Heatco HP Series Installation and user guide

OPERATION, SERVICE

AND MAINTENANCE MANUAL

IAS 9-90:1991 Gas-Fired, Desiccant Type Dehumidifiers and Air Conditioners

Gas Unit Heaters, Gas Packaged Heaters, Gas Utility Heaters, And Gas-Fired Duct

Furnaces [ANSI Z83.8:2016 Ed.6]

Gas Unit Heaters, Gas Packaged Heaters, Gas Utility Heaters, And Gas-Fired Duct

Furnaces [CSA 2.6:2016 Ed.6]

Gas-Fired Central Furnaces [ANSI Z21.47:2016 Ed.7]

Gas-Fired Central Furnaces [CSA 2.3:2016 Ed.7]

This manual must be kept with the appliance for future reference.

HP-USM-MAN-E-2016-2

HP SERIES

AIR HEATER MODULE

3035443

The Air Heater modules covered by these instructions become a component of a “Listed” product, subject to

the guidelines of application provided in these instructions and designated by the Certifying Agency in the

Manufacturer’s Listing Procedure

The information provided in this manual applies to the air heater module, installed in the air handling /

dehumidification unit and to its operation, maintenance, and service. Refer to the information provided by

the equipment manufacturer for all other components.

Table of Contents

Inspection…………………………………………………………………..3

Unit Installation / Clearances……..…………………………………..3

Combustion Air Supply…………………………………………………...3

Outdoor Installation…………………………..………………………….4

Indoor Installation…………………………………………………..……5

Vertically Vented – Category I ……………………………….5, 6

Horizontally Vented – Category III………………………….6, 7

Separated Combustion …………………………………………7, 8

Gas Supply Piping and Connections…………………………………. 9

Gas Input………………………………………………………….…………10

Operation and Safety …………………………………………………… 10

Start-up……….…………………………………………………... 10

Failure to Ignite…………………………….………………..…..11

Gas Pressures & Adjustment, Gas Valve…….………...….. 11, 12

Burner Flames…………………………………………….…..…. 12

Shutdown…………………………………………………….….…13

Normal Operation…………………………………………..……13

Operating Controls ……………………………………………….……....13

Annual Maintenance & Inspection …………………………………….14

Module Component ID ……………………………………………………15

Inspection on Arrival

1. Inspect equipment upon arrival in accordance with unit manufacturer’s instructions and follow their

recommendations if any damage has occurred.

2. Prior to installation locate manufacturer’s rating plate and verify that furnace is equipped for the available fuel

supply and power supply at the point of installation.

Unit Installation, Location & Clearances

Verify the following at installation before placing the equipment into service:

1. Electrical supply matches the voltage marked on the furnace module Rating Plate.

2. Gas supply provided matches the Gas Type marked on the furnace module Rating Plate.

3. Furnace module is installed in orientation marked on vestibule. Orientation is specific to airflow direction

through the heating section of the unit.

4. There is an adequate supply of fresh air for the combustion and ventilation process. Combustion air

openings in the cabinet should be sized to provide 1 sq. in of free area per 4000 Btuh of input.

5. A properly designed vent system is connected to the furnace module unit to convey the products of

combustion (flue gases) outside the building. For outdoor applications be sure the flue gases are directed

away from any combustion air inlets.

6. Furnace module is installed in a non-combustible duct or cabinet. Module may be located on positive or

negative side of circulating air blower.

7. An air flow proving switch is installed and wired to prove operation of the system circulating air blower.

8. An auxiliary Manual Reset Limit is installed to shut-off furnace module in the event of low airflow conditions

due to filter blockage, coil blockage and or damper failure.

9. A drain tube is installed for disposal of condensate, if the furnace module is equipped with modulating

controls or is located downstream of cooling system.

10. Equipment access panels and doors are sized and located to provide easy access for servicing, adjustment

and maintenance of the furnace installed. Provide at least 36” (0.9m) clearance for removal of access panel.

Combustion Air Supply

All gas fired furnaces need an ample supply of air for proper and safe combustion of the fuel gas. If sufficient

quantities of combustion air are not available to the heater, poor combustion and inefficient operation will result. The

heating unit cabinet combustion air openings should be sized to provide 1 sq. in of free area per 4000 Btuh of input.

For outdoor installations combustion air inlet and flue gas outlet must be located in the same pressure zone to

minimize effects of wind on burner and heater performance.

Indoors, locate heating unit to ensure an adequate supply of fresh air to replace air used in the combustion and

ventilation process. Install air openings that provide a total free area in accordance with the National Fuel Gas Code

(ANSI Z223.1 or NFPA 54) in the United States or CAN/CGA B-149 Installation Code in Canada.

WARNING!

The presence of chlorine vapors in the combustion air supplied to gas-

fired heaters presents a substantial corrosion hazard.

