps 1-8).

CAUTION: Due to high voltage on pilot spark

wire and pilot electrode, do not touch when

energized. See Hazard Levels, page 2.

Individual burners may be cleaned using air pressure. Use an air nozzle

to blow out scale and dust accumulation from the burner ports. Alter-

nately, blow through burner ports and venturi.

The ignition controller of the intermittent electronic ignition pilot sys-

tem is visibly located on the back of the heater. (See Figure 31.) Do not

attempt to disassemble the ignition controller. There are no field re-

placeable components in the control enclosure. However, each heating

season the lead wires should be checked for insulation deterioration

and good connections.

CAUTION: Eye protection is recommended.

Use a fine wire to dislodge any stubborn particles. Do not use anything

that might change the port size.

When any service is completed, be careful to reassemble correctly to

ensure that no unsafe conditions are created. When re-lighting, always

follow the lighting instructions on the heater.

Proper operation of the electronic spark ignition system requires a

minimum flame signal of .2 microamps as measured by a

microampmeter.

33. Pilot and Ignition System

For further information and check out procedure on the intermittent

electronic ignition pilot system, refer to the manufacturer's control op-

erating instructions supplied with the heater.

The pilot can be serviced by opening the bottom access panel of the

heater. Follow the first four steps of instructions for Burner Rack Re-

Form 436, Page 24

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Figure 31

- Ignition

Controller

Location

CAUTION: Eye protection is recommended.

36. Heat Exchanger

The outside of the heat exchanger can be cleaned from the front of the

heater with an air hose and/or a brush. Remove all accumulated dust

and grease deposits.

The inner surfaces of the heat exchanger can be reached for cleaning

with the burner rack removed. (See Paragraph 32.) Cleaning can be

done with a long furnace brush or a heavy wire to which steel wool has

been attached. Brush up and down inside each heat exchanger tube

until all foreign material is removed. A flashlight is helpful in examin-

ing the upper section of the tube.

Ignition

Controller

for Spark

Pilot

37. Fan or Blower

Remove dirt and grease from the motor.

On fan model units, remove dirt and grease from the fan guard and

blades. Use care when cleaning the fan blades to prevent causing mis-

alignment or imbalance. Check that the hub of the fan blades is secure

to the shaft.

34. Burner Orifices

Heaters are shipped with orifices of proper size and type for gas and

altitude specified on the order. When ordering replacement orifices,

give BTUH content, specific gravity of gas, and altitude, as well as

model and serial number of the heater.

On blower models, remove the grease and dirt from the blower hous-

ing and check the belt for wear and proper tension (See Paragraph 14.)

Main Burner Orifices (sea level)

Lubricate if the motor has oil cups or grease fittings. The motor sup-

plied as standard has lifetime lubrication and sleeve bearings.

Model

Size

Natural Gas

Drill Orifice

Propane Gas

Orifice

On blower models, check current draw to motor rating plate.

Qty Drill Size

Qty

Size

P/N

Fan Models: Follow these instructions for replacement of the fan guard,

fan motor or fan blades.

100

125

165

200

250

300

39650

84853

38678

11833

11831

95936

63003

64676

11830

96344

1. If the heater is installed, turn off the gas and disconnect the electric

power.

1.2MM

1.3MM

2. Remove the left outer side panel (left when facing the rear of the

unit). Disconnect the fan motor wires.

3. Depending on the date that the heater was manufactured, it will have

either a lower-half fan guard only, two-piece full fan guard, or a one-

piece full fan guard. If the unit has a two piece fan guard, remove the

tension mounted upper half fan guard and the four screws that hold the

lower half. If the unit has a one-piece fan guard, remove all of the

screws that retain the fan guard. Remove the assembled parts (the fan

guard, the motor and the fan blade).

1.65MM

400

Pilot

Orifice

11831 12 1.65MM

Natural - P/N 103034

Propane - P/N 98695

4. Disassemble and replace whatever parts are needed and reassemble

using whatever part(s) are being replaced and the original parts. If the

fan guard is being replaced, it is important that the same hardware be

used for attaching the motor to the fan guard as was used with the

original guard. These screws are especially made to cut through the

coating on the fan guard to provide adequate grounding for the motor.

WARNING: Do not use this table for gas conversion.

Additional parts are required; contact your Reznor

Distributor.

Fan

Motor

35. Flash Carryover

See Figure 32. The burner carryover system receives its gas supply

from the main burner ports. Check the carryover assembly and also the

main burner ports for cleanliness. Clean with air pressure.

