Cumberland SUPER-SAVER XL SS-225-XL-240 User manual

CUMBERLAND 1004 E. Illinois St. Assumption, IL 62510 Phone [phone] Fax [phone]
Manual Part No. 4801-3030 Rev 1-15
-
FOR YOUR SAFETY
If you smell gas:
1. Open windows
2. Don’t touch electrical switches
3. Extinguish any open flames
4. Immediately call your gas supplier
CONSIGNES DE SECURITE
Si vous sentez une odeur de gaz:
1. Ouvrez les fenetres
2. Ne touchez pas aux interrupteurs electriques
3. Etegnex toute flamme hue
4. Contactez immediatement votre compangie
de gaz
FOR YOUR SAFETY
Do not store or use gasoline or any
flammable vapors and liquids in the
vicinity of this or any other appliance
CONSIGNES DE SECURITE
II es interdit dutiliser des liquides
inflammables ou degageant des
vapeurs inflammables, a proximite
de tout appareil fonctionnant au gaz
Agricultural Building Heater –Direct Spark Igniter
Retain Instructions For Future Reference
MODEL
BTUH
kW
SS-225-XL-240
225,000
65.9
 Direct Spark Ignition  Wash Down Design
SUPER-SAVER XLTMHEATER
Owner’s Manual

Part No. 4801-3030 Rev. 1-15 Page 2of 22 Super Saver XL-240 Heater
GENERAL HAZARD WARNING
Failure to comply with 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. If you need assistance or
heater information such as an instruction manual, labels, etc. contact the
manufacturer.
WARNING
Keep solid combustibles, such as building materials, paper or
cardboard, feathers, and dust a safe distance away from the heater as
recommended by the instructions. Never use the heater in spaces which
contain or may contain volatile airborne combustibles, or products such
as gasoline, solvents, paint thinner, dust particles, or unknown
chemicals. Failure to follow these instructions may result in a fire or
explosion, property damage, personal injury or loss of life.
WARNING
Not for home or recreational vehicle use. Installation of this heater in a
home or recreational vehicle may result in a fire or explosion, property
damage, personal injury or loss of life.
WARNING
Proper gas supply pressure must be provided to the inlet of the appliance.
Refer to rating plate for proper gas supply pressure, gas pressure in
excess of the maximum inlet pressure specified at the appliance inlet can
cause fires or explosions, leading to the serious injury, death, building
damage or loss of livestock.
USE OF EQUIPMENT
The intended use of this appliance is the heating of agricultural animal
confinement buildings.
ELECTRICAL
The electrical connections and grounding of the appliance shall be in
compliance with the National Electrical Code ANSI/NFPA 70.





Part No. 4801-3030 Rev. 1-15 Page 3of 22 Super Saver XL-240 Heater
HEATER DIMENSIONS
WEIGHT
130 lb. (60 kg)
HEIGHT
30 in. (76.2 cm)
WIDTH
24-1/2 in. (62.2 cm)
DEPTH
19-1/4 in. (48.9 cm)
Table Of Contents
1. Specifications And Requirements..................4
2. Warnings And Cautions.................................5
3. Maintenance And Warranty...........................6
4. Installation......................................................7
5. User Instructions............................................8
6. Outside Mount (Optional)...............................9
7. Component And Wiring Diagram.................10
8. Ladder Type Schematic Diagram................11
9. Servicing Instructions...................................12
10. Pipe Sizing Guidelines.................................17
11. Parts & Assemblies......................................19
1. Specifications And Requirements
MINIMUM CLEARANCES
Heater must be located a minimum of 12 inches (305 mm) from ceiling, a minimum of 12 inches (305 mm) from wall,
a minimum of 20 inches (305 mm) from ground, and positioned so that livestock are unable to come in contact with
heater or within 10 feet (3 meters) of hot air discharge. (See Figure 1 - Installation Instructions).
Be Sure To Check Delivery!
Locate packing slip and make sure
all of the listed parts are enclosed.
If not, call your Cumberland
Distributor immediately.
Adjustable Wrench
Gas Leak Testing Solution
Pipe Glue
1/4(7 mm)
Nut Driver
Install screw hooks with hammer or drill.
Model No.
Maximum Input
Ventilation
(air required to support combustion)
SS-225-XL
225,000 BTUH (65.9 kW)
1000 CFM (1699 m3/hr)
LP/Propane
Gas
Maximum 14 in. W.C. (34.8 mbar) and minimum 12.5 in. W.C. (31.1 mbar) inlet gas supply
pressure acceptable at gas regulator connection. Burner manifold pressure 11 in. W. C. (27.4
mbar) at maximum input. Gas pressure should be checked by a certified gas technician while
heater is in operation.
Natural
Gas
Maximum 14 in. W.C. (34.8 mbar) and minimum 5 in. W.C. (12.5 mbar) inlet gas supply pressure
acceptable at gas regulator connection. Burner manifold pressure of 3.5 in. W. C. (8.7 mbar) at
maximum input. Gas pressure should be checked by a certified gas technician while heater is in
operation.
Refer to heater ratings plate for unit voltage, amperage, and frequency ratings.

