SunStar SPS 100-L5, Installation And Operation Instructions Manual

Page 1: ...phone in your building IMMEDIATELY IMMEDIATELY IMMEDIATELY IMMEDIATELY call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department DO NOT DO NOT DO NOT DO NOT store or use gasoline or other store or use gasoline or other store or use gasoline or other store or use gasoline or other flammable vapors and liq...

Page 2: ...2 2 Connecting the TISS System 26 13 0 Gas Connections and Regulations 29 14 0 Instructions for Pressure Test Gauge Connection 31 15 0 Electrical Connections 32 16 0 Venting 35 17 0 Air for Combustion 39 17 1 Direct Outside Air for Combustion 39 18 0 Lighting and Shutdown Instructions 41 19 0 Sequence of Operation 41 20 0 Control Component Location 42 21 0 Cleaning and Annual Maintenance 43 22 0 T...

Page 3: ...hr input of installed heaters Never use the heater as a support for a ladder or other access equipment Do not hang anything from the heater Supply all installation materials necessary that are not included with the heater Check the nameplate to make sure that the burner is correct for the gas type in the building and the installation altitude 3 0 GENERAL INFORMATION This heater is a self contained...

Page 4: ...ans This heater is not an explosion proof heater This heater is not an explosion proof heater This heater is not an explosion proof heater This heater is not an explosion proof heater Where the possibility of exposure to volatile and low flash point materials exists it could result in property damage or death This heater must not be installed in a spray booth where the heater can operate during th...

Page 5: ...es are posted on the damaged by temperatures 90ºF above ambient temperature Clearances to combustibles are posted on the damaged by temperatures 90ºF above ambient temperature Clearances to combustibles are posted on the burner burner burner burner box In areas used for storage of combustible materials w box In areas used for storage of combustible materials w box In areas used for storage of comb...

Page 6: ...on1 1 1 1 Fresh Air Fresh Air Fresh Air Fresh Air Connection Connection Connection Connection1 1 1 1 Electrical Electrical Electrical Electrical Supply Supply Supply Supply Current Current Current Current Rating Rating Rating Rating Natural or Propane MPT Male 4 4 Round 4 Round 120 Volt 60Hz 1 Phase 1 74 Amp 1 See Section 16 0 for vent sizes when multiple heaters are connected into a common vent M...

Page 7: ...y Qty Qty Qty Qty Qty 42912080 10 Ft Tube with 24 Hole Flange Aluminized 1 1 1 42912169 10 Ft Tube with 6 Hole Flange Alumi Therm 1 1 41932101 10 Ft Tube less Flanges Hot Rolled 1 2 3 4 43319100 Reflector 9 11 1 2 3 4 5 30462980 Tube Coupling 1 2 3 4 43318000 Tube Hanger Support Bracket 13 1 2 3 4 5 43980010 Wire Hanger 1 2 3 4 5 Body Fastener Kit included in body packages Body Fastener Kit includ...

Page 8: ...zed Aluminized Aluminized 40 Ft Pkg 40 Ft Pkg 40 Ft Pkg 40 Ft Pkg 44137090 44137090 44137090 44137090 20 Ft Pkg 20 Ft Pkg 20 Ft Pkg 20 Ft Pkg 44135030 44135030 44135030 44135030 40 Ft 40 Ft 40 Ft 40 Ft Pkg Pkg Pkg Pkg 44137090 44137090 44137090 44137090 30 Ft Pkg 30 Ft Pkg 30 Ft Pkg 30 Ft Pkg 44136050 44136050 44136050 44136050 Part Part Part Part Each Body Package Includes Each Body Package Inclu...

Page 9: ... body packages 42907210 42907210 42907210 42907210 42907190 42907190 42907190 42907190 429072 429072 429072 4290722 2 2 20 0 0 0 42907200 42907200 42907200 42907200 42873000 U Bolt 4 2 5 3 02127110 Hex Nut 5 16 18 8 5 10 6 02189020 HWHSM Screw 10 16 x TEKS 14 8 18 10 U U U U Bend Package Bend Package Bend Package Bend Package 43208020 43208020 43208020 43208020 43208020 43208020 43208020 43208020 ...

