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Installation Instructions and Service Manual

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1. Type of Equip Unit Heater Duct Furnace Indoor Rooftop Serial Number Model Number Name Plate Voltage Name Plate Amperage Type of Gas Natural LP Tank Capacity Ibs Rating BTU __ F kg ____ _ C o Are all panels doors vent caps in place Has the unit suffered any external damage Damage Does the gas piping and electric wiring appear to be installed in a professional manner Has the gas and electric been inspected by the local authority having jurisdiction Is the gas supply properly sized for the equipment Were the installation instructions followed when the equipment was installed Have all field installed controls been installed Do you understand all the controls on this equipment f not contact your wholesaler DO NOT START this equipment unless you fully understand the controls GENERAL GAS HEATING With power and gas off With power and gas on Make certain all packing has been removed Inlet gas pressure in W C or kPa 1 Tighten all electrical terminals and connections 1 Pilot amp main burner ignition Check damper linkages for tightness Manifold gas pressure in W C or kPa Check all fans amp blowers for free movement L1 Cycle on HIGH LIMIT 1 Check all controls for proper settings Cycle firestat and or freezestat 1 Check all set screws blowers and bearings Check electronic modulation Set at
2. 6 7 SUSPENSION eR EE 7 Electrical Connections Wiring Diagrams 8 9 10 11 Combustion All PIPING dat yet epee ces 12 Exhaust e RE 12 13 14 Gas enm ER 15 Pipe 16 17 18 OPERATION Explanation COmtrols C l a ae uum Shan 19 Primary Air Shutter Adjustments dente ese ee 19 Shit DOW cive dex va Pinot eant unu eed 19 MAINT ENANGE gt 20 COMPONENT PARIS enetues et eene voe metre deum s dey xa desse pudeat 21 TROUBLESHOOTING CHART iadaa 22 23 24 25 26 WARRANTY e ird Lait Face a CARA iu a SS bas 27 START UP INSPECTION SHEET doe ober Ee pode sentia hades gene ces ia dees oe 28 GENERAL SAFETY INFORMATION The duct furnace design is certified by CSA International for use with natural and LP propane gases ANSI and Standards as well as Canadian installation codes referred to in this manual are the ones that were applicable at the time that the design was certified In addition the duct furnace may be installed on the downstream side of a cooling coil without need of a bypass duct If the unit is to be installed at altitudes ex
3. 11 INSTALLATION Continued FAN TIME DELAY CONTROL OPTIONAL Leads from the fan time delay control are factory wired to the junction box when ordered as an optional component The fan time delay control is a time delay relay approximately 45 seconds ON 65 seconds OFF The fan time delay control is rated at 17 amps NOTICE The start up fan delay should not exceed 90 seconds from a cold start IMPORTANT For all wiring connections refer to the wiring diagram shipped with your unit either affixed to the side jacket or enclosed in the installation instructions envelope Should any original wire supplied with the heater have to be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Should any high limit wires have to be replaced they must be replaced with wiring material having a temperature rating of 200 C minimum COMBUSTION AIR PIPING AWARNING Never operate duct furnaces without combustion air and flue gas piping in place or severe personal injury or death may occur A WARNING CARBON MONOXIDE Your venting system must not be blocked by any snow snow drifts or any foreign matter Inspect your venting system to ensure adequate ventilation exists at all times Failure to heed these warnings could result in Carbon Monoxide Poisoning symptoms include grogginess lethargy inappropriate tiredness or flu like symptoms The
4. A WARNING This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts Installation must be in accordance with local codes or in absence of local codes with the latest edition of ANSI Standard Z223 1 N F P A No 54 National Fuel Gas Code All of the ANSI and NFPA Standards referred to in these installation instructions are those that were applicable at the time the design of this appliance was certified The ANSI Standards are available from the American National Standards Institute Inc 11 West 42nd Street New York NY 10036 or www ansi org The NFPA Standards are available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 These duct furnaces are designed for use in airplane hangars when installed in accordance with ANSI NFPA No 409 and in public garages when installed in accordance with NFPA No 88A and NFPA 88B If installed in Canada the installation must conform with local building codes or in the absence of local building codes with CGA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CGA B149 2 Installation Codes for Propane Gas Burning Appliances and Equipment These duct furnaces have been designed and certified to comply with CGA 2 6 Also see sections on installation in AIRCRAFT HANGARS and PUBLIC GARAGES A WARNING Do not alter the duct furnace in any
5. SUSPENSION Refer to Figure 4 for typical suspension arrangements A CAUTION The Separated Combustion Duct Furnace must be hung level from side to side and from 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 A WARNING Ensure that all hardware used in the suspension or for duct furnace is more than adequate for the job Failure to do so may result in extensive property damage severe personal injury or death Figure 4 Typical 4 Point Duct Suspending Arrangement de m di i cw L CaL B c p MM 4 m ee e NST ARIA UTI iac EE SSS 00 NN x m A D4284 3 8 16 Treaded Suspension Rod amp Jam Nut By Installer Outside Jacket Panel Duct 3 8 16 Speed Grip Nut Retainer D4285 N Section S S Detail Showing Recommended Method Of Suspension Typical A WARNING MAKE CERTAIN THAT THE STRUCTURE TO WHICH THE FURNACE IS TO BE MOUNTED IS CAPABLE OF SAFELY SUPPORTING ITS WEIGHT UNDER CIRCUMSTANCES MUST THE GAS LINES THE VENTING SYSTEM OR THE ELECTRICAL CONDUIT BE USED TO SUPPORT THE HEATER OR SHOULD ANY OTHER OBJECTS I E LADDER PERSON LEAN AGAINST THE HEATER GAS LINES VENTING SYSTEM OR ELECTRICAL CONDU
6. 16000 CLEARANCES A WARNING Unger no circumstances should combustible material be located within the clearances specified in Table 3 Failure to provide proper clearance could result in personal injury or equipment damage from fire Maintain adequate clearances around air openings into the combustion chamber Table 3 Minimum Clearances Sides 18 457mm Top 6 152mm Bottom 25 635mm Flue 6 152mm When clearances required for accessibility are greater than the minimum required safety clearances the accessibility clearances take precedence NOTICE Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials Atmospheres containing commercial solvents or chlorinated hydrocarbons will produce corrosive acids when coming in contact with the flames This will greatly reduce the life of the duct furnace and may void the warranty Avoid such areas NOTICE If the gas duct furnace is to be used in a building classified as having a hazardous atmosphere the installation must comply with the standards set by the National Board of Fire Underwriters Consult the authorities having jurisdiction before starting the job The Separated Combustion Duct Furnace must be installed on the positive pressure side of the air circulation blower INSTALLATION NOTICE Furnace sizing should be based on heat loss calculations whe
7. 0098 Ave 113 A A 3NDH 01 24 PgR TTT HOLIAS 3ald SOLOW 501 3954 83A U I8 NVJ SOLON LVLSOWSSHL 5013954 2 m 8 8 2 T Q 193NNDOSId wa y qa qa Qui o dos ee m lVISUWS3HL UR 01395 AVT3d 3WIL goce secnm enum 0 SERE e 09717611 3NI1 er a NVJ3 33A D 18 Tw azaay WIsoOLIId 131DIA LA do 268 3 0002 LIMIT S3ana3ousd dA LAVIS 4381912 M 00985 HOIH NV 122 NV DNIdId ONILN3A 5 NOILO3NNOO B3EWON 3NIA 0 Aviad 007 001 m ivisiond ao 1915 1 mm 3 601 15931 19 30 SNILV3 504 SNOILINALSNI o 1SIX3 GQINOHS 1103 02 l 3oNvan A0 9NIAVH NDILVTWISNI 01 5333 1 lt NOLLO3NNU2 109 DN NUILO3NND3 z 31949 09 3SVHd LINQ LONG 138 03 5 C300 1d3a e All v Di G LOA SIT 38 LSAW 11 139v d33 SYOLONGNOD 34409 gt NOILOSNNOD JAIM 1293ds328 LON SI OILVWOLRV Sm 115 00 E Nae 3 A 38 LSAW 3Hl 38 15 LINN x SNULLdD lN3NDdWDU2 TWNOILdo NV 31 13 747