Part No. 4801-3030 Rev. 1-15 Page 4of 22 Super Saver XL-240 Heater
2. Warnings and Cautions
C A U T I O N !
1. Installation must comply with all local, state, and national codes. In the absence of Local codes,
in accordance with CAN1-B149.1 or .2. Installation Codes (Canada).
2. Follow safety, maintenance, and test firing instructions packaged with Heater.
3. Refer to model specifications label for gas type (LP or Natural Gas).
4. Check all connections for gas leaks.
5. Gas supply and regulator must be installed outside building.
6. The hose assembly should be protected from traffic, building materials, and any contact with hot
surfaces both during use and while in storage.
7. Do not open doors, or move or handle heater while hot, burning, or connected to power supply.
8. Turn power off before servicing. (Heater may start at any time if power is connected).
9. Heater is not recommended for heating human living quarters.
10. Not to be used for heating where flammable liquids and vapors are stored or used.
11. Inadequate gas volume and (or) pressure will directly influence the combustion efficiency of the
heater. Adequate gas volume and (or) pressure is the responsibility of the installer.
12. Adequate ventilation must be provided.
13. Combustion and ventilation air must not be obstructed.
14. Not for use with duct work other than types provided by manufacturer.
15. Position heater properly before use. Heater must be level and in accordance with minimum
clearances.
16. For safety, this heater is equipped with air flow proving switch and manual-reset high limit switch.
17. Keep temperature of fuel containers below 100° F (37.8°C). Containers must be installed
outside building.
18. Heater must not be operated for one hour following wash-down.
WARNING
When Heater Is Connected To Remote Thermostat
Heater May Start At Any Time!

ELECTRICAL GROUNDING INSTRUCTIONS
This appliance requires a three prong (grounding) plug
for your protection against electrical shock and should be plugged
directly into a properly grounded three-prong receptacle.

Part No. 4801-3030 Rev. 1-15 Page 5of 22 Super Saver XL-240 Heater
3. Maintenance and Warranty
MAINTENANCE
1. The appliance area should be kept clear & free from combustible materials, gasoline and other
flammable vapors, and liquids.
2 The flow of combustion and ventilation air must not be obstructed.
3. Your Super Saver XL Heater should be inspected before each use, and at least annually by a qualified
service person.
4. The hose should be visually inspected prior to each use of the heater. If it is evident there is excessive
abrasion or wear or the hose is cut, it must be replaced prior to the heater being put into operation.
The replacement hose assembly shall be that specified by the manufacturer. (See parts list).
5. Inspect heater and gas connections periodically for gas leaks with an approved gas leak testing
solution (soap and water work well).
6. Keep heater clean at all times.
A. Open doors and blow out dust with high pressure air hose. Be sure interior of burner
and flared end are kept clean.
B. Burner orifice and direct spark ignition assembly must be kept clean and free of
carbon build-up.
C. Check blower wheel regularly for dust accumulation and clean periodically for
maximum airflow.
D. Thermostat coils must be kept clean to assure proper temperature control.
E. Heater must be cool before wash down. Do not operate heater for one hour following
wash-down.
DISCLAIMER
This appliance rating is based on the use of ANSI LC-2 test gases including LP (2500 BTU/ft3,
93.15 MJ/m3) and natural gas (1075 BTU/ft3, 40 MJ/m3). Cumberland makes no guarantees
regarding the proper operation of this appliance when these conditions are not met.