Page 10: ...ty Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty Qty 42912169 10 Ft Tube with 6 Hole Flange Alumi Therm 1 1 41932100 10 Ft Tube less Flanges Aluminized 3 2 2 3 41932050 5 Ft Tube less Flanges Aluminized 2 43319100 Reflector 9 11 4 2 3 3 43319050 Reflector 4 11 2 30462980 Tube Coupling 3 2 4 3 43318000 Tube Hanger Support Bracket 13 4 2 5 3 43980010 Wire Hanger 4 2 5 3 Body Fastener Kit included ...

Page 11: ...art 43488000 Bend Reflector Package Part 43488000 Bend Reflector Package Part 43488000 Bend Reflector Package Part 43488000 Option for SPU Series Only Contains U Bend Reflector 43490000 QTY 1 U Bend End Reflector 43490050 QTY 1 Speed Clips 02266010 QTY 11 10 16 x Self Drilling Screws 02189020 QTY 4 Installation Form 43489000 QTY 1 30 3 4 78cm Length 24 61cm F F F F 31 Hanger Tube Support Part 4331...

Page 12: ... 30 Ft 60 Ft SPU 125 15 Ft 30 Ft SPS 150 40 Ft 60 Ft SPU 150 20 Ft 30 Ft SPS 175 50 Ft 70 Ft SPU 175 25 Ft 35 Ft SPS 200 50 Ft 70 Ft SPU 200 25 Ft 35 Ft NOTES NOTES NOTES NOTES 1 In all configurations the control unit must be connected directly to either a the 24 hole flange of the 10 ft aluminized steel starting body section for 10 ft 20 ft and 30 ft systems or b the 6 hole flange of the 10 ft al...

Page 13: ...ction as shown POISONOUS GAS AND SOOT HAZARD 60 FT SYSTEM 50 FT SYSTEM 20 FT SYSTEM 30 FT SYSTEM 40 FT SYSTEM LEGEND Burner Box 10ft Aluminized Tube 24 Hole Flange or 10ft Alumi Therm Tube 6 Hole Flange Coupling 10ft Aluminized or HRS Tube model dependent 2ft Aluminized Steel Turbulator sections 70 FT SYSTEM 10 FT SYSTEM 2ft Stainless Steel Turbulator sections Stainless Steel Turbulator closest to...

Page 14: ...ube Support Hanger Bracket 108 274cm 12 30cm 12 30cm 4 Tube Coupling typical Bottom View 108 274cm 600 1524cm 108 274cm 108 274cm 108 274cm 108 274cm 12 30cm 12 30cm 12 30cm 12 30cm 108 274cm Models SPS 40 75 14 36cm 108 274cm 240 610cm 12 30cm 108 274cm 480 1219cm 108 274cm 12 30cm 108 274cm 108 274cm 12 30cm Models SPS 50 125 360 914cm 108 274cm 12 30cm 12 30cm 108 274cm 108 274cm Flue Terminal ...

Page 15: ...122cm 5 FT Tube Assembly 14 36cm 120 305cm 108 274cm Burner Box Flue Terminal 10 FT Tube Assembly typical 15 38cm 108 274cm 48 122cm 31 Tube Support Hanger Brackets typical at control end Shipped with U Bend Package Wire Hangers typical U Bend 13 Tube Support Hanger Brackets typical 4 Tube Coupling typical 13 Tube Support Hanger Brackets typical 6 16cm Flue Terminal 18 46cm 31 79cm End View Burner...

Page 16: ... hanging points to be used for suspension for a typical 40ft long system There must be two hanging points on the first tube and one on each of the other tubes Maximum 6 distance from control box to the tube support hanger bracket 8 9 8 10 8 10 Not More Than 10 10 Self Drill Screws Typical all tube supports tube couplings and flue terminal Typical Overlap Turbulator See specifications section 5 for...

