Rapid UHDS 100, Installation, Operation & Service Manual

Page 1: ...all flammable objects liquids and vapors the minimum required clear ances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage WARNING Installation must be done by a contractor qualified in the installation and service of gas fired heating equipment or your gas supplie...

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Page 3: ...der tous les objets liquides ou vapeurs inflammables à la distance minimale de l unité de chauffage requise avec les matériaux combustibles Certains objets prendront feu ou exploseront s ils sont placés à proximité de l unité de chauffage Le non respect de ces instructions peut entraîner la mort des blessures corporelles ou des dommages matériels AVERTISSEMENT L installation doit être effectuée pa...

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Page 5: ...ting System 12 SECTION 8 Air Supply 18 8 1 Separated Combustion Installation 18 8 2 Building Ventilation 18 8 3 Outside Combustion Air Supply 18 SECTION 9 Gas Piping 19 9 1 Connections 19 SECTION 10 Wiring 21 10 1 Positioning Thermostats 21 10 2 Low Voltage Thermostat with One Heater 21 10 3 UHD X S Series Internal Wiring Diagram 22 10 4 UHD X S Series Ladder Wiring Diagram 23 10 5 Electrical Conn...

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Page 7: ... Horizontal Vent Termination 16 Figure 12 Concentric Vent Box 16 Figure 13 Concentric Vertical and Horizontal Vent Termination Separated Combustion Heater 17 Figure 14 Gas Connection 20 Figure 15 Automatic Burner Control Sequence 26 Figure 16 Gas Valve for Models UHD X S 75 125 26 Figure 17 Manual Reset Limit Switch 29 Figure 18 LED Diagnostic Codes 29 There are references in this manual to variou...

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Page 9: ...d and operated under the general concepts of reasonable use and installed using the best building practices This equipment is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the equipment by a person responsible for their safety Childr...

Page 10: ...1031102 Vent Length Label 91039505 Vent to Outdoors Label 91010427 Warning Label 91010429 Rating Plate Label 91039804 Installation Label 91010431 Instruction Location Label 91010433 Lighting Instruction Label 91010425 Venting Arrangement Label 91010426 Manual Reset Switch Label 91010428 Proposition 65 Label 91070015 For separated combustion units only ...

Page 11: ...102 Vent Length Label 91039505 Vent to Outdoors Label 91010427 Warning Label 91010429 Rating Plate Label 91039804 Installation Label 91010431 Instruction Location Label 91010433 Lighting Instruction Label 91010425 Venting Arrangement Label 91010426 Proposition 65 Label 91070015 For separated combustion units only ...

Page 12: ...backing of the adhesive strips on the rear surface and position the tag on a wall near the heater A copy of the wall tag P N 91039833 is illustrated on the back cover Know your model number and installed configuration Model number and installed configuration are found on the heater serial plate and throughout the Installation Operation and Service Manual 2 2 Corrosive Chemicals Rapid Engineering L...

Page 13: ...tible material using shelf mounting brackets See Page 10 Figure 6 and Page 10 Figure 7 for details May be suspended from above See Page 9 Section 6 2 or from wall brackets of sufficient strength to support the heater as listed in the Technical Data Table on Page 44 Section 16 2 Drop rods must be a minimum of 3 8 diameter mild steel Four suspension points 3 8 nuts are located on top of the heater M...

Page 14: ... F 50 C above room temperature Building materials with a low heat tolerance such as plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installer s and owner s responsibility to assure that adjacent materials are protected from degradation Maintain clearances from heat sensitive equipment and work stations Consult local Fire Marshal Fire Insurance...

Page 15: ... Refer to Natural Gas and Propane Installation Code Standard CSA B149 1 latest revision 5 4 Electrical The heater must be electrically grounded in accordance with the following codes United States Refer to National Electrical Code NFPA 70 latest revision Wiring must conform to the most current National Electrical Code local ordinances and any special diagrams furnished Canada Refer to Canadian Ele...

Page 16: ...r must be installed on the positive pressure side of the circulating air blower Air flow through the heater must be as shown on Page 8 Figure 4 and may not be reversed The air flow must be adjusted such that it is within the acceptable range shown on Page 8 Section 6 1 2 The minimum inlet duct lengths shown on Page 8 Section 6 1 1 should be observed Pressure drop through the heat exchanger at vari...

