notice - dominion energy

NOTICE:

The information contained on the following page(s) was produced prior to May 1, 2014. On that date Reznor became part of

Nortek, Inc.

References to any other company affiliations are no longer valid.

©2014 Reznor, LLC. All Rights Reserved.Trademark notice: Reznor is registered in at least the United States.0514 PDF Form Cover1

Form RZ-NA-I-FE/BE, Mfg P/N 98807 Rev 10, Page 1

Index by PageBelt Tension ............................................. 17Blower/Filter Cabinet (Optional) ............ 23Blower Motor .......................................... 17Blower Rotation ...................................... 18Blower Speed Adjustment ....................... 17Bottom Access ......................................... 24Burners .............................................. 19, 24Burner Air Adjustment ............................ 19Burner Rack Removal .............................. 24Carryover, Flash ...................................... 25Check Installation and Start-Up .............. 20Clearances .................................................. 6Combustion Air Proving Switch .............. 19Combustion Air ......................................... 6Confined Space Installation ....................... 6Dimensions ................................................ 3Disconnect Switch ................................... 12Duct Flange (Blower Model Option) ...... 21Electrical Supply and Connections .......... 12Fan Blade ................................................. 25

Index by PageFan Control ........................................ 18, 26Fan Motor ............................................... 17Gas Piping and Pressures ........................ 10Guard Options (Blower Model) .............. 22Hanger Kits (Optional) .............................. 7Hazard Intensity Levels ............................ 2Heat Exchanger ........................................ 25High Altitude Combustion Air

Pressure Switch .......................... 5, 11High Altitude Operation ............................ 5Ignition System .................................. 19, 25Installation Codes ...................................... 2Limit Control ..................................... 18, 26Location (Heater) ....................................... 5Louvers, Vertical (Optional) .................... 21Maintenance ............................................ 23Maintenance Schedule ............................. 23Manifold Pressure ................................... 11Multiple Heater Control Option ............. 23

Index by PageNozzles, Downturn Air (Optional) ......... 21Optional Equipment ................................ 20Operating Sequence ................................. 19Orifices, Burner and Pilot ........................ 25Pilot ................................................... 19, 25Polytube Adapter (Blower Model

Option) .......................................... 21Service ...................................................... 23Spark Gap ................................................ 25Suspending the Heater ............................... 6Thermostat and Connections ................... 12Troubleshooting ....................................... 27Uncrating and Preparation ......................... 2Valve, Gas .......................................... 19, 26Venter Motor and Relay .......................... 26Venting ................................................. 8, 25Warranty .................................................... 2Wiring Diagrams ................................. 13-16

GENERALInstallation should be done by aqualified agency in accordance withthe instructions in this manual andin compliance with all codes and re-quirements of authorities having ju-risdiction. The instructions in thismanual apply to the unit heater mod-els listed below.

WARNING: Improper installation, adjustment,alteration, service, or maintenance can cause propertydamage, injury or death. Read the installation,operation, and maintenance instructions thoroughlybefore installing or servicing this equipment.

Table of ContentsInstallation and Operation ........................ Paragraph 1-24 ...... Pages 1-19Check Installation and Start-Up ................. Paragraph 25 ........... 0Optional Equipment .................................. Paragraph 26-32 .... Pages 21-23Service/Maintenance/Troubleshooting ... Paragraph 33-43 .... Pages 23-28

FOR YOUR SAFETYIf you smell gas:1. Open windows.2. Don't touch electrical switches.3. Extinguish any open flame.4. Immediately call your gas supplier.

FOR YOUR SAFETYThe use and storage of gasoline or otherflammable vapors and liquids in opencontainers in the vicinity of this appliance ishazardous.

WARNING: Gas-fired appliances are notdesigned for use in hazardous atmospherescontaining flammable vapors or combustibledust, in atmospheres containing chlorinatedor halogenated hydrocarbons, or in appli-cations with airborne silicone substances. SeeHazard Levels, Page 2.

INSTALLATION FORM RZ-NA-I-FE/BEObsoletes RGM 436 (Version B)

APPLIES TO: Installation/Operation/Service

Model FE and BEGas-Fired, Power-Vented

Unit Heaters

ModelFE

ModelBE

Model Fuel Vent Air DeliveryFE Gas-Fired Power Propeller Fan

BE Gas-Fired Power Centrifugal Blower (heater may be attached to ductwork)

REFERENCES: Replacement Parts, Form RZ-NA 726Gas Conversion, Form RZ-NA 434/436-GC

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Form RZ-NA-I-FE/BE, Mfg P/N 98807, Rev 10, Page 2

1. Installation CodesThe gas-fired unit heaters covered in this manual are design-certified bythe Canadian Standards Association (CSA) to ANSI Z83.8a and CGA2.6a for industrial/commercial installations in the United States andCanada. All heaters are available for use with either natural or propanegas. The type of gas, the firing rate, and the electrical characteristics areon the unit rating plate.These units must be installed in accordance with local building codes. Inthe absence of local codes, in the United States, the unit must be in-stalled in accordance with the National Fuel Gas Code (latest edition).A Canadian installation must be in accordance with the CAN/CGAB149.1 and B149.2 Installation Code for Gas Burning Appliances andEquipment. These codes are available from CSA Information Services,1-800-463-6727. Local authorities having jurisdiction should be con-sulted before installation to verify local codes and installation proce-dure requirements.

Special Installations (Aircraft Hangars/Garages)Installations in aircraft hangars should be in accordance with ANSI/NFPA No. 409 (latest edition), Standard for Aircraft Hangars; in publicgarages in accordance with ANSI/NFPA No. 88A (latest edition), Stan-dard for Parking Structures; and for repair garages in accordance withANSI/NFPA No. 88B (latest edition), Standard for Repair Garages.ANSI/NFPA-88 (latest edition) specifies overhead heaters must beinstalled at least eight feet above the floor. In Canada, installations inaircraft hangars should be in accordance with the requirements of theenforcing authorities, and in public garages in accordance with CAN/CGA B149 codes.ANSI/NFPA 409 (latest edition) specifies a clearance of ten feet to thebottom of the heater from the highest surface of the top of the wing orengine enclosure of whatever aircraft would be the highest to be housedin the hangar, and a minimum clearance of eight feet from the floor inother sections of aircraft hangars, such as the offices, and shops whichcommunicate with areas used for servicing or storage. The heaters mustbe located so as to be protected from damage by aircraft or other objectssuch as cranes and movable scaffolding. In addition, the heaters must belocated so as to be accessible for servicing, adjustment, etc.

WARRANTY: Warranty is void if......a. Unit Heaters are used in atmospheres containing flammable

vapors or atmospheres containing chlorinated or halogenatedhydrocarbons or airborne silicone substances.

b. Wiring is not in accordance with the diagram furnished withthe heater.

c. Unit is installed without proper clearances to combustible ma-terials or located in a confined space without proper ventila-tion and air for combustion. (See Paragraphs 7 and 8.)

d. Fan-type unit heater is connected to a duct system.

HAZARD INTENSITY LEVELS1. DANGER: Failure to comply will result in se-

vere personal injury or death and/or propertydamage.

2. WARNING: Failure to comply could result insevere personal injury or death and/or prop-erty damage.

3. CAUTION: Failure to comply could result inminor personal injury and/or property damage.

3. Uncrating and PreparationThis unit was test operated and inspected at the factory prior to cratingand was in operating condition. If the heater has incurred any damage inshipment, document the damage with the transporting agency and im-mediately contact your Reznor Distributor.Check the rating plate for the gas specifications and electrical character-istics of the heater to be sure that they are compatible with the gas andelectric supplies at the installation site. Read this booklet and becomefamiliar with the installation requirements of your particular heater. Ifyou do not have knowledge of local requirements, check with the localgas company or any other local agencies who might have requirementsconcerning this installation. Before beginning, make preparations fornecessary supplies, tools, and manpower.Check to see if there are any field-installed options that need to beassembled to the heater prior to installation. Each of the option pack-ages includes a list of components and step-by-step instructions. For abrief description of optional hanger kits, refer to Paragraph 9. For abrief explanation of other frequently specified field-installed options,see Paragraphs 26-32. After becoming familiar with the instructions,assemble and install the options that are required for your heater.If the heater was ordered with a vent cap, it will be shipped in aseparate carton.Unless the crate bottom has been removed for option installation, leaveit attached until after the heater has been suspended. If the crate bottomhas been removed, the bottom of the heater must be supported withplywood or appropriately placed boards. Without adequate support,the bottom access panel could be damaged.To protect the unit during shipping, the blower model has specialsupports that must be removed before installation. Follow these in-structions to remove:

Blower Support Legs -- Remove the two blower support legs andscrews.Motor Shipping Block - Remove the wooden block located under themotor bracket. Find the two rubber pads shipped in the instructionenvelope. Place these pads on the ends of the motor bracket bolts.Motor Shipping Plate -- Blower models that are equipped with mo-tors of 3/4 HP or less have a metal shipping plate attached betweenthe motor and the blower housing. Remove and discard the shippingplate. Note: On units factory equipped with an optional belt guard,the belt guard must be removed in order to reach the shipping plate.

2. WarrantyRefer to limited warranty information on the warranty card in the"Owner's Envelope".


4. DimensionsFan-Type, Power-Vented Unit Heater

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Suspension Notes: Use Dimension "G" for two-point suspension and "E" and "F" for four-point suspension. (Two-point suspension is standard; four-point is op-tional. Four-point suspension is available either factory or field installed.)

Size A B C D E F G H J K L M NNat Pro

25 29-25/32 13-9/16 27-1/16 31-7/16 5-27/32 14-7/16 14-1/32 4 10-9/32 16 1/2 1/2 9-13/16 350 29-25/32 13-9/16 27-1/16 31-7/16 5-27/32 14-7/16 14-1/32 4 10-9/32 16 1/2 1/2 9-13/16 375 29-25/32 15-9/16 27-1/16 31-7/16 5-27/32 14-7/16 14-1/32 4 10-17/32 16 1/2 1/2 10-7/16 3

100 29-25/32 17-9/16 30-7/16 31-7/16 5-27/32 14-7/16 14-1/32 4 12-29/32 16 1/2 1/2 10-7/16 3125 29-25/32 23-5/16 30-7/16 31-7/16 5-27/32 14-7/16 14-1/32 5 14-7/16 16 1/2 1/2 11-9/16 2-5/8165 39-15/16 20-5/16 35-7/16 35-15/16 4-7/8 19-15/32 15-23/32 5 14-9/32 24 1/2 1/2 11-11/16 4-19/32200 39-15/16 23-5/16 36-3/16 35-15/16 4-7/8 19-15/32 15-23/32 5 14-13/32 24 1/2 1/2 11-11/16 4-19/32250 39-15/16 28-13/16 36-3/16 35-15/16 4-7/8 19-15/32 15-23/32 5 12-11/32 24 1/2 1/2 11-11/16 4-19/32300 39-15/16 28-13/16 36-11/16 35-15/16 4-7/8 19-15/32 15-23/32 6 12-11/32 24 3/4 1/2 11-11/16 3-19/32400 39-15/16 37-1/16 37-5/16 35-15/16 4-7/8 19-15/32 15-23/32 6 13 24 3/4 1/2 11-11/16 3-19/32