WARNING!

This furnace is not listed or suitable for drying or process applications. Use in

such applications voids any warranty and manufacturer disclaims any

responsibility for the furnace and /or application.

Outdoor Installation

The venting system is designed for direct discharge of flue gases to the outdoors. The vent discharge opening should

be located to provide an unobstructed discharge to the outside. Vent duct should pitch down toward outlet, to ensure

that any condensate that occurs in vent duct drains away from combustion blower fan housing. The duct opening

should be protected by a ½ in. x ½ in. (12mm x 12mm) mesh screen. An optional rain hood may be used over the

discharge opening to prevent wind driven rain from entering the vent duct but should not intersect the flue gas

discharge path. See Figure 1 below.

Figure 1 – Outdoor Horizontal Venting

Outdoor units must be individually vented, unless provided with a special vent system by the manufacturer.

Where sufficient clearance for proper horizontal venting cannot be provided, or in jurisdictions requiring a 4-foot

(1.23 m) separation between flue gas discharge and combustion air inlet, flue gases need to be vented vertically.

Refer to Figure 2 for preferred venting arrangements.

Vent pipe must terminate at least 12 inches (305 mm). above the cabinet. The vent must be located on the same

side of the appliance as the combustion air inlet opening. Condensation in the vent pipe is likely during heater

operation. A capped “T” fitting is used to collect condensate from the vent pipe. Provide a drain fitting at the base of

“T” to remove condensate. Disposal of condensate must be in accordance with local codes and ordinances.

Figure 2 – Outdoor Vertical Venting

Do not locate unit near building ventilators or exhausts, or areas where corrosive chemical vapors can

be drawn into combustion air supply.

Do not install units in locations where flue products can be drawn in the adjacent building openings

such as windows, fresh air intakes, etc.

Indoor Installations

Location

Locate heating unit to ensure an adequate supply of fresh air to replace air used in the combustion and ventilation

process. The heating unit must be installed in a location with adequate clearances to provide for adequate

combustion air space, service and inspection, and proper clearances from combustible construction. The heating unit

shall be located in such a manner that it does not interfere with the circulation of air in the heated space.

Venting Indoor Installations

Furnace modules must be connected to a venting system to convey flue gases outside of the heated space.

Proper venting of the heating units is the responsibility of the installer. Venting materials are provided by others.

Vertically Vented Duct Furnaces – Category I (See Figure 3)

Non-condensing appliances operating at negative pressure are classified Category I. Category I Vent systems must be sized

and installed in accordance with the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) Chapter 13 in the United

States or CAN/CGA-B149 Natural and propane gas installation code, Section 8 and Annex C, in Canada. UL Listed

Type B Vent or single wall metal pipe may be used. If used, single wall vent pipe shall have seams and joints sealed with

pressure sensitive aluminum tape or silicone rubber sealant, rated for 480 oF (249 oC) or higher. Joints should be secured with at

least two corrosion resistant fasteners. When custom designed systems provided by a vent system manufacturer are field

installed, proper heating unit operation must be verified, including flue gas analysis of each heater.

1. Maximize the height of the vertical run of vent pipe. A minimum of five (5) feet (1.5m) of vertical pipe is required.

The top of the vent pipe must extend at least 18 in. ( 457 mm) above the highest point on the roof. (Use Listed

Type B vent for external runs).

2. An approved weatherproof vent cap must be installed to the vent termination.

3. Horizontal runs should be pitched upward ¼” per foot (21mm/m) and should be supported at 3 foot (1m)

maximum intervals. It is best to keep horizontal runs less than 75% of vertical height to avoid possible need to

upsize vent pipe.

4. Design vent pipe runs to minimize the use of elbows. Each 90o elbow is equivalent to 5 feet (1.5m) to 7 feet

(2.13m) of straight vent pipe run depending on pipe diameter.

5. Vent pipe should not be run through unheated spaces. If such runs cannot be avoided, insulate vent pipe to

prevent condensation inside vent pipe. Insulation should be a minimum of ½” (12.7mm) thick, foil faced material

suitable for temperatures up to 500 oF (260 oC).

6. Dampers must not be used in vent piping runs. Spillage of flue gases into the occupied space could result.

7. Vent connectors serving Category 1 heaters must not be connected into any portion of a mechanical draft system

operating under positive pressure.

WARNING!

Gas-fired furnaces are not designed for use in hazardous atmospheres

containing flammable vapors or combustible dust, in atmospheres containing

chlorinated or halogenated hydrocarbons, or in applications with airborne

substances containing silicone.

Table 1 – Vent Connector Diameter

Gas Input (Btuh) Gas Input (W) Diameter of Flue Vent

50,000 – 149,999 21,980 – 43,958 5” (126 mm)

150,000 – 400,000 43,960 – 117,228 6” (152 mm)

401,000 – 600,000 117,229 – 175,842 7” (178mm)

Figure 3 – Indoor Vertical Venting

Condensate

Drain

Roof

18 in. Min.

