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Mestek TUBULAR INDOOR GAS-FIRED DUCT FURNACE Installation Instructions And Service Manual

Tubular gas-fired duct furnace;
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TUBULAR INDOOR GAS-FIRED DUCT FURNACE
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 THE POINT OF
INSTALLATION. RECORD THE UNIT MODEL AND SERIAL No.(s) IN THE SPACE PROVIDED. RETAIN FOR FUTURE
REFERENCE.
Unit No.
The use and storage of gasoline or other fl ammable vapors and liquids in open containers
in the vicinity of this appliance is hazardous.
can cause property damage, injury, or death. Read the installation, operating and
maintenance instructions thoroughly before installing or servicing this equipment.
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, 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.
RECEIVING INSTRUCTIONS
Inspect shipment immediately when
received to determine if any damage
has occurred to the unit dur ing
shipment. After the unit has been
u n c ra t e d , c h e ck fo r a ny v i s i bl e
damage to the unit. If any damage is
found, the consignee should sign
the bill of lading indicating such
damage and immediately file claim
for damage with the transportation
company.
01/14
INSTALLATION INSTRUCTIONS AND SERVICE MANUAL
If you smell gas:
1. Open windows.
2. Do not touch electrical switches.
3. Extinguish any open fl ame.
4. Immediately contact your gas supplier.
Improper installation, adjustment, alteration, service, or maintenance
APPROVED FOR USE IN CALIFORNIA
Install, operate, and maintain unit in accordance with the manufacturer's
INSTALLER'S RESPONSIBILITY
Serial No.
FOR YOUR SAFETY
FOR YOUR SAFETY
260 NORTH ELM ST., WESTFIELD, MA 01085
TEL: (413) 568-9571
TDII-1
J30-09349
FAX: (413) 562-8437
www.mestek.com

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Summary of Contents for Mestek TUBULAR INDOOR GAS-FIRED DUCT FURNACE

  • Page 1 J30-09349 INSTALLATION INSTRUCTIONS AND SERVICE MANUAL TUBULAR INDOOR GAS-FIRED DUCT FURNACE 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 THE POINT OF INSTALLATION.

  • Page 2: Table Of Contents

    Gas Pipe Sizing …...........… 9 Pipe Installation …..........… 10, 11 DESCRIPTION The Tubular Indoor Gas-Fired Duct Furnace is a factory a minimum of 82% thermal effi ciency, and approved for assembled, power vented, and low static pressure type use in California. Do not alter these units in any way. If duct furnace with a low profi...

  • Page 3: General Safety Information

    GENERAL SAFETY INFORMATION Failure to comply with the general Use only the fuel for which the heater is designed (see safety information may result in extensive rating plate). Using LP gas in a heater that requires property damage, sever personal injury, or death. natural gas, or vice versa, will create the risk of gas leaks, carbon monoxide poisoning and explosion.

  • Page 4: Dimensional Data

    DIMENSIONAL DATA Table 1 - Tubular Duct Furnace Dimensions Unit Capacity Dimensional Data - inches (mm) “A” Overall Unit Height 10.3 13.7 20.2 23.5 26.7 (262) (348) (432) (513) (597) (678) (762) “B” Height to Centerline Flue 10.5 11.9 11.6 (193) (267) (302)

  • Page 5: Performance Data

    PERFORMANCE DATA Table 2 - Tubular Duct Furnace Performance Data INPUT OUTPUT (Max.) (Min.) Min. Temp. Rise P.D. Max. Temp. Rise P.D. UNIT Deg. F in. W.C. Deg. F in. W.C. SIZE (kW) (kW) (kW) (cu. m/s) (Deg. C) (kPa) (cu.

  • Page 6: Installation

    INSTALLATION LOCATING UNITS NOTICE: If the gas duct furnace is to be used in a building classified as having a hazardous atmosphere, the installation must comply with D o n o t i n s t a l l d u c t f u r n a c e s i n the standards set by the National Board of Fire corrosive or flammable atmospheres! Premature Underwriters.

  • Page 7: Ductwork

    INSTALLATION (continued) DUCTWORK BYPASS Properly designed and installed ductwork, providing a When a gas duct furnace is installed to operate in uniformly distributed fl ow of air across all surfaces of the conjunction with a summer air conditioning system, the heat exchanger, is essential to satisfactor y unit CFM air delivery of the system blower should be adjusted performance and life of the equipment.

  • Page 8: Suspension

    INSTALLATION (continued) SUSPENSION Figure 5 - Typical Suspension 3/8" THREADED SUSPENSION ROD & JAM NUT BY INSTALLER OUTSIDE JACKET PANEL (UNIT) SECTION A-A SCALE 1:1 D9376 D9376 Ensure that all hardware used in Make certain that the lifting the suspension of each duct furnace is more than methods used to lift the duct furnace are capable adequate for the job.

