SunStar SPS Series Installation And Operation Instruction Manual
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SunStar SPS Series Installation And Operation Instruction Manual

Infrared radiant tube heater
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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.
INFRARED RADIANT TUBE HEATER
Single and Two Stage Push Through System (Positive Pressure)
SPS SERIES:
SPU SERIES:
!INSTALLER: This manual is the property of the owner. Please present this manual to the
owner when you leave the job site.
▲WARNING: Improper installation, adjustment, alteration, service, or maintenance can
cause property damage, injury or death. Read the installation, operation and maintenance
instructions thoroughly before installing or servicing this equipment.
IF YOU SMELL GAS:
! DO NOT try to light any appliance.
! DO NOT touch any electrical switch; DO NOT use any
telephone in your building.
! 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.
!IMPORTANT: SAVE THIS MANUAL FOR FUTURE REFERENCE.
Post Office Box 36271 (28236) • 306 West Tremont Avenue (28203) • Charlotte, North Carolina
Phone (704) 372-3486 • Fax (704) 332-5843 • www.sunstarheaters.com • email: info@sunstarheaters.com
Models:
(40, 50, 75, 100, 125, 150, 175, 200) N5/L5/N7/L7
(40, 50, 75, 100, 125, 150, 175, 200) N5/L5/N7/L7
FOR YOUR SAFETY
Manufactured for:
SUNSTAR HEATING PRODUCTS, INC.
DO NOT store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
Form 43343320
Dec 2017

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  • Page 1 !IMPORTANT: SAVE THIS MANUAL FOR FUTURE REFERENCE. Manufactured for: SUNSTAR HEATING PRODUCTS, INC. Post Office Box 36271 (28236) • 306 West Tremont Avenue (28203) • Charlotte, North Carolina Phone (704) 372-3486 • Fax (704) 332-5843 • www.sunstarheaters.com • email: info@sunstarheaters.com...

  • Page 2: Table Of Contents

    7.0) Typical Layouts – SPS/SPU Series ....................12 7.1) Typical Assembly Layout – (SPS SHOWN)..................13 8.0) Dimensions – SPS Series ........................ 14 8.1) Dimensions – SPU Series ....................... 15 8.2) Heater Assembly / Joining of Tube Sections ................16 9.0)

  • Page 3: Safety

    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.
  • Page 4 Consult your local fire marshal or insurance company. SPS Series Only: Since straight tube heaters are always hotter at the control end than at the flue terminal end, always observe the minimum recommended mounting heights shown on the specification sheets and in Section 5.0) of this manual.

  • Page 5: Minimum Clearances To Combustibles

    NFPA54 requires that the installer must post signs that will “specify the maximum permissible stacking height to maintain the required clearances from the heater to combustibles.” SunStar recommends posting these signs adjacent to the heater thermostat or other suitable location that will provide enhanced visibility.

  • Page 6: Specifications

    16 ft. * MOUNT HEATERS AS HIGH AS POSSIBLE. Minimums are shown as a guideline for human comfort and uniform energy distribution for complete building heating applications. Consult your SunStar representative for the particulars of your installation requirements. Model Identification:...
  • Page 7 BURNER PACKAGE NUMBERS SINGLE STAGE CONTROLS TWO STAGE CONTROLS MODEL NO. PART NO. GAS TYPE MODEL NO. PART NO. GAS TYPE SPS/SPU 40-N5 44150010 NATURAL SPS/SPU 40/25-N7 44150510 NATURAL SPS/SPU 50-N5 44150030 NATURAL SPS/SPU 50/30-N7 44150530 NATURAL SPS/SPU 75-N5 44150050 NATURAL SPS/SPU 75/50-N7 44150550...
  • Page 8 Body Fastener Kit (included in body packages) 42907210 42907190 42907210 42907200 42873000 U-Bolt 02127110 Hex Nut, 5/16-18 02189020 HWHSM Screw, #10-16 x ½” TEKS C. SPS 40-200 Series Body Package Descriptions – ALC Option (Aluminized Calorized) (Package Part Number is indicated on the outside of each corresponding carton.) 10Ft.
  • Page 9 D. SPU 40-200 Body Package Descriptions (Package Part Number is indicated on the outside of each corresponding carton.) 20Ft. 30Ft. 40Ft. 50Ft. Systems System System System System SPU Body Packages – Aluminized/Hot Rolled or 20 Ft. pkg 30 Ft. pkg 40 Ft.
  • Page 10 E. SPU 40-200 Series Body Package Descriptions – ALC Option (Aluminized Calorized) (Package Part Number is indicated on the outside of each corresponding carton.) 20Ft. 30Ft. 40Ft. 50Ft. Systems System System System System SPU Body Packages – Aluminized/Aluminized or 20 Ft. pkg 30 Ft.

