Nortek Reznor UDSA-4 Manual
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Nortek Reznor UDSA-4 Manual

Gas fired balanced flue/fan assisted flue unit heater
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Gas fi red Balanced fl ue / Fan assisted fl ue unit heater
Please read this document carefully before commencing installation, commissioning and/or servicing.
Leave it with the user or attached to the appliance or gas service meter after installation.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. All
work must be carried out by appropriately qualifi ed persons.
The manufacturer does not take any responsibility in the event of non-observance of the regulations concerning
the connection of the apparatus causing an evil operation possibly resulting in damage to the apparatus and/or
environment in which the unit is installed.
UDSA-4
INSTALLATION
COMMISSIONING
SERVICING
These appliances meet the following EC Directives:
DIR 2009/142/EC:GAD
DIR 2004/108/EC:EMC
DIR 2006/95/EC: LVD
DIR 2006/42/EC:MD
WARNING
1607UDSA-4GBEN
1607UDSA-4GBEN, Pag. 1/40

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Summary of Contents for Nortek Reznor UDSA-4

  • Page 1 1607UDSA-4GBEN UDSA-4 Gas fi red Balanced fl ue / Fan assisted fl ue unit heater INSTALLATION COMMISSIONING SERVICING These appliances meet the following EC Directives: DIR 2009/142/EC:GAD DIR 2004/108/EC:EMC DIR 2006/95/EC: LVD DIR 2006/42/EC:MD WARNING Please read this document carefully before commencing installation, commissioning and/or servicing. Leave it with the user or attached to the appliance or gas service meter after installation.

  • Page 2: Table Of Contents

    INDEX Warnings ..........................3 1. General ........................4 2. Installation codes .......................4 3. Warranty ........................4 4. Uncrating and preparation ..................4 5. Dimensions ........................5 6. Technical data ......................6 7. Flueing requirements ....................8 8. Unit heater location ....................12 9. Hanging the unit ......................13 10. Gas piping and pressures ...................15 11.

  • Page 3: Warnings

    Warnings FOR YOUR SAFETY What to do if you smell gas: • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier. •...

  • Page 4: General

    1. General Models UDSA-4 are design certifi ed to the CE EN1020 standard for use in indus- trial and commercial installations only. All models and sizes are available for use with either natural or propane gas. The type of gas, the input rate and the electrical supply requirement is shown on the heater rating plate.

  • Page 5: Dimensions

    5. Dimensions & Clearances (horizontal orientation = standard) Figure 1 Top view Rear view (all mod. except 035-4,043-4,050-4) Rear view (only mod. 035-4,043-4,050-4) Front view Side view Legend: 1. Combustion air inlet 2. Flue connection 3. External gas connection 4. Electrical connections 5.
  • Page 6 Clearances (mm) Units must be installed so that the minimum clearances in the following table are provided for combustion air space, inspection and service and for proper spacing from combustible materials. Table 2 : Clearances (mm) Model Z (*) 008-4 → 030-4 035-4 →...

  • Page 7: Technical Data

    6. Technical data Table 4 : Technical data Model 008-4 011-4 015-4 020-4 025-4 030-4 035-4 Combus on air and fl ue, type B instal. (1) Combus on air and fl ue, type C instal. (1) C12, C32, C42,C52, C62, C82 Flue &...

  • Page 8: Flueing Requirements

    7. Flue Model UDSA-4 heaters may be installed as Type-B and Type-C installations. requirements Flue must be in accordance with BS6230 or BS5440. Local requirements may apply in addition to national requirements. These unit heaters are designed to operate safely and effi...
  • Page 9 Venter outlet attachment requirements: Flue outlet Depending on the size of fl ue pipe as determined in table 5, attach either the fl ue pipe directly to the collar or a taper-type connector. WARNING : Single wall fl ue pipe exposed to cold air or run through unheated areas should be insulated to avoid condensation.
  • Page 10 Figure 3 : Type B appliances : Combustion air and fl ue pipe sockets All mod. exc. 035-4, 043-4, 050-4 & 100-4 Only mod. 035-4, 043-4 & 050-4 Only mod. 100-4 1) Flue pipe outlet collar 2) Combustion air inlet opening 3) Protection grill (option) (02 25094) It is important to ensure that there is an adequate air supply at all times for both Air supply...
  • Page 11 Combustion air inlet Balanced fl ue air heaters are designed to be fi tted with a combustion air inlet duct that obtains outdoor air and a fl ue pipe that exhausts fl ue products to outdoors. pipe & fl ue pipe Both the fl...