Page 17: ...ole for Alumi Therm Steel Tubes Gasket Burner Box Typical Overlap U Bend Tube Coupling Typical each tube joint Reflector 31 Tube Support Brk with U Bolt Clamp 5 16 Hex Nuts 8 10 6 hanging points to be used for suspension for a typical 40ft long system There must be two hanging points on the first tube and one on each of the other tubes Maximum 6 distance from burner box to the tube support hanger ...

Page 18: ...d c 5 Heaters subject to vibration must be provided with vibration isolating hangers 6 Heaters must not be supported by gas or electric supply lines and must be suspended from a permanent structure with adequate load capacity SunStar recommends that the body sections be suspended using chains with turnbuckles This will allow slight adjustments after assembly and heater expansion contraction during...

Page 19: ...t alumi therm steel starting body section for 40 ft 50 ft 60 ft and 70 ft systems 4 Assemble a tube support hanger bracket 4 from the end of the heat exchanger tube having the mounting flange Align the tube such that the welded seam is facing down toward the ground F F F Failure to assemble the tube with the seam facing down will VOID the ailure to assemble the tube with the seam facing down will ...

Page 20: ...properly to ensure the integrity of the tube connections Two 10 self connections Two 10 self connections Two 10 self connections Two 10 self drilling screws drilling screws drilling screws drilling screws MUST MUST MUST MUST be installed be installed be installed be installed at every coupling as shown in the instru at every coupling as shown in the instru at every coupling as shown in the instru ...

Page 21: ...NEVER reuse a coupling reuse a coupling reuse a coupling reuse a coupling Always install a new coupling only Always install a new coupling only Always install a new coupling only Always install a new coupling only and and and and torque as per instructions above and the diagrams above torque as per instructions above and the diagrams above torque as per instructions above and the diagrams above to...

Page 22: ...natural expansion and contraction of the heater when in operation Note The heaters can expand and contract up to 1 Note The heaters can expand and contract up to 1 Note The heaters can expand and contract up to 1 Note The heaters can expand and contract up to 1 3 4 3 4 3 4 3 4 3 Secure the reflectors as shown in Detail A using 10 x 1 2 self drilling sheet metal screws at each tube support hanger b...

Page 23: ...ctions and the elbow together and secure with tube couplings as described in Section 10 1 90 Deg Elbow Tube Coupling 13 330mm 13 330mm Self Drilling Screws QTY 2 per coupling 11 1 ADDING OPTIONAL CORNER REFLECTOR SPS ONLY 1 Place the corner reflector over the reflectors of both body sections 2 Secure by sliding speed clips on the reflector edges One speed clip is required for each side of reflecto...

Page 24: ...or Make sure that the speed clips fit tightly over both the U U U U Bend Reflector Bend Reflector Bend Reflector Bend Reflector and the reflector on each body section Use two self drilling screws to permanently secure both sides to the reflectors 3 Place the End Reflector End Reflector End Reflector End Reflector flush with the U U U U Bend Reflector Bend Reflector Bend Reflector Bend Reflector as...

Page 25: ...rner casting to the gas manifold 3 Disconnect spark lead and sensing wire 4 Pull burner forward from the gas manifold and then out through the side of the box as shown 5 Screen Tab 5 Slide screen over burner until the tab stops against the rear of the burner cup 6 Check that the spark gas is 1 8 between the electrode and the burner casting as shown 7 Check that the flame sensor is aligned as shown...

Page 26: ...elow Failure to install the Failure to install the Failure to install the Failure to install the control box in an UPRIGHT position will VOID the manufacturer s warranty control box in an UPRIGHT position will VOID the manufacturer s warranty control box in an UPRIGHT position will VOID the manufacturer s warranty control box in an UPRIGHT position will VOID the manufacturer s warranty Angle Mount...

Page 27: ...d spring retainer clamp ing retainer clamp ing retainer clamp ing retainer clamp not included not included not included not included must also be installed Instructions Instructions Instructions Instructions 1 Make sure that the gap between the burner box and end of reflector is 3 and the reflector is securely attached to the reflector support bracket Make adjustments if necessary 3 Gap between bu...

