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Thomas & Betts UDAP User's Manual

1. Form RZ NA I UDA Mfg 195673 Rev 5 Page 1 Hazard Levels of Warnings in this Manual 1 General BOTH this manual and the correct venting manual are REQUIRED for installation of this heater 2 Installation Codes Form RZ NA I UDA P N 195673 Rev 5 Page 2 HAZARD INTENSITY LEVELS 1 DANGER Failure to comply will result in severe personal injury or death and or property damage 2 WARNING Failure to comply could result in severe personal injury or death and or property damage 3 CAUTION Failure to comply could result in minor personal injury and or property damage Model UDAP 30 to 125 and Model UDAS 30 to 125 are design certified by the Canadian Standards Association for use in residential industrial and commercial installations Models UDAP 150 to 400 and UDAS 150 to 400 are design certified by the Canadian Standards Association for use in industrial and commercial in stallations only All models and sizes are available for use with either natural or propane gas The type of gas the input rate and the electrical supply requirement is shown on the heater s rating plate Check the rating plate to determine if the heater is appropriate for the intended installation Installation requires both this manual AND the venting manual Venting Manual by Model Venting Instruction Manual by Form No Standard Power Vent Installation each heater has its own dedicated vent Form RZ NA I V PV Look for Matching La
2. to W without causing momentary glitches in the fan blower output The fan remains energized as long as the call for fan remains without a call for heat If a call for heat W occurs during continuous fan the fan blower will de ener gize A call for fan is ignored while in lockout Undesired Flame If flame is sensed longer than 20 seconds while the gas valve is de energized the control shall energize the venter motor and fan blower motor on heat speed When flame is no longer sensed the venter motor will run through postpurge and the fan blower motor will run through the selected heat fan off delay time The control will do a soft lockout but will still respond to open limit and flame The FLAME yellow LED shall flash rapidly when lockout is due to undesired flame Gas Valve Relay Fault If the control senses the gas valve as energized for more than one second when the control is not attempting to energize the gas valve or the gas valve is sensed as not energized when it is supposed to be energized then the control will lockout with green LED off The control assumes either the contacts of the relay driving the gas valve have welded shut or the sensing circuit has failed The venter motor is forced off to open the pressure switch to stop gas flow unless flame is present Form RZ NA I UDA Mfg 195673 Rev 5 Page 21 20 Ignition System cont d Fault Modes cont d Lockout 21 Gas Valve 22 Fan Motor If the
3. Defective venter motor Manual valve not open Air in the gas line O Nn Gas pressure too high or too low 4 No Spark a Loose wire connections b Transformer failure Incorrect spark gap d Spark cable shorted to ground Spark electrode shorted to ground f Burner not grounded g Circuit board not grounded h Unit not properly grounded 1 Integrated circuit board fuse blown j Faulty intergrated circuit board 5 Lockout device interrupting control circuit by above causes 6 Interlock door switch open UDAS only 7 Combustion air proving switch not closing 8 Faulty combustion air proving switch 9 Main valve not operating a Defective valve b Loose wire connections 1 Turn on power check supply fuses or main circuit breaker Turn on built in disconnect switch Model UDAS only replace switch if not operating 2 Turn up thermostat check control transformer output 3 Correct cause Replace fuse type ATC or ATO 32VDC 3A 4 Tighten connections at circuit board and or motor terminals 5 Replace intergrated circuit board 6 Replace venter motor See Paragraph 31 1 Open manual valve 2 Bleed gas line initial startup only 3 Supply pressure should be 5 14 w c for natural gas or 11 14 w c for propane gas 4 a Be certain all wire connections are solid b Be sure 24 volts is available c Maintain spark gap at 1 8
4. Defective integrated circuit board Defective motor or starter Motor overload device cycling on and off Low or high voltage supply Defective motor WN Poor air flow 4 Defective bearing or lubrication 8 9 1 2 3 Improper thermostat location or adjustment 1 2 3 1 Check valve outlet pressure See Rating plate for manifold pressure Check air throughput See thermostat manufacturers instructions Check wiring and connections Replace board Replace motor or starter Nej N po Check motor load against motor rating plate Replace motor if needed 1 Correct electric supply 2 Replace motor 3 Clean motor fan fan guard filter and coils 4 Lubricate bearings motor permitting or replace motor FOR SERVICE OR REPAIR FOLLOW THESE STEPS IN ORDER Contact the Installer Name Address Phone SECOND THIRD Model No Thomas amp 8etts Form RZ NA I UDA P N 195673 Rev 5 Page 36 Contact Unit Serial No Contact the nearest distributor See Yellow Pages If no listing contact Authorized Factory Representative 1 800 695 1901 Press 1 REZNOR Thomas amp Betts Corporation 150 McKinley Avenue Mercer PA 16137 Phone 724 662 4400 Date of Installation 800 695 1901 www ReznorOnLine com 2003 Thomas amp Betts Corporation All rights reserved MANUFACTURER OF HEATING COOLING AND VENTILATING SYSTEMS Printed in the U
5. REZNOR iomasesetts Warnings y E Installation Operation Check Test Startup Maintenance Service Burner Orifice Burner Removal California Warning Label Installation Codes Confined Space UDAP Dimensions meae a Disconnect Built in UDAS Door Switch UDAS Downturn Nozzle Option Electrical Connections a Flame Rollout Switch Gas Piping and Pressures Valve General mee Hanging the Heater Hazard Intensity Levels Heat Exchanger Maintenance Ignition System Limit Control 4 Location Heateo eee 9 IMaintenance Schedule 28 Pressure Switch Combustion Air 675533 Replacement Parts See Form P UD 6 2 26 Suspending Heater es 4 WechnicallData e 6 Thermostat Option d nrowd bleatene mee ree eee 9 o o oO 33 Troubleshooting 34 36 Uncrating and Preparation 3 Valve Outlet Pressure 2 14 Nent System 34 Menter 32 Venting Model UDAP Use Form I V PV Venting Model UDAP CV Use Form I V CV Venting Model UDAS Use Form I V SC Warranty eee Winne sere 23 25
6. only Startup Equilibrium Setpoint Setpoint L abel Switch Cold 2 Color P N Negative Pressure Measured in w c 1 10 1 10 092 075 060 078 LtBlue 197029 097 078 060 078 LtBlue 197029 0 88 units are equipped with a temperature activated auto reset limit control The control is factory set and is non adjustable If the setpoint is reached the limit control will interrupt the electric supply to the gas valve This safety device pro vides protection in the case of motor failure or lack of airflow due to a restriction at the inlet or outlet For location see FIGURE 18 page 31 CAUTION The auto reset limit control will continue to shut down the heater until the cause is corrected Never bypass the limit control hazardous conditions could result See Hazard Intensity Levels page 2 Sizes 30 125 are equipped with a temperature activated manually reset flame rollout switch The flame rollout switch is located at the top of the burner assembly It is factory set and is non adjustable If the setpoint is reached the flame rollout acts to interrupt the electric supply to the gas valve If the flame rollout switch activates identify and correct the cause before resetting the switch Refer to the Mainte nance Section for information on probable causes and instructions on resetting the flame rollout switch For location see FIGURE 18 page 31 DANGER If the manual reset flame rollou
7. 132800 112000 180000 149400 126000 200000 166000 140000 240000 199200 168000 Size 350 184500 153135 132300 210000 174300 129150 205000 170150 Feet 0 2000 0 610 350000 290500 245000 Size 400 400000 332000 280000 2001 3000 611 915 329000 273070 230300 3760001312080 263200 3001 4000 916 1220 322000 267260 225400 368000 305440 257600 4001 5000 1221 1525 315000 261450 220500 360000 298800 252000 5001 6000 1526 1830 308000 255640 215600 352000 292160 246400 6001 7000 1831 2135 301000 249830 210700 344000 285520 240800 7001 8000 2136 2440 294000 244020 205800 336000 278880 235200 8001 9000 2441 2745 287000 238210 200900 328000 272240 229600 9001 10000 2746 3045 280000 232400 196000 320000 265600 224000 147000 252000 209160 176400 143500 246000 204180 172200 BTUH Inputs and Capacities by Altitude in CANADA for Models UDAP and UDAS Normal Tuer Minimum Normal Thermal Minimum Normal Tamal Minimum Normal Tierna Minimum EEE Input Input Input as Input Input Input Input Output Input Capacit Capacit Capacit Capacit Feet Meters Size 30 Size 45 Size 60 Size 75 0 2000 0 610 30000 24600 30000 45000 37350 45000 60000 49800 42000 75000 62250 52500 2001
8. 210 128 320 195 610 372 Note When sizing supply lines consider possibilities of future expansion and increased requirements Refer to National Fuel Gas Code for additional information on line sizing WARNING All piping must be in accordance with requirements outlined in the National Fuel 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 Gas Connection Size Gas Code ANSI Z223 1a latest edition or CAN CGA B149 1 and B149 2 See Paragraph 2 Gas supply piping installation should conform with good practice and with local codes Support gas piping with pipe hangers metal strapping or other suitable material do not rely on the heater to support the gas pipe The heater is orificed for operation with natural gas having a heating value of 1000 x 50 BTUH per cubic ft or propane gas with a heating value of 2500 100 BTUH per cubic ft If the gas at the installation does not meet these specifications consult the factory for proper orificing Pipe joint compounds pipe dope shall be resistant to the action of liquefied petro leum gas or any other chemical constituents of the gas being supplied Install a ground joint union and manual shutoff valve upstream of the unit control system as shown in FIGURE 10 Installation of atrap with a minimum 3 76mm dri
9. IMPORTANT Shipping brackets are attached with cabinet screws When removing shipping brackets re insert ALL screws into the cabinet Form RZ NA I UDA Mfg 195673 Rev 5 Page 3 5 Dimensions M and N Hanger Dimensions for both 2 pt and 4 pt Suspension FIGURE 1 Model UDAP N Power Vented Fan Model R Hanger Dimension for d 1 2 pt Suspension Combustion PandQ p ir Inlet Hanger Dimensions R for 4 pt Thermostat Suspension TOP VIEW Connection 30 125 Vertical 150 400 Horizontal 3 8 16 Female Thread all suspension points K 9 _ Line Voltage Inlet connects at circuit board i Vent Collar see Technical Data for size External Gas Connection 1 1 4 I 32 pci EEEE EAT CAXXYAYXYYT11 E RIGHT SIDE VIEW Access Panel L Iva 3777 T NNNM RENNES UGG REZNOR 26 5 8 26 5 8 150 175 200 225 250 300 350 400 C D E F G H J K M N P 10 13 13 16 26 21 9 16 5 3 16 6 1 2 2 11 16 3 7 8 17 378 11 16 4 5 16 13 9 9716 7 8 13 13 13 16 27 5 8 21 9 16 7 7 8 6 1 2 5 1 2 3 7 8 17 3 8 11 16 4 5 16 13 10 1 2 21 13 13 16 28 5 8 21 9 16 14 1 2 6 1 2 8 3 4 3 7 8 17 3 8 11 16 4 5 16 13 10 1 2 21 13 13 16 29 3 8 21 9 16 8 3 4 3 7 8 17 3 8 11 16 4 5 16 13 10
10. P N 195673 Rev 5 Page 24 FLAME LED SPARK TRANSFORMER CAPACITOR SEE NOTE 7 SPARK GAP WD 185306 REV 2 FIGURE 15C Typical Wiring Diagram for Model UDAP or Model UDAS Two Stage Gas Valve GD 5 1 1 E g K 30 VA LINE 1 60 FACTORY WIRING SYSTEM TRANSFORMER z9 1 Y lt zi 2g c 1 FIELD WIRING 5 d t i OPTIONAL FACTORY EN S NE WIRING a5 5 lt 1 e KZ ra x S8 I 5 WIRE NUT oo p E 25 O E 2 5 Bz F g 8 H g 8 i H i it i g ES 2 SS An 2 ES TE FQ 2 7 1 4 5 p DOOR INTERLOCK or go 1 UDAS ONLY 1 g 1 o 52 RAY M K CAPACITOR 58 111 LED FLASH CODES SEE NOTE 6 1 GREEN LED CRC 1 LIMIT CONTROL STEADY ON NORMAL OPERATION NO CALL FOR HEAT 1 R R FAST FLASH NORMAL OPERATION CALL FOR HEAT ar 1 FLASH IN LOCKOUT FROM FAILED IGNITIONS OR FLAME We 2 FLASH PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS OF VENTER ENERGIZED FLASH LIMIT SWITCH OR ROLLOUT SWITCH OPEN FLAME ROLLOUT 4 FLASH PRESSURE SWITCH IS CLOSED BEFORE MODELS 30 125 ONLY VENTER IS ENERGIZED STEADY OFF INTERNAL CONTROL FAULT OR NO POWER YELLOW LED ALT STEADY FLAME SENSED HONEYWELL HONEYWELL PRESSURE SWION TWO STAGE TWO STAGE SLOWFLASH WEAK FLAME GAS V
