Sterling SDFW Installation And Maintenance Instructions Manual

Direct gas-fired heater

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MAINTENANCE MANUAL FOR SDFW & SDFI

ATTENTION:

READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY

BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA

PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE

AGREE WITH THOSE AT POINT OF INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No.(s)

IN THE SPACE PROVIDED. 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.

L'utilisation et l'entreposage d'essence ou d'autres liquides ou produits émettant des

vapeurs inflammables dans des récipients ouverts à proximité de cet appareil est dangereux.

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.

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.

AVERTISSEMENT : Une installation déficiente, de même qu'un mauvais réglage,

modification, entretien ou maintenance peuvent occasionner des dommages matériels,

corporels voire causer la mort. Lire attentivement les instructions d'installation,

d'utilisation et d'entretien avant d'installer ou d'intervenir sur cet appareil.

Install, operate and maintain unit in accordance with manufacturer's instructions to avoid

exposure to fuel substances or substances from 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.

HVAC PRODUCTS

INSTALLATION, OPERATION AND

DIRECT GAS-FIRED HEATERS

FOR YOUR SAFETY

POUR VOTRE SÉCURITÉ

WARNING

INSTALLER'S RESPONSIBILITY

4830 Transport Drive, Dallas, TX 75247 Phone: 214-638-6010 Fax: 214-905-0806

www.sterlinghvac.com

HVAC PRODUCTS

POUR VOTRE SÉCURITÉ

Si vous sentez une odeur de gaz :

1. Ouvrez les fenêtres.

2. Ne pas actionner d'interrupteur.

3. Éteindre toute flamme ouverte.

4. Appelez immédiatement votre

fournisseur de gaz.

(S)DFIM-3

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Summary of Contents for Sterling SDFW

