Lennox International Inc Heating System T CLASS TM SEPARATED COMBUSTION UNIT HEATERS User Manual

INSTALLATION  
INSTRUCTIONS  
Litho U.S.A.  
2003  
©
TUA*S(N,L)(A,S)F  
*045, 060, 075, 100, and 125  
Lennox Industries Inc.  
Dallas, Texas, USA  
T-CLASSTM SEPARATED COMBUSTION  
UNIT HEATERS  
Table Of Contents  
Unit Dimensions………………………………  
Shipping………………………………………  
Requirements…………………………………  
Unit Heater Installation………………………  
1, 2 Leak Check………………………………………..  
13  
14  
16  
16  
17  
3
3
4
4
Start-up Operation………………………………...  
Heating Sequence of Operation…………………  
Ignition Control LED………………………………  
Adjustments…………………….………………….  
Combustion  
&
Ventilation  
Air…………………  
Venting…………………………………………  
Electrical Connections………………………  
5
Service……………………………………………..  
Wiring Diagram………………….………………..  
19  
20  
12  
Gas Connection……………………………… 13  
RETAIN THESE INSTRUCTIONS  
FOR FUTURE REFERENCE  
WARNING  
If the information in this manual is not  
followed exactly, a fire or explosion  
,
may result causing property damage  
personal injury or loss of life.  
WHAT TO DO IF YOU SMELL GAS:  
Do not try to light any appliance.  
Extinguish any open flame.  
Do not touch any electrical switch; do not use any  
phone in your building.  
Do not store or use gasoline or  
other flammable vapors and  
liquids in the vicinity of this or any  
other appliance.  
Immediately call your gas supplier from a neighbor's  
phone. Follow the gas supplier's instructions.  
If you cannot reach your gas supplier; call the fire  
department.  
Installation and service must be  
performed by a qualified installer,  
service agency or the gas supplier.  
P/N: 065354800  
ORGINATED: 5/04  
REVISED: 11/04  
SUPERSEDES: NEW  
Technical literature form number 504,955M  
 
100 and 125 UNIT DIMENSIONS  
5-1/2  
(140)  
THREADED STUDS  
24-7/16  
(621)  
AIR  
FLOW  
21-5/16  
(541)  
32-3/8  
(822)  
HEAT  
EXCHANGER  
(ALUMINIZED STEEL)  
7-1/4  
(184)  
1/2  
(13)  
TOP VIEW  
36-1/2  
(927)  
32-3/8  
(822)  
8-1/2  
(216)  
DIRECT  
DRIVE FAN  
7-3/8  
(187)  
FLUE  
OUTLET  
THUMB  
SCREW  
ELECTRIC  
BOX  
21  
(533)  
7 (178)  
7-3/4  
(197)  
SERVICE  
ACCESS  
DOOR  
SITE  
GLASS  
COMBUSTION AIR INLET  
ADJUSTABLE  
LOUVERS  
GAS  
INLET  
SIDE VIEW  
BACK VIEW  
TABLE 1  
UNIT CLEARANCES  
Top  
Sides  
mm  
25  
Access Panel  
Bottom  
Rear  
mm  
457  
Single Wall Vent*  
in  
1
mm  
25  
in  
1
in  
mm  
457  
in  
mm  
0
in  
in  
6
mm  
152  
Model  
TUA45S, TUA60S, TUA75S,  
TUA100S, TUA125S  
18  
0
18  
*Except for listed clearance thimbles  
Page 2  
 
Requirements – CSA in Canada  
Shipping  
The heater is completely assembled. Two mounting  
brackets are included with the 45, 60, and 75 size units.  
Check the unit for shipping damage. The receiving party  
should contact the last carrier immediately if any shipping  
damage is found.  
The instructions are intended only as a general guide and  
do not supersede local codes in any way. Authorities  
having jurisdiction should be consulted before installation.  
The installation must conform with local building codes or  
in the absence of local codes, with the current code CSA-  
B149.1 “Installation Code for Natural Gas Burning  
Appliances and Equipment." All electrical wiring and  
grounding for the unit must also comply with the  
Canadian Electrical Code CSA C22.1, current edition.  
Requirements – CSA in the USA  
Installation of gas unit heaters must conform with local  
building codes or, in the absence of local codes, with the  
current National Fuel Gas Code ANSI Z223.1.  
Installation in aircraft hangers must be in accordance with  
the current Standard for Aircraft Hangers ANSI/NFPA No.  
409.  
Installation in parking structures must be in accordance  
with the current Standard for Parking Structures  
ANSI/NFPA No. 88A.  
These unit heaters are CSA International certified for the  
clearances to combustible material listed on the rating  
plate and table 1. Adequate clearance shall be provided  
around the appliance and around air inlet terminals.  
Provision shall be made for service accessibility to the  
heater. Note that fire protection clearances may be  
exceeded to provide additional space for service and  
accessibility.  
Installation in repair garages must be in accordance with  
the current Standard for Repair Garages ANSI/NFPA No.  
88B.  
GARAGE INSTALLATIONS:  
1- In a storage area, clearance from heaters to  
combustible materials must be such that the material  
shall not attain a temperature above 160°F by  
continuous operation of the unit.  
2- Eight foot minimum clearance from the floor to the  
bottom of the heater must be maintained. Refer to the  
CSA-B149 Codes.  
These units are approved for residential applications.  
Residential applications are defined as installations for  
heating non-living spaces that are attached to, adjacent  
to or part of a structure that contains space for family  
living quarters. For installation in a residential garage  
these units must be installed so that burners and ignition  
source are located no less than 18" (457mm) above floor.  
Heater must be located or protected to avoid physical  
damage by vehicles. Refer to the National Fuel Gas  
Code, ANSI Z223.1, current edition.  
AIRCRAFT HANGER:  
1- In an area where aircraft are housed or serviced, 10'  
minimum clearance from highest surface of aircraft to  
bottom of the heater must be maintained.  
2- In other areas, 8' minimum clearance from the floor to  
bottom of heater must be maintained.  
3- Heaters should be located so as to be protected from  
damage from aircraft or other appliances needed for  
servicing of aircraft. Refer to requirements of the  
enforcing authorities.  
Authorities having jurisdiction should be consulted before  
installation.  
The National Fuel Gas Code is available from:  
American National Standard Institute Inc.  
11 West 42nd Street  
New York, NY 10036  
These units are CSA International design certified. These  
unit heaters are certified for installation clearances to  
combustible material as listed in table 1 and on unit rating  
plate. Accessibility and service clearances must be  
observed in addition to fire protection clearances.  
All electrical wiring and ground for unit must be in  
accordance with the regulations of the current National  
Electric Code ANSI/NFPA No. 70.  
RESIDENTIAL INSTALLATIONS:  
These units are approved for residential applications.  
Residential applications are defined as installations for  
heating non-living spaces that are attached to, adjacent  
to or part of a structure that contains space for family  
living quarters. For installation in a residential garage,  
these units must be installed so that burners and ignition  
source are located no less than 18" (457mm) above floor.  
Heater must be located or protected to avoid physical  
damage by vehicles. Refer to CSA-B149.1, current  
edition.  
The National Electric Code is available from:  
National Fire Protection Association  
1 Batterymarch Park  
PO Box 9101  
Be sure to check with local codes and ordinances for  
additional requirements.  
Quincy, MA 02269-9101  
Page 3  
 