Part No. 4801-3030 Rev. 1-15 Page 6of 22 Super Saver XL-240 Heater
Limited Warranty
Warranty
The GSI Group, LLC. (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under
normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival
at port of discharge, whichever is earlier. The end-user’s sole remedy (and GSI’s only obligation) is to repair or replace, at GSI’s
option and expense, products that in GSI’s judgment, contain a material defect in materials or workmanship. Expenses incurred by
or on behalf of the end-user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the
end-user.
Warranty Extensions: The Limited Warranty period is extended for the following products:
Product
Warranty Period
AP Fans and
Flooring
Performer Series Direct Drive
Fan Motor
3 Years
All Fiberglass Housings
Lifetime
All Fiberglass Propellers
Lifetime
AP/Cumberland
Flex-Flo/Pan Feeding Systems
2 Years
Cumberland
Feeding/Watering
Systems
Feeder System Pan Assemblies
5 Years **
Feed Tubes (1.75" & 2.00")
10 Years *
Centerless Augers
10 Years *
Watering Nipples
10 Years *
Grain Systems
Grain Bin Structural Design
5 Years
Grain Systems
Farm Fans
Zimmerman
Portable & Tower Dryers
2 Years
Portable & Tower Dryer Frames
and Internal Infrastructure †
5 Years
GSI further warrants that the frame, basket and excluding all auger and auger drive components of the portable and tower
dyer shall be free from defects in materials for a period of time beginning on the twelfth (12th) month from the date of purchase
and continuing until the sixtieth (60th) month from the date of purchase (extended warranty period). During the extended
warranty period, GSI will replace the frame or basket components that prove to be defective under normal conditions of use
without charge, excluding the labor, transportation, and/or shipping costs incurred in the performance of this extended
warranty.
Conditions and Limitations:
THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH
ABOVE. SPECIFICALLY, GSI MAKES NO FURTHER WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING,
WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE
IN CONNECTION WITH: (i) PRODUCT MANUFACTURED OR SOLD BY GSI OR (ii) ANY ADVICE, INSTRUCTION,
RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR EMPLOYEE OF GSI
REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR
PURPOSE, OR DESIGN OF SUCH PRODUCTS.
GSI shall not be liable for any direct, indirect, incidental or consequential damages, including, without limitation, loss of
anticipated profits or benefits. The sole and exclusive remedy is set forth in the Limited Warranty, which shall not exceed the
amount paid for the product purchased. This warranty is not transferable and applies only to the original end-user. GSI shall
have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent or
distributor.
GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which
it manufactured. Modifications to products not specifically delineated in the manual accompanying the equipment at initial
sale will void the Limited Warranty.
This Limited Warranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration,
accident or which have been improperly/inadequately maintained. This Limited Warranty extends solely to products
manufactured by GSI.
Prior to installation, the end-user has the responsibility to comply with federal, state and local codes which apply to the
location and installation of products manufactured or sold by GSI.
* Warranty prorated from list price:
0 to 3 years –no cost to end-user
3 to 5 years –end-user pays 25%
5 to 7 years –end-user pays 50%
7 to 10 years –end user pays 75%
** Warranty prorated from list price:
0 to 3 years –no cost to end-user
3 to 5 years –end-user pays 50%
†Motors, burner components and
moving parts not included. Portable
Dryer screens included. Tower Dryer
screens not included.

Part No. 4801-3030 Rev. 1-15 Page 7of 22 Super Saver XL-240 Heater
4. Installation
4.1 Hanging The Heater
Chain Suspension
Cable Suspension
Mount heater with screw hooks and chains so that
back of heater is at least 12 inches (305 mm) from
ceiling and wall. Heater must be a minimum of 20
inches (500 mm) from floor, and located so livestock
and combustible materials are unable to come in
contact with heater or within 10 ft (3 meters) of hot air
discharge.
If frequent height adjustment is required, use
cables and pulleys. Main line cable would be
connected to a winch.
4.2 Directions For Leveling
Adjust cables or chains as required
to level the heater. Use a
carpenter's level to check that the
heater is level.
4.3 Installing Dual-Flare Duct
Fold Dual-Flare duct to shape as
shown in Fig. 1. Install Dual-Flare
duct to heater exhaust (Fig. 1) as
shown with sheet metal screws
provided. This provides a multi-
directional heat flow that may be set
by bending flaps.
4.4 Connecting the Gas Supply
For gas connection (Fig. 2) attach
regulator to the Hi-Pressure Line (A)
at outside of building. Connect
flexible hose (B) to low pressure end
of regulator with special brass
coupling. See page 1 for LP, and
natural gas requirements.
Gas regulator
Hi-Pressure Line
Fig. 2
A
B
High Pressure
Line
Gas Regulator
Flexible
hose
Fig. 2
Attach Flare
Duct To
Heater With
Sheet Metal
Screws
Adjust Flap To
Direct Heat Flow
Flare Duct
Fig. 1

