Table of Contents
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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.
Model No.
The use and storage of gasoline or other flammable vapors and liquids in open containers
in the vicinity of this appliance is hazardous.
Improper installation, adjustment, alteration, service, or maintenance can
cause property damage, injury, or death. Read the installation, operating, and
maintenance instruction thoroughly before installing or servicing this equipment.
APPROVED FOR USE IN CALIFORNIA WHEN EQUIPPED WITH SPARK IGNITION
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 problem that may be found.
RECEIVING INSTRUCTIONS
Inspect shipment immediately when
received to determine if any damage
has occurred to the unit during
shipment. After the unit has been
uncrated, check for any visible
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.
12/05
INSTALLATION AND SERVICE MANUAL
INDOOR GAS-FIRED DUCT FURNACE
(NATURAL OR POWER VENTED)
If you smell gas:
1. Open windows.
2. Don't touch electrical switches.
3. Extinguish any open flame.
4. Immediately contact your gas supplier.
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) 564-5540
www.sterlinghvac.com
MODELS: QV (E) (D,S) (100, 125, 150, 200, 225,
Look in direction of air flow to determine if your unit is right or left hand
accessible. Models QVS/QVES are available with standard right hand
access to service the burner drawer. Left hand is optional.
HVAC PRODUCTS
FAX: (413) 562-5311
250, 300, 350, 400) (S)
(S) DISM-15
J30-05373
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Table of Contents
Related Manuals for Sterling NATURAL INDOOR GAS-FIRED DUCT FURNACE
Summary of Contents for Sterling NATURAL INDOOR GAS-FIRED DUCT FURNACE
- Page 1 (S) DISM-15 INSTALLATION AND SERVICE MANUAL J30-05373 INDOOR GAS-FIRED DUCT FURNACE (NATURAL OR POWER VENTED) 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.
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Page 2: Table Of Contents
MODEL TYPE DESIGNATION Figure 1 = Natural Vented (Standard) Duct Furnace (Bottom Access, Standing Pilot) (Optional Intermittent Pilot) Figure 2 = Natural Vented Side Service Duct Furnace (Side Access, Standing Pilot) (Optional Intermittent Pilot) Figure 3 = Power Vented Duct Furnace (Bottom Access, Rear Vent Position, Spark Ignition) Figure 4 = Side Service Power Vented Duct Furnace (Side Access, Rear Vent Position, Spark Ignition) TABLE OF CONTENTS GENERAL SAFETY INFORMATION ...................... -
Page 3: General Safety Information
GENERAL SAFETY INFORMATION Use only the fuel for which the heater is designed (see Failure to comply with the general safety information may result in extensive rating plate). Using LP gas in a heater that requires natural property damage, severe personal injury or death. gas, or vice versa, will create the risk of gas leaks, carbon monoxide poisoning and explosion. -
Page 4: Specifications
SPECIFICATIONS Figure 1 - Standard Duct Furnace (Natural Vent) — Bottom Service Access Table 1 - Natural Vent Duct Furnace UNIT GAS INLET WEIGHT SIZE (mm) (mm) (mm) (mm) (mm) NAT. (kg) 17-7/8 15-1/2 17-1/8 23-7/8 6 RV (454) (394) (435) (606) (152) RV... -
Page 5: Specifications
SPECIFICATIONS Figure 3 - Power Vented Furnace — Bottom Service Access Table 2 - Power Vented Duct Furnace UNIT D (Dia) GAS INLET WEIGHT SIZE (mm) (mm) (mm) (mm) (mm) NAT. (kg) 17-7/8 15-1/2 17-1/8 23-7/8 (454) (394) (435) (102) (606) (78) 20-5/8... -
Page 6: Performance Data
PERFORMANCE DATA Table 3 INPUT OUTPUT (MAX) (MIN) MIN. Temp. Rise P.D. in. MAX. Temp. Rise P.D. in. UNIT Deg. F. of Water Deg. F. of Water SIZE (kW) (kW) (kW) (cu. m/s) (Deg. C.) (kPa) (cu. m/s) (Deg. C.) (Pascals) 0.12 2469... -
Page 7: Installation
INSTALLATION PUBLIC GARAGES: In repair garages, duct furnaces Do not install duct furnaces in corrosive must be installed in a detached building or room separated or flammable atmospheres! Premature failure of, or from repair areas as specified in the latest edition of NFPA severe damage to the unit will result! 88B, Repair Garages. - Page 8 INSTALLATION DUCTWORK COMBUSTION INLET AIR VENTILATION Properly designed and installed ductwork, providing a Inlet Air From Another Room — If the duct furnace is uniformly distributed flow of air across the surfaces of installed in a tightly constructed room or compartment, the heat exchanger, is essential to satisfactory unit provide two inlet air openings.
