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Space-Ray PGR 100-L5, Installation And Operation Instructions Manual, Page: 15 / 62

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Space-Ray PGR 100-L5 Installation And Operation Instructions Manual Download Page 15

 

Form 43343120 

-14- 

July 2021 

9.0)

 

 TYPICAL SUSPENSION METHODS 

 

Various means of suspending the heater can be used.  See the following drawings for typical examples. 
1.

 

Use only noncombustible materials for suspending hangers and brackets. 

2.

 

A minimum No. 2 chain with a working load limit of 115 lbs. is required. 

3.

 

Turnbuckles can be used with chains to allow leveling of the burner box.  A

ll “S” hooks and eye bolts must be 

manually crimped closed by the installer. See Figure A 

4.

 

For outdoor installations Space-Ray recommends that the body section be suspended using the adjustable 
suspension brackets (supplied as accessories) shown in Figure B. An optional method to suspend the body 
section using 3/8

” threaded rod and n

uts (not supplied) as shown in Figure C. 

5.

 

For indoor installations the heater may be suspended by chain. See Figure D. 

6.

 

Heaters must not be supported by gas or electric supply lines and must be suspended from a  permanent 
structure with adequate load capacity. 
 

 

      

Summary of Contents for PGR 100-L5

Page 1: ...damage injury or death Read the installation operation and maintenance instructions thoroughly before installing or servicing this equipment IF YOU SMELL GAS FOR YOUR SAFETY 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...

Page 2: ...at Connections 33 14 0 Venting 37 15 0 Air for Combustion 42 15 1 Direct Outside Air for Combustion 42 16 0 Lighting and Shutdown Instructions 44 17 0 Sequence of Operation Single Stage N5 L5 44 18 0 Control Component Location 46 19 0 Cleaning and Annual Maintenance 47 20 0 Troubleshooting Guide Single Stage N5 L5 48 20 1 Troubleshooting Guide Two Stage N7 L7 51 21 0 Replacing Parts 54 21 1 Remova...

Page 3: ... Installation and Operation Instructions Where unvented heaters are used gravity or mechanical means shall be provided to supply and exhaust at least 4 CFM per 1 000 Btu 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 th...

Page 4: ...or indoor installation only Not for use in residential dwellings This heater is for Indoor Installation and Covered Patio Golf Range and Restaurant Installation only and can be used in either Vented or Unvented mode The term Unvented actually means Indirect Vented While the products of combustion are expelled into the building national codes require ventilation in the building to dilute these prod...

Page 5: ... heater at all times NOTE 1 The clearances specified above must be maintained to combustibles and other materials that may be damaged by temperatures 90ºF above ambient temperature Clearances to combustibles are posted on the burner box In areas used for storage of combustible materials where they may be stacked below the heater NFPA54 requires that the installer must post signs that will specify ...

Page 6: ...on Control Option Suffix Gas Type Description N5 Natural Single Stage Gas Valve Single Stage Input L5 Propane Single Stage Gas Valve Single Stage Input N7 Natural Two Stage Gas Valve Modulating Input High Low Fire L7 Propane Two Stage Gas Valve Modulating Input High Low Fire Type Gas Gas Pipe Connection Tube Diameter Flue Connection1 Fresh Air Connection1 Electrical Supply Current Rating Natural o...

Page 7: ...STAGE CONTROLS MODEL NO PART NO GAS TYPE MODEL NO PART NO GAS TYPE PGR 40 N5 44620010 NATURAL PGR 40 25 N7 44620510 NATURAL PGR 50 N5 44620030 NATURAL PGR 50 30 N7 44620530 NATURAL PGR 60 N5 44620050 NATURAL PGR 60 40 N7 44620550 NATURAL PGR 75 N5 44620070 NATURAL PGR 75 50 N7 44620570 NATURAL PGR 80 N5 44620090 NATURAL PGR 80 55 N7 44620590 NATURAL PGR 100 N5 44620110 NATURAL PGR 100 65 N7 446206...

Page 8: ...ger Bracket with rollers 2 6 40517059 Tube Retainer Strap 3 7 42873000 U Bolt 3 8 42894100 Reflector 28 x 119 5 1 9 42895150 Reflector End Burner End 1 10 42896160 Reflector End U Bend End 3 5 lip 1 11 44616100 Support Grille End Reflector 2 12 44616500 Cross Brace Assembly Grill Support 1 13 44617000 Side Rail 61 4 14 44618009 Suspension Bracket Body 2 15 30366090 Decorative Grille 28 x 59 75 2 1...