.
Secure mounting brackets to unit with retained  
screws.  
Unit Heater Installation  
6- To support unit, secure mounting bracket to ceiling  
joist or truss. Unit may also hang on rods as shown  
in figure 1.  
INSTALL UNIT HEATER  
SUPPORT  
RODS  
MOUNTING BRACKETS  
(45, 60, & 75 MODELS  
ONLY)  
100 and 125 size units may not be inverted, 3/8” X 16  
threaded inserts are provided in the top the cabinet.  
Two threaded inserts are along one edge of the cabinet,  
two inserts are in the panel that divides the heat  
exchanger section from the control compartment.  
1- Cut threaded rods to desired length and thread a  
3/8” nut onto the rod.  
2- Slide a flat washer onto the threaded rod AFTER  
the nut (7/16” I.D. X 1” O.D. X 1/16” THK washer).  
3- Screw the rods (four) into the threaded inserts on  
the unit.  
4- Tighten nuts to secure unit to rods.  
NORMAL POSITION (ABOVE) ALL MODELS  
Combustion and Ventilation Air  
MOUNTING  
Adequate facilities for supplying air for combustion and  
ventilation must be provided. All gas fired appliances  
require air to be used for the combustion process. If  
sufficient quantities of combustion air are not available,  
the heater or another appliance will operate in an  
inefficient manner, resulting in incomplete combustion  
which can result in the production of excessive carbon  
monoxide.  
SUPPORT  
RODS  
BRACKETS (45, 60,  
&75 MODELS ONLY)  
CAUTION - Insufficient combustion air can cause  
headaches, nausea, dizziness, asphyxiation or death.  
This unit must be provided with a combustion air pipe  
that is connected to the outside atmosphere. Outdoor  
air used for combustion must be free of the following  
substances or the life of the heat exchanger will be  
adversely affected: chlorine, carbon tetrachloride,  
cleaning solvent, halogen refrigerants, acids, cements  
and glues, printing inks, fluorides, paint removers,  
varnishes, or any other corrosives.  
OPTIONAL INVERTED POSITION (ABOVE)  
45, 60, AND 75 MODELS ONLY  
FIGURE 1  
45, 60, and 75 size units may be installed in the normal  
position or inverted 180° as shown in figure 1 depending  
on desired location as governed by clearances, vent  
connection, air direction, gas supply, electrical supply  
and service accessibility.  
TABLE 2  
MAXIMUM HORIZONTAL VENT LENGTHS  
Model  
45, 60, 75  
100, 125  
1- Rotate louvers directing airflow as desired.  
2- Choose location for mounting brackets.  
3- Remove the mounting brackets from their shipping  
location (attached to the top of the unit) and replace  
the screws that held the brackets in their shipping  
location.  
No. of Elbows  
Ft (M)  
Ft (M)  
1
2
3
4
5
25 (7.6)  
20 (6.1)  
15 (4.6)  
10 (3.0)  
5 (1.5)  
25 (7.6)  
20 (6.1)  
15 (4.6)  
10 (3.0)  
5 (1.5)  
4- Remove and retain screws along top edge (bottom  
edge when inverted) of front of unit.  
5- Align screw holes on mounting bracket with holes  
along top edge (either upright or inverted) of unit.  
Page 4  
 
Venting and Combustion Air Inlet  
be 3” (76mm) diameter on 45 units and 4” (100mm)  
diameter on 60/75/100/125 units.  
A-General Recommendations and Requirements  
NOTE - The vent is a passageway, vertical or nearly so,  
used to convey flue gases from an appliance, or its vent  
connector, to the outside atmosphere. The vent  
connector is the pipe or duct that connects a fuel-gas  
burning appliance to a vent or chimney. The combustion  
air inlet is a pipe that connects the appliance to the  
outside atmosphere to convey oxygen from the air to  
the appliance burner.  
3- Keep the vent and air inlet runs as short as possible  
with a minimum number of elbows. Refer to the  
(American) National Fuel Gas Code ANSI Z223.1 or  
(Canada) CSA-B149 Installation Code for maximum  
vent and vent connector lengths. Horizontal run of  
the vent connector from the induced draft blower to  
the chimney/vent cannot exceed the values in table  
2. Single wall vent connector shall not be insulated.  
4- If a single wall vent is used in an unheated area it  
shall be insulated with a minimum of 1/2" thick foil  
faced fiberglass 1-1/2# density insulation. Failure to  
do so will result in condensation of flue gases.  
Unit heaters must be vented in compliance with all local  
codes or requirements of the local utility, the current  
standards of the (American) National Fuel Gas Code,  
ANSI Z223.1 or (Canada) CSA-B149 Installation Codes,  
and the following instructions.  
A vent connection flange and a combustion air pipe  
connection flange are attached to the back of the unit.  
Single wall vent material shall have all seams and joints  
sealed with pressure sensitive aluminum tape or  
silicone rubber sealant. Aluminum tape must meet the  
provisions of SMACNA AFTS-100-73 Standards. The  
aluminum tape has a temperature rating of 400°F  
5- The unit may be vented vertically as a single  
appliance or as a common vent with other gas-fired  
appliances. In common venting situations, vent  
connectors for other appliances must maintain a 4"  
(100mm) vertical separation between the vent  
connectors. Refer to common venting tables in the  
(American) National Fuel Gas Code ANSI Z223.1 or  
(Canada) CSA-B149 Installation Code for proper  
vent size.  
(204°C). Silicone rubber sealant must have  
a
temperature rating of 482°F (250°C), i.e., Dow Corning  
RTV-736 or equivalent. All joints shall be secured with  
at least two corrosion resistant screws. All joints must  
be checked for gas tightness after installation.  
Single wall vent shall not pass through any attic, interior  
wall, concealed space, or floor.  
6- Clearance to combustible material is 6" (152mm) for  
single wall vent material except where a listed  
clearance thimble is used. Clearance to combustible  
material for type B-1 vent or factory-built chimney is  
per manufacturer’s instructions. Clearance to  
combustible material is 1” on vertical sections of the  
concentric vent/adapter/cap kit.  
B-Vertical Vents Using Metal Vent Pipe- Commercial  
and Residential Installations  
7- The vent connector shall be supported without any  
dips or sags. Vertical vents shall be supported in  
accordance with their listing and manufacturers’  
instructions. All horizontal vent connector runs shall  
have a slope up to the vertical vent of at least 1/4"  
per foot (1mm per 50mm).  
These separated combustion unit heaters are listed as  
Category I appliances for vertical vent installations.  
1-These unit heaters are to be vented with NFPA- or  
ANSI- approved chimneys, U.L. listed type B-1 gas  
vents, single wall metal pipe, or listed chimney lining  
system for gas venting where applicable, as well as  
the modifications and limitations listed in figure 2.  
Seal single wall vent material according to the  
section A-General Recommendations and  
Requirements. Air inlet pipe may be single wall  
metal pipe or U.L. listed single wall metal flex  
connector. A concentric vent/adapter/cap kit as  
specified in these instructions may be used for  
vertical termination. Refer to table 3.  
8- All vertical type B-1 vents, single wall vents, or listed  
chimney lining system must be terminated with a  
listed vent cap or listed roof assembly.  
9- The vent must extend at least 3' (1m) above the  
highest point where it passes through a roof of a  
building and at least 2’ (0.6m) higher than any part  
of a building within a horizontal distance of 10'  
(3.05m) unless otherwise specified by the  
(American) National Fuel Gas Code, ANSI Z223.1  
or (Canada) CSA-B149 Installation Codes. The vent  
must extend at least 5' (1.6m) above the highest  
connected equipment flue collar.  
2- The vent connector shall be 3" (76mm) diameter on  
45 units, 4" (100mm) diameter on 60/75 units, and  
5” (127mm) on 100/125 units. The air inlet pipe shall  
Page 5  
 