11. 11 12 Gas Pipi ng WARNING This appliance is equipped for a maximum gas and supply pressure of 1 2 pound 8 ounces or 14 inches water column Supply pressure higher than 1 2 pound requires installation of Pressures an additional lockup type service regulator external to the unit WARNING 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 Test Pressures Below 1 2 PSI Before testing close the manual valve on the heater Sizi ng Capacity of Piping Gas Cubic Feet per Hour based on 0 3 w c Pressure Drop Specific Gravity for Natural Gas 0 6 Natural Gas 1000 BTU Cubic Ft Supply Specific Gravity for Propane Gas 1 6 Propane Gas 2550 BTU Cubic Ft Li ne Length Diameter of Pipe of 1 2 3 4 1 1 1 4 1 1 2 2 Pipe Natural Propane oy e s 190 116 s 214 730 445 no 2100 1281 T m 50 f ar fios e 63 70 s 9 fisoj f so z6 sso 342 1090 so 43 26 90 55 170 104 350 214 530 990 7 907 Tao a ea 1 o 390195 fao 29 9 1 5 1007 1 34 21 72 44 130 79 275 168 410 250 780 476 150 31 19 64 39 12 73 250 153 232 710 433 175 28 17 5 36 to 67 225 137 350 214 650 397 207 26 16 ss 34 100 61
12. 12 1 16 22 23 42 35 3 8 13 1 16 8 13 16 9 16 2 25 11 16 1 3 8 8 3 16 22 3 16 15 5 8 26 5 8 38 3 16 38 3 16 MODEL UDAP DIMENSIONS mm 2 i A B C D E F G H J K M N P Q R 308 676 254 351 660 548 132 165 68 98 441 17 110 330 243 60 384 676 330 351 686 548 200 165 140 98 441 17 110 330 267 75 384 676 330 351 702 548 200 165 140 98 441 17 110 330 267 100 587 676 533 351 727 548 368 165 222 98 441 17 110 330 267 587 676 533 351 746 548 368 165 222 98 441 17 110 330 267 511 970 406 584 1067 899 216 210 138 165 652 35 208 564 416 664 970 559 584 1067 899 332 224 229 165 652 35 208 564 397 867 1041 762 584 1067 899 433 229 300 186 703 35 208 564 411 FIGURE 2 With Optional Downturn Nozzle Dimension U Applies to UDAP and UDAS Form RZ NA I UDA P N 195673 Rev 5 Page 4 Options CD2 and CD4 inches 100 125 150 175 200 225 250 300 350 400 19 7 8 505 25 U8 638 32 813 both FIGURE 3 Model UDAS Separated Combustion Fan for both 2 pt and 4 pt Suspension Model R Hanger Dimension for Combustion Air Connection 1 2 Pt Suspension see Technical Data for size x EY R Thermostat S Conn
13. 4 0 7 3 22 3 26 4 6 8 5 27 41 22 4 9 9 1 28 0 20 4 3 8 2 262 24 49 8 8 28 3 21 4 6 8 5 28 7 24 5 2 9 4 32 0 20 5 5 11 3 17 3 0 M 4 3 7 3 21 0 32 5 2 8 8 26 6 27 5 2 9 4 27 7 25 4 6 8 2 25 0 30 5 2 9 1 27 4 26 49 8 5 27 1 29 5 5 9 8 31 4 25 6 1 10 7 33 5 21 3 7 M 4 3 7 3 19 5 39 5 5 8 8 25 6 32 5 5 94 26 8 30 4 9 82 23 8 35 5 5 9 1 26 5 31 5 2 8 5 2559 34 5 8 9 8 29 9 30 6 4 11 0 32 9 25 43 M 4 3 6 7 18 0 45 5 5 8 5 24 1 37 5 8 9 1 25 6 34 4 9 7 9 22 3 41 5 5 9 1 25 3 36 5 2 82 24 4 40 6 1 9 8 29 0 34 7 0 10 7 32 0 29 49 M 4 0 6 1 162 51 5 5 8 2 22 6 42 5 8 8 8 24 1 39 4 9 7 3 20 4 47 5 8 8 5 23 8 41 5 2 7 6 22 6 45 6 4 9 4 27 4 38 7 0 10 7 30 8 33 5 5 M 3 4 5 2 13 4 58 5 2 79 20 7 48 5 8 8 5 22 6 44 43 6 7 18 3 53 55 8 2 21 9 46 49 7 3 20 1 51 6 1 9 1 25 9 43 7 0 10 7 26 9 37 Location Locate the heater so that it is a minimum of five feet 1 5M above the floor and in R dati compliance with the clearances in Paragraph 8 ecommenaations WARNING If touched the vent pipe and internal heater surfaces that are accessible from outside the heater will cause burns Suspend the heater a minimum of 5 feet 1 5M above the
14. 4500 611 1373 27000 22140 27000 40500 33615 40500 54000 44820 37800 67500 56025 47250 Feet Meters Size 100 Size 125 Size 150 Size 175 0 2000 105000 120000 100800 150000 124500 105000 175000 145250 122500 2001 4500 611 1373 79380 66150 108000 90720 110250 Feet Size 200 Size 225 Size 250 Size 300 0 2000 0 610 200000 166000 140000 225000 186750 157500 250000 207500 210000 2001 4500 611 1373 180000 151200 126000 202500 170100 141750 225000 189000 157500 270000 226800 189000 Feet Meters Size 350 Size 400 0 2000 0 610 350000 290500 245000 400000 332000 280000 2001 4500 611 1373 315000 264600 220500 360000 302400 252000 Form RZ NA I UDA Mfg 195673 Rev 5 Page 15 13 Burner 14 Electrical Supply and Connections CAUTION Route wires so that they do not contact the flue wrapper or venter housing 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 C except for limit control flame rollout and sensor lead wires which must be 150 C See Hazard Levels page 2 FIGURE 12 Supply Wiring Connections at the Circuit Board DSI Integrated Control Module 24V Control Wiring Connections 15 Thermostat and Connections This heater has a one piece CO RE burner assembly patent pending designed
15. Fan Motor RPM 1050 1050 1050 1050 1050 1050 1050 1050 Fan Diameter inches 18 18 18 20 20 24 24 24 Sound Level dba 15 ft 51 52 53 56 56 59 61 62 CSA ratings for altitudes to 2000 ft Size show C co Se Smaller and or larger vent and combustion air pipe diameters may be nis for gas connection to a single stage gas valve not supply line size permissible For Model UDAS refer to the Venting Installation Manual for Separated Combustion Units For Model UDAP refer to the Venting Installation Manual for Power Vented units For a Model UDAP with Option AV6 refer to the Venting Installation Manual for Common Venting P MOCP 2 25 x largest motor FLA smallest motor FLA Answer is rounded to the next lower standard circuit breaker size All other information is this table is based on a heater equipped with a standard 115 volt open fan motor Form RZ NA I UDA P N 195673 Rev 5 Page 6 T H ig h Altitude If the heater is being installed at an elevation above 2000 ft 610M the input rate will have to derated This is done by adjusting the valve outlet pressure O perati on In addition if the heater is being installed at an altitude above 6000 ft 1830M the pressure switch will have to be changed If ordered with the unit as Option DJ20 or DJ21 the pressure switch is shipped separately Gas valve adjustment for high altitude can only be done after heater is operating see Paragraph 12 Adjusting
16. Switch UDAS only Fan Motor Burner Assembly 0 Terminal Board 24V Disconnect Switch UDAS only iR Electrical Box UDAS only Remove cover to connect pt Transformer Circuit Board 29 Ignition System FIGURE 19 DSI Integrated Control Module Circuit Board lt Sizes 30 125 Transformer supply and access n4 4 disconnect switch wires Always replace cover Control Panel Assy located on the Control Compartment Pressure Switch Bottom P Sizes 150 400 eae MAS ie Mu Capacitor Circuit Board DSI Integrated Optional DSI Integrated Fan Motor Control Module Cap Control Module _ DSI Integrated Control Module circuit board See FIGURE 19 The module monitors the operation of the heater including ignition The only replaceable com ponent is the 3 amp Type ATC or ATO fuse If the fuse is blown the problem is most likely an external overload Correct the problem and replace the fuse Do not attempt to disassemble the control module However each heating season check the lead wires for insulation deterioration and good connections Proper operation of the direct spark ignition system requires a minimum flame signal of 1 0 microamps as measured by a microampmeter For further information and check out procedure on the direct sp
17. WARNING Gas fired appliances are not designed for use in V3 Series Fan Type Unit Heaters Installation Operation FORM RZ NA I UDA L nr FOR YOUR SAFETY bes to do if you smell gas Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call your fire department FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WARNING Improper installation adjustment 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 hazardous atmospheres containing flammable vapors or combustible dust in atmospheres containing chlorinated or halogenated hydrocarbons or in applications with airborne silicone substances See Hazard Levels page 2 WARNING Should overheating occur or the gas supply fail to shut off shut off the manual gas valve to the appliance before shutting off the electrical supply WARNING Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and replace any gas control that has been under water
18. air change per hour was assumed to be sufficient However current construction methods using more insu lation vapor barriers tighter fitting and gasketed doors and windows weather stripping and or mechanical exhaust fans may now require the introduction of outside air through wall openings or ducts The requirements for combustion and ventilation air depend upon whether the unit is located in a confined or unconfined space An unconfined space is defined as aspace whose volume is not less than 50 cubic feet per 1000 BTUH of the installed appliance Under ALL conditions enough air must be provided to ensure there will not be a negative pressure condition within the equipment room or space WARNING Model and UDAP CV 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 Do not install a unit in a confined space without providing wall openings leading to and from the space Provide openings near the floor and ceiling for ventilation and air for combustion as shown in FIGURE 5 depending on the combustion air source as noted in Items 1 2 and 3 below 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 openi
19. are created When re lighting always follow the lighting instructions on the heater i Maintenance Schedule The following procedures should be carried out at least 2 9 nte nance annually See FIGURE 18 and Paragraphs 26 39 Sch edule e Clean all dirt lint and grease from the combustion air opening UDAP and venter assembly e Clean all dirt lint and grease from the fan blade fan guard and motor NOTE If replacement Check the heat exchanger both internally and externally parts are required Check the burner for scale dust or lint accumulation Clean if needed use only factory authorized Check the vent or vent combustion air system for soundness Clean openings parts Replace any parts that do not appear sound Check the wiring for any damaged wire Replace damaged wiring See Para graph 14 for replacement wiring requirements Form RZ NA I UDA P N 195673 Rev 5 Page 28 26 Heat This heater is equipped with a TCORE heat exchanger patent pending Remove any external dirt or dust accumulation Visually check the heat exchanger Exchanger y y cna 9 for cracks and holes If a crack or hole is observed replace the heat exchanger Maintenance NOTE Inspection of the lower portion of the heat exchanger is done with the burner removed See the Burner Service section below for information on inspect ing the lower portion of the heat exchanger 27 Burner This heater is equipped with a TCORE bu
20. cooled and or the flue system resistance is reduced Form RZ NA I UDA Mfg 195673 Rev 5 Page 17 16 Combustion Air Proving Switch cont d Pressure Switch Settings uu Mies pey Label Switch 2 Color P N Negative Pressure Measured in w c The two Tables on the left below list the approximate water column negative pres sure readings and switch setpoints for sea level operating conditions for Model UDAP and Model UDAP CV heaters The Table on the right lists the approximate water column differential pressure readings and switch setpoints for sea level op erating conditions for Model UDAS heaters 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 Differential Pressure Measured in w c 30 45 60 75 60 110 085 065 083 Yellow 197028 200 225 250 300 2 30 160 350 400 260 180 140 160 Red 201159 100 0 85 0 72 0 50 0 68 Orange 196388 100 0 85 0 72 0 55 0 73 White 196362 125 0 75 0 60 0 40 0 58 Green 197030 125 0 75 0 60 0 45 0 63 Pink 197032 150 175 0 75 0 65 0 40 0 58 Green 197030 150 175 0 75 0 60 0 40 0 58 Green 1197030 Model UDAP CV with Opt AV6 30 45 60 75 100 17 Limit Control 18 Flame Rollout Switch Sizes 30 125