Figure 33 -

Proper Position

of the Fan

Blade on the

Motor Shaft

Fan Hub

Flash

Carryover

Model

Size

Set Screw

Torque In-Lbs

“A” Hub to

Motor

Be sure the fan

blade is in proper

position on the

shaft. Position the

fan as shown in

Figure 33 accord-

ing to the chart on

the right.

80 + or - 10

1-1/4" (32mm)

3/8"(10mm)

Figure 32 -

Burner

Rack Flash

1/8" (3mm)

100-125 120 + or - 10

2-1/2" (64mm)

Carryover

165-400 150 + or - 10

2-1/2" (64mm)

Mfg P/N 98807 Rev 8, Page 25

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37. Fan (cont'd)

38. Venter Motor

Position the assembly on the heater. Attach the fan guard at the center

mounts. (IMPORTANT: If replacing the fan guard, use the screws

that held the original fan guard. These specially designed screws will

cut through the coating on the fan guard to provide a ground for the fan

motor.)

Remove dirt and grease from the motor housing. Power venter motor

is permanently lubricated.

The vent relay controls the venter motor. If the relay contacts fail to

close the venter motor will not run. If the relay contacts fail to open,

the venter motor will not shut off, preventing the combustion air pres-

sure switch from opening.

Rotate the fan blade to check for adequate clearance. If adjustment is

required, loosen the mounting screws, re-position the fan guard, and

tighten the screws. Rotate the fan blade and re-check for adequate clear-

ance. Repeat this procedure until the assembly is positioned properly.

39. Operating Gas Valve

The gas valve requires no field maintenance except careful removal of

external dirt accumulation and checking of wiring connections. Instruc-

tions for testing pressure settings are in Paragraph 10.

5. If necessary, drill the required upper and lower fan guard mounting

holes. Attach the fan guard at all upper and lower mounting points

using either the screws removed or field-installed sheet metal screws.

6. Reconnect the fan motor wires and replace the outer side panel.

CAUTION: The operating valve is the prime

safety shutoff. All gas supply lines must be free

of dirt or scale before connecting to the unit

to ensure positive closure. See Hazard Levels,

page 2.

7. Restore power to the heater and turn on the gas. Light, following the

instructions on the lighting instruction plate. Check for proper opera-

tion.

40. Fan and Limit Controls

If it is determined that the fan or limit control needs replacing, use only factory-authorized replacement parts that are designed for your heater.

Instructions for replacing fan or limit control:

1. Turn off the electric power and shut off the gas supply.

2. Remove the outer left side panel (left when facing the back of the unit). Remove the access panel. (See Figure 34.)

3. Remove defective controls and install new controls in the same mounting holes. Use only factory-authorized replacement parts.

4. Replace access panel and side panel.

5. Turn on the electric power and the gas supply.

6. Relight following the lighting instructions on the heater.

Figure 34 -

Access to

Controls

Limit

Control

Fan

Control

Remove

Control

Access

Panel

41. Vent System

Check the vent system at least once a year. Inspection should include all

joints, seams, and the vent cap. Replace any defective parts.

Form 436, Page 26

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42. Troubleshooting

TRO UB LE

P RO B AB LE C AUS E

REMEDY

Venter motor will

not start

1. No power to unit.

1. Turn on power, check supply fuses, or circuit breaker. If unit is equipped with

unit-mounted disconnect switch, check circuit breaker (See Paragraph 11).

2. Turn up thermostat; check control transformer output.

3. Replace relay.

2. No 24 volt power to venter relay.

3. Venter relay defective.

4. Defective motor or capacitor.

4. Replace motor or capacitor.

Pilot will not light 1. Manual valve not open.

1. Open manual valve.

(spark ignition

system)

2. Air in gas line.

3. Dirt in pilot orifice.

4. Gas pressure too high or too low.

5. Kinked pilot tubing.

2. Bleed gas line.

3. Remove and clean with compressed air or solvent (do not ream).

4. Adjust supply pressure. (See Paragraph 10).

5. Replace tubing.

6. Pilot valve does not open.

7. No spark:

6. If 24 volt available at valve, replace valve.

a) Loose wire connections

b) Transformer failure.

a) Be certain all wires connections are solid.

b) Be certain 24 volts is available.

c) Incorrect spark gap.

c) Maintain spark gap at .100".

d) Spark cable shorted to ground.

e) Spark electrode shorted to ground.

f) Drafts affecting pilot.

d) Replace worn or grounded spark cable.

e) Replace pilot if ceramic spark electrode is cracked or grounded.

f) Make sure all panels are in place and tightly secured to prevent drafts at pilot.

g) Ignition control not grounded.

h) Faulty ignition controller.

g) Make certain ignition control is grounded to furnace chassis

h) If 24 volt is available to ignition controller and all other causes have been

eliminated, replace ignition control.

