Sterling GG-45, GG-105, GG-120, GG-60, GG-75 User Manual

...
4.2 (9)

(S) DSGG-IOM-1

J30-08511

INSTALLATION INSTRUCTIONS AND PARTS LIST

TUBULAR GAS FIRED DIRECT SPARK PROPELLER UNIT HEATERS

– FOR RESIDENTIAL INSTALLATIONS –

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 THESEAGREE 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.

 

Serial No.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier, call your fire department.

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

Install, operate, and maintain unit in accordance with the 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 may 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, 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 fi le claim for damage with the transportation company.

04/08

HVAC PRODUCTS

260 NORTH ELM ST., WESTFIELD, MA 01085 TEL: (413) 564-5540 FAX: (413) 562-5311

www.sterlinghvac.com

MODELS: GG-30, 45, 60, 75, 90, 105, 120

Please utilize this toll free number to contact your local representative 800-490-2290.

TABLE OF CONTENTS

SPECIFICATIONS

 

OPERATION

 

Basic Description ....................................................

2

Explanation of Controls and Operation

.................. 31

Performance & Specification Data ......................

4, 5

Main Burner Orifice Schedule ...............................

32

GENERAL SAFETY INFORMATION

 

Adjustments ..........................................................

32

Installation Codes ...............................................

2, 3

High Altitude Operation ..................................

32, 33

Special Precautions ............................................

2, 3

MAINTENANCE

 

INSTALLATION

 

Servicing & Cleaning ............................................

33

Locating Units .....................................................

6, 7

TROUBLESHOOTING GUIDE .............................

34 -38

Combustion Air ...................................................

6, 7

IDENTIFICATION OF PARTS ..............................

39, 40

Proper Clearances ..............................................

6, 7

WARRANTY ...............................................................

41

Suspension of Units ............................................

6, 7

MODEL NUMBER .....................................................

42

Gas Supply Piping ..............................................

8, 9

INSPECTION SHEET.................................................

43

ELECTRICAL CONNECTIONS ............................

10-15

 

 

VENTING

 

 

 

General.............................................................

16-17

 

 

Standard Combustion ......................................

18-25

 

 

Separated Combustion ....................................

26-30

 

 

NOTICE: It is the equipment owners responsibility to provide any scaffolding or other apparatus required to perform emergency service or annual/periodic maintenance to this equipment.

DESCRIPTION

The Residential Tubular Gas Fired Unit Heater is a factory assembled, power vented, low static pressure type propeller fan unit heater designed to be suspended within the space to be heated. THESE HEATERS ARE NOT TO BE CONNECTED TO DUCTWORK. These Tubular Unit Heaters are design certified under ANSI Z83.8 for Industrial/Commercial use and IAS .10.96 U.S.

Figure 1 - Tubular 30 thru 120 Propeller Unit Heaters

(2nd ed.) “Unit Heaters for Residential Installation”. The designs are certified by ETL as providing a minimum of 80% thermal efficiency, and approved for use in California. Do not alter these units in any way. If you have any questions after reading this manual, contact the manufacturer.

GG120

GG030

See Identification of Parts throughout this manual.

The following 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 concerning the product:

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury, or substantial property damage.

Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury, or substantial property damage.

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.

2

GENERAL SAFETY INFORMATION

Failure to comply with the general safety information may result in extensive property damage, severe personal injury, or death.

This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts.

Installation must be made 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 CSA Information Services 1-800-463-6727. The NFPA Standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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 unit heaters have been designed and certified to comply with CGA 2.6.

Do not alter the unit heater in any way or damage to the unit and/or severe personal injury or death may occur!

Disconnect all power and gas supplies before installing or servicing the heater. If the power disconnect is out of sight, lock it in the open position and tag it to prevent unexpected application of power. Failure to do so could result in fatal electric shock, or severe personal injury.

Ensure that all power sources conform to the requirements of the unit heater, 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 gas connections should be made and leaktested by a suitably qualifi ed individual, per instructions in this manual. Also follow procedures listed on "Gas Equipment Start-Up Sheet" located in this manual.

Use only the fuel for which the heater is designed (see rating plate). Using LP gas in a heater that requires natural gas, or vice versa, will create risk of gas leaks, carbon monoxide poisoning, and explosion.

Conversion to a fuel other than that listed on the rating plate is permitted only with a factory supplied, ETL approved conversion kit.