  • Page 12: Unit Heater Location

    8. Location Use the minimum clearances in section 5 and the throw data in the technical data heater table of section 6 when determining where to suspend the heater. Recommended minimum height is 2.5mm. Remark: Flue requirements may affect location. WARNING: If touched, the vent pipe and internal heater surfaces Consult section 7...

  • Page 13: Hanging The Unit

    9. Hanging Before suspending the heater, check the supporting structure to verify that it has the heater suffi cient load-carrying capacity to support the weight of the unit. Leave the unit on the pallet. If the bottom of the unit is not supported or protected WARNING: damage can occur.
  • Page 14 Figure 7 : When desired the heaters may be supported by wall brackets. Supporting in this Wall bracket kits (optional) manner allows the heaters to be placed in close proximity to the ceiling or mounted directly to the vertical supporting structures of the building. There are 2 different wall bracket designs for UDSA-4 models as shown in the illustrations below.

  • Page 15: Gas Piping And Pressures

    10. Gas Piping Warning : This appliance is equipped for a maximum gas supply pressure of 50 mbar. pressures WARNING : Pressure testing supply piping Test pressures above 50mbar : Disconnect the heater and manual valve from the WARNING: All com- gas supply line which is to be tested.

  • Page 16: Electrical Supply And Connections

    11. Electrical The electrical installation may only be carried out by an appropriately qualifi ed supply and person current to IEE Regulations. The supply line to the heater should include a main switch. The minimum clearance distance between the contacts must be connections more than 3 mm.
  • Page 17 WIRING DIAGRAM (for illustrative purposes) 1607UDSA-4GBEN, Pag. 17/40...

  • Page 18: Check Installation And Start Up

    12. Check  Check suspension. Unit must be secure.Verify that no other parts are fi tted which installation are not individually supported and secured.  Check clearances from combustibles. Requirements are in section 5. & start-up  Check vent system to be sure that it is installed according to the instructions in section 7, venting requirements.
  • Page 19 Operating 1. Set thermostat to the lowest setting. instructions and 2. Turn off all electric power to the heater. operating sequence Shut the gas cock at the inlet of the unit. Wait fi ve (5) minutes to clear out any gas. Then smell for gas, including near the fl...
  • Page 20 Burner gas pressure The gas pressure is set for the required heat input before the appliance leaves the adjustment factory. Provided that the gas supply to the air heater is in accordance with the supply pressure described on the appliance data plate, the operating pressure will not require adjustment.
  • Page 21 Figure 10 : HONEYWELL gas valve (type 050-4 -> 100-4) Legend Gas inlet Gas outlet Inlet pressure tap Outlet pressure tap 6.3mm AMP terminals and screws for wiring 6.3mm AMP terminals Earth terminal/screw (line voltage models only) Pressure regulator adjustment screw Table 8 : Burner jets and pressures 008-2 011-2...
  • Page 22 Ignition This heater is equipped with a direct spark integrated control relay. The control relay monitors the safety devices and controls the operation of the venter motor system and the gas valve between heat cycles. Normal The time line below illustrates a normal heat cycle. Heat Cycle Operating Sequence...

  • Page 23: Maintenance Schedule

    13. Maintenance The material contained in the MAINTENANCE AND SERVICE Section of this & Service manual is designed to aid a qualifi ed service technician in maintaining and servic- ing this equipment. This heater will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a heater that is operated under nor- mal conditions should be inspected and cleaned at the start of each heating season (inspection and maintenance at least once a year).

  • Page 24: Heat Exchanger Maintenance

    Figure 11b - Control panel assy located on a removable bracket 1) Control relay (ER) 2) Terminal blocks 3) Connector 4) Pressure switch (S3) 5) Electronic burner relay fuse 3.15AF 14. Heat -CORE ® This heater is equipped with a patented heat exchanger.

  • Page 25: Burner Maintenance

    15. Burner -CORE ® This heater has a unique one-piece burner assembly designed to provide Maintenance controlled fl ame stability without lifting or fl ashback. The burner can be removed as a unit for inspection or service : see below for removal instructions. Inspect the burner/control compartment annually to determine if cleaning is neces- sary.
  • Page 26 6. Remove burner Figure 13a a) Locate the burner body front support. Remove the screws that attach it to the secondary air shield. Refer to fi g. 14 for component defi nitions. b) Holding the venturi tube, slide the entire burner slightly to the right to disengage the burner from the supports on the left.