  • Page 11: Accessory Packages

    6.1) ACCESSORY PACKAGES A. End Reflector Accessory Package, Part #43341000 (1 pkg. per SPS Series or 2 pkgs. per SPU Series) Contains: End Reflector, #43320000……QTY–2 Speed Clips, #02266010……QTY–8 B. Elbow Accessory Package, Part #43208010 (Option for SPS Series Only) Contains: Elbow, #43175000……QTY–1...
  • Page 12 E. U-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 ½ Self-Drilling Screws, #02189020……QTY–4 Installation Form, #43489000……QTY-1 F. 31” Hanger/Tube Support, Part #43318500 (Option for Angle Mounting of SPU Series) G.

  • Page 13: Typical Layouts - Sps/Spu Series

    7.0) TYPICAL LAYOUTS – SPS/SPU SERIES EMITTER LENGTH BODY LENGTH MODEL MODEL Min. Max. Min. Max. SPS 40 10 Ft. 20 Ft. SPU 40 10 Ft. 10 Ft. SPS 50 20 Ft 40 Ft. SPU 50 10 Ft. 20 Ft. SPS 75 20 Ft.

  • Page 14: Typical Assembly Layout - (Sps Shown)

    7.1) TYPICAL ASSEMBLY LAYOUT – (SPS SHOWN) Form 43343320 Dec 2017 -13-...

  • Page 15: Dimensions - Sps Series

    8.0) DIMENSIONS – SPS SERIES Typical Dimensions Up to 60 Ft. Shown. Form 43343320 -14- Dec 2017...

  • Page 16: Dimensions - Spu Series

    8.1) DIMENSIONS – SPU SERIES Typical Dimensions Up to 50 Ft. Shown. Form 43343320 Dec 2017 -15-...

  • Page 17: Heater Assembly / Joining Of Tube Sections

    8.2) HEATER ASSEMBLY / JOINING OF TUBE SECTIONS Form 43343320 -16- Dec 2017...
  • Page 18 Form 43343320 Dec 2017 -17-...

  • Page 19: Typical Suspension Methods

    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 operation.

  • Page 20: Angle Mounting Of Heaters

    Consult your Sunstar Representative if you have any questions prior to the installation concerning particulars of your application.

  • Page 21: Assembly Of Extension Section

    5. Suspend the chain to attach the wire hanger and the tube support bracket. Insert the tube into the wire hanger and then raise the tube support bracket end up to the suspension chain, use “S” hooks to attach the wire hanger and tube support bracket to the chain.
  • Page 22 See typical assembly overview (Section 8.0)) for typical complete assembly. Assemble additional extension sections as required for all systems. (See Sections 7.0), and 8.0) for typical layout details.) Join the tube sections together and secure with tube couplings as described below: The following coupling tightening instructions MUST be followed properly to ensure the integrity of the tube connections.

  • Page 23: Inserting Turbulators

    4. Slide the next tube into the coupling. 5. Make sure both tube ends are butted together. 6. Finish tightening both bolts to 40-60 ft.lbs. torque to ensure a complete seal. 7. Use the two Self-drilling screws through the pre-punched holes to secure the tubes in the coupling. 8.

  • Page 24: Adding Body Reflectors

    MODEL 2 Ft. Turbulator Sections SPS/U 40 SPS/U 50 SPS/U 75 SPS/U 100 SPS/U 125 SPS/U 150 SPS/U 175 SPS/U 200 10.3) ADDING BODY REFLECTORS 1. Slide the reflectors on the tube support/hanger brackets and through the wire hangers. 2. The tube at the coupling joints must be covered. Slide the reflectors together and provide an overlap of two (2”) inches for the first reflector overlap after the control unit.