Make certain that the power source conforms to the electrical requirements of the heater.

Do not depend upon a thermostat or other switch as sole means of disconnecting power when installing or servicing heater. Always disconnect power at main circuit breaker as described above. Failure to do so could result in fatal electric shock.

Special attention must be given to any grounding information pertaining to this heater. To prevent the risk of electrocution, the heater must be securely and adequately grounded. This should be accomplished by connecting a ground conductor between the service panel and the heater.To ensure a proper ground, the grounding means must be tested by a qualified electrician.

Do not insert fingers or foreign objects into heater 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 heater 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.

Do not attach ductwork to this product or use it as a makeup air heater. Such usage voids the warranty and will create unsafe operation.

In cases in which property damage may result from malfunction of the heater, a back-up system or temperature sensitive alarm should be used.

Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply.

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 conditions. 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 = 0.305 m

1000

BTU/cu. ft. = 37.5 MJ/m3

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 kg

liter/second = CFM x 0.472

1 psig = 6.894 kPa

meters/second = FPM ÷ 196.8

1 cubic foot = 0.028m3

3

Table 1 - Performance and Dimensional Data - Tubular 30 thru 120 Propeller Unit Heater

Unit Size

30

45

60

75

90

105

120

PERFORMANCE DATA†

 

 

 

 

 

 

 

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)

(10.7)

(14.2)

(17.8)

(21.4)

(24.9)

(28.5)

Thermal Efficiency (%)

81

81

81

81

81

81

81

Free Air Delivery - CFM

370

550

740

920

1,100

1,300

1,475

(cu. m/s)

(.175)

(.260)

(.349)

(.434)

(.519)

(.614)

(.696)

Air Temperature Rise - Deg. F

60

60

60

60

60

60

60

(Deg. C)

(15)

(15)

(15)

(15)

(15)

(15)

(15)

Full Load Amps at 120V

3.0

3.0

3.7

4.1

6.4

6.4

6.4

Maximum Circuit Ampacity

3.5

3.5

4.4

4.8

7.5

7.5

7.5

MOTOR DATA: Motor HP

1/20

1/20

1/12

1/12

1/10

1/10

1/10

Motor (kW)

(0.04)

(0.04)

(0.06)

(0.06)

(0.075)

(0.075)

(0.075)

Motor Type

SP

SP

SP

SP

SP

SP

SP

R.P.M.

1650

1650

1050

1050

1050

1050

1050

Motor Amps @ 115V

1.9

1.9

2.6

2.6

4.2

4.2

4.2

DIMENSIONAL DATA - inches (mm)

 

 

 

 

 

 

 

“A” Jacket Height

12-3/8

12-3/8

15-7/8

15-7/8

22-5/8

22-5/8

22-5/8

 

(314)

(314)

(403)

(403)

(574)

(574)

(574)

“B” Overall Height

13-1/4

13-1/4

16-13/16

16-13/16

23-9/16

23-9/16

23-9/16

 

(337)

(337)

(427)

(427)

(598)

(598)

(598)

“C” Overall Depth

25-7/8

25-7/8

26-3/16

26-3/16

26-3/8

26-3/8

26-3/8

 

(632)

(632)

(665)

(665)

(670)

(670)

(670)

“D1” Center Line Height of Flue*

8-1/2

8-1/2

10-3/8

10-3/8

13-5/8

13-5/8

13-5/8

 

(216)

(216)

(263)

(263)

(346)

(346)

(346)

“D2” Center Line Height of Air Intake

8-1/2

8-1/2

8

8

8-5/8

8-5/8

8-5/8

 

(216)

(216)

(203)

(203)

(219)

(219)

(219)

“E” Fan Diameter

10

10

14

14

16

16

16

 

(254)

(254)

(356)

(356)

(406)

(406)

(406)

“F” Discharge Opening Height

10-13/16

10-13/16

14-7/16

14-7/16

21-3/16

21-3/16

21-3/16

 

(275)

(275)

(367)

(367)

(538)

(538)

(538)

“G” Vent Connection Diameter

4

4

4

4

4

4

4

 

(102)

(102)

(102)

(102)

(102)

(102)

(102)

“H1” Center Line of Flue Connection From Side

7-1/4

7-1/4

7-1/4

7-1/4

7-3/4

7-3/4

7-3/4

 

(184)

(184)

(184)

(184)

(197)

(197)

(197)

