Sterling GG-105 manual

(S) DSGG-IOM-1 J30-08511 INST ALLER'S RESPONSIBILITY Installer Please Note: This equipment has been test fired and inspected. It has been shipped free from def ects from our f actor y . Howe ver , shipment and installation problems such as loose wires , leaks, or loose f asteners ma y occur . It is the installer's responsibility to inspec[...]

2 T ABLE OF CONTENTS The f ollowing terms are used throughout this manual, in addition to the ETL requirements to bring attention to the presence of potential hazards, or to important information concer ning the product: Indicates an imminently hazar dous situation which, if not av oided, will result in death, serious injur y , or substantial pr op[...]

3 GENERAL SAFETY INFORMA TION Failure to compl y with the general safety inf ormation may result in e xtensive property damage, severe personal injury , or death. This product m ust be installed by a licensed plumber or gas fi tter when installed within the Commonwealth of Massachusetts. Installation must be made in accor dance with local codes, o[...]

4 T ab le 1 - Perf ormance and Dimensional Data - T ubular 30 thru 120 Pr opeller Unit Heater Unit Size 30 45 60 75 90 105 120 PERFORMANCE D A T A† Input - BTU/Hr . 30,000 45,000 60,000 75,000 90,000 105,000 120,000 (kW) (8.8) (13.2) (17.6) (22.0) (26.4) (30.8) (34.2) Output - BTU/Hr . 24,300 36,450 48,600 60,750 72,900 85,050 97,200 (kW) (7.1) ([...]

5 Figure 2 - Dimensional Drawing – T ubular 30 thru 120 Pr opeller Unit Heater DIMENSIONS .XXX ST ANDARD UNITS DIMENSIONS IN P ARENTHESIS (XXX) MILLIMETERS[...]

6 INST ALLA TION Do not install unit heaters in corrosive or fl ammable atmospheres! Premature failure of, or severe damage to the unit will result! A void locations where extreme drafts can affect b urner operation. Unit heaters must not be installed in locations where air for comb ustion would contain chlorinated, halogenated or acidic vapors. I[...]

7 INST ALLA TION (continued) The Unit Heater ma y be mounted by f astening the hanging brack ets directly to ceiling joists or by suspending from f our rods. See Figures 3, 4 and 5. Make certain that the lifting methods used to lift the heater and the method of suspen- sion used in the fi eld installation of the heater are capable of unif ormly su[...]

8 GAS PIPING T o a void dama ge 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 dama ge the unit gas valve and result in a fi re hazard. Do not rely on a shut-off v alve to isolate the unit while conducti[...]

9 Do not over tighten the inlet gas piping into the valve. This ma y cause stresses that will crack the v alve! NO TICE: Use pipe joint sealant resistant to the action of liquefied petroleum gases regar dless of gas conducted. Check all pipe joints f or leakage using a soap solution or other appro ved method. Never use an open flame or se vere pers[...]

10 HAZARDOUS V OL T A GE! DISCONNECT ALL ELECTRIC PO WER INCLUDING REMO TE DISCONNECTS BEFORE SER VICING. Failure to disconnect power bef ore servicing can cause severe personal injury or death. Standard units are shipped f or use on 115 volt, 60 hertz, single phase electric power . The motor name-plate and electrical rating of the transf or mer sh[...]

11 ELECTRICAL CONNECTIONS (continued) Figure 11A - Honeywell Contr ol Board Figure 10A - UT Control Boar d[...]

12 ELECTRICAL CONNECTIONS (continued) Figure 10B - T ub ular Propeller Units 30-120 with Natural and Propane (LP) Gas with Single Stage Gas Control and UT Control Boar d NO TICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater . If using a standard low v oltage thermostat with a sub-base switch f or fan c[...]

13 Figure 10C - T ub ular Propeller Units 60-120 with Natural and Propane (LP) Gas with Optional T w o Stage Gas Control and UT Control Boar d ELECTRICAL CONNECTIONS (continued) NO TICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater . If using a standard low v oltage thermostat with a sub-base switch f [...]

14 ELECTRICAL CONNECTIONS (continued) Figure 11B - T ub ular Propeller Units 30-120 with Natural and Propane (LP) Gas with Single Stage Gas Control and Honeywell Contr ol Board NO TICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater . If using a standard low v oltage thermostat with a sub-base switch f o[...]

15 Figure 11C - T ub ular Propeller Units 30-120 with Natural and Propane (LP) Gas with Optional T w o Stage Gas Control and Honeywell Contr ol Board ELECTRICAL CONNECTIONS (continued) NO TICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater . If using a standard low v oltage thermostat with a sub-base sw[...]

