Form I-UDB (Version B.4) Obsoletes I-UDB (Version B.3) Installation / Operation Applies to: Model UDBP and Model UDBS Series High Static Blower-Type Unit Heaters ! WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
Table of Contents Contents 1.0 General.............................................................. 2-4 1.1 Hazard Labels and Notices...................................... 2 1.2 General Installation Information.............................. 3 1.3 Warranty..................................................................... 3 1.4 Installation Codes..................................................... 3 2.0 Unit Heater Location......................................... 4-6 2.1 Heater Throw ................
CAUTION Models UDBP & UDBS unit heaters should not be installed in an environment where the ambient temperature is below 50°F. The low space temperature may result in condensate forming in the heat exchanger. BOTH this manual and the correct venting manual are REQUIRED for installation of this heater. Model Venting Instruction Manual by Form No. Look for Matching Label on Venting Manual and Heater UDBP Form I-UD-V-PV, Standard Power Vent Installation (Each heater has its own dedicated vent.
2.0 Unit Heater Location Use the clearances in Paragraph 4.1; the combustion air requirements in Paragraph 6.2; the throw tables, sound data, mounting height requirements, and location recommendations in Paragraphs 2; the weights in Paragraph 5.1; and the venting requirements in the Venting Manual to determine where to suspend the heater. 2.
Dimensions X, Y, Z (meters) Model UDBP and Model UDBS with Standard Horizontal Louvers at Mounting Heights of 1.5 - 5.5M Motor Speed 30 H Low Speed Medium Speed High Speed X 45 Y Z Louver Angle* X Y 60 Louver Angle* Z X Y 75 Louver Angle* Z X Y 100 Louver Angle* Z X Y 125 Louver Angle* Z X Y Louver Angle* Z 1.5M 2.1 4.6 11.6 -27° 2.1 5.2 13.4 -20° 3.4 7.9 23.8 -15° 3.4 7.3 22.6 -13° 3.0 7.0 22.6 -16° 3.0 6.7 21.0 -14° 2.4M 2.1 4.0 9.8 -44° 2.7 5.
2.0 Unit Heater Location (cont’d) NOTE: Venting requirements may affect location. Consult the Venting Manual for this heater before making final determination. 2.3 Location Recommendations Locate the heater so that it is a minimum of five feet (1.5M) above the floor and in compliance with the clearances in Paragraph 4.1. WARNING If touched, the vent pipe and internal heater surfaces that are accessible from outside the heater will cause burns. Suspend the heater a minimum of 5 feet (1.
3.2 Preparing for Installation Read this booklet and become familiar with the installation requirements of your particular heater. If you do not have knowledge of local requirements, check with the local gas company or any other local agencies who might have requirements concerning this installation. Before beginning, make preparations for necessary supplies, tools, and manpower. IMPORTANT: Shipping brackets are attached with cabinet screws.
3.0 Uncrating and Preparation (cont’d) FIGURE 2 Installing High Altitude Pressure Switch required above 6000 ft (1830M) elevation 3.2 Preparing for Installation (cont’d) If the pressure switch needs to be changed, do that before the heater is operated; follow the instructions in FIGURE 2. Model UDBP Size 30 High Altitude Switch P/N 60 75 100 125 150 175 200 225 250 300 197032 0.35 0.45 0.35 1.05 Purple Pink Purple Brown Negative Pressure OFF Setpoint ("w.c.
4.2 Dimensions FIGURE 5 - Model UDBP, Power Vented Fan Model (30-125 vertical; 150-400 horizontal) (For size, see Techanical Data, page 42.
4.0 Clearances and Dimensions (cont’d) 4.2.
5.0 Hanging the Heater 5.1 Weights Before suspending the heater, check the supporting structure to be used to verify that it has sufficient load-carrying capacity to support the weight of the unit.
5.0 Hanging the Heater (cont’d) If ordered with swivel connectors for 1” pipe, Option CK10, use field-supplied hardware to attach the swivels at the suspension holes. Suspend with 1” pipe. See FIGURE 8. Be sure the threaded swivel connectors are locked to the hanger bars as illustrated. 6.0 Mechanical Swivel Hanger 3/8 Hex Nut 3/8 Lock Washer Field-supplied 3/8 Hex Nut and Lock Washer FIGURE 8 - Swivel Connectors to Suspend the Heater from 1” Pipe, Option CK10 6.1.