Part No. 4801-3030 Rev. 1-15 Page 8of 22 Super Saver XL-240 Heater
5. User Instructions
Before turning on gas, check main supply valve to be sure it is open (Fig. 3). Be sure to check all
connections for leaks with a Gas Leak Testing solution, (soap and water work well). Check to see if gas
valve knob is in the ON position. If not, turn counter-clockwise until knob “clicks” into the ON position.
(This may not apply to all units). Turn on gas by turning ball valve handle into vertical position.
5.1 Connecting Electrical Power
Make sure a circuit breaker or similar cutoff device is provided to permit disconnection of
electrical power to heater for service and cleaning. This heater is designed to be wired directly,
with no plugs and outlets necessary. All electrical work should be performed by a certified electrician.
The wiring diagrams on pages 7-8 show how to wire a line power supply directly to the heater‟s
terminal block. If no adjustments are made, the heater will operate every time power is supplied and
the on/off switch is activated. If an external thermostat is to be used (See Component & Wiring
Diagram), the heater will operate only when power is supplied, the on/off switch is activated, and the
thermostat indicates a call for heat.
5.2 Starting Up
Adjust thermostat higher than house
temperature. Allow 20 seconds for
heater to ignite. On initial start up or
when heater has not been in service
for some time, heater may require
more than one attempt to purge air
and ignite heater. (IF HEATER
FAILS TO IGNITE. REFER TO
TROUBLE SHOOTING GUIDE).
Adjust thermostat to desired house
temperature.
5.3 Shutting OFF Heater
Shut off main gas supply valve, close
ball valve, and disconnect electrical
power.
C A U T I O N !
LIMITING EXCESS CARBON DIOXIDE (CO2 )
In order to prevent hazardous accumulation of CO2 gases, the heater must
operate ONLY in a properly ventilated room.
Ventilation requirements are given in 'Specifications and Requirements' on page 1.
Both installer and operator must ensure that the building’s ventilation rate never drops
below the noted limits.
To Heater
To Gas
Supply
Gas Ball Valve
Shown in
"ON" Position
Fig. 3

Part No. 4801-3030 Rev. 1-15 Page 9of 22 Super Saver XL-240 Heater
6. Outside Mount (Optional)
Cumberland heaters are available in Outside Mount (OSM) models. These heaters are designed to be mounted to
the outside wall of a building. This saves valuable space inside the building and ensures fresh air intake for the
heater. If you have purchased one of our OSM heaters, please read the following before installing your new heater.
1. Before disposing of the box, cut the installation template
from the side.
2. Position template on outside of building where heater is
to be mounted. Be sure the template is level.
3. Drill 6.3 mm (1/4) holes through all 8 X‟s shown on
template. NOTE: Opening for duct measures 254 mm
(10) width (W) x 254mm (10) height (H). See Detail A.
4. Locate 4 X‟s for thru-wall extension duct and cut from
one hole to the next until opening is removed. See Detail
A.
5. If additional support is needed, add support by fastening
two 2' x 4' boards on outside of wall where heater
support brackets are to be positioned. The two 2' x 4'
boards are to be fastened to studs inside the wall. See
Detail B.
6. Assemble heater support bracket as shown in Detail C.
7. Insert thru-wall extension duct assembly through
opening in wall. The „varmint‟ flap, located inside the
thru-wall extension duct, should be positioned as shown
in Detail D.
8. Bend extension duct mounting flange into a rectangle
and fasten around exhaust outlet on front of heater with
sheet metal screws provided.
9. Place heater on support bracket. Support bracket must
be level before heater is set in place.
10. Slide thru-wall extension duct assembly into
mounting flange, and secure with sheet metal
screws.
11. Place outer flashing seal around thru-wall extension
duct and secure with sheet metal screws to inside
of wall.
12. Fasten directional duct to extension duct mounting
flange, then bend deflectors until they force heated
air in the desired direction.
13. To continue with installation of your heater, see
„User Instructions‟ section on the next page.
C A U T I O N !
The minimum side clearance to combustible walls must be 305 mm (12 inches).
The minimum clearance between the appliance and rear wall must be 305 mm (12 inches).
Weeds, snow, or other materials must not be allowed to accumulate on heater or adjacent to heater. Heater and
thru-wall extension duct must be a minimum of 500 mm (20 inches) above ground and out of reach of livestock.
Detail B
Detail A
H
W
W = 254 mm (10)
H = 254 mm (10)
Detail C
1
2
3
4
5
6
7
8
9
10
11
12
13
Detail D
Legend
1. Wall (By others)
2. Rain shield, included with OSM heater.
3. Door, included with OSM heater.
4. Mounting brace, included with OSM kit.
5. Gas shutoff valve, included with heater.
6. Thru-wall extension duct, included with OSM kit.
7. Dual flare duct. Use T-duct included with heater
or use optional OSM Y-duct ordered separately.
8. Extension flange, included with OSM kit.
9. Gas hose, optional ordered separately.
10. 2 x 4 Framing for Brace, not included
11. „Varmint‟ flap, included with OSM kit.
12. Inner flashing seal, included with OSM kit.
13. Outer flashing, included with OSM kit.