Page 17: ...ter must be installed in accordance with clearances to combustibles as indicated on the serial plate wall tag and throughout the manual See Page 6 Section 4 6 3 Wall Mounting For typical suspension See Page 10 Figure 7 Wall mounted heaters blowing parallel to the wall can only be installed with the service door away from the wall The wall mounting brackets must be attached to a suitable wall using...

Page 18: ...rt Number Qty Wall Shelf Mounting Bracket Kit 12011002K 1 Wall Suspension Mounting Bracket Kit 12011001K 1 Shelf Mounting Bracket Kit 12011000K 1 Description Part Number Qty Wall Suspension Mounting Bracket Kit 12011001K 1 Wall Mounting Bracket Arm Left 111WALL1L 1 Wall Mounting Bracket Arm Right 111WALL1R 1 Wall Mounting Bracket Vertical 111WALL2 2 Wall Mounting Bracket Diagonal 111WALL3 2 5 16 x...

Page 19: ...r inlet located within 10 3 1 m Vent must terminate at least 4 1 2 m below 4 1 2 m horizontally from or 1 3 m above any door operable window or gravity air inlet into any building NFPA 54 ANSI Z223 1 latest revision National Fuel Gas Code specifies a 4 1 2 m horizontal vent terminal clearance from gas and electric meters regulators and relief equipment 7 2 2 Canadian Requirements The vent shall no...

Page 20: ... be common vented up to four heaters For vent lengths greater than 10 3 0 m condensation will form Insulation is recommended and condensation drains may be desired Venting through the top of the heater cabinet is not recommended if vent lengths are longer than 10 3 m UHD X S 75 only In this case vent from the rear of the heater cabinet then run the vent vertically and use a condensate drain at the...

Page 21: ...stat so that the equipment will operate continuously 5 For any equipment having a draft hood test for draft hood equipment spillage at the draft hood relief opening after five minutes of main burner operation Use the flame of a match or candle 6 After it has been determined that each piece s of equipment connected to the venting system properly vents when tested as outlined above return doors wind...

Page 22: ...W PROFILE DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 14 of 45 Figure 9 Standard Vented Heater Vertical and Horizontal Vent Termination Model Vent Diameter Part Number UHD X 75 125 4 10 cm 90502102 ...

Page 23: ...ct opposition between streams of combustion gases Roof 2 6 m Minimum Type B vent cap 7 18 cm or 8 20 cm may be used These are not available from the manufacurer Roof Flashing Approved Thimble If Applicable Type B Vent Pipe 4 10 cm Single Wall Pipe 4 10 cm Single Wall Pipe D Area must equal sum of open area of individual vents D Single Wall Pipe The last section of vent pipe passing through the roo...

Page 24: ... cm 90502102 4 10 cm Single Wall Vent Pipe By Others Seal joint between single wall and Type B vent with silicone sealant Use 3 sheetmetal screws equally spaced around joint Use 3 sheetmetal screws equally spaced around collar Concentric Vent Box 6 15 cm Single Wall Inlet Air Pipe By Others One piece of 4 10 cm diameter 1 4 6 cm airspace type B vent Selkirk Model RV or equivalent By others Combust...

Page 25: ...ombustion Heater Description Part Number Qty Concentric Vent Kit UHVK1 Concentric Vent Box Top Side Assembly 90504113 1 Concentric Vent Box Bottom Assembly 90504112 1 Screw 6 x 3 8 Self Drilling 91119100 14 4 10 cm Vent Terminal with Baffle Plate 90502102R 1 6 15 cm Combustion Air Terminal 90502103 1 ...

Page 26: ...e combustion air supply is required separated combustion model UHD X S heaters must be used Caution If the building has a slight negative pressure or corrosive contaminants such as halogenated hydrocarbons are present in the air an outside combustion air supply to the heater is required Seal all combustion air pipe joints The outside air terminal must not be more than 1 31 cm above the vent termin...

Page 27: ...yout drawing contact the local gas supplier An isolating valve and union connection should be used and fitted into the supply adjacent to the heater A minimum 1 8 NPT plugged tapping accessible for test connection must be installed immediately upstream of the gas supply connection to the heater For suspended heaters an approved metal flexible connection between the isolating valve and the heater m...

Page 28: ...UHD LOW PROFILE DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 20 of 45 Figure 14 Gas Connection ...

Page 29: ...Code CSA C22 1 Part I latest revision 10 1 Positioning Thermostats A room thermostat should be mounted on a vibration free wall or column at a height of approximately 5 1 5 m from the floor to measure the ambient temperature It should be clear of both cold drafts and the direct path of warm air from the heater Avoid mounting thermostat on outside walls or in areas directly exposed to radiant heat ...

