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 Stage Pull Through System (Negative Pressure) Models: SIR25, SIR35, SIR45 – (N5/L5) !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) 14.0) 15.0) 15.1) 16.0) 17.0) 18.0) 19.0) 20.0) 21.0) 21.1) 21.2) 21.3) 21.4) 21.5) 22.0) 23.0) 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 Combustible material must be located outside the clearance dimensions listed. Failure to do so may result in death, serious injury or property damage. 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.
5.0) Model No. SIR 25 SIR 35 SIR 45 SPECIFICATIONS Total Heat Btu/hr Exchanger Heater Flue Restrictor Plate I.D. & Part # Length Length Input 25,000 7/8” #42741120 16’ 9’-3” 35,000 1” #42741041 45,000 1-1/8” #42741031 Minimum * Mounting Height @ @ Natural Gas Propane Gas Horizontal 45º Angle #42 (0.094) 1.45mm (0.057) 8’ 8’ #35 (0.110) 1.75mm (0.069) 8’ 8’ 1/8” (0.125) 5/64” (0.078) 8’ 8’ Orifice Size * MOUNT HEATERS AS HIGH AS POSSIBLE.
6.1) ACCESSORY PACKAGES A. Exhaust Hood Package, Part #42924000 7 1/2 (19cm) 7 1/2 (19cm) Contains: 3 3/4 (10cm) Exhaust Hood Assembly, #42925540……QTY–1 #8-18 x ½ Self-Drilling Screws, #02189030……QTY–2 3 1/2 (9cm) 4 (10cm) Bird Screen Front View Side View B. Deflector Kit, Part #43504010 The Deflector Kit is available for use to reduce the clearances to combustibles below the heater. Refer to the Minimum Clearances to Combustibles Table in Section 4.0) when using this Deflector Kit.
7.0) DIMENSIONS – SIR SERIES 111 (280cm) 15 (381mm) 10 1/2 (267mm) 80 (203cm) 5 1/2 (140mm) Side View Reflector 5 1/4 (133mm) Hanger Bracket (QTY-2) Emitter Tube 18 1/2 (470mm) Bottom View 7 1/2 (191mm) 8 FT Body Section 9 (23cm) Draft Inducer (vertical mounting) Strain Relief Bushing Motor Leads 8 (20cm) Control Box 7 (18cm) 1/4 O.D.
Exhauster assembly Restrictor airplate -8- Control Box Mounting flange (6-hole) Reflector, control end Reflector Mounting flange (3-hole) Reflector clamp with screw U bolt clamp & 5/16 Hex nuts 3 (control box to reflector) Suspension chain with turnbuckle 5-1/2 (control box to chain) 3 OD x 8 tube 80 Tube support/ hanger bracket U bend Reflector, foot end 10-1/2 Control box Side View 3 5-1/2 reflector Suspension chain 8.
9.0) TYPICAL SUSPENSION METHODS SUSPENSION HAZARD Burner must be secured to the mounting flange with nuts. All materials used to suspend the heater must have a minimum working load of 115 lbs. All S Hooks must be crimped closed. Never use the heater to support a ladder or other access equipment. Failure to do so may result in death, serious injury or property damage. Various means of suspending the heater can be used. See the following drawings for typical examples. 1.
10.0) HEATER ASSEMBLY CUT HAZARD Sheet metal parts, particularly reflectors and vent have sharp edges. Always use gloves when handling. Failure to do so may result in death, serious injury or property damage. During field assembly of the heater, the recommended procedure is as follows: 1. Put the suspension in place (according to Section 7.0) using proper suspension method (see Section 9.0).
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.
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). 8 Strain Relief Bushing 1/4 O.D.
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. Multiple draft inducer positions can also be used as shown in the diagrams. This allows for the desired configuration of flue venting. Vertical 45 Deg.
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. MANIFOLD PRESSURE – COMBINATION GAS VALVE IS FACTORY SET 1. Turn the gas valve to the “OFF” position. Remove the 1/8” plug from the combination gas valve at the outlet pressure tap and connect a 1/8” nipple to the tapped hole. Connect the test gauge to the nipple.
13.0) ELECTRICAL CONNECTIONS ELECTRIC SHOCK HAZARD Disconnect electrical power and gas supply before servicing. This appliance must be connected to a properly grounded electrical source. Failure to do so may result in death or serious injury. 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.
SCHEMATIC WIRING DIAGRAM — Direct Spark Ignition 120V MOT GL TRANS AS RL 25V 25V GND IG/S MOT GL TRANS RL AS SM IG/S V AL Motor Green Light 24V Transformer Red Light Air Switch Ignition Module Ignitor / Sensor Gas Valve Amber Light Moteur Témoin vert Transformateur 24ÊV Témoin rouge pressostat Bloc d'allumage électrode Robinet à gaz Témoin ambre SM AL V SCHEMATIC WIRING DIAGRAM 42785000 Rev. C 10/04 FIELD CONNECTION AND THERMOSTAT WIRING DIAGRAMS A.