Page 1 (S)DFIM-3 HVAC PRODUCTS INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR SDFW & SDFI DIRECT GAS-FIRED HEATERS ATTENTION: READ THIS MANUAL AND ALL LABELS ATTACHED TO THE UNIT CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THESE UNITS! CHECK UNIT DATA PLATE FOR TYPE OF GAS AND ELECTRICAL SPECIFICATIONS AND MAKE CERTAIN THAT THESE AGREE WITH THOSE AT POINT OF INSTALLATION.
Page 2: Table Of Contents
SECTION I - FORWARD Table of Contents As is the case with any fine piece of equipment, care Section I: Forward and Table of Contents ....2 must be taken to provide the proper attention to the Section II: General Information ........2 operation and maintenance details of this machine.
Page 3: Section Iii: Installation
SECTION III - INSTALLATION FOR CANADIAN INSTALLATIONS ONLY Open the cover on the electrical control box located on the unit. Inspect all wire terminals and wiring termina- 1. All installations must conform with local building codes, or, in the absence of local codes, with tions to ensure that all connections are tight.
Page 4 C. Location of Accessories Check the supply voltage before energizing the unit. Where applicable, standard or optional accessories will The maximum voltage variation should not exceed ± 10%. Phase voltage unbalance must not exceed 2%. be placed inside the fan section of the unit for shipment, and must be removed and installed by the mechanical or electrical contractor.
Page 5: Section Iv: Pre-Start Up
Une tuyauterie adéquatement dimensionnée doit être 5. Field wiring shall have a temperature rating of at posée jusqu'à l'unité. Veuillez noter que la pression de least 105°C. The minimum size of the supply cable la tuyauterie d'alimentation en gaz doit correspondre à circuit shall be sufficient for the maximum ampacity celle spécifiée sur la plaque d'identification, lorsque of the heater.
Page 6: Section V: Unit Start Up
16. If inlet duct is attached to the heater, a purge 11. Check burner for proper location and alignment. timer must be provided and set to purge 4 12. Check that filters and accessories are installed correctly. times the inlet duct volume. 13.
Page 7 Honeywell Flame Safeguard Control Unit Start-Up: Systems without Pilot Watch D.C. voltmeter carefully. The reading should be steady and between 2.0 to 5.0 volts D.C. If the reading Setting Burner is too low, slowly turn the needle valve in or out until satisfactory readings are obtained.
Page 8: Section Vi: Unit Shut Down
Setting Main Flame Install manometer at test port on the last tee of the D. Air Pressure Switches – The high air pressure switch is checked by removing the sensing tube from burner manifold or modulating valve. the entering air side of the burner. Switch operation will shut off the burner.
Page 9 SECTION VII - TROUBLE SHOOTING HONEYWELL RM7895A,B,C,D/EC7895A,C; RM7896A,B,C,D 7800 SERIES RELAY MODULES PRINCIPAL TECHNICAL FEATURES 5. MAIN FLAME ESTABLISHING PERIOD (MFEP) The RM7895, RM7896 provides all customary flame (RM7895C,D/EC7895C; RM7896C,D) safeguard functions as well as significant advance- a. Airflow lockout feature is enabled and the airflow ments in safety, annunciation, and system diagnostics.
Page 10 SECTION VII - TROUBLE SHOOTING continued Causes for hold conditions in the INITIATE sequence: 2. `Main Flame Establishing Period (MFEP): 1. AC line dropout detection. a. After Ignition Trials, and with the presence of 2. AC line noise that can prevent a sufficient reading flame, the main fuel valve, terminal 9, is pow- of the line voltage inputs.
Page 11 SECTION VII - TROUBLE SHOOTING continued SETTINGS AND ADJUSTMENTS Figure 6 - Selectable Site-Configurable Jumpers Selectable Site-Configurable Jumpers The relay module has three site-configurable jumper SELECTABLE CONFIGURATION JUMPERS options, see Fig. 6 and Table 7. If necessary, clip the RUN/TEST SWITCH (EC7895C;...
Page 12 SECTION VII - TROUBLE SHOOTING continued Figure 2 - Wiring Subbase and Sequence Chart for RM7895A,B/EC7895A; RM7896A,B Q7800 FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION TRANSFORMER LINE VOLTAGE ALARM MAIN VALVE BURNER MOTOR (BLOWER) (L1) BURNER CONTROLLER/LIMITS LOCKOUT INTERLOCK (INCLUDING AIRFLOW SWITCH) INTERMITTENT...
Page 13 SECTION VII - TROUBLE SHOOTING continued Figure 3 - Wiring Subbase and Sequence Chart for RM7895C,D/EC7895C,D; RM7896C,D Q7800 FOR DIRECT SPARK IGNITION (OIL OR GAS) IGNITION TRANSFORMER LINE VOLTAGE ALARM MAIN VALVE BURNER MOTOR (BLOWER) (L1) BURNER CONTROLLER/LIMITS LOCKOUT INTERLOCK (INCLUDING AIRFLOW SWITCH).
Page 14 SECTION VII - TROUBLE SHOOTING continued United Technologies Electronics Controls 4. With main burner operating, check the gas control Operation of the Series 1016-400 Direct Spark flow rate using the meter clocking method or check Ignition Control pressure using a manomeer connected to the On a call for heat a five second pre-purge is initiated.
Page 15 SECTION VII - TROUBLE SHOOTING continued Check Safety Shutdown Performace WARNING: Fire or explosion hazard. Can cause property damage, severe injury or death. Perform the safety shutdown test any time work is done on a gas system. NOTE: Read steps 1 through 7 before starting, and compare to the safety sutdown or safety lockout tests recommended for the intermittent pilot (IP) ignition module.
Page 16 SECTION VII - TROUBLESHOOTING continued System with Pilot Symptom Cause Remedy A. If blower does not 1. Low or no voltage. 1. Check power source. operate. 2. Check and replace. 2. Fuse(s) blown. 3. Customer interlock not closed or 3. Close or connect customer interlock.
