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Sterling SDRIOM-2 manual

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Table of contents for the manual

  • Page 1

    FOR Y OUR SAFETY If y ou smell gas: 1. Open Windo ws 2. Don’ t touch electrical s witches. 3. Extinguish any open flame. 4. Immediately call y our gas supplier . A TTENTION: READ THIS MANUAL AND ALL LABELS A TT A CHED T O THE UNIT C AREFULL Y BEFORE A TTEMPTING T O INST ALL, OPERA TE OR SER VICE THIS UNIT! CHECK UNIT RA TING PLA TE FOR TYPE OF GA[...]

  • Page 2

    2 SECTION II - GENERAL INFORMA TION I. As is the case with any fine piece of equipment, car e must be tak en to pr ovide the pr oper attention to the operation and maintenance details of this machine. This manual of instructions has been pr epared in or der for you to become w ell-acquainted with those details, and in doing so , you will be able to[...]

  • Page 3

    3 This equipment must be installed and wir ed in accordance with regulations of the National Boar d of Fir e Under - writers, National Electrical Code, and local gov erning bodies. The following r ecommendations are not intended to supplant any r equirements of federal, state , or local codes ha ving jurisdiction. Authorities having jurisdiction sh[...]

  • Page 4

    4 D . Electrical Connections NO TE: Before installing an y wiring, check the unit rating plate for supply po wer rating. All electrical connections and wiring must conform to the curr ent edition of: ANSI/NFP A No . 70 National Electrical Code and applicable state and local codes. Entr y location for all field-installed and contr ol wiring is locat[...]

  • Page 5

    5 SECTION IV - PRE ST AR T -UP A. Pre Start-Up All equipment has been factor y tested, adjusted, metered and inspected to meet conditions set at the time the order was placed. Only minimal adjustments should be r equired. All information in this service manual is typical. All products are semi-custom and changes ma y occur . Suggested T ools and In[...]

  • Page 6

    6 SECTION V - UNIT ST AR T -UP Close or replace all doors and service panels. T urn main disconnect switch off. V erify the incoming line voltage matches the unit nameplate rating. If the voltage is ov er ±10% of nameplate rating or phase voltage unbalance is ov er 2%, notify the contractor or power compan y . T urn Heat OFF/ON switch to the OFF p[...]

  • Page 7

    7 SECTION VI - UNIT SHUTDO WN C. Gas Pressure Switches - Operate unit in Heat mode. The low pr essure s witch will trip out and must be r eset befor e resuming operation when the inlet gas valv e is turned off during operation. The high pressur e swi tch ma y be checked out by r educing the setting of its trip point below unit operating pr essure. [...]

  • Page 8

    1. Low or no voltage. 2. Fuse(s) blown. 3. Customer interlock not closed or connected. 4. Fan Off-On switch in Off position. 5. Time clock, night setback thermo- stat or field installed controls open. 6. Freeze protection tripped. 7. Damper motor not operating, or its end switch not making. 8. Overload protection on motor starter tripped. 9. Belts [...]

  • Page 9

    9 SECTION VII – TR OUBLESHOO TING Symptom Cause Remedy C. continued D . Burner will not respond to tem- perature. 9. Defective gas valve or actuator . 10. Defective spark r od or out of position. (see spark rod diagram #P-001004) 11. Flame rod not sensing flame. (see spark rod diagram #P-001003) 12. Defective r egulator . 13. Blocked v ent lines [...]

  • Page 10

    10 SECTION VII – TR OUBLESHOO TING P-001004 P-001003[...]

  • Page 11

    1. Modulating valve improperl y installed (or see Symptom “L ”). 1. Shor t circuit or no voltage to the amplifier . 2. Open circuit in TD114 Remote T emperature Selector circuit or wiring. 3. Shor t circuit in TS114 Discharge Air Sensor circuit of wiring. 4. Faulty amplifier . 1. Shor t circuit or open circuit in Modulator Coil. 2. Plunger miss[...]

  • Page 12

    12 Symptom P ossible Cause Field T est Remedy E. Continuous High Fire (Electr onics Problem). F. Continuous High Fire (Electr onics OK). G. Incorr ect Maximum Fir e. H. Erratic or Pulsating Flame 1. Shor t circuit in TD114 Remote T emperature Selector circuit or wiring. 2. Open circuit in TS114/TS1007 Discharge or Inlet Air Sensor circuit or wiring[...]