Sizing Gas Supply Line Capacity of Piping Cubic Feet per Hour based on 0.3" w.c. Pressure Drop Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft) Specific Gravity for Propane Gas -- 1.
6.0 Mechanical (cont’d) 6.1.2 Valve Outlet or Orifice Pressure Setting (cont’d) on standby. Incorrect inlet pressure could cause excessive valve outlet gas pressure immediately or at some future time. If natural gas supply pressure is too high, install a regulator in the supply line before it reaches the heater. If natural gas supply pressure is too low, contact your gas supplier. 6.
Manifold Pressure Settings by Altitude for CANADA Altitude Natural Gas (inches w.c.) Feet Meters 0-2000 0-610 Propane Gas (inches w.c.) Single-Stage and Two-Stage Single-Stage and Two-Stage Two-Stage High Fire Low Fire Two-Stage High Fire Low Fire 2001-4500 611-1373 3.5 1.8 10.0 5.0 2.8 1.5 8.1 4.1 2. Locate the 1/8” output pressure tap on the valve (See FIGURE 10, page 14). Turn the knob or switch on the top of the valve to “OFF”.
6.0 Mechanical (cont’d) 6.1 Gas Piping and Pressures (cont’d) 6.1.
FIGURE 11 - Definition of Confined Space and Required Openings for Combustion Air Confined Space: A space whose volume is less than 50 cubic feet per 1000 BTUH of the installed appliance input rating 1. Air from inside the building -- openings 1 square inch free area per 1000 BTUH. Never less than 100 square inches of free area for each opening. See (1) in FIGURE 11. 2. Air from outside through duct -- openings 1 square inch free area per 2000 BTUH.
6.0 Mechanical (cont’d) 6.
If the duct resistance is low, the blower may deliver too high an air volume; or if the heater is operated without ductwork, the blower may deliver excess air to overload the motor, causing the overload protector to cycle the motor. Reducing the blower speed will correct these conditions. If ductwork is added to an installation, it may be necessary to increase the blower speed. Decreasing blower speed will increase outlet temperature; increasing blower speed will decrease outlet temperature.
6.0 Mechanical (cont’d) 6.4.3 Blower and Belt Guards Guard options are designed to provide complete protection from the rotating drive and blower. Guards ordered as Option AZ6 or AZ7 are factory installed. Guards ordered as Option CD10 or CD12 are shipped separately for field installation. The blower guard only (Options AZ7 and CD12) is for Sizes 30-125 which have a direct drive motor. Both guards are used on Sizes 150-400 which have a belt drive. The belt guard includes a ground wire and screw.
CAUTION: Route wires so that they do not contact the flue wrapper or venter housing. The electrical supply enters at the rear of the heater (See FIGURE 17). Model UDBS includes a built-in disconnect switch. The switch on UDBS 30-125 has a 20A@115V and a 10A@230V inductive rating. The switch on UDBS 150-400 has a 30A@115V and a 15A@230V inductive rating. Model UDBS supply wiring connections are made inside the sealed electrical box.
7.0 Electrical Supply and Wiring (cont’d) 7.
FIGURE 18B - Typical Wiring Diagram for Model UDBP or Model UDBS, Sizes 30-125, Two Stage 40 VA SYSTEM TRANSFORMER 115/1/60 BK Y 115 VOLT W BR G G GRD SCREW BK BK G DISCONNECT SWITCH (UDBS ONLY) R 24V TERMINAL STRIP WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W G SEC COM L1 NEUTRAL NEUTRAL L1 P3-1 Y P3-2 W1 G NEUTRAL W THREE SPEED BLOWER MOTOR (SEE NOTE #6) P3-3 DOOR INTERLOCK (UDBS ONLY) R R P3-4 R W R ATO OR