8. Optional lockout device interrupting control 8. Reset lockout by interrupting control at thermostat.

circuit by above causes.

9. Faulty combustion air proving switch.

9. Replace combustion air proving switch.

Pilot lights, main

1. Manual valve not open.

1. Open manual valve.

valve will not open 2. Main valve not operating.

(Spark Ignition

system)

a) Defective valve.

a) If 24 volt is measured at valve connections and valve remains closed, replace

valve.

b) Loose wire connections.

b) Check and tighten all wiring connections.

3. Ignition control does not power main valve. 3.

a) Loose wire connections.

a) Check and tighten all wiring connections.

b) Flame sensor grounded. (Pilot lights - spark b) Be certain flame sensor lead is not grounded or insulation or ceramic is not

continues)

cracked. Replace as required.

c) Gas pressure incorrect.

c) Set supply pressure at 5" w.c. to 14" w.c. for natural gas and 11" w.c. to 14"

w.c. for propane gas.

d) Cracked ceramic at sensor.

d) Replace sensor.

e) Faulty ignition controller.

e) See Paragraph 33. If all checks indicate no other cause, replace ignition

controller. DO NOT ATTEMPT TO REPAIR IGNITION CONTROLLER.

THIS DEVICE HAS NO FIELD REPLACEABLE PARTS.

1. Check manifold pressure (See Paragraph 10).

2. Check air throughput (See Paragraph 15).

No heat (Heater

O perating)

1. Incorrect manifold pressure or orifices.

2. Cycling on limit control.

3. Improper thermostat location or adjustment. 3. See thermostat manufacturer's instructions.

Cold air delivered 1. Fan control improperly wired

O n Start-up 2. Defective fan control.

1. Connect as per wiring diagram.

2. Replace fan control.

During O peration 3. Incorrect manifold pressure.

Motor will not run 1. Circuit open.

2. Fan control inoperative.

3. Check manifold line pressure (See Paragraph 10).

1. Check wiring and connections. .

2. Replace fan control.

3. Defective motor or capacitor.

3. Replace motor or capacitor.

Motor turns on

and off while

1. Fan control improperly wired.

2. Defective fan control.

1. Connect as per wiring diagram.

2. Replace fan control.

burner is operating 3. Poor contact between fan control and heat

3. Check for bent mounting or loose mounting screws.

(See motor cuts out

on overload

below)

exchanger tube. Surface contact is required.

4. Motor overload device cycling on and off.

5. Low ambient temperature (less than 40^oF)

causing false cycling.

4. Check motor load against motor rating plate. Replace motor if needed.

5. Install fan delay relay kit (See Paragraph 17.)

Fan motor cuts

out on overload

1. Low or high voltage supply .

2. Defective motor.

1. Correct electric supply.

2. Replace motor.

3. Poor air flow.

4. Defective bearing or lubrication.

1. Improper motor pulley and/or adjustment.

3. Clean motor, fan and fan guard.

4. Lubricate bearings or replace motor.

1. See instructions in Paragraph 14.

Blower motor

2. Improper static pressure in the duct system. 2. Adjust duct system dampers.

3. Low voltage. 3. Check power supply.

cuts out on

overload

Mfg P/N 98807 Rev 8, Page 27

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FOR SERVICE OR REPAIR, FOLLOW THESE STEPS IN ORDER:

FIRST:

Contact the installer.

Name

_______________________________________________________________________________________

Address ________________________________________________________________________________________

________________________________________________________________________________________

Phone ________________________________________________________________________________________

SECOND:

Contact the nearest distributor (See telephone Yellow Pages.)

THIRD:

Contact:

REZNOR^®/Thomas & Betts Corporation

150 McKinley Avenue

Mercer, PA 16137

Phone: (724) 662-4400

Model No. ______________________________________________________________________________________________

Unit Serial No. __________________________________________________________________________________________

Date of Installation _______________________________________________________________________________________

Printed in the U.S.A.

Trademark Note: Reznor^®is registered in the United States and other countries. All other trade-

marks are the property of their respective organizations.

MANUFACTURER OF GAS, OIL, ELECTRIC HEATING AND VENTILATING SYSTEMS

999 10M YL Form 436 (Version A.8)

Form 436, Page 28

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