8. BUSTION AIR PI APPROVED TERMINALS NG 3 FT MIN 12 IN gt 6 FT MIN EXCEPT AS PITCH PIPES DOWN TOWARDS TERMINAL CAPS 1 4 IN PER FOOT OF RUN TO AL NOTED IN COM LOW FOR CONDENSATE PING SECTION 24 IN EXHAUST DRAINAGE 18 IN COMBUSTION AIR MINIMUM DISTANCE FROM INTAKE TO GRADE OR BUILDING PROJECTION IS 2765 aPPRBVED TERMINAL SEE INSTRUCTIONS VERTICAL PIPE EXTENSIUN OVER 12 IN MUST BE INSULATED METAL FACE PLATE IF CONDENSATION BECOMES A PROBLEM i FIBERGLASS OR EQUIVALENT METAL INSULATION MIN 2 IN THICK SLEAVE 2 IN MIN 2 IN MIN CAT 2766 VENT PIPE DIAMETER DY SEE TABLE 1 Figure 10A Horizontal Vent Installation APPROVED TERMINAL 2 IN MIN VENT PIPE DIAMETER SEE TABLE 1 41 METAL SLEAVE 2767 I T 4 8 IN MIN SEE INSTRUCTIONS 14 ki METAL FACE PLATE FIBERGLASS UR EQUIVALENT INSULATION MIN 2 IN THICK NOTE DO NOT TERMINATE HORIZONTAL VENT WHERE CONDENSATE COULD CREATE A NUISANCE OR HAZARD OR COULD CAUSE BUILDING OR EQUIPMENT DAMAGE GAS AWARNING To avoid damage or possible personal injury do not connect gas piping to this unit until a supply line pressu
9. Gas Type Natural Gas Propane LP Gas Manifold 3 5 in W C 10 5 in W C Pressure 0 9 kPa 2 6 kPa 14 in W C Max 14 in W C Max Supply Inlet 3 5 kPa 3 5 kPa Pressure 5 5 W C Min 13 0 in W C Min 1 4 kPa 3 2 kPa For single stage applications only at normal altitudes into the valve This may cause stresses that will crack the valve NOTICE Use pipe joint sealant resistant to the action of liquefied petroleum gases regardless of gas conducted AWARNING Check all pipe joints for leakage using a soap solution or other approved method Never use an open flame or severe personal injury or death may occur 16 Figure 12 Burner Components Intermittent Pilot Ignition BURNER DRAWER COMMON PARTS MAIN BURNERS BURNER MANIFOLD AIR SHUTTERS BURNER SPRINGS MAIN BURNER ORIFICE TRANSFORMER PILOT TUBING NOP ON gt CONTROLS 8A MAIN GAS VALVE HONEYWELL 8B MAIN GAS VALVE WHITE RODGERS 9 HONEYWELL IGNITOR 10 HONEYWELL PILOT BURNER 11 HONEYWELL PILOT ORIFICE 12 HONEYWELL ELECTRODE SENSOR LEAD 13 HIGH LIMIT LOCATED ON THE REAR HEADER PLATE OF THE HEAT EXCHANGER AIR INLET SIDE 17 GAS INPUT RATE CAUTION Never overfire the duct furnace as this may cause unsatisfactory operation or shorten the life of the heater Check the gas input rate as follows Refer
10. 3 Blocked heat exchanger 3 Clean heater 4 Air leak into combustion chamber 4 Determine cause and repair or draft hood accordingly Gas odor 1 Shut off gas immediately 1 Inspect all gas piping and repair 2 Blocked heat exchanger venting 2 Clean heat exchanger flue 3 Drafts around heater 3 Eliminate drafts Refer to Installation 4 Negative pressure in building 4 See Installation 5 Blocked draft hood 5 Clean draft hood 22 Table 7 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION G Delayed ignition Excessive primary air Close air shutter Refer to Operation 2 Main burner ports clogged near 2 Clean main burner ports pilot 3 Pressure regulator set too low 3 Reset manifold pressure Refer to Operation 4 Pilot decreases in size when 4 Supply piping is inadequately main burners come on sized Refer to Installation 5 Pilot flame too small 5 Clean pilot orifice Refer to Operation 6 Drafts around ventor 6 Eliminate drafts Refer to Installation 7 Improper venting 7 Refer to Installation H Failure to ignite 1 Main gas valve off 1 Open all manual gas valves 2 Lack of power at unit 2 Replace fuse or turn on power supply 3 Thermostat not calling for heat 3 Turn up thermostat 4 Defective limit switch 4 Check limit switch with continuity tester If open replace high limit 5 Imp
11. anticipator Tighten all connections Adjust thermostat for longer cycles Refer to Operation Check for proper air supply across heat exchanger Relocate thermostat do not mount thermostat on unit Eliminate drafts Refer to Installation Replace ignitor Jumper high limit switch terminals 1 and 2 If burner operates normally replace switch M Noisy power ventor Power ventor wheel loose Replace or tighten 2 Power ventor wheel dirty 2 Clean power ventor wheel 3 Power ventor wheel rubbing 3 Realign power ventor wheel housing 4 Bearings are dry 4 Oil bearings on power ventor motor Refer to label on motor N Pilot will not light or will not 1 Main gas valve off 1 Open all manual gas valves stay lit 2 Pilot adjustment screw turned 2 Refer to Operation too low on combination main gas valve 3 Air in gas line 3 Purge air from gas line 4 Incorrect lighting procedure 4 Follow lighting instruction label adjacent to gas valve 5 Dirt in pilot orifice 5 Remove pilot orifice Clean with compressed air or solvent Do not ream 6 Extremely high or low gas 6 Refer to Operation pressure 7 Drafts around unit 7 Eliminate drafts Refer to Installation 8 Pilot valve not opening faulty 8 Inspect and correct wiring wiring 9 No spark faulty wiring 9 Inspect and correct ignition system wiring See symptoms W X amp Y
12. 1064 152 156 400 48 1 8 45 3 4 47 3 8 6 3 4 1 2 or 3 4 383 1222 1162 1203 152 174 TNOTE D dia equals the air inlet opening and the flue discharge opening Figure 1 Separated Combustion Duct Furnace T D pia FLUE OPENING STANDARD HORIZONTAL AN INCREASER IS SUPPLIED VENT PDSITIUN BY THE MFR FDR 300 350 400 UNIT SIZES F 37 000 INSTALLER IF DNE IS RED HANGING 29 750 756 i 4125 30000 q HANGING gt 3 8 16UNC i i lt NUT RETAINERS wa FOR HANGING H H ue 0 36 00 Ka FRONT AND REAR BRENT a REAR HI LIMIT HI LIMIT 5 Be 750 ACCESS ACCESS i 654 H 1125 gt a A AND REAR INLET m INLET m 29 000 29 000 737 737 40 000 40 000 1 016 1 016 100 250 300 400 DIMENSIONS XXX STANDARD UNITS DIMENSIONS IN PARENTHESIS XXX MILLIMETERS CONNECTOR SHOWN ACCEPTS 6 DIA 152 PIPE PERFORMANCE DATA Table 2 Input Output Max Min Min Temp Rise P D Max Temp Rise P D Unit MBH MBH MBH CFM Deg F in of W C CFM Deg F in of W C Size kW kW kW cu m s Deg C kPa m s Deg C kPa 100 100 50 80 822 90 0 10 3 700 20 2 03 29 3 14 6 23 4 0 388 50 0 02 1 746 11 0 51 125 125 62 5 100 1 028 90 0 09 4 625 20 1 92 36 6 18 3 29 3 0 485 50 0 02 2 183 11 0 48 150 150 75 120 1 233 90 0 09 5 550
13. S SCDFM 3 J30 05374 INSTALLATION INSTRUCTIONS AND SERVICE MANUAL STERLING SEPARATED COMBUSTION GAS FIRED INDOOR 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 POINT OF INSTALLATION RECORD THE UNIT MODEL AND SERIAL No s IN THE SPACE PROVIDED RETAIN FOR FUTURE REFERENCE Model No Serial No FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous 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 AWARNING 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 APPROVED FOR USE IN CALIFORNIA AWARNING 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 ma
14. a HORIZONTALLY VENTED exhaust system must be atleast 12 inches 305mm from the exterior wall that it passes through In addition the termination point other than that specified in Table 1 D dia flue opening Never use PVC ABS or other non metallic pipe for venting To do so may result in serious damage to the unit or severe personal injury or death 10 Any run of single wall vent pipe passing through an unheated space must be insulated with an insulation suitable to 550 F The combustion and exhaust vent air systems must be installed to prevent collection of condensate Pitch horizontal pipes downward 1 4 inch per foot 21mm m toward the terminal caps to facilitate drainage see Figure 9A Vertical vent pipes should be arranged as depicted in Figure 9 The equivalent length of the vent system must not be less than 5 feet 1 5m and must not exceed 50 feet 15 2m Equivalent length is the total length of straight sections PLUS 15 feet 4 6m for each 90 elbow and 5 feet 1 5m for each 45 elbow Each slip joint must be secured with at least three corrosion resistant screws Two full turns of 3M 425 Aluminum Foil Tape or its equivalent must be used to seal each joint General Electric RTV 108 Dow Corning RTV 732 or an equivalent may be used instead of the tape For horizontal vent systems longer than 5 feet 1 5m the system must be supported from overhead building structures at 3 foot 1m intervals The e
