INSTALLATION AND OPERATION INSTRUCTIONS OWNER / INSTALLER: For your safety this manual must be carefully and thoroughly read and understood before installing, operating or servicing this heater. SUNSTAR ECLIPSE INFRARED RADIANT TUBE HEATER Single and Two Stage Pull Through System (Negative Pressure) Models: SIR25, SIR35, SIR45 – (N5/L5) SIR35, SIR45 – (N7/L7) !INSTALLER: This manual is the property of the owner. Please present this manual to the owner when you leave the job site.
TABLE OF CONTENTS SECTION 1.0) 2.0) 3.0) 4.0) 5.0) 6.0) 6.1) 7.0) 8.0) 9.0) 10.0) 11.0) 12.0) 13.0) 13.1) 13.2) 14.0) 15.0) 15.1) 16.0) 17.0) 17.1) 18.0) 19.0) 20.0) 20.1) 21.0) 21.1) 21.2) 21.3) 21.4) 21.5) 22.0) 23.0) 24.0) DESCRIPTION PAGE Safety ................................................................................................................................................... 2 Installer Responsibility ...................................................................................
1.0) SAFETY This heater is a self-contained infrared radiant tube heater. Safety information required during installation and operation of this heater is provided in this manual and the labels on the product. The installation, service and maintenance of this heater must be performed by a contractor qualified in the installation and service of gas fired heating equipment. All personnel in contact with the heater must read and understand all safety information, instructions and labels before operation.
INSTALLATION REQUIREMENTS The installation must conform to local building codes or in the absence of local codes, with the National Fuel Gas Code ANSI Z223.1/NFPA54 or the Natural Gas and Propane Installation Code CSA B149.1. Heaters shall be installed by a licensed contractor or licensed installer. Clearances to combustibles as outlined in this manual should always be observed.
4.0) MINIMUM CLEARANCES TO COMBUSTIBLES Minimum clearances to combustibles shall be measured from the outer surfaces as shown in the following diagram. For reduced clearances below the heater, use the Deflector Kit (Part No. 43504010), described in Section 6.1), and maintain the minimum clearances specified in the notes below. Follow the instructions packaged with the kit for installation.
5.0) Model No. SPECIFICATIONS (2-stage) Btu/hr Heat Total Low Exchanger Heater Input Length Length Btu/hr High Input SIR25 25,000 SIR35 35,000 SIR45 45,000 n/a 25,000 31,500 16’ Orifice Size Flue Restrictor Plate I.D. & Part # Natural Gas Propane Gas 7/8” 42741120 #42 (0.094) #52 (0.064) 1” 42741041 #35 (0.110) 1.75mm (0.069) 1-1/8” 42741031 1/8” (0.125) 5/64” (0.078) 9’-3” Minimum * Mounting Height @ @ Horizontal 45º Angle 8’ 8’ 8’ * MOUNT HEATERS AS HIGH AS POSSIBLE.
CONTROL/DRAFT INDUCER PACKAGE NUMBERS 1-STAGE CONTROLS 2-STAGE CONTROLS MODEL NO. SIR25-N5 SIR25-L5 SIR35-N5 SIR35-L5 SIR45-N5 SIR45-L5 PART NO. GAS TYPE 43501030 43501040 43501050 43501060 43501070 43501080 MODEL NO. NATURAL PROPANE NATURAL PROPANE NATURAL PROPANE SIR35-N7 SIR35-L7 SIR45-N7 SIR45-L7 PART NO. GAS TYPE 43501090 43501100 43501110 43501120 NATURAL PROPANE NATURAL PROPANE B. Body Package Descriptions Part Description QTY #43468000, 8Ft. Body Package .................................
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9.0) TYPICAL SUSPENSION METHODS Various means of suspending the heater can be used. See the following drawings for typical examples. 1. Use only noncombustible materials for suspending hangers and brackets. 2. A minimum No. 2 chain with a working load limit of 115 lbs. is required. 3. Turnbuckles can be used with chains to allow leveling of the heater. All “S” hooks and eye bolts must be manually crimped closed by the installer. 4. When using rigid means for heater suspension (rod, flat bar, etc.