Size A B C D E F G H J K L M NNat Pro

25 756 344 687 799 148 367 356 102 261 406 13 13 249 7650 756 344 687 799 148 367 356 102 261 406 13 13 249 7675 756 395 687 799 148 367 356 102 267 406 13 13 265 76100 756 446 773 799 148 367 356 102 328 406 13 13 265 76125 756 592 773 799 148 367 356 127 367 406 13 13 294 67165 1014 516 900 913 124 498 399 127 363 610 13 13 297 117200 756 592 919 913 124 498 399 127 366 610 13 13 297 117250 756 732 919 913 124 498 399 127 314 610 13 13 297 117300 756 732 932 913 124 498 399 152 314 610 19 13 297 91400 756 941 948 913 124 498 399 152 330 610 19 13 297 91

Dimensions (inches)

Dimensions (mm)

Figure 1A - Model FE Dimensions - inches (mm)


4. Dimensions (cont'd)Blower-Type, Power-Vented Unit Heater

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Dimensions (mm)Size A B CH D E FD GA C H J KA B L

Hanger Nat Pro25 756 344 1102 799 148 367 1559 102 261 406 13 1350 756 344 1270 799 148 367 1559 102 261 406 13 1375 756 395 1270 799 148 367 1559 102 267 406 13 13100 756 446 1270 799 148 367 1559 102 328 406 13 13125 756 592 1207 799 148 367 1674 127 367 406 13 13165 1014 516 1549 913 124 495 1934 127 363 610 13 13200 1014 592 1689 913 124 495 1934 127 366 610 13 13250 1014 732 1689 913 124 495 1934 127 314 610 13 13300 1014 732 1689 913 124 495 1934 152 314 610 19 13400 1014 941 1689 913 124 495 1934 152 330 610 19 13

Size A B CH D E FD GA C H J KA B LHanger Nat Pro

25 29-25/32 13-9/16 43-3/8 31-7/16 5-27/32 14-7/16 61-3/8 4 10-9/32 16 1/2 1/250 29-25/32 13-9/16 50 31-7/16 5-27/32 14-7/16 61-3/8 4 10-9/32 16 1/2 1/275 29-25/32 15-9/16 50 31-7/16 5-27/32 14-7/16 61-3/8 4 10-17/32 16 1/2 1/2100 29-25/32 17-9/16 50 31-7/16 5-27/32 14-7/16 61-3/8 4 12-29/32 16 1/2 1/2125 29-25/32 23-5/16 47-1/2 31-7/16 5-27/32 14-7/16 65-29/32 5 14-7/16 16 1/2 1/2165 39-15/16 20-5/16 61 35-15/16 4-7/8 19-15/32 76-1/8 5 14-9/32 24 1/2 1/2200 39-15/16 23-5/16 66-1/2 35-15/16 4-7/8 19-15/32 76-1/8 5 14-13/32 24 1/2 1/2250 39-15/16 28-13/16 66-1/2 35-15/16 4-7/8 19-15/32 76-1/8 5 12-11/32 24 1/2 1/2300 39-15/16 28-13/16 66-1/2 35-15/16 4-7/8 19-15/32 76-1/8 6 12-11/32 24 3/4 1/2400 39-15/16 37-1/16 66-1/2 35-15/16 4-7/8 19-15/32 76-1/8 6 13 24 3/4 1/2

Size M A N A P A R A S B T B U A W A XE Y ZHanger

25 3-23/32 20-15/16 17-3/4 5-1/4 10-3/4 8-7/16 14-3/4 6-3/16 31-7/32 9-13/16 350 3-23/32 20-15/16 17-3/4 5-1/4 10-3/4 8-7/16 14-3/4 6-3/16 31-7/32 9-13/16 375 2-23/32 20-15/16 17-3/4 5-1/4 12-3/4 8-7/16 14-3/4 6-3/16 31-7/32 10-7/16 3100 1-23/32 20-15/16 17-3/4 5-1/4 14-3/4 8-7/16 14-3/4 6-3/16 31-7/32 10-7/16 3125 1-11/32 20-15/16 17-3/4 5-1/4 20-1/2 8-7/16 20-1/2 6-3/16 35-3/4 11-9/16 2-5/8165 2-27/32 25-15/16 25-1/4 7-1/4 17-1/2 11-7/16 20-1/2 7-15/16 36-11/16 11-11/16 4-19/32200 1-11/32 25-15/16 25-1/4 7-1/4 20-1/2 11-7/16 20-1/2 7-15/16 36-11/16 11-11/16 4-19/32250 5-29/32 40-9/16 25-1/4 7-1/4 26 11-7/16 26 7-15/16 36-11/16 11-11/16 4-19/32300 5-29/32 40-9/16 25-1/4 7-1/4 26 11-7/16 26 7-15/16 36-11/16 11-11/16 3-19/32400 6-25/32 50-9/16 25-1/4 7-1/4 34-1/4 11-7/16 34-1/4 7-15/16 36-11/16 11-11/16 3-19/32

Figure 1B - Model BE Dimensions - inches (mm)


5. High Altitude OperationIf the heater is being installed in an altitude above 2000 ft (610M),check the rating plate to determine what must be done to prepare theheater for high altitude operation.NOTE: A heater equipped with a two-stage valve must be factory-built for high altitude installation.Check the rating plate, determine which circumstance below applies,and follow the instructions.

• If the altitude range on the rating plate agrees with the altitudeat the site, no further action is required. Proceed with the instal-lation.

• If the altitude range on the rating plate reads "Sea Level" andthe altitude at the site is between 2000 ft and 6000 ft (610Mto 1830M) and the heater has a single-stage gas valve, installthe heater and follow the instructions in Paragraph 11 to derate bymanifold gas pressure adjustment.

• If the altitude range on the rating plate reads "Sea Level" andthe altitude at the site is above 6000 ft (1830M) and theheater has a single-stage gas valve, in addition to adjusting themanifold pressure, it will be necessary to replace the combustionair pressure switch. Order the listed below and replace the switchbefore suspending the heater.After the heater is installed, follow the instructions in Paragraph11 to derate by adjusting the manifold gas pressure.

High Altitude Combustion Air Pressure SwitchP/N Description159180 #PPS10027-2733

E Use with 4-point suspension with blower cabinet.F Contactor is standard on Models 300 and 400; optional on other

sizes.G Contactor location with optional three phase motors on Sizes 50,

75, 100 and 125.H Deduct 6-5/8" (168mm) on Sizes 50, 75, and 100 when equipped

with direct drive motor.

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A When equipped with optional blower cabinet.B When equipped with optional duct flange.C Dimension includes a 3/4" flange on the rear of the blower

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

installing hanger kit Option CK19, suspension pointschange; see Paragraph 9.

Size M A N A P A R A S B T B U A W A XE Y ZHanger

25 94 532 481 133 273 214 375 157 793 249 7650 94 532 481 133 273 214 375 157 793 249 7675 69 532 481 133 324 214 375 157 793 265 76

100 44 532 481 133 375 214 375 157 793 265 76125 34 532 481 133 521 214 521 157 908 294 67165 72 659 641 184 445 291 521 202 932 297 117200 34 659 641 184 521 291 521 202 932 297 117250 150 1030 641 184 660 291 660 202 932 297 117300 150 1030 641 184 660 291 660 202 932 297 91400 172 1284 641 184 870 291 870 202 932 297 91

6. Unit Heater LocationCAUTION: Avoid installing a unit heater inextremely drafty areas. Extreme drafts can shortenthe life of the heat exchanger and/or cause safetyproblems.

For best results, the heater should be placed with certain rules in mind. Ingeneral, a unit should be located from 8 to 12 feet (2.4-3.7M) above thefloor. Units should always be arranged to blow toward or along exposedwall surfaces, if possible. Where two or more units are installed in thesame room, a general scheme of air circulation should be maintained forbest results.Suspended heaters are most effective when located as close to the work-ing zone as possible, and this fact should be kept in mind when determin-ing the mounting heights to be used. However, care should be exercised toavoid directing the discharged air directly on the room occupants.Partitions, columns, counters, or other obstructions should be taken intoconsideration when locating the unit heater so that a minimum quantity ofairflow will be deflected by such obstacles.When units are located in the center of the space to be heated, the airshould be discharged toward the exposed walls. In large areas, units shouldbe located to discharge air along exposed walls with extra units providedto discharge air in toward the center of the area.At those points where infiltration of cold air is excessive, such as atentrance doors and shipping doors, it is desirable to locate the unit so thatit will discharge directly toward the source of cold air from a distance of15 to 20 feet (4.6-6.1M).Units should not be installed closer than 18 inches (457mm) from anywall.

CAUTION: Do not locate the heater where it maybe exposed to water spray, rain or dripping water.

Figure 2-Pressure SwitchLocation (above6000 ft, replacewith a pressureswitch set for highaltitude operation)

Pressure Switch


Figure 3 -Confined Space: Aspace whose volume isless than 50 cubic feetper 1000 BTUH of theinstalled applianceinput rating

Figure 4 -Suspension

NOTE: If the installation includes an optional stepdown transformerkit (Option CF or CG), the stepdown transformer bracket is part of theheater suspension and must be installed prior to hanging the heater.Follow the instructions on the installation sheet included with the op-tion kit.A fan-type unit heater is equipped with standard two-point suspen-sion. A 3/8-16 threaded hanger bracket assembly is located on each sideof the heater. If a fan-type unit has been ordered with optional, factory-installed, four-point suspension (Option BJ6), it will have two threadedhanger brackets on each side.A blower-type heater is equipped with standard four-point suspen-sion. Two 3/8-16 threaded hanger bracket assemblies are located oneach side of the unit. Each hanger bracket assembly is designed forthreaded rod attachment.For both "standard" and "optional" suspension point dimensions, seeDimension Tables in Paragraph 3. (Note: If installing Option CK19hanger kit, suspension points change; see Figure 7.)

WARNING: Suspend the heater only from thethreaded hanger brackets. Do not suspend fromthe heater side panel.

When the heater is lifted for suspension, the bottom must be protected.If the wooden crate bottom has been removed, the bottom of the heaterwill have to be supported with plywood or other appropriately placedmaterial. If the bottom is not supported, the bottom access panel couldbe damaged. Also, when lifting a blower unit, support the blower andmotor to prevent the unit from tipping.

* When supplied with optional downturn nozzle, bottom clearance is42"(1067mm). For service purposes, on standard units, bottomclearance exceeding minimum (12" or 305mm) is not required butmay be desirable.

** For servicing purposes only, rear must remain full open.All fuel-burning equipment must be supplied with the air that entersinto the combustion process and is then vented to the outdoors. Suffi-cient air must enter the equipment location to replace that exhaustedthrough the heater vent system. In the past, the infiltration of outsideair assumed in heat loss calculations (one air change per hour) wasassumed to be sufficient. However, current construction methods uti-lizing more insulation, vapor barriers, tighter fitting and gasketed doorsand windows or weather-stripping, and mechanical exhaust fans maynow require the introduction of outside air through wall openings orducts.The requirements for combustion and ventilation air depend uponwhether the unit is located in a confined or unconfined space. An "un-confined space" is defined as a space whose volume is not less than 50cubic feet per 1000 BTUH of the installed appliance. Under all condi-tions, enough air must be provided to ensure there will not be a negativepressure condition within the equipment room or space. For specificrequirements for confined space installation, see Paragraph 8.