Part No. 4801-3030 Rev. 1-15 Page 10 of 22 Super Saver XL-240 Heater
6
6
5
5
4
4
3
2
3
1
2
2
COM
240 Volts A.C. 50/60 Hz Single Phase
IND
L1
LED
MV
PS2
PS1
W
FS
R
X
C
DIAGNOSTIC
INDICATOR
1
DSI
CPC
CONNECTOR
DSI
HV
REMOVE JUMPER FOR DIRECT WIRE THERMOSTAT OPTION
COMPONENT AND WIRING DIAGRAM
CONTROL BOX
8
7
THERMOSTAT OPTIONS
Low Voltage Control
Direct Wire Thermostat
or Controller
Piggy-Back
Thermostat
INSIDE HEATER
7
8
7. Component and Wiring Diagram

Part No. 4801-3030 Rev. 1-15 Page 11 of 22 Super Saver XL-240 Heater
8. Ladder Type Schematic Diagram
SPARK
IGNITER
BLACK
WHITE
LADDER TYPE SCHEMATIC DIAGRAM
240 Volts A.C. 50/60 Hz Single Phase
LEG 1
LEG 2
GROUND
LINE VOLTAGE
THERMOSTAT
10 AMP FUSE
ON / OFF
TRANSFORMER
24 VAC-40VA, 50/60 Hz
LINE VOLTAGE
LOW LINE
UNITED TECHNOLOGIES
Direct Spark Ignition Control
FLAME SENSOR
PROBE
GND
REDUNDANT
VALVE
MAIN
VALVE
HIGH LIMIT
SWITCH
SAIL SWITCH
IND
L1
COM
R
PS1
X
PS2
W
MV
C
FS
MOT
HV
GND

Part No. 4801-3030 Rev. 1-15 Page 12 of 22 Super Saver XL-240 Heater
9. Servicing Instructions
9.1 United Technologies Direct Spark Ignition System
IMPORTANT!
Inspect and check operation of this appliance monthly. Follow the
instructions below. If a problem is detected, contact a qualified
technician to make any necessary repairs.
In an effort to minimize the time required to trouble shoot this system:
1. Turn off the gas supply at the main gas valve.
2. Disconnect electric power to system at main fuse of circuit breaker, if connected.
3. Visually inspect equipment for apparent damage. Check wiring for loose
connections.
4. Inspect igniter for visible cracking or scale deposits. Inspect flame sensor for
position or deposits shorting sensor to burner.
5. After performing the above inspections, restore gas supply, and electric power to the
equipment. Close thermostat contacts to cycle the system. If a “no heat” condition
persists, the three visual indicators listed below will help determine if system is
operating properly.
The igniter will spark.
The main burner flame will ignite.
The main burner flame will continue to burn after the igniter is
turned off.
Trouble shooting the system consists of checking for these three visual indications.
The Visual Check Charts define the proper action if any of these indications do not
occur.
1
2
3