21. gas valve was sensed as closed when it should be open and has not de energized after the venter motor was shutoff for 15 seconds then the venter motor is re energized to vent the unburned gas Soft Lockout The control shall not initiate a call for heat or call for continuous fan while in lockout The control will still respond to an open limit and undesired flame Lockout shall automatically reset after one hour Lockout may be manually reset by removing power from the control for more than one second or removing the thermostat call for heat for more than one and less than 20 seconds Hard Lockout If the control detects a fault on the control board the status LED will be de energized and the control will lockout as long as the fault remains A hard lockout will automatically reset if the hardware fault clears Power Interruption During a momentary power interruption or at voltage levels below the minimum operating voltage line voltage or low voltage the system will self recover without lockout when voltage returns to the operating range Power interruptions of less than 80mS shall not cause the control to change operat ing states Power interruptions greater than 80mS may cause the control to inter rupt the current operating cycle and re start The main operating gas valve is powered by the 24 volt control circuit through the thermostat and safety controls The main control valve is of the diaphragm type providing regulated gas fl
22. hub of the fan blades is secure to the shaft Follow these instructions for replacement of the fan guard fan motor and or fan blades 1 If the heater is installed turn off the gas and disconnect the electric power 2 Open the access door and disconnect the fan motor wires capacitor wires at the capacitor and ground screw 3 Remove the assembled parts the fan guard the motor and the fan blade 4 Disassemble and replace whatever parts are needed and reas semble using whatever part s are being replaced and the original parts Be sure the fan blade is in the proper position on the shaft refer to the illustration and table in FIGURE 21 Position the assembly on the heater Attach the fan guard 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 ad equate clearance Repeat this procedure until the assembly is posi tioned properly 5 Reconnect the fan motor wires according to the wiring diagram and close the access panel Restore power to the heater and turn on the gas Light following the instructions on the lighting instruction plate Check for proper operation ON Remove dirt and grease from the motor casing the venter housing and the venter wheel Venter motor bearings are permanently lubricated Follow these instruc tions for replacement of the venter motor and
23. on the integrated circuit board The circuit board See FIGURE 12 is located inside on the bottom of the control compartment The circuit board is polarity sensitive It is advisable to check the electrical supply to be certain that the black wire is the hot wire and that the white wire is the neutral wire The supply connection made to L1 on the circuit board must be the hot wire 1097 83 210X MSCI SEC MODEL 1097 210 C POO ja Spark Transformer NEUTRALS Supply Wiring Connections NOTE Circuit board is polarity sensitive hot wire must be connected to Terminal L1 000 e 0000 0 m D g o LA 0 a e 0 For all models the terminal strip for 24 volt thermostat connections is located on the outside of the cabinet at the back of the heater See FIGURE 13 Wires from the terminal strip are factory wired to the circuit board Use either an optional thermostat available with the heater or a field supplied 24 volt thermostat Install according to the thermostat manufacturer s instructions pay ing particular attention to the requirements regarding the location of the thermo Stat Form RZ NA I UDA P N 195673 Rev 5 Page 16 Make sure that the heat anticipator setting on the thermostat is 0 6 amps or in accordance with the amperage value noted on the wiring diagram of your heate
24. operated and inspected at the factory prior to crating and was in operating condition If the heater has incurred any damage in shipment document the damage with the transporting agency and contact an authorized Reznor Dis tributor If you are an authorized Distributor follow the FOB freight policy proce dures as published by Thomas amp Betts for Reznor products Check the rating plate for the gas specifications and electrical characteristics 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 particular 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 beginning make preparations for necessary supplies tools and manpower Ifthe installation includes optional vertical louvers downturn nozzle ceiling mount ing bracket hanger kit high altitude kit multiple heater control and or stepdown transformer install these options before the heater is suspended Follow the in structions included in the option package option packages are shipped separately Other shipped separate items could include a vent combustion air kit high tem perature tape a thermostat bracket kit a thermostat and or a thermostat guard Be sure all options ordered are at the installation site
25. part has been under water Imme diately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Operating 1 Set thermostat at lowest setting Instructions and 2 Turn off all electric power to the appliance Operating Seq uence 3 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Open the access door and locate the gas control ON OFF knob on the gas valve See FIGURE 16 Form RZ NA I UDA P N 195673 Rev 5 Page 26 FIGURE 16 Gas Valve 4 Turn the gas control knob clockwise to OFF ON OFF Control Knob 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP and follow the steps in the WARNINGS printed above or on the Operating Label on the heater If you do not smell gas proceed to the next step Turn the gas control knob counterclockwise to ON Top View ie Close the access door Gas Control Knob shown in the 6 7 8 Turn on the electric power to the heater 9 Set the thermostat to the desired setting ON position NOTE If the appliance does not operate follow the instructions To Turn Off Gas to Appliance printed below and on the Operating Label on the heater and call your service technician 10 Thermostat calls for heat energizing the venter motor 11 Vente
26. sum mer exhaust fan Close fireplace dampers 4 Light the heater following the lighting instructions Adjust the thermostat for continued operation Verify that combustion products are venting properly After determining that the heater vents properly return doors windows exhaust fans and fireplace dampers to their previous conditions If improper venting is observed the venting system must be corrected With the unit in operation measure valve outlet gas pressure If operated at high altitude adjust outlet gas pressure for altitude See information and instructions in Paragraph 12 Form RZ NA I UDA Mfg 195673 Rev 5 Page 27 24 Sta rtu Turn the unit off and on pausing two minutes between each cycle Observe for smooth ignition cont d Place the Owner s Envelope containing the Limited Warranty this booklet and any control or optional information in an accessible location near the heater Follow the instructions on the envelope DANGER The gas burner in this gas fired equipment is designed and equipped to provide safe 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 that vents all flue prod
27. the valve outlet pressure is done after the heater is in operation follow the instructions in Paragraph 12 Capacities and inputs for derated units are also listed in Paragraph 12 If the pressure switch needs to be changed do that before the heater is operated follow the instructions in FIGURE 4 FIGURE 4 Installing High Altitude Pressure Switch required above 6000 ft 1830M elevation Model UDAP 30 4s 60 75 100 125 150 175 200 225 250 300 350 400 tion AV6 for Common Venting 4 60 75 100 Negative Pressure OFF Setpoint w c 060 045 0 55 0 50 Label color Model UDAS a Size 150 175 200 225 250 300 350 400 igh Altitude Switch P N Tae 196388 197030 197031 201160 201161 Differential Pressure OFF Setpoint w c 060 050 040 035 10 f 130 Label color Brown Instructions for Changing Pressure Switch 1 In the control compartment locate the pressure switch Sizes 30 125 On the back wall of the control compartment Sizes 150 400 On the bracket on the bottom of the control compartment Mark and disconnect the two wires attached to the pressure switch Disconnect the sensing tube from the pressure switch Locate the two screws holding the switch mounting bracket Remove the Pressure Switch screws save screws and the pressure switch Using the same screws install the high altitude pressure switch Attach the sensing tube and wires 8 ea
28. wheel assembly Keep all hardware removed to be used in re assembling and installing the replacement parts 1 Turn off the gas and disconnect the electric power 2 Open the burner control compartment access panel 3 Disconnect the three venter motor wires at the DSI control capacitor wires at the capacitor if applicable and ground screw located on the control panel 4 Sizes 30 and 45 Disconnect the gas train and move it out of the way Discon nect the gas supply at the union outside of the cabinet At the gas valve mark and disconnect the wires Carefully remove the burner orifice and orifice adapter locking nut Slide the orifice adapter out through the bracket on the burner push ing the gas train to the right This will move the gas train out of the way Form RZ NA I UDA P N 195673 Rev 5 Page 32 5 Holding the venter motor remove the three or four screws that attach the venter motor mounting plate to the venter housing Remove the motor and wheel as sembly from the heater 6 Re assemble with the replacement venter motor and wheel assembly See FIG URE 22 7 Follow the wiring diagram to connect the venter wires 8 Sizes 30 and 45 Reconnect the gas supply at the union outside of the cabinet Leak test the connection with leak detecting solution 9 Replace the access panel Restore power to the heater and turn on the gas Light FIGURE 22 Venter Wheel following the instructions on the lighting instruction plate
29. when the switch resets Operate the furnace If the flame rollout switch trips again determine and correct the cause before reset ting the switch If there is damage to the control compartment repairs must be made before resetting the switch If it is determined that the flame rollout switch needs replacing use only the fac tory authorized replacement part that is designed for that size of heater For location see FIGURE 18 page 31 The disconnect switch is located in the sealed electrical box inside the con trol compartment with the toggle on the rear of the heater If it is determined that the disconnect switch needs replacing use only the factory authorized replacement part that is designed for the heater Always replace electrical box cover 38 Disconnect Switch UDAS only 39 Vent or Vent Combustion Air System Check the complete system at least once a year Inspection should include all joints seams concentric adapter box UDAS inlet air guard or inlet air cap UDAS and the vent terminal cap Clean openings Replace any defective parts 40 Troubleshooting Is there a spark across gap at DSI Integrated Control Module Circuit Board Trial YES NO Troubleshooting igni
30. 0V MODELS 100 400 UDAP amp UDAS SERIES 30 VA FACTORY WIRING SYSTEM TRANSFORMER E E FIELD WIRING _ OPTIONAL FACTORY WIRING gt WIRE NUT et BR 115 208 230 TERMINAL STRIP PR FUSE DOOR INTERLOCK UDAS ONLY R R 1 LED FLASH CODES GREEN LED 2 LINE 1 60 BK DISCONNECT SWITCH UDAS ONLY BK CAPACITOR SEE NOTE 6 LIMIT CONTROL STEADY ON NORMAL OPERATION NO CALL FOR HEAT FAST FLASH NORMAL OPERATION CALL FOR HEAT w2 RR 1 1 FLASH IN LOCKOUT FROM FAILED IGNITIONS OR FLAME LOSSES 2 FLASH PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS O T O OF VENTER ENERGIZED 3 FLASH LIMIT SWITCH OR ROLLOUT SWITCH OPEN FLAME ROLLOUT 4 FLASH PRESSURE SWITCH IS CLOSED BEFORE VENTER IS MODELS 30 125 ONLY ENERGIZED STEADY OFF INTERNAL CONTROL FAULT OR NO POWER YELLOW LED STEADY ON FLAME SENSED SLOW FLASH WEAK FLAME PRESSURE SWITCH FAST FLASH UNDESIRED FLAME VALVE OPEN amp NO CALL FOR HEAT FAN OFF DELAY GAS VALVE VENTER MOTOR FLAME OK LED ELECTRODE DSI CONTROL FLAME GROUND OPERATING SEQUENCE CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150 400 SET THERMOSTAT SECOND STAGE ANTICIPATOR AT 0 6 AMPS AND FIRST STAGE ANTICIPATOR AT MINIMUM JUMPER THERMOSTAT TERMINALS G TO W1 AND RH TO RC IF FAN CONTROL FROM THERMOSTAT FAN SWITCH IS DESIRED Form RZ NA I UDA