WARNING: These power-vented unit heaters aredesigned to take combustion air from the space inwhich the unit is installed and are not designed forconnection to outside combustion air intake ducts.Connecting outside air ducts voids the warrantyand could cause hazardous operation. See HazardLevels, Page 2.

8. Combustion Air Requirementsfor a Heater Located in aConfined Space

Do not install a unit in a confined space without providing wall open-ings leading to and from the space. Provide openings near the floor andceiling for ventilation and air for combustion as shown in Figure 3,depending on the combustion air source as noted in Items 1, 2, and 3below the illustration.

7. Clearances and CombustionAir

Units must be installed so that the following clearances are provided forcombustion air space, service and inspection, and for proper spacingfrom combustible construction. Clearance to combustibles is defined asthe minimum distance from the heater to a surface or object that isnecessary to ensure that a surface temperature of 90°F above the sur-rounding ambient temperature is not exceeded.Model Required Clearances (inches and mm)Size Top Flue Sides Bottom Rear

Collector25-400 6"(152) 6"(152) 18"(457) 12"(305) * 24" (610)**

Add total BTUH of all appliances in the confined space and divide byfigures below for square inch free area size of each (top and bottom)opening.1. Air from inside the building -- openings 1 square inch free area per1000 BTUH. Never less than 100 square inches free area for eachopening. See (1) in Figure 3.2. Air from outside through duct -- openings 1 square inch free areaper 2000 BTUH. See (2) in Figure 3.3. Air direct from outside -- openings 1 square inch free area per 4000BTUH. See (3) in Figure 3.NOTE: For further details on supplying combustion air to a confinedspace, see the National Fuel Gas Code ANSI Z223.1a (latest edition ).

9. Suspending the HeaterBefore suspending the heater, check the supporting structure to beused to verify that it has sufficient load-carrying capacity to supportthe weight of the unit.

Net Weight (lbs and kg)Model SizeType 25 50 75 100 125 165 200 250 300 400Fan lbs 76 83 92 101 132 154 175 209 226 281

kg 34 38 42 46 60 70 79 95 103 127Blower lbs 97 104 118 130 180 206 240 278 301 395

kg 44 47 54 59 82 93 109 126 137 179


Figure 5 - Two-Point Suspensionwith SwivelConnections(fan modelsonly)

All blower models have legs that support the blower assembly dur-ing shipping. After the unit is suspended, these legs should be re-moved.Be sure that the threaded hanger rods are locked to the heater asshown in Figure 4.

WARNING: Unit must be level for properoperation. Do not place or add additional weightto the suspended heater. See Hazard Levels, page2.

If an optional downturn air nozzle is used, the unit must be sus-pended from four points to ensure level suspension. Two hangerbrackets are included in the downturn option package and must befield-installed on fan-type units with standard two-point suspen-sion. For additional information, refer to Paragraph 27 and the in-structions that are furnished with the option package.When blower-type units are equipped with an optional blower/filter cabinet, there are two suspension points on the blower cabi-net hanger bar. Suspend a unit equipped with a blower/filter cabinetfrom four points, using the two heater hanger bracket assembliesclosest to the front of the heater and the two suspension points onthe blower/filter cabinet.If one of the optional, field-installed hanger kits has been ordered foryour heater, it will have been shipped separately. Each option pack-age includes a list of components and complete, step-by-step assem-bly instructions.Optional, Field-Installed Hanger Kits:1) Four-Point Suspension (fan models only) - Option CK7This option kit is designed to convert a fan-type heater from stan-dard two-point suspension to four-point suspension. The kit con-tains two additional hanger brackets.2) Two-Point Swivel Connectors (fan models only) - Option

CK8 (See Figure 5)The purpose of this option kit is to adapt the standard hanger bracketso that the heater can be suspended from 1", threaded, stationarypipe. The swivel connector screws "into" the threaded hanger bracketon the heater and "onto" the 1" threaded pipe used for hanging theheater. The kit includes two swivel hanger connector assemblies andtwo lock washers.

Figure 7 - Suspension Dimensions for Model B Heaterwith Hanger Kit Option CK19

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3) Four-Point with Swivel Connectors (fan-models only) - OptionCK9 (See Figure 6)

This option package is designed to convert a fan-type heater from stan-dard two-point suspension to four-point suspension with swivel con-nectors. By installing this kit the standard fan-type heater can be hungfrom four 1", threaded, stationary pipes. The kit includes two hangerbracket assemblies, four swivel hanger connector assemblies and fourlock washers.4) Four-Point Swivel Connectors - Option CK10 (See Figure 6)This option package is used on a heater that is already equipped withfour-point suspension to adapt it for suspension from four 1", threaded,stationary pipes. The kit includes four swivel hanger connector assem-blies and four lock washers.

5) Special Four-Point Suspension with Nearly Equal Loading(applies to blower models only) - Option CK19 (See Figure 7)

This suspension option is designed for special applications when a sus-pension system is needed that has nearly equal loading at all four suspen-sion points. Use this option in installations with spring isolation de-signed for seismic protection or when threaded rod hangers are longerthan twelve inches.Suspension points change with the addition of hanger kit Option CK19;see Figure 7.

Figure 6 - Four-Point Suspension with SwivelConnections (Applies to bothfan and blower models)

Dimensions (inches)Size A B25-50 11-7/8 9-1/875 13-7/8 11-1/8100 15-7/8 13-1/8125 21-5/8 18-7/8165 18-5/8 15-7/8200 21-5/8 18-7/8250 27-1/8 24-3/8300 27-1/8 24-3/8400 35-3/8 32-5/8

Dimensions (mm)Size A B25-50 302 23275 352 283100 403 333125 549 479165 473 403200 549 479250 689 619300 689 619400 899 829


Venter Outlet Attachment Requirements:• If the pipe used in the vent run is larger than the diameter of the

venter outlet (See Vent Length Table 2), Make the transition atthe venter outlet.

• A minimum of 12" (305mm) of straight pipe is required at theventer outlet (or transition fitting) before installing an elbow inthe vent system. An elbow should never be attached directly tothe venter. An elbow attached to the straight pipe can be in anyposition at or above horizontal. See Figure 8.

2. Vent PipeIf installed with a horizontal vent run, use either vent pipe ap-proved for a Category III heater or appropriately sealed 26-gaugegalvanized steel or equivalent single-wall pipe.If at least half of the equivalent length of the vent system is verti-cal, vent pipe approved for a Category I heater may be used.Single-wall pipe or double-wall (Type B) vent pipe are suitable foruse with a Category I heater.Use only one of the flue pipe diameters listed in the Vent LengthTables for the furnace size being installed.

2A. Vent Pipe Diameter ReductionIf at least half of the equivalent length of the vent system is verti-cal, the vent pipe diameter may be reduced one inch from thestandard diameter listed in Vent Length Table 1. Only single-wallpipe is suitable for use when reducing the pipe diameter. A taper-type reducer must be used. The maximum allowable vent lengthremains the same. If required, double-wall pipe may be used at theterminal end as shown in Figures 9 and 10. (Use the equivalentlength for elbows as shown in Vent Length Table 1 for the standardvent pipe diameter. All elbows used in the vent system must beconsidered.)

Figure 8 - Alternate Vent Directions (vent in anyposition above horizontal;minimum of 12" (305mm)of straight pipe isrequired before anelbow)

3. Vent Length TablesTable 1: Maximum Permissible Vent Lengths

Vent Maximum Equivalent StraightModel Pipe Vent Length* Length** - ft (M)

Diameter ft (M) 90° Elbows 45° Elbows25 4" 30 ft (9.1 M) 3.5' (1 M) 1.8' (.5 M)50 4" 40 ft (12.2 M) 5' (1.5 M) 2.5' (.8 M)75 4" 50 ft (15.2 M) 7' (2.1 M) 3.5' (1.1 M)

100 4" 50 ft (15.2 M) 7' (2.1 M) 3.5' (1.1 M)125 5" 50 ft (15.2 M) 5' (1.5 M) .5' (.8 M)165 5" 50 ft (15.2 M) 9' (2.7 M) 4.5' (1.4 M)200 5" 50 ft (15.2 M) 8' (2.4 M) 4.0' (1.2 M)250 5" 50 ft (15.2 M) 10' (3.0 M) 5' (1.5 M)300 6" 50 ft (15.2 M) 11' (3.4 M) 5.5' (1.7 M)400 6" 50 ft (15.2 M) 15' (4.6 M) 7.5' (2.3 M)

Table 2: Optional Maximum Permissible Vent Lengths(Requires an increase in vent pipe diameter.)

Vent Maximum Equivalent StraightModel Pipe Vent Length* Length** - ft (M)

Diameter ft (M) 90° Elbows 45° Elbows100 5" 60 ft (18.3 M) 8' (2.4 M) 4.0' (1.2 M)165 6" 60 ft (18.3 M) 10' (3.0 M) 5.0' (1.5 M)200 6" 60 ft (18.3 M) 12' (3.7 M) 6.0' (1.8 M)250 6" 70 ft (21.3 M) 8' (2.4 M) 4.0' (1.2 M)300 7" 70 ft (21.3 M) 13' (4.0M) 6.5' (2.0 M)400 7" 90 ft (27.4 M) 14' (4.3M) 7.0' (2.1M)

*Note 1: If the system contains all vertical pipe or a combination ofhorizontal and vertical vent pipe, the Maximum Permissible Vent Lengthshown in Tables 1 and 2 may be increased one foot for each foot verticalrise up to a maximum increase of 10 feet for Model sizes 25 thru 100 andup to 20 feet for Model sizes 125 thru 400.**Reduce the maximum vent length by the amount indicated for eachelbow.

4. Vent System JointsVent system joints depend on the installation and the type of pipe beingused.• If using single wall, 26-gauge or heavier galvanized pipe, secure slip-fit

connections using sheet metal screws or rivets. Seal pipe joints eitherwith tape suitable for 550°F (such as Option FA1, P/N 98266) or high-temperature silicone sealant.

• If using Category III vent pipe, follow pipe manufacturer's instructionsfor joining pipe sections. When attaching Category III pipe to the venteroutlet or the vent cap, make secure, sealed joints following a procedurethat best suits the style of Category III pipe being used.

• If using double-wall (Type B) vent pipe (allowed only if 1/2 of theequivalent vent length is vertical), follow pipe manufacturer's instruc-tions for joining pipe sections. For joining double-wall pipe to the venteroutlet collar, single-wall pipe, and/or the vent cap, follow the instruc-tions below.

10. VentingThese power-vented unit heaters are designed to operate safely and efficiently with either a horizontal or vertical vent. (Horizontal vent run isrecommended for maximum fuel savings.)