7.0 Electrical Supply and Wiring (cont’d) 7.
FIGURE 18D - Typical Wiring Diagram for Model UDBP or Model UDBS, Sizes 150-400, Two Stage CUSTOMER'S DISCONNECT SWITCH BLOWER MOTOR CONTACTOR CONTACTS L2 INTERNALLY PROTECTED BLOWER MOTOR T2 R OR W L3 T3 L1 T1 LINE/1/60 OR 208-230/3/60 FACTORY WIRING FIELD WIRING OPTIONAL FACTORY WIRING R R OR BK OPTIONAL FIELD WIRING G GRD LUG Y 40 VA SYSTEM TRANSFORMER BK GRD 6 5 2 BK BR Y 115/208/230 VOLT 24V TERMINAL STRIP R 3 CONTROL SWITCH (UDBS ONLY) Y WIRING CODE BLACK - BK BROWN - BR R
7.0 Electrical Supply and Wiring (cont’d) 7.5.1 Combustion Air Proving (Pressure) Switch The combustion air proving switch is a pressure sensitive switch that monitors air pressure to ensure that proper combustion airflow is available. On Model UDBP, the switch is a single pole/normally open device which closes when a negative pressure is sensed in the venter housing.
7.5.4 Gas Valve The main operating gas valve is powered by the 24-volt control circuit through the thermostat and safety controls. The main control valve is of the diaphragm type providing regulated gas flow preset at the factory. (For location, see FIGURE 22, page 35.) WARNING The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting the unit to ensure positive closure. See Hazard Levels, page 2. 7.5.
8.2 DDC Controls, Options D10 and D14 8.0 Controls and Operation (cont’d) If the heater was ordered with Option D10 or D14, it is equipped with a Novar Minio control module. The Novar control with its accompanying relays and power transformer are mounted in the control compartment of the unit. See FIGURE 19A. This control offers a wide variety of input and output points that can be configured to meet a wide range of building management applications.
8.3 Ignition System This heater is equipped with a direct spark integrated control module (circuit board). The module monitors the safety devices and controls the operation of the blower and venter motors and the gas valve between heat cycles. FIGURE 20 – DSI Integrated Control Module (circuit board) LED lights are visible through a viewport on Model UDBS. Remove door panel to view LED lights on Model UDBP.
8.0 Controls and Operation (cont’d) Normal Heat Cycle Operating Sequence (cont’d) 8.3 Ignition System (cont’d) 5) Steady Heat - Control inputs are continuously monitored to ensure limit and pressure switches are closed, flame is established, and the thermostat call for heat remains. When the thermostat call for heat is removed, the control de-energizes the gas valve and begins post-purge and fan/blower off delay timing.
Continuous Blower Operation Fault Modes When the thermostat calls for continuous blower (G) without a call for heat, the blower motor is energized after a .25 second delay. NOTE: This brief on delay is to allow the “G” terminal to energize slightly before “Y” and an external changeover relay to switch from “G” to “W” without causing momentary glitches in the fan/blower output. The blower remains energized as long as the call for fan remains without a call for heat.
9.0 Commissioning 9.1 Check the installation prior to startup: Check to be sure that all screws used to hold shipping brackets were and Startup re-installed in the heater cabinet. Check suspension. Unit must be secure and level. Check clearances from combustibles. Requirements are in Paragraph 4.1. Check vent system to be sure that it is installed according to the instructions in the appropriate Vent Installation Manual as listed in Paragraph 1.2.2.
FIGURE 17 - Gas Valve Top View ON/OFF Switch 9.3 Check installation after startup: 4. On the top of the valve, turn the gas control switch to “OFF” or the knob clockwise to “OFF”. 5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! and follow the steps in the WARNINGS printed above or on the Operating Label on the heater.
9.0 Commissioning 9.3 Check installation after startup (cont’d) and Startup Place the "Literature Bag" containing the Limited Warranty, this booklet, the venting manual, and any control or optional information in an accessible location near the (cont’d) heater. IMPORTANT: After at least 8 hours but not longer than a week of operation, recheck the blower wheel, all set screws, blower pulley, motor pulley, and belt tension. Make any required adjustments.