Part No. 4801-3030 Rev. 1-15 Page 13 of 22 Super Saver XL-240 Heater
9.2 1016 Direct Spark Ignition
Status Indicator Error Conditions
The status indicator LED will not be lit with power applied to the board and the control operating
properly. However, if the control is not operating properly, the status indicator LED will flash in
one of the following error codes.
1. Status Indicator Flashing One Time
When the status indicator LED shows the error code of a single repeated flash, the control is
in lock-out, because the sail switch was stuck closed.
2. Status Indicator Flashing Two Times
When the status indicator LED shows the repeating error code of two flashes, the control is in
lock-out because the control circuits did not receive the “closed” signal from the high limit
switch, the sail switch, and the low gas pressure switch*within the required amount of time.
*ONLY HEATERS FOR USE WITH LP/PROPANE GAS ARE EQUIPPED WITH A LOW
GAS PRESSURE SWITCH.
3. Status Indicator Flashing Three Times
When the status indicator LED shows the repeating error code of three flashes, the control is
in lock-out due to either a failed ignition attempt, a gas valve error, or a false flame sensed
during the pre-purge of warm-up periods. If false flame has been sensed, the control will
return to normal operation, and begin a new ignition sequence when the false flame is no
longer present.
4. Status Indicator Flashing Four Times
When the status indicator LED shows the repeating error code of four flashes, the gas valve
is energized during no call for heat.
9.3 Checking Manifold Pressure
To be performed by a certified gas technician only!
1. Unplug heater from power source and turn ball valve to OFF position.
2. Remove outlet pressure tap plug from gas control valve and connect pressure gauge.
3. Return electrical power to heater and plug to power source and turn ball valve to ON
position.
4. To obtain an accurate manifold pressure reading, heater must be cycled on and off
several times to stabilize the pressure regulator diaphragm.
5. Return the heater to operation and read pressure gauge.
6. If necessary, adjust pressure regulator on gas control valve to the acceptable manifold
pressure found on rating plate and page 1 of owner’s manual.
7. Remove pressure regulator adjustment screw.
8. Using a screwdriver, turn inner adjustment screw clockwise to increase or counter
clockwise to decrease manifold pressure to burner.
9. Always replace cap screw and tighten firmly to prevent gas leakage.
10. Unplug heater from power source and turn ball valve to OFF position.
11. Remove pressure gauge and replace outlet pressure tap plug.
12. Return heater to operation and observe through at least one complete cycle to ensure all
controls are operating properly.
13. Perform gas leak test at outlet pressure tap plug. (Soap and water work well).

Part No. 4801-3030 Rev. 1-15 Page 14 of 22 Super Saver XL-240 Heater
Does igniter
spark ?
Is 24V present
across module
terminals
X and COM ?
Is 24V
present
across module
terminals
Ps1 and PS2 ?
Is line voltage
present across module
terminals L1 and C ?
Does igniter have
carbon or dust
build-up?
Remove igniter.
Clean igniter with fine
steel wool or emery
cloth. Spark gap
should be 1/8”.
Reinstall igniter.
Disconnect igniter wire.
Connect ohm meter to igniter
wire terminals. Is resistance
greater that 100 ohms?
Replace igniter wire Replace 1016
United Technologies
control.
9.4 Chart 1 First Visual Check
Chart 1
First Visual Check

Part No. 4801-3030 Rev. 1-15 Page 15 of 22 Super Saver XL-240 Heater
M
9.5 Chart 2 Second Visual Check
Chart 2
Second Visual Check
NOTE: All voltage readings 10% - 15%

Part No. 4801-3030 Rev. 1-15 Page 16 of 22 Super Saver XL-240 Heater
Igniter remains
sparking with main
burner flame
present.
Replace 1016
United
Technologies
Control
Replace 1016
United
Technologies
Control.
Is control
box C
terminal wired
to burner ground ?
DSI system cycle
complete.
9.6 Chart 3 Third Visual Check
Chart 3
Third Visual Check