WARNING: Units installed in multiples require individual vent pipe runs and vent caps. Manifolding ofvent runs is not permitted due to possible recirculation of combustion products into the building and possibleback pressure effects on the combustion air proving switch.Specific Venting Requirements (read all before installing)

1. Venter (Flue) OutletVenter Outlet Size:

Model Size Outlet Diameter25-100 4"

125-250 5"300-400 6"


Figure 9 - Horizontal Vent Terminals

Structure Minimum Clearances for Vent TerminationLocation (all directions unless specified)

Forced air inlet within 10 ft (3.1m) 3 ft (0.9m) aboveCombustion air inlet of another appliance 6 ft (1.8m)Door, window, or gravity air inlet 4 ft (1.2m) horizontally (any building opening) 4 ft (1.2m) below

3 ft (0.9m) aboveElectric meter, gas meter * and relief equipment 4 ft (1.2m) horizontallyGas regulator * 3 ft (0.9m)Adjoining building or parapet 6 ft (1.8m)Grade (ground level) 7 ft (2.1m) above*Do not terminate the vent directly above a gas meter or service regulator.

Instructions for attaching double-wall (Type B) vent pipe to theventer outlet, a single-wall pipe run, or to the vent cap (usethese instructions for either full length double-wall or termi-nal only):Hardware and Sealant Required: 3/4" long sheetmetal screws; and atube of silicone sealant1) Look for the "flow" arrow on the vent pipe; attach according to thearrow. Slide the pipe so that the venter outlet, the single-wall pipe, orthe vent cap is inside the double-wall pipe.2) Drill a hole through the pipe into the outlet collar, the single-wallpipe, or the vent cap. (Hole should be slightly smaller than the sheetmetal screw being used.) Using a 3/4" long sheet metal screw, attachthe pipe. Do not overtighten. Repeat, drilling and inserting two addi-tional screws evenly spaced (120° a part) around the pipe.3) Use silicone sealant to seal any gaps. If there is an annular opening,run a large bead of sealant in the opening. The bead of sealant must belarge enough to seal the opening, but it is not necessary to fill the fullvolume of the annular area.

5. Vent System SupportSupport lateral runs every six feet, using a non-combustible materialsuch as strap steel or chain. Do not rely on the heater for support ofeither horizontal or vertical vent pipe

6. CondensationSingle wall vent pipe exposed to cold air or run through unheated areasmust be insulated. Where extreme conditions are anticipated, install ameans of condensate disposal.

7. Vent Terminal (Pipe and Vent Cap)The vent system must be terminated with a suitable vent cap that is thesame size as the vent run.Heaters must be equipped with the heater manufacturer's vent cap, aType L Breidert Air-x-hauster® vent cap, or equivalent. Use of a ventcap supplied by the pipe manufacturer is not permitted; the vent capmust be the type approved for use with this heater. A different stylevent cap could cause nuisance problems or unsafe conditions.See the illustrations in Figures 9 and 10 for requirements of both verti-cal and horizontal vent termination. The vent terminal section may beeither single-wall or double-wall (Type B) vent pipe. If double-wallpipe is used in the vent terminal with a single-wall vent run, follow theinstructions in No. 4, Vent System Joints, to attach the vent cap and toconnect the double-wall pipe to the single-wall vent pipe run.

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Single-Wall Vent Run and Single-Wall Terminal End Single-Wall Vent Run and Double-Wall Terminal End

Horizontal Vent Terminal Clearances:The location of the termination of the hori-zontal vent system must be in accordancewith National Fuel Gas Code Z223.1. Re-quired minimum clearances are listed onthe right.Products of combustion can cause discol-oration of some building finishes and dete-rioration of masonry materials. Applyinga clear silicone sealant that is normally usedto protect concrete driveways can protectmasonry materials. If discoloration is anesthetic problem, relocate the vent or in-stall a vertical vent.


11. Gas Piping and PressuresWARNING

This appliance is equipped for a maximum gassupply pressure of 1/2 pound, 8 ounces, or 14inches water column. Supply pressure higher than1/2 pound requires installation of an additionalservice regulator external to the unit.

PRESSURE TESTING SUPPLY PIPINGTest Pressures Above 1/2 PSI: Disconnect the heater andmanual 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 manualvalve on the heater.

All piping must be in accordance with requirements outlined in theNational Fuel Gas Code ANSI/Z223.1a (latest edition) or CAN/CGA-B149.1 and B149.2 (See Paragraph 1). Gas supply piping installationshould conform with good practice and with local codes.Unit heaters for natural gas are orificed for operation with gas having aheating value of 1000 (+ or - 50) BTUH per cubic ft. If the gas at theinstallation does not meet this specification, consult the factory forproper orificing.Pipe joint compounds (pipe dope) shall be resistant to the actionof liquefied petroleum gas or any other chemical constituents ofthe gas being supplied.Install a ground joint union and manual shut-off valve upstream of theunit control system, as shown in Figure 11. The 1/8" plugged tapping inthe shut-off valve provides connection for supply line pressure testgauge. The National Fuel Gas Code requires the installation of a trapwith a minimum 3" drip leg. Local codes may require a minimum dripleg longer than 3" (typically 6").Gas connection sizes are included in the Dimensional Tables in Para-graph 3. After all connections are made, disconnect the pilot supply atthe control valve and bleed the system of air. Reconnect the pilot lineand leak-test all connections by brushing on a soap solution.

Figure 11 - SupplyPiping Connection

WARNING: All components of a gas supplysystem must be leak tested prior to placingequipment in service. NEVER TEST FORLEAKS WITH AN OPEN FLAME. Failure tocomply could result in personal injury, propertydamage or death.

Manifold or Orifice Pressure SettingsMeasuring manifold gas pressure cannot be done until the heater is inoperation. It is included in the steps of the "Check-Test-Start" proce-dure in Paragraph 25. The following warnings and instructions apply.

WARNING: Manifold gas pressure must neverexceed 3.5" w.c. for natural gas and 10" w.c. forpropane gas.

For Natural Gas: When the heater leaves the factory, the combinationgas valve is set so that the manifold gas pressure is regulated to 3.5" w.c.Inlet supply pressure to the valve for natural gas must be a minimum of5" 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 combinationgas valve is set so that the manifold gas pressure is regulated to 10" w.c.

Figure 10 - Vertical Vent Terminals

10. Venting (cont'd)

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Single-Wall Vent Run and Single-Wall Terminal End Single-Wall Vent Run and Double-Wall Terminal End


Sizing a GasSupply Line

Capacity of PipingCubic Feet per Hour based on 0.3" w.c. Pressure Drop

Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft)Sp ecific Gravity for Prop ane Gas -- 1.6 (Propane Gas -- 2550 BTU/Cubic Ft)

Length Diameter of Pipeof 1/2" 3/4" 1" 1-1/4" 1-1/2" 2"

Pipe Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane20' 92 56 190 116 350 214 730 445 1100 671 2100 128130' 73 45 152 93 285 174 590 360 890 543 1650 100740' 63 38 130 79 245 149 500 305 760 464 1450 88550' 56 34 115 70 215 131 440 268 670 409 1270 77560' 50 31 105 64 195 119 400 244 610 372 1105 67470' 46 28 96 59 180 110 370 226 560 342 1050 64180' 43 26 90 55 170 104 350 214 530 323 990 60490' 40 24 84 51 160 98 320 195 490 299 930 567

100' 38 23 79 48 150 92 305 186 460 281 870 531125' 34 21 72 44 130 79 275 168 410 250 780 476150' 31 19 64 39 120 73 250 153 380 232 710 433175' 28 17 59 36 110 67 225 137 350 214 650 397200' 26 16 55 34 100 61 210 128 320 195 610 372

Note: When sizing sup p ly lines, consider p ossibilit ies of future expansion and increased requirements. Refer to National Fuel Gas Code for additional information on line sizing.

Inlet supply pressure to the valve for propane gas must be a mini-mum of 11" w.c. and a maximum of 14" w.c.Before attempting to measure or adjust manifold gas pressure, theinlet supply pressure must be within the specified range both whenthe heater is in operation and on standby. Incorrect inlet pressurecould cause excessive manifold gas pressure immediately or at somefuture time. If natural gas supply pressure is too high, install aregulator in the supply line before it reaches the heater. If naturalgas supply pressure is too low, contact your gas supplier.

Instructions on How to Check ManifoldPressure (can only be done after heater isinstalled):1) With the manual valve positioned to prevent flow to the mainburners, connect a manometer to the 1/8" pipe outlet pressure tapin the valve. NOTE: A manometer (fluid-filled gauge) is recom-mended rather than a spring type gauge due to the difficulty ofmaintaining calibration of a spring type gauge.2) Open the valve and operate the heater. Measure the gas pressureto the manifold. Normally adjustments should not be necessary tothe factory preset regulator.If adjustment is necessary, set pressure to correct settings by turn-ing the regulator screw IN (clockwise) to increase pressure. Turnregulator screw OUT (counterclockwise) to decrease pressure.

Derating by Manifold Pressure Adjustmentfor High Altitude OperationIf the heater is being installed above 2000 ft (610M) and it wasdetermined in Paragraph 5 that derating by manifold pressure ad-justment is permissible, follow the instructions below.Instructions for Derating a Heater by Adjusting ManifoldPressure (The heater must have a single-stage gas valveand must be factory-equipped for sea level operation.)1. Check the rating plate to be certain that the heater is equipped

for sea level operation. Do not attempt to derate by manifold gaspressure adjustment if the heater is factory equipped for highaltitude. Do not attempt to adjust manifold pressure on heatersequipped with two stage gas valves.

2. Determine the required manifold pressure for the elevation wherethe heater will be operating. If unsure of the elevation, contactthe local gas supplier.

Manifold Pressure Settings by ElevationAltitude Natural Gas Propane Gas

Feet Meters (inches W.C.) (inches W.C.)0- 2000 1-610 3.5 10.0

2001-3000 911-915 2.8 7.73001-4000 916-1220 2.5 7.14001-5000 1221-1525 2.3 6.45001-6000 1526-1830 2.1 5.86001-7000 1831-2135 1.9 5.27001-8000 2136-2440 1.7 4.68001-9000 2441-2745 1.5 4.1

3. With the manual valve positioned to prevent flow to the main burners,connect a manometer to the 1/8” pipe outlet pressure tap in the valve.Use a fluid-filled manometer that is readable to the nearest tenth of aninch w.c.

4. Remove the cap from the pressure adjusting screw and adjust the mani-fold pressure to the pressure setting selected from the table. Cycle themain burners once or twice to properly seat the adjustment spring inthe valve.Re-check the pressure. If necessary, re-adjust the pressure. When thepressure is correct, remove the manometer and replace the cap. Checkfor leaks at the pressure tap fitting.

5. With the heater operating determine that the inlet pressure to the heaterfor natural gas is between 5 and 14 inches w.c. and for propane between10 and 14 inches w.c. Take this reading as close as possible to heater(Most heaters are now equipped with gas valves that have an inletpressure tap.) If the inlet pressure is not within the specified range,the inlet pressure must be corrected and Steps 3 and 4 repeated.

6. If altitude is above 6000 ft (1830M), verify that the pressure switchhas been changed.High Altitude Combustion Air Pressure SwitchP/N Description159180 #PPS10027-2733

7. Find the Manifold Pressure Adjustment label in the plastic bag thatcontained these instructions. Using a permanent marker, fill-in thepressure setting. Adhere the label on the heater near the gas valve so thatit is conspicuous to someone servicing the valve and /or heater.