“H2” Center Line of Air Intake From Side

2-3/4

2-3/4

2-3/4

2-3/4

3-1/2

3-1/2

3-1/2

 

(70)

(70)

(70)

(70)

(89)

(89)

(89)

Vent Size Requirements - Standard Combustion

 

 

 

 

 

 

 

Category I Horizontal**

4

4

4

5

5

5

5

 

(102)

(102)

(102)

(127)

(127)

(127)

(127)

Category III Horizontal

4

4

4

4

4

4

4

 

(102)

(102)

(102)

(102)

(102)

(102)

(102)

Category I & III Vertical

4

4

4

4

4

4

4

 

(102)

(102)

(102)

(102)

(102)

(102)

(102)

Vent Size Requirements - Separated Combustion

 

 

 

 

 

 

 

Exhaust Diameter**

4

4

4

4

5

5

5

 

(102)

(102)

(102)

(102)

(127)

(127)

(127)

Intake Air Diameter

4

4

4

4

5

5

5

 

(102)

(102)

(102)

(102)

(127)

(127)

(127)

Unit Weight - lbs.

57

60

75

87

96

103

112

(kgs)

(27)

(29)

(34)

(37)

(45)

(48)

(49)

Shipping Weight - lbs.

67

70

90

96

109

143

152

(kgs)

(32)

(33)

(41)

(44)

(51)

(66)

(67)

*For all installations, the flue collar is included with the unit and should be field installed per the instructions included with the unit.

**4-5" reducer supplied where required.

Ratings shown are for unit installations at elevations between 0 and 2,000 ft (0 to 610m). For unit installations in U.S.A. above 2,000 ft. (610m), the unit input must be derated 4% for each 1,000 ft. (305m) above sea level; refer to local codes, or in absence of local codes, refer to the latest edition of the National Fuel Gas Code, ANSI Standard Z223.1 (N.F.P.A. No. 54), (also refer to Table 6).

4

Figure 2 - Dimensional Drawing – Tubular 30 thru 120 Propeller Unit Heater

DIMENSIONS .XXX STANDARD UNITS

DIMENSIONS IN PARENTHESIS (XXX) MILLIMETERS

5

INSTALLATION

Do not install unit heaters in corrosive or flammable atmospheres! Premature failure of, or severe damage to the unit will result!

Avoid locations where extreme drafts can affect burner operation. Unit heaters 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!

Since the unit is equipped with an automatic gas ignition system, the unit heater must be installed such that the gas ignition control system is not directly exposed to water spray, rain or dripping water.

NOTICE: Location of unit heaters is related directly to the selection of sizes. Basic rules are as follows:

MOUNTING HEIGHT: If the unit heater is installed in a garage, it must be installed with a minimum clearance above the floor of 18 inches (457mm).

AIR DISTRIBUTION: Direct air towards areas of maximum heat loss. When multiple heaters are involved, circulation of air around the perimeter is recommended where heated air flows along exposed walls. Satisfactory results can also be obtained where multiple heaters are located toward the center of the area with heated air directed toward the outside walls. Be careful to avoid all obstacles and obstructions which could impede the warm air distribution patterns.

Unit heaters 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 unit heaters are operated to maintain lower than 50°F (10°C), hot fl ue gases are cooled inside the heat exchanger to a point where water vapor (a flue gas by-product) condenses onto the heat exchanger walls.The result is a mildly corrosive acid that prematurely corrodes the aluminized heat exchanger and can actually drip water down from the unit heater onto fl oor surface. Additional unit heaters should be installed if a minimum 50°F (10°C) thermostat setting cannot be maintained.

Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply.

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and replace any gas control which has been underwater.

AIR FOR COMBUSTION: The unit heater shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and the maintenance of ambient air at safe limits under normal conditions of use. The unit heater shall be located in such a manner as not to interfere with proper circulation of air within the confined space. When buildings are so tight that normal infiltration does not meet air requirements, outside air shall be introduced per Sections 1.3.4.2 and 1.3.4.3 of ANSI Z223.1 for combustion requirements. A permanent opening or openings having a total free area of not less than one square inch per 5,000 BTU/Hr (1.5 kW) of total input rating of all appliances within the space shall be provided.

NOTICE: Unit Heater sizing should be based on heat loss calculations where the unit heater output equals or exceeds heat loss.