Page 30: ...ternal Wiring Diagram IMPORTANT For field wiring into service junction box or if any of the original wire supplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 221 F 105 C and 600 V For supply connections use No 14 AWG or larger wires ...

Page 31: ...TANT For field wiring into service junction box or if any of the original wire supplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 221 F 105 C and 600 V For supply connections use No 14 AWG or larger wires ...

Page 32: ...LLATION OPERATION AND SERVICE MANUAL 24 of 45 10 5 Electrical Connection to the Heater IMPORTANT Junction box is not provided with heater Conduit can also be attached directly to heater with wire junction made within the heater cabinet ...

Page 33: ...rom the heater inlet pipe up to the main gas valve inlet test nipple 11 1 3 Mechanical Checks 1 Check that the flue and air intake for separated combustion units is installed in accordance with the instructions in this manual and local regulations See Page 11 Section 7 11 2 Begin Start Up 11 2 1 Before Operating the Heater To ensure that all the controls are in safe working order operate the heate...

Page 34: ... ts 10 Seconds Signals Output By Control Required Incoming Signals Flue Blower Pressure Switch P C NO NC 30 Seconds Purge Purge time begins at pressure switch change over 30 Seconds Post If at any stage the flame fails the control will retry for ignition The control has four trials for ignition before a one hour lockout PSI IN C ON OFF Regulator Outlet Pressure Gas Inlet Inlet Pressure TOP VIEW EN...

Page 35: ... 15 minutes and then re check settings Adjust pressure setting if necessary 2 Check gas flow rate at gas meter 3 Turn off heater and electrical supply 4 Remove the manometer and refit all covers to the valve and tighten the screw of the outlet pressure tap 11 3 Pressure Switch The pressure switch is factory pre set for each model and is not adjustable 11 4 Turning Off the Heater Set the thermostat...

Page 36: ... Reset Limit Switch The limit thermostat is located inside the hinged access door of the heater See Page 40 Section 15 3 This control protects against excessive heat build up inside the burner compartment Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp WARNING Failure to follow these instructions can result in death electric shock injury or property ...

Page 37: ...ature limit switch persistently trips there is a fault which must be investigated by a contractor qualified in the installation and service of gas fired heating equipment 12 4 1 Simple Troubleshooting Burner Faults If the burner fails to ignite for any reason it will retry for ignition four trials total After four unsuccessful ignition trials the control will put the heater into lockout for one ho...

Page 38: ...in burner which may have formed in the injectors or venturi of the burner 4 Check condition of ignition electrode and flame probe Clean off any deposits which may have formed check condition of ceramic insulators Replace as necessary See Page 40 Section 15 3 13 3 Heat Exchanger Maintenance The heat exchanger will remain clean unless a problem has developed with combustion Inspect the heat exchange...

Page 39: ...eck control settings and operation The Vicinity of the Heater Do not store or use flammable objects liquids or vapors near the heater Immediately remove these items if they are present See Page 5 Section 3 Vehicles and Other Objects Maintain the clearances to combustibles Do not hang anything from or place anything on the heater Make sure nothing is lodged in between the heat exchanger tubes Immed...

Page 40: ...hould be 1 8 3 2 mm Thermostat There should be no exposed wire or damage to the device or wiring See Page 21 Section 10 Suspension Points Make sure the heater is hanging securely Look for signs of wear on the suspension materials or ceiling See Page 9 Figure 5 Silicone Tubing Ensure tight secure fit on all pressure fittings at pressure switch and vent box Gas Valve Verify that cap covering pressur...

Page 41: ...re to follow these instructions can result in death electric shock injury or property damage Burn Hazard Allow heater to cool before service Tubing may still be hot after operation Explosion Hazard Turn off gas supply to heater before service DANGER Electrical Shock Hazard Disconnect electric before service Heater must be connected to a properly grounded electrical source ...

Page 42: ...UHD LOW PROFILE DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 34 of 45 14 1 General ...

Page 43: ...ing For Automatic Ignition Burner Systems For optimum heater performance use only replacement parts sold and supplied by Rapid Engineering LLC Conduct start up procedure as shown on Page 25 Section 11 If problems persist contact Bananza at www bananza com ...