Page 17 SECTION VII - TROUBLESHOOTING continued System with Pilot continued Symptom Cause Remedy D. continued 5. Type of gas (natural - LP) 5. Replace with factory required supplied different from factory type of gas. required type. Note: components may change. 6a. UV Sensor - clean lens, check 6.
Page 18: Section Vii: Troubleshooting Guide
TROUBLESHOOTING GUIDE System without Pilot Symptom Cause Remedy A. If blower does not 1. Low or no voltage. 1. Check power source. operate. 2. Fuse(s) blown. 2. Check and replace. 3. Customer interlock not closed or 3. Close or connect customer connected.
Page 19 TROUBLESHOOTING GUIDE System without Pilot continued Symptom Cause Remedy C. continued 9. Defective gas valve or actuator. 9. Check power to gas valves. If gas pressure matches unit rating plate and valve does not open, replace gas valve or actuator. 10.
Page 20 TROUBLESHOOTING GUIDE P-001004 P-001003 – 20 –...
Page 21: Troubleshooting Guide
TROUBLESHOOTING GUIDE Series 14 Discharge Temperature Control ® Reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy A. No Gas Flow. 1. Modulating valve 1. Arrow on side of valve 1. Install properly. improperly installed (or should point in direction of see Symptom “L”).
Page 22 TROUBLESHOOTING GUIDE Series 14 Discharge Temperature Control continued ® Reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy F. Continuous 1. Foreign object holding 1. Remove bottom plate and 1. Clean seat. Clean valve or High Fire valve open.
Page 23 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Series 14 Discharge Temperature Control continued Reproduced with permission from Maxitrol ® Company Symptom Possible Cause Field Test Remedy I. Incorrect 1. Inlet Air sensor is 1. Inlet Air Sensor changes 1. Sensed temperature will Discharge Air used.
Page 24 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Series 44 Room Temperature Control ® Reproduced with permission from Maxitrol Company Symptom Possible Cause Field Test Remedy A. No Gas Flow. 1. Valve improperly 1. Arrow on side of valve 1. Install properly. installed. should point in direction of gas flow.
Page 25 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Series 44 Room Temperature Control continued Reproduced with permission from Maxitrol ® Company Symptom Possible Cause Field Test Remedy E. Continuous 1. Faulty amplifier. 1. Follow procedures 1. If amplifier is proven at Minimum outlined in “Preliminary fault, install replacement Discharge Air Circuit Analysis”...
Page 26 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Series 44 Room Temperature Control continued Reproduced with permission from Maxitrol ® Company Symptom Possible Cause Field Test Remedy I. Incorrect High 1. Inlet pressure too low. 1. Read inlet pressure at 1. Increase inlet pressure if Fire.
Page 27: Section Viii: Maintenance Schedule And Lubrication Requirements
SECTION VIII - MAINTENANCE SCHEDULE AND LUBRICATION REQUIREMENTS Periodic maintenance is essential to the efficient f. Inspect all electrical components, connections and operation and extended service life of this equipment. terminals. Clean and tighten where necessary. Failure to provide maintenance as recommended may g.
Page 28 An insufficient amount the same type and size. In addition, Sterling not only of grease is suggested by a bearing showing no suggests, but insists, that air filters be checked every...
Page 29 D. Belt Tensions and Adjustments B Section Belt tension is adjusted during the initial run-in and test small Pounds periods at the factory. However, the belts are run as pulley Pounds Force for slack as possible to prevent excessive damage to the diameter Belt Force for...
Page 30 G. Heater The mixing plates on the burner may display 1. At least a yearly inspection is recommended “hairline” cracks. These cracks are normal, and for heating installations and more frequently caused by thermal stresses occurring during for process applications in year-round combustion.
Page 31: Section Ix: Maxitrol Valve Adjustments And Preliminary Circuit Analysis
SECTION IX - MAXITROL VALVE ADJUSTMENTS AND PRELIMINARY CIRCUIT ANALYSIS MR212 Valve M411, 511, 611 Valve High Fire Manifold Adjustments High Fire Manifold Adjustments 1. Disconnect wires from amplifier terminal #4 (Series 1. Disconnect wires from amplifier terminal #4 (Series 14), or #2 and #4 (Series 44).
Page 32 PRELIMINARY CIRCUIT ANALYSIS – SYSTEM 14 PRELIMINARY CIRCUIT ANALYSIS – SYSTEM 44 For ease in troubleshooting, it is advisable to wire the This Preliminary Circuit Analysis will provide identifica- system as follows (this differs from the normal connec- tion of faulty components, improper wiring or calibra- tion).
Page 33: Section X-Replacement Parts
Section 4 Figure 1 1. With proper voltages observed thus far and modu- lator 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 34: Section Xi: Recirculation
SECTION XI - RECIRCULATION WARNING: On Heaters, which recirculate room If gas fork trucks or other fossil fuel powered equip- air, outside ventilation air must be provided in ment are utilized in the conditioned area, additional accordance with the information shown on the ventilation requirements for the facility must be ad- heater nameplate.
Page 35 – 35 –...
Page 36 HVAC PRODUCTS 4830 Transport Drive, Dallas, TX 75247 Phone: 214-638-6010 Fax: 214-905-0806 www.sterlinghvac.com...

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