15. made by a qualified LP gas dealer or installer He will insure that proper joint compounds are used for making pipe connections that air is purged from lines that a thorough test is made for leaks before operating the heater and that it is properly connected to the propane gas supply system Before any connection is made to the existing line supplying other gas appliances contact the local gas company to make sure that the existing line is of adequate size to handle the combined load 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 Specific Gravity Gas Nominal Iron Internal Length of Pipe Feet meters Pipe Size Dia 10 20 30 40 50 60 70 80 90 100 125 150 175 200 in in 3 0 6 1 9 1 12 2 15 2 18 3 21 3 24 4 27 4 30 5 38 1 45 7 53 3 61 0 1 2 0 622 175 120 97 82 73 66 61 57 53 50 44 40 37 35 4 96 3 40 2 75 2 32 2 07 1 87 1 73 1 61 1 50 1 42 1 25 1 13 1 05 0 99 3 4 0 824 360 250 200 170 151 138 125 118 110 103 93 84 7T 72 10 2 7 08 5 66 4 81 4 28 3 91 3 54 3 34 3 11 2 92 2 63 2 38 2 18 2 04 1 1 049 680 465 375 320 285 260 240 220 205 195 175 160 145 135 19 3 13 2 10 6 9 06 8 07 7 36 6 80 6 23 5 80 5 52 4 96 4 53 411 3 82 11 4 1 380 1400 950 770 66
16. will in turn notify the distributor or manufacturer b shipment to the Manufacturer of that part of the Product thought to be defective Goods can only be returned with prior written approval of the Manufacturer All returns must be freight prepaid c determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship 4 Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period 5 THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED AND ALL SUCH OTHER WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL SPECIAL OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION In the interest of product improvement we reserve the right to make changes without notice 27 GAS EQUIPMENT START UP Customer Job Name amp Number PRE INSPECTION INFORMATION With power and gas off
17. x 5 TaUTESVSTINVN 31994435 8 13 10 Figure 8 Standard Wiring Diagram for Unit with Hot Surface Ignition System HA HA qu g d aa X543 lt WOO 1915 G L 1 p 1 1 E 1 9999 SP HE quee 5H GND NI 39 ASH D 3A WA q3sn LONO Eod 00S6AS 1915 10 o Lo lt F AW13C WIL 34 01 JVala ang ay E 1 1 1 INGON 8 boa MEN Gane 3 D123NNU2 HA bog 0096AS 00S6AS Pg AL emi oSred E V 1014 0 10719 rod TA AD AV 132 201 E H H e ad ol bd lt ad 1 AVIS AWIL I LIWN E 013944 SIDA bg ve E Aa VA 06 EE IJ3W23J dX Ave P6 BED H 01 NIT 83A D 18 NV 4 HOLIMS Jai sS 01 a AV 134 IVISUNS3HI 5 J LUN AL AD 801 3980 __
18. 0 580 530 490 460 430 400 360 325 300 280 39 6 26 9 21 8 18 7 16 4 15 0 13 9 13 0 12 2 11 3 10 2 9 20 8 50 7 93 11 2 1 610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 59 5 41 3 33 4 28 0 25 5 22 9 21 2 19 5 18 4 17 6 15 6 14 2 13 0 12 2 2 2 067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800 112 77 9 62 3 53 8 47 6 43 0 39 6 36 8 34 5 32 6 28 9 26 9 24 1 22 7 21 2 2 469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280 178 123 99 7 85 0 75 0 68 0 63 7 58 0 55 2 52 4 46 7 42 5 38 8 36 2 3 3 068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280 311 218 177 150 135 122 110 105 97 7 92 0 83 5 75 0 69 4 64 6 4 4 026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 6000 5500 5000 4600 651 447 362 309 275 249 229 212 204 190 170 156 142 130 1 Determine the required Cu Ft Hr by dividing the rated heater input by 1000 For SI Metric measurements Convert unit Btu Hr to kilowatts Multiply the units input kW by 0 0965 to determine Cubic Meters Hour from the table 3 FOR PROPANE GAS Multiply the Cu Ft Hr Cubic Meters per Hour value by 0 633 then use the table the metric conversion factors listed in General Safety section for more SI unit measurements conversions 15 2 F
19. 1 134 83A U 18 3 501 3944 SCION 2 AD 013944 IVISUW33HLI 01 LOANNOISIC g N A A 18 SOLOW pS aes SOLOW e 09 1 6511 NI et 19150 83 J 313 AD 18 E 2 30077 WISsOLIId 1301A LA do 268 3 9002 539 0 32088 dN 184915 SaS NGLEINOL 0229 H9IH 3 ONY ONIdId ONILN3A NULLO3NND2 N3SWON 0 AW Tad AWIL 9013934 2 gt 002 001 31IHA H 5 15931 19 30 DNILVM 503 SNULLOQNISNI D LSIX3 HS NULLO3NNO2 IVISIShT 3D 1915 1 39NVMD NU FH 3anivN3dW3l V NOLLVTWISNI OL 333438 GO NDIL33NND3 ay m 1109 NDILO3NNDO ON D NOILO3NNDJ 123811 31949 09 dSVHd 51 12900 s alg 39V 438 UNO E yoo CERA 5 v oL 10A Gi z S NBILShaWEOS 2 38 LSAW LI 3394838 01 33dd02 gt NOILISNNOD lt 1 LON SI NOI vds o 1 3ONvIlddv T3INDDNO 38 LSAW IIN x SNOILdO WWNOILdO BIST I31V3Vd3S 5 SV 350438 9 NDIL23NNU2 UN SUSHI 8 LIN Land 121515 ama 78 30 41 133NNDOSIQ
20. 10 Defective gas valve 10 Replace gas valve 24 Table 7 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION O Power ventor will not run Loose wiring Check and tighten all wiring connections per diagrams Thermostat wires tagged W and G must be connected together unless special thermostats are used if so see thermostat wiring diagram See Electrical Connections 2 Defective motor overload 2 Replace motor protector or defective motor 3 Defective power ventor relay 3 Check 24V across 1 and 3 terminals on fan relay If 24V is present jumper terminals numbered 2 and 4 If motor runs the relay is defective and must be replaced If 24V in not present check wiring per wiring diagrams P Power ventor motor turns 1 Fan relay heater element 1 Be sure ventor relay heater on and off while burners improperly wired terminals are connected per are operating diagrams 2 Defective ventor relay switch 2 Replace ventor motor 3 Motor protector cycling on and off 3 Check motor amps against motor name plate rating check voltage replace power ventor motor if defective 4 Motor not properly oiled 4 Refer to label on motor Q Power ventor motor will 1 Improperly wired ventor relay 1 Check all wiring not stop 2 Main burners not lighting while 2 Refer to H amp N Symptoms thermostat calls for heat 3 Defective ventor relay 3 Replac
21. 20 1 81 43 9 22 0 85 1 0 582 50 0 02 2 620 11 0 45 175 175 87 5 140 1 439 90 0 09 6 475 20 1 86 51 2 25 6 41 0 0 679 50 0 02 3 056 11 0 46 200 200 100 160 1 645 90 0 09 7 401 20 1 90 58 6 29 3 46 9 0 776 50 0 02 3 493 11 0 47 225 225 112 5 180 1 850 90 0 09 8 326 20 1 93 65 9 32 9 52 7 0 873 50 0 02 3 930 11 0 48 250 250 125 200 2 056 90 0 09 9 251 20 1 96 73 2 36 6 58 6 0 970 50 0 02 4 366 11 0 49 300 300 150 240 2 467 90 0 10 11 101 20 2 00 87 8 43 9 70 3 1 164 50 0 02 5 240 11 0 50 350 350 175 280 2 878 90 0 10 12 951 20 2 02 102 5 51 2 82 0 1 358 50 0 02 6 113 11 0 50 400 400 200 320 3 289 90 0 10 14 801 20 2 05 117 1 58 6 93 7 1 552 50 0 02 6 986 11 0 51 Ratings are shown for elevations up to 2 000 feet 610M above sea level Above 2 000 feet 610M input must derated 4 for each 1 000 feet 305M above sea level When units are installed in Canada any reference to derations at altitudes in excess of 2 000 feet 610M are to be ignored At altitudes of 2 000 to 4 500 feet 610 to 1372M the units must be orificed to 9096 of the normal altitude rating and be so marked in accordance with the CSA certification Pressure Drop inches water AT Temperature Rise TEMPERATURE RISE AND PRESSURE DROP GRAPH 1 6000 8000 Airflow CFM 5 10000 12000 14000
22. 435 X OV H 98 lt 031719905 59 JIJIA ONIDIANSS 380438 N3 Dd a NOILISNNOD ON 5 Ag LINN LONG 5 2 3Hl 30 JIx 193909514 0111 2 65 SNISSUNO JHIA AIANLIVANNYW AG 031959435 18 Figure 7 Standard Wiring Diagram for Unit with Johnson Ignition System JAWA 596 TI3AA3NDH Po SS CEA 9 a 1918 0 1 2 zi YAWAOASNVAL Ave t 1 AST zm ml AS AV130 3WIL NI SNI gt 201 3941 OV ASIT NOI a 1 L 300419373 92520 105 1 SES AN E Ld MOLINSI 0249 p P 1 1 G AVIAN 54015934 1 HH Bd pog aa Av130 EHE E 5013954 SLIDA i ve ENT 1 1 3 VA 0S Ste 3W3D3X Ave E 01 i 1 w _____ KU dh mm J 4 au 201 394
23. Burner orifice too large 3 Check with local gas supplier for proper orifice size and replace Refer to Operation Flame pops back 1 Excessive primary air 1 Close air shutter Refer to Operation 2 Burner orifice too small 2 Check with local gas supplier for proper orifice size and replace Refer to Operation Noisy flame 1 Too much primary air 1 Close air shutter 2 Noisy pilot 2 Reduce pilot gas Refer to Operation 3 Irregular orifice causing whistle or 3 Replace orifice resonance 4 Reset manifold pressure Refer to 4 Excessive gas input Operation Replace regulator section of combination gas valve or complete valve or Check with local gas supplier for proper orifice size and replace Refer to Operation Yellow tip flame some 1 Insufficient primary air 1 Open air shutter Refer to yellow tipping on propane Operation gas is permissible 2 Clogged burner ports 2 Clean main burner ports 3 Misaligned orifices 3 Replace manifold assembly 4 Clogged draft hood 4 Clean draft hood 5 Air shutter 5 Check for dust or lint at air mixer opening and around air shutter 6 Insufficient combustion air 6 Check for obstruction in combustion air inlet cap and piping See Installation Floating flame 1 Blocked Venting 1 Clean flue Refer to Installation 2 Insufficient combustion air 2 Check for obstruction in combustion air inlet cap and piping See Installation