Page 9: ...rollers 2 6 40517059 Tube Retainer Strap 3 7 42873000 U Bolt 3 8 42894080 Reflector 28 x 100 0 1 8a 42894100 Reflector 28 x 119 5 1 9 42895150 Reflector End Burner End 1 10 42896150 Reflector End U Bend End 1 lip 1 11 44616100 Support Grille End Reflector 2 12 44616500 Cross Brace Assembly Grill Support 2 13 44617000 Side Rail 61 6 14 44618009 Suspension Bracket Body 2 15 30366090 Decorative Grill...

Page 10: ...r Time Delay QTY 2 Illuminated Switch OFF LOW HIGH QTY 2 F Kit 2 Stage Relay Board Part 44195000 Contains Relay Board 30709058 QTY 1 Enclosure 30709059 QTY 1 Cord Connector 30635040 QTY 2 G Hanger Bracket Adjustable Part 44618050 Contains Strut Bracket 44618069 QTY 1 Base Bracket 44618079 QTY 2 Hex Head Screw 3 8 x 1 2 02112010 QTY 4 Hex Nut 3 8 02127130 QTY 4 Spring Lockwasher 3 8 QTY 4 H Vent Ki...

Page 11: ...s a Before hanging heater sections first determine the actual layout of the system See section 8 0 for complete heater dimensions Consideration must also be taken for flue pipe fresh air ducting gas piping clearances to combustibles etc before hanging heater Typical suspension methods are shown in Section 9 0 7 2 TYPICAL ASSEMBLY LAYOUT WITH TURBULATORS ...

Page 12: ...Form 43343120 July 2021 11 8 0 DIMENSIONS PGR SERIES Typical Dimensions decorative grille not shown 20FT Body Section Models PGR 40 50 60 75 80 100 125 30FT Body Section Models PGR 75 80 100 125 ...

Page 13: ...port 2 8 44617000 Side Rail 61 4 9 44618009 Suspension Bracket Body 2 10 44618050 Hanging Bracket Assembly accessory 2 11 30366090 Decorative Grille 28 x 59 75 2 12 02112010 Hex Head Cap Screw 3 8 16 x 1 2 4 13 02127130 Nut Hex 3 8 16 4 14 02130130 Lockwasher Spring 3 8 4 15 02189030 Screw Hex Washer Head 8 18 x 1 2 TEKS 34 16 02192010 Screw Hex Washer Head 10 x 1 2 6 17 02104080 Nut Speed 10 6 18...

Page 14: ...mbly Grill Support 2 8 44617000 Side Rail 61 6 9 44618009 Suspension Bracket Body 2 10 44618050 Hanging Bracket Assembly assessory 2 11 30366090 Decorative Grille 28 x 59 75 3 12 02112010 Hex Head Cap Screw 3 8 16 x 1 2 4 13 02127130 Nut Hex 3 8 16 4 14 02130130 Lockwasher Spring 3 8 4 15 02189030 Screw Hex Washer Head 8 18 x 1 2 TEKS 47 16 02192010 Screw Hex Washer Head 10 x 1 2 8 17 02104080 Nut...

Page 15: ...S hooks and eye bolts must be manually crimped closed by the installer See Figure A 4 For outdoor installations Space Ray recommends that the body section be suspended using the adjustable suspension brackets supplied as accessories shown in Figure B An optional method to suspend the body section using 3 8 threaded rod and nuts not supplied as shown in Figure C 5 For indoor installations the heate...

Page 16: ...ion 30FT Body Models PGR 50 60 75 80 100 125 10 0 HEATER ASSEMBLY 7 Pre assemble the adjustable suspension brackets accessories only or 3 8 threaded rod field supplied to the hanger brackets Install these to the ceiling at the dimensions outlined in section 9 0 using best building practices ...

Page 17: ...Open the body packaging and lift the pre assembled body section up and out 10 Roll the pre assembled body section over and place on the sawhorses to begin the assembly 11 Assemble the turbulators together by interlocking the slotted end portions Slide these into the exhaust tube section until they are flush with the tube end Refer to the table below for the required quantity of turbulators for eac...