VENT AND AIR INTAKE TERMINATION ON SINGLE WALL VENT  
DOUBLE WALL (TYPE B-1) TERMINATION  
SINGLE WALL TERMINATION  
ROOF FLASHING  
ROOF FLASHING  
ROOF PITCHED  
FROM 0" TO 45"  
ROOF PITCHED  
FROM 0" TO 45"  
12" MAX  
CLEARANCE TO BE  
AS SPECIFIED ON  
TYPE “B" VENT PIPE.  
2" CLEARANCE  
THIMBLE  
SHALL NOT BE A  
CONCEALED SPACE  
SEAL JOINT BETWEEN SINGLE WALL VENT AND “B"  
VENT AND THE ANNULAR SPACE OF THE “B" VENT.  
FIGURE 2  
used as an alternative to the thimble. When using a  
type B-1 vent termination use the clearances specified  
by the vent manufacturer. Seal the connection  
between the single wall and double wall pipes and the  
annular space of the double wall pipe as shown in  
figure 2. Inside edge of vent termination tee or  
Belmont cap must be at least 12 inches from outside  
wall as shown in figure 3.  
C-Horizontal Venting - General  
Common venting is not allowed with horizontal vent.  
The minimum horizontal vent length is three feet (914mm).  
1- If possible, do not terminate the horizontal vent  
through a wall that is exposed to prevailing wind.  
Exposure to excessive winds can affect unit  
performance. If such a termination is necessary, use a  
wind block to protect the vent termination from direct  
winds.  
2- Vent termination must be free from obstructions and at  
least 12" (306mm) above grade level and maximum  
snow height.  
3- Do not terminate vent directly below roof eaves or  
above a walkway, or any other area where condensate  
dripping may be troublesome and may cause some  
staining. Avoid windows where steam may cause  
fogging or ice buildup.  
4- When horizontally vented, minimum clearance for  
termination from any door, window, gravity air inlet,  
gas or electric meter, regulators, and relief equipment  
is 4 ft. (1.2m) for U.S. installations. Refer to NFPA  
54/ANSI Z223.1 in the U.S.A. and CSA B149.1 and .2  
in Canada or with authorities having local jurisdiction.  
In Canada, vent termination must have a minimum 6  
ft. (1.8mm) horizontal clearance from gas and electric  
meters and relief devices as specified in the Canadian  
B149.1, Natural Gas Installation Code.  
9- All horizontal vents must terminate with a tee or with a  
cap as specified in table 4. Opening end of tee used  
for termination must face downward. Addition of ¼”  
(6mm) mesh corrosion resistant material as a bird  
screen in the tee or cap openings may be used.  
9- For horizontal venting, the vent pipe shall be  
supported with hangers no more than 3ft. (1m) apart  
to prevent movement after installation.  
10-Clearance to combustible material is 6" (152mm) for  
single wall vent material except where a listed  
clearance thimble is used. Clearance to combustible  
material for type B-1 vent or factory-built chimney is  
per manufacturer’s instructions. Clearance to  
combustible material is 1” at the sides, 1” below, and  
3” above on horizontal installations of the concentric  
vent/adapter/cap kit  
D-Horizontal Venting-Commercial  
1- Horizontal commercial installations are for buildings  
that are not attached to living spaces. The vent may  
be single wall vent material installed according to  
5- Vent termination must be a minimum of 4' (1.2m)  
below or 4’ (1.2m) horizontally from any soffit vent or  
under-eave vent.  
the  
sections  
Venting  
A-General  
Recommendations and Requirements and C-  
Horizontal Venting - General and D-Horizontal  
Venting - Commercial. Refer to figures 3, 4, and 5.  
The air inlet may be single wall vent material or U.L.  
listed single wall flex connector.  
6- Vent must be a minimum of 6' from an inside corner  
formed by two exterior walls. If possible, leave a 10'  
clearance.  
7- Vent termination must be a minimum of 10' (3m) from  
any forced air inlet (includes fresh air inlet for other  
appliances, such as a dryer).  
8- When termination is routed through an exterior  
combustible wall the vent must be supported using a  
listed clearance thimble. Where local authorities  
permit, a single section of type B-1 vent pipe may be  
2- Refer to table 2 for maximum vent lengths. The vent  
pipe diameter for horizontal commercial installations  
shall be 3” (76mm) on 45 units, 4” (100mm) on  
60/75 units, 5” (127mm)on 100/125 units.  
Page 6  
 
stainless steel. Seal single wall vent material  
3- The air inlet diameter shall be 3” (76mm) on  
45/60/75 units and 4” (100mm) on 100/125 units.  
Refer to table 4 for diameter and termination  
requirements.  
4- Select a wall termination point that will maintain ¼”  
rise per foot slope of horizontal run of vent pipe.  
The vent may be single wall material minimum 26  
GSG (0.46mm) galvanized steel or equivalent grade  
stainless steel. Seal single wall vent material  
according  
Recommendations  
to  
the  
section  
and  
A-General  
Requirements.  
Condensate drainage can be collected in a tee pipe  
section (figure 4) or allowed to drip through the vent  
termination, if permitted by local authorities (figure  
5).  
5- For upward sloped vent a condensate tee and drain  
must be installed within the first 5’ (1.5m) from the  
unit heater to protect the appliance. If a flexible  
condensate drain line is used, the drain line must  
according  
to  
the  
section  
A-General  
Recommendations and Requirements. In areas  
where local authorities having jurisdiction permit, a  
downward slope of maximum ¼” per foot is also  
acceptable. In such cases, the vent must be listed  
special vent for Category III appliances or single  
wall vent pipe constructed of number 26 GSG  
(0.46mm) galvanized steel or equivalent grade  
include  
a
loop filled with water to prevent  
combustion products from entering the structure. If  
the unit is shut down for an extended period of time  
and will be exposed to sub-freezing temperatures,  
the condensate may freeze.  
CONDENSATE DRAIN THROUGH TEE PIPE AND DRAIN LOOP  
UPWARD SLOPE ON HORIZONTAL VENT-COMMERCIAL INSTALLATION  
MAY BE SINGLE WALL (26 GSG) GALV. OR EQUIVALENT STAINLESS STEEL SEALED ACCORDING TO  
THESE INSTALLATION INSTRUCTIONS. SLOPE:+ 1/4 INCH FOR 1 FOOT RUN MINIMUM.  
12” (30.5 CM) MIN. FROM WALL TO  
VENT TERMINATION  
VENT TERMINATION  
(TERMINATIONS MAY  
USE WIRE MESH BIRD  
SCREEN)  
12” (30.5 CM) MIN. FROM  
AIR INLET TO VENT  
TERMINATION (MAY  
BE HORIZONTAL OR  
VERTICAL CLEARANCE)  
LISTED THIMBLE  
THROUGH  
COMBUSTIBLE WALL  
12” (30.5 CM) MINIMUM ABOVE  
HIGHEST SNOWFALL  
AIR INLET  
TERMINATION  
DRAIN LOOP WITH WATER  
TRAP (TO CONDENSATE DRAIN)  
NOTE - MINIMUM HORIZONTAL LENGTH 3 FT. (91.4 CM) NOT  
INCLUDING TERMINATION. REFER TO TABLE 2 FOR  
MAXIMUM LENGTH AND NUMBER OF ELBOWS.  
GROUND LEVEL  
COMMON VENTING NOT ALLOWED WHEN HORIZONTALLY VENTING THE UNIT HEATER.  
FIGURE 3  
Venting Concentric Kit - Commercial. The air inlet  
may be single wall material or U.L. listed single wall  
flex vent connector.  
E-Horizontal Venting Concentric Kit - Commercial  
1-Horizontal commercial installations are for buildings  
that are not attached to living spaces. The only  
concentric vent/adapter/cap kit that may be used is  
the kit supplied by Lennox Industries. The kit may be  
used with 45/60/75 units. The vent used to connect  
from the concentric adapter to the unit may be single  
wall material minimum 25 GSG (0.46mm)  
galvanized steel or equivalent grade stainless steel  
installed according to the sections Venting A-  
General Recommendations and Requirements  
and C-Horizontal Venting General and D-  
Horizontal Venting–Commercial and E-Horizontal  
2-The vent pipe diameter for horizontal commercial  
installations shall be 3” (76mm) on 45 units and 4”  
(100mm) on 60/75 units. Refer to table 4.  
3-Refer to table 2 for maximum vent lengths.  
4-Refer to figure 7 for kit termination, figure 3 for  
upward slope with condensate trap, figure 4 for  
downward slope with trap, and figure 5 for  
downward slope with condensate drain through cap  
where permitted by local authorities.  
Page 7  
 