24. Check belt tightness Cycle and check all other controls not listed Check operation of remote panel BLOWER With power and gas off o Entering air temp F or C Check voltage L1 12 L3 Discharge air temp high fire F or C Check rotation of main blower External static pressure in W C Check motor amps L1 12 L3 1 Cycle by thermostat or operating control 1 Blower RPM Check air filters Record quantity 8 size Remarks
25. IONS 4119 lt _ SEE DETAIL A A REF REF NO DESCRIPTION NO DESCRIPTION 1 Blower Housing Assembly 14 Junction Box Cover 2 Speed Nut 15 Snap Bushing 3 Motor 16 Relay Motor 4 Washer Plain 17 Draftor Stack Assembly 5 Plate Adapter 18 Tubing Aluminum Formation 6 Blower Wheel 19 Male Connector 7 Mounting Bracket Pressure Switch 20 Locknut 8 Mounting Bracket Junction Box 21 Hole Plug 9 Screw S T 22 Pressure Switch Cover 10 Screw Machine L 3 4 23 Drill Screw 11 Nut Keps Ext Lock Washer 24 Junction Box Base 12 Air Pressure Switch 25 Relay Purge 13 Drill Screw NOTES 1 For item No 6 use counter clockwise rotation 2 DO NOT OVERTIGHTEN CELCON NUT HAND TIGHTEN ONLY DO NOT USE TOOLS Approximate 1 3 turn maximum or 8 inch pounds is sufficient from the point where the tube does not slip in or out 3 Flue Sizes 100 175 units 4 dia flue outlet Reducer required To be supplied by installer 200 250 units 5 dia flue outlet no adaptor required on flue 300 400 units 6 dia flue outlet Increaser required To be supplied by manufacturer 21 Table 7 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION Flame lifting from burner ports Pressure regulator set too high Reset manifold Pressure Refer to Operation 2 Defective regulator 2 Replace regulator section of combination gas valve or complete valve 3
26. IT FOR SUPPORT FAILURE TO HEED THESE WARNINGS MAY RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH INSTALLATION Continued ELECTRICAL CONNECTIONS A WARNING HAZARDOUS VOLTAGE disconnect ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING Failure to disconnect power before servicing can cause severe personal injury or death Standard units are shipped for use on 115 volt 60 hertz single phase electric power The motor name plate and electrical rating of the transformer should be checked before energizing the duct furnace electrical system All external wiring must conform to the latest edition of ANSI No 70 National Electrical Code and applicable local codes in Canada to the Canadian Electrical Code Part 1 CSA Standard C22 1 CAUTION Do not use any tools i e screwdriver pliers etc across the terminals to check for power Use a voltmeter A CAUTION USE COPPER CONDUCTORS ONLY UNIT TERMINALS ARE NOT DESIGNED TO ACCEPT OTHER TYPES OF CONDUCTORS Failure to do so may cause damage to the equipment It is recommended that the electrical power supply to each duct furnace be provided by a separate fused and permanently live electrical circuit A disconnect switch of suitable electrical rating should be located as close to the gas valve as possible Each duct furnace must be electrically grounded in accordance with the latest edition
27. OR NATURAL GAS Select the pipe size directly 4 Refer to PIPE INSTALLATION Install the gas piping in accordance with applicable local codes Check gas supply pressure Each duct furnace must be connected to a manifold pressure and a gas supply capable of supplying its full rated capacity as specified in Table 5 A field LP tank regulator must be used to limit the supply pressure to a maximum of 14 W C 3 5 kPa All piping should be sized in accordance with the latest edition of ANSI Standard Z223 1 National Fuel Gas Code in Canada according to CGA B149 See Tables 1 4 amp 5 of this manual for correct gas piping size If gas pressure is excessive on natural gas applications install a pressure regulating valve in the line upstream from the main shutoff valve Adequately support the piping to prevent strain on the gas manifold and controls To prevent the mixing of moisture with gas run the take off piping from the top or side of the main Duct furnaces are shipped with a combination valve which includes a Manual A valve b Manual B valve c Solenoid valve d Pilot safety e Pressure regulator Pipe directly into the combination valve see Figure 11 A 1 8 N P T plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the appliance Provide a drip leg in the gas piping near the gas duct furnace A ground joint union and a manual gas shutoff v
28. Pa must be maintained for proper operation of the duct furnace If the unit is equipped with a pressure regulator on the combination gas valve follow steps a through d above If the unit is not so equipped the propane gas supply system pressure must be regulated to attain this manifold operating pressure 18 Table 6 Main Burner Orifice Schedule TYPE OF GAS NATURAL PROPANE HEATING 1075 BTU F 2500 BTU Ft INPUT VALUE 40 1 MJ m 93 1 MJ m9 IN NO OF 1000 MANIFOLD 8 5 W C 10 5 W C BURNER PRESSURE 0 9 kPa 2 6 kPa ORIFICES FT 96 40 100 ORIFICE DRILL 42 54 120 50 125 ORIFICE DRILL 42 54 FT HR 140 60 150 ORIFICE DRILL 42 54 163 70 175 ORIFICE DRILL 42 54 f FT 186 80 200 ORIFICE DRILL 42 54 210 90 225 ORIFICE DRILL 42 54 i FT 233 100 250 ORIFICE DRILL 42 54 19 FT 280 120 300 ORIFICE DRILL 42 54 12 326 140 350 ORIFICE DRILL 42 54 14 FT 372 160 400 ORIFICE DRILL 42 54 38 This schedule is for units operating at normal altitudes of 2000 ft 610m or less Special orifices are required for installations above 2000 feet 610m When installed in Canada any references to deration at altitudes in excess of 2000 feet 610m are to be ignored At altitudes of 2000 to 4500 feet 610 to 1372m the unit heaters must be orificed to 90 of the nor
29. Reassemble the gas duct furnace by replacing all parts in reverse order Complete the appropriate unit start up procedure as given in the Operation section of this manual see unit lighting instruction plate and the unit nameplate Check the burner adjustment See Primary Air Shutter Adjustment section in this manual Check all gas control valves and pipe connections for leaks Check the operation of the automatic gas valve by lowering the setting of the thermostat stopping the operation of the gas duct furnace The gas valve should close tightly completely extinguishing the flame on the main burners Inspect and service the blower section of the system Check and test the operational functions of all safety devices supplied with your unit Figure 15 Internal Furnace Assembly MANIFOLD amp MAIN BURNERS INCLUDED IN BURNER COMPARTMENT ASS Y Figure 16 Power Venter Assembly REDUCER TO SUIT IF REQ SEE NOTE 3 STD HORIZONTAL LEFT VENT POSITION FACTORY INSTALLED POSITION 019 THIS END ALTERNATE VERTICAL VENT POSITION FIELD MODIFICATION USE THIS ASSEMBLY FOR ALTERNATE lt FIELD MODIFIED HORIZONTAL RIGHT VENT POSITION 2 ALT HORIZONTAL RIGHT VENT POSITION FIELD MODIFICATION POWER USE THIS ASSEMBLY FOR ALT VERTICAL VENT AND STD EN FACTORY INSTALLED HORIZONTAL LEFT VENT POSIT
30. There may be momentary and spasmodic orange flashes in the flame This is caused by the burning of airborne dust particles and should not be confused with yellow tipping which is a stable or permanent situation when there is insufficient primary air Figure 13 Main Burner Flames A N x N A f N r 4N Q O CJ co J N V N NORMAL LIFTING YELLOW TIPPING YELLOW FLAME HARD FLAME TOO MUCH AIR MARGINAL TOO LITTLE AIR SHUT DOWN 1 Turn the valve selector knob to the OFF position 2 Turn off the electricity 3 To relight follow Initial Lighting instructions 19 PERIODIC SERVICE A WARNING Open all disconnect switches and secure in that position before servicing unit Failure to do so may result in personal injury or death from electrical shock A WARNING Gas tightness of the safety shut off valves must be checked on at least an annual basis To check gas tightness of the safety shut off valves turn off the manual valve upstream of the appliance combination control Remove the 1 8 inch pipe plug on the inlet side of the combination control and connect a manometer to that tapping Turn the manual valve on to apply pressure to the combination control Note the pressure reading on the manometer then turn the valve off A loss of pressure indicates a leak If a leak is detected use a soap solution to che