Page 44: ... www rapidengineering com Replace ignition control Use General Troubleshooting section to trace the fault Heater Operating TROUBLESHOOT ENDS No Repair or replace as required Is inlet burner gas pressure correct Is live and neutral polarity correct Is flame probe circuit correct Is there a current flowing in the flame probe circuit with no flame present Yes No Does lockout occur when there is a fla...

Page 45: ...outlet of the valve rise when valve turns on No Yes Is gas pressure at inlet of the valve correct for gas type Note pressure found No Yes START For optimum heater performance use only replacement parts sold and supplied by Rapid Engineering LLC Conduct start up procedure as shown on Page 25 Section 11 If problems persist contact Rapid Engineering LLC at www rapidengineering com Blower Operating TR...

Page 46: ...that the gas flow direction of the valve is correct Use a minimum amount of gas seal on the thread joint Check that all the joints are leak free Reset gas valve See Page 27 Section 11 2 2 IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVE IS USED WHEN REPLACING THESE CONTROLS Carbon Monoxide Hazard WARNING Use only genuine RAPID replacement parts per this installation operation and service manual Fai...

Page 47: ...Quantity 5 6 7 Natural Gas Orifice Marking 49 46 46 P N 91930049 91930046 91930046 Propane Orifice Marking 1 15 mm 1 25 mm 1 25 mm P N 91930115 91930125 91930125 Remove four screws to remove manifold Ensure gas tight fitting of orifices Ensure correct alignment with burners Ensure all pipe joints are gas tight ...

Page 48: ... steel 409 stainless steel Description Part Number Qty Spark Electrode 90427411 1 Automatic Ignition Flame Probe 90439300 1 Transformer 90436900K 1 Ignition Module 90434008 1 Inshot Burners UHD X S 75 92000002 5 Inshot Burners UHD X S 100 92000002 6 Inshot Burners UHD X S 125 92000002 7 Limit Switch 90412104 1 Manual Reset Limit Switch 75 only 90412106 1 To replace the electrode or flame probe rem...

Page 49: ...late to the vent box To remove the blower from the mounting plate remove screws Refit in reverse order To change the vent and air intake orientation from back to top remove the blower and mounting plate as above Remove intake and exhaust covers from top of the heater Rotate the blower mounting plate and gasket clockwise until the flue adapter lines up with the top hole Secure screws If applicable ...

Page 50: ...se Ensure correct location of ignition cable and all other wiring 15 8 Limit Switches 15 8 1 Removal and Replacement 1 Remove the electrical connections to the switch 2 Unscrew the two screws securing the switch 3 Fit a new switch with two screws 4 Reconnect the electrical connections and test operation MODEL UHD X S 75 UHD X S 100 UHD X S 125 Pressure Switch Kit P N 90439804 90439805 90439810 Col...

Page 51: ...0 6 0 15 2 2 8 7 1 6 8 17 3 2 5 6 4 3 3 8 4 1 9 4 8 20 3 51 6 10 4 26 4 0 6 1 5 0 5 1 4 UHD X S 100 in cm 28 7 73 0 22 7 57 6 22 3 56 6 17 6 44 7 18 6 47 2 2 0 5 0 6 0 15 2 2 7 6 9 8 6 21 8 3 3 8 4 1 9 4 8 20 3 51 6 10 4 26 4 0 6 1 5 0 5 1 4 UHD X S 125 in cm 28 7 73 0 22 7 57 6 22 3 56 6 17 6 44 7 18 6 47 2 2 0 5 0 6 0 15 2 2 7 6 9 8 6 21 8 3 3 8 4 1 9 4 8 20 3 51 6 10 4 26 4 0 6 1 5 0 5 1 4 ...

Page 52: ...ure Rise Maximum Air Volume F C 22 12 22 12 20 11 Heat Exchanger Pressure Drop Maximum Air Volume in wc 0 36 0 55 0 98 Flue Size Air Intake in cm 4 10 All models Duct Size Width in cm 16 3 4 43 21 3 4 55 21 3 4 55 Duct Size Height in cm 15 7 8 40 15 7 8 40 15 7 8 40 Weight lb kg 81 36 7 92 41 7 97 44 Recomended Mounting Height to Heater Base ft m 12 3 66 20 6 10 20 6 10 Model UHD X S 75 UHD X S 10...

Page 53: ...te and or serial number are removed defaced modified or altered in any way The ownership of the RAPID UHD Series is moved or transferred This warranty is nontransferable Rapid Engineering LLC is not permitted to inspect the damaged controller and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your controller contact your installing professional S...

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