Page 28: ...ary diagram below to increase or decrease the tension as necessary diagram below to increase or decrease the tension as necessary Spring Retainer Clamp 3 Mark the other end of the sleeve with tape or other marker Use the top of the retainer as a reference 4 Loosen screws 2 Tape one end of the sleeve to the burner box or use a marker 5 Pull one end of the sleeve and wire inside until the marker is ...

Page 29: ...ned as shown using using using using the bottom hole pattern the bottom hole pattern the bottom hole pattern the bottom hole pattern of the clamp Follow procedures described earlier for all other adjustments Angle Mounted Body Section Re position wire clamp using bottom hole pattern End View Step 5 Failure to re position the wire clamp at the bottom hole pattern will shorten the life expectancy of...

Page 30: ...d flexible connector supplied with this heater is required for connections between the rigid piping and the heater A union should be installed before the burner box inlet An approved shut off valve should be installed within 6 feet of the union 8 The gas pipe flexible hose and connections must be self supporting The gas pipe work must not bear any of the weight of the heater or any other suspended...

Page 31: ...y The gas connector is 36 long for Gas Appliances ANSI Z21 24 CSA 6 10 is supplied for installation in US only The gas connector is 36 long for Gas Appliances ANSI Z21 24 CSA 6 10 is supplied for installation in US only The gas connector is 36 long and and and and 1 2 nominal ID and must be installed as shown above in 1 2 nominal ID and must be installed as shown above in 1 2 nominal ID and must b...

Page 32: ...e at the Outlet Pressure T Outlet Pressure T Outlet Pressure T Outlet Pressure Tap ap ap ap shown below and connect a 1 8 nipple to the tapped hole Connect the test gauge to the nipple Turn on the gas supply 2 With the main burner operating check the burner manifold pressure using a water column manometer Gauges that measure pressure in pounds per square inch are not accurate enough to measure or ...

Page 33: ...trically 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 The wiring providing power to the heater shall be connected to a permanently live electrical circuit one that is not controlled by a light switch 4 The power supply to the unit should be protected with a fused disconnect switch...

Page 34: ...ne voltage GROUND MONITORING LIGHTS Lampes témoins 42874020 Rev F 1 2011 Red Light Amber Light L1 Black L2 Black ribbed Black White Black ribbed Black Green Violet Orange Red Green Violet Black White Red Blue White Fuse 2A Fusible Optional Low Voltage 24V Thermostat Remove jumper wire Red Red jumper Terminal Block TISS Tube Integrity Safety Switch Red Terminal Block Plaque à bornes Red Green Termi...

Page 35: ...THERMOSTAT CONNECTIONS LINE VOLTAGE 120V THERMOSTAT CONNECTIONS LINE VOLTAGE 120V THERMOSTAT CONNECTIONS LINE VOLTAGE 120V THERMOSTAT CONNECTIONS MULTIPLE HEATERS MULTIPLE HEATERS MULTIPLE HEATERS MULTIPLE HEATERS Burner Control Box Ground N Neutral L1 Hot 120V Line voltage thermostat Continue To Additional Heaters Power Supply Cord 120V Receptacle TH C Receptacle TH C Jumper factory installed for...

Page 36: ...G BASIC FLUE VENTING BASIC FLUE VENTING 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 Model Model Model Heat Heat Heat Heat exchanger exchanger exchanger exchanger length ft length ft length ft length ft Max...

Page 37: ...tible material shall be 6 inches This may be reduced when the combustible material is protected as specified in the National Fuel Gas Code or the authority having jurisdiction 8 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 pip...

Page 38: ...TING CONNECTIONS INTO A COMMON VENT OR MANIFOLD MULTIPLE HEATER VENTING CONNECTIONS INTO A COMMON VENT OR MANIFOLD Requirements for venting of multiple heaters are the same as described for SINGLE HEATER VENTING SINGLE HEATER VENTING SINGLE HEATER VENTING SINGLE HEATER VENTING except as follows 1 The common vent size and total vent height is normally determined by the number of heaters per common ...

