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Sterling SDRIOM-2 Installation, Operation And Maintenance Manual

Digital gas-fired heater
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PHONE: 214-638-6010 FAX: 214-905-0806 www.sterlinghvac.com
INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR
SDR MODEL DIRECT GAS-FIRED HEATERS
ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY
BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THIS UNIT! CHECK UNIT RATING
PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE
AGREE WITH THOSE AT POINT OF INSTALLATION. RETAIN FOR FUTURE REFERENCE.
The use and storage of gasoline or other flammable vapors and liquids in open containers
in the vicinity of this appliance is hazardous.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause
property damage, injury or death. Read the installation, operating and maintenance
instructions thoroughly before installing or servicing this equipment.
WARNING: Install, operate and maintain unit in accordance with manufacturer's
instructions to avoid exposure to fuel substances or substances for incomplete combustion
which can cause death or serious illness. The state of California has determined that these
substances may cause cancer, birth defects, or other reproductive harm.
Installer Please Note: This equipment has been test fired and inspected. It has been shipped free
from defects from our factory. However, during shipment and installation, problems such as loose
wires, leaks or loose fasteners may occur. It is the installer's responsibility to inspect and
correct any problems that may be found.
POST AND MAINTAIN THESE INSTRUCTIONS IN LEGIBLE CONDITION
HVAC PRODUCTS
4830 TRANSPORT DRIVE, DALLAS,TX 75247
FOR YOUR SAFETY
FOR YOUR SAFETY
If you smell gas:
1. Open Windows
2. Don't touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
lINSTALLER'S RESPONSIBILITY
SDRIOM-2
PN# 94.2000.03
P
c

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Summary of Contents for Sterling SDRIOM-2

  • Page 1 It is the installer’s responsibility to inspect and correct any problems that may be found. POST AND MAINTAIN THESE INSTRUCTIONS IN LEGIBLE CONDITION HVAC PRODUCTS FOR YOUR SAFETY FOR YOUR SAFETY lINSTALLER’S RESPONSIBILITY SDRIOM-2 PN# 94.2000.03...

  • Page 2: Table Of Contents

    I.As is the case with any fine piece of equipment, care must be taken to provide the proper attention to the operation and maintenance details of this machine. This manual of instructions has been prepared in order for you to become well-acquainted with those details, and in doing so, you will be able to give your Direct Gas-Fired System the care and attention which any piece of equipment needs and deserves.

  • Page 3: Section Iii: Installation

    This equipment must be installed and wired in accordance with regulations of the National Board of Fire Under- writers, National Electrical Code, and local governing bodies. The following recommendations are not intended to supplant any requirements of federal, state, or local codes having jurisdiction.
  • Page 4 D. Electrical Connections WARNING: Open all disconnect switches and secure in that position before wiring unit. Failure to do so may result in personal injury or death from electrical shock. WARNING: Controls must be protected from water. Do not allow water to drip on the ignition system.

  • Page 5: Section Iv: Pre Start-Up

    A. Pre Start-Up All equipment has been factory tested, adjusted, metered and inspected to meet conditions set at the time the order was placed. Only minimal adjustments should be required. All information in this service manual is typical. All products are semi-custom and changes may occur.

  • Page 6: Section V: Unit Start-Up

    Close or replace all doors and service panels. Turn main disconnect switch off. Verify the incoming line voltage matches the unit nameplate rating. If the voltage is over ±10% of nameplate rating or phase voltage unbalance is over 2%, notify the contractor or power company. Turn Heat OFF/ON switch to the OFF position.

  • Page 7: Section Vi: Unit Shut Down

    C. Gas Pressure Switches - Operate unit in Heat mode. The low pressure switch will trip out and must be reset before resuming operation when the inlet gas valve is turned off during operation.The high pressure switch may be checked out by reducing the setting of its trip point below unit operating pressure.

  • Page 8: Section Vii - Troubleshooting

    SECTION VII – TROUBLESHOOTING System without Pilot Symptom A. If blower does not operate. B. If there is no voltage at ignition control. C. Burner does not light after 5 sec- onds pre purge of flame safeguard relay and there is voltage at igni- tion control.
  • Page 9 SECTION VII – TROUBLESHOOTING System without Pilot continued Symptom C. continued D. Burner will not respond to tem- perature. Cause 9. Defective gas valve or actuator. 10. Defective spark rod or out of position. (see spark rod diagram #P-001004) 11. Flame rod not sensing flame. (see spark rod diagram #P-001003) 12.
  • Page 10 SECTION VII – TROUBLESHOOTING P-001004 P-001003...