  • Page 9: Conversion Of Access Side

    INSTALLATION (continued) PIPE SIZING CONVERSION OF ACCESS SIDE To provide adequate gas pressure to the gas unit heater, The tubular duct furnace is built and shipped as left side size the gas piping as follows: access – when looking in the direction of airfl ow, gas and 1.

  • Page 10: Pipe Installation

    INSTALLATION (continued) Table 4 - Gas Pipe Size Maximum Capacity of Pipe in Cubic Feet of Gas per Hour (Cubic Meters per Hour) for Gas Pressures of 0.5 psig (3.5 kPa) or Less, and a Pressure Drop of 0.5 Inch Water Column (124.4 Pa) (Based on a 0.60 Specifi...

  • Page 11: Pipe Installation

    INSTALLATION (continued) Figure 6 - Pipe Installation, Standard Controls Table 5 - Gas Supply Pressure* Natural Gas Propane Gas 1,050 BTU/Ft 2,500 BTU/Ft Heating Value (39.1 MJ/m (93.1 MJ/m Manifold Pressure Single Stage (inch WC) 10.0 Application (kPa) (0.87) (2.49) Two Stage (inch WC) 10.0...

  • Page 12: Electrical Connections

    ELECTRICAL CONNECTIONS THERMOSTAT WIRING AND LOCATION: HAZARDOUS VOLTAGE! NOTICE: The thermostat must be mounted on a DISCONNECT ALL ELECTRIC vertical, vibration-free surface, free from air currents, POWER INCLUDING REMOTE and in accordance with the furnished instructions. DISCONNECTS BEFORE SERVICING. Failure to Mount the thermostat approximately 5 feet (1.5m) above disconnect power before the fl...
  • Page 13 ELECTRICAL CONNECTIONS (continued) Figure 7d – Tubular Duct Furnaces Equipped with Natural Gas or Propane (LP) Gas, Single Stage...
  • Page 14 ELECTRICAL CONNECTIONS (continued) Figure 7e - Tubular Duct Furnaces Equipped with Natural Gas or Propane (LP) Gas, Two Stage...

  • Page 15: General Venting Information

    VENTING NOTICE: All vertical and horizontal venting arrangements for Tubular Duct Furnaces are Category III venting. ANSI now organizes vented appli- Category I Category III ances into four categories. Includes non-condensing appliances Appliances are non-condensing and with negative vent pressure, like the operate with a positive vent pressure.
  • Page 16 VENTING (continued) VENTING FOR POWER VENTED DUCT FURNACES (CATEGORY III) (continued) Horizontal portions of the venting system shall be Each unit must have an individual vent pipe and vent supported at maximum intervals of 4 feet (1.2m) to terminal per furnace section! Each unit MUST NOT be prevent sagging.

  • Page 17: Standard Combustion

    VENTING (continued) VERTICALLY VENTED DUCT FURNACES (CATEGORY III) Observe the following precautions when venting the unit: 4. Use as few elbows as possible. 5. Avoid running vent pipe through unheated spaces. 1. Use fl ue pipe of the same size as the fl ue connections 6.
  • Page 18 VENTING (continued) HORIZONTALLY VENTED DUCT FURNACES (CATEGORY III) Observe the following precautions when venting the unit: 5. Through the wall vent for these appliances shall NOT terminate over public walkways, or over an area where the condensate or vapor could create a 1.
  • Page 19 VENTING (continued) Figure 8A - Vertically Vented Category III, Standard Combustion Approved Vent Terminal 2 ft Min. Use Insulated Stack Outdoors (0.61 m Min) Thimble Roof 5 ft. Min. (1.52 m Min.) 6" (152 mm) Min. Distance from pipe to ceiling 1/4"...

  • Page 20: Separated Combustion

    VENTING (continued) NOTICE: Combustion and exhaust venting instructions below describe two-pipe venting of a duct furnace confi gured for separated combustion. If converting the duct furnace to separated combustion, an Air Inlet Kit (X9) is required and instructions included with the kit must be followed to complete the conversion process.
  • Page 21 VENTING (continued) EXHAUST VENTING 5. Any run of single wall vent pipe passing through an unheated space must be insulated with an insulation suitable to 550°F (288°C). N e v e r o p e r a t e s e p a r a t e d 6.