• Check gas valve to ensure that gas flow is being shutoff completely. • Check the vent or vent/combustion air system for soundness. Clean openings. Replace any parts that do not appear sound. • Check the wiring for any damaged wire. Replace damaged wiring. (See Paragraph 7 for replacement wiring requirements.
10.2 Maintenance Procedures (cont’d) CAUTION: Use of eye protection is recommended. 10.2.2 Burner Maintenance 2 This heater is equipped with a TCORE ® burner. Inspect the burner/control compartment annually to determine if cleaning is necessary. If there is an accumulation of dirt, dust, and/or lint, clean the compartment and follow the instructions below to remove and clean the burner. Burner Removal Instructions (Refer to FIGURE 23.) 1.
Inspect the Lower Portion of the Heat Exchanger (with burner assembly removed) Clean all foreign material from the burner and venturi. After the burner is thoroughly clean, replace the end cap making certain that it is tight against the burner housing. NOTE: If any of the burner components are damaged or deteriorated, replace the burner assembly. At the burner flame entrance of each tube, shine a bright light into each heat exchanger section.
10.0 Maintenance and Service (cont’d) 10.2.4 Ignition System (cont’d) FIGURE 25 - Ignitor showing required Spark Gap measurement 10.2 Maintenance Procedures (cont’d) Flame Sensor - Refer to FIGURE 22 and locate the flame sensor. Disconnect the wire; remove the screw and the flame sensor. Clean with an emery cloth. 10.2.5 Venter Motor and Wheel Flame Sensor Remove dirt and grease from the motor casing, the venter housing, and the venter wheel.
The combination gas valve must be checked annually to ensure that the valve is shutting off gas flow completely. Instructions: 1) Locate the 1/8” NPT pressure tap on the combination valve. FIGURE 27 - Pressure Tap for Checking Gas Flow Shutoff NOTE: Operational pressure settings and instructions for checking pressure settings are in Paragraph 6.1.
10.0 Maintenance and Service (cont’d) 10.3 Troubleshooting Check the Lights on the DSI Integrated Control Module (Circuit Board) The integrated circuit board monitors the operation of the heater and includes two LED signal lights that indicate normal operation and various abnormal conditions. If the heater fails to operate properly, check this signal to determine the cause and/or to eliminate certain causes. LED is visible through viewport on Model UDBS. Remove access panel on Model UDBP.
General Troubleshooting PROBLEM Venter motor will not start Burner will not light PROBABLE CAUSE REMEDY 1. No power to unit. 1. Turn on power; check supply fuses or main circuit breaker. Turn on built-in control switch (Model UDBS only); replace switch if not operating. 2. No 24 volt power to integrated circuit board. 2. Turn up thermostat; check control transformer output. 3. Integrated circuit board fuse blown. 3. Correct cause. Replace fuse (type ATC or ATO, 32VDC, 3A). 4.
APPENDIX TECHNICAL DATA - Sizes 30 - 125 (Data applies to both Models UDBP and UDBS unless noted otherwise.) Size BTUH kw/h Input Heating Capacity Thermal Efficiency (%) BTUH kw/h Natural Propane Output Heating Capacity A Gas Connection (inches) B Vent Connection Size C (inches diameter) Control Amps (24 volt) Full Load Amps (with standard HP 115V motor) Maximum Over Current Protection (115V) D Normal Power Consumption (watts @ full load, medium speed) °F Minimum Discharge Air See Paragraph 2.
INDEX A Abnormal Heat Cycle Functions 30 Adjusting Blower Speed 18 Aircraft Hangars 3 APPENDIX 42 B Belt 18 Belt Drive 19 Belt Guard in Option AZ6 and CD10 20 Blower 18 Blower Guard in Options AZ6, AZ7, CD10, and CD12 20 Clean the Burner 36 Burner Maintenance 36 Burner Orifice 37 Burner Removal 36 C California Warning Label 3 Certification 2 Checking Gas Flow Shutoff 39 Check installation after startup 33 Check the installation prior to startup 32 Check the Lights 40 Chlorine 6 Circuit Board (DSI Integ
INSTALLATION RECORD - To be completed by the installer: Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ ________________________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Company _______________