31. 1 3000 611 915 98700 82908 69090 112800 94752 78960 141000 117030 98700 164500 136535 115150 3001 4000 916 1220 96600 81144 67620 110400 92736 77280 138000 114540 96600 161000 133630 112700 1221 1525 94500 108000 90720 4001 5000 5001 6000 1526 1830 92400 79380 66150 77616 64680 105600 88704 75600 135000 112050 94500 73920 132000 109560 92400 157500 130725 110250 154000 127820 107800 Size 200 0 2000 0 610 200000 166000 140000 225000 186750 157500 250000 207500 175000 300000 249000 210000 Size 225 Size 250 Size 300 189000 156870 2001 3000 611 915 188000 156040 131600 211500 175545 148050 235000 195050 3001 4000 916 1220 184000 152720 128800 207000 171810 144900 230000 190900 4001 5000 1221 1525 180000 149400 126000 202500 168075 141750 225000 186750 157500 270000 224100 189000 5001 6000 1526 1830 176000 146080 123200 198000 164340 138600 220000 182600 154000 264000 219120 184800 6001 7000 1831 2135 172000 142760 120400 193500 160605 135450 215000 178450 150500 258000 214140 180600 164500 282000 234060 197400 161000 276000 229080 193200 Meters 7001 8000 2136 2440 168000 139440 117600 8001 9000 2441 2745 164000 136120 114800 9001 10000 2746 3045 160000
32. ALVE GAS VALVE FAST FLASH UNDESIRED FLAME VALVE OPEN amp NO CALL FOR HEAT BL FAN OFF DELAY VENTER ELECTRODE CAPACITOR o TRANSFORMER SEE NOTE 7 DSI CONTROL FLAME SPARK GAP GROUND OPERATING SEQUENCE 1 SET THERMOSTAT AT LOWEST SETTING FAN SWITCH AT AUTO POSITION OPTION CL18 ONLY 2 TURN ON MANUAL GAS VALVE FIELD CONTROL WIRING 3 TURN ON POWER TO UNIT 4 SET THERMOSTAT AT DESIRED SETTING TOTAL WIRE DISTANCE FROM MIN RECOMMENDED 5 LOW STAGE OF THERMOSTAT CALLS FOR HEAT ENERGIZING THE VENTER MOTOR LENGTH UNIT TO CONTROL WIRE GUAGE 6 VENTER PRESSURE SWITCH CLOSES FIRING UNIT AT LOW RATE CA NPE 7 BURNER FLAME IS SENSED AND IN 30 SECONDS THE FAN MOTOR IS ENERGIZED 150 75 8 HIGH STAGE OF THERMOSTAT CALLS FOR HEAT FIRING UNIT AT FULL RATE 250 125 16 WIRE 9 SET FAN SWITCH ON POSITION FOR CONTINUOUS FAN OPERATION OPTION CL18 ONLY 350 175 14 GA WIRE 10 IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT WIRING CODE SEE LIGHTING INSTRUCTIONS BRONN ER NOTES REDER 1 THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS THERMOSTAT ORANGE O 2 DOTTED WIRING INSTALLED BY OTHERS YELLOW Y 3 CAUTION IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE GREEN SO APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERA
33. Check for proper Position on Shaft operation Venter Wheel Venter Motor Plate Venter Wheel Venter Motor Plate Sizes 30 75 Fan Sizes 100 175 Fan Motor Mounting L Motor Mounting Bracket Bracket Motor Sizes 100 400 Motor Sizes Venter wheel has 30 75 different appearance on Sizes 200 400 Motor spacing is the same oot oon 5 16 8mm inside 5 16 8mm inside 32 Ope rati ng The gas valve requires no field maintenance except careful removal of external G V dirt accumulation and checking of wiring connections Instructions for testing as valve pressure settings re in Paragraph 12 WARNING The operating valve is the Single E Optional prime safety shutoff All gas supply Stage y Two lines must be free of dirt or scale before Gas EN Stage connecting to the unit to ensure positive Valve closure See Hazard Levels page 2 E ti Valve See FIGURE 18 page 31 for location If it is determined that the pressure switch needs replacing use only the factory autho rized replacement part that is designed for the model and size of heater being serviced 33 Combustion Air Pressure Switch NOTE A unit operating above 6000 ft elevation requires a high altitude pressure switch See Paragraph 7 3 4 Li m it C ntrol If it is determined that the limit control needs replacing use only a factory authorized replacemen
34. K DISCONNECT SWITCH BK Wi LIMIT CONTROL STEADY ON NORMAL OPERATION NO CALL FOR HEAT FAST FLASH NORMAL OPERATION CALL FOR HEAT 1 L 1 FLASH IN LOCKOUT FROM FAILED IGNITIONS OR FLAME LOSSES 2 FLASH PRESSURE SWITCH DOES NOT CLOSE WITHIN 30 SECONDS OF VENTER ENERGIZED 3 FLASH LIMIT SWITCH OR ROLLOUT SWITCH OPEN FLAME ROLLOUT 4 FLASH PRESSURE SWITCH IS CLOSED BEFORE VENTER IS MODELS 30 125 ONLY ENERGIZED Y STEADY OFF INTERNAL CONTROL FAULT OR NO POWER YELLOW LED STEADY ON FLAME SENSED SLOW FLASH WEAK FLAME PRESSURE SWITCH Js FAST FLASH UNDESIRED FLAME VALVE OPEN amp NO CALL FOR HEAT FAN OFF DELAY Fs Fw oro GAS VALVE peo Ed FLAME R on ELECTRODE BR DSI CONTROL FLAME GROUND OPERATING SEQUENCE SET THERMOSTAT AT LOWEST SETTING FAN SWITCH AT AUTO POSITION OPTION CL2 ONLY TOTAL WIRE TURN ON MANUAL GAS VALVE LENGTH TURN ON POWER TO UNIT SET THERMOSTAT AT DESIRED SETTING 150 THERMOSTAT CALLS FOR HEAT ENERGIZING THE VENTER MOTOR 250 VENTER PRESSURE SWITCH CLOSES FIRING UNIT AT FULL RATE 350 BURNER FLAME IS SENSED AND IN 30 SECONDS THE FAN MOTOR IS ENERGIZED IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT SEE LIGHTING INSTRUCTIONS SET FAN SWITCH AT ON POSITION FOR CONTINUOUS FAN
35. OPERATION OPTION CL2 ONLY NOTES THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS THERMOSTAT DOTTED WIRING INSTALLED BY OTHERS CAUTION IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 C EXCEPT FOR SENSOR LEAD WIRE FLAME ROLLOUT AND LIMIT WIRING WHICH MUST BE 150 C USE 18 GA WIRE FOR ALL WIRING ON THE UNIT LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5 OF SUPPLY LINE VOLTAGE CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS 150 400 AND 208 230V MODELS 100 400 Form RZ NA I UDA Mfg 195673 Rev 5 Page 23 LED SPARK TRANSFORMER FIELD CONTROL WIRING DISTANCE FROM UNIT TO CONTROL 75 125 175 WIRING CODE BLACK BK BROWN BR RED R ORANGE O YELLOW Y GREEN G BLUE BL PURPLE PR WHITE W SEE NOTE 6 CAPACITOR VENTER MOTOR rr ig CAPACITOR SEE NOTE 7 SPARK GAP MIN RECOMMENDED WIRE GAUGE 18 GA WIRE 16 GA WIRE 14 GA WIRE UDAP amp UDAS SERIES WD 185139 REV 1 AG1 23 Wiring Diagrams cont d FIGURE 15B Typical Wiring Diagram for Model UDAP or Model UDAS Single Stage with Optional Air Recirculation OPT CL18 T874F THERMOSTAT Q674C SUBBASE SEE NOTES 8 AND 9 1 2 3 4 5 6 8 9 SET THERMOSTAT AT LO
36. S A Trademark Note Reznor TCORE and V 3 are trademarks of Thomas amp Betts 1 03 YL Form RZ NA I UDA Version 5
37. STATES for Model UDAP and Model UDAS ALTITUDE Meters Thermal Output Size 30 The input and or the capacity of the heater changes with the derate The tables below list inputs and capacities at altitudes from sea level to 10 000 ft 3045M Minimum Normal Thermal Output Capacit 62250 0 2000 0 610 30000 24600 30000 45000 37350 45000 60000 49800 42000 75000 2001 3000 611 915 28200 23124 28200 42300 35109 42300 56400 46812 39480 70500 58515 3001 4000 916 1220 27600 22632 27600 41400 34362 41400 55200 45816 38640 69000 57270 48300 4001 5000 1221 1525 27000 22140 27000 40500 33615 40500 54000 44820 37800 67500 56025 47250 5001 6000 1526 1830 26400 21648 26400 39600 32868 39600 52800 43824 36960 66000 54780 46200 38700 32121 53535 45150 6001 7000 1831 2135 25800 21156 25800 7001 8000 2136 2440 25200 20664 25200 37800 31374 38700 51600 42828 36120 64500 37800 50400 41832 35280 63000 52290 44100 8001 9000 2441 2745 24600 20172 24600 36900 30627 36900 49200 40836 34440 61500 51045 43050 9001 10000 2746 3045 24000 19680 24000 36000 29880 36000 48000 39840 33600 60000 49800 42000 0 2000 0 610 105000 88200 73500 120000 100800 84000 150000 124500 105000 175000 145250 122500 200
38. TURE RATING OF AT LEAST 105 C EXCEPT FOR SENSOR BLUE BL LEAD WIRE FLAME ROLLOUT AND LIMIT WIRING WHICH MUST BE 150 C PURPLE PR 4 USE 18 GA WIRE FOR ALL WIRING ON THE UNIT WHITE W 5 LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5 OF SUPPLY LINE VOLTAGE 6 CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS 150 400 AND 208 230V MODELS 100 400 7 CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150 400 U DAP amp U DAS SERIES 8 SET THERMOSTAT FIRST STAGE ANTICIPATOR AT 0 6 AMPS AND 9 JUMPER THERMOSTAT TERMINALS RH TO RC WD 185244 REV 3 AG2 Form RZ NA I UDA Mfg 195673 Rev 5 Page 25 24 Check to be sure that all screws used to hold shipping brackets were re installed in the heater cabinet Instal lation Check suspension Unit must be secure and level and Sta rtu Check clearances from combustibles Requirements in Paragraph 8 Check vent system to be sure that it is installed according to the instructions in the appropriate Vent Installation Manual as listed in Paragraph 1 Check piping for leaks and proper gas line pressure Bleed gas lines of Check the trapped air See Paragraph 12 installation prior Check electrical wiring Be sure all wire gauges are as recommended A service disconnect switch should be used Verify that fusing or circuit break to startup ers are adequate for the load use Check pol
39. WEST SETTING FAN SWITCH AT AUTO POSITION FIELD CONTROL WIRING TURN ON MANUAL GAS VALVE TURN ONIPOWERETO UNIT TOTAL WIRE DISTANCE FROM MIN RECOMMENDED SET THERMOSTAT AT DESIRED SETTING LENGTH UNIT TO CONTROL WIRE GAUGE LOW STAGE OF THERMOSTAT CALLS FOR HEAT ENERGIZING THE FAN MOTOR a o 18 GA WIRE HIGH STAGE OF THERMOSTAT CALLS FOR HEAT ENERGIZING THE VENTER MOTOR mu dos 16 GA WIRE VENTER PRESSURE SWITCH CLOSES FIRING UNIT AT FULL RATE HAGA NIRE SET FAN SWITCH AT ON POSITION FOR CONTINUOUS FAN OPERATION 350 175 IF THE FLAME IS EXTINGUISHED DURING MAIN BURNER OPERATION THE INTEGRATED CONTROL SYSTEM CLOSES THE MAIN VALVE AND WIRING CODE MUST BE RESET BY INTERRUPTING POWER TO THE CONTROL CIRCUIT BLAGK BK SEE LIGHTING INSTRUCTIONS BROWN BR NOTES RED R THE FOLLOWING CONTROLS ARE FIELD INSTALLED OPTIONS THERMOSTAT ORANGE DOTTED WIRING INSTALLED BY OTHERS YELLOW Y CAUTION IF ANY OF THE ORIGINAL WIRING AS SUPPLIED WITH THE GREEN G APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL Bi HAVING A TEMPERATURE RATING OF AT LEAST 105 C EXCEPT FOR SENSOR PURPLE LEAD WIRE FLAME ROLLOUT AND LIMIT WIRING WHICH MUST BE 150 C USE 18 GA WIRE FOR ALL WIRING ON THE UNIT WHITE W LINE AND FAN MOTOR BRANCH WIRE SIZES SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROPS BEYOND 5 6 OF SUPPLY LINE VOLTAGE CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON 115V MODELS 150 400 AND 208 23
40. after fan off delay is com pleted Pressure Switch If the pressure switch opens before the trial for ignition period the venter motor will run through the pressure switch recognition delay 2 sec onds the gas valve will be de energized and the venter motor will run through the postpurge time The control will re start the heat cycle at the pressure switch proving state if the call for heat still exists Pressure switch opening for less than 2 seconds during the trial for ignition period shall not interrupt the heat cycle Gas valve will de energize while the pressure switch is open If the pressure switch opens after a successful ignition the control will de energize the gas valve If flame is lost before the end of the 2 second pressure switch recog nition delay the control will respond to the loss of flame If the pressure switch remains open for 2 seconds and the flame remains the control de energizes the gas valve the venter motor runs through post purge and the fan blower motor runs on heat speed through the selected fan off delay When the fan off delay is over the fan blower motor is de energized and a heat cycle is begun if the call for heat still exists When the thermostat calls for continuous fan G without a call for heat the fan motor is energized after a 25 second delay NOTE This brief on delay is to allow G terminal to energize slightly before Y and an external changeover relay to switch from