12. Electrical Supply and ConnectionsAll electrical wiring and connections, including electrical groundingMUST be made in accordance with the National Electric Code ANSI/NFPA No. 70 (latest edition) or, in Canada, the Canadian ElectricalCode, Part I-C.S.A. Standard C22.1. In addition, the installer should beaware of any local ordinances or gas company requirements that mightapply.Check the rating plate on the heater for the supply voltage and currentrequirements. A separate line voltage supply with fused disconnectswitch should be run directly from the main electrical panel to theheater. All external wiring must be within approved conduit and have aminimum temperature rise of 60°C. Conduit from the disconnect switchmust be run so as not to interfere with the service panels of the heater.The electrical supply connects at the top back of the heater in the leftcorner (left when facing the back of the heater). A threaded hole isprovided for a standard 1/2" electrical fitting.The wiring access panel is easily removed for field connections. Con-sult the wiring diagram supplied with your heater. Replace the panelafter the wiring connections are made.If the heater has field-installed options that require electrical connec-tions, consult the instruction sheet and wiring diagram supplied in theoption package.

Figure 12 - ElectricalConnections

RemoveAccess

Panel tomake

connections

with the appliance must be replaced, it must bereplaced with wiring material having a temperaturerating of at least 105°C, except for limit controland sensor lead wires which must be 150°C. SeeHazard Levels, page 2.

13. Thermostat and ThermostatConnections

A thermostat is not standard equipment but is an installation require-ment. Use either an optional thermostat available with the heater or afield-supplied thermostat. Install according to the thermostatmanufacturer's instructions. Make sure that the heat anticipator settingon the thermostat is in accordance with the amperage value noted onthe wiring diagram of your heater.Terminal Strip Connections - The standard heater is equipped witha two-screw terminal connector strip (See Figure 14) for easy connec-tion to the low voltage controls (24V). When factory-installed optionsrequire two-stage thermostat control, the heater is equipped with a SP-ST relay and a four-screw terminal connector strip (See Figure 15).If your heater requires field installation of the four-screw terminal stripand the relay, follow the instructions packaged with the relay or ther-mostat option.

If equipped withunit-mounteddisconnectswitch, on/offtoggle switch isnear accesspanel toelectricalsupply junctionbox.

Circuit breakerbutton forOption AI-1unit-mounteddisconnectswitch

Threaded Hole forStandard 1/2"

Fitting

Figure 13 - Optional Unit-Mounted Disconnect

Field Wiring fromDisconnect in

Conduit

Note: Fan-type heaterswith optional built-indisconnect switch, havean on/off switch locatednear the electricalsupply access panel.

WARNINGS: On a heater with a unit disconnectswitch (Option AI-1), if the power is turned off atthe switch, the supply lead in the electrical supplyjunction box (Figure 12) remains energized. Ifservice is to be done in the supply junction box,turn off the power at the remote disconnect switch.If you turn off the power supply, turn off the gas.

The operating sequence of the heater can be found on the heater wiringdiagram and is published in Paragraph 25, Check Installation and Start-Up. Typical wiring diagrams are on the next four pages, showingstandard single-stage heating with spark pilot with and without lock-out.

CAUTION: If any of the original wire as supplied

A fan-type heater may beequipped with a built-in fuseddisconnect switch (Option AI-1). If the heater is equipped witha built-in disconnect switch, atwo-position toggle (on/off)switch is located near the elec-trical supply access panel (SeeFigures 12 and 13).This switch may be used to dis-connect the power when servic-ing the heater other than in thesupply junction box.Specific wiring diagrams that in-clude standard and factory-in-stalled options are included withthe heater. Check the wiring dia-gram to identify optional equip-ment.

Figure 14 - Two ScrewTerminal Connector Strip

Figure 15 - Four ScrewTerminal Connector Strip

(Paragraph 13 continued on page 17.)

Two Screw TerminalConnector Strip for 24-

volt Wiring

Four Screw TerminalConnector Strip for

24-Volt Wiring


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TYPICAL WIRING DIAGRAMS -- Pages 13 - 16CAUTION: If any of the original wire as supplied withthe appliance must be replaced, it must be replacedwith wiring material having a temperature rating of atleast 105°C, except for limit control and sensor leadwires which must be 150°C. See Hazard Levels, page2.

Field Control Wiring Length and GaugeTotal Wire Distance from MinimumRecommended

Length Unit to Control Wire Gauge150' (45.7 m) 75' (22.9 m) #18 gauge250' (76.2 m) 125' (38.1 m) #16 gauge

350' (106.7 m) 175' (53.3 m) #14 gauge

Fan-Type, Power-Vented Model with Intermittent Spark Pilot, Single-Stage Heating,Natural or Propane


Blower-Type, Power-Vented Model Sizes 25-100 with Intermittent Spark Pilot, Single-Stage Heating,Natural or Propane, Direct Drive

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Model S izeSpeed *Medium Low *High Medium High *Medium Low *High Medium LowUse these Two Motor Wires

*Blue and White

Red and

White

*Black and

White

Blue and White

Black and

White

*Blue and White

Red and

White

*Black and

White

Blue and White

Red and

White*Factory-wired speed

25 50 75 100


Blower-Type, Power-Vented Model Sizes 50-250 with Intermittent Spark Pilot, Single-StageHeating, Natural or Propane, Belt Drive (NOTE: Belt drive is standard on Sizes 125-250; optionalon Sizes 50-100.)

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Blower-Type, Power-Vented Model Sizes 165-400 with Intermittent Spark Pilot, Single-stageHeating, Natural or Propane, Belt Drive, Motor Contactor (NOTE: Motor contactor is standard onSizes 300 and 400; optional on other sizes.

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14. Fan MotorFan motors are equipped with thermal overload protection of the auto-matic reset type. Should the motor refuse to run, it may be because ofimproper current characteristics. Make certain that the correct voltageis available at the motor.NOTE: If the unit is equipped with an optional totally enclosed motor,the horsepower may be larger than the standard motor. Refer to themotor nameplate to verify horsepower.

15. Blower MotorBlower Model Sizes 25-100 are standardly equipped with a directdrive motor; an optional belt drive motor is available on Sizes 50-100.Blower Model Sizes 125-400 have an adjustable belt drive motor.As part of the Check/Test/Start (Paragraph 25), check the belt forproper tension. Proper belt tension is important to the long life of thebelt and motor. A loose belt will cause wear and slippage. Too muchtension will cause excessive motor and blower bearing wear. Adjust thebelt tension by turning the adjusting screw on the motor base until thebelt can be depressed 1/2-3/4" (13-19mm). (See Figure 17.) After cor-rect tension is achieved, re-tighten the locknut on the adjusting screw.Most blower motors are equipped with thermal overload protection ofthe automatic reset type. If a motor is not equipped with thermaloverload protection, the unit will be equipped with a starter. The ad-

13. Thermostat Connections (cont'd)There are some unique wiring requirements with the installation of the optional controls (relay and two-stage). Figure 16 illustrates the wiring of therelay and the connections required for optional thermostat control.

Multiple Heater Control - These unit heaters are not designed for multiple unit connection to one thermostat. If you require that more than oneunit be controlled by a single thermostat, it will be necessary to use relays in the circuit. Options CL31 and CL32 provide the necessary parts andinstructions for multiple heater control. For more information on these options, see Paragraph 31.

justable setting on the starter will be factory set to match the amp drawof the motor and sealed. No change should be made to starter set unlessthe original motor is replaced.Starters are supplied from the factory for manual reset operation. If anoverload condition is experienced, the condition must be corrected, andthe starter must be manually reset.After the installation is complete including all ductwork, the amp drawof the motor should be checked with an amp meter to verify that themotor amp rating on the motor nameplate is not being exceeded. Ampsmay be adjusted downward by reducing blower speed for by increasingthe duct system static pressure. The temperature rise must be withinthe range specified on the unit rating plate.

'(&C��+7--�

Figure 16 - Wiring Diagrams for Optional Controls

575/3/60

Figure 17 -Adjusting BeltTension


16. Blower Speed AdjustmentThe blower speed may be adjusted to achieve the desired outlet tem-perature, as long as the adjustment is within the temperature rise andthe static pressure limits shown on the heater rating plate. Direct drivemotors are factory set as indicated in the chart below. Belt drivemotors are factory set at the mid-point between maximum and mini-mum blower speeds.If the duct resistance is low, the blower may deliver too high an airvolume; or if the heater is operated without ductwork, it may deliversufficient excess air to overload the motor, causing the overload protec-tor to cycle the motor. Reducing the blower speed will correct theseconditions. If ductwork is added to an installation, it may be necessaryto increase the blower speed. Decreasing blower speed will increaseoutlet temperature; increasing blower speed will decrease outlet tem-perature.

Blower Model Sizes 25-100 with Direct DriveDirect drive blower motors have multi-speed taps for speed adjust-ment. If your installation requires an adjustment of the blower speed,the motor may be re-wired to an alternate tap by following these in-structions.1. Turn off the gas and the electric power.2. Remove the left (left when facing the back of the unit) outer side

panel of the heater to reveal the wiring connections.3. Consult the wiring diagram on the heater and follow the below chart

to choose the wire for the desired adjustment. The asterisk(*) indi-cates the factory-wired speed.

Model Size Speed Use these Two Motor Wires25 *Medium *Blue and White

Low Red and White50 *High *Black and White

Medium Blue and White High Black and White

75 *Medium *Blue and White Low Red and White*High *Black and White

100 Medium Blue and White Low Red and White

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

6. Replace the belt and adjust the belt tension. Adjust tension byturning the adjusting screw on the motor base until the belt can bedepressed 1/2-3/4" (13-19mm). (See Figure 17.) Re-tighten the locknut on the adjusting screw.

7. Turn on the gas and electric. Light the heater following the instruc-tions on the lighting instruction plate.

8. Check the motor amps with an amp meter. The maximum motoramp rating on the motor nameplate must not be exceeded.

CAUTION: An external duct system staticpressure not within the limits shown on the ratingplate or improper adjustment of the motor pulleyor belt may overload the motor.

17. Blower RotationEach blower housing is marked for proper rotation. Rotation may bechanged on single-phase motors by re-wiring in the motor terminal box.Three-phase motors may be reversed by interchanging two wires onthe 3-phase supply connections.

18. Fan Control1. A fan control provides the following:

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

(b) Fan or blower operation as long as the unit is hot.2. The fan control provides additional safety by keeping the fan or

blower in operation in the event that the gas valve fails to closewhen the thermostat is satisfied.

3. To be sure that the fan or blower can continue to operate, the powersupply to the heater MUST NOT be interrupted except whenservicing the unit.

4. If the customer wants the heater off at night, the gas valve circuitSHOULD BE OPENED by a single pole switch wired in series withthe thermostat. Some thermostats are provided with this feature.Multiple units controlled from a single thermostat are shut off in thesame manner. For proper operation, be sure the fan control wiring isobserved.

WARNING: If you turn off the power supply, turnoff the gas. See Hazard Levels, page 2.