16 VENTING* All unit heaters m ust be vented! All V enting installations shall be in accordance with the latest edition of P ar t 7, V enting of Equipment of the National Fuel Gas Code , ANSI Z223.1, or applicable pro visions of local building codes . Ref er to notes* below f or Canadian installations. Refer to Figures 12-19. CARBON MONO XIDE! Y ou[...]

17 VENTING - GENERAL GUIDELINES V enting Categories Non Condensing Condensing Negative V ent I II Pressure P ositive V ent III IV Pressure The f ollowing guidelines apply to all categories to f ollow . T ab le 4 Do not damper or add heat recov er y devices to the fl ue piping. F ailure to open such a damper pr ior to operating the gas unit heater [...]

18 4 . Slope horizontal runs upward from the gas unit heater at least 1/4-inch per f oot (21mm/m) minimum. Horizontal V ent Connector length should not e xceed 75% of the vertical height of the vent pipe f or single wall, or 100% of the v er tical height f or B-V ent connectors . Maximum v ent connector length is 10 f eet (3m). For e xceptions see [...]

19 T ab le 5 - Category I Horizontal V enting Requirements - Standard Comb ustion V ent Maxim um Number Maxim um Horizontal Minim um Extension Unit Diameter Elbows V ent Length V er tical Rise Distance Size (in) * (Ft.) (In.) from W all (In.) 30 4 1 5 8 36 4 2 10 18 36 45 4 1 10 24 36 4 1 15 24 36 4 2 5 24 36 60 4 2 10 18 36 75 5 2 7 24 36 90 5 2 7[...]

20 Figure 14 - V ent Support D- 068 39A[...]

21 HORIZONT ALL Y VENTED , CA TEGOR Y III - Figure 15 Obser v e the follo wing precautions when venting the unit: 1. Use fl ue pipe of the same siz e as the fl ue connection(s) on the gas unit heater , 4" (102mm). All heaters must be v ented with a single or double w all pipe listed f or categor y III positive pressure vent systems . T ype B[...]

22 VER TICALL Y VENTED , CA TEGOR Y III – Figure 17 & 19 Obser v e the follo wing precautions when venting the unit: 1. Use fl ue pipe of the same size as the fl ue connection(s) on the gas unit heater , 4" (102mm). All heaters must be v ented with a single or double w all pipe listed f or positive pressure v ent systems. 2. Each unit [...]

23 Figure 15A - Category III Horizontal V enting Requirements Using Single W all V ent Pipe Figure 15B - Category III Horizontal V enting Requirements Using T ype B Double W all V ent Pipe Figure 15C - T ype B Draft Hood Connector[...]

24 Figure 16 Figure 17 VENTING (continued)[...]

25 VENTING (continued) Figure 18 Figure 19[...]

26 INST ALLA TION - VENTING – CA TEGOR Y III COMBUSTION AIR VENTING AND PIPING Never operate unit heater s without combustion air and flue gas piping in place or severe per sonal injury or death may occur! CARBON MONO XIDE! Y our venting system must not be bloc ked by any sno w , sno w drifts, or any f oreign matter . Inspect your venting system [...]

27 VENTING (continued) 4. Use single wall pipe constructed of 26 GA galvaniz ed steel or a material of equivalent durability and corrosion resistance f or the vent system. F or installations in Canada, use corrosion resistant and gas-tight, listed vent pipe conf or ming with local building codes , or in the absence of local building codes , with cu[...]

28 Figure 22 - V ertical Intake/V ent Installation Figure 21 - Concentric V ent Installation[...]

29 Figure 23 - Horizontal Intake/V ent Installation Figure 24 - Horizontal Intake/V ent Installation VENTING (continued) Vent Terminal (1.8M Min.) Adjacent Building D 3330 6'-0" Min. (0.9M Min.) 3'-0" Min. Building Overhang[...]

30 VENTING (continued) AIR INLET COLLAR Remov e screen and mounting plate from air inlet on rear panel of unit by remo ving 4 screws . Secure inlet collar and gasket to inlet opening re-using the 4 scre ws remov ed in step one. EXHA UST AIR COLLAR Secure 5-4” reducer to flue collar on rear panel of unit sizes 090, 105 and 120. Seal per e xhaust v[...]

31 OPERA TION PO WER VENTED PROPELLER UNITS DIRECT SP ARK IGNITION EXPLANA TION OF CONTROLS (See Figure 25): 1 . Each Unit Heater comes equipped with a power vent system that consists of a po wer venter motor and blo wer , pressure s witch, and sealed flue collector in place of the conv entional draft diverter . 2 . The power v enter motor is energ[...]