  • Page 13

    4. With test resistor connected (per item H2) and TD114 locally connected (per item H3) turn TD114 selector dial through entir e modulating range. Obser ve D .C. voltage acr oss modulator terminals. 1. Inlet Air Sensor changes 1° or each 3.5°, 5° or 8° outside temperature change from 60° (pr edetermined - turndown varies with model used). 2. C[...]

  • Page 14

    14 Symptom P ossible Cause Field T est Remedy 1. V alve impr operly installed. 1. Open circuit in modulator coil. 2. Plunger missing, jammed or improperl y installed. 3. Ruptured main or balancing diaphragm. 1. No voltage to the amplifier . 2. Shor t in modulator coil circuit. 3. Shor t in TS144 cir cuit. 4. Faulty amplifier . 1 . Incorrect by-pass[...]

  • Page 15

    15 Symptom P ossible Cause Field T est Remedy E. continued F . Incorr ect Maximum or Minimum Discharge Air T emperature. G. Continuous High Fire (Electr onics OK). H. Continuous High Fire (Electr onics Problem). I. Incorr ect High Fire J. Continuous Maximum Discharge Air T emperature. K. Burned out T ransformer . No V oltage to Amplifier . 3. Follo[...]

  • Page 16

    16 L. Incorr ect Space T emperature 1. Incorrect maxim um discharge air temperature setting (A1044). 2. Incorrect minim um discharge air temperature setting (A1044). 3. Insufficient burner capacity . 4. Incorrect space temperature calibration. 1. Check to see if heater is delivering air at maxim um discharge air setting. 2. Check to see if heater i[...]

  • Page 17

    1. T urn off gas supply . 2. Set thermostat or controller abov e r oom temperature to call for heat. 3. W atch for ignition spark or for glow at hot surface igniter either immediately or follo wing prepurge. See IP module specifications. 4. Time the length of the spark operation. See the IP module specifications. 5. After the module locks out, open[...]

  • Page 18

    18 B. Lubrication Instructions Item Manufactur er Bearing T ype A slight showing of gr ease at the seals with accompanying normal bearing temperature indicates pr oper lubrication. Normal temperature can range fr om “cool” to “hot to the touch” depending on size, speed and surr ounding conditions. Excessive bearing temperatur e indicates fa[...]

  • Page 19

    19 D . Belt T ension and Adjustment Belt tension is adjusted during the initial run-in and test periods at the factor y . Howe ver , the belts are run as slack as possible to pre v ent excessive damage to the bearings, yet tight enough to pr event slippage. It is necessar y , therefor e, to check belt tension during the first few months of operatio[...]

  • Page 20

    20 c. Put system back into operation and view burner while cycling through full firing range. This will giv e a visual check for block ed burner por ts. Clean burner ports as necessar y using a #47 drill. Burner plates should be cleaned with a wire brush at least once a year . 2. Inspect the flame r od and ignition electr ode for dirt and moisture.[...]

  • Page 21

    21 SECTION X - MAXITROL V AL VE ADJUSTMENTS AND PRELIMINAR Y CIRCUIT ANAL Y SIS MR212 V alve High Fire Manif old Adjustments 1. Disconnect wires fr om amplifier terminal #4 (Series 14), or #2 and #4 (Series 44). This causes the valve to call for continuous high fir e . 2. Remove seal ca p (A) and turn regulator pr essure adjusting scre w to obtain [...]

  • Page 22

    22 PRELIMINAR Y CIRCUIT ANAL Y SIS - SY STEM 14 For ease in tr oubleshooting, it is advisable to wire the system as follows (this diff ers fr om the normal connection). The Discharge Air Sensor is disconnected and replaced with a 10,000 ohm,1/2 watt test resistor (terminals 3 and 4). If inlet air sensor is being used, disconnect and replace with a [...]

  • Page 23

    23 Section 4 1. With proper v oltages observed thus far and modulator responding cor rectl y , wire the system (see Figure 1), except ha v e TS144 connected in place of jumper . Set A1044 MIN temperature selector at least 10°F abo ve outdoor temperature. Set A1044 MAX temperature selector at mid-range. Heater is now under control by TS144 Discharg[...]

  • Page 24

    24 FOR CANADIAN INST ALLA TIONS ONL Y 1. All installations must conform with local building codes, or , in the absence of local codes, with current CAN/CGA-B149- Installation Codes For Gas Burning Appliances and Equipment. 2. All electrical connections must be in accordance with Canadian Electrical Code, Part 1, CSA Standard C22.1. All electrical c[...]