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Page 9: Suspension
SUSPENSION The duct furnace must be hung level from side to side and front to back, from four suspension points provided at the top of the unit. Failure to do so will result in poor performance and/or premature failure of the unit. Refer to Figure 7 for typical suspension arrangements. MAKE CERTAIN THAT THE LIFTING METHODS USED TO LIFT THE UNIT HEATER ARE CAPABLE OF SUPPORTING THE WEIGHT OF THE... -
Page 10: Electrical Connections
ELECTRICAL CONNECTIONS * Thermostat wires tagged “W” and “G” must be connected together except when using a general purpose “SPDT” HAZARDOUS VOLTAGE! 24VAC relay and a standard thermostat with subbase, or when using Honeywell T834H-1009 or T834H-1017 DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE thermostats. -
Page 11: Venting
VENTING ANSI now organizes vented Category I Category III appliances into four categories. Includes non-condensing Appliances are non-condensing appliances with negative vent and operate with a positive vent Venting Categories pressure, like the traditional pressure. atmospheric unit heater. Category IV Condensing Condensing Category II... - Page 12 5. Use as few elbows as possible. 10. Avoid installing units in areas under negative 6. Tape flue pipe joints with fireproof paper or material. pressure due to large exhaust fans or air 7. Avoid running vent pipe through unheated spaces. conditioning.
- Page 13 Each unit must have an individual vent pipe and vent Figure 10 terminal per furnace section! Each unit MUST NOT be (Optional) connected to other vent systems or to a chimney. Top Vent Position Units are shipped from the factory set up for vertical Rear, Front, venting.
- Page 14 Figure 12A Figure 12B...
- Page 15 Figure 13A Figure 13B...
- Page 16 Figure 14 Horizontal Left Vent Position (Rear View of Heater) Reducer/Increaser To Horizontal Flue Where Applicable Vent Termination Power Venter Tee With Drip Leg & Cleanout Cap At Lowest Point Of Vent System (Typ.) D4072 Figure 15 Horizontal Right Vent Position (Rear View of Unit Heater) To Horizontal Flue Reducer/Increaser...
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Page 17: Gas Piping
GAS PIPING To avoid equipment damage or possible personal injury, do not connect gas piping to this unit until a supply line pressure/leak test has been completed. Connecting the unit before completing the pressure/leak test may damage the unit gas valve and result in a fire hazard. Do not rely on a shut off valve to isolate the unit while conducting gas pressure/leak tests. -
Page 18: Pipe Installation
PIPE INSTALLATION 1. Install the gas piping in accordance with Check all pipe joints for leakage applicable local codes. using a soap solution or other approved method. 2. Check gas supply pressure. Each duct furnace must Never use an open flame or severe personal injury or death may occur. -
Page 19: Operation
OPERATION NATURAL VENTED UNITS WITH STANDING PILOT (Figures 1 and 2) It is the installer’s responsibility START-UP to check all safety controls! Check and test the Open the manual shutoff gas valve to the duct furnace operational functions of all safety devices and, with the union connection loose, purge air from the supplied with this unit, and ensure that all are gas line. - Page 20 Figure 18 - Burner Components — Standing Pilot Components Also refer to Figures 1, 2 and 21 thru 25 for component locations. Standing Pilot Parts/Controls BURNER DRAWER - COMMON PARTS: Main Burners Main Burner Orifice Burner Manifold Transformer/Junction Box Air Shutters Pilot Tubing Burner Springs CONTROLS:...
- Page 21 OPERATION UNITS WITH INTERMITTENT PILOT IGNITION Optional for Natural Vented (Standard) Duct Furnaces (Figures 1 and 2) It is the installer’s responsibility START-UP to check all safety controls! Check and test the 1. Open the manual valve supplying gas to the duct operational functions of all safety devices furnace, and with the union connection loose, supplied with this unit, and ensure that all are...
- Page 22 OPERATION POWER VENTED DUCT FURNACES WITH INTERMITTENT (SPARK) PILOT IGNITION Mandatory Ignition for Power Vented Duct Furnaces (Figures 3 and 4) It is the installer’s responsibility 2. The high limit switch interrupts the flow of electric current to the main gas valve in case the heater to check all safety controls! Check and test the operational functions of all safety devices becomes overheated.