32 PRIMAR Y AIR SHUTTER ADJUSTMENT Primar y air adjustment is made at the factory . No fi eld adjustments are necessary . GAS INPUT RA TE Check the gas input r ate as follo ws (Refer to General Saf ety Information section f or metric conversions). Never o verfi re the unit heater , as this may cause unsatisfactory operation, or shor ten the life [...]

33 9.3 9.2 9.0 8.9 8.7 8.5 8.3 8.1 NA TURAL GAS MAINTENANCE PERIODIC SER VICE 3. Remov e ser vice access panel. 4. T o clean or replace the burner , remove retainer from around manif old orifi ce, disconnect fl ame sensor and igniter from control board, remov e bur ner assemb ly mounting screws . See Figure 25. 5 . With the burner remov ed, wire [...]

34 1. Check f or proper or ifi ce size . Refer to “Operation”. 2. T est and reset manifold pressure. 1. Replace orifi ce . 2. T est and reset manifold pressure. 1. Clean main burner por ts. 2. Align manifold assemb ly . 3. Clean combustion air inlet openings. 4. Check gas input and manif old pressures. 1. Clean Flue. Refer to “Installation?[...]

35 1. Relocate thermostat awa y from outside wall or drafts . 2. Check thermostat circuit for open and close on terminal str ip on heater “R” and “W”. 3. Check thermostat circuit for shorts “staples piercing wires”. 4. Check f or 24v on gas valve terminals when thermostat is not calling. 5. Refer to “Installation”. 1. Tighten all el[...]

36 1. Incorrect manifold pressure or input. 1. Unit is ov er fi red. 2. Air fl ow is lo w . 3. Defectiv e switch. 4. Defectiv e control board. 1. Loose wiring or connections. 2. Motor ov erload is tr ipped or bad motor . 3. Bad control board. 1. P ower venter improperly wired. 2. Motor ov erload cycling or defective motor . 3. Defectiv e control [...]

37 Line v oltage power can cause product dama ge , severe injury or death. Only a trained e xperienced service technician should perform this tr ouble- shooting. 1. Check the system thermo- stat to make sure it is call- ing f or heat. (Do not cycle the thermostat on and off at this time.) 2. Remov e the access panel. Do not interrupt power to the c[...]

38 T ab le 10B - T roub leshooting with LED Indicator Assistance for Hone ywell Control Boar d Not Applicable Not Applicable 1. Check pressure s witch to see if open to star t, if not replace switch. 2. Air fl ow s witch jumpered. Remove jumper and chec k operation. 1. Look for obstruction or restrictions in appliance air intake or fl ue outlet t[...]

39 IDENTIFICA TION OF P ARTS RESIDENTIAL TUBULAR 30-120 MBH UNIT SIZES 1 V estible P anel/T ube Assembly (Heat Exchanger) 2 Br acket/Gas T rain 3 Manif old 4 Burner Assembly 5 *Standard Orifi ce Natural Gas or Propane (LP) Gas 6 Spark Ignitor 7 Flame Sensor 8 Gas V alve Natural or Propane (LP) Gas 9 Manual Rollout Safety Switch 10 T ransformer , 5[...]

40 IDENTIFICA TION OF P ARTS RESIDENTIAL TUBULAR 30-120 MBH UNIT SIZES Figure 28 - Internal Furnace Components Figure 26 - Propeller P ar ts Figure 27 - Component P ar ts Figure 29 - P ower V entor Assembl y D4810 NO TE: No rubber grommets are supplied with the 30 and 45 unit sizes. Gas V alve D4430 F an Guard F an Blade Hardware Hardware Motor D69[...]

41 HO W T O ORDER REPLA CEMENT P ARTS Please send the f ollowing inf or mation to your local representativ e: if fur ther assistance is needed, contact the manuf acturer's customer ser vice depar tment. •Model Number •Serial Number •P ar t Description and Number as shown in Replacement par ts Catalog LIMITED W ARRANTY Residential P ower [...]

42 11 - Supply V olta ge [SV] 1 - 115/1/60 4 - 208/3/60 7 - 575/3/60 2 - 208/1/60 5 - 230/3/60 Z - Other 3 - 230/1/60 6 - 460/3/60 Note: Supply V oltage [SV] 2 thru 7 includes a fi eld mounted step do wn transf ormer. 12 - Motor T ype [MT] 1 - Open Drip Proof (Standard) 2 - T otally Enclosed [Capacities 060 through 120 Only] 13 - Development Le ve[...]

43 Customer ____________________________________ Job Name & Number _________________________ PRE-INSPECTION INFORMA TION With power and gas off. T ype of Equip: Unit Heater Serial Number _________________________ Model Number __________________________ Name Plate V oltage: _____________ Name Plate Amperage: _____________ T ype of Gas: Natural L[...]

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