  • Page 25: Adding Optional 90º Elbow (Sps Only)

    11.0) ADDING OPTIONAL 90º ELBOW (SPS ONLY) 1. The optional 90º elbow must be located a minimum of 10 ft. after the burner box. 2. Hang the body sections in a 90º ("L") shaped pattern. Allow spacing for the elbow. The distance from one end of the elbow to the centerline of the opposite leg is 13"...

  • Page 26: Adding 180º U-Bend (Spu Only)

    11.2) ADDING 180º U-BEND (SPU ONLY) 1. Hang body sections parallel with each other. The centerline distance from tube at each body section should be 18” as shown. 2. Join tube ends of body sections and the U-Bend together and secure with tube couplings as described in Section Error! Reference source not found..

  • Page 27: Attaching Burner Screen - (200M Btu Models Only)

    12.0) ATTACHING BURNER SCREEN – (200M BTU MODELS ONLY) A burner screen is assembled with the burner. If necessary, the burner screen must be field adjusted as shown below before operation of the heater. 1. Pull burner screen forward from the gas manifold and slide screen over burner until the tab stops against the rear of the burner cup (approximately 4 - 3/16”...
  • Page 28 The burner box weights 38 lbs. Use caution when handling it. Failure to install the burner box in an upright position and lights facing the floor will void the manufacturer’s warranty. Form 43343320 Dec 2017 -27-...

  • Page 29: Connecting The Tiss System

    12.2) CONNECTING THE TISS SYSTEM Description: The TISS (Tube Integrity Safety System) is designed to shut the main burner off in the event that a burnout occurs in the first 10ft. section of firing tube. Note: When replacing the firing tube a new TISS wire assembly PN 44176510 (spring and spring retainer clamp not included) must also be installed.
  • Page 30 3. Hold the spring retainer clamp and pull the TISS wire assembly to end of reflector at overlap joint. Slide spring retainer clamp over end of reflector as shown. Step 3 4. After attachment of the TISS, check to make sure that there is sufficient tension on the wire. Follow the diagram below to increase or decrease the tension as necessary.
  • Page 31 ANGLE MOUNTED HEATERS ONLY 5. If heaters are to be angle mounted, the TISS wire holder clamp must first be re-positioned as shown using the bottom hole pattern of the clamp. Follow procedures described earlier for all other adjustments. Step 5 Failure to re-position the wire clamp at the bottom hole pattern will shorten the life expectancy of the TISS wire assembly.

  • Page 32: Gas Connections And Regulations

    13.0) GAS CONNECTIONS AND REGULATIONS IMPORTANT BEFORE CONNECTING THE GAS TO THE HEATER 1. Connect to the supply tank or manifold in accordance with the latest edition of National Fuel Gas Code (ANSI Z223.1), and local building codes. Authorities having jurisdiction should be consulted before the installation is made.
  • Page 33 US ONLY: Connector MUST be installed in “” configuration. Use only the 36” long connector that was furnished with this heater. US ONLY: A gas connector certified for use on a tubular type infrared heater per the standard for Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 is supplied for installation in US only.

  • Page 34: Instructions For Pressure Test Gauge Connection

    14.0) 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 Gauges that measure pressure in pounds per square inch are not accurate enough to measure or set the manifold pressure.
  • Page 35 Figure 1 TO ADJUST REGULATOR (two stage gas valves): Turn on power and energize main gas valve solenoid. Do not energize the HI solenoid. Remove regulator cover screw from the low outlet pressure regulator (see Figure 2 below) and turn screw ...

  • Page 36: Electrical Connections

    GAS PRESSURE TABLE SUPPLY PRESSURE MANIFOLD PRESSURE GAS TYPE High Low (2-stage only) Minimum* Maximum Natural Gas 3.5” W.C. 1.4” W.C. 5” W.C. 14” W.C. Propane Gas 10.0” W.C. 4.0” W.C. 11” W.C. 14” W.C. * Minimum permissible gas supply pressure for purpose of input adjustment. 7”...