10.0) HEATER ASSEMBLY During field assembly of the heater, the recommended procedure is as follows: 1. Install suspension (according to Section 7.0) using proper suspension method (see Section 9.0). Trapeze Method Individual Suspension Method 2. Lift the tube section and suspend it into place. When lifting, caution should be used to avoid damaging the assembly. Make sure that the long axis of heater is level.
3. Assembly the reflector onto the tube section. Leave 3” space between the tube flange and the reflector for later mounting of control box and draft inducer. 4. Place the flanges of the control end reflector flush with the end of the first reflector. Secure by sliding speed clips onto reflector edges. Evenly space 6 speed clips on sides and top of reflectors to provide a snug fit. Place foot end reflector on the opposite end of the reflector and secure as above. 5.
7. Slip the plastic vacuum air tube over the 1/4” O.D. aluminum tube end of the draft inducer and the air switch probe in the control box. The air tube should be shortened to prevent a downward sag which could allow condensation build-up in the tube. 8. Insert motor lead wires through the strain relief bushing of the control box and connect to L1 and L2 of terminal block. Refer also to the wiring diagram in Section 13.0). 9.
ANGLE MOUNTED HEATERS ONLY 10. The heater can be mounted horizontally or up to an angle of 45º maximum from horizontal. When the heater is to be angle mounted adjacent to a sidewall, make sure the draft inducer assembly is on the lower side of the heater so that the control box access panel is easily accessible. Make sure the long axis of heater is level. 11. Multiple draft inducer positions can also be used as shown in the diagrams. This allows for the desired configuration of flue venting. 11.
10. After all gas connections have been made, make sure the heater and all gas outlets are turned off before the main gas supply is turned on slowly. Turn the gas supply pressure on and check for leaks. To check for leaks, check by one of the methods listed in Appendix D of the National Fuel Gas Code. 11. If a 2nd stage regulator is used, the ball valve down stream in the supply line must be closed when purging the gas lines to prevent gas seeping through it. If initial gas pressure is higher than 14” w.c.
12.0) INSTRUCTIONS FOR PRESSURE TEST GAUGE CONNECTION SUPPLY PRESSURE 1. The installer will provide a 1/8” N.P.T. tapped plug, accessible for test gauge connection immediately upstream of the gas supply connection to the heater. OUTLET GAS PRESSURE CHECK AND ADJUSTMENTS WHITE-RODGERS GAS VALVES Gauges that measure pressure in pounds per square inch are not accurate enough to measure or set the manifold pressure.
GAS PRESSURE TABLE GAS TYPE Natural Gas MANIFOLD PRESSURE High Low (2-stage only) 3.5” W.C. 1.4” W.C. SUPPLY PRESSURE Minimum* Maximum 5” W.C. 14” W.C. Propane Gas 10.0” W.C. 4.0” W.C. 11” W.C. *Minimum permissible gas supply pressure for purpose of input adjustment. 14” W.C.
13.0) ELECTRICAL CONNECTIONS 1. All electric wiring shall conform to the latest edition of the National Electrical Code (ANSI/NFPA No. 70), or the code legally authorized in the locality where the installation is made. 2. The unit must be electrically grounded in accordance with the National Electrical Code (ANSI/NFPA No. 70-latest edition). In Canada, refer to current standard C22.1 Canadian Electrical Code Part 1. 3.
SINGLE STAGE CONTROLS - INTERNAL CONNECTION WIRING DIAGRAM SINGLE STAGE CONTROLS - SCHEMATIC WIRING DIAGRAM SINGLE STAGE CONTROLS - THERMOSTAT WIRING DIAGRAMS A.