NOTE: Low ambient temperatures (less than 40°F) may cause falsecycling of the fan/blower. To prevent this, a time delay relay can beadded to the unit (available with single-stage gas valve only) to activatethe fan/blower electrically independent of the heat exchanger or theroom temperature. The low ambient fan control relay can be factoryinstalled; Option BF8 will appear on the heater wiring diagram. Or, therelay can be field installed; order Option CQ3 (P/N 113779). This relayis in addition to the fan control The fan control is a safety device andshould never be removed from the heater circuit.

19. Limit ControlAll models are equipped with an automatic, non-adjustable reset limitcontrol that acts to interrupt the electric supply to the redundant mainoperating valve in case of motor failure or lack of airflow due to restric-tions at the inlet or outlet.

4. Cut the crimped cap from the end of the wire that you intend to useand strip the insulation.

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

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

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

Blower Model Sizes 50-400 with Belt DriveThe belt drive on these units is equipped with an adjustable pulleywhich permits adjustment of the blower speed. Follow these instruc-tions to adjust the blower speed.1. Turn off the gas and the electric power.2. Loosen belt tension and remove the belt.3. Loosen the set screw on the side of the pulley away from the motor.4. To increase the blower speed, decreasing outlet temperature,

turn the adjustable half of the pulley inward. To decrease theblower speed, increasing the outlet temperature, turn the ad-justable half of the pulley outward. One turn of the pulley willchange the speed 8-10%.


Figure 18 - Air Shutter Adjustment Screws -- AlternateTurning Screws When Adjusting Shutter

20. Combustion Air ProvingSwitch

The combustion air proving switch is a pressure sensitive switch thatmonitors air pressure to ensure that proper combustion air flow is avail-able. The switch is a single pole - normally open - device which closeswhen a decreasing pressure is sensed in the outlet duct of the flue gascollection box.On start-up when the heater is cold, the sensing pressure is at the mostnegative level, and as the heater and flue system warm up, the sensingpressure becomes less negative. After the system has reached equilib-rium (about 20 minutes), the sensing pressure levels off.If a restriction or excessive flue length or turns cause the sensing pressureto become less than the switch setpoint, the pressure switch will func-tion to shut off the main burners. The main burners will remain off untilthe system has cooled and/or the flue system resistance is reduced. TheTable on the right lists the approximate water column negative pressurereadings and switch setpoints for sea level operating conditions.

DANGER: Safe operation of this unit requiresproper venting flow. NEVER bypass combustion airproving switch or attempt to operate the unit withoutthe venter running and the proper flow in the ventsystem. Hazardous conditions could result. SeeHazard Levels, page 2.

21. Gas ValveMain operating valve is powered by the 24-volt control circuit throughthermostat and safety controls. The main control valve is of the dia-phragm type with magnetic pilot servo bleed operators, providing regu-lated gas flow preset at the factory. The valve body also incorporates amagnetic valve providing pilot gas control for the electronic ignitor sys-tem and redundant or dual valve safety shutoff function.

WARNING: The operating valve is the primesafety shutoff. All gas supply lines must be free ofdirt or scale before connecting the unit to ensurepositive closure. See Hazard Levels, page 2.

22. Pilot and Ignition SystemThese unit heaters are equipped with a spark ignited intermittent safetypilot system that shuts off the pilot gas flow between heat cycles. Inaddition, propane units are equipped with a spark pilot system thatincorporates a lockout device that stops the gas flow to the pilot if thepilot fails to light in 120 seconds. The spark pilot with 100% lockoutrequires manual reset by interruption of the thermostat circuit. Propaneunits require the lockout; natural gas units may be equipped with eitherstandard spark pilot or spark pilot with lockout (Option AH3). Refer tothe wiring diagram with your heater for pilot system identification andproper wiring.The ignition controller in the spark pilot system provides the high volt-age spark to ignite the pilot gas and also acts as the flame safety device.After ignition of the pilot gas, the control electronically senses the pilotflame. (A separate solid metal probe in the pilot burner assembly isemployed for the flame sensing function. A low voltage electrical signal isimposed on that metal probe which is electrically isolated from ground.When the pilot flame impinges on the flame sensing probe, the flame acts

as a conduction path to ground. The pilot flame rectifies and com-pletes the DC circuit. The ignition controller acknowledges the flameand energizes the main gas valve.)

23. BurnersThese unit heaters have individually formed steel burners with accu-rately die-formed ports to give controlled flame stability without lift-ing or flashback with either natural or propane gas. The burners arelightweight and factory mounted in an assembly which permits themto be removed as a unit for inspection or service.

24. Burner Air AdjustmentAll sizes of these unit heaters that are equipped with standard alumi-nized burners are designed to operate without burner air shutters whenfueled with either natural or propane gas. However, Sizes 165 through400 equipped with optional stainless steel burners (Option AD2)require air shutters (Option AE1) when used with propane gas (Op-tion AA2).Optional air shutters, either factory or field installed, are available forany size model for use where unusual conditions cause excess primaryaeration.Before making any adjustments to the air shutters, allow the heater tooperate for about fifteen minutes. The air shutter adjustment screwscan be reached by opening the bottom panel. (Remove the two screwslocated at the rear of the bottom panel and allow the panel to hingedown from the front.) The adjustment screws for the air shutters arevisible at the rear of the burner rack. See Figure 18.

Model Start-Up Equilibrium Set Point Set PointSize Cold "OFF" "ON"

25-400 -1.0" w.c. -0.60" w.c. -0.47" w.c. -0.64"w.c.

When making the adjustment, close the air shutters no more than isnecessary to eliminate the problem condition.Observe the flame for yellow-tipping. A limited amount of yellow-tipping is permissible for liquefied petroleum gases. Other fuels shouldnot display any yellow-tipping.Two adjustment screws are used (See Figure 18). Rotating the screwsclockwise closes the shutters, reducing the primary air supply. Coun-terclockwise rotation opens the shutters, increasing the primary airsupply. The two adjustment screws should be rotated alternately toopen or close the shutters. Attempting to gain adjustment by notalternating between the two screws may cause the shutters to bind.After proper adjustment has been completed, eliminating the problemcondition, close the bottom panel and replace the retaining screws.

DANGER: Failure to install and/or adjust airshutters according to directions could causeproperty damage, personal injury, and or death.


25. Check Installation and Start-UpCheck the installation prior to start-up: 5. Thermostat calls for heat, energizing the venter motor.

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

7. Fan control senses heat exchanger temperature, energizingthe fan or blower motor.

8. If the flame is extinguished during the main burner operation,the safety switch closes the main valve and recycles the sparkgap.On units equipped with lockout device, if the pilot is notestablished within 120 seconds, the unit locks out and mustbe reset by interrupting power to the control circuit. (Seelighting instructions on the heater.)

Check installation after start-up:With the unit in operation, measure manifold gas pressure.See Paragraph 11.

Turn the unit off and on, pausing two minutes between eachcycle. Observe for smooth ignition.

Blower Model - Check motor amps with an amp meter. Themaximum amp rating on the motor nameplate must not beexceeded.

Place 'Owner's Envelope" containing Limited Warranty Card,this booklet, and any optional information in an accessiblelocation near the heater. Follow the instructions on the enve-lope.

Check suspension. Unit must be secure and level.

Blower Model - Check to be sure that all shipping supportshave been removed. Rubber feet must be on the motor bracketbolts. See Paragraph 3.

Check clearances from combustibles. Requirements are shownin Paragraph 7.

Check vent system to be sure that it is installed according tothe instructions in Paragraph 10.

Check piping for leaks and proper gas line pressure. Bleedgas lines of trapped air. See paragraph 11.

Check electrical wiring. Be sure all wire gauges are as recom-mended. A service disconnect switch should be used. Verifythat fusing or circuit breakers are adequate for the load use.

Check that any field-installed options have been included inthe installation.

Blower Model - Check belt tension. See Paragraph 15.

Start-Up -- Typical Operating Sequence:1. Set thermostat at lowest setting.2. Turn on main and pilot manual gas valves.3. Turn on the power to the unit.4. Set the thermostat to desired setting.

DANGER: The gas burner in this gas-fired equipment is designed and equipped to provide safe andeconomically controlled complete combustion. However, if the installation does not permit the burner toreceive the proper supply of combustion air, complete combustion may not occur. The result is incompletecombustion which produces carbon monoxide, a poisonous gas that can cause death. Safe operation ofindirect-fired gas burning equipment requires a properly operating vent system which vents all flue productsto the outside atmosphere. FAILURE TO PROVIDE PROPER VENTING WILL RESULT IN A HEALTHHAZARD WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH.Always comply with the combustion air requirements in the installation codes and in Paragraphs 7 and 8.Combustion air at the burner should be regulated only by manufacturer-provided equipment. NEVERRESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. Indoorunits installed in a confined space must be supplied with air for combustion as required by Code and inParagraph 8 of this heater installation manual. MAINTAIN THE VENT SYSTEM IN STRUCTURALLYSOUND AND PROPERLY OPERATING CONDITION.


28. Optional Duct Flange - Option CD9 (Blower Models only)Blower-type unit heaters may be connected to ductwork. The duct flange option is designed to adapt the heater outlet (supply side) for connectionto ductwork.Ductwork connection sizes are shown in the chart below.Follow the installation instructions included with the option package.

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

26. Optional Vertical Louvers -Option CD1

The purpose of the addition of optional vertical louvers is to increasethe air pattern spread. The vertical louver assembly is designed to befield assembled and installed. Refer to the instructions packagedwith Option CD1 for a list of components and step-by-step instal-lation instructions (Do not add optional vertical louvers to a fan-type heater with downturn nozzle Option CD3. See Paragraph 27.)

CAUTION: To avoid getting burned, adjustlouvers prior to heater operation. If louvers needre-adjusting after start-up, wear protectivegloves.

27. Optional Downturn Air Nozzles- Options CD2, CD3, CD4, andCD5

Unit heaters may be specified with optional downturn air nozzles todirect the discharge tempered air. The nozzles are shipped separately forfield assembly and installation. The horizontal louvers are removed fromthe heater and re-installed into the outlet of the downturn nozzle.The addition of a downturn nozzle requires four-point heater suspension.Two hanger brackets are included with downturn nozzle options and mustbe added to fan-type heaters with standard two-point suspension. Sus-pension point dimensions are found in Dimension Charts in Paragraph 4.On fan-type heaters, do not install Option CD5 or use vertical louverswith Option CD3.

Figure 19 -OptionalVerticalLouvers

Sizes "A" Range ofAir Deflection

25-125 9" (229mm) 25o-65o

165-400 13" (330mm) 25o-65o

Figure 20 - OptionalDownturn Nozzles

Sizes "A" Range ofAir Deflection

25-125 16-1/2" (419mm) 50o-90o

165-400 23-1/2" (597mm) 50o-90o

Model BE Duct Connection Sizes (inches and mm) with Optional Duct FlangeSize 25-50 75 100 125 165 200 250-300 400Height 15-7/8 15-7/8 15-7/8 15-7/8 23-7/8 23-7/8 23-7/8 23-7/8

403 403 403 403 606 606 606 606Width 10-3/4 12-3/4 14-3/4 20-1/2 17-1/2 20-1/2 26 34-1/4

273 324 375 521 445 521 660 870

29. Optional Polytube Adapter - Options CD6, CD8, and CD11 (BlowerModels only)

The polytube adapter option is designed to adapt this blower-type heater for use with polytube ductwork. The use of polytubes for air distributionis common in greenhouse applications and some industrial applications. A polytube distribution system delivers warm air to a specific area, reducingthe need for complete area heating. The polytube adapter is available in three installation designs making it adaptable to many applications andbuilding structures.