  • Page 37: Single Stage (N5/L5) Internal And Thermostat Connections

    15.1) SINGLE STAGE (N5/L5) INTERNAL AND THERMOSTAT CONNECTIONS SINGLE STAGE CONTROLS - INTERNAL CONNECTION WIRING DIAGRAM SINGLE STAGE CONTROLS - SCHEMATIC WIRING IGNITION MODULE TERMINAL DESIGNATIONS DIAGRAM 24VAC/R 24 VAC Supply to Module TH/W Thermostat Input PS/W Pressure Switch Input System Ground Valve Power Valve Ground...
  • Page 38 SINGLE STAGE CONTROLS - THERMOSTAT WIRING DIAGRAMS SINGLE STAGE CONTROLS A. LINE VOLTAGE (120V) THERMOSTAT CONNECTIONS – SINGLE HEATER B. LINE VOLTAGE (120V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS Form 43343320 Dec 2017 -37-...

  • Page 39: Two Stage (N7/L7) Internal And Thermostat Connections

    C. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – SINGLE HEATERS D. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS (utilizing a fan center relay) 15.2) TWO STAGE (N7/L7) INTERNAL AND THERMOSTAT CONNECTIONS TWO STAGE CONTROLS - INTERNAL CONNECTION WIRING DIAGRAM Form 43343320 -38- Dec 2017...
  • Page 40 TWO STAGE CONTROLS - SCHEMATIC WIRING IGNITION MODULE TERMINAL DESIGNATIONS DIAGRAM 24VAC/R 24 VAC Supply to Module TH/W Thermostat Input PS/W Pressure Switch Input System Ground Valve Power Valve Ground 120/240 VAC Input (Hot) Blower Output TWO STAGE CONTROLS - THERMOSTAT WIRING DIAGRAMS TWO STAGE CONTROLS Form 43343320 Dec 2017...
  • Page 41 A. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – SINGLE HEATERS B. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS Form 43343320 -40- Dec 2017...

  • Page 42: Venting

    C. LOW VOLTAGE (24V) 3 WAY MANUAL SWITCH CONNECTIONS – MULTIPLE HEATERS 16.0) 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.
  • Page 43 Heat Maximum Fresh air Max. combination of Maximum vent length ft. Model exchanger intake length ft (4” fresh air and vent ft. (4” diameter) length ft diameter) (4” diameter) SPS/U 40 SPS/U 40 SPS/U 50 SPS/U 50 SPS/U 50 SPS/U 75 SPS/U 75 SPS/U 75 SPS/U 100...
  • Page 44 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 pipe through an exterior combustible wall, refer to latest edition of the National Fuel Gas Code or the authority having jurisdiction.
  • Page 45 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 except as follows: 1. The common vent size and total vent height is normally determined by the number of heaters per common vent, length of horizontal connector runs, and connector fall.
  • Page 46 Multiple Heater Vertical Venting Arrangement Multiple Heater Horizontal Venting Arrangement VENT SIZING TABLE — Multiple Heater Venting Number of Heaters Horizontal and vertical Vertical Only SPS/SPU 40 4” 4” 4” 4” SPS/SPU 50 4” 4” 4” 5” SPS/SPU 75 4” 4”...

  • Page 47: Air For Combustion

    If the heater is installed less than 2 ft. from the ceiling, a combustion air inlet kit PN 44129510 must be provided to allow for expansion/contraction of straight tube heaters (SPS series). In colder climates, where necessary, insulate the outside combustion air duct.
  • Page 48 In multiple heater applications, the combustion air intake may be ducted individually or common ducted in the same configuration as shown for venting in Section 16.0). For combustion air intake duct sizing, please refer to the Vent Sizing Table and use the diameter indicated, based on the number of heaters per duct. All vent terminations and Combustion Air Intake Terminations must be at least 6”...

  • Page 49: Lighting And Shutdown Instructions

    18.0) LIGHTING AND SHUTDOWN INSTRUCTIONS 1. Turn on the gas and electrical supply. Rotate the gas valve knob counter-clockwise  to the “ON” position. 2. Set the thermostat to call for heat. The blower motor will energize. 3. Ignition should occur after the 15-second pre-purge. 4.

  • Page 50: Sequence Of Operation - Two Stage (N7/L7)

    Note: When the SPS / SPU is operated by a thermostat interrupting the line voltage (120V) to the heater then the post purge function is disabled. If the flame is not sensed during sequence T3 then the burner will automatically begin re-ignition sequence T2. The ignition sequence will be repeated three times with a 60 second inter-purge.