CONDENSATE DRAIN THROUGH TEE PIPE AND DRAIN LOOP  
DOWNWARD SLOPE ON HORIZONTAL VENT-COMMERCIAL INSTALLATION  
MAY BE SINGLE WALL (26 GSG) GALV. OR EQUIVALENT STAINLESS STEEL SEALED ACCORDING TO  
THESE INSTALLATION INSTRUCTIONS. SLOPE: - 1/4 INCH FOR 1 FOOT RUN MINIMUM.  
12” (30.5 CM) MIN. FROM WALL TO  
VENT TERMINATION  
AIR INLET  
TERMINATION  
VENT TERMINATION  
12” (30.5 CM) MIN. FROM  
AIR INLET TO VENT  
TERMINATION (MAY  
BE HORIZONTAL OR  
VERTICAL CLEARANCE)  
LISTED THIMBLE  
THROUGH  
COMBUSTIBLE WALL  
DRAIN LOOP WITH WATER  
TRAP (TO CONDENSATE DRAIN)  
12” (30.5 CM) MINIMUM ABOVE  
HIGHEST SNOWFALL  
NOTE - MINIMUM HORIZONTAL LENGTH 3 FT. (91.4 CM) NOT  
INCLUDING TERMINATION. REFER TO TABLE 2 FOR  
MAXIMUM LENGTH AND NUMBER OF ELBOWS.  
(TERMINATIONS MAY  
USE WIRE MESH BIRD  
SCREEN)  
GROUND LEVEL  
COMMON VENTING NOT ALLOWED WHEN HORIZONTALLY VENTING THE UNIT HEATER.  
FIGURE 4  
CONDENSATE DRAIN THROUGH VENT TERMINATION  
DOWNWARD SLOPE ON HORIZONTAL VENT-COMMERCIAL INSTALLATION  
MAY BE SINGLE WALL (26 GSG) GALV. OR EQUIVALENT STAINLESS STEEL SEALED ACCORDING TO  
THESE INSTALLATION INSTRUCTIONS. SLOPE: - 1/4 INCH FOR 1 FOOT RUN MINIMUM.  
12” (30.5 CM) MIN. FROM WALL TO  
VENT TERMINATION  
AIR INLET  
TERMINATION  
VENT TERMINATION  
12” (30.5 CM) MIN. FROM  
AIR INLET TO VENT  
TERMINATION (MAY  
BE HORIZONTAL OR  
VERTICAL CLEARANCE)  
LISTED THIMBLE  
THROUGH  
COMBUSTIBLE WALL  
12” (30.5 CM) MINIMUM ABOVE  
HIGHEST SNOWFALL  
NOTE - MINIMUM HORIZONTAL LENGTH 3 FT. (91.4 CM) NOT  
INCLUDING TERMINATION. REFER TO TABLE 2 FOR  
MAXIMUM LENGTH AND NUMBER OF ELBOWS.  
(TERMINATIONS MAY  
USE WIRE MESH BIRD  
SCREEN)  
GROUND LEVEL  
COMMON VENTING NOT ALLOWED WHEN HORIZONTALLY VENTING THE UNIT HEATER.  
FIGURE 5  
Page 8  
 
TABLE 3  
VERTICAL VENT REQUIREMENTS  
MODEL  
45  
INSTALLATION  
FLUE TYPE  
AIR INLET TYPE  
FLUE  
DIA.  
AIR  
INLET  
DIA.  
VENT CAP  
OTHER  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
RESIDENTIAL  
COMMERCIAL  
or  
SINGLE WALL  
3”  
3”  
3”  
4”  
4”  
4”  
5”  
5”  
5”  
3”  
3”  
3”  
4”  
4”  
4”  
4”  
4”  
4”  
U.L. APPROVED  
U.L. APPROVED  
MAY USE ONE  
SECTION OF B-  
VENT  
SINGLE WALL or  
METAL FLEX VENT  
TYPE B VENT  
SINGLE WALL or  
METAL FLEX VENT  
CONCENTRIC  
SINGLE WALL or  
METAL FLEX VENT  
SINGLE WALL  
SINGLE WALL or  
METAL FLEX VENT  
TYPE B VENT  
SINGLE WALL or  
METAL FLEX VENT  
CONCENTRIC  
SINGLE WALL or  
METAL FLEX VENT  
SINGLE WALL  
SINGLE WALL or  
METAL FLEX VENT  
TYPE B VENT  
SINGLE WALL or  
METAL FLEX VENT  
CONCENTRIC  
45  
45  
4” CONCENTRIC  
VENT/ ADAPTER/CAP  
KIT REQUIRED  
60, 75  
60, 75  
60, 75  
100, 125  
100, 125  
100, 125  
U.L. APPROVED  
MAY USE ONE  
SECTION OF B-  
VENT  
U.L. APPROVED  
4” CONCENTRIC  
VENT/ ADAPTER/CAP  
KIT REQUIRED  
U.L. APPROVED  
MAY USE ONE  
SECTION OF B-  
VENT  
U.L. APPROVED  
5” CONCENTRIC  
VENT/ ADAPTER/CAP  
KIT REQUIRED  
SINGLE WALL or  
METAL FLEX VENT  
RESIDENTIAL  
HORIZONTAL VENTING - RESIDENTIAL INSTALLATION  
UPWARD SLOPE  
MAY BE SINGLE WALL (26 GSG) GALV. OR EQUIVALENT STAINLESS STEEL SEALED ACCORDING TO THESE INSTALLATION  
INSTRUCTIONS OR A SINGLE SECTION OF TYPE B-1 VENT. SLOPE:+ 1/4 INCH FOR 1 FOOT RUN MINIMUM.  
12” (30.5 CM) MIN. FROM WALL TO  
VENT TERMINATION  
VENT TERMINATION  
(TERMINATIONS MAY  
USE WIRE MESH BIRD  
SCREEN)  
12” (30.5 CM) MIN. FROM  
AIR INLET TO VENT  
TERMINATION (MAY  
BE HORIZONTAL OR  
VERTICAL CLEARANCE)  
LISTED THIMBLE  
THROUGH  
COMBUSTIBLE WALL  
12” (30.5 CM) MINIMUM ABOVE  
HIGHEST SNOWFALL  
AIR INLET  
TERMINATION  
NOTE - MINIMUM HORIZONTAL LENGTH 3 FT. (91.4 CM) NOT  
INCLUDING TERMINATION. MAXIMUM HORIZONTAL VENT  
LENGTH 5 FT. (1.5M) PLUS ONE 90-DEGREE ELBOW.  
GROUND LEVEL  
COMMON VENTING NOT ALLOWED WHEN HORIZONTALLY VENTING THE UNIT HEATER.  
FIGURE 6  
Page 9  
 