41. allations in aircraft hangars should be in accordance with ANSI NFPA No 409 latest edition Standard for Aircraft Hangars in public garages in accordance with ANSI NFPA No 884A latest edition Standard for Parking Structures and for repair garages in accordance with ANSI NFPA No 88B latest edition Stan dard for Repair Garages In Canada installations in aircraft hangars should be in accordance with the requirements of the enforcing authorities and in public ga rages in accordance with CAN CGA B149 codes If the heater is being installed in the state of California the installer MUST attach a warning label on the outside of the access door The California Warning label is shipped in the owner s envelope along with this manual the warranty form and any other paperwork that applies If installation is in California select a location on the heater access panel Be sure the surface is clean and dry and adhere the label If the heater is being installed in the Commonwealth of Massachusetts these units must be installed by a licensed plumber or licensed gas fitter Refer to the limited warranty information on the Warranty Card in the Owner s Envelope Warranty is void if a Wiring is not in accordance with the diagram furnished with the heater b The unit is installed without proper clearance to combustible materials c A fan model is connected to a duct system or if the air delivery system is modified This unit was test
42. alve open flame and no call for heat 2 Flashes Pressure Switch Did Not Close within 30 Fan Blower OFF Delay Settings dip switches Seconds of Venter Motor SW SW 2 Time 3 Flashes High Limit or Flame Rollout Switch Open Off 120 seconds factory setting 4 Flashes Pressure switch is closed before venter On 90 seconds motor is energized On 160 seconds Steady OFF Blown Fuse No Power or Defective Board On On 180 seconds Normal Heat Cycle 1 Call for Heat The thermostat calls for heat by energizing the W terminal The control checks to see that the limit switch is closed and the pressure switch is Operati ng open If the limit switch is open the control responds as defined in the Abnormal Sequen ce Heat Cycle Limit Switch Operation If the pressure switch is closed the control will do four flashes on the green LED and wait indefinitely for the pressure switch to open If the pressure switch is open the control proceeds to prepurge 2 Prepurge The control energizes the venter motor and waits for the pressure switch to close If the pressure switch does not close within 30 seconds of the venter motor energizing the control will do two flashes on the green LED The control will leave the venter motor energized indefinitely as long as the call for heat remains and the pressure switch is open Form RZ NA I UDA Mfg 195673 Rev 5 Page 19 20 Ignition System cont d Normal Heat Cycle Operating Sequence cont d Ab
43. arity Verify that line voltage exists between the black L1 and earth ground O If installed in California verify that California Warning Label is displayed Heater WARNINGS For your safety read before operating If you do Startup not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Before operating smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call your fire department Use only your hand to turn the gas control ON OFF knob on the gas valve Never use tools If the valve ON OFF knob will not turn by hand do not try to repair it Call a qualified service technician Force or attempted repair may result in a fire or explosion Should overheating occur or the gas supply fail to shut off turn off the manual gas valve to the appliance before shutting off the electrical supply Do not use this appliance if any
44. ark ignition sys tem refer to Paragraph 20 and the Troubleshooting Flow Chart in Paragraph 40 Only replaceable part is a Type ATC or ATO 3 amp fuse Color Code Violet P N 201685 Form RZ NA I UDA Mfg 195673 Rev 5 Page 31 29 Ignition System cont d Ignitor t 4 5 D Flame Sensor 30 Fan Motor Fan Blades and Guard FIGURE 21 Fan Blade Position on the Shaft Dimension A 100 2 3 8 60 150 2 3 8 60 225 250 2 51 300 350 1 7 8 400 1 3 8 31 Venter Motor and Wheel Replacement Instructions Ignitor Refer to FIGURE 18 and locate the ignitor Disconnect the wire re move the screw and the ignitor Clean the ignitor assembly with an emery cloth Spark gap must be maintained to 1 8 See FIGURE 20 FIGURE 20 Ignitor showing required Spark Gap measurement EE IMPORTANT When re assembling the brown ground wire must remain attached to the ignitor CAUTION Due to high voltage on the spark wire and electrode do not touch when energized See Hazard Levels page 2 Flame Sensor Refer to FIGURE 18 and locate the flame sensor Disconnect the wire remove the screw and the flame sensor Clean with an emery cloth Remove dirt and grease from the motor the fan guard and blades Use care when cleaning the fan blades to prevent causing misalignment or imbalance Check that the
45. bel on Venting Manual and Heater Label with Red Square Label with inverted Blue Triangle Installation must be equipped with Option AV6 Form RZ NA I V CV Label with Green Circle Separated Combustion Form RZ NA I V SC Both this installation manual and the appropriate venting manual are shipped with the heater Verify that the literature is correct for the heater being installed If either manual is missing or incorrect contact your distributor before beginning installation The instructions in this manual apply only to the models listed Installation should be done by a qualified agency in accordance with these in structions The qualified service agency installing this heater is responsible for the installation These units must be installed in accordance with local building codes In the ab sence of local codes in the United States the unit must be installed in accordance with the National Fuel Gas Code ANSI Z223 1 A Canadian installation must be in accordance with the CAN CGA 149 Installation Codes These codes are avail able from CSA Information Services 1 800 463 6727 Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements Special Installations Aircraft Hangars Repair Garages Parking Garages California Warning Label Massachusetts Requirement 3 Warranty 4 Uncrating and Preparation Inst
46. closed flame is established and the thermostat call for heat remains When the thermostat call for heat is removed the control de energizes the gas valve and begins post purge and fan blower off delay timing 6 Post Purge The venter motor output remains on for a 45 second post purge period after the thermostat is satisfied 7 Fan Blower Off Delay The fan blower motor is de energized after a blower off delay as selected by the dip switches Timing begins when the thermostat is satisfied Delay times are as follows SW1 SW2 Time OFF OFF 120 seconds default when shipped OFF 90 seconds ON OFF 160 seconds ON ON 180 seconds Interrupted Thermostat Call for Heat If the thermostat demand for heat is removed before the flame is recognized the control will run the venter motor for the post purge period and de energize all outputs If the thermostat demand for heat is removed after successful ignition the control will de energize the gas valve run the venter motor through post purge and run the fan blower motor on heat speed for the selected delay off time Ignition Retry If flame is not established on the first trial for ignition period the control de energizes the gas valve and the venter motor remains energized for an inter purge period of 10 seconds The spark and gas valve are then re energized and the control initiates another trial for ignition If flame is not established on the second trial for ignition the control d
47. cracked Replace as required c Supply pressure should be 5 14 w c for natural gas or 11 14 w c for propane gas d Replace sensor Burner cycle on and off 1 Gas pressure too high ortoo low 2 Burner not grounded 3 Circuit board not grounded 4 Faulty integrated circuit board 5 Combustion air proving switch not closing 6 Faulty combustion air proving switch 7 Flame sensor grounded Cracked ceramic at sensor Incorrect polarity 1 Supply pressure should be 5 14 w c for natural gas or 11 14 w c for propane gas 2 Make certain integrated circuit board is grounded to ignitor 3 Make certain integrated circuit board is grounded to furnace chassis 4 If 24 volt is available to the integrated circuit board and all other causes have been eliminated replace board 5 a Make sure unit is properly vented b Remove obstructions from vent c Replace faulty tubing to pressure switch 6 Replace combustion air proving switch 7 Be certain flame sensor lead is not grounded or insulation or ceramic is not cracked Replace as required 8 Replace sensor Reverse line volt leads to integrated circuit board No heat Heater Operating venter motor will not run Fan or venter motor turns on and off while burner is operating Fan or venter motor cuts out on overload Incorrect valve outlet pressure or orifice Cycling on limit control Circuit open
48. crew attaching to secondary air shield Support remains attached to burner Secondary Air Shield Burner Assembly Venturi Tube Slide right rotate inward Disconnect gas train at orifice and outside the heater slide to the right S d Air Baffl 7 On vane a dey Control Bracket Screws Orifice Adapter Locking Nut Mark locations before removing Loosen bracket slide right Form RZ NA I UDA Mfg 195673 Rev 5 Page 29 27 Burner Maintenance cont d Burner Removal cont d Inspect and Clean the Burner Re Install the Burner 28 Burner Orifice Form RZ NA I UDA P N 195673 Rev 5 Page 30 size Each baffle is held in place by one screw For re assembly on the secondary air shield mark the location top and bottom of each baffle Remove all baffles 8 Remove Burner Assembly a Locate the burner body supports Depending on the size the burner will have two or more supports At each support remove the one screw that attaches it to the secondary air shield b Holding the venturi tube slide the entire burner assembly slightly to the right to disengage the burner from the supports on the left Then rotate the open end of the venturi tube inward toward the heater Carefully pull the burner assembly out of the cabinet With the burner assembly removed shine a flashlight on the burner ribbons Look for carbon buildup scale dust lint and or anything that m
49. d Replace worn or grounded spark cable e Replace if ceramic spark electrode is cracked or grounded f Make certain integrated circuit board is grounded to ignitor Make certain integrated circuit board is grounded to furnace chassis h Make certain unit is properly field grounded to earth ground and properly phased L1 to hot lead L2 to neutral i Correct cause Replace fuse type or ATO 32VDC j If 24 volt is available to the integrated circuit board and all other causes have been eliminated replace board 5 Reset lockout by interrupting control at the thermostat or main power 6 Close access door or replace switch 7 a Make sure unit is properly vented b Remove obstructions from vent c Replace faulty tubing to pressure switch 8 Replace combustion air proving switch 9 a If 24 volt is measured at the valve connections and valve remains closed replace valve b Check and tig hten all wiring connections Form RZ NA I UDA Mfg 195673 Rev 5 Page 35 40 Troubleshooting cont d PROBLEM cont d PROBABLE CAUSE cont d REMEDY cont d Burner will not light cont d 10 Integrated circuit board does not power main valve a Loose wire connections b Flame sensor grounded C Incorrect gas pressure d Cracked ceramic at sensor 10 a Check and tighten all wiring connections b Be certain flame sensor lead is not grounded or insulation or ceramic is not
50. e energizes the gas valve energizes the fan blower motor on heat speed and venter motor remains energized The fan blower motor is shut off after the longest selectable fan delay time 180 seconds When the fan blower motor de energizes the spark and gas valve are re energized and the control initiates another trial for ignition This fan delay is self healing feature for an open auxiliary limit switch If flame is not established on the third trial for ignition period the control de energizes the gas valve and the venter motor remains energized for an inter purge period of 10 seconds The control then re energizes the gas valve and spark and initiates another trial for ignition Continuous Fan Operation Fault Modes If flame is not established on the fourth trial for ignition initial try plus 3 re tries the control de energizes the gas valve and goes into lockout The control goes to one flash on the green LED to indicate ignition failure lockout Limit Switch Operation The limit switch is ignored unless a call for heat is present W energized If the limit switch is open and a call for heat is present the control de energizes the gas valve and turns the fan blower motor on heat speed and runs the venter motor When the switch re closes or the call for heat is lost the control runs the venter motor through post purge and runs the blower fan motor through the selected fan off delay The control will return to normal operation