  • Page 22: Separated Combustion

    VENTING (continued) Figure 9A - Vertical Inlet/Vent Locations, Separated Combustion 10 ft. (3.04m) Min. to Wall or Adjoining Building Breidert Type L or Fields Combustion Air Approved Terminal Inlet 12 in. Min. (305 mm) Exhaust 2 ft. (.609m) Min Plus Max Snow 3 ft.
  • Page 23 VENTING (continued) Figure 10A - Vertical Arrangement, Single Wall Vent System to Single Wall Termination D3619C Figure 10B - Horizontal Arrangement, Single Wall Vent System to Single Wall Termination D3620F...
  • Page 24 VENTING (continued) Figure 11A - Vertical Arrangement, Single Wall Vent System to Double Wall Termination D3662D Figure 11B - Horizontal Arrangement, Single Wall Vent System to Double Wall Termination D3661F...

  • Page 25: Operation

    OPERATION TUBULAR DUCT FURNACE DIRECT SPARK IGNITION EXPLANATION OF CONTROLS: 2. Open the supply gas valve on the duct furnace. 1. The duct furnace is equipped with a power vent 3. Turn ON the electrical power. system that consists of a power vent motor and 4.

  • Page 26: Gas Input Rate

    OPERATION (continued) GAS INPUT RATE Table 7 - Main Burner Orifi ce Schedule – Standard Check the gas input rate as follows (Refer to General Altitude* Safety Information section for metric conversions). TYPE OF GAS NATURAL PROPANE 1050 BTU/Ft 2500 BTU/Ft HEATING VALUE INPUT Never over-fi...
  • Page 27 OPERATION (continued) Table 7A High Altitude Deration - United States Manifold Pressure Altitude BTU Output Natural Gas Liquid Propane Feet Meters Inches W.C. Inches W.C. Percentage 0-2,000 0-610 10.0 2491 100% 2,001-3,000 611-915 2292 3,001-4,000 916-1220 2092 4,001-5,000 1221-1525 1918 5,001-6,000 1526-1830 1744...

  • Page 28: Maintenance

    MAINTENANCE PERIODIC SERVICE 2. Turn off the manual gas valve and electrical power to the duct furnace. NOTICE: The duct furnace and vent system should 3. Remove access panel. be checked once a year by a qualifi ed technician. 4. To clean or replace the burners: a.

  • Page 29: Identification Of Parts

    IDENTIFICATION OF PARTS TUBULAR DUCT FURNACE Figure 13 – Tubular Duct Furnace, Exploded View D9373 D9373 Tubular Duct Furnace Component Index: 25. Top panel 1. Vestibule panel/tube 8. Gas inlet grommet 18. Flue collector gasket assembly (heat 9. Flame sensor 19.

  • Page 30: Troubleshooting Guides

    Table 8A – Tubular Duct Furnace Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION A. Flame pops back. 1. Burner orifi ce too small. 1. Check with local gas supplier for proper orifi ce size and replace. Refer to “Gas Input Rate” section of this manual. 1.
  • Page 31 Table 8A – Tubular Duct Furnace Troubleshooting Guide (continued) SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION G. Failure to ignite. 1. Gas leak. Shut off gas supply 1. Open all manual valves, check for immediately! leaks. Inspect all gas piping and repair accordingly.
  • Page 32 Table 8A – Tubular Duct Furnace Troubleshooting Guide (continued) SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION J. Rapid burner cycling. 1. Loose electrical connections at 1. Tighten all electrical connections. thermostat or gas valve. 2. Unit cycling on high limit. 2. Check for proper air supply across heat exchanger and proper gas supply.
  • Page 33 Table 8A – Tubular Duct Furnace Troubleshooting Guide (continued) SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION N. High limit is tripping. 1. Unit is over fi red. 1. Refer to “Gas Input Rate” in the Operation section of this manual. Check orifi ce size. Replace if too large. 2.
  • Page 34 Table 8B - Tubular Duct Furnace Troubleshooting with LED Indicator Assistance No Cycling or appliance power or thermostat call for heat 2. Remove the appliance burner compartment door. Do since appliance failure has occured. not interrupt power to the control board by opening any electrically interlocked panels.

  • Page 35: Warranty

    LIMITED WARRANTY Tubular Duct Furnaces The “Manufacturer” warrants to the original owner at original installation site that the above model Gas-Fired Heater (“the Product”) will be free from defects in material or workmanship for (1) year from the date of shipment from the factory, or one and one-half (1-1/2) years from the date of manufacture, whichever occurs fi...

  • Page 36: Equipment Start-Up Sheet

    GAS EQUIPMENT START-UP Customer ____________________________________ Job Name & Number _________________________ PRE-INSPECTION INFORMATION With power and gas off. Type of Equip: Duct Furnace Serial Number _________________________ Model Number __________________________ Name Plate Voltage: _____________ Name Plate Amperage: _____________ Type of Gas: Natural Tank Capacity _______ lbs.

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