- Page 23 Figure 19 - Burner Components — IntermIttent Pilot Ignition Also refer to Figures 1 thru 4 and 21 thru 25 for component locations. Burner Drawer Common Parts: Main Burners Burner Manifold Air Shutters Burner Springs Main Burner Orifice Transformer Pilot Tubing *NOTE: Manifold shown for duct furnaces with bottom service access (Figures 1 and 3.)
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Page 24: Gas Input Rate
TABLE 7 - MAIN BURNER ORIFICE SCHEDULE* GAS INPUT RATE TYPE OF GAS NATURAL PROPANE Never overfire the duct furnace, as 1075 BTU/Ft 2500 BTU/Ft HEATING this may cause unsatisfactory operation or shorten INPUT VALUE (40.1 MJ/m (93.1 MJ/m NO. OF the life of the heater. -
Page 25: Maintenance
MANIFOLD PRESSURE ADJUSTMENT PILOT ADJUSTMENT If the manifold pressure requires minor adjustment, 1. Remove the pilot adjustment cap. remove the cap from the pressure regulator and turn the 2. Adjust the pilot screw to provide a properly sized adjustment screw clockwise to increase the pressure, or flame. - Page 26 DUCT FURNACE COMPONENTS (Natural and Power Vented) "PACKAGED" GAS VALVE PILOT OBSERVATION PORT PILOT BURNER ASSEMBLY PARTS BURNER "DRAWER" FLAME CARRYOVER MAIN BURNER Figure 21 - Duct Furnace Components Figure 22 - Burners/Controls THERMOCOUPLE OR ELECTRODE/SENSING LEAD LOCATION Figure 23 - Burner Assembly Parts...
- Page 27 POWER VENTER ASSEMBLY (Power Vented Duct Furnaces Only ) Figure 24 REF. REF. DESCRIPTION DESCRIPTION BLOWER HOUSING ASSEMBLY SNAP BUSHING SPEED NUT RELAY MOTOR STRAIGHT CONNECTOR WASHER, PLAIN SHIELD (PRESSURE SWITCH) PLATE ADAPTOR ANTI-SHORT BLOWER WHEEL FLEX CONDUIT (23" LONG) MOUNTING BRACKET FLEX CONDUIT (24"...
- Page 28 INSTALLATION INSTRUCTIONS FOR FIELD REPLACEMENT OF POWER VENTER MOTOR Never service any compartment NOTICE: All hardware (screws, nuts, washers) that without first disconnecting all electrical and gas will be removed from the unit will be reused for this supplies. Refer to unit’s wiring diagram. This motor replacement.
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Page 29: Troubleshooting Guide
Troubleshooting Guide Table 8 SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION A. Flame lifting from burner 1. Pressure regulator set too high. 1. Reset manifold pressure. Refer to ports. "Operation". 2. Defective Regulator. 2. Replace regulator section of combin- ation gas valve or complete valve. 3. - Page 30 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION 6. Tripped block vent (spill) switch.** 6. Check blocked vent (spill) switch and reset. See venting. 7. Defective gas valve. 7. Replace gas valve. 8. Defective thermostat 8. Check thermostat and replace if defective.
- Page 31 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION 7. Defective thermocouple 7. Check thermocouple connection, (Standing pilot units only). and replace if defective. 8. Drafts around unit. 8. Eliminate drafts. Refer to "Installa- tion". 9. Pilot valve not opening (faulty 9. Inspect and correct all wiring. wiring).* 10.
- Page 32 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE(S) CORRECTIVE ACTION T. Too much heat. 1. Thermostat malfunction. 1. Replace thermostat. 2. Heater runs continuously. 2. Check wiring per diagrams; Check operation at valve. Look for short (such as staples piercing thermostat wiring), and correct; Replace gas valve;...
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Page 33: Replacement Parts
HOW TO ORDER REPLACEMENT PARTS Please send the following information to your local representative. If further assistance is needed, contact the manufacturer's customer service department. • Model number • Serial Number (if any) • Part description and Number as shown in the Replacement Parts Catalog. LIMITED WARRANTY Gas-Fired Duct Furnaces The “Manufacturer”... - Page 34 NOTES...
- Page 35 GAS EQUIPMENT START-UP Customer ____________________________________ Job Name & Number _________________________ PRE-INSPECTION INFORMATION With power and gas off. Type of Equip: Indoor Duct Furnace Serial Number _________________________ Model Number __________________________ Name Plate Voltage: _____________ Name Plate Amperage: _____________ Type of Gas: Natural Tank Capacity _______ lbs.