51. ection P and Q TOP VIEW 30 45 150 400 Hanger Horizontal ng t 60 125 Vertical Dimensions for 4 pt Q 3 8 16 Female Thread Suspension all suspension points Line Voltage External Vent Connection Inlet connects in H Gas see Technical sealed electrical box Connection Data for size 1 14 32 a L RIGHT SIDE VIEW Access Panel VV iis av77 om Re EY PEE ES REZNOR WSS MODEL UDAS DIMENSIONS inches 1 16 MM E 265 8 75 15 13 E 13 1627 5 8 3 E 118 6 1 2 5 1 2 3 7 8 17 3 8 mE yis 13 i 1 2 34 4 2 150 175 20 1 8 38 3 16 16 35 3 8 8 1 2 8 1 4 5 7 16 6 1 2 25 11 16 1 3 8 8 3 16 22 3 16 16 3 8 4 1 8 8 5 16 200 225 be 1 8 38 3 16 m sam 3 8 13 1 16 8 13 16 ES 6 1 2 25 11 1611 3 8 8 3 16 22 annissis 5 9 16 8 5 16 300 EIE 35 3 8 17 B 13 16 7 5 16 27 1 1 16 1 3 8 8 3 16 22 3 16116 3 16 9 1 16 8 9 16 Form RZ NA I UDA Mfg 195673 Rev 5 Page 5 6 Technical Data TECHNICAL DATA Sizes 30 125 Data applies to both Models and UDAS unless noted otherwise beat B Gas Connection inches Vent Connection inches diameter C Combustion Air Inlet Size 30 45 60 75 100 125 2 BTUH 30 000 45 000 60 000 75 000 105 000 120 000 Inp
52. eiling Suspension Kit no hanger rods FIGURE 9 Model UDAS Plug the unused suspension points on the control side of the heater with 3 8 16 screws and flat washers Be sure the threaded hanger rods are locked to the heater as illustrated 3 8 threaded rod field supplied Add a 3 8 nut and washer to lock the hanger rod to the heater Recommended maximum hanger rod length is 6 feet 1 8M If ordered with swivel connectors for 1 pipe Option CK8 or CK10 attach the swivels at the threaded nut retainers Suspend with 1 pipe See FIGURE 7B Lock the swivel connector to the heater The connector is threaded for hanging from a 1 pipe Be sure the threaded swivel connectors are locked to the heater as illustrated f If ordered with a ceiling suspension kit Option CK22 follow the illustrated in structions in the kit See FIGURE 8 Available for Sizes 30 125 Allows the heater to be installed one inch from the ceiling Model UDAS Whether using the suspension points or the hanger kit when in stalling a Model UDAS the unused suspension points on the control side of the heater MUST be plugged Plug these holes with the 3 8 16 bolts and flat wash ers shipped in the bag with the heater See FIGURE 9 Plug any unused suspension points on the control side with the 3 8 16 bolts and flat washers provided Form RZ NA I UDA Mfg 195673 Rev 5 Page
53. ems 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 Model UDAP 150 175 200 225 54 so 67 72 96 101 172 187 203 215 269 294 306 24 27 30 33 44 46 78 ss 92 98 122 133 139 30 45 60 75 100 125 150 175 200 225 250 300 350 400 55 8 73 97 102 173 188 204 216 270 295 307 as 27 st 33 44 46 78 ss 93 o8 122 134 138 When the heater is lifted for suspension support the bottom of the heater with plywood or other appropriately placed material If the bottom is not supported damage could occur Before hanging verify that all screws used for holding ship ping brackets were re installed in the cabinet The heater is equipped for either two point or four point suspension A 3 8 16 threaded nut retainer is located at each suspension point See Dimensions in Para graph 5 and the illustration in FIGURE 7A FIGURE 7A Suspending the Heater with Rods from the Threaded Nut Retainers either two or four point suspension WARNING Unit must be level for proper operation Do not place or add additional weight to the suspended heater Hazard Levels page 2 FIGURE 7B Swivel Connectors to Suspend the Heater from 1 Pipe Option 2 pt or CK10 4 pt FIGURE 8 Suspending the Heater using Option CK22 C
54. erate 1 Determine the required valve outlet pressure for the elevation where the heater will be operating If unsure of the elevation contact the local gas supplier Valve Outlet Pressure Settings by Elevation Manifold Pressure Settings by Altitude for the UNITED STATES gS Natural Gas inches w c Propane Gas inches w c Feet Meters Single Stage and Two Stage Single Stage and Two Stage Two Stage High Fire Low Fire Two Stage High Fire Low Fire Manifold Pressure Settings by Altitude for CANADA Altitude Natural Gas inches w c Propane Gas inches w c Feet Single Stage and Two Stage Single Stage and Two Stage Two Stage High Fire Low Fire Two Stage High Fire Low Fire 0 2000 2001 4500 611 1373 2 Locate the 1 8 output pressure tap on the valve See FIGURE 11 Turn the knob on the top of the valve to OFF Connect a manometer to the 1 8 pipe outlet pressure tap in the valve Use a water column manometer that is readable to the nearest tenth of an inch 3 Single Stage and Two Stage High Fire Turn the knob on the top of the valve to ON Remove the cap from the pressure adjusting screw and adjust the gas train pressure to the pressure selected from the table above Adjust pressure by turning the regulator screw IN clockwise to increase pressure or OUT coun terclockwise to decrease pressure Two Stage Low Fire Disconnect the wire from the HI terminal on the gas valve and check the lo
55. floor 10 Unit Heater Location cont d NOTE Venting requirements may affect location Consult the Venting Manual for this heater before making final determination Hazards of Chlorine applies to location of Model UDAS heater with regard to combustion air inlet 11 Hanging the Heater WARNINGS Check the supporting structure to be used to verify that it has sufficient load carry ing capacity to support the weight of the unit Suspend the heater only from the threaded nut retainers or with a man ufacturer provided kit Do NOT suspend from the heater cabinet Form RZ NA I UDA P N 195673 Rev 5 Page 10 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 2 4 3 7M above the floor Units should always be arranged to blow toward or along exposed wall surfaces 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 working zone as possible and this fact should be kept in mind when determining the mounting heights to be used However care should be exercised to avoid directing the dis charged air directly on the room occupants Partitions columns counters or other obstructions should be taken into consider ation when locating the unit heater so that a minimum quantity of airflow wil
56. for natural gas and 10 for propane gas For Natural Gas When the heater leaves the factory the combination gas valve is set so that the valve outlet gas pressure for a single stage valve or high fire of a two stage valve is regulated to 3 5 w c Inlet supply pressure to the valve for natural gas must be a minimum of 5 w c or as noted on the rating plate and a maximum of 14 w c For Propane Gas When the heater leaves the factory the combination gas valve is set so that the valve outlet gas pressure for a single stage valve or high fire of a two stage valve is regulated to 10 w c Inlet supply pressure to the valve for propane gas must be a minimum of 11 w c and a maximum of 14 w c Before attempting to measure or adjust valve outlet gas pressure the inlet supply pressure must be within the specified range both when the heater is in operation and on standby Incorrect inlet pressure could cause excessive valve outlet gas pressure immediately or at some future time If natural gas supply pressure is too high install a regulator in the supply line before it reaches the heater If natural gas supply pressure is too low contact your gas supplier Instructions 1 Locate the 1 8 output pressure tap on the valve See FIGURE 11 page 14 With the manual valve turned off to prevent flow to the gas valve connect a manometer to the 1 8 pipe outlet pressure tap in the valve NOTE manom eter fluid filled gauge is recommended rat
57. h the secondary air baffles as marked Baffles may be different sizes and each must be attached in the correct location 3 Attach the Control Assembly Carefully slide the control assembly into position Re attach with the same screws Check to be sure all wire connec tions are secure 4 Attach the Gas Train Slide the gas train so that the orifice adapter is through the bracket Fasten the gas train to the bracket with the locking nut Install the gas orifice Re connect the wires to the gas valve 5 Close the access panel 6 Reconnect the gas supply at the union outside of the cabinet Leak test the connection with leak detecting solution 7 Turn on the electric and the gas Check for proper operation Burner orifice usually only needs to be replaced when installing a gas conversion kit If ordering a replacement orifice only give BTUH content and specific grav ity of gas as well as the model and serial number of the unit When removing or replacing the burner orifice be careful not to damage the venturi tube and or the bracket FIGURE 18 Location of Controls Flame Sensor Venter Motor Size 30 75 Flame Rollout Switch Sizes 30 125 Pressure Switch High Temperature illustrated venter m tor Sizes 30 125 Limit Control is in the same location for all models but appear ance is different Model UDAS has a collar for combustion air pipe not illustrated Interlock Door
58. her than a spring type gauge due to the difficulty of maintaining calibration of a spring type gauge 2 Open the manual valve and operate the heater NOTE On Model UDAS depress and hold the door safety switch Measure the outlet pressure of the gas valve Normally when operating at sea level adjustments should not be neces sary to the factory setting For high altitude settings see next paragraph If adjustment is necessary remove the cap from the adjustment screw s Set pressure to correct settings by turning the regulator screw IN clockwise to increase pressure Turn regulator screw OUT counterclockwise to decrease pressure Form RZ NA I UDA Mfg 195673 Rev 5 Page 13 12 Gas Piping and Pressures cont d Derate by Valve Outlet Pressure Adjustment for High Altitude Operation This adjustment can only be done after the heater is in operation It is included in the startup procedures NOTE If elevation is above 6000 ft 1830M a high altitude pressure switch is required see Paragraph 7 FIGURE 11 Top View of Valves showing Outlet Pressure Tap and Adjustment Locations Single Stage Valve Output 3 Adjustment 1 8 Output Pressure Tap Screw Inlet Pressure Tap Two Stage Valve Adjust High Adjust Low Pressure Pressure Output Output a Inlet Pressure i i Tap 1 8 Output Pressure Tap Instructions for High Altitude D
59. ight restrict flow through the spaces between the burner ribbons Holding the burner assembly so that any foreign material will fall away from the burner use a stiff bristle brush to loosen and remove any foreign material s If the burner is excessively dirty remove one of the burner end caps Remove the four screws that hold the end cap to the burner housing Lightly tap the end cap to remove it Clean all foreign material from the burner and venturi After the burner is thor oughly clean replace the end cap making certain that it is tight against the burner housing NOTE If any of the burner components are damaged or deteriorated replace the burner assembly Inspect the Lower Portion of the Heat Exchanger with burner assembly removed At the burner flame entrance of each tube shine a bright light into each heat exchanger section With the light shining into the heat exchanger observe the outside for visible light Repeat this procedure with each heat exchanger section If any light is observed replace the heat exchanger Instructions to Re Install the Burner Refer to FIGURE 17 1 Attach the Burner Assembly Holding the venturi tube slide the entire burner assembly into position Align the supports on the left side with the slots in the burner shield sliding the supports into the slots On the right re attach each burner body support to the secondary air shield 2 Attach the Secondary Air Baffles Sizes 60 400 only Re attac
