Sunnydaze DECOR BAO-132 85000 BTU Forced Air Propane Heater Instruction Manual

Sunnydaze DECOR BAO-132 85000 BTU Forced Air Propane Heater

PRODUCT INFORMATION

READ THE INSTRUCTIONS CAREFULLY:
Read and follow all instructions. Place instructions in a safe place for future reference. Do not allow anyone who has not read these instructions to assemble, light, adjust, or operate the heater.

WARNING : If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
• Service must be performed by a qualified service agency.

This is an unvented portable heater. It uses air (oxygen) from the area in which it is used. Adequate combustion and ventilation air must be provided. Refer to page 3.

Forced Air means that a blower or fan pushes the air through the heater. Proper combustion depends upon this airflow; therefore, the heater must not be revised, modified or operated with parts removed or missing. Likewise, safety systems must not be circumvented or modified in order to operate the heater.

IMPORTANT : Read and understand this manual before assembling, starting, or servicing the heater. Improper use of a heater can cause serious injury. Keep this manual for future reference.

GENERAL HAZARD WARNING:

• Failure to comply with the precautions and instructions provided with this heater can result in death, serious bodily injury, and property loss or damage from hazards of fire, explosion, burn, asphyxiation, carbon monoxide poisoning, and/or electrical shock.
• Only persons who can understand and follow the instructions should use this heater.

Any modification to the product or failure to follow recommended care will void the product warranty.

WARNING!
Manufacturer and seller expressly disclaim any liability from personal injury, property damage, or loss, whether direct or indirect, or incidental, resulting from the incorrect attachment, improper use, inadequate maintenance, or neglect of this product.

SAFETY

WARNING : Fire, burn, inhalation, and explosion hazard. Keep solid combustibles, such as building materials, paper, or cardboard, a safe distance away from the heater as recommended by the instructions. Never use the heater in spaces that do or may contain volatile or airborne combustibles or products such as gasoline, solvents, paint thinner, dust particles, or unknown chemicals.

WARNING : Not for home or recreational vehicle use.

The heater is designed for use as a construction heater by ANSI Z83.7•CGA2.14. (Check with your local fire safety authority if you have questions about heater use.) Other standards govern the use of fuel gases and heating products for specific uses. Your local authority can advise you about these. The primary purpose of construction heaters is to provide temporary heating of buildings under construction, alteration, or repair. Properly used, the heater provides safe, economical heating. Products of combustion are vented into the area being heated. We cannot foresee every use which may be made of this heater. Check with your local fire safety authority if you have questions about heater use.

Propane Gas:
Propane gas is odorless. An odor-making agent is added to propane gas. The odor helps you detect a propane gas leak. However, the odor added to propane gas can fade. Propane gas may be present even though no odor exists.

Carbon Monoxide Poisoning:
Early signs of carbon monoxide poisoning resemble the flu with headache, dizziness, and/or nausea. If you have these signs, the heater may not be working properly. Get fresh air at once! Check for proper ventilation and have the heater serviced.

IMPORTANT SAFETY INFORMATION

1. Install and use the heater with care. Follow all local ordinances and codes. In the absence of local ordinances and codes, refer to the Standard for Storage and Handling of Liquefied Petroleum Gas, ANSI/NFPA 58, and the Propane Gas Installation Code, CAN/CGA B149.2. This instructs on the safe storage and handling of propane gases.
2. Use only the electrical voltage and frequency specified on the model plate. The electrical connections and grounding of the heater shall follow the National Electric Code, ANSI/NFPA 70 or Canadian Electrical Code, Part 1
3. Electrical grounding instructions – This appliance is equipped with a three-prong (grounding) plug for your protection against shock hazards and should be plugged directly into a properly grounded tthree-prongreceptacle or extension cord.
4. Use only a three-prong, grounded extension cord.
5. Use only the hose and factory preset regulator provided with the heater.
6. Use only propane gas set up for vapor withdrawal.
7. Provide adequate ventilation. Before using the heater, provide at least a three-square-foot opening of fresh, outside air for each 100,000 BTU (105,500 KJ/Hr) of rating.
8. For indoor use only. Do not use a heater outdoors.
9. Do not use the heater in a basement or below ground level. Propane gas is heavier than air. If a leak occurs, propane gas will sink to the lowest possible level.
10. Keep the appliance area clear and free from combustible materials, gasoline, paint thinner, and other flammable vapors and liquids.
11. Do not use the heater in areas with high dust content. Dust is combustible.
12. Minimum heater clearances from combustibles: Outlet: 8 ft. (2.4 m), Sides: 2 ft. (0.61 m), Top: 6 ft. (1.83 m), Rear: 2 ft. (0.61 m).
13. The heater must be located at least 7 ft. (2.13 m) in the USA or 10 ft. (3 m) in Canada from any propane gas container. And the heater shall not be directed toward propane gas containers.
14. Not intended for use on finished floors.
15. Never block the air inlet (rear) or the air outlet (front) on the heater.
16. Keep the eater away from strong drafts, water spray, rai,n or dripping water.
17. Do not leave the heater unattended.
18. Keep children and animals away from the heater.
19. Check the hose before each use of the heater. If highly worn or cut, replace with a hose specified by the manufacturer before using the heater.
20. Locate the heater on a stable and level surface if the heater is hot or operating.
21. To prevent injury, wear gloves when handling the heater.
22. Never attach ductwork to the heater.
23. Do not alter the heater. Keep the heater in its original state.
24. Never move, handle, or service a hot, operating, or plugged-in heater. Severe burns may result. You must wait 15 minutes after turning the heater off.

UNPACKING

1. Remove all items from the carton.
2. Remove all packing items applied to the heater for shipment. Keep plastic cover caps (attached to the inlet connector and hose/regulator assembly) for storage.
3. Check all items for shipping damage. If the heater is damaged, contact customer service via one of the methods mentioned at the top of page 1.

PRODUCT IDENTIFICATION

THEORY OF OPERATION

The Fuel System:
The hose/regulator assembly attaches to the propane gas supply. The propane gas moves through the automatic control valve and out the nozzle.

The Ignition System:
The spark transformer and spark plug to light the main burner.

The Safety Control System:
This system causes the heater to shut down if the flame goes out.

NOTE : Some parts are located differently on some heater models.

PROPANE SUPPLY
Propane gas and propane tank(s) are to be furnished by the user. Use this heater only with a propane vapor withdrawal supply system. The installer must conform with local codes or, in the absence of local codes, with the Standard for the Storage and Handling of Liquefied Petroleum Gases, ANSI/NFPA 58 and Propane Gas Installation Code, CAN/CGA B149.1. The amount of propane gas ready for use from propane tanks varies. Two factors decide this amount:

1. The amount of propane gas in the tank(s)
2. The temperature of the tank(s)

The chart below shows the number of 100 lb (45 kg) tanks needed to run this heater.

Smaller tanks can be used for limited run times but it is recommended to use larger tanks for optimum performance.

INSTALLATION

WARNING :
Review and understand the warnings in the Safety section, page 3. They are needed to operate the heater safely. Follow all local codes when using this heater.

WARNING :
Test all gas piping and connections for leaks after installation or servicing. Never use an open flame to check for a leak. Apply a mixture of liquid soap and water to all joints. Bubbles forming show a leak. Correct all leaks at once.

1. Provide an appropriate propane supply system (see Propane Supply).
2. Connect the fuel gas connector fitting on the hose/ regulator assembly to the propane tank(s). Turn counterclockwise into the threads on the tank valve. Tighten firmly using a wrench.
3. Connect the hose to the inlet connector (see Figure 4). Tighten firmly using a wrench.
   IMPORTANT : Use extra hose or piping if needed. Install extra hose or piping between hose/regulator assembly and propane tank. The regulator supplied with the eater must be used.

VENTILATION

WARNING : Follow the minimum fresh, outside air ventilation requirements. If proper fresh, outside air ventilation is not provided, carbon monoxide poisoning can occur. Provide proper fresh, outside air ventilation before running the heater.

Provide a fresh air opening of at least three square feet for each 100,000 Btu/Hr (105,500 KJ/Hr) rating. Provide additional fresh air if more heaters are being used.

OPERATION

WARNING : Review and understand the warnings in the Safety section, page 3. They are needed to operate the heater safely. Follow all local codes when using this heater.

TO START HEATER

1. Read and carefully follow all installation, ventilation, and safety information.

2. Place the heater on a stable and level surface. Make sure the front or rear of the heater aisnot exposed to strong drafts.

3. Plug the power cord of the heater into a three-prong, grounded extension cord. The extension cord must be at least 6 ft. (1.83 m) long, UL/CSA listed, and of proper size. Extension Cord Wire Size Requirements Up to 100 ft (30.5 m) long, use 16 AWG-rated cords. 101 to 200 ft (30.78 to 61 m) long, use a 14 AWG rated cord.

4. Plug the extension cord into a 120 volt/60 hertz, 3-prong, grounded outlet. The motor will start. The fan will turn, forcing air out the front of the heater.

5. Open the ropane supply valve on the propane tank(s) slowly.
   NOTE : If not opened slowly, the excess flow check valve on the propane tank will stop gas flow. You may hear a click from the excess-flow check valve closing. If this happens, reset the excess-flow check valve by closing the propane supply valve and opening it again slowly.

6. Press and hold in fuel valve button. The heater should ignite within a few seconds.
   NOTE : If the heater fails to ignite, the hose may have air in it. If so, keep the fuel valve button pressed and wait 20 seconds. Release the automatic control valve button and wait 20 seconds for unburned fuel to exit the heater. Repeat this step if necessary.

7. After the eater ignites, wait 30 seconds; this activates the automatic control system. Release the control knob.

WARNING : Be sure the motor and fan are running before pushing in automatic control valve button. Flames could flash outside the heater if the motor and fan are not running.

TO STOP HEATER

1. Tightly close the propane supply valve on the propane tank(s).
2. Wait a few seconds. The heater will burn gas remaining in the supply hose.
3. Unplug the heater power supply cord.

WARNING : If the heater is unplugged or a power outage occurs while the heater is running, the thermal limit device will stop fuel flow. A few seconds occur before the thermal limit device activates. During this short time, flames may appear outside the heater. This is normal.

MAINTENANCE

WARNINGS

• Never service the heater while it is plugged in, connected to propane supply, operating or hot. Severe burns and electrical shock can occur.
• Keep the heater clear and free from combustible materials, gasoline, and other flammable vapors and liquids.
• Do not block the flow of combustion or ventilation air.

1. Keep the heater clean. Clean the heater annually or as needed to remove dust and debris. If the heater is dirty or dusty, clean the heater with a damp cloth, and use household cleaners on difficult spots.
2. Inspect the heater before each use. Check connections for leaks. Apply a mixture of liquid soap and water to the connections. Bubbles forming show a leak. Correct all leaks at once.
3. Inspect the hose/regulator assembly before each use. If the hose is highly worn or cut, replace wit ith a hose specified by the manufacturer.
4. Have the heater inspected yearly by a qualified service agency.

STORAGE

CAUTION : Disconnect the heater from the propane supply tank(s).

1. Store propane tank(s) in a safe manner. When the heater is stored indoors, the connection between the propane supply cylinder and the heater must be disconnected.
2. Store propane cylinder(s) ibylocal laws and regulations. In the absence of local codes, follow the Standard for the Storage and Handling of Liquefied Petroleum Gases, ANSI/NFPA 58, and Propane Storage and Handling Code, CSA B149.2.
3. Place plastic cover caps over brass fittings on the inlet connector and hose/regulator assembly.
4. Store in a cool, dry location. Do not store in locations that are exposed to water or high moisture.
5. Covering the heater while in storage will help prevent dust and debris build-up. Ensure the heater is fully cool before covering.

WARNING!
Manufacturer and seller expressly disclaim any liability from personal injury, property damage, or loss, whether direct or indirect, or incidental, resulting from the incorrect attachment, improper use, inadequate maintenance, or neglect of this product.

SERVICE PROCEDURES

WARNING: Never service the heater while it is plugged in, connected to a propane supply, operating, or hot. Severe burns and electrical shock can occur.

ELECTRICAL SYSTEM
The entire electrical system for this heater is contained within the motor. If any part of the electrical system is damaged, you must replace the motor.

MOTOR

1. With the heater on its side, remove the access panel.
2. Access the ground screw through the underside of the heater base. Remove the ground screw. Disconnect the green motor wire and the green power cord wire from the underside of the shell (see Figure 5).
3. Remove two black wires from the motor to the terminal board.
4. Carefully push the motor wires through the hole in the bottom of the shell.
5. Use a nut driver to remove the three screws holding the motor mount to the shell (see Figure 5).
6. Carefully pull the motor and fan out of the shell.
   • IMPORTANT : Be careful not to damage the fan. Do not set the motor and fan down with the weight resting on the fan. This could damage the fan pitch.
7. Use a hex wrench to loosen the set screw, which holds the fan to the motor shaft (see Figure 6). Remove the an, taking care not to damage the fan blade pitch.
8. Use a nut driver to remove the two nuts that attach the motor to the motor mount.
9. Discard the old motor.
10. Attach the new motor to the motor mount with two nuts. Tighten nuts firmly.
11. Place the fan onto the new motor shaft, making sure the set screw contacts the flat surface of the motor shaft. Tighten the set screw firmly (40-50 inchpounds [46.08-57.60 kilogram- centimeters]).
12. Carefully route the motor wires through the hole in the shell. Place the motor, motor mount, and fan guard into the rear of the heater shell (see Figure 5).
13. Insert three screws through the heater shell and into the fan guard (see Figure 5). Firmly tighten the screws.

FAN

1. Remove the motor, the motor mount, and the fan (see Motor, steps 1 through 8, page 8).
2. Clean the fan using a soft cloth moistened with kerosene or solvent.
3. Dry the fan thoroughly.
4. Replace the fan with the new motor shaft. Make sure the set screw contacts the flat surface on the motor shaft (see Figure 6, page 8). Tighten the set screw firmly (40-50 inch-pounds [46.08-57.60 kilogram-centimeters]).
5. Place the motor and the fan guard into the rear of the heater shell. Make sure the power cord is properly located (see Figure 7).
6. Insert three screws through the heater shell and into the fan guard (see Figure 7). Tighten screws firmly.

IGNITER

1. Remove the motor and fan the guard from the heater (see Motor, page 8, steps 1 through 6).
2. Remove the black igniter wire from the Piezo igniter. Access the igniter wire through the underside of the heater base (see Figure 8). Push the wire up through the notch in the filler panel.
3. Use a nut driver or standard screwdriver to remove the igniter mounting screw from the rear head (see Figure 8).
4. Install the new igniter by attaching it to the rear head with the igniter mounting screw.
5. Run the igniter wire from the new igniter through a notch in the filler panel. Attach the igniter wire to the Piezo igniter.
6. Set the gap between the igniter electrode and the target plate to 0.17″ (43.18 cm) (see Figure 9).
7. Place the motor and fan guard into the rear of the heater shell (see Motor, page 8, steps 11, 12, 13).

CAUTION : Damage caused while servicing the heater is not covered by the limited warranty.

TROUBLESHOOTING

WARNING :
Never service heater while it is plugged in, connected to the propane supply, operating, or hot. Severe burns and electrical shock can occur.

WARNING:
Do not use the heater in areas with high dust content. Dust is combustible.

WARNING!
Manufacturer and seller expressly disclaim any liability from personal injury, property damage, or loss, whether direct or indirect, or incidental, resulting from the incorrect attachment, improper use, inadequate maintenance, or neglect of this product.

SPECIFICATIONS

ALL MODELS

• Electrical Input: 115V, 60 Hz, 1Ø, 2a Direct Spark Ignition
• Primary Flame Control: Thermocouple-operated gas valve
• Minimum Ambient Temp. Rating: 0°F (-17.8° C)

60,000 BTU/HR MODEL

• 40,000-60,000 BTU/hr (11.7-17.5 kW)
• Fuel Consumption: 1.8 – 2.7 pounds/hr (0.84 – 1.26 kg/hr)
• Fuel Orifice Port No.: 18
• Fuel Orifice Port Size: 0.0196″ (0.50 mm)
• Average Air Temp. Rise: 200° F (111° C)
• Fuel: Propane/LP Gas
• Gas Supply Pressure to Regulator: Max – Bottle Pressure, Min – 10 psig (68.9 kPa)
• Gas Supply Pressure Regulator Out: 10psig (68.9 kPa)

85,000 BTU/HR MODEL

• 50,000-85,000 BTU/hr (14.6-25.0 kW)
• Fuel Consumption: 2.3 – 3.9 pounds/hr (1.05 – 1.78 kg/hr)
• Fuel Orifice Port No.: 18
• Fuel Orifice Port Size: 0.024″ (0.60 mm)
• Average Air Temp. Rise: 200° F (111° C)
• Fuel: Propane/LP Gas
• Gas Supply Pressure to Regulator: Max – Bottle Pressure, Min – 10 psig (68.9 kPa)
• Gas Supply Pressure Regulator Out: 10psig (68.9 kPa)

125,000 BTU/HR MODEL

• 75,000-125,000 BTU/hr (21.9-36.6 kW)
• Fuel Consumption: 3.5 – 5.8 pounds/hr (1.57 – 2.62 kg/hr)
• Fuel Orifice Port No.: 18
• Fuel Orifice Port Size: 0.030″ (0.75 mm)
• Average Air Temp. Rise: 400° F (232° C)
• Fuel: Propane/LP Gas
• Gas Supply Pressure to Regulator: Max – Bottle Pressure, Min – 20 psig (137.8 kPa)
• Gas Supply Pressure Regulator Out: 10psig (137.8 kPa)

WIRING DIAGRAM

CONNECTION DIAGRAM
SCHEMATIC DIAGRAM

If any original wiring as supplied with the heater must be replaced, it must be replaced with type AWG 105ºC wire or its equivalent except as indicated (’Type SF2-200. “SCI- 250ºC)

HEATER DIAGRAM

CAUTION:
The heater may vary from illustration. The diagram shows a breakdown of the entire unit. Some parts may not be serviceable or replaced. Use only original replacement parts. This heater must use design-specific parts. Do not substitute or use generic parts. Improper replacement parts could cause serious or fatal injuries. This will also protect your warranty coverage for parts replaced under warranty.

PARTS LIST

CAUTION:
This list contains all parts shown on the heater diagram on page 12. The diagram shows a breakdown of the entire unit. Some parts may not be serviceable or replaced. The heater may vary from illustration. Use only original replacement parts. This heater must use design-specific parts. Do not substitute or use generic parts. Improper replacement parts could cause serious or fatal injuries. This will also protect your warranty coverage for parts replaced under warranty.

WARNING!
Manufacturer and seller expressly disclaim any liability from personal injury, property damage, or loss, whether direct or indirect, or incidental, resulting from the incorrect attachment, improper use, inadequate maintenance, or neglect of this product.

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