  • Page 51: Control Component Location

    20.0) CONTROL COMPONENT LOCATION Form 43343320 -50- Dec 2017...

  • Page 52: Cleaning And Annual Maintenance

    21.0) 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.

  • Page 53: Troubleshooting Guide - Single Stage (N5/L5)

    22.0) TROUBLESHOOTING GUIDE – SINGLE STAGE (N5/L5) Form 43343320 -52- Dec 2017...
  • Page 54 TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED) Form 43343320 Dec 2017 -53-...
  • Page 55 TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED) Form 43343320 -54- Dec 2017...

  • Page 56: Troubleshooting Guide - Two Stage (N7/L7)

    22.1) TROUBLESHOOTING GUIDE – TWO STAGE (N7/L7) Form 43343320 Dec 2017 -55-...
  • Page 57 TROUBLESHOOTING GUIDE – TWO STAGE (CONTINUED) Form 43343320 -56- Dec 2017...
  • Page 58 TROUBLESHOOTING GUIDE – TWO STAGE (CONTINUED) Form 43343320 Dec 2017 -57-...

  • Page 59: Replacing Parts

    23.0) REPLACING PARTS 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 25.0) for all replacement parts. 23.1) REMOVAL OF MAIN BURNER AND ELECTRODES The main burner can be inspected without removing the burner housing from the heat exchanger tube.

  • Page 60: Removing Gas Valve And Manifold Assembly

    23.2) REMOVING GAS VALVE AND MANIFOLD ASSEMBLY 23.3) AIR SWITCH PRESSURE CHECK Form 43343320 Dec 2017 -59-...

  • Page 61: Ignition System Checks

    1. Open hinged access panel. 2. Add tubing to connect the air switch tubing P1 + and P2 - with the connector tees and the probes P1+ and P2+. 3. Connect plastic tubing of a digital or inclined water manometer with a 0-2” scale onto the connector tees. 4.

  • Page 62: Installation Data

    IGNITION MODULE DIAGNOSTICS Flame Fault If at any time the main valve fails to close completely and maintains a flame, the full time flame sense circuit will detect it and energize the combustion blower. Should the main valve later close completely removing the flame signal, the combustion blower will power off following the post purge period.

  • Page 63: Replacement Parts Guide

    25.0) REPLACEMENT PARTS GUIDE BURNER BOX Item No. Part No. Description Qty. Fasteners 02295040 PHTCS #6-32 x 3/8" 02266010 Speed Clips (for air inlet plate) 02261030 HHTCS #8-32 x 3/8" (green coated) 02242050 PHTCS #8-32 x 3/8" 02242070 PHTCS #8-32 x 1/2” 02123170 RHMS #8-32 x 3/4"...
  • Page 64 Labels/Manual 42848010 Label, Nameplate – Single Stage 42848120 Label, Nameplate – Two Stage 42013010 Label, Logo (SunStar) (Not Shown) 43344060 Label, Clearances to Combustibles 42874020 Label, Wire Connection Diagram – Single Stage 42874030 Label, Wire Connection Diagram – Two Stage...
  • Page 65 Form 43343320 -64- Dec 2017...
  • Page 66 ALL ILLUSTRATIONS ARE INTENDED TO GIVE THE GENERAL IMPRESSION OF UNITS ONLY. OTHER COMBINATIONS OF 5 FT. AND 10 FT. SECTIONS, AND ONES WITH OR WITHOUT THE ELBOW PACKAGE ARE POSSIBLE. PLEASE CONSULT WITH YOUR SUNSTAR SALES REPRESENTATIVE. WE RESERVE THE RIGHT TO ALTER ANY SPECIFICATION WITHOUT NOTICE. Form 43343320...

  • Page 67: Warnings Card

    26.0) WARNINGS CARD Copies of this card may be ordered at no charge under part no. 43344980 for installation near the heater. Form 43343320 -66- Dec 2017...

This manual is also suitable for:

Spu seriesSps 40-n5Spu 40-n5Sps 40/25-n7Spu 40/25-n7Sps 50-n5 ... Show all

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