31. alve should be installed ahead of the unit heater controls to permit servicing The manual shutoff valve must be located external to the jacket See Figure 11 Make certain that all connections have been adequately doped and tightened A CAUTION Do not over tighten the inlet gas piping Figure 11 Pipe Installation Standard Controls A MANUAL SHUT OFF VALVE WITH 1 8 IN N P T PLUGGED TAPPING ACCESSIBLE FOR TEST GAGE CON NECTION MUST BE INSTALLED IMMEDIATELY UPSTREAM OF THE GAS SUPPLY CONNECTION TO THE APPLIANCE WHEN INSTALLED WITHIN THE COMMONWEALTH OF MASSACHUSETTS A T HANDLE AS COCK MUST BE USED REL 7 H3 TO UNIT GAS VALVE 3 MIN GROUND JOINT UNION Cem MIN PLUGGED 8 IN N P T TEST DRIP POCKET D3631C GAGE CONNECTION Never use an open flame to detect gas leaks Explosive conditions may exist which will result in personal injury or death The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system in excess of 1 2 psig 8 5 kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 8 5 kPa Table 5 Gas Requirements
32. bustion air system must be installed to prevent collection of condensate Pitch horizontal pipes downward 1 4 inch per foot 21mm m toward the inlet cap to facilitate drainage Vertical combustion air pipes should be arranged as depicted in Figure 9 The equivalent length of the combustion air system must not be less than 5 feet 1 5m and must not exceed 50 feet 15 2m Equivalent length is the total length of straight sections PLUS 15 feet 4 6m for each 90 elbow and 5 feet 1 5m for each 45 elbow T NOTICE For optimum performance keep the combustion air system as straight as possible 8 Each slip joint must be secured with at least three corrosion resistant screws Two full turns of 3M 425 Aluminum Foil Tape or its equivalent must be used to seal each joint General Electric RTV 108 Dow Corning RTV 732 or an equivalent may be used instead of the tape For horizontal combustion air systems longer than 5 feet 1 5m the system must be supported from overhead building structures at 3 foot 1m intervals EXHAUST VENTING A WARNING Never operate duct furnaces without combustion air and flue gas piping in place or severe personal injury or death may occur Vent system installation must be in accordance with the latest edition of National Fuel Gas Code NFPA 54 ANSI Z223 1 National Fuel Gas Code In Canada installation must be in accordance with CGA B149 1 Installation Code for Natural Gas Burning Applianc
33. ceeding 2 000 feet 610m above sea level derate the input by 4 for each 1 000 feet 305m rise above sea level Special orifices are required for installations above 2 000 feet When units are installed in Canada any reference to derations at altitudes in excess of 2 000 feet 610m are to be ignored At altitudes of 2 000 to 4 500 feet 610 to 1372m the units must be orificed for 90 of normal altitude rating and be so marked in accordance with CSA certification The following terms are used throughout this manual in addition to the CSA requirements to bring attention to the presence of potential hazards or to important information concerning the product Indicates imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage A WARNING Indicates an imminently hazard ous situation which if not avoided could result in death serious injury or substantial property damage A CAUTION Indicates an imminently hazardous situation which if not avoided may result in minor injury or property damage NOTICE Used to notify of special instructions on installation operation or maintenance which are important to equipment but not related to personal injury GENERAL SAFETY INFORMATION A WARNING Failure to comply with the general safety information may result in extensive property damage severe personal injury or death
34. ck all threaded connections If no leak is found combination control is faulty and must be replaced before putting appliance back in service NOTICE The heater and vent system should be checked once a year by a qualified technician Should maintenance be required perform the following inspection and service routine 1 Inspectthe area near the unit to be sure that there is no combustible material located within the minimum clearance requirements listed in Table 3 A WARNING Under no circumstances should combustible material be located within the clearances specified in Table 3 Failure to provide proper clearances could result in personal injury or equipment damage from fire Figure 14 Combustion Chamber MANIFOLD PILOT ASSY RETAINER SPRING AIR SHUTTERS 20 10 11 Turn off the manual gas valve and electrical power to the duct furnace To clean or replace the main burners open the bottom panel and compress the spring by moving the burner toward the manifold Slide the opposite end of the burner downward from the locating slot while retaining spring is still compressed Pull the burners away from the heater With the burners removed wire brush the inside surfaces of the heat exchanger Remove any dirt dust or other foreign matter from the burners using a wire brush and or compressed air Ensure that all parts are unobstructed Inspect and clean the pilot burner if necessary
35. combustion air system installation must be in accordance with the latest edition of National Fuel Gas Code NFPA 54 ANSI Z223 1 National Fuel Gas Code In Canada installation must be in accordance with CGA B149 1 Installation Code for Natural Gas Burning Appliances and Equipment or CGA B149 2 Installation Code for Propane Burning Appliances and Equipment A Breidert Type L or Fields inlet cap furnished by the customer must be installed at the termination point of the combustion air system Figures 9 amp 10 NOTICE The top of the cap is to be no less than 12 inches from the top of the exhaust vent cap See Figures 9 amp 10 3 Each duct furnace MUST have its own combustion air system It MUST NOT be connected to other air intake systems 12 4 Use single wall pipe constructed of 26 gauge galvanized steel or material of equivalent durability and corrosion resistance for the combustion air System For installations in Canada use pipe constructed from 025 inch thick aluminum or 0 018 inch thick stainless steel A WARNING Never use a pipe a diameter other than that specified in Table 1 D dia flue opening Never use PVC ABS or other non metalic pipe for venting To do so may result in serious damage to the unit or severe personal injury or death 5 Longruns of single wall combustion air piping passing through an unheated space may require insulating if condensation becomes noticeable The com
36. ct furnace will affect the operation of the furnace and void the warranty INSTALLATION Continued If uniform air distribution is not obtained install additional baffles and or turning vanes in the ductwork Access panels large enough to observe smoke and reflected light and to detect the presence of leaks in the heating equipment are required both upstream and downstream from the gas duct furnace These panels must be sealed to prevent air leaks If allowed by local regulations install canvas connectors between the ductwork and fan discharge opening to eliminate the transmission of sound Figures 2 amp 3 illustrate recommended ductwork designs for both the straight through and elbowed air inlet arrangements AIR FLOW The installation is to be adjusted to obtain an air throughput within the range specified on the appliance rating plate Figure 2 Recommended Design for Field Installation of Ductwork for Straight through Arrangement CANVAS CONNECTOR FAN WHEEL AIR BAFFLE FX m MIN E IN GAS DUCT A FURNACE DIMENSION A 1 1 2 X DIMENSION B Figure 3 Recommended Ductwork Design for Elbowed Arrangement TURNING VANES v AIR BRE S CX CANVAS OS CONNECTOR _ LZ 8 GAS DUCT FURNACE 05626 2A lt x 610MM MIN N SYSTEM FAN U