  • Page 11: Section Vii: Troubleshooting Guide

    United Technologies Electronics Controls Operation of the Series 1016-400 Direct Spark Ignition Control On a call for heat a five second pre-purge is initiated. Upon completion of the pre-purge, the gas valve and 60 Hz spark are energized. When flame is detected, the con- trol enters the steady state heating condition.
  • Page 12 Series 14 Discharge Temperature Control continued Symptom Possible Cause E. Continuous High 1. Short circuit in TD114 Fire (Electronics Remote Temperature Problem). Selector circuit or wiring. 2. Open circuit in TS114/TS1007 Discharge or Inlet Air Sensor circuit or wiring. 3. Jumper not connected across amplifier terminals 2 &...
  • Page 13 Series 14 Discharge Temperature Control continued Symptom Possible Cause H. continued 4. Faulty Amplifier or erratic voltage supply. I. Incorrect Discharge 1. Inlet Air sensor is used. Air Temperature 2. Incorrect wiring. 3. System out of calibration. 4. Improper TS114 location.
  • Page 14 Series 44 Room Temperature Control Symptom Possible Cause A. No Gas Flow. 1. Valve improperly installed. B. Continuous Low 1. Open circuit in Fire (Electronics modulator coil. OK). 2. Plunger missing, jammed or improperly installed. 3. Ruptured main or balancing diaphragm. C.
  • Page 15 Series 44 Room Temperature Control continued Symptom Possible Cause E. continued 3. Incorrect space temperature calibration. F. Incorrect 1. Improper TS144 Maximum or location. Minimum Discharge Air Temperature. 2. Incorrect discharge air temperature calibrations. G. Continuous High 1. Foreign material Fire (Electronics holding valve open.
  • Page 16 Series 44 Room Temperature Control continued L. Incorrect Space 1. Incorrect maximum Temperature discharge air temperature setting (A1044). 2. Incorrect minimum discharge air temperature setting (A1044). 3. Insufficient burner capacity. 4. Incorrect space temperature calibration. Control circuits external to Series 44 can cause burner malfunction. Always check manual valve to be certain gas is on, and check limit controls for normal operation.

  • Page 17: Section Viii: Maintenance Schedule And Lubrication Requirements

    1. Turn off gas supply. 2. Set thermostat or controller above room temperature to call for heat. 3. Watch for ignition spark or for glow at hot surface igniter either immediately or following prepurge. See IP module specifications. 4. Time the length of the spark operation. See the IP module specifications.
  • Page 18 B. Lubrication Instructions Item Manufacturer All 3 phase fan U.S., Baldor or motors (1 HP to equal 20 HP) ODP,TEFC Recommendation: See following note. All 1 phase motors Century, G.E. or (Fractional HP) equal ODP,TEFC or TEAO Recommendation: See following note. Fractional HP Century, G.E.
  • Page 19 D. Belt Tension and Adjustment Belt tension is adjusted during the initial run-in and test periods at the factory. However, the belts are run as slack as possible to prevent excessive damage to the bearings, yet tight enough to prevent slippage. It is necessary, therefore, to check belt tension during the first few months of operation, and to check for proper tension weekly during the first 60 days, after which...

  • Page 20: Section Ix: Maxon Np-I Airflo® Burners

    c. Put system back into operation and view burner while cycling through full firing range. This will give a visual check for blocked burner ports. Clean burner ports as necessary using a #47 drill. Burner plates should be cleaned with a wire brush at least once a year.

  • Page 21: Section X: Maxitrol Valve Adjustments And Preliminary Circuit Analysis

    SECTION X - MAXITROL VALVE ADJUSTMENTS AND PRELIMINARY CIRCUIT ANALYSIS MR212 Valve High Fire Manifold Adjustments 1. Disconnect wires from amplifier terminal #4 (Series 14), or #2 and #4 (Series 44). This causes the valve to call for continuous high fire. 2.
  • Page 22 PRELIMINARY CIRCUIT ANALYSIS - SYSTEM 14 For ease in troubleshooting, it is advisable to wire the system as follows (this differs from the normal connection). The Discharge Air Sensor is disconnected and replaced with a 10,000 ohm,1/2 watt test resistor (terminals 3 and 4).

  • Page 23: Section Xi: Replacement Parts

    Section 4 1. With proper voltages observed thus far and modulator responding correctly, wire the system (see Figure 1), except have TS144 connected in place of jumper. Set A1044 MIN temperature selector at least 10°F above outdoor temperature. Set A1044 MAX temperature selector at mid-range.

  • Page 24: Section Xii: Recirculation

    All electrical connections must conform to the current edition of the Canadian Electrical Code, Part 1 CSA Standard C22.1 and applicable local codes. WARNING: On heaters, which recirculate room air, outside ventilation air must be provided in accodance with the information shown on the heater nameplate.

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