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SUNPAK Heater Service/Parts

The following sections are intended for service techs only.

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Removal of Burner

a. Remove grille by removing two (2) screws at one end of the grill near control door. Pull downward at the end and grill will be loose. The end of the grill is supported by two (2) pins that enter two (2) holes in the reflector's far end.

b. Remove top of heater by removing six (6) screws holding top in place.

c. The burner can be removed without removing the pilot-electrode assembly. However, extreme care should be taken to prevent the burner from contacting the fragile electrode when removing or reinstalling the burner. To remove the pilot-electrode assembly, disconnect the orange wire from the module connected to the electrode. Detach the pilot tubing. Remove the two screws holding the pilot-electrode in place.

d. Remove burner clip securing mixer inside control compartment. Be careful not to damage white insulation pads.

e. Remove 3/8" hex locknut located inside the burner orifice bracket holding piping assembly to burner. A 7/8" 12-point wrench is recommended to loosen the 3/8" locknut.

f. Remove two (2) screws holding the end of the burner. Carefully slide burner down and out. When reinstalling, be sure both ends of the burner are beneath the reflector end flanges.

g. To reinstall burner, reverse procedure.

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Removal of RAM-3 Direct Spark Ignition Control

a. Disconnect two 24 VAC power leads.
b. Disconnect two gas valve leads.
c. Disconnect igniter lead from control.
d. Disconnect green ground lead from casing.
e. Remove two (2) 8-32 x 1 1/4 screws and nuts holding control module in place. Screw heads are located on exterior front side of heater above control compartment door.
f. If insufficient removal clearance, loosen control assembly and move out of way.


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Trouble Shooting

1. If no spark from electrode; or if gas valve doesn't work then:

a. Check power supply. There should be 24 VAC between the low voltage power wires. Use voltmeter between inlet 24 VAC wire and ground terminal at the electrode plate to measure 24 VAC.

b. Check continuity. Use ohmmeter. For example, check resistance between valve wire and ground. Should show almost no resistance (0 ohms) through valve. If high resistance, check wire connectors.

c. Check spark gap. Spark gap should be 7/64" (.109") between electrode tip, and pilot hood. If gap is too large, spark will occur at wrong location. If gap is too small it may not be hot enough to light pilot burner.

d. Be sure connectors are fully inserted into ignition control (See Wiring Diagram on rating plate).

2. If insufficient gas flow then:

a. Manual gas valve not full "ON". Turn valve handle to full "ON" position.

b. Burner orifice plugged. Remove heater top, remove burner orifice (use 1/2" hex wrench) and thoroughly clean. Spiders often crawl into orifice hole and make a web, blocking the orifice.

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Parts Exploded View

click to enlarge

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Trouble Shooting Guide

Problem
Possible Causes
No Spark to Pilot
  • Voltage under 24 VAC
  • Bad Fuse (Ram-3 Module Only)
  • Improper spark gap (7/64" or .109")
  • Loose ground wire
  • Broken Electrode
  • Faulty Ignition Module
Burner Won't Light
  • Air in gas line
  • Low gas pressure
  • Bad Gas Valve
  • Manual Gas Valve turned "OFF"
Inconsistent Operation
  • Variable gas pressure (improperly sized gas line)
  • Variable Voltage
  • Wind exceeding 10 mph
  • Tip angle exceeding 30 degrees
  • Debris inside burner
  • Erratic winds
Deterioration of Front Grill
  • Sunpak heater must be installed in such a manner as to allow the products of combustion or hot gases to vent out the top of the heater. When operating normally, only radiant heat passes through the front grill. If conditions exist which force hot gases through the front grill of the heater, the installation must be altered to correct the condition.
Rumbling Burner Noise
  • Rumbling burner noise, flare out of burner, and losses of radiant heat are all symptoms of a damaged infrared burner. These symptoms may occur any time after the heater has warmed up. Under these conditions the burner has been damaged and must be replaced. Discontinue use of the heater until heater is repaired.

 

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