F-Horizontal Venting-Residential Two Pipes  
1-For horizontal residential installations these units are  
certified as Category I appliances. The vent may be  
single wall material minimum 25 GSG (0.46mm)  
galvanized steel or equivalent grade stainless steel or  
a single section of type B-1 vent installed according to  
the sections Venting A-General Recommendations  
and Requirements and C-Horizontal Venting  
General and F-Horizontal Venting–Residential Two  
Pipes. Refer to figure 6.  
2-The vent pipe diameter for horizontal residential  
installations shall be 4” (100mm) on 45 units and 5”  
(127mm) on 60/75/100/125 units. Refer to table 4 for  
vent diameter and termination requirements.  
3-The maximum vent length is 5’ (1.5m) plus one 90-  
degree elbow.  
4-The vent must maintain a ¼” rise per foot of slope  
upwards toward the termination  
TABLE 4  
HORIZONTAL VENT REQUIREMENTS  
MODEL  
45  
INSTALLATION  
RESIDENTIAL  
FLUE TYPE  
AIR INLET TYPE  
FLUE DIA.  
INLET AIR  
DIA.  
VENT CAP  
INLET AIR CAP  
MAX. VENT  
LENGTH (MIN.  
VENT LENGTH 3’)  
SINGLE WALL  
4”  
TEE or  
4” BELMONT  
TEE or  
3” BELMONT  
4” CONCENTRIC  
VENT/ ADAPTER/CAP  
KIT REQUIRED  
TEE or  
3” BELMONT  
TEE or  
3” BELMONT  
4” CONCENTRIC  
VENT/ ADAPTER/CAP  
KIT REQUIRED  
5’ MAY USE ONE  
SECTION OF  
B-VENT  
SINGLE WALL PIPE or  
METAL FLEX VENT  
CONCENTRIC  
SINGLE WALL PIPE or  
METAL FLEX VENT  
SINGLE WALL  
3”  
45  
45  
RESIDENTIAL  
COMMERCIAL  
4”  
3”  
5’  
3”  
3”  
25’ MAY USE ONE  
SECTION OF  
B-VENT  
SINGLE WALL PIPE or  
METAL FLEX VENT  
CONCENTRIC  
SINGLE WALL PIPE or  
METAL FLEX VENT  
45  
COMMERCIAL  
RESIDENTIAL  
3”  
3”  
25’  
60, 75  
SINGLE WALL  
5”  
4”  
TEE or  
5” BELMONT  
TEE or  
4” BELMONT  
4” CONCENTRIC  
VENT/ ADAPTER/CAP  
KIT REQUIRED  
TEE or  
4” BELMONT  
TEE or  
4” BELMONT  
4” CONCENTRIC  
VENT/ ADAPTER/CAP  
KIT REQUIRED  
5’ MAY USE ONE  
SECTION OF  
B-VENT  
SINGLE WALL PIPE or  
METAL FLEX VENT  
CONCENTRIC  
SINGLE WALL PIPE or  
METAL FLEX VENT  
SINGLE WALL  
60, 75  
60, 75  
RESIDENTIAL  
COMMERCIAL  
4”  
4”  
5’  
4”  
4”  
25’ MAY USE ONE  
SECTION OF B-  
VENT  
SINGLE WALL PIPE or  
METAL FLEX VENT  
CONCENTRIC  
SINGLE WALL PIPE or  
METAL FLEX VENT  
60, 75  
COMMERCIAL  
RESIDENTIAL  
4”  
4”  
25’  
100, 125  
SINGLE WALL  
5”  
4”  
5”  
4”  
TEE or  
5” BELMONT  
TEE or  
4” BELMONT  
TEE or  
5” BELMONT  
TEE or  
5’ MAY USE ONE  
SECTION OF  
B-VENT  
SINGLE WALL PIPE or  
METAL FLEX VENT  
SINGLE WALL  
100, 125  
COMMERCIAL  
5’ MAY USE ONE  
SECTION OF  
B-VENT  
SINGLE WALL PIPE or  
METAL FLEX VENT  
4” BELMONT  
Page 10  
 
and G - Horizontal Venting Concentric Kit -  
Residential. Refer to figure 7. The air inlet may be  
single wall material or U.L. listed single wall flex vent  
connector.  
G-Horizontal Venting Concentric Kit - Residential  
1-For horizontal residential installations the 45/60/75  
units are certified as Category I appliances with a  
concentric vent/adapter/cap kit. The only concentric  
vent/adapter/cap kits that may be used are the kits  
supplied by Advanced Distributor Products. The vent  
used to connect from the concentric adapter to the  
unit may be single wall material minimum 25 GSG  
(0.46mm) galvanized steel or equivalent grade  
stainless steel installed according to the sections  
Venting A - General Recommendations and  
Requirements and C - Horizontal Venting General  
2-The vent pipe diameter for horizontal residential  
installations shall be 4” (100mm) on 45/60/75 units.  
Refer to table 4.  
3-The maximum vent length is 5’ (1.5m) plus one 90-  
degree elbow.  
4-The vent must maintain a ¼” rise per foot of slope  
upwards toward the termination.  
HORIZONTAL VENTING – CONCENTRIC VENT INSTALLATION  
VENT AND AIR INLET CONNECTORS FROM UNIT TO CONCENTRIC ADAPTER MAY BE SINGLE WALL (26 GSG) GALV. OR  
EQUIVALENT STAINLESS STEEL SEALED ACCORDING TO THESE INSTALLATION INSTRUCTIONS. SLOPE VENT + 1/4 INCH  
FOR 1 FOOT RUN MINIMUM. AIR INLET MAY ALSO BE U.L. LISTED SINGLE WALL FLEX VENT CONNECTOR.  
VENT TERMINATION  
AND AIR INLET  
TERMINATION  
LISTED THIMBLE  
THROUGH  
COMBUSTIBLE WALL  
12” (30.5 CM) MINIMUM ABOVE  
HIGHEST SNOWFALL  
NOTE - MINIMUM HORIZONTAL LENGTH 3 FT. (91.4 CM) NOT  
INCLUDING TERMINATION.  
GROUND LEVEL  
COMMON VENTING NOT ALLOWED WHEN HORIZONTALLY VENTING THE UNIT HEATER.  
FIGURE 7  
H-Removal Of Unit From Common Vent  
3- In so far as is practical, close all building doors and  
windows and all doors between the space in which  
the appliances remaining connected to the common  
venting system are located and other spaces of the  
building. Turn on clothes dryers and any appliances  
not connected to the common venting system. Turn  
on any exhaust fans, such as range hoods and  
bathroom exhausts, so they will operate at maximum  
speed. Do not operate a summer exhaust fan. Close  
fireplace dampers.  
In the event that an existing unit heater is removed from  
a venting system commonly run with separate gas  
appliances, the venting system is likely to be too large to  
properly vent the remaining attached appliances. The  
following test should be conducted while each appliance  
is in operation and the other appliances are not in  
operation, yet remain connected to the common venting  
system. If the venting system has been installed  
improperly, the system must be corrected.  
4- Follow the lighting instructions. Place the appliance  
being inspected in operation. Adjust thermostat so  
appliance will operate continuously.  
5- Test for spillage at the draft hood relief opening after  
five minutes of main burner operation. Use the flame  
of a match or candle, or smoke from a cigarette,  
cigar, or pipe.  
1- Seal any unused openings in the common venting  
system.  
2- Visually inspect the venting system for proper size  
and horizontal pitch. Determine there is no blockage  
or restriction, leakage, corrosion, or other  
deficiencies which could cause an unsafe condition.  
Page 11  
 
Electrically ground unit in accordance with local codes  
or, in the absence of local codes, in accordance with the  
current National Electrical Code (ANSI/NFPA No. 70) in  
the U.S.A., and in Canada with the current Canadian  
Electrical Code, Part 1 (CSA C22.1).  
6- After it has been determined that each appliance  
remaining connected to the common venting system  
properly vents when tested as outlined above, return  
doors, windows, exhaust fans, fireplace dampers  
and any other gas-burning appliance to their  
previous condition of use.  
Make line voltage connections as shown in figure 8.  
Connect field wiring as shown on wiring diagram on  
unit. Also refer to typical diagram in this manual. An  
additional thermostat wire must be run to terminal “G"  
on heater when continuous blower is desired.  
7- If improper venting is observed during any of the  
above tests, the common venting system must be  
corrected. The common venting system should be  
resized to approach the minimum size as  
determined by using the appropriate tables in  
Appendix G in the current standards of the National  
Fuel Gas Code, ANSI Z223-1 in the U.S.A. and the  
appropriate Category I Natural Gas and Propane  
appliances venting sizing tables in the current  
standards of the CSA-B149.1 and .2 in the Natural  
Gas and Propane Installation Code in Canada.  
LINE VOLTAGE FIELD WIRING  
UNIT ELECTRICAL BOX  
L1  
BLACK  
NOTE - Local codes may supersede any of the above  
provisions.  
N
WHITE  
Electrical Connections  
NOTE - These unit heaters use a direct spark ignition  
system. There is no pilot necessary as the spark lights  
the main burner as the gas valve is turned on. The direct  
spark ignition control board emits radio noise as the  
sparking process is underway. The level of energy may  
be sufficient to disturb a logic circuit in a microprocessor  
controlled thermostat. It is recommended that an  
isolation relay be used when connecting the unit heaters  
to a microprocessor controlled thermostat. Install the  
thermostat according to instructions provided. Select  
circuit protection and wire size according to the unit  
rating plate. Install a separate disconnect switch  
(protected by either fuse or circuit breaker) near the unit  
so that power can be turned off for servicing. Connect  
wiring through knockout on the junction box located on  
the side of the unit heater. Refer to heater wiring  
diagram for connection information. Use 18 gauge wire  
or larger for thermostat connections.  
FIGURE 8  
Page 12  
 