37. ditions All precautions must be taken to perform this operation in a safe manner Unless otherwise specified the following conversions may be used for calculating SI unit measurements 1 foot 2 0 305 m 1000 BTU cu ft 37 5 MJ m 1 inch 25 4 mm 1000 BTU per hour 0 293 kW 1 gallon 3 785 L 1 inch water column 0 249 kPa 1 pound 0 453 CFM x 0 472 1 psig 6 894 kPa FPM 196 8 1 cubic foot 0 028m SPECIFICATIONS Table 1 A B C D Dia T Gas Inlet Weight Unit in in in in in Ib Size mm mm mm mm Nat LP kg 100 17 7 8 15 1 2 17 1 8 4 1 2 1 2 161 454 394 435 102 73 125 20 5 8 18 1 4 19 7 8 4 1 2 1 2 180 524 464 505 102 82 150 20 5 8 18 1 4 19 7 8 4 1 2 1 2 188 524 464 505 102 85 175 23 3 8 21 22 5 8 4 1 2 1 2 207 594 533 575 102 93 200 26 1 8 23 3 4 25 3 8 5 1 2 1 2 227 664 603 645 127 103 225 28 7 8 26 1 2 28 1 8 5 3 4 1 2 or 3 4 246 733 673 714 127 116 250 31 5 8 29 1 4 30 7 8 5 3 4 1 2 or 3 4 266 803 743 784 127 121 300 37 1 8 34 3 4 36 3 8 6 3 4 1 2 or 3 4 305 943 883 924 152 138 350 42 5 8 40 1 4 41 7 8 6 3 4 1 2 or 3 4 344 1083 1022
38. e pu Q 193NNDOS1q H y STON ig E tere IVLSUNS3HI 013934 Pr ss mg HOIH 5014954 ts e 09 1 81 NI 21 E NVj3 33A UD 18 waaay WwiIdsOl3Id 1301A LA do 268 3 9002 LIWI1 S3ana329Usd dN 14915 Salsa n S SH ANY OLINDI NV 9NIdld NLIN3A lt M3EWDN IAIA 0 AV 130 DIE 00v 001 H B 3 S01 15937 19 30 DNILYY 303 SNOLLODSISNI D LSIx3 27152214 80 1715 1 x Lona xe z m 5 3 n1v33dN3l Y DNIAVH NOILYVIWLSNI OL 53335 j lt NOLLO3NNO2 Jarm 209 UN NU NULLO3NNDJ 123310 z 31949 09 ASWHd gt 2 LINN S BIO 3MIA 03997933 5 e v 1N3NDdWD2 Di 5 LDA GU NDILSOQSWDO x 38 5 LI 035971934 SNDIOnINUO 400 ISN P LON 51 NOI 3093805 45 j LSAW 0 T30NDDMO 38 15 LINQx SNOLLdO IN3NUdWDO WNDILdD Bist I31V3Vd3S 13119915 SV IXIA ONIOIAYSS 380338 N3 Dd F NULLO3NNUO DN SYSHLO Lana S o 5 Oi 78 WNIOIMU JHL 30 IX 193NNDOSIT NULinv2 x SNISSUSS JUDA qamnaw nN 31v23vd3S 5
39. e using a soap solution or other approved method Never use an open flame to detect gas leaks Explosive conditions may exist which could result in property damage personal injury or death A WARNING Before attempting to light or 2 The power ventor is energized by the room thermostat relight the pilot wait 5 minutes to allow gas when a demand for heat is sensed The pressure which may have accumulated in the burner switch measures the differential pressure between compartment to escape Failure to heed this the air inlet and the exhaust vent systems If the warning could result in property damage differential is correct the indirect spark ignition system personal injury or death is energized 2 Turnon electrical power The duct furnace should now A WARNING Under no circumstances is the be under the control of the thermostat Set the unitto be fired if the power ventor is not operable or severe personal injury or death may occur thermostat to it s highest setting the power ventor motor should start and burner ignition occur Turn the thermostat to the lowest setting The burners and 3 The indirect spark ignition system consists of an ignition module a dual combination gas valve and a spark ignited pilot burner When the pressure switch is closed the pilot valve opens as a spark is generated to light the pilot When the flame is sensed by the flame sensing circuit the spark ceases and the main
40. e ventor relay R Not enough heat 1 Incorrect gas input 1 Refer to Operation 2 Heater undersized 2 This is especially true when heated space is enlarged Have heat loss calculated and compare to heater output 8096 of input Your gas supplier or installer can furnish this information If heater is undersized add additional heaters 3 Thermostat malfunction 3 Replace thermostat 4 Heater cycling on high limit 4 Check air movement through heat exchanger Check voltage to fan motor Clean power ventor motor 5 Check outside dampers if used 5 Adjust dampers accordingly T Too much heat 1 Thermostat malfunction 1 Replace thermostat 2 Heater runs continuously 2 Check wiring diagrams Check operation at valve Look for short such as staples piercing thermo stat wiring and correct Replace gas valve Refer to Operation U Cold air is delivered on start up Fan relay heater element improperly wired Be sure fan relay heater terminal are connected per diagrams 25 Table 7 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION V Cold air is delivered during heater operation Incorrect manifold pressure or input Voltage to unit too high Air through put too high Refer to Operation Check motor voltage with fan running Should be 115 volts AC Refer to Operation W No spark Thermostat not callin
41. er switch as sole means of disconnecting power when installing or servicing duct furnace Always disconnect power at main circuit breaker as described above Failure to do so could result in electrical shock Special attention must be given to any grounding information pertaining to this duct furnace To prevent the risk of electrocution the furnace must be securely and adequately grounded This should be accomplished by connecting a ground conductor between the service panel and the furnace To ensure a proper ground the grounding means must be tested by a qualified electrician Do not insert fingers or foreign objects into furnace or its air moving device Do not block or tamper with the heater in any manner while in operation or just after it has been turned off as some parts maybe hot enough to cause injury This furnace is intended for general heating applications ONLY It must NOT be used in potentially dangerous locations such as flammable explosive chemical laden or wet atmospheres In cases in which property damage may result from malfunction of the furnace a back up system or temperature sensitive alarm should be used CAUTION The open end of piping systems being purged shall not discharge into areas where there are sources of ignition or into confined spaces UNLESS precautions are taken as follows 1 by ventilation of the space 2 control of the purging rate 3 elimination of all hazardous con
42. es and Equipment or CGA B149 2 Installation Code for Propane Burning Appliances and Equipment A Breidert Type L or Fields vent cap furnished by the customer must be installed at the termination point of the vent system Figures 9 amp 10 3 INSTALLATION Continued Each unit MUST have its own vent system It MUST NOT be connected to other vent systems or to a chimney Use single wall pipe constructed of 26 gauge galvanized steel or material of equivalent durability and corrosion resistance for the vent system For installation in Canada use corrosion resistant and gas tight listed vent pipe conforming with local building codes or in the absence of local building codes with current CAN CGA B149 1 Installation Codes for Natural Gas Burning Appliances and Equipment or CAN CGA B149 2 Installation Codes for Propane Gas Burning Appliances and Equipment A WARNING Never use a pipe of a diameter For a VERTICAL vent pipe section that passes through a floor or roof an opening 4 inches 102mm greater in diameter is required The opening must be insulated and flashed in accordance with applicable installation codes A HORIZONTAL section of an exhaust vent system that passes through a combustible wall must be constructed and insulated as shown in Figure 10A 11 The top of a VERTICALLY VENTED exhaust system must extend at least 3 feet 1m above the roof surface that it passes through The point of termination for
43. g for heat No low voltage Close thermostat contacts 2 Check for 24V across 24V terminals 58600 Spark gap closed or too wide 3 Set gap to 0 1 Broken or cracked ceramic on 4 Replace pilot assembly spark electrode X Spark present but pilot Loose S8600 connections 1 Check all connections term does not light PV feeds 24V to pilot valve Improper gas pressure 2 Check pressure pressure that is either too high or too low may cause a problem Is spark in pilot gas stream 3 Spark should arc from electrode No pilot gas do not use match 4 Check pilot line for kinks Ensure to test presence of gas is easily there are no drafts detected by the odor Y Pilot lights Main valve Loose S8600 connections 1 Check connections term does not energize MV feeds main valve Cracked or broken sensor ceramic 2 Replace pilot assembly Check sensor spark lead for 3 Replace if needed continuity 4 f present replace main valve if Measure 24 volts from term not replace 58600 Igniter MV to term MV PV Z Hi Limit switch tripping Unit is overfiring 1 Manifold pressure too high adjust Burner orifices may be too large verify replace if req d Air flow too low 2 Increase air flow check fan size Check for proper voltage Defective switch 3 Replace 26 HOW ORDER REPLACEMENT PARTS Please send the following information to your local