B. LINE VOLTAGE (120V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS PER THERMOSTAT C. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – SINGLE HEATER PER THERMOSTAT Order 24V Relay Kit (Part No. 43274000) for Low Voltage (24V) thermostat connection. D.
13.
TWO STAGE CONTROLS - SCHEMATIC WIRING DIAGRAM TWO STAGE CONTROLS - THERMOSTAT WIRING DIAGRAMS A.
B. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS PER THERMOSTAT C.
D.
14.0) VENTING This is a category lll appliance. A. BASIC FLUE VENTING — Venting must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1-latest edition) or the authority having jurisdiction. Other venting references are in the equipment volume of the ASHRAE Handbook. Model SIR 25 SIR 35 SIR 45 Heat exchanger length ft 15 15 15 Maximum vent length ft.
9. Single-wall metal pipe shall not originate in any unoccupied attic or concealed space and shall not pass through any attic, inside wall or concealed space, or through any floor. For the installation of a single-wall metal pipe through an exterior combustible wall, refer to latest edition of the National Fuel Gas Code or the authority having jurisdiction. 10. A venting system shall terminate at least 3 ft. above any forced air inlet located within 10 ft. VENT TERMINATION (RESIDENTIAL INSTALLATIONS) 1.
SINGLE HEATER VENTING (HORIZONTAL THROUGH SIDEWALL) This heater, when horizontally vented, must be installed with the approved venting system. When venting the heater horizontally through a combustible outside sidewall, the same requirements listed previously for venting Vertical Through The Roof apply except as follows: 1. For horizontal venting, the vent lengths may be as follows: Minimum Equivalent Length = 5 ft. of pipe Maximum Equivalent Length = 75 ft.
A Y-connector must be used to the common vent. 2. Material for connectors and Y-connectors should be constructed of galvanized sheet metal or other approved noncombustible corrosion resistant material as allowed by state or local codes. All common vent pipe should be insulated flue pipe or double-wall, Type B vent. 3. Avoid unnecessary bends. Limit to two (2) 90º elbows. 4. The entire length of vent connector shall be readily accessible for inspection, cleaning and replacement. 5.
Multiple Heater Venting (Connections into a Manifold) VENT SIZING TABLE — Multiple Heater Venting SIR 25 SIR 35 SIR 45 1 4” 4” 4” Number of Heaters 2 3 4 4” 4” 5” 4” 5” 5” 4” 5” 5” COMMON VENT DIAMETER (If a size is not available use the next larger size.) 5 5” 6” 6” THE ABOVE ILLUSTRATIONS AND TABLE OF VENT SIZES FOR COMMON VENTING OF MULTIPLE HEATERS ARE IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE ANSI Z223.
15.0) AIR FOR COMBUSTION If indoor combustion air is to be supplied for a tightly enclosed area, one square inch of free area opening shall be provided below the heater for each 1,000 Btu/hr per hour of heater input. When outside air is used, the opening below the heater shall be one square inch of free area for each 4,000 Btu/hr of heater input. In contaminated atmospheres or high humidity areas, optional outside air for combustion is recommended.
-30- Form 43471010 Dec 2017
16.0) LIGHTING AND SHUTDOWN INSTRUCTIONS 1. Turn on the gas and electrical supply. 2. Set the thermostat to call for heat. The blower motor will energize. 3. Ignition should occur after the 30-second air pre-purge. 4. If ignition fails, the unit will spark for approximately 21 seconds and go into safety lockout. Turn the thermostat (power) off for 60 seconds to take the system out of lockout. 5.
17.1) SEQUENCE OF OPERATION – TWO STAGE (N7/L7) The chart below shows the sequence of operation for the normal operating cycle for a two stage heater (N7/L7). .If the flame is not sensed during sequence T3 or T4, then the burner will automatically begin ignition as in sequence T2. If the flame is not re-established the heater will go to lockout.
18.0) CONTROL COMPONENT LOCATION NOTE: Access panel only opens to 90.