Page 18: ...ust tube of the heater using 8 sheet metal screws provided Note The draft hood is required for UNVENTED use only If the heater is to be VENTED use the 4 flue adapter collar PN 30504500 and the end reflector accessory having 2 slotted holes PN 42895160 The optional accessories vent kit PN 44622000 is required Refer also to the Venting Section 14 of the manual ...

Page 19: ...ange and set at specified distance Install sheet metal screws through first hanging bracket and into reflector to keep it in place Note 20Ft models require 1 reflector only 14 Place the reflector end to the top end portion of the reflector and secure with 2 8 sheet metal screws provided DO NOT insert any other screws at this time ...

Page 20: ...rizontally and the burner control must be positioned upright as shown below Failure to install the burner control in an UPRIGHT position will VOID the manufacturer s warranty 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 ...

Page 21: ...e When replacing the firing tube a new TISS wire assembly PN 44176510 spring and spring retainer clamp not included must also be installed Instructions A Make sure that the gap between the burner box and end of reflector is 3 5 and the reflector is securely attached to the reflector support bracket Make adjustments if necessary Step 1 Failure to maintain 3 5 gap as shown will result in pre mature ...

Page 22: ...Form 43343120 July 2021 21 Step 2 C 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 ...

Page 23: ...Form 43343120 22 July 2021 D 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 Step 4 ...

Page 24: ...n the burner end of heater and align with edge of reflector The side rail rests inside the reflector lip Attach each side rail to the reflector from the top using 3 8 sheet metal screws provided 18 Slide end of side rail into flange of end reflector and secure with 1 8 sheet metal screw provided Finish securing the end reflector using 4 8 sheet metal screws provided 19 Secure support grille to end...

Page 25: ... Install 2 side rails on the center section of heater Attach each side rail to the reflector from the top using 3 8 sheet metal screws provided Attach each side rail using 1 speed clip and 10 screw provided on each side of the grill support Note The center double grill support and side rails are used on the 30Ft models only 23 Slide one decorative grille panel into the side rails of the center sec...

Page 26: ...ach side rail to the reflector from the top using 3 8 sheet metal screws provided Attach each side rail using 1 speed clip and 10 screw provided on each side of the grill support Note The center double grill support and side rails are used on the 30Ft models only 26 Slide the remaining decorative grille panel into the side rails of the foot end section of the heater 27 Attach the foot end reflecto...

Page 27: ...ibit a CSA or U L approved 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 G The gas pipe flexible hose and connections must be self supporting The gas pipe work must not bear any of the weight of the heat...

Page 28: ...installation in US only The gas connector is 36 long and 1 2 nominal ID and must be installed as shown above in one plane and without sharp bends kinks or twists CANADA ONLY A Type I hose connector should be used that is certified as being in compliance with the Standard for Elastomeric Composite Hose and Hose Couplings for Conducting Propane and Natural Gas CAN CGA 8 1 and is of length of 36 6 in...

Page 29: ...all electrical power to the system to connect manometer hoses 2 Turn the pressure test screw 3 32 Hex in the center of the boss not more than one turn counterclockwise Attach a 5 16 hose and manometer over the tapered outlet pressure boss on the valve see Figures 1 and 2 below If regulator needs to be adjusted see instructions below TO ADJUST REGULATOR single stage gas valves 1 Turn on power and e...

Page 30: ...3 Energize main gas valve solenoid as well as the HI terminal 4 Remove regulator cover screw from the high outlet pressure regulator see Figure 2 below and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw and tighten securely DO NOT EXCEED THE PRESSURES SHOWN IN THE GAS PRESSURE TABLE 5 After testing pressure and adjusting the regulat...

Page 31: ... unit should be protected with a fused disconnect switch or circuit breaker A service switch as required by local codes shall be located in the vicinity of the heater check local codes for allowable distances and should be identified as Heater Service Switch All electrical wiring must be located in accordance with the required Clearances to Combustibles from the heater as listed on the nameplate o...

Page 32: ...CONTROLS INTERNAL CONNECTION WIRING DIAGRAM SINGLE STAGE CONTROLS SCHEMATIC WIRING DIAGRAM IGNITION MODULE TERMINAL DESIGNATIONS 24VAC R 24 VAC Supply to Module TH W Thermostat Input PS W Pressure Switch Input GND System Ground V1 Valve Power V2 Valve Ground L1 120 240 VAC Input Hot IND Blower Output ...