Gas Connection  
Leak Check  
When connecting gas supply, the length of the run from  
the meter must be considered in determining the pipe  
size. A line pressure of 7" w.c. (1.74 kPa) for natural gas  
should be maintained when sizing piping. A line pressure  
of 13” w.c. (3.23 kPa) should be maintained for liquefied  
petroleum (LP) gas. A minimum of 5.0" w.c. for natural  
gas or 10.4" w.c. for LP/propane gas should be  
maintained for proper unit operation. For correct sizing of  
piping, refer to the (American) National Fuel Gas Code  
ANSI Z223.1 or (Canada) CSA-B149 Installation Code or  
consult the utility having jurisdiction.  
After gas piping is completed, carefully check all piping  
connections, (field and factory), for gas leaks. Use a soap  
solution or other preferred means.  
CAUTION - DO NOT use matches, candles, flame or  
other sources of ignition to check for gas leaks.  
IMPORTANT - The heater and its individual shut off valve  
must be disconnected from the gas supply piping system  
during any pressure testing of that system at test  
pressures in excess of 1/2 psig (3.45kPa).  
The appliance must be isolated from the gas supply  
piping system by closing its individual manual gas shutoff  
valve during any pressure testing of the gas supply  
system at test pressures equal to or less than 1/2 psig  
(3.45kPa). See figure 10.  
A drip leg should be installed in the vertical pipe run to the  
unit. In some localities, codes may require that a manual  
main shutoff valve and union (furnished by installer) be  
installed external to the unit. Union must be of the ground  
joint type. A drip leg should be readily accessible to permit  
cleaning and emptying. See figure 9. Leave a minimum of  
4" (102mm) clearance between electric box and drip leg.  
NOTE - In case emergency shutdown is required, shut  
down main gas valve and disconnect main power to unit.  
These devices should be properly labeled by the installer.  
A 1/8" NPT plugged tap shall be installed immediately  
upstream of the gas supply connection to the heater.  
GAS SUPPLY TO UNIT HEATER  
NOTE - Compounds used on threaded joints of gas piping  
must be resistant to the actions of liquefied petroleum  
gases.  
MANUAL MAIN SHUT-OFF  
VALVE WILL NOT  
ISOLATE  
GAS VALVE  
HOLD NORMAL  
TEST PRESSURE  
GAS SUPPLY CONNECTION  
CAP  
UNIT HEATER  
FIGURE 10  
MANUAL  
MAIN SHUT-OFF VALVE  
(Furnished by Installer)  
GROUND  
JOINT UNION  
1/8 NPT  
PLUGGED TAP  
GAS FLOW  
DRIP LEG  
FIGURE 9  
Page 13  
 
START-UP AND OPERATION  
Operation for Honeywell VR8205 Series Gas Valve  
(Figure 11)  
Unit Start-Up  
FOR YOUR SAFETY READ BEFORE LIGHTING  
1- STOP! Read the safety information at the beginning  
of this section.  
2- Set thermostat to lowest setting.  
WARNING  
!
1
HONEYWELL VR8205 SERIES GAS VALVE  
Electric shock hazard. Can cause injury  
or death. Do not use this heater if any  
part has been under water. Immediately  
call a qualified service technician to in-  
spect the furnace and to replace any part  
of the control system and any gas con-  
trol which has been under water.  
MANIFOLD PRESSURE ADJUSTMENT SCREW  
MANI-  
FOLD  
PRESS-  
URE  
TAP  
! WARNING  
ON  
Danger of explosion. Can cause injury or  
product or property damage. If over-  
heating occurs or if gas supply fails to  
shut off, shut off the manual gas valve to  
the appliance before shutting off electri-  
cal supply.  
OFF  
INLET  
PRESSURE  
TAP  
GAS VALVE SHOWN IN OFF POSITION  
!
WARNING  
FIGURE 11  
3-Turn off all electrical power to appliance.  
4-This appliance is equipped with an ignition device  
which automatically lights burners. DO NOT  
attempt to light the burners manually.  
5-Turn the manual knob on gas valve clockwise to  
OFF. Do not force.  
6-Wait five (5) minutes to clear out any gas. If you  
then smell gas, STOP! Immediately call your  
gas supplier from a neighbor's phone. Follow the  
gas supplier's instructions. If you do not smell  
gas, go to next step.  
Electric shock hazard. Can cause injury or  
death. Before attempting to perform any  
service or maintenance, turn the electrical  
power to unit OFF at disconnect switch(es).  
Unit may have multiple power supplies.  
WARNING  
!
Danger of explosion and fire. Can cause  
injury or product or property damage. You  
must follow these instructions exactly.  
BEFORE LIGHTING smell all around the appliance area  
for gas. Be sure to smell next to the floor because some  
gas is heavier than air and will settle on the floor.  
7-Turn manual knob on gas valve counterclockwise  
to ON.  
8-Close the unit door.  
Use only your hand to push in or turn the gas control  
knob. Never use tools. If the knob will not push in or turn  
by hand, do not try to repair it, call a qualified service  
technician. Force or attempted repair may result in a fire  
or explosion.  
9-Turn on all electric power to unit.  
10- Set thermostat to desired setting.  
11- The combustion air blower will start. The burners  
will light within 40 seconds.  
12- If unit does not light first time (gas line not fully  
purged) it will attempt up to two more ignitions  
before locking out.  
13- If lockout occurs, repeat steps 1 through 10.  
14- If appliance still will not operate, follow the  
instructions “To Turn Off Gas to Unit" and call  
your service technician or gas supplier.  
These unit heaters are equipped with an automatic  
spark ignition system. There is no pilot. In case of a  
safety shutdown, move thermostat switch to OFF, then  
return the thermostat switch to HEAT position.  
Page14  
 
Gas Valve Operation for White Rodgers 36E Series  
Valve (Figure 12)  
Gas Valve Operation for Robertshaw 2000DER  
Series Valve (Figure 13)  
1- STOP! Read the safety information at the beginning  
1- STOP! Read the safety information at the beginning  
of this section.  
of this section.  
2- Set thermostat to lowest setting.  
2- Set the thermostat to lowest setting.  
3- Turn off all electrical power to appliance.  
3- Turn off all electrical power to appliance.  
4- This appliance is equipped with an ignition device  
4- This appliance is equipped with an ignition device  
which automatically lights burner. DO NOT attempt  
to light the burners manually.  
which automatically lights burner.  
DO NOT  
attempt to light the burners manually.  
WHITE RODGERS 36E GAS VALVE  
ROBERTSHAW 2000DER GAS VALVE  
MANIFOLD  
PRESSURE TAP  
GAS VALVE KNOB  
SHOWN IN OFF POSITION  
MANIFOLD PRESSURE  
ADJUSTMENT SCREW  
OFF  
NO  
OFF  
MANI-  
FOLD  
PRESSURE  
TAP  
INLET  
PRESSURE  
TAP  
GAS VALVE KNOB  
SHOWN IN OFF POSITION  
INLET  
PRESSURE  
TAP  
MANIFOLD PRESSURE  
ADJUSTMENT SCREW  
UNDER CAP  
FIGURE 12  
FIGURE 13  
5- Turn knob on gas valve 180° either way to OFF.  
5- Depress knob on gas valve; knob will snap to OFF.  
6- Wait five minutes to clear out any gas. If you then  
smell gas, STOP! Immediately call your gas  
supplier from a neighbor's phone. Follow the gas  
supplier's instructions. If you do not smell gas go to  
next step.  
6- Wait five minutes to clear out any gas. If you then  
smell gas, STOP! Immediately call your gas  
supplier from a neighbor’s phone. Follow the gas  
supplier’s instructions. If you do not smell gas go  
to next step.  
7- Turn knob on gas valve 180° either way to ON.  
8- Close unit door.  
7- Turn knob on gas valve 90° counterclockwise to  
ON.  
9- Turn on electrical power to unit.  
10-Set thermostat to desired setting.  
8- Close unit door.  
9- Turn on electrical power to unit.  
10-Set the thermostat to desired setting.  
11- The combustion air blower will start. The burners  
will light within 40 seconds.  
11-The combustion air blower will start. The burners  
will light within 40 seconds.  
12-If unit does not light first time (gas line not fully  
purged) it will attempt up to two more ignitions  
before locking out.  
12-If unit does not light first time (gas line not fully  
purged) it will attempt up to two more ignitions  
before locking out.  
13-If lockout occurs, repeat steps 1 through 10.  
14-If appliance still will not operate, follow the  
instructions “To Turn Off Gas to Unit" and call  
your service technician or gas supplier.  
13-If lockout occurs, repeat steps 1 through 10.  
14-If appliance still will not operate, follow the  
instructions “To Turn Off Gas to Unit" and call  
your service technician or gas supplier.  
Page 15  
 