44. gas valve opens to supply gas to the main burners Once the thermostat is satisfied the vent system and gas valve are simultaneously de energized stopping all gas flow to the unit The high limit switch interrupts the flow of electrical current to the main gas valve if the duct furnace becomes overheated The optional fan switch delays the operation of the fan for approximately 45 seconds once the thermostat is closed and continues fan operation for approximately 65 seconds after the thermostat opens The start up fan delay must not exceed 90 seconds from a cold start The wall thermostat supplied optionally is a temperature sensitive switch that operates the vent and ignition systems to control the temperature of the space being heated NOTICE The thermostat must be mounted on a vertical vibration free surface free from air currents and in accordance with the furnished instructions power ventor should stop operating immediately Reset the thermostat to the desired operational setting PRIMARY AIR SHUTTER ADJUSTMENT After the unit has been operating for at least 15 minutes adjust the primary air flow to the burners Turn the friction locked manually rotated air shutters clockwise to close and counterclockwise to open For correct air adjustment close the shutter until yellow tips in the flame appear Then open the air shutter to the point just beyond where the yellow tipping disappears Refer to Figure 12 NOTICE
45. initial heat anticipator setpoint should equal the thermostat s current amperage draw when the unit is firing This setpoint should be measured for the best results Use the recommended ranges for a guide If further information is needed consult your thermostat manufacturer s instructions Recommended heat anticipator setting ranges 25 ft 7 6m T stat wiring 50 ft T stat wiring 0 85 to 0 90 A 0 90 to 1 1 A Max setting on t stat Figure 6 Standard Wiring Diagram for Unit with Honeywell Ignition System 110 ve V 0S Ah _ 90 T13 A3NUH qu q 191 1 K 2 Saree a XIWADASNYAL Ave 1 EEI zm AS 3WIL NI 3NI1 op lt q 5538 SDULJ3Vaa 3y NOI ANS E 0 LOW Are bi E 3 390519373 UE 5 a Fel e pos d AW GT 105 AW MDLINSI 00985 51 SDIINDI bd cx E AYTA par 5014954 HAH 2 1 pog aa e bg AVIS AWIL oO 3 T LIWII E 3013954 E 1 1 l 1 1 1 1 1 1 1 1 1 l 1 1
46. mal altitude rating and be so marked in accordance with the CSA certification deri ADJUSTMENT Remove the PILOT ADJUSTMENT CAP 5 Adjust the pilot screw to provide a properly sized flame 3 A proper flame is a soft steady flame that envelops 3 s to 1 2 inch 9 5 to 12 7mm of the flame sensor 4 Replace the pilot adjustment cap MANIFOLD PRESSURE ADJUSTMENT If the manifold pressure requires adjustment remove the cap from the pressure regulator and turn the adjustment screw clockwise to increase the pressure and counterclockwise to decrease the pressure The adjusted manifold pressure should not vary more than 1096 from the pressures specified in Table 6 OPERATION A CAUTION Never operate the unit beyond the specified limits or severe damage to and or premature failure of the unit will result INITIAL LIGHTING 1 Open the manual gas valve in the gas supply line to the duct furnace Loosen the union in the gas supply line to purge it of air Tighten the union and check for EXPLANATION OF CONTROLS 1 Each Separated Combustion Duct Furnace comes equipped with a power vent system that consists of a power ventor motor and blower pressure switch and sealed flue collector See Figure 16 A CAUTION The addition of external draft hoods or power ventors is not permitted Addition of such devices may cause serious unit malfunction or failure leaks NOTICE Check all pipe joints for leakag
47. of the National Electrical Code ANSI NFPA No 70 or CSA Standard C22 1 Sample wiring diagrams are shown in Figures 6 7 and 8 THERMOSTAT WIRING AND LOCATION NOTICE The thermostat must be mounted on a vertical vibration free surface free from air currents and in accordance with the furnished instructions Mount the thermostat approximately 5 feet 1 5m above the floor in an area where it will be exposed to a free circulation of average temperature air Always refer to the thermostat instructions as well as our unit wiring diagram and wire accordingly Avoid mounting the thermostat in the following locations 1 Cold Areas Outside walls or areas where drafts may affect the operation of the control 2 Hot Areas Areas where the sun s rays radiation or warm air currents may affect the operation of the control 3 Dead Areas Areas where the air cannot circulate freely such as behind doors or in corners NOTICE Thermostat wires tagged W and G must be connected together except when using a general purpose SPDT 24VAC relay and standard thermostat with a subbase or when using a Honeywell T834H or T834N thermostat Also refer to Figure 5 for other wiring connections Figure 5 C1267G TO UNIT HEATER pT BLACK BLUE 5 OR RED FOR LOW VOLTAGE THERMOSTAT WIRING WITHOUT SUMMER FAN SWITCH OPERATION THERMOSTAT HEAT ANTICIPATOR ADJUSTMENTS The
48. re leak test has been completed Connecting the unit before completing the pressure leak test may damage the gas valve and result in fire hazard A WARNING Do not rely on a shut off valve to isolate the unit while conducting gas pressure leak tests These valves may not be completely shut off exposing the gas valve to excessive pressure and damages PIPE SIZING To provide adequate gas pressure to the gas duct furnace size the gas piping as follows 1 Find cu ft hr by using the following formula _ Input Cu ft hr BTU Cu ft 2 Referto table 4 Match Length of Pipe in Feet with appropriate Gas Input Cu Ft Hr figure This figure can then be matched to the pipe size at top of the column Example It is determined that a 67 foot 20 4m run of gas pipe is required to connect a 200 MBTU gas duct furnace to a 1 000 BTU cu ft 0 29kW natural gas supply 200 000 BTU Hr _ 1 000 BTU Cu ft 200 Cu ft hr Using Table 4 a 1 inch pipe is needed PIPING NOTICE See General Safety Information section for English Metric unit conversion factors NOTICE If more than one duct furnace is to be served by the same piping arrangement the total cu ft hr input and length of pipe must be considered NOTICE If the duct furnace is to be fired with LP gas consult your local LP gas dealer for pipe size information NOTICE Heater installation for use with propane bottled gas must be
49. re the furnace output equals or exceeds heat loss CAUTION Do not install duct furnaces in a corrosive or flammable atmosphere Premature failure of or severe damage to the unit will result CAUTION Duct furnaces must not be installed in locations where air for combustion would contain chlorinated halogenated or acidic vapors If located in such an environment premature failure of the unit will occur ACCESSIBILITY The Separated Combustion Duct Furnace is a bottom service access type Allow a minimum of 25 inches 635mm at the bottom of the unit to facilitate servicing the burners and pilot Provision should be made to assure accessibility for recurrent maintenance purposes AIRCRAFT HANGARS Separated Combustion Duct Furnaces must be installed in aircraft hangars as follows Duct furnaces must be at least 10 feet 3 05m above the upper surface of wings or engine enclosures of the highest aircraft to be stored in the hangar and 8 feet 2 44m above the floor in shops offices and other sections of the hangar where aircraft are not stored or housed In Canada installation is suitable in aircraft hangars when acceptable to the enforcing authorities PUBLIC GARAGES In repair garages duct furnaces must be installed in a detached building or room separated from repair areas as specified in the latest edition of NFPA 88B Repair Garages In parking structures duct furnaces must be installed so