  • Page 27: Burner Orifi Ce

    Inspect and clean the With the burner assembly removed, shine a fl ashlight on the burner ribbons. Look for carbon buildup, scale, dust, lint, and/or anything that might restrict fl ow through burner the spaces between the burner ribbons. Holding the burner assembly so that any foreign material will fall away from the burner, use a stiff bristle brush to loosen Figure 15 and remove any foreign material(s).

  • Page 28: Fan Assembly

    Figure 16a Ignitor showing required spark gap measurement Figure 16b Flame sensor Caution : Due to high Flame sensor - Refer to fi gure 11a and locate the fl ame sensor. Disconnect the wire, remove the screw and the fl ame sensor. Clean with an emery cloth.. voltage on the spark wire and electrode, do not touch Control relay - See fi...

  • Page 29: Venter Motor And Wheel

    3. Remove the fan assembly (fan guard, motor and fan blade). 4. Disassemble and replace parts as needed, then reassemble. Be sure the fan blade is in the proper position on the shaft; refer to the illustration and table in table below for types 008, 011, 015 & 020. Position the assembly on the heater and attach the fan guard.
  • Page 30 Venter wheel position on UDSA models 008-4 - 020-4 shaft (Rotation clockwise from motor shaft end) Figure 18a Venter motor Motor mounting plate bracket Venter wheel Motor cooling fan 8 mm UDSA models 025-4 - 030-4 (Rotation clockwise from motor shaft end) Figure 18b Venter wheel...

  • Page 31: Gas Valve

    UDSA models 035-4 - 100-4 (Rotation counter clockwise from motor shaft end) Figure 18c Venter motor plate Motor mounting bracket Venter wheel Motor cooling 8 mm 20. Operating The main operating quick opening gas valve is powered through the thermostat and safety controls.

  • Page 32: Combustion Air Pressure Switch

    21. Combustion The combustion air pressure switch ensures that proper combustion airfl ow is avail- air pressure able. The switch senses the differential pressure between the negative pressure in the fl ue gas collector box and the pressure in the control section. switch On startup when the heater is cold, the sensing pressure is at the most negative level, and as the heater and fl...

  • Page 33: Flue And Combustion Air System

    23. Flue and Check the complete system at least once a year. Inspection should include all joints, combustion seams, concentric adapters and the fl ue terminal cap. Replace any defective or heavily corroded parts. air piping 24. Trouble- The integrated control relay monitors the operation of the heater. If the heater fails shooting to operate properly, review the fl...
  • Page 34 2/ Air heater does not operate and lock-out indicator light is on 1607UDSA-4GBEN, Pag. 34/40...
  • Page 35 1607UDSA-4GBEN, Pag. 35/40...
  • Page 36 3/ Air fan does not operate 1607UDSA-4GBEN, Pag. 36/40...
  • Page 37 General Troubleshooting PROBLEM PROBABLE CAUSE REMEDY Venter motor 1. No power to unit 1. Turn on power, check supply fuses or circuit breaker. will not start 2. No power to venter motor 2. Check connections at burner relay and/or venter motor terminals. 3.

  • Page 38: Parts List

    25. Parts list Description UDSA-4 Part number Control relay 03 25324 Spark ignitor 05 25162 Flame sensor 03 401US 195292 Limit control LC3 03 24959 03 Limit control LC1 03 24959 04 Pressure switch 030’ 30 60621 100 Pressure switch 035’...
  • Page 39 CERTIFICATE EC DECLARATION OF CONFORMITY OF MACHINERY (Annex II 1 A of EC Machinery Directive 2006/42/EC) Nortek Global HVAC Belgium nv J&M Sabbestraat 130/A000 B-8930 Menen, Belgium Hereby declares that the following gas-fi red unit heaters: UDSA-4 Types 008, 011, 015, 020, 025, 030, 035, 043, 050, 055, 064, 073, 085, 100...
  • Page 40 Registered in England N° 1390934. Registered offi ce: 10 Norwich Street, London, EC4A 18D Nortek Global HVAC is a registered trademark of the Nortek Global HVAC Limited. Because of continuous product innovation. Nortek Global HVAC reserves the right to change product specifi cation without due notice.

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