Page 33: ...3343120 32 July 2021 SINGLE STAGE CONTROLS THERMOSTAT WIRING DIAGRAMS SINGLE STAGE CONTROLS I LINE VOLTAGE 120V THERMOSTAT CONNECTIONS SINGLE HEATER J LINE VOLTAGE 120V THERMOSTAT CONNECTIONS MULTIPLE HEATERS ...

Page 34: ...E 24V THERMOSTAT CONNECTIONS SINGLE HEATERS L LOW VOLTAGE 24V THERMOSTAT CONNECTIONS MULTIPLE HEATERS utilizing a fan center relay 13 6 TWO STAGE N7 L7 INTERNAL AND THERMOSTAT CONNECTION TWO STAGE CONTROLS INTERNAL CONNECTION WIRING DIAGRAM ...

Page 35: ...GNITION MODULE TERMINAL DESIGNATIONS 24VAC R 24 VAC Supply to Module TH W Thermostat Input PS W Pressure Switch Input GND System Ground V1 Valve Power V2 Valve Ground L1 120 240 VAC Input Hot IND Blower Output TWO STAGE CONTROLS THERMOSTAT WIRING DIAGRAMS TWO STAGE CONTROLS ...

Page 36: ...Form 43343120 July 2021 35 A LOW VOLTAGE 24V THERMOSTAT CONNECTIONS SINGLE HEATERS B LOW VOLTAGE 24V THERMOSTAT CONNECTIONS MULTIPLE HEATERS ...

Page 37: ... VOLTAGE 24V 3 WAY MANUAL SWITCH CONNECTIONS MULTIPLE HEATERS D TWO STAGE 60 MINUTES TIMER SWITCH WIRING FOR INDIVIDUAL HEATERS E For recessed wall application with 7 x7 faceplate Note Dual heater Timer Switch is available PN 44610540 ...

Page 38: ... vent pipe diameter 34 Joints between sections of piping shall be fastened by sheet metal screws or other approved means and should be sealed to prevent leakage of flue gas into building Aluminum or Teflon tape suitable for 550ºF 3M Company tapes 433 or 363 or silicone sealant is recommended 35 All portions of the vent pipe shall be supported to prevent from sagging 6 spacing is recommended 36 Whe...

Page 39: ...h passes through the combustible sidewall 41 An approved vent cap Breidert or equal must be attached to the end of the vent pipe NOTE To minimize problems associated with condensation in long horizontal runs vent pipe can be insulated 42 Use the following correction factors to obtain the equivalent length when elbows are used Subtract 10 ft for each elbow beyond 15 ft from the heater Subtract 15 f...

Page 40: ...ion level as determined by local codes Less than 3 ft 0 9m from a combustion air inlet Less than 3 ft 0 9m from any other building opening or any gas service regulator Less than 7 ft 2 1m above public walkways Directly over areas where condensate or vapor could create a nuisance or hazard or be harmful to the operation of gas utility meters regulators relief valves or other equipment Building mate...

Page 41: ... no less than that shown in the following Vent Sizing Table A Y connector must be used to the common vent 49 Material for connectors and Y connectors should be constructed of galvanized sheet metal or other approved noncombustible corrosion resistant material as allowed by state or local codes All common vent pipe should be insulated flue pipe or double wall Type B vent 50 Avoid unnecessary bends ...

Page 42: ...enting Arrangement VENT SIZING TABLE Multiple Heater Venting Number of Heaters Horizontal and vertical Vertical Only 1 2 3 4 PGR 40 4 4 4 4 PGR 50 4 4 4 5 PGR 60 4 4 4 5 PGR 75 4 4 5 6 COMMON VENT DIAMETER If a size is not available use the next larger size ...

Page 43: ...RECT 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 include paints solvents corrosive vapors or any other foreign particles that may cause damage to the heater or result in poor combustion Outside combustion air can ...

Page 44: ...ed in the same configuration as shown for venting in Section 14 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 higher than anticipated snow depth ...

Page 45: ...nto lockout and the valve relay will be de energized immediately The blower will be turned off following a post purge period of approximately 30 seconds 57 If the heater does not light manually reset the thermostat or shut off power completely for 5 minutes before attempting to relight 58 To permanently shut down the heater turn off the gas and electrical supply NOTE The lighting and shutdown inst...

Page 46: ... is not re established the heater will go to lockout 19 1 SEQUENCE OF OPERATION TWO STAGE N7 L7 The chart below shows the sequence of operation for the normal operating cycle of the PGR PTU N7 L7 when connected to a permanent 120V power supply and the heater is turned on and off by a remote 24V thermostat Note If the flame is not sensed during sequence T3 then the burner will automatically begin r...

Page 47: ...Form 43343120 46 July 2021 18 0 CONTROL COMPONENT LOCATION ...

Page 48: ... 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 11 0 G Burner Box In order to extend the longevity of the heater the heat exchanger tube and the ...

Page 49: ...Form 43343120 48 July 2021 20 0 TROUBLESHOOTING GUIDE SINGLE STAGE N5 L5 ...

Page 50: ...Form 43343120 July 2021 49 TROUBLESHOOTING GUIDE SINGLE STAGE CONTINUED ...

Page 51: ...Form 43343120 50 July 2021 TROUBLESHOOTING GUIDE SINGLE STAGE CONTINUED ...

Page 52: ...Form 43343120 July 2021 51 20 8 TROUBLESHOOTING GUIDE TWO STAGE N7 L7 ...

Page 53: ...Form 43343120 52 July 2021 TROUBLESHOOTING GUIDE TWO STAGE CONTINUED ...

Page 54: ...Form 43343120 July 2021 53 TROUBLESHOOTING GUIDE TWO STAGE CONTINUED ...

Page 55: ...he gas manifold 61 Disconnect Spark lead and sensing wire 62 Pull burner forward from the gas manifold and then out through the side of the box as shown 63 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 64 Flame sensor should be clean and free from debris 65 Check ceramic on the spark electrode for replacem...

Page 56: ...Form 43343120 July 2021 55 21 10 REMOVING GAS VALVE AND MANIFOLD ASSEMBLY 21 11 AIR SWITCH PRESSURE CHECK ...

Page 57: ...eter 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 meter lead to the electronic control FC terminal g Restart the system and read the meter The flame sensor current must be steady and measure at least 0 7 microamps h If the meter reads les...

Page 58: ... the combustion blower will power off following the post purge period Fault Conditions Error Mode LED Indication Internal Control Failure Steady On Air Flow Fault 1 Flash Gas valve failure stuck open 2 Flashes Ignition Lockout 3 Flashes The LED located on the ignition module will flash ON for second then OFF for second during a fault condition The pause between fault codes is 3 seconds 22 0 INSTAL...

Page 59: ...asting Machined 1 16 44146090 Manifold Support Bracket painted 1 17 44146060 Manifold Support Clamp 1 17a 44146058 Manifold Extension Bracket with set screw 1 18 30703000 Blower Assembly Regal Beloit 1 18a 30703050 Blower Assembly McMillian alternate 1 19 30632510 Spark Module Fenwal 24V 35 615950 197 1 20 30702010 Flame Sensor PSE GF24 1 21 30702020 Electrode PSE GF25 1 21a 30743000 Terminal Bloc...

Page 60: ...8b 30186230 Air Switch set point 45 WC ORANGE LABEL PGR 125 for McMillan blower 1 48c 30186270 Air Switch set point 34 WC GREEN LABEL PGR 125 1 48d 30186240 Air Switch set point 75 WC PINK LABEL PGR 80 100 1 Labels Manual 49 42848000 Label Nameplate Single Stage 1 49a 42848110 Label Nameplate Two Stage 1 50 42013000 Label Logo Space Ray Not Shown 1 51 43344210 Label Clearances to Combustibles 1 52...

Page 61: ...local hardware store 2 Please order by PART NUMBER not by Item Number 3 Replacement Part Prices are available when ordering 4 Please refer to complete Model Number when ordering ALL ILLUSTRATIONS ARE INTENDED TO GIVE THE GENERAL IMPRESSION OF UNITS ONLY WE RESERVE THE RIGHT TO ALTER ANY SPECIFICATION WITHOUT NOTICE ...

Page 62: ... 43343120 July 2021 61 24 0 WARNINGS CARD Copies of this card may be ordered at no charge under part no 43344990 for installation near the heater Scan warranty QR code on the right to register your product ...

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