50. 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 SEPARATED COMBUSTION DUCT FURNACE T The Manufacturer warrants to the original owner at original installation site that our Separated Combustion Duct Furnace Product will be free from defects in material or workmanship for one 1 year from the date of shipment from the factory If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period the Manufacturer will repair or replace at its option that part of the Product which is shown to be defective 2 This limited warranty does not apply a if the Product has been subjected to misuse or neglect has been accidentally or intentionally damaged has not been installed maintained or operated in accordance with the furnished written instructions or has been altered or modified in any way by any unauthorized person b to any expenses including labor or material incurred during removal or reinstallation of the Product c to any damage due to corrosion by chemicals including halogenated hydrocarbons precipitated in the air d to any workmanship of the installer of the Product 3 This limited warranty is conditional upon a advising the installing contractor who
51. roper thermostat or 5 Check wiring per wiring diagrams transformer wiring at gas valve 6 Defective gas valve 6 Replace gas valve 7 Defective thermostat 7 Check thermostat and replace if defective 8 Defective transformer 8 Be sure 115 volts is supplied to the transformer primary then check for 24 volts at secondary terminal before replacing 9 Loose wiring 9 Check and tighten all wiring connections per diagrams 10 Defective ignition control 10 Replace if necessary Also see W X amp Y symptoms J Condensation of water 1 Condensation of water vapor 1 Refer to Installation Venting vapor K Burner won t turn off 1 Poor thermostat location 1 Relocate thermostat away from drafts 2 Defective thermostat 2 Replace thermostat 3 Improper thermostat or 3 Check wiring diagrams transformer wiring at gas valve 4 Short circuit 4 Check operation at valve Look for short such as staples piercing thermostat wiring and 5 Defective or sticking gas valve correct 6 Excessive gas supply pressure 5 Replace gas valve 6 Refer to Operation 23 Table 7 Troubleshooting Guide SYMPTOMS POSSIBLE CAUSE S CORRECTIVE ACTION L Rapid burner cycling Loose wire connections at gas Excessive thermostat heat Unit cycling on high limit Poor thermostat location Draft on pilot Defective ignitor control Defective high limit valve or thermostat
52. that the burner flames are located a minimum of 18 inches 457mm above the floor or protected by a partion not less than 18 inches 457mm high Refer to the latest edition of NFPA 88A Parking Structures In Canada installation must be in accordance with the latest edition of CGA B149 Installation Codes for Gas Burning Appliances and Equipment Separated Combustion Duct Furnaces should not be installed to maintain low temperatures and or freeze protection of buildings A minimum of 50 F 10 C thermostat setting must be maintained If duct furnaces are operated to maintain lower than 50 F 10 C hot flue gases are cooled inside the heat exchanger to the point where water condenses onto the heat exchanger walls The result is a mildly corrosive acid which prematurely corrodes the aluminized heat exchanger and can actually drip water down from the duct furnace onto the floor surface Additional duct furnaces should be installed if a minimum of 50 F 10 C thermostat setting cannot be maintained DUCTWORK Properly designed and installed ductwork providing a uniformly distributed flow of air across the surfaces of the heat exchanger is essential to satisfactory unit performance and life of the equipment All duct flanges seams must be sealed to prevent air leaks Sealant tape must be suitable for temperatures of 250 F 121 C minimum AWARNING Any attempt to straighten the 90 duct connection flanges on the du
53. to General Safety Information section for metric conversions 1 Turn off all gas appliances that use gas through the same meter as the unit heater 2 Turn the gas on to the unit heater 3 Clock the time in seconds required to burn 1 cubic foot of gas by checking the gas meter 4 Insert the time required to burn one cubic foot of gas into the following formula and compute the input rate 3600 Sec per Hr x BTU Cu Ft Input Rate Time Sec For example assume the BTU content of one cubic foot of gas is 1000 and that it takes 18 seconds to burn one cubic foot of gas 3600 x 1000 18 200 000 NOTICE If the computation exceeds or is less than 95 of the gas BTU hr input rating see Table 2 adjust the gas pressure Adjust the gas pressure as follows 1 NATURAL GAS Best results are obtained when the duct furnace is operating at its full rated input with the manifold pressure of 3 5 inches W C 0 9 kPa Adjustment of the pressure regulator is not normally necessary since it is preset at the factory However field adjustment may be made as follows a Attach manometer at the pressure tap plug below the control outlet b Removethe regulator adjustment screw cap located on the combination gas valve c With a small screwdriver rotate the adjustment screw clockwise to increase pressure d Replace regulator adjustment screw cap PROPANE GAS An exact manifold pressure of 10 0 inches W C 2 5 k
54. way or damage to the unit and or severe personal injury or death may occur A WARNING Never service any component without first disconnecting all electrical and gas supplies to the unit or severe personal injury or death may occur A CAUTION Ensure that all power sources conform to the requirements of the duct furnace or damage to the unit will result Follow installation instructions CAREFULLY to avoid creating unsafe conditions All wiring should be done and checked by a qualified electrician using copper wire only All external wiring must conform to applicable local codes and to the latest edition of the National Electric Code ANSI NFPA No 70 All gas connections should be made and leak tested by a suitably qualified individual per instructions in this manual Also follow procedures listed on the Gas Equipment Start Up sheet located in this manual Use only the fuel for which the duct furnace is designed see rating plate Using LP gas in a heater that requires natural gas of vice versa will create risk of gas leaks carbon monoxide poisoning and explosion A WARNING Do not attempt to convert furnace for use with a fuel other than the one intended Such conversion is dangerous as it will create the risks previously listed Make certain that the power source conforms to the electrical requirements of the furnace A WARNING Do not depend upon a thermostat or oth
55. xhaust vent system must remain at a minimum of 6 inches 152mm from all combustible materials Any part of the vent system that passes through a combustible material must be properly insulated NOTICE Increasing the clearance distance may be necessary If there is a possibility of distortion or discoloration of adjacent materials 13 must be at least 3 feet 1m above grade or above snow line more than 6 feet 2m from the combustion air inlet of another appliance more than 3 feet 1m from any building opening and more than 4 feet 1 3m from and not directly above any electric meter gas meter regulator or relief equipment See Vent Intake Installations in Figures 9 amp 10 Figure 9 Vertical Intake Vent Installation 6 FT MIN TO WALL R ADJOINING BUILDING EX APPROVED TERMINAL COMBUSTION AIR INLET ROOF FLASHING w MEI H 5 Y 9 TEE WITH DRIP LEG AND CLEANOUT CAP 18 IN CAT 2764 A Size according to expected snow depths If excessive condensation develops a drip leg with a condensate drain may be required Insulating pipes may eliminate the problem Figure 9A Horizontal Intake Vent Locations BUILD OVERHANG eq ADJACENT BUILDING Figure 10 Vertical Vent Installation
56. y cause cancer birth defects or other reproductive harm INSTALLER S RESPONSIBILITY 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 RECEIVING INSTRUCTIONS Inspect shipment immediately when en EZ ERE received to determine if any damage has occurred to the unit during uu 1 CRAL IN shipment After the unit has been HVAC PRODUCTS uncrated check for any visible 260 NORTH ELM ST WESTFIELD MA 01085 damage to the unit If any damage is TEL 413 564 5540 FAX 413 562 5311 found the consignee should sign www sterlinghvac com the bill of lading indicating such amp damage and immediately file claim SA A MESTEK COMPANY for damage with the transportation MODELS QVSD 100 thru 400 company 09 08 5 GENERAL SAFETY INFORMATION SEPARATED COMBUSTION DUCT FURNACE 1 2 3 SPECIFICATIONS iacit esc a e ba ui utn fue poa EC d i eadera A 4 PERFORMANCE DATA e nmmEEEEEmUE M TT 5 eI nic 6 INSTALLATION LOCATION sats 6 DUctWork AIF FIOW

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