C.
14.0) VENTING CARBON MONOXIDE HAZARD Heaters installed in an unvented mode require a minimum ventilation flow of 4 CFM per 1,000 Btu/hr of total installed capacity. In buildings with airborne contamination the heater must be installed with fresh air for combustion. Failure to do so may result in death, serious injury, property damage or illness from Carbon Monoxide poisoning. A. BASIC FLUE VENTING — Venting must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.
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.
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.
• The connector length should be no more than 75% of the vertical portion of vent above the connector. • Where possible, use a Y-connector to the common vent. 2. Material for 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 double-wall, Type B vent. 3. Avoid unnecessary bends. Limit to two (2) 90º elbows. 4.
Multiple Heater Venting (Connections into a Manifold) Total vent height Connector rise 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.
Vertical Through the roof 3 ft.
16.0) LIGHTING AND SHUTDOWN INSTRUCTIONS Never operate the heater with the access panel open or removed. The access panel must be closed tightly during operation. Failure to do so may result in death, serious injury or property damage. 1. Turn on the gas and electrical supply. Rotate the gas valve knob counter-clockwise 4 to the “ON” position. 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.
18.
19.0) CLEANING AND ANNUAL MAINTENANCE ELECTRIC SHOCK & EXPLOSION HAZARD Disconnect electrical power and gas supply before servicing. Failure to do so may result in death or serious injury. 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.
Form #43471010 Mar 09 Yes No Check blower wheel. Is there any damage? -29- Troubleshooting continued on the next page. Yes Yes Does the red monitoring light come on? No No No Yes Repair connection. Replace transformer. No Connect this wire of the red light to the transformer terminal along with the white wire from ignition module. No Is the other wire of the red light connected to the terminal common of transformer? No Yes Clean out hose and probe.
-30- Form #43471010 Mar 09 Troubleshooting continued on the next page. Yes Does the amber light stay on until call for heat ends? No Yes 30 seconds after startup, does the amber monitoring light No come on? Troubleshooting continued from the previous page. No No See next page for troubleshooting sequence. Yes Is there a spark across igniter/sensor gap? Yes Is the knob on the gas valve in the ON position? (Its shipped No from the factory at OFF position) Turn the knob to ON position.
Form #43471010 Mar 09 -31- Yes No No Purge the gas supply line. Has all the air been purged from the gas supply lines? Yes Thermostat is not working properly. Replace it if necessary. No Yes No Is the green light still on? Adjust the spark gap to 3/16. Check the spark gap. Is it 3/16? Troubleshooting continued from the previous page. Troubleshooting ends. Yes Call for heat ends and the heater shuts off? Troubleshooting continued from the previous page. Adjust supply gas pressure.
21.0) REPLACING PARTS ELECTRIC SHOCK & EXPLOSION HAZARD Disconnect electrical power and gas supply before servicing. Failure to do so may result in death or serious injury. Only use genuine SunStar 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 A 2 1 Access panel only opens to 90 . 3 3/16 4 5 6 1.
21.2) REMOVING MAIN BURNER AND GAS VALVE The main burner can be inspected without removing the burner housing from the heat exchanger tube. 4 3 1 2 6 5 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.
Multipurpose Meter 25V (GND) 25V VALVE VALVE (GND) X Red (+) Black (-) Module FLAME SENSOR CURRENT CHECK - use microamp scale - 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.
23.0) Item No. 1 1a 2 3 4 5 6 7 8 9 10 12 13 14 REPLACEMENT PARTS GUIDE Part No. 42737000 42928000 03721000 30347000 42740000 03723000 43221000 42744000 42742000 42739000 40504020 42741120 42741041 42741031 DRAFT INDUCER COMPONENTS Description Draft Inducer Assembly Motor Replacement Kit 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. Flue Pipe Starting Collar Restrictor Plate, 7/8” I.D.
Item No. 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 37 38 39 40 41 Part No. 03988150 42750000 42751000 42752000 42447000 30186201 30279980 42709000 30281000 42759000 30295000 30314070 30331040 42398040 42398060 42398050 42757000 30333070 30333080 42701000 03259xxx 42700000 30148000 42755000 42753000 CONTROL COMPONENTS Description Plastic Vacuum Air Tube, 15” long Cabinet Assembly Access Panel Air Inlet Plate (Perforated) Sight Glass Air Switch, set @0.11” W.C.
INSTRUCTIONS FOR HORIZONTAL VENTING ONLY Wall Mur 43470060 6/05 Alternate Supply Locations Optional Second Stage Regulator with Vent Leak Limiter if required to reduce the Supply Pressure below 14 W.C. Recommended Gas Pressure 2 PSIG Flexible Connector Gas Supply Piping 14 - 17 (356 - 432mm) Sediment Trap (Drip Leg) Control Box 43344050 Rev.
BODY COMPONENTS Item No. 1 2 3 3a 4 5 6 7 8 9 10 11 Part No.