19.0) CLEANING AND ANNUAL MAINTENANCE This heater must be cleaned and serviced annually by a qualified contractor before the start of each heating season and at any time excessive accumulation of dust and dirt is observed. Maximum heating efficiency and clean combustion will be maintained by keeping the heater clean. To clean the heater, turn off all electrical and gas supply to the heater. The contractor shall check the following during periodic maintenance.
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TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED) -36- Form 43471010 Dec 2017
TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED) Form 43471010 Dec 2017 -37-
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TROUBLESHOOTING GUIDE – TWO STAGE (CONTINUED) Form 43471010 Dec 2017 -39-
TROUBLESHOOTING GUIDE – TWO STAGE (CONTINUED) -40- Form 43471010 Dec 2017
TROUBLESHOOTING GUIDE – TWO STAGE (CONTINUED) Form 43471010 Dec 2017 -41-
21.0) REPLACING PARTS Only use genuine Space-Ray replacement parts. Parts are available from the factory for replacement by a licensed person. Refer to the Replacement Parts Guide in Section 23.0) for all replacement parts. 21.1) REMOVAL OF SPARK ELECTRODE 1. Disconnect electrical supply and open access panel. 2. Pull out the ignition cable hooked to spark electrode. 3. Remove two mounting screws. 4. Take out the spark electrode. Check that the spark gap is 3/16”. 5. Check spark electrode.
21.2) REMOVING MAIN BURNER AND GAS VALVE The main burner can be inspected without removing the burner housing from the heat exchanger tube. 1. Disconnect electrical supply and gas connection at the restrainer nipple. 2. Open the access panel and disconnect the wires from gas valve. 3. Remove the burner clamp and screws. 4. Remove the burner and gas valve assembly from the cabinet. 5. Unscrew the burner from the manifold. 6. Check the orifice.
21.4) IGNITION SYSTEM CHECKS TO CHECK IGNITION CABLE. a. Make sure that the ignition cable does not touch any metal surface. b. Make sure that connections to the stud terminal and the igniter/sensor are clean and tight. c. Make sure that the ignition cable provides good electrical continuity. TO CHECK IGNITION SYSTEM GROUNDING. (Nuisance shutdowns are often caused by a poor or erratic ground.) A common ground is required for the module, igniter, flame sensor and main burner. a.
21.5) MOTOR AND BLOWER WHEEL CHECK If draft inducer motor fails to run: a. Check power supply to junction box. b. Check for loose or broken motor lead wire. c. Check to see that blower wheel turns freely and is not rubbing housing. Blower wheel may have worked loose from shaft and jammed against housing. d. Check for blower wheel damage; replace if necessary. If no damage, readjust blower wheel on shaft & retighten set screw. e. If all above does not correct, replace motor. 22.
23.0) Item No. 1 1a 2 3 4 5 6 7 8 9 10 11 12 13 14 REPLACEMENT PARTS GUIDE Part No. 42737990 42928000 03721000 30347000 42740000 03723000 43221000 42744000 42742000 42739000 40504020 42741120 42741041 42741031 n/a DRAFT INDUCER COMPONENTS Description Kit. Draft Inducer Replacement Kit, Motor Replacement Motor Motor Spacer (4 per motor) Motor Plate Blower Wheel Draft Inducer Gasket Sensing Tube, Draft Inducer Sensing Tube Bracket Blower Housing Sub-Assembly 4” O.D.
Item No. 15 16 17 18 19 20 21 22 23 24 24a 24b 25 26 27 28 29 30 31 32 33 33a 34 34a 35 37 38 39 40 41 Item No. 42 42a 43 43a 44 45 46 47 47a 48 49 50 51 52 53 54 55 56 Form 43471010 Dec 2017 Part No.
-48- Form 43471010 Dec 2017
BODY COMPONENTS Item No. 1 2 3 3a 4 5 6 7 8 9 10 Part No.
24.0) WARNINGS CARD Copies of this card may be ordered at no charge under part no. 43344980 for installation near the heater.