(457 mm)

Thimble

“H”

Vertical Height

Listed Vent

Terminal

Use Insulated

Vent Outdoors

“L”

Lateral Run

1/4in. (6mm) pitch per

1ft. (305mm)

horizontal run

See Table 1 for minimum

vent diameter for input rating

See Tables in

ANSI Z223.1 or CSA B149.1

for “H” and “L” Dimensions

Horizontally Vented Duct Furnaces -Category III System (See Figure 4)

Pressures in Category III venting systems are positive and therefore care must be taken to avoid flue products from

entering the heated space. Use only Category III vent materials listed to UL1738 / ULC S636 for vent pipe and

fittings.

All field installed vent pipe and fittings must be from the same manufacturer. DO NOT intermix vent system

parts from different vent manufacturers. Follow instruction provided with approved venting materials used.

All vent pipe joints must be sealed to prevent leakage into the heated space. Follow instruction provided with

approved venting materials used. See Table 1 above for proper sizing of vent pipe diameter.

The total equivalent length of vent pipe must not exceed 50 ft. (15.25m). Equivalent length of 5 or 6 in. 90o elbows

is 5 ft. (1.5 m), and for a 7in. 90o elbow is 7 feet (2.13 m). 45o Elbows are half of the equivalent length of 90o.

The vent system must also be installed to prevent collection of condensate. Pitch horizontal pipe runs downward ¼

in. per foot (21mm per meter) toward the outlet to permit condensate drainage. Insulate vent pipe exposed to cold

air or routed through unheated areas. Insulate vent pipe runs longer than 10 ft. (3m). Insulation should be a minimum

of ½ in. (12mm) thick foil faced material suitable for temperatures up to 500 oF. Maintain 6in. (152mm) clearance

between vent pipe and combustible materials.

A Tee Fitting termination or Vent Cap listed for horizontal venting must be provided. Termination inlet diameter must

be same as the required vent pipe diameter. The vent terminal must be at least 12 in. (305mm) from the exterior wall

that it passes through to prevent degradation of building material by flue gases. The vent terminal must be located at

least 18 inches (0.45m), above grade, or in snow areas, above snow line to prevent blockage. Additionally, the vent

terminal must be installed with a minimum horizontal clearance of 4 ft. (1.2m) from electric meters, gas meters,

regulators or relief equipment.

Figure 4 – Indoor Horizontal Venting

EACH APPLIANCE MUST HAVE ITS OWN INDIVIDUAL VENT PIPE AND TERMINAL.

Do not connect vent system from horizontally vented units to other vent systems or a chimney.

Through the wall vents shall not terminate over public walkways, or over an area where condensate or vapor could

create a nuisance or hazard. Provide Vent termination clearances to building or structure features as follows:

Structure Minimum Clearance

Door, Window or gravity inlet 4 ft. (1.2 m) below

4 ft. (1.2 m) horizontally

1 ft. (305 mm) above

Forced air inlet within 10 ft. (3m) 3 ft. (.91 m) above

Adjoining building or parapet 6 ft. (1.8 m)

Adjacent public walkways 7 ft. (2.1 m) above grade

Two-Pipe Separated Combustion Systems

The furnace must be mounted with the burner section in a reasonably airtight vestibule compartment, as these

systems provide combustion air from outside the heated space and vent the products of combustion outdoors.

Additionally the heating unit must include the following:

1.) For vent pipe and fittings conveying flue gases, use only Category III vent materials listed to UL1738 /

ULC S636 from same vent manufacturer. DO NOT intermix vent system parts from different vent

manufacturers. Follow instruction provided with approved venting materials used.

2.) For combustion air piping, use of 24-gauge galvanized steel single wall pipe is acceptable. Tape joints with

aluminum foil tape and secure with corrosion resistant screws.

3.) Inlet air pipe must be same size as exhaust vent pipe based on input ratings.

4.) Exhaust and vent piping must not exceed a combined 50 equivalent feet in length. Minimize use of elbows.

Each 90o elbow is equivalent to 5 feet (1.5m) to 7 feet (2.13m) of straight vent pipe run depending on pipe diameter.

5.) See Figure 5 for recommended vent terminations and air inlet fittings for venting configuration. Proper

installation of air inlet and flue gas exhaust piping are essential to proper operation of the heat module.

NOTE: The inlet and outlet terminals must be located in the same pressure zone to provide for safe

appliance operation.

Separated combustion systems may not be common vented. Each heater must have its own

individual air supply and flue gas exhaust vent.

If vent system application cannot meet the criteria provided or in diagrams below, contact a manufacturer of venting

systems and materials for assistance with system design.