60. l 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 At those points where infiltration of cold air is excessive such as at entrance 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 4 6 6 1M CAUTION Do not locate the heater where it may be exposed to water spray rain or dripping water The presence of chlorine vapors in the combustion air of gas fired heating equip ment presents a potential corrosion hazard Chlorine found usually in the form of freon or degreaser vapors when exposed to flame will precipitate from the com pound and go into solution with any condensation that is present in the heat ex changer or associated parts The result is hydrochloric acid which readily attacks all metals including 300 grade stainless steel Care should be taken to separate these vapors from the combustion process This may be done by wise location of the unit vent and combustion air terminals with regard to exhausters or prevailing wind directions Chlorine is heavier than air Keep these facts in mind when deter mining installation location of the heater in relation to building exhaust syst
61. ng Confined Space A space whose volume is less than 50 cubic feet per 1000 BTUH of the installed appliance input rating Confined 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 opening See 1 in FIGURE 5 2 Air from outside through duct openings 1 square inch free area per 2000 BTUH See 2 in FIGURE 5 3 Air direct from outside openings 1 square inch free area per 4000 BTUH See 3 in FIGURE 5 NOTE For further details on supplying combustion air to a confined space see the National Fuel Gas Code ANSI Z223 1a latest edition 10 Unit Heater Location Heater Throw FIGURE 6 Throw for Fan Models UDAP and UDAS NOTE Throws listed are with standard adjustable horizontal louvers at the angles listed angle is relative to the top of the heater Throw pattern changes with the addition of optional vertical louvers and or downturn nozzles Use the sound data in Paragraph 6 clearances in Paragraph 8 the combustion air requirements in Paragraph 9 the throw tables mounting height requirements and location recommendations below the weights in Paragraph 11 and the venting requirements in the Venting Manual to determine where to suspend the heater Louver angle listed in the table is relative to the top of the heater 7 is the point when the air velocity dro
62. normal Heat Cycle Functions Form RZ NA I UDA P N 195673 Rev 5 Page 20 When the pressure switch is proven closed the control begins the prepurge time If flame is present any time while in prepurge the prepurge time is restarted If flame is present long enough to cause lockout the control responds as defined in Fault Modes Undesired Flame The control runs the venter motor for a 20 second prepurge time then proceeds to the ignition trial period 3 Ignition Trial Period The control energizes the spark and main gas valve The venter remains energized If flame is sensed during the first 16 seconds the spark is de energized and the control proceeds to heat fan blower on delay If flame has not been sensed during the first 16 seconds the control de energizes the spark output and keeps the gas valve energized for an additional one second flame proving period If flame is not present after the flame proving period the control de energizes the gas valve and proceeds with ignition re tries as specified in Ab normal Heat Cycle Ignition Re try If flame is present the control proceeds to the fan blower on delay 4 Fan Blower On Delay The control waits for 30 seconds from the time the gas valve opened and then energizes the fan blower motor The gas valve and venter motor remain energized The control proceeds to steady heat mode 5 Steady Heat Control inputs are continuously monitored to ensure limit and pressure switches are
63. ow preset at the factory For location see FIGURE 18 page 31 WARNING The operating valve is the prime safety shutoff gas supply lines must be free of dirt or scale before connecting the unit to ensure positive closure See Hazard Levels page 2 The fan motor is equipped with thermal overload protection of the automatic reset type Should the motor refuse to run it may be because of improper current char acteristics Make certain that the correct voltage is available at the motor NOTE If the unit is equipped with an optional totally enclosed motor or optional voltage the horsepower may be larger than the standard motor Refer to the motor nameplate to verify horsepower Form RZ NA I UDA P N 195673 Rev 5 Page 22 23 Wiring Diagrams FIGURE 15 Typical Wiring Diagram for Model or Model UDAS Single Stage OPT CL3 T874F OR OPT CL1 WR 130 341 THERMOSTAT SEE NOTE 8 OPT CL2 W R 1C30 341 THERMOSTAT W S23 6 SUBBASE SEE NOTE 8 wns CAPACITOR IS REMOTE MOUNTED AND INCLUDED ONLY ON MODELS 150 400 SET THERMOSTAT ANTICIPATOR AT 0 6 AMPS 30 VA FACTORY WIRING SYSTEM TRANSFORMER mE CES FIELD WIRING OPTIONAL FACTORY WIRING 3 WIRE NUT e BR TERMINAL STRIP 115 208 230 FUSE DOOR INTERLOCK UDAS ONLY ATO OR ATC R o o Iu CRD 5 LED FLASH CODES GREEN LED LINE 1 60 UDAS ONLY B
64. p leg is required The unit is equipped with a nipple that extends outside the cabinet The gas con nection is either 1 2 or 3 4 Gas Connection inches 30 45 60 75 100 125 150 175 200 225 250 300 350 400 Form RZ NA I UDA P N 195673 Rev 5 Page 12 FIGURE 10 Gas connection is at the pipe nipple that extends outside the cabinet Illustration shows both a vertical and horizontal gas supply requirements are the same Valve Outlet or Orifice Pressure Setting NOTE Gas Conversion Kits are available for changing from propane gas to natural gas or natural gas to propane gas factory authorized conversion kit MUST be used Check Valve Outlet Pressure can only be done after heater is operating NOTE If operating at high altitude outlet pressure requires adjustment Follow instructions on page 14 Leak test all connections by brushing on a leak detecting solution Ground Joint Union M 1 shutoff To Gas Valve lt anual shuto inside the cabinet horizontal or vertical Pipe nipple extending ae Manual shutoff outside the cabinet To Gas Valve inside the cabinet Measuring valve outlet gas pressure cannot be done until the heater is in opera tion It is included in the steps of the Check Test Start procedure in Paragraph 24 The following warnings and instructions apply WARNING Valve outlet gas pressure must never exceed 3 5
65. ps below 50 feet 15 2M per minute 300 350 400 5 3 5 5 aH x y zilzq x lt lt A A 24 73 26 15 28 90 93 20 14 27 86 29 94 24 17 31 105 20 18 34 113 17 24 69 32 17 31 91 25 15 27 82 30 17 90 l 26 16 28 89 29 18 32 103 25 20 35 110 21 24 64 30 18 31 88 30 16 27 78 30 85 4 19 32 98 0 21 36 108 25 22 59 45 18 30 80 40 20 32 95 34 23 35 105 26 16 ft 13 19 38 23 35 101 33 1g ft 11 18 85 43 23 35 97 37 Dimensions X Y and Z meters Model UDAP and Model UDAS with Standard Horizontal Louvers at Mounting Heights of 1 5 5 5M 30 45 60 75 100 125 FPES 5 g t 5 55 2 5 z 5 5 Y Z 2 2 153 lt lt lt E lt 15 M 1 8 4 3 91 21 2 1 4 9 12 2 20 24 5 5 13 8 16 2 7 6 1 17 4 14 18 0 18 3 0 67 19 9 14 24M 192 24 30M 40 73 183 30 37M 43 70 17 4 36 43M 43 6 16 1 43 49M 14 3 50 55M 12 2 57 300 350 400 5 ES gt 5 PES ES 5 5 s X Y 2 5 2 Y 2 5 5 5 5 Y Ze d 4 lt d lt mE lt d 4 lt lt 2 4M
66. r Make thermostat connections at the terminal strip on the back of the heater The strip has four terminals R G W1 and W2 refer to the wiring diagram FIGURE 13 Terminal Rear View Model UDAP Strip for 24 volt wiring is on the outside rear of the heater NOTE The size of heater illustrated has a vertical Terminal Terminal gt terminal strip Some sizes Strip Strip have a horizontal terminal strip Rear View Model UDAS Disconnect Switch Built in Supply Wiring Supply Entrance Wiring Entrance Unit Mounted If the heater was ordered with Option CM3 a kit for mounting the thermostat on Thermostat the rear of the heater is shipped separately Follow the instructions in the option package to attach the bracket Option CM3 Select a snap action thermostat when using the unit mounted thermostat bracket Do not use a mercury switch thermostat because the vibration may cause exces sive unit cycling Be careful with the thermostat leads shorting the thermostat wires to a metal surface will cause the transformer to fail Multi ple Heater If the heater was ordered with a multiple heater control option one thermostat can Control Option be used to control up to six heaters The option includes a 40VA transformer that replaces the
67. r pressure switch closes firing the unit 12 Burner flame is sensed and in 30 seconds after the gas valve is energized the fan motor is energized 13 If the flame is extinguished during the main burner operation the integrated control system closes the main valve and must be reset by interrupting power to the control circuit See lighting instructions on the heater TO TURN OFF GAS TO THE APPLIANCE 1 Set thermostat to lowest setting 2 If service is to be performed turn off all electric power to the appliance 3 Open the access door 4 Turn the gas control knob clockwise to OFF Do not force 5 Close the access door Check installation Vent System Testing Procedure Model after s tartup 1 Seal any openings in the system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 1 and B149 2 Installation Code for Gas Burning Appliances and Equipment and the venting installation manual Determine that there is no blockage or restriction leakage corrosion or other deficiencies that could cause an unsafe condition 3 In so far as practical close all building doors and windows and all doors between the space where the heater is and other spaces of the building Turn on clothes dryers and exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a
68. rances Units must be installed so that the clearances in the table are provided for combus tion air space inspection and service and for proper spacing from combustible construction Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface tempera ture of 90 F above the surrounding ambient temperature is not exceeded Clearances Size Flue Connector Access Panel Side Bottom inches mm inches mm inches mm inches pss ps a s iss am 2 3 47 Suspend the heater so that the bottom is a minimum of 5 feet 1 5M above the floor Form RZ NA I UDA Mfg 195673 Rev 5 Page 7 9 Combustion Air applies to Model UDAP and Model UDAP CV Note For Model UDAS see Venting Manual for combustion air requirements Combustion Air Requirements for a Heater Located in a Confined Space applies to Model UDAP and Model UDAP CV FIGURE 5 Definition of Confined Space and Required Openings for Combustion Air Form RZ NA I UDA P N 195673 Rev 5 Page 8 This heater must be supplied with the air that enters into the combustion process and is then vented to the outdoors Sufficient air must enter the equipment location to replace that exhausted through the heater vent system In the past the infiltra tion of outside air assumed in heat loss calculations one
69. rner patent pending H Inspect the burner control compartment annually to determine if cleaning is nec Maintenance iem boe g essary If there is an accumulation of dirt dust and or lint clean the compartment and follow the instructions below to remove and clean the burner CAUTION Use of eye protection is recommended Burner Removal 1 Outside the cabinet shut the gas supply off at the manual valve ahead of the Instructions Refer 2 Turn off electric supply to FIGURE 1 7 3 Disconnect the gas supply at the union outside of the cabinet 4 Remove the access panel 5 Disconnect the Gas Train and Move Out of the Way At the gas valve mark and disconnect the wires Carefully remove the burner orifice and orifice adapter locking nut Slide the orifice adapter out through the bracket on the burner pushing the gas train to the right This will move the gas train out of the way 6 Move the Control Assembly Remove the two screws holding the control assembly bracket Being careful not to disconnect any wires slide the control FIGURE 17 Burner assembly to the right Removal UDAP 7 Remove Secondary Air Baffles Sizes 60 400 only Vertical along the right illustrated same process side of the burner locate the flat plate s identified as the secondary air for both UDAP and UDAS baffle s The quantity of baffles could be one to four depending on heater Burner Body Support at least two per unit Remove s