Part No. 4801-3030 Rev. 1-15 Page 17 of 22 Super Saver XL-240 Heater
b
Gate
valve
Arbitrary Piping System
a
c
d
e
f
g
Heaters
Heaters
30
m
8
m
Gas meter
8
m
tees
10. Pipe Sizing Guidelines
10.1 Calculating HVR & ELOP
1. Using a system schematic, label each piping
section of the system starting at the meter or
regulator. A different pipe section starts
where the gas demand of the system
changes, usually at a junction.
2. Determine the Heating Value Required
(HVR) in BTUH (BTU's per hour) for each
section of pipe.
HVR = (no. heaters supplied by pipe
section) X (heat output per heater)
3. Determine the Equivalent Length Of Pipe (ELOP)
required for sufficient gas service.
ELOP = (length from meter to most remote heater)
+ (Minor loss equivalents of the system)
IMPORTANT: Use the ELOP value from this
equation for size determination of all pipe sections.
4. Use the ELOP value from step 3, and the HVR of
each pipe section to determine the required pipe size
for either natural gas (NG) (Table 1) or liquid propane
(LP) (Table 2) from the table 'Maximum Capacity Of
Pipe'.
10.2 Directions for Reading Pipe Size From Tables:
EXAMPLE: Four 40,000 BTUH (12 kW) heaters will be installed on the gas pipe line in the 'Arbitrary Piping System'
diagram below. NOTE: Values given in English and Metric equivalent units.
1. Determine the HVR value for each pipe section of the system.
Pipe Section
No. Of Heaters
HVR Calculation
HVR Value
BTUH
kW
BTUH
kW
a-b
4
4 x 40,000
4 x 12
160,000
48
b-c
2
2 x 40,000
2 x 12
80,000
24
c-e
1
1 x 40,000
1 x 12
40,000
12
b-d
1
1 x 40,000
1 x 12
40,000
12
b-f
1
1 x 40,000
1 x 12
40,000
12
c-g
1
1 x 40,000
1 x 12
40,000
12
2. Determine the ELOP. Length from meter to most remote heater = length from a to e (or g) = 100ft (30m) + 25ft
(8 m) = 125ft (38 m) Minor loss equivalents from Table 1 = 1 gate valve x 2ft/valve (1 m/valve) + 3 tees x 11
ft/tee (4 m/tee) =35ft (13 m). Calculated ELOP = 125ft (38 m) + 35ft (13 m) = 160 ft (51 m) Tabulated ELOP =
200ft (60 m) Round up to the nearest table value.
3. In the appropriate table, NG (Table 2) or LP (Table 3), select the column showing the ELOP or the next longer
length, if the table does not give the exact length. Use this column to compare table values to the HVR values.
Use the Natural Gas table (Table 2) in this example. From step 2,
ELOP = 200ft (60 m) Locate the column labeled 200ft
(60 m) in Table 2.
4. Select a pipe section and read down the ELOP column to
find the maximum gas capacity that matches the HVR for
that particular pipe section. If the exact value is not
listed, choose the next larger value in the column. In this
example, start with pipe section c-e. For pipe section c-
e, HVR = 40,000 BTUH (12 kW). From Table 2, column
200 ft, 40 (12) is not listed (NOTE: The table values are
in thousands of BTUH's). The next larger value of 72
(21) is read from the table, corresponding to 72,000
BTUH (21 kW).
5. Follow the row leftward until you reach the columns
labeled 'Internal Diameter' and 'Nominal pipe size'. Read
the pipe size for the particular pipe section. For
example, for pipe section c-e, the pipe size is ¾ inch
(0.824 in.) (19.1 mm). Repeat for each pipe section.