Figure 5 – Separated Combustion Venting

Horizontal Venting

Note: Be sure that the vent cap used for horizontal venting applications is approved for horizontal application.

Certain manufacturer’s vent terminals are approved for vertical installation only.

Vertical Venting

Gas Supply, Piping and Connections

1. Installation of piping must conform with local building codes and ordinances, or in the absence of local codes with

ANSI Z223.1 the National Fuel Gas Code. In Canada, installation must be in accordance with CAN/CGA –B149.1

for Natural gas and B149.2 for propane units.

2. Properly support gas valve with back-up wrench, during supply pipe installation.

3. Gas piping must be sized for the total Btu input of all units (heaters) serviced by a single supply.

4. Be sure that gas regulators servicing more than one heater have the proper pipe and internal orifice size for the

total input of all heaters serviced by the regulator.

5. Minimum inlet gas pressure required for Natural gas operation is 5.0 “w.c. and for Propane (LP) gas is 11.0”

w.c. Maximum inlet pressure for either gas is 13.5” w.c., with the furnace operating.

6. A 1/8” NPT tap is provided on the inlet side of the gas valve to the heater (See Figure 8). A fitting suitable for

connection to a pressure gauge capable of measuring gas pressure should be connected to each heater

serviced by a single regulator so that gas pressure at each heater can be measured with all heaters in operation.

(See Figure 6)

Figure 6

7. A drip leg (sediment trap) and a manual shut off valve must be provided immediately upstream of the gas control

on the heating unit. To facilitate servicing of unit, installation of a union is recommended. (See Figure 7)

Figure 7

The individual duct furnace inlet gas supply pipe connection size is ¾” NPT for gas inputs up to 400,000

Btuh and 1” NPT for gas inputs between 401,000 and 600,000 Btuh for all control systems.

Unit 1 Unit 2 Unit 3

Max. 13.5” w.c.

Min. 5.0” w.c. Natural Gas

Min. 11.0” w.c. Propane Gas

Pressure

Regulator

Gas

Supply

WARNING !

1. All field gas piping must be pressure /

leak tested prior to operation. NEVER

use and open flame to check for leaks.

Use a soap solution or other leak

detecting solution for testing.

2. Gas pressure to appliance controls

must never exceed 13.5” w.c. (1/2 PSI)

WARNING !

1. When pressure testing at ½ PSI or

less, close the manual shut-off valve

on the appliance before testing.

2. When pressure testing gas supply

line at ½ PSI or higher, close manual

gas valve and disconnect heater from

supply line to be tested. Cap or plug

the supply line.

Gas Input Rate

The correct heat capacity of the heater module is controlled by the burner orifices and the gas manifold pressure.

The manifold pressure is factory set, but should be checked at the time of start-up as described below.

Operating & Safety Instructions

1. This heater module does not have a pilot. It is equipped with a direct spark ignition device that

automatically lights the gas burner. DO NOT try to light burners by hand.

2. BEFORE OPERATING, leak test all gas piping up to heater gas valve. Smell around the unit area for

gas. DO NOT attempt to place heater in operation until source of gas leak is identified and corrected.

3. Use only hand force to push and turn the gas control knob to the “ON” position. NEVER use tools. If

knob does not operate by hand, replace gas valve prior to staring the unit. Forcing or attempting to

repair the gas valve may result in fire or explosion.

4. Do not attempt to operate unit, if there is indication that any part or control has been under water. Any

control or component that has been under water must be replaced prior to trying to start the unit.

Start-up

1. Turn thermostat or temperature controller to its lowest setting

2. Turn off gas supply at the manual shut-off valve

3. Turn off power to the unit at the disconnect switch.

4. Remove access panel or open door to unit vestibule housing the gas heater.

5. Move gas control knob to “Off” position.

6. Install a tapped fitting for attachment to a manometer, or other gauge suitable for 14.0” w.c., in the inlet

pressure tap, and for 10.0” w.c., in the manifold pressure tap.

7. Wait 5 minutes for any gas to clear out. If you smell gas, see Step 2 above and correct leak. If you

don’t smell gas or have corrected any leaks, go to the next step.

8. Turn gas control knob to “On” position

9. Open all manual gas valves

10. Turn power on at disconnect switch

11. Set thermostat or controller to its highest position to initiate call for heat and maintain operation of

unit.*

12. Draft Inducer will run for a 15 to 30 second pre-purge period (See Sequence of Operation provided)

13. At the end of the pre-purge the direct spark will be energized and gas valve will open

14. Burners ignite.

*Note: If modulating controls are provided on heater module, a separate set-up sheet is included with this

manual. Refer to that set-up sheet for complete start-up instructions

FOR YOUR SAFETY

The use and storage of gasoline or other

flammable vapors and liquids in open containers

in the vicinity of this appliance is hazardous.

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