CLEARANCES: Each Gas Unit Heater shall be located with respect to building construction and other equipment so as to permit access to the Unit Heater. Clearance between vertical walls and the vertical sides of the Unit Heater shall be no less than 1 inch (25.4mm). However, to ensure access to the control box and fan, a minimum of 18" (457mm) is required for the fan, and control box side. A minimum clearance of 1 inch (25.4mm) must be maintained between the top of the Unit Heater and the ceiling. The bottom of the Unit Heater must be no less than 1 inch (25.4mm) from any combustible. The distance between the flue collector and any combustible must be no less than 1 inch (25.4mm). Also see AIR FOR COMBUSTION and VENTING sections.

NOTICE: Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials.

MOUNTING: The Unit Heater may be mounted with the vent outlet, gas and electrical connections to the right or left of the air moving fan. The Unit Heater is shipped with the connections to the right of the fan when looking in the direction of the air flow. If connections to the right are required, remove hanger brackets from face of unit and attach as pictured in Figure 3. If connections to the left are required, invert the heater (180°), mount the hanging brackets as above, and remove, invert, and replace the control access panel and the air discharge louvers.

6

INSTALLATION (continued)

The Unit Heater may be mounted by fastening the hanging brackets directly to ceiling joists or by suspending from four rods. See Figures 3, 4 and 5.

Make certain that the lifting methods used to lift the heater and the method of suspension used in the field installation of the heater are capable of uniformly supporting the weight of the heater at all times. Failure to heed this warning may result in property damage or personal injury!

Make sure that the structure to which the unit heater is to be mounted is capable of safely supporting its weight. Under no 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 the electrical conduit for support. Failure to heed these warnings may result in property damage, personal injury, or death.

Unit Heaters must be hung level from side to side and from front to back, see Figures 3, 4 and 5. Failure to do so will result in poor performance and/or premature failure of the unit.

Ensure that all hardware used in the suspension of each unit heater is more than adequate for the job. Failure to do so may result in extensive property damage, severe personal injury, or death!

Refer to Figures 3, 4 and 5 for suspension of units.

Figure 3 - Hanger Bracket Installation Instructions

Figure 4 - Heater Mounting (Steel Construction)

Figure 5 - Heater Mounting (Wood Construction)

7

= 75 Cu. ft./hr

GAS PIPING

To avoid 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. These valves may not be completely shut off, exposing the gas valve to excessive pressure and damage.

PIPE SIZING

To provide adequate gas pressure to the gas unit heater, size the gas piping as follows:

1. Find the cu. ft./hr. by using the following formula:

Cu. ft./hr. = Input BTU

2.Refer to Table 2. 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 the top of the column.

Example:

It is determined that a 67 foot (20.4m) run of gas pipe is required to connect a 75 MBTU gas unit heater to a 1,000 BTU/cu ft. (0.29kW) natural gas supply.

75,000 BTU/Hr

1,000 BTU/cu. ft. . Using Table 2, a 3/4 inch pipe is needed.

NOTE: See General Safety Information section for English/Metric unit conversion factors.

NOTICE: If more than one unit heater 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 gas unit heater 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 MADE BY A QUALIFIED L.P. GAS DEALER OR INSTALLER. HE WILL ENSURE 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 2 - 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

77

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)

(4.11)

(3.82)

1 1/4

1.380

1400

950

770

660

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)

1 1/2

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)

2 1/2

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 input by 1000. For SI/Metric measurements: Convert BTU/Hr. to kilowatts. Multiply the units inputs (kW) by 0.0965 to determine Cu. Meters./Hr. 2. FOR NATURAL GAS: Select pipe size directly from the table. 3. FOR PROPANE GAS: Multiply the Cu. Ft./Hr. value by 0.633; then, use the table. 4. Refer to the metric conversion factors listed in the General Safety section for SI Unit measurement conversions.

8

PIPE INSTALLATION

1.Install the gas piping in accordance with applicable local codes.

2.Check gas supply pressure. Each unit heater must be connected to a gas supply capable of supplying its full rated capacity as specifi ed in Table 3. A fi eld LP tank regulator must be used to limit the supply pressure to a maximum of 14 in. 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 & 2 for correct gas piping size, and also refer to Tables 3, 7 and 8. If gas pressure is excessive on natural gas applications, install a pressure regulating valve in the line upstream from the main shutoff valve.

3.Adequately support the piping to prevent strain on the gas manifold and controls.

4.To prevent the mixing of moisture with gas, run the take-off piping from the top, or side, of the main.