Ignition Control LED  
To Turn Off Gas To Unit  
The ignition control board contains a green LED which  
indicates the following:  
1- Set thermostat to lowest level.  
2- Turn off all electrical power to unit if service is to be  
performed.  
TABLE 5  
IGNITION CONTROL LED  
3- Honeywell VR8205 series valve: turn knob on gas  
LED  
UNIT OPERATION  
valve 90° clockwise  
to OFF.  
Slow  
Flash*  
Normal Operation - No call for heat  
White Rodgers 36E series valves: turn knob on gas  
valve 180° either way to OFF.  
Fast  
Flash  
Normal Operation - Call for heat  
Current signal at FLAME terminal 0.6 to 1.0 microamps  
Robertshaw DER2000 series valves: depress knob  
on gas valve; knob will snap to OFF.  
2 Flashes  
System lockout - failed to detect or sustain flame  
Current signal at FLAME terminal <0.6 microamps  
Heating Sequence of Operation  
3 Flashes  
Combustion air inducer proving switch failed closed  
before CAB is energized or failed open after CAB is  
energized  
1- When the thermostat calls for heat, the combustion  
air blower starts immediately.  
4 Flashes  
5 Flashes  
High limit or rollout switch open  
Flame sensed and gas valve not energized  
Loss of power  
2- Combustion air inducer proving switch proves  
blower operation before allowing power to the  
ignition controller. This switch is factory set and no  
adjustment is necessary.  
Steady  
Off  
Steady  
On  
Ignition control failure  
3- After prepurge of approximately 30 seconds, the  
spark ignition is energized and the solenoid valves  
open in the gas valve.  
*When thermostat is placed in continuous fan mode LED will  
slowly flash.  
4- The spark then ignites the gas, the ignition sensor  
proves the flame and the combustion process  
continues.  
Optional Gas Conversion Kit  
5- In the event that the flame is not detected after the  
first 10-second trial for ignition, the controller will  
repeat steps 3 and 4 an additional two times before  
locking out the gas valve. Ignition control will then  
automatically repeat steps 3, 4, and 5 after 60  
minutes.  
A natural to LP/propane gas changeover kit is required  
to convert unit. Refer to the installation instructions  
supplied with the changeover kit for conversion  
procedure.  
To interrupt the 60-minute lockout period, move  
thermostat from “Heat" to “OFF" then back to  
“Heat." Heating sequence then restarts at step 1.  
6- The burners shall light without noticeable crossover  
delay. There shall be no flame lifting from the burner  
heads, flashback or burning within the burner. The  
flames shall be predominantly blue in color and  
shall be approximately centered in the tubes with no  
apparent impingement taking place.  
7- The ignition control will energize the fan  
approximately 45 seconds after ignition is  
established.  
8- After the thermostat demand is satisfied the gas  
valve is closed; 5 seconds after the demand is  
satisfied the combustion air blower is shut off.  
9- The control center shall shut off the system fan  
approximately 120 seconds after the gas valve is  
de-energized.  
Page 16  
 
ADJUSTMENTS  
Limit Control  
High Altitude  
Units may be fired at full input up to 2000 ft. (610m)  
above sea level. Above 2000 ft. (610m), manifold  
pressure must be reduced by 4 percent for each 1000  
feet above sea level or as specified by local authority  
having jurisdiction. Adjust pressure regulator to  
pressure shown in table 6 for natural gas and table 7  
for LP/propane gas. The combustion air blower proving  
switch is factory set. No adjustment is necessary.  
The limit control switch is factory set and not field  
adjustable.  
Louver Vane Adjustment  
Rotate louver vanes to direct airflow upward,  
downward, straight, or any combination of these  
directions.  
Combustion Air Inducer Proving Switch  
Gas Pressure  
This combustion air inducer proving switch checks for  
proper combustion air inducer operation before  
allowing an ignition trial. The switch is factory set and  
no field adjustment is necessary.  
Check gas line pressure with unit firing at maximum  
rate. A minimum of 5.0" w.c. for natural gas or 10.4"  
w.c. for LP/propane gas should be maintained for  
proper unit operation. After line pressure has been  
checked and adjusted, check manifold pressure.  
Correct manifold pressure is shown on the unit rating  
plate. See figures 11, 12 and 13 for gas pressure  
adjustment screw location. A natural gas to LP/propane  
gas changeover kit is required to convert unit. Refer to  
installation instructions provided with changeover kit for  
conversion procedure.  
Flame Rollout Switch  
The flame rollout switch(es) on 45, 60 or 75 units are  
located on the burner box top, behind the ignition  
control board. The flame rollout switch on 100 or 125  
units is located on the manifold bracket above the top  
burner. This normally closed switch opens on a  
temperature rise. Check for adequate combustion air  
and proper venting before manually resetting switch.  
TABLE 6  
NATURAL GAS MANIFOLD PRESSURES - in.wg. (kPa)  
ALTITUDE FT. (M)  
2001-3000  
(610-914)  
4001-5000  
6001-7000  
8001-9000  
0-2000  
(0-610)  
3001-4000  
5001-6000  
7001-8000  
9001-10000  
MODEL  
(1220-1524)  
(1829-2134)  
(2439-2743)  
(915-1219)  
2.5 (0.62)  
2.5 (0.62)  
2.5 (0.62)  
2.5 (0.62)  
2.5 (0.62)  
(1524-1829)  
2.0 (0.50)  
2.0 (0.50)  
2.0 (0.50)  
2.0 (0.50)  
2.0 (0.50)  
(2134-2438)  
1.6 (0.40)  
1.6 (0.40)  
1.6 (0.40)  
1.6 (0.40)  
1.6 (0.40)  
(2744-3048)  
1.3 (0.32)  
1.3 (0.32)  
1.3 (0.32)  
1.3 (0.32)  
1.3 (0.32)  
TUA045SN 3.5 (0.87)*  
TUA060SN 3.5 (0.87)*  
TUA075SN 3.5 (0.87)*  
TUA100SN 3.5 (0.87)*  
TUA125SN 3.5 (0.87)*  
2.7 (0.67)  
2.7 (0.67)  
2.7 (0.67)  
2.7 (0.67)  
2.7 (0.67)  
2.2 (0.55)  
2.2 (0.55)  
2.2 (0.55)  
2.2 (0.55)  
2.2 (0.55)  
1.8 (0.45)  
1.8 (0.45)  
1.8 (0.45)  
1.8 (0.45)  
1.8 (0.45)  
1.4 (0.35)  
1.4 (0.35)  
1.4 (0.35)  
1.4 (0.35)  
1.4 (0.35)  
*No adjustment required.  
Page 17  
 