WARNINGS: This adapter is to be used only on units equipped with a blower. At no time should the freearea in the polytube be less than the listed minimum. Failure to comply with these warnings could result insevere personal injury, death and/or property damage.


30. Optional Guards -Options CD10 & CD12(Blower Models only)

These guard options are designed to provide complete pro-tection from the rotating drive and/or blower components.Option CD12 is designed for use with Sizes 25-100 withstandard direct drive motor. This kit includes only the blowerinlet guard.Option CD10 is designed for use on Sizes 50-400 with abelt driven motor and includes both the belt guard and theblower inlet guard.

Figure 22 - Optional Guards

OptionalBeltGuardInstalled

Optional Blower InletGuard Installed

Figure 21 - Polytube AdapterThe polytube adapter option package does not includepolytubing. Polytubing can be obtained from a supply dis-tributor such as FOF Products, Inc., P. O. Box E, 1505Racine Street, Delevan, WI 53115; ACME Engineering Co.,P.O. Box 978, Muskogee, OK 74402; or any local green-house supply distributor. Some local code authorities re-quire the polytube material to be a listed material. Consultcode authority having jurisdiction and the polytube sup-plier to determine the appropriate polytube material andrecommended methods of suspension.

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

Illustration shows OptionCD8, Polytube Adapter forFloor-Mounted Heater.Options CD6 and CD11are for Suspended Heaters.

Conversion Table(Diameter to Area)

Diameter Area ofof the Hole the Hole(inches) (sq in)2-1/2 4.912-1/4 3.982 3.141-7/8 2.761-1/2 1.761 0.785

CFM at Poly tube M inimum Free Suggested Hole Sizes and LocationsSize .25" Diameter Area (square Length of Polytube

ESP (inches) Inches) 50 Ft 75 Ft 100 Ft 125 Ft 150 FtNumber 37pairs 75 pairs 75 pairs

75 925 18 110 Diameter 1-1/2" 1" 1"Spacing 16" 12" 16"Number 50 pairs 50 pairs 100 pairs 94 pairs

100 1235 18 145 Diameter 1-1/2" 1-1/2" 1" 1"Spacing 12" 18" 12" 16"Number 40 pairs 60 pairs 60 pairs 125 pairs

125 1540 18 185 Diameter 1-7/8" 1-1/2" 1-1/2" 1"Spacing 15" 15" 20" 12"Number 40 pairs 60 pairs 60 pairs 125 pairs

130 1600 24 190 Diameter 1-7/8" 1-1/2" 1-1/2" 1"Spacing 15" 15" 20" 12"Number 50 pairs 50 pairs 75 pairs 75 pairs 75 pairs

165 2035 24 240 Diameter 1-7/8" 1-7/8" 1-1/2" 1-1/2" 1-1/2"Spacing 12" 18" 16" 20" 24"Number 42 pairs 42 pairs 60 pairs 60 pairs 100 pairs

200 2465 24 300 Diameter 2-1/4" 2-1/4" 1-7/8" 1-7/8" 1-1/2"Spacing 14" 21" 20" 25" 18"Number 40 pairs 60 pairs 60 pairs 60 pairs 60 pairs

250 3085 24 360 Diameter 2-1/2" 2" 2" 2" 2"Spacing 15" 15" 20" 25" 30"Number 75 pairs 75 pairs 75 pairs 75 pairs 75 pairs

300 3700 24 425 Diameter 2" 2" 2" 2" 2"Spacing 9" 12" 16" 20" 24"Number 60 pairs 60 pairs 60 pairs 100 pairs 100 pairs

400 4935 24 550 Diameter 2-1/2" 2-1/2" 2-1/2" 1-7/8" 1-7/8"Spacing 10" 15" 20" 15" 18"

Holes

29. Optional Polytube Adapter - Options CD6, CD8, and CD11 (BlowerModels only) (cont'd)


Figure 23 - Optional Field-Installed Blower/Filter Cabinet

Blower Cabinetwithout Filters(Option CW1)

31. Optional Blower/Filter Cabinet -Options CW1, CW2, or CW3(Blower Models Only)

The blower/filter cabinet option is available for all sizes. The blower/filtercabinet is shipped separately for field assembly and installation. The cabinet isadaptable for use with either 1" or 2" filters and may be connected to a returnair duct (includes 3/4" duct flange). Option CW1 does not include filters; CW2includes 1" permanent aluminum filters; and CW3 includes 2" permanent alu-minum filters.

Blower Cabinetwith Filters(Option CW2 orCW3) -- side panelremoved toillustrate interiorof cabinet

Model Filter Replacement P/NSize Qty Size 1" Filter 2" Filter

25-125 1 20 x 20 101608 101621165-200 1 16 x 25 101609 101622

1 20 x 25 101610 101623250-300 2 16 x 20 101607 101620

2 20 x 20 101608 101621400 2 16 x 25 101609 101622

2 20 x 25 101610 101623

32. Optional MultipleHeater Control -Options CL31 & CL32

The multiple heater control options are designed to per-mit the control of up to six heaters (one master and fiveslave units) with a single thermostat or a time clock andsingle/multiple thermostats. For maximum safety, the multiple control is one in thelow voltage circuit. These multiple heater control op-tions may not be used with two-stage gas valves.

Figure 24 - Multiple Heater Control Wiring with Options CL31 and/or CL32

SERVICE AND MAINTENANCEWARNING: If you turn off the power supply, turn off the gas. See Hazard Levels, page 2.

3. Blower Models - Clean the blower, the belt guard, the inlet guard,and motor of all dirt and grease. Check the blower belt for tensionand wear. Replace a worn belt that may fail before the next sched-uled maintenance check.

4. Clean the heat exchanger both internally and externally.5. Check the pilot burner and main burners for scale, dust, or lint

accumulation. Clean as needed.6. Check the vent system for soundness. Replace any parts that do

not appear sound.7. Check the wiring for any damaged wire. Replace damaged wiring.

(See Paragraph 12 for replacement wiring requirements.)

This unit will operate with a minimum of maintenance. To ensurelong life and satisfactory performance, a heater that is operated undernormal conditions should be inspected and cleaned at the start of eachheating season. If the heater is operating in an area where an unusualamount of dust or soot or other impurities are present in the air, morefrequent maintenance is recommended.The following procedures should be carried out at least annually (SeeParagraphs 33-42 for specific instructions.):1. Clean all dirt and grease from the primary and secondary combus-

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


Figure 31 -IndividualBurners

Figure 30 -Burner RackCompletelyRemoved

Burner Assembly Support Brackets

Figure 29 Burner Orifices

Figure 25 -BottomAccessPanel Open

Pushhingepin toremovebottompanel

PilotLocation

Figure 28 -Burner RackHinged Down

PilotTubing

FlameSensor Lead

Figure 26 - Spark Pilot Location

Burner Rack Supportwith Indexing

Figure 27 - Burner Rack Supportand Retaining Screws

Burner RackSupport on unitsmanufacturedprior to 8/91 wasnot indexed

Screws

33. Burner Rack RemovalThese unit heaters have a convenient bottom access panel. The pilot isattainable with the bottom panel open. With the access panel removed,the burner rack assembly will hinge down for removal. Use the follow-ing step-by-step instructions for removal of the bottom access paneland the complete burner rack assembly.

Instructions for Burner Rack Removal (SeeFigures 25-28.)1. Shut the gas supply off ahead of the combination valve.2. Turn off electric supply.3. Remove the two sheet metal screws located at the rear of the bottom

panel.4. Allow bottom panel to hinge down from the front.5. Push in one of the two spring-loaded hinge pins located at the front

of the bottom panel (inside), and completely remove the bottompanel.

NOTE: Use only factory-authorized replacement parts.

SERVICE AND MAINTENANCE (cont'd)

6. The bottom of thepilot is now vis-ible. Do the fol-lowing:

(a) Disconnect the pi-lot tubing from the pi-lot burner.(b) Disconnect theflame sensing wireand high tension(spark) lead from theignition controller. 7A. Heaters manufactured beginning 8/91 (Serial No. Date Code

AQH) - The burner rack is indexed as illustrated in Figure 27. Whilesupporting the burner rack, remove the screws (two or three) thathold the burner rack support. (For screw location, refer to Figure27.) Remove the burner rack support allowing the burner rack as-sembly to swing down (See Figure 28).

7B. Heaters manufactured prior to 8/91 (Serial No. Date Code AQH)Loosen the sheet metal screws (two or three) located at the front ofthe burner rack assembly. See Figures 27. These screws retain theburner rack support. While supporting the burner rack assembly,slide the burner rack support and remove it from the screws, allow-ing the burner rack assembly to swing down (See Figure 28).

8. To Remove the Burner Rack -- With the burner rack assembly"hanging" down, lift up on the rear and slide the assembly up andout of the manifold support brackets.

9. To remove the individual burners:a. Remove the flash carryover

(one screw per burner).b. With the burner rack upside

down, remove the sheet metalscrews (located at the rear) thatretain the burner holddown.

c. Lift the rear of the burner up-ward slightly and pull back, re-moving the individual burners.

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


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��- �9�0Figure 33 - PilotBurner Spark Gap

CAUTION: Due to high voltage on pilot spark wireand pilot electrode, do not touch when energized.See Hazard Levels, page 2.

Figure 34 -PilotAssembly

Figure 32 - Pilot Removal

Pilot HoleCover Plate

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10. To replace the burner rack assembly and the bottom panel,reverse the above procedure (Steps 1-8).Individual burners may be cleaned using air pressure. Use an air nozzleto blow out scale and dust accumulation from the burner ports. Alter-nately, blow through burner ports and venturi.

CAUTION: Eye protection is recommended.Use a fine wire to dislodge any stubborn particles. Do not use anythingthat might change the port size.When any service is completed, be careful to reassemble correctly toensure that no unsafe conditions are created. When re-lighting, alwaysfollow the lighting instructions on the heater.

34. Pilot and Ignition SystemThe pilot can be serviced by opening the bottom access panel of theheater. Follow the first four steps of instructions for Burner RackRemoval, Paragraph 33. The pilot can be removed to check the wiring,the spark gap, or to remove the orifice for cleaning. When the pilot is re-installed, be sure to include the pilot hole cover plate.Spark gap must be maintained to .100". (See Figure 33.)In the event the pilot flame is short and/or yellow, check the pilotorifice for blockage caused by lint or dust accumulation.Remove the pilot orifice and clean with air pressure. Check and cleanthe aeration slot in the pilot burner.

The ignition controller of the intermittent electronic ignition pilotsystem is visibly located on the back of the heater. (See Figure 35.) Donot attempt to disassemble the ignition controller. There are no fieldreplaceable components in the control enclosure. However, each heat-ing season the lead wires should be checked for insulation deteriorationand good connections.

Proper operation of the electronic spark ignition system requiresa minimum flame signal of .2 microamps as measured by amicroampmeter.For further information and check out procedure on the intermittentelectronic ignition pilot system, refer to the manufacturer's controloperating instructions supplied with the heater.