5.Standard Unit Heaters are supplied with a combination valve which includes:

a.Manual "A" valve

b.Manual "B" valve

c.Solenoid valve

d.Pressure regulator

Pipe directly into the combination valve (see Figure 6).

6.Gas valve has a pressure test post requiring a 3/32" hex head wrench to read gas supply and manifold pressures. Open 1/4 turn counterclockwise to read, turn clockwise to close and reseat. A 5/16" ID hose fits the pressure post.

7.Provide a drip leg in the gas piping near the gas unit heater. A ground joint union and a manual gas shutoff valve 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 6)

8.Make certain that all connections have been adequately doped and tightened.

Do not over tighten the inlet gas piping 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.

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!

Figure 6 - Pipe Installation, Standard Controls

D3631C

Never use an open flame to detect gas leaks. Explosive conditions may exist which may 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 (3.5 kPa).

Table 3 - Gas Piping Requirements

GAS PIPING REQUIREMENTS*

GasType

Natural Gas

Propane (LP) Gas

Manifold

3.5 in. W.C.

10.0 in. W.C.

Pressure

(0.9 kPa)

(2.5 kPa)

 

 

 

 

14.0 in. W.C. Max.

14.0 in. W.C. Max.

Supply Inlet

(3.5 kPa)

(3.5 kPa)

Pressure

 

 

5.0 in. W.C. Min.

11.0 in W.C. Min.

 

 

(1.2 kPa)

(2.7 kPa)

 

 

 

*For single stage application only at altitudes below 2,001 feet.

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 (3.5 kPa).

9

ELECTRICAL CONNECTIONS

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 unit heater electrical system. All external wiring must conform to the latest edition of ANSI/NFPA No. 70, National Electrical Code, and applicable local codes; in Canada, to the Canadian Electrical Code, Part 1, CSA Standard C22.1.

Do not use any tools (i.e. screwdriver, pliers, etc.) across terminals to check for power. Use a voltmeter.

It is recommended that the electrical power supply to each unit heater 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 and controls as possible. Each unit heater must be electrically grounded in accordance with the latest edition of the National Electrical Code, ANSI/NFPA No. 70, or CSA Standard C22.1. Refer to Figures 7, 8, 9, 10A, 10B, 10C, 11A, 11B and 11C.

Figure 7 - Low-voltage Thermostat Wiring

Single Stage

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 AreasOutside walls or areas where drafts may affect the operation of the control.

2.Hot AreasAreas where the sun's rays, radiation, or warm air currents may affect the operation of the control.

3.Dead AreasAreas where the air cannot circulate freely, such as behind doors or in corners.

THERMOSTAT HEAT ANTICIPATOR ADJUSTMENTS:

The 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 .35 Amps

NOTICE: The start-up fan delay should not exceed 30 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.

Figure 8 - Low Voltage Thermostat Wiring

Two Stage

Figure 9 - T834H or T834N

 

Thermostat Wiring

 

W

R

 

 

R

G W1 W2

 

G

 

 

 

D6922C

10

ELECTRICAL CONNECTIONS (continued)

Figure 10A - UT Control Board

Figure 11A - Honeywell Control Board

11

ELECTRICAL CONNECTIONS (continued)

Figure 10B -Tubular Propeller Units 30-120 with Natural and Propane (LP) Gas with Single Stage Gas Control and UT Control Board

NOTICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater. If using a standard low voltage thermostat with a sub-base switch for fan control,connect the G terminal of the thermostat to the G terminal of the unit heater.

12

Sterling GG-45, GG-105, GG-120, GG-60, GG-75 User Manual

ELECTRICAL CONNECTIONS (continued)

Figure 10C -Tubular Propeller Units 60-120 with Natural and Propane (LP) Gas with OptionalTwo Stage Gas Control and UT Control Board

NOTICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater. If using a standard low voltage thermostat with a sub-base switch for fan control,connect the G terminal of the thermostat to the G terminal of the unit heater.

13

ELECTRICAL CONNECTIONS (continued)

Figure 11B -Tubular Propeller Units 30-120 with Natural and Propane (LP) Gas with Single Stage Gas Control and Honeywell Control Board

NOTICE: See Figures 7, 8, 9, 10B, 10C, 11B and 11C for connecting the thermostat to the unit heater. If using a standard low voltage thermostat with a sub-base switch for fan control,connect the G terminal of the thermostat to the G terminal of the unit heater.

14

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