TABLE 7  
LP/PROPANE GAS MANIFOLD PRESSURES - in.wg. (kPa )  
ALTITUDE FT. (M)  
2001-3000  
(610-914)  
4001-5000  
6001-7000  
8001-9000  
0-2000  
(0-610)  
3001-4000  
(915-1219)  
5001-6000  
7001-8000  
9001-10000  
(2744-3048)  
MODEL  
(1220-1524)  
(1829-2134)  
(2439-2743)  
(1524-1829)  
(2134-2438)  
TUA045SL  
TUA060SL  
TUA075SL  
TUA100SL  
TUA125SL  
9.5 (2.37)*  
9.5 (2.37)*  
9.5 (2.37)*  
9.0 (2.24)*  
9.0 (2.24)*  
7.4 (1.84)  
7.4 (1.84)  
7.4 (1.84)  
7.0 (1.74)  
7.0 (1.74)  
6.7 (1.67)  
6.7 (1.67)  
6.7 (1.67)  
6.4 (1.59)  
6.4 (1.59)  
6.1 (1.52)  
6.1 (1.52)  
6.1 (1.52)  
5.8 (1.44)  
5.8 (1.44)  
5.5 (1.37)  
5.5 (1.37)  
5.5 (1.37)  
5.2 (1.30)  
5.2 (1.30)  
4.9 (1.22)  
4.9 (1.22)  
4.9 (1.22)  
4.7 (1.17)  
4.7 (1.17)  
4.4 (1.10)  
4.4 (1.10)  
4.4 (1.10)  
4.2 (1.05)  
4.2 (1.05)  
3.9 (0.97)  
3.9 (0.97)  
3.9 (0.97)  
3.7 (0.92)  
3.7 (0.92)  
3.4 (0.85)  
3.4 (0.85)  
3.4 (0.85)  
3.2 (0.80)  
3.2 (0.80)  
*No adjustment required.  
TABLE 8  
Gas Flow Rate (Ft.3/Hr.)  
Gas Flow  
Seconds for 1  
Gas Meter Size  
Revolution  
10  
½ cu ft Dial  
180  
150  
129  
113  
100  
90  
1 cu ft Dial  
Check for proper gas flow to the unit heater.  
360  
300  
257  
225  
200  
180  
164  
150  
1. Operate unit at least 15 minutes before checking  
gas flow. Determine the time in seconds for one  
revolution of gas through the meter.  
2. Compare the number of seconds and the gas  
meter size in table 8 to determine the gas flow rate.  
Multiply the gas flow rate by the heating value to  
determine the unit input rate. If manifold pressure is  
correct and the unit input rate is incorrect, check  
gas orifices for proper size and restriction.  
12  
14  
16  
18  
20  
22  
24  
26  
82  
75  
69  
64  
138  
129  
3. Remove temporary gas meter if installed.  
28  
30  
32  
34  
60  
56  
53  
120  
113  
106  
NOTE – To obtain accurate reading, shut off all other  
gas appliances connected to meter.  
36  
50  
100  
38  
47  
95  
40  
45  
90  
42  
43  
86  
44  
41  
82  
46  
39  
78  
48  
38  
75  
50  
36  
72  
52  
35  
69  
54  
33  
67  
56  
32  
64  
58  
60  
31  
30  
62  
60  
Natural = 1000 btu/cu ft  
LP = 2500 btu/cu ft  
Note: Table assumes standard temperature (60°F), barometric  
pressure (30 in Hg), and fuel heating values (btu/cu ft). Fuel heating  
values may vary, contact local fuel supplier to obtain actual heating  
value of fuel being supplied.  
Page 18  
 
SERVICE  
CAUTION - Turn off gas and electrical power to unit  
Combustion Air Blower  
before performing any maintenance or service  
operations on this unit. Remember to follow lighting  
instructions when putting unit back into operation after  
service or maintenance.  
Under normal operating conditions, the combustion air  
blower should be checked and cleaned prior to the  
heating season with the power supply disconnected.  
Use a small brush to clean blower wheel.  
Burners  
Electrical  
1- Periodically examine burner flames for proper  
appearance during the heating season.  
2- Before each heating season examine the burners  
for any deposits or blockage that may have  
occurred.  
1- Check all wiring for loose connections.  
2- Check for correct voltage at unit (unit operating).  
3- Check amperage draw.  
Flue and Air Inlet  
3- Clean burners as follows:  
a-Turn off both electrical and gas supplies to unit.  
b-Disconnect gas supply piping, high tension and  
sensor leads. Remove gas manifold. Remove  
burner tray.  
c-Clean burners as necessary. Make sure that  
burner heads line up properly to ensure flame  
crossover. Check spark gap on electrode and  
adjust if required. The gap should be between  
0.110 inch and 0.140 inch (2.79mm to 3.56mm).  
The gap may be checked with appropriately sized  
twist drills or feeler gauges.  
Check all vent and air inlet joints for tightness. Ensure  
that connections are sealed and that there are no  
blockages.  
Failure to Operate  
If unit fails to operate check the following:  
1- Is thermostat calling for heat?  
2- Is main disconnect closed?  
3- Is there a breaker tripped or a fuse blown?  
4- Is gas turned on at meter?  
5- Is manual shutoff valve open?  
d-Reinstall burner tray, gas manifold, high tension  
and sensor leads. Reconnect gas supply piping.  
e-Restore electrical power and gas supply. Follow  
lighting instructions to light unit. Check burner  
flame.  
6- Is unit ignition system in lock out? If unit locks out  
again, call service technician to inspect unit.  
7- Is combustion air inducer proving switch closed?  
Obstructed flue will cause unit to shut off at  
combustion air inducer proving switch. Check flue  
passage and outlet.  
Flue Passageway and Flue Box  
Repair Parts  
The flue passages and flue box should be inspected  
and cleaned prior to each heating season. The  
sequence of operation should be as follows:  
1- Turn off both electrical and gas supply to unit.  
2- Disconnect combustion air blower wiring.  
3- Remove screws securing flue box to unit. Remove  
flue box. If necessary, remove blower assembly  
from flue box. Clean flue box with wire brush.  
4- Remove turbulator retention bracket and  
turbulators. Clean turbulators with wire brush.  
5- Remove burners as described in section “Burners"  
section.  
When ordering repair parts include the complete unit  
model number listed on the unit rating plate. For  
example: TUA045SNAF1.  
6- Clean tubes with a wire brush.  
7- Reassemble unit. The combustion air and flue box  
gaskets should also be replaced during  
reassembly.  
8- Restore electrical power and gas supply. Follow  
lighting instructions to light unit. Check operation of  
unit.  
Page 19  
 
MAXIMUM LOAD NOT TO  
EXCEED 20 VA AT 24 V CLASS 2.  
(2)S47 USED ON 60 & 75 MODELS  
ONLY.  
DISCONNECT ALL POWER  
BEFORE SERVICING.  
BLUE  
FOR PROPER GROUNDING  
REFER TO LOCAL CODES.  
BROWN  
RED  
ORANGE  
BLUE  
YELLOW  
BLUE  
GREEN/YELLOW  
DESCRIPTION  
WIRING DIAGRAM  
6/03  
KEY  
A3  
B3  
COMPONENT  
CONTROL, BURNER, IGNITION  
MOTOR, BLOWER  
HEATING UNITS ˘ GAS GCI−3A  
B6  
GV1  
S10  
MOTOR, COMBUSTION AIR BLOWER  
VALVE, GAS  
LIMIT, PRIMARY GAS  
TUA45/60/75/100/125S(N,L(A,S)F  
S18  
SWITCH, COMB. AIR INDUCER PROVE  
SWITCH, FLAME ROLLOUT 1  
SWITCH, FLAME ROLLOUT 2  
SWITCH, LOW GAS PRESSURE  
TRANSFORMER, CONTROL  
SWITCH, DOOR  
(1)S47  
(2)S47  
S43  
T1  
Supersedes Form No.  
New Form No.  
065329500  
DS  
Page 20  
 

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