Figure 35- IgnitionControllerLocation

IgnitionControllerfor SparkPilot

Figure 36 -Burner

Rack FlashCarryover

FlashCarryover

36. Flash CarryoverSee Figure 36. The burner carryover system receives its gas supplyfrom the main burner ports. Check the carryover assembly and also themain burner ports for cleanliness. Clean with air pressure.

35. Burner OrificesHeaters are shipped with orifices of proper size and type for gas andaltitude specified on the order. When ordering replacement orifices,give BTUH content, specific gravity of gas, and altitude, as well asmodel and serial number of the heater.

CAUTION: Eye protection is recommended.

37. Heat ExchangerThe outside of the heat exchanger can be cleaned from the front of theheater with an air hose and/or a brush. Remove all accumulated dust andgrease deposits.

CAUTION: Eye protection is recommended.The inner surfaces of the heat exchanger can be reached for cleaningwith the burner rack removed. (See Paragraph 33.) Cleaning can be donewith a long furnace brush or a heavy wire to which steel wool has beenattached. Brush up and down inside each heat exchanger tube until allforeign material is removed. A flashlight is helpful in examining theupper section of the tube.

38. Fan or BlowerRemove dirt and grease from the motor.On fan model units, remove dirt and grease from the fan guard andblades. Use care when cleaning the fan blades to prevent causing mis-alignment or imbalance. Check that the hub of the fan blades is secure tothe shaft.


40. Venter MotorRemove dirt and grease from the motor housing. Power venter motor ispermanently lubricated.The vent relay controls the venter motor. If the relay contacts fail toclose the venter motor will not run. If the relay contacts fail to open, theventer motor will not shut off, preventing the combustion air pressureswitch from opening.

41. Operating Gas ValveThe gas valve requires no field maintenance except careful removal ofexternal dirt accumulation and checking of wiring connections. Instruc-tions for testing pressure settings are in Paragraph 11.

WARNING: The operating valve is the primesafety shutoff. All gas supply lines must be free ofdirt or scale before connecting to the unit to ensurepositive closure. See Hazard Levels, page 2.

42. Fan and Limit ControlsIf it is determined that the fan or limit control needs replacing, use onlyfactory-authorized replacement parts that are designed for your heater.Instructions for replacing fan or limit control:1. Turn off the electric power and shut off the gas supply.2. Remove the outer left side panel (left when facing the back of the

unit). Remove the access panel. (See Figure 38.)3. Remove defective controls and install new controls in the same

mounting holes. Use only factory-authorized replacement parts.4. Replace access panel and side panel.5. Turn on the electric power and the gas supply.6. Relight following the lighting instructions on the heater.

Figure 38 -Access toControls

39. Vent SystemCheck the vent system at least once a year. Inspection should includeall joints, seams, and the vent cap. Replace any defective parts.

RemoveControlAccessPanel

FanControl

LimitControl

On blower models, remove the grease and dirt from the blower housingand check the belt for wear and proper tension (See Paragraph 15.)Lubricate if the motor has oil cups or grease fittings. The motor sup-plied as standard has lifetime lubrication and sleeve bearings.On blower models, check current draw to motor rating plate.Fan Models: Follow these instructions for replacement of the fanguard, fan motor or fan blades.1. If the heater is installed, turn off the gas and disconnect the electricpower.2. Remove the left outer side panel (left when facing the rear of theunit). Disconnect the fan motor wires.3. Depending on the date that the heater was manufactured, it will haveeither a lower-half fan guard only, two-piece full fan guard, or a one-piece full fan guard. If the unit has a two piece fan guard, remove thetension mounted upper half fan guard and the four screws that hold thelower half. If the unit has a one-piece fan guard, remove all of the screwsthat retain the fan guard. Remove the assembled parts (the fan guard,the motor and the fan blade).4. Disassemble and replace whatever parts are needed and reassembleusing whatever part(s) are being replaced and the original parts. If thefan guard is being replaced, it is important that the same hardware beused for attaching the motor to the fan guard as was used with theoriginal guard. These screws are especially made to cut through thecoating on the fan guard to provide adequate grounding for the motor.Position the assembly on the heater. Attach the fan guard at the centermounts. (IMPORTANT: If replacing the fan guard, use the screws thatheld the original fan guard. These specially designed screws will cutthrough the coating on the fan guard to provide a ground for the fanmotor.) Rotate the fan blade to check for adequate clearance. If adjustment isrequired, loosen the mounting screws, re-position the fan guard, andtighten the screws. Rotate the fan blade and re-check for adequateclearance. Repeat this procedure until the assembly is positioned prop-

Figure 37 -Proper Positionof the Fan Bladeon the MotorShaft Fan HubA

FanMotor

Be sure the fanblade is in properposition on theshaft. Position thefan as shown inFigure 37 accord-ing to the chart onthe right.

Model Set Screw “A” Hub toSize Torque In-Lbs Motor25 80 + or - 10 1-1/4" (32mm)50 80 + or - 10 3/8"(10mm)75 80 + or - 10 1/8" (3mm)

100-125 120 + or - 10 2-1/2" (64mm)165-400 150 + or - 10 2-1/2" (64mm)

erly.5. If necessary, drill the required upper and lower fan guard mountingholes. Attach the fan guard at all upper and lower mounting pointsusing either the screws removed or field-installed sheet metal screws.6. Reconnect the fan motor wires and replace the outer side panel.7. Restore power to the heater and turn on the gas. Light, following theinstructions on the lighting instruction plate. Check for proper opera-tion.

38. Fan or Blower (cont'd)


43. TroubleshootingTRO UBLE PRO BABLE CAUSE REMEDYVenter motor will not start

1. No power to unit. 1. Turn on power, check supply fuses, or circuit breaker. If unit is equipped with unit-mounted disconnect switch, check circuit breaker (See Paragraph 12).

2. No 24 volt power to venter relay. 2. Turn up thermostat; check control transformer output. 3. Venter relay defective. 3. Replace relay. 4. Defective motor or capacitor. 4. Replace motor or capacitor.

Pilot will not light 1. Manual valve not open. 1. Open manual valve.(spark ignition 2. Air in gas line. 2. Bleed gas line.system) 3. Dirt in pilot orifice. 3. Remove and clean with compressed air or solvent (do not ream).

4. Gas pressure too high or too low. 4. Supply pressure should be 5-14"w.c. for natural gas or 10-14" w.c. for propane gas. (See Paragraph 11.)

5. Kinked pilot tubing. 5. Replace tubing.6. Pilot valve does not open. 6. If 24 volt available at valve, replace valve. 7. No spark: 7. a) Loose wire connections a) Be certain all wires connections are solid.b) T ransformer failure. b) Be certain 24 volts is available. c) Incorrect spark gap. c) Maintain spark gap at .100".d) Spark cable shorted to ground. d) Replace worn or grounded spark cable. e) Spark electrode shorted to ground. e) Replace pilot if ceramic spark electrode is cracked or grounded. f) Drafts affecting pilot. f) Make sure all panels are in place and tightly secured to prevent drafts at pilot.

g) Ignition control not grounded. g) Make certain ignition control is grounded to furnace chassish) Faulty ignition controller. h) If 24 volt is available to ignition controller and all other causes have been

eliminated, replace ignition control. 8. Optional lockout device interrupting control circuit by above causes.

8. Reset lockout by interrupting control at thermostat.

9. Faulty combustion air proving switch. 9. Replace combustion air proving switch. Pilot lights, main 1. Manual valve not open. 1. Open manual valve.valve will not open 2. Main valve not operating. 2.(Spark Ignition system)

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

b) Loose wire connections. b) Check and tighten all wiring connections.3. Ignition control does not power main valve. 3.a) Loose wire connections. a) Check and tighten all wiring connections.b) Flame sensor grounded. (Pilot lights - spark continues)

b) Be certain flame sensor lead is not grounded or insulation or ceramic is not cracked. Replace as required.

c) Gas pressure incorrect. c) Supply pressure should be 5-14"w.c. for natural gas or 10-14" w.c. for propane gas. (See Paragraph 11.)

d) Cracked ceramic at sensor. d) Replace sensor.e) Faulty ignition controller. e) See Paragraph 34. If all checks indicate no other cause, replace ignition

controller. DO NOT ATTEMPT TO REPAIR IGNITION CONTROLLER. THIS DEVICE HAS NO FIELD REPLACEABLE PARTS.

No heat (Heater 1. Incorrect manifold pressure or orifices. 1. Check manifold pressure (See Paragraph 16).O perating) 2. Cycling on limit control. 2. Check air throughput (See Paragraph 16).

3. Improper thermostat location or adjustment. 3. See thermostat manufacturer's instructions. Cold air delivered 1. Fan control improperly wired 1. Connect as per wiring diagram. O n Start-up 2. Defective fan control. 2. Replace fan control. During O peration 3. Incorrect manifold pressure. 3. Check manifold line pressure (See Paragraph 11).Motor will not run 1. Circuit open. 1. Check wiring and connections. .

2. Fan control inoperative. 2. Replace fan control. 3. Defective motor or capacitor. 3. Replace motor or capacitor.

Motor turns on 1. Fan control improperly wired. 1. Connect as per wiring diagram.and off while 2. Defective fan control. 2. Replace fan control.burner is operating (See motor cuts out

3. Poor contact between fan control and heat exchanger tube. Surface contact is required.

3. Check for bent mounting or loose mounting screws.

on overload 4. Motor overload device cycling on and off. 4. Check motor load against motor rating plate. Replace motor if needed. below) 5. Low ambient temperature (less than 40°F)

causing false cycling. 5. Install fan delay relay kit (See Paragraph 18.)

Fan motor cuts 1. Low or high voltage supply . 1. Correct electric supply.out on overload 2. Defective motor. 2. Replace motor.

3. Poor air flow. 3. Clean motor, fan and fan guard. 4. Defective bearing or lubrication. 4. Lubricate bearings or replace motor.

Blower motor 1. Improper motor pulley and/or adjustment. 1. See instructions in Paragraph 15. cuts out on 2. Improper static pressure in the duct system. 2. Adjust duct system dampers.overload 3. Low voltage. 3. Check power supply.


FOR SERVICE OR REPAIR, FOLLOW THESE STEPS IN ORDER:

FIRST: Contact the installer.

Name _______________________________________________________________________________________

Address ________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

Phone ________________________________________________________________________________________

SECOND: Contact the nearest distributor (See Yellow Pages). If no listing,contact Authorized Factory Representative, 1-800-695-1901 (Press 1)

THIRD: Contact: REZNOR®/Thomas & Betts Corporation150 McKinley AvenueMercer, PA 16137Phone: (724) 662-4400

Model No. ______________________________________________________________________________________________

Unit Serial No. __________________________________________________________________________________________

Date of Installation _______________________________________________________________________________________

800-695-1901 www.RezSpec.com©2004 Thomas & Betts Corporation, All rights reserved. Printed in the U.S.A.MANUFACTURER OF GAS, OIL, ELECTRIC HEATING AND VENTILATING SYSTEMSTrademark Note: Reznor® is registered in the United States and other countries. All othertrademarks are the property of their respective organizations.704 OG POD Form RZ-NA-I-FE/BE

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