70. rol board s fault mode monitoring circuits LED signal lights The integrated circuit board monitors the operation of the heater and includes two that indicate normal operation and various abnormal conditions If the heater fails to operate properly check this signal to determine the cause and or to eliminate certain causes See operating sequence in Paragraph 20 Do not attempt to Control Status Steady ON Fast Flash heat Normal Operation No call for heat Normal Operation Call for System Lockout Failed to repair the DSI integrated control module the only field replace able component is the fuse Green LED Codes 4 Flashes Pressure Switch is Closed Before Venter Motor is Energized Steady OFF Blown fuse No Power or Defective Board Flame Status Yellow LED Codes detect or sustain flame 2 Flashes 3 Flashes General Troubleshooting PROBLEM PROBABLE CAUSE Pressure Switch Did Not Close within 30 Seconds of Venter Motor High Limit or Flame Rollout Switch Open Steady ON Flame is sensed Slow Flash Weak flame current below 1 0 microamps 50 Undesired Flame valve open and no call for heat Fast Flash REMEDY Venter motor will not start Burner will not light No power to unit No 24 volt power to integrated circuit board Integrated circuit board fuse blown No power to venter motor Integrated circuit board defective
71. standard transformer in the master unit and a relay assembly that CL31 and Option attaches to the slave unit Option CL31 provides for control of two heaters If CL32 control of additional heaters is desired up to six total Option CL32 which is the relay assembly only must be added to each of the slave heaters The option packages are shipped separately and include complete instructions on installation and wiring The combustion air proving switch is a pressure sensitive switch that monitors air pressure to ensure that proper combustion airflow is available On Model UDAP 16 Combustion Air Proving the switch is a single pole normally open device which closes when a negative pressure is sensed in the venter housing On Model UDAS the switch senses the Switch differential pressure between the negative pressure in the venter housing and the Pres sure pressure in the cabinet For switch location see FIGURE 18 page 31 On startup when the heater is cold the sensing pressure is at the most negative Switch level and as the heater and flue system warm up the sensing pressure becomes less negative After the system has reached equilibrium about 20 minutes the sensing pressure levels off If a restriction or excessive flue length or turns cause the sensing pressure to be outside the switch setpoint the pressure switch will function to shutoff the main burner The main burner will remain off until the system has
72. t part that is designed for the amp 8 size of heater For approximate limit location see FIGURE 18 page 31 If itis determined that the door switch needs replacing use only 35 Door Switch a factory authorized replacement part that is designed for the U D AS on ly 1 heater For approximate switch location see FIGURE 18 page 31 See FIGURE 18 page 31 for location Use a voltmeter to verify that there are 24 volts output from the transformer If the trans former is not functioning it must be replaced Use a replacement transformer identical to the factory installed model Form RZ NA I UDA Mfg 195673 Rev 5 Page 33 36 Transformer The cause of a flame rollout switch activating must be determined Activation of the manually reset flame rollout switch could be caused by one or more of the following Restricted or plugged heat exchanger Pressurization of the heat exchanger 37 Flame Rollout Switch Sizes 30 125 only Restricted combustion air inlet or exhaust outlet in combination with a defective pressure switch Building exhaust Electrical power interruption during operation If a flame rollout switch trips inspect the burner control compartment for signs of excessive heat and burned wiring mM If the compartment appears normal reset by depressing the red button on the i switch 15 to 20 minutes are required for the switch to cool sufficiently for reset i ting A distinct click will be felt
73. t switch activates identify and correct the cause before resetting the switch Never bypass the flame rollout switch hazardous conditions could result See Hazard Intensity Levels page 2 Form RZ NA I UDA P N 195673 Rev 5 Page 18 1 9 Doo r Switch All sizes of Model UDAS heaters are equipped with a door switch which prevents the heater from operating when the service door panel is open The service panel Model of a Model UDAS is equipped with a pliable gasket material that fully seals the U D AS door to provide added protection from building air entering the combustion zone on y of the heater For switch location see FIGURE 18 page 31 2 0 iti This heater is equipped with a direct spark integrated control module circuit board lgnition The module monitors the safety devices and controls the operation of the fan and System venter motors and the gas valve between heat cycles FIGURE 14 DSI Integrated Control Module circuit board 1097 83 210X HSCI as 99g Thermostat Connections esa 24VAC GOH ANSI 221 20 AUTOMATIC 3 Dip Switch LED Lights Flame Status Yellow LED Codes Control Status Green LED Codes Steady ON Flame is sensed Steady ON Normal Operation No call for heat Slow Flash Weak flame current below 1 0 Fast Flash Normal Operation Call for heat microamps 50 1 Flash System Lockout Failed to detect or sustain Fast Flash Undesired Flame v
74. to provide controlled flame stability without lifting or flashback with either natu ral or propane gas The burner can be removed as a unit for inspection or service see Maintenance Section for removal instructions electrical wiring and connections including electrical grounding MUST be made in accordance with the National Electric Code ANSI NFPA No 70 latest edition or in Canada with CSA Standard C22 1 In addition 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 require ments dedicated line voltage supply with disconnect switch should be run di rectly from the main electrical panel to the heater All external wiring must be within approved conduit and have a minimum temperature rise rating of 60 Conduit must be run so as not to interfere with the heater access panel If the installation requires a stepdown transformer Option follow the instructions shipped with the option package for attaching the transformer to the heater The electrical supply enters at the rear of the heater See FIGURE 13 Model UDAS includes a built in disconnect switch 20A 115V 10A 230V Rating Model UDAS supply wiring connects to leads located inside a sealed electrical box To maintain the sealing feature of the electrical box always replace the cover plate Model UDAP supply wiring connects directly to leads
75. tor YES Does gas _NO E mere yes Check high pate spark voltage at voltage wire ignite niji control continuity Is there minimum Is the flame Clean flame Is there 24V P1 2 Replace flame current at the sensor corroded control sensor to power control flame sensor module 15 there Je minimum flame current Replace control lithe Sensor YES Replace flame Check wiring located in flame and or 24VAC at the control module sesnsor correctly transformer output module Check connections to flame m Reposition Is gas sensor and or moisture in the T flame sensor flowing burner assembly Check gas pressure and supply voltage Is the ignitor Renlace gas Is there If either are low position correct in the 9 24VAC at the gas valve correct and repeat gas flow valve startup m Check wiring and Iethere 24VAC Replace Reposition from gas valve output on ignition Form RZ NA I UDA P N 195673 Rev 5 Page 34 spark ignitor connections to gas valve control module to chassis control module Check the Lights on the DSI Integrated Control Module Circuit Board IMPORTANT When using a multimeter to troubleshoot the 24 volt circuit place the meter s test leads into the 5 or 9 pin connectors located on the ignition control Do not remove connectors or terminals from the electrical components Doing so can result in misinter preted readings due to the ignition cont
76. ucts 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 Paragraph 9 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 Model UDAP units installed in a confined space must be supplied with air for combustion as required by Code and in Paragraph 9 of this heater installation manual MAINTAIN THE VENT OR VENT COMBUSTION AIR SYSTEM IN STRUCTURALLY SOUND AND PROPER OPERATING CONDITION M Al NTE N AN C E WARNING If you turn off the power supply turn off the gas See Hazard AND SERVICE Levels page 2 The material contained in the MAINTENANCE AND SERVICE Section of this manual is designed to aid a qualified service person in maintaining and servicing this equipment This heater will operate with a minimum of maintenance To en sure long life and satisfactory performance a heater that is operated under normal 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 When any service is completed be careful to reassemble correctly to ensure that no unsafe conditions
77. ut Heating Capacity kw 8 8 13 2 17 6 22 0 30 8 35 2 Thermal Efficiency 82 83 83 83 83 83 Output Heating Capacity BTUH 24 600 37 350 49 800 62 250 87 150 99 600 ee ee 72 110 Natural 1 2 1 2 1 2 1 2 1 2 1 2 Propane inches diameter UDAS onl 1 0 1 0 Fan Diameter inches Sound Level Control Amps 24 volt 1 0 1 0 1 0 1 0 Full Load Amps 115 volt 2 4 3 3 3 9 5 1 Maximum Over Current Protection 115V p 15 15 15 15 Normal Power Consumption watts 155 217 276 354 Discharge Air Temperature Rise F 50 55 o eo e 6 456 629 M RM FPM M minute UE f ose oem F oo ae fia Enclosed Fan Motor RPM dba 15ft dba 15 ft TECHNICAL DATA Sizes 150 400 Data applie Size BTUH W Input Heating Capacity Thermal Efficiency 96 s to both Models UDAP and UDAS unless noted otherwise Control Amps 24 volt Full Load Amps 115 volt Maximum Over Current Protection 115V gt Normal Power Consumption watts Discharge Air Temperature Rise F Air Volume Discharge Air Opening Area BTH kw 48 6 54 7 60 8 72 9 85 1 97 2 Propane 1 2 3 4 3 4 3 4 3 4 3 4 Vent Connection inches diameter 5 5 5 5 5 6 6 6 Combustion Air Inlet inches diameter UDASonly __6 6 6 6 6 6 6 6 oo 60 6o eo co 6o eo M minute M i 0 TE m Mimimus 229 26 unte Open Enclosed
78. w fire pressure Turn the regulator screw to adjust the low fire outlet pressure to the Low Fire pressure selected from the table Re connect the wire to the gas valve 4 Turn up the thermostat NOTE On Model UDAS depress and hold the door safety switch Cycle the burner once or twice to properly seat the adjustment spring in the valve Re check the pressure s When the outlet pressure is right for the installation remove the manometer and replace the cap Check for leak at the pressure tap fitting 5 With the heater operating determine that the inlet pressure to the heater for natural gas is between 5 and 13 5 inches w c and for propane between 10 and 13 5 inches w c Take this reading as close as possible to the heater Heaters are equipped with gas valves that have an inlet pressure tap If the inlet pressure is not within the specified range the inlet pressure must be corrected and Steps 3 and 4 repeated 6 Find the High Altitude Adjustment label in the plastic bag that contained these instructions Using a permanent marker fill in the appropriate information from the tables on page 15 Select a location for the label on the outside of the heater access panel so that it will be conspicuous to anyone operating or servicing the unit Be sure the surface is clean and dry and adhere the label Form RZ NA I UDA P N 195673 Rev 5 Page 14 High Altitude Capacity Changes BTUH Inputs and Capacities by Altitude in the UNITED

Thomas & Betts UDAP User's Manual

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Thomas &amp; Betts UDAP User's Manual

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Thomas & Betts UDAP User's Manual