Page 39: ...nt terminal 6 15cm minimum Y Connector See Vent Sizing Table for diameter See Vent Sizing Table for diameter 1 2 12mm fall per 20 ft 6m toward vent terminal Flue Collar Adaptor Flue Collar Adaptor VENT SIZING TABLE VENT SIZING TABLE VENT SIZING TABLE VENT SIZING TABLE Multiple Heate Multiple Heate Multiple Heate Multiple Heater Venting r Venting r Venting r Venting Number of Heaters Number of Heat...

Page 40: ...d the air inlet screen must be maintained at all times In larger open areas of buildings infiltration normally is adequate to provide air for combustion 17 1 DIRECT OUTSIDE AIR FOR COMBUSTION Outside combustion air should be supplied directly to the heater when the building is subject to negative pressure or when contaminants or high humidity are present in the building air These contaminants incl...

Page 41: ...ng Table Vent Sizing Table and use the diameter indicated based on the number of heaters per duct Flue vent termination must be 1 ft 30 cm higher than combustion air inlet cap Combustion Air Intake SIDE VIEW straight configuration Combustion Air Cap Leslie VersaCap Type B 4 Diameter Single Wall Pipe Flashing 1 2 12mm fall per 20ft 6m toward vent terminal Horizontal Through Sidewall 6 15cm Minimum ...

Page 42: ...l be de energized immediately The blower will be turned off following a post purge period of approximately 30 seconds 5 If the heater does not light manually reset the thermostat or shut off power completely for 5 minutes before attempting to relight 6 To permanently shut down the heater rotate the gas valve knob clockwise to the OFF position and turn off the gas and electrical supply NOTE T NOTE ...

Page 43: ...ord 120V 9 Burner Sight Glass 10 Indicator Light Amber Gas Valve 11 Indicator Light Red Air Switch 12 Tube Flange Connection 13 Main Burner 14 Flame Screen 200m BTU units only 15 Electrode 16 Flame Sensor 17 Main Burner Orifice 18 Air Restrictor Plate 2 9 4 3 6 7 8 10 11 5 12 25 Note This panel must remain closed for burner operation Note This panel must remain closed for burner operation 30 3 32 ...

Page 44: ...for any signs of damage fatigue or corrosion If there are any signs of damage to the gas connection or leaks found in the gas piping immediately stop using the heater until the gas pipe and connections have been repaired or replaced Check that the gas lines are not bearing the weight of the heater See also Section 13 0 Burner Box Burner Box Burner Box Burner Box In order to extend the longevity of...

Page 45: ...t tube and reflector is there a hole Check TISS wire for a break if it is close to the terminal repair Otherwise replace TISS wire Replace heat exchanger tube reflector and TISS No Yes Is there 24V between both terminals of the thermostat connection and ground No Yes Does the system have a 24V individual thermostat No Yes Is 120V at the terminal block in the blower Check that red wire is connected...

Page 46: ...inspect flame sense electrode Is it clean and the ceramic intact Repair or replace flame sense electrode Yes Check the gas supply pressure with all the heaters on Does it stay above the minimum required No No Yes Check the air intake and vent are there any blockages No Yes Is a cold air stopper installed in the fresh air intake No Yes Is the heater properly grounded No Yes No Yes No Yes No Yes No ...

Page 47: ...essure No Yes Is there are spark to the side of the burner cup No Yes Check electrode spark gap Is it 1 8 Troubleshooting continued from previous page Yes Replace gas valve Remove blockage Restart troubleshooting Adjust manifold pressure Restart troubleshooting No Yes Remove burner and check the orifice Is it clean and free from blockage Adjust spark gap carefully Restart troubleshooting Yes No Re...

Page 48: ...sconnect electrical supply and Remove cover 1 2 Remove screw securing burner casting to the gas manifold 3 Disconnect Spark lead and sensing wire 4 Pull burner forward from the gas manifold and then out through the side of the box as shown 5 Check that the spark gap is 1 8 between the electrode and the burner casting as shown Spark electrode should be clean and free from debris 6 Flame sensor shou...

Page 49: ...t wires from gas valve Step 4 Remove 6 screws from end panel Rotate gas valve and manifold assembly slightly counter clockwise and slide out from housing Step 2 23 3 AIR SWITCH PRESSURE CHECK P1 P2 P1 P2 0 65 WC Connector Tees Air Switch Digital or Inclined Water Manometer scale 0 2 w c Temporary 1 4 ID Silicone plastic tubing for pressure test Common C Normally open NO Red Wire Orange Wire Black ...

Page 50: ...ch passes through the flame from the sensor to ground The minimum flame current necessary to keep the system from lockout is 0 7 microamps a Turn off heater at thermostat b Connect a meter dc microammeter scale in series with the ground lead as shown in the diagram Connect the meter as follows Connect the black negative meter lead to the electronic control FC terminal Connect the red positive mete...

Page 51: ...W S1 Error Mode Error Mode Error Mode Error Mode LED Indication LED Indication LED Indication LED Indication Internal Control Failure Internal Control Failure Internal Control Failure Internal Control Failure Steady On Steady On Steady On Steady On Air Flow Fault Air Flow Fault Air Flow Fault Air Flow Fault 1 Flash 1 Flash 1 Flash 1 Flash Gas valve failure stuck open Gas valve failure stuck open G...

Page 52: ...Components Burner Components Burner Components Burner Components 15 42700500 Burner Investment Casting Machined 1 16 44146080 Manifold Support Bracket 1 16a 44146070 Shim Plate 1 17 44146060 Manifold Support Clamp 1 17a 44146050 Manifold Extension Bracket 1 18 30703000 Blower Assembly 1 19 30632500 Spark Module Fenwal 24V 35 615935 197 1 20 30702010 Flame Sensor PSE GF24 1 21 30702020 Electrode PS...

Page 53: ...25 150 175 200 1 Labels Manual Labels Manual Labels Manual Labels Manual 49 42848010 Label Nameplate SunStar 1 50 42013010 Label Logo SunStar Not Shown 1 51 43344060 Label Clearances to Combustibles 1 52 42874020 Label Wire Connection Diagram 1 54 42875000 Label Warning installation configuration chemical 1 55 43269010 Label 24V Thermostat Connection 1 56 43269020 Label TISS Connection 1 57 432690...

Page 54: ... 63 57 55 54 58 59 49 59 60 51 56 65 66 67 68 2 Stage Thermostat 43269060 rev A HI C LO 3b 21a 4 6 6 GAS TYPE SUPPLY PRESSURE Pression de Sortie Type de Gaz MAXIMUM MINIMUM MANIFOLD PRESSURE Pression a l echappement INPUT Btu Hr Consommation Btu Hr ORIFICE SIZE Dimensions bec Veilleuse MODEL NO No de Modelè Installation in 1 Aircraft hangers must be in accordance with the standard for Aircraft Han...

Page 55: ...luminized Steel ALC Heat Treated Aluminized Steel ALC Heat Treated Aluminized Steel 18 30504500 Flue Adapter Collar HRS Hot Rolled Steel HRS Hot Rolled Steel HRS Hot Rolled Steel HRS Hot Rolled Steel 19 44152240 Turbulator See Section 5 0 for quantities ATC Heat Treated Alumi ATC Heat Treated Alumi ATC Heat Treated Alumi ATC Heat Treated Alumi Therm Steel Therm Steel Therm Steel Therm Steel Requir...

Page 56: ...980 July 2012 Installation Code and Annual Inspections Installation and Service of SunStar equipment must be performed by a qualified contractor and conform with all requirements set forth in the SunStar Installation and Operating Instructions and any National and Local codes pertaining to the installation service and operation of the equipment Annual inspection is recommended prior to the heating...