Part No. 4801-3030 Rev. 1-15 Page 18 of 22 Super Saver XL-240 Heater
Table 1
Minor Loss Equivalents
Fitting
2" (5.08 cm) IPS Or Smaller
2” (5.08 cm) IPS To 4” (10.16 cm) IPS
Feet per fitting
Meters per fitting
Feet per fitting
Meters per fitting
45Elbow
1
1
5
2
90Elbow
2
2
10
3
Tee
4
4
20
6
Gate Valve
1
1
3
1
Angle Valve
9
9
60
18
Swing Valve
5
5
30
9
-
Table 2. Maximum Capacity Of Pipe In Thousands Of BTU per Hour
Nominal
Internal
Natural Gas (Methane) @ Pressure Drop Of 0.5 in w.c. (0.2 mbar)
Iron Pipe
Diameter,
Values listed are for 0.6 sp.gr. based on Heat Of Combustion of 1000 BTU/cu .ft
Size,
(IPS)
Length Of Pipe, Feet (multiply ft by 0.3 to convert to meter)
Inch*
Inch*
10
20
30
40
50
60
70
80
90
100
150
200
250
300
1/2
.622
175
120
97
82
73
66
61
57
53
50
40
35
29
25
3/4
.824
360
250
200
170
151
138
125
118
110
103
84
72
59
53
1
1.049
680
465
375
320
285
260
240
220
205
195
160
135
109
100
1-1/4
1.380
1400
950
770
660
580
530
490
460
430
400
325
280
219
206
1-1/2
1.610
2100
1460
1180
990
900
810
750
690
650
620
500
430
325
309
2
2.067
3950
2750
2200
1900
1680
1520
1400
1300
1220
1150
950
800
614
596
2-1/2
2.469
6300
4350
3520
3000
2650
2400
2250
2050
1950
1850
1
1500
0
1280
966
950
3
3.068
11000
7700
6250
5300
4750
4300
3900
3700
3450
3250
2650
6
2280
1855
1680
4
4.026
23000
15800
12800
10900
9700
8800
8100
7500
7200
6700
5500
1
4600
3783
3432
Table values given in BTUH/1000. To convert to kW, multiply table values by 0.3
* 1 inch = 25.4 mm
Pipe Sizes Determined For Diagram
Pipe Section
Max Gas Capacity Value Determined From Table 2
Pipe Size Determined From Table 2
BTUH
kWh
inches
mm
a-b
280,000
82
1-1/4 in
31.8
b-c
135,000
40
1 in
25.4
b-d
72,000
21
¾ in
19.1
b-f
72,000
21
¾ in.
19.1
c-e
72,000
21
¾ in.
19.1
c-g
72,000
21
¾ in .
19.1
Table 3. Maximum Capacity Of Pipe In Thousands Of BTU per Hour
Nominal
Internal
Liquid Propane (LP) @ Pressure Drop Of 0.5 in w.c.
Iron Pipe
Diameter,
Values listed are for 1.6 sp.gr. based on Heat Of Combustion of 2500 BTU/cu .ft
Size,
(IPS)
Length Of Pipe, Feet (multiply ft by 0.3 to convert to meter)
Inch*
Inch*
10
20
30
40
50
60
70
80
90
100
125
150
1/2
.622
275
189
152
129
114
103
96
89
83
78
69
63
3/4
.824
567
393
315
267
237
217
196
185
173
162
146
132
1
1.049
1071
732
590
504
448
109
378
346
322
307
275
252
1-1/4
1.380
2205
1496
1212
1039
913
834
771
724
677
630
567
511
1-1/2
1.610
3307
2299
1858
1559
1417
1275
1181
1086
1023
976
866
787
2
2.067
6221
4331
3465
2992
2646
2394
2205
2047
1921
1811
1606
1496
Table values given in BTUH/1000. To convert to kW, multiply table values by 0.3.
* 1 inch = 25.4 mm
IMPORTANT
Tables 2 and 3 are based on values given in the Gas Engineers Handbook and are intended as a guide only.
Consult your gas supplier for gas capacity and pipe size information for your particular piping system.

Part No. 4801-3030 Rev. 1-15 Page 19 of 22 Super Saver XL-240 Heater
11. Parts & Assemblies
When ordering service parts, please specify the country, model number, date of manufacture, voltage, frequency,
gas type, inside or outside mount, and whether the heater is constructed of galvanized or stainless steel.
1045-1305 Natural Gas
1045-0100 LP/Propane Gas
1021-2501
0404-2344
3005-2130
3005-0102
3005-0107
6401-2889
1007-1614
6401-2879
1903-0111 240V
1018-1110
0404-2358
1010-1317 LP/Propane Gas
1010-2500 Natural Gas

Part No. 4801-3030 Rev. 1-15 Page 20 of 22 Super Saver XL-240 Heater
0404
-
2340
-
6401-2867
6401
-
1145
6401
-
1140
0404
-
2341
1004
-
1406
0404
-
2342
3002-6010
1041
-
1488
1009
-
1500
3001
-
0111
1021
-
1500
1021
-
1496
1041
-
1491
1021
-
1495
3004
-
0100 LP/Propane Gas
3004
-
0101 Natural Gas
1041
-
5004
SEE MODEL NO.
1004
-
1422
1004
-
1102
6401
-
1308
1004
-
6029
1001
-
2597
8089